647412EN (23/04/2018)
MLT 634 120 PS ST3B MT 732 100D ST3B S1
MLT 634 120 ST3B S1 MT 732 EASY 75D ST3B S1
MLT 732 100D ST3B S1 MT 932 100D ST3B S1
MT 932 EASY 75D ST3B S1
MLT 735 100 ST3B
MLT 735 120 PS ST3B MT 1030 EASY 75D ST3B S1
MT 1030 EASY 75D ST3B S2
MLT 735 120 ST3B
MLT 741 100 ST3B
MLT 741 120 PS ST3B
MLT 741 120 ST3B
REPAIR MANUAL
647412EN
2
DATE OF ISSUE
OBSERVATION
14 / 12 / 2013
- 1st ISSUE
04 / 12 / 2014
- UPDATED
- Integration of M
T 732 EASY 75D ST3B S1
MT 932 EASY 75D ST3B S1
MLT 732 100D ST3B S1
02 / 03 / 2015
- UPDATED
29 / 01 / 2016
- UPDATED : Integration of MT 1030 EASY 75D ST3B S1
28 / 10 / 2016
- UPDATED : Integration of MT 1030 EASY 75D ST3B S2
25 / /10 / 2017
- Partial UPDATE : GR80-04 + GR40-04 BRAKE CONTROL AND ADJUSTMENT
23 / 04 / 2018
- Partial UPDATE : GR80-04
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.
647412EN
3 3
HOW TO USE THIS REPAIR MANUAL ?
2
00
00
1GENERAL CHARACTERISTICS AND SAFETY
10
TRANSMISSION
20
GENERAL, CHARACTERISTICS AND SAFETY
ENGINE
30
AXLE
- GENERAL INSTRUCTIONS AND SAFETY NOTICE
50
60
BOOM
55
40
BRAKE
70
HYDRAULIC
80
ELECTRICITY
FRAME - BODYWORK
90
OPTIONS - ATTACHMENTS
110
85
DRIVER’S CAB
4
3
General instructions and safety
notice
00
00
4
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
1
2
Before carrying out any operation on an electrically powered
component, activate the battery cut-off.
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.
(29/09/2011)
00-M173EN
M
R
547982 : See the repair manual N° 547982.
70 - HYDRAULIC : See the group N° 70 called «Hydraulic».
00-M173EN
(29/09/2011)
BOOM
HYDRAULICS
ELECTRICITY
00
10
20
30
FRAME - BODY
90
OPTIONS - ATTACHMENTS
110
DRIVER'S CAB
40
BRAKE
50
AXLE
70
TRANSMISSION
80
ENGINE
85
GENERAL
- GENERAL INSTRUCTIONS AND SAFETY
NOTICE
- GENERAL CHARACTERISTICS AND
SPECIFICATIONS
- GENERAL LOCATION
- GENERAL CONTROL AND ADJUSTMENT
00
GENERAL CHARACTERISTICS AND SAFETY
00
GENERAL INSTRUCTIONS AND SAFETY NOTICE
pages
PREAMBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
MAINTENANCE POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
RULES FOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
(29/01/2016)
00-00-M218EN
00
2
GENERAL INSTRUCTIONS AND SAFETY
NOTICE
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-M218EN
(29/01/2016)
MAINTENANCE POSITION
2
1
4
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.
(29/01/2016)
3
00
GENERAL INSTRUCTIONS AND SAFETY
NOTICE
00-00-M218EN
GENERAL INSTRUCTIONS AND SAFETY
NOTICE
00
4
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.
Before carrying out any operation on an electrically powered
component, activate the battery cut-off.
1
2
b
Press the battery switch at least 30 seconds after disconnecting
the electrical contact with the ignition key.
b
Before carrying out any welding operations, think of
disconnecting computers.
If the telehandler does not have a battery isolating switch, disconnect
the battery terminals then gather them.
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.
00-00-M218EN
(29/01/2016)
5
00
GENERAL INSTRUCTIONS AND SAFETY
NOTICE
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.
(29/01/2016)
00-00-M218EN
GENERAL INSTRUCTIONS AND SAFETY
NOTICE
00
6
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-M218EN
(29/01/2016)
00
GENERAL CHARACTERISTICS AND SPECIFICATIONS
pages
CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
FLUIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– DIMENSIONS MT / MLT (EXCEPT MT 1030) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– DIMENSIONS MT 1030 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
(07/07/2016)
00-01-M218EN
00
2
GENERAL CHARACTERISTICS AND
SPECIFICATIONS
CHARACTERISTICS
Designation
Truck weight with MT / MLT
forks (kg)
MLT PS
Boom weight (kg)
Weight
AV
distribution per
AR
axle with forks
Front (PS)
(kg)
Rear (PS)
Pulling force (daN)
MLT
634 120
+ PS
ST3B
7340
7530
1250
3200
4140
3260
4270
5650
MLT
MLT
MLT
732 100D 735 100/120 741 100/120
+ PS
+ PS
ST3B S1
ST3B
ST3B
7080
7475
MT
932 100D
ST3B S1
7585
MT
732 EASY
75D
ST3B S1
6780
ST3B S1
7980
MT
MT
932 EASY 1030 EASY
75D
75D
ST3B S1 ST3B S1/S2
7145
7720
7630
1390
3375
4100
3340
4290
5235
1390
3225
4360
1390
3280
3500
1680
3450
4530
1680
3445
3700
1760
6110
5300
5770
5530
8160
Type
EN590 / ASTM D975
MANITOU GOLD
Cooling liquid (protection -35°)
MANITOU Automatic transmission oil
MANITOU ISO VG 46 Hydraulic oil
MANITOU Mineral brake fluid
R134A gas
Special MANITOU oil for immersed brakes
MANITOU SAE80W90 Mechanical transmission oil
Quantity
120 ℓ
10 ℓ
20.5 ℓ
16.6 ℓ
135 ℓ
1ℓ
950 g ±50
8.1 ℓ
0.8 ℓ
1390
7230
1390
3370
3710
3390
3840
5235
MT
732 100D
FLUIDS
Designation
Fuel tank
Engine oil
Cooling system
Gearbox
Hydraulic tank
Brake system
Air-conditioning system
Axle differential
Wheel reduction gear
Data obtained from
Instruction Manuals:
i 647444 of 06/12/2013
i 647449 of 18/06/2014
i 647480 of 08/04/2016
DIMENSIONS
DIMENSIONS MT / MLT (except MT 1030)
Item
A (mm)
B (mm)
C (mm)
C1 (mm)
D (mm)
D1 (mm)
D2 (mm)
E (mm)
F (mm)
F1 (mm)
G (mm)
G1 (mm)
G2 (mm)
I (mm)
J (mm)
K (mm)
L (mm)
N (mm)
O (mm)
P2 (°)
P3 (°)
R (mm)
S (mm)
T (mm)
U1 (mm)
U2 (mm)
V (mm)
V1 (mm)
V2 (mm)
W (mm)
Y (°)
Z (°)
00-01-M218EN
MLT
634 120
+ PS
ST3B
1200
2560
1142
1245
4436
4539
3889
5636
1935
1935
450
435
435
734
980
1260
45
1715
125
47,5
53
3535
7391
3450
2345
2545
4650
1200
3769
2402
12
134
MLT
732 100D
ST3B S1
1200
2560
1440
1378
4743
4681
3931
5948
2050
2050
450
435
435
742
890
1260
45
1715
125
38
53
3747
6675
3519
2299
2488
4829
1310
3954
2340
13
134
MLT
MLT
735 100/120 741 100/120
+ PS
+ PS
ST3B
ST3B
1200
1200
2810
2810
1192
1192
1287
1128
4712
4755
4807
4691
4115
4158
5912
5955
1935
1935
1935
1935
450
450
435
435
435
435
710
753
980
980
1260
1260
45
45
1715
1715
125
125
38
38
53
53
3685
3685
7716
7716
3575
3575
2345
2345
2545
2545
4885
4885
1310
1310
3919
3919
2402
2402
13
13
134
134
MT
732 100D
MT
732 EASY 75D
MT
932 100D
MT
932 EASY 75D
ST3B S1
1200
2560
1440
1378
4743
4681
3931
5948
2050
2050
450
435
435
742
890
1260
45
1715
125
38
53
3747
6675
3519
2299
2488
4829
1310
3954
2340
13
134
ST3B S1
1200
2810
1193
1128
4761
4696
4193
5961
1930
1930
450
435
435
742
890
1260
45
1715
125
38
53
3685
6685
3490
2299
2488
4800
1310
3800
2340
13
134
ST3B S1
1200
2560
1373
1314
4676
4617
3932
5881
2050
2050
450
435
435
742
890
1260
45
1715
125
38
53
3550
7616
3519
2299
2488
4829
1310
3757
2340
13
134
ST3B S1
1200
2810
1128
1064
4696
4632
4193
5896
1930
1930
450
435
435
758
890
1260
45
1715
125
38
53
3685
7620
3460
2299
2488
4770
1310
3800
2340
13
134
(07/07/2016)
3
00
GENERAL CHARACTERISTICS AND
SPECIFICATIONS
D1
L
A
G2
G1
Y
Z
D2
B
D
C
P3
P2
G
N
U1 (MLT)
U2
C1
I
U1 (MT)
E
J
F1
F
W
K
V
O
R
V2
T
V1
S
(07/07/2016)
00-01-M218EN
00
4
GENERAL CHARACTERISTICS AND
SPECIFICATIONS
DIMENSIONS MT 1030
Item
A (mm)
B(mm)
C(mm)
C1(mm)
D(mm)
D1(mm)
D2(mm)
E(mm)
F(mm)
F1(mm)
G(mm)
G1(mm)
G2(mm)
G3(mm)
I(mm)
J(mm)
K(mm)
L(mm)
N(mm)
O(mm)
P2(°)
P3(°)
R(mm)
S(mm)
T(mm)
U1(mm)
U2(mm)
V(mm)
V1(mm)
V2(mm)
V3(mm)
W(mm)
W1(mm)
W2(mm)
Y(°)
Z(°)
00-01-M218EN
MT
1030 EASY
75D
ST3B S1/S2
1200
2690
1513
1602
4992
5081
4050
6192
1930
1930
450
450
435
220
789
890
1260
45
1715
125
44
53
3545
7810
3640
2299
2488
4950
1310
3752
4200
2340
2210
1132
11,9
113,7
(07/07/2016)
00
GENERAL LOCATION
pages
LOCATION OF NAME AND IDENTIFICATION PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
(10/06/2013)
00-03-M218EN
00
2
GENERAL LOCATION
LOCATION OF NAME AND IDENTIFICATION PLATE
Key:
1 - Manufacturer's plate
2 - Rear drive axle plate
3 - Air-conditioning compressor
4 - Engine plate
5 - Angle gear box
6 - Front drive axle plate
7 - Gear box
8 - Hydraulic pump
9 - Distributor
10 - Cab plate
MANITOU
10A..........
..........
P0............
38/09
8
9
10
7
1
6
5
2
4
3
4
00-03-M218EN
(10/06/2013)
00
GENERAL CONTROL AND ADJUSTMENT
pages
STANDARD TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
(17/11/2014)
00-04-M218EN
2
GENERAL CONTROL AND ADJUSTMENT
00
STANDARD TIGHTENING TORQUES
See the table below for standard torque to use (unless otherwise indicated in the service manual,
example: 15 N.m ± 2 (tolerance N.m)).
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 (N.m) :
Ø x “coarse” pitch
Grade 8.8
Grade 10.9
Ø x “fine” pitch
Grade 8.8
Grade 10.9
M6 x 1
8,2
12,1
-
-
-
M8 x 1,25
20
30
M8 x 1
22
32
M10 x 1,5
40
59
M10 x 1,25 (x 1)
43 (46)
63 (68)
M12 x 1,75
69
102
M12 x 1,5 (x 1.25)
74 (78)
108 (115)
M14 x 2
111
163
M14 x 1,5
123
181
b
b
M16 x 2
175
256
M16 x 1,5
190
279
M18 x 2,5
240
352
M18 x 1,5
279
410
M20 x 2,5
341
501
M20 x 1,5
391
574
M22 x 2,5
470
691
M22 x 1,5
531
780
M24 x 3
588
864
M24 x 2
659
967
M27 x 3
874
1284
M27 x 2
965
1418
M30 x 3,5
1181
1735
M30 x 2
1351
1984
M33 x 3,5
1614
2371
M33 x 2
1821
2674
M36 x 4
2068
3037
-
-
-
For hexagon screws with flanges (NF E 25-030-1) :
Apply an increased torque of +10%.
Where washers are used, the following coefficient is to be applied (FD E 25-502) :
Plate : +0%
-
Smooth tapered washer (CL): +5%
-
Spring (or Grower) washer without jaws (W) : +10%
Conical, internal teeth (CDJ-JZC) : +15%.
2 - With marking (N.m) :
4
5
4T
------------
6
7
6T
------------
8
8T
------------
11
7T
5T
Ø x Pitch
(flange : 4.8T)
(flange : 8.8T)
(flange : 10.9T)
(flange : 11.9T)
M6 x 1
5 .4 (5.5)
6 .5
7 .8 (7.5)
11
12 (12)
(15.5)
(17.5)
(flange : 6.8T)
M8 x 1,25
13 (13)
16
19 (19)
25
29 (29)
(38)
(42)
M10 x 1,25
25 (27)
32
39 (39)
52
61 (61)
(80)
(89)
M12 x 1,25
47 (50)
59
72 (71)
95
108 (110)
(145)
(160)
M14 x 1.5
75 (78)
91
108 (110)
147
172 (175)
(230)
(260)
M16 x 1.5
113 (120)
137
172 (170)
226
265 (270)
(360)
(400)
b
use the upper class where spring (or Grower) washers are used.
00-04-M218EN
(17/11/2014)
10
ENGINE
- ENGINE CHARACTERISTICS AND
SPECIFICATIONS
- ENGINE CIRCUITS FLOW DIAGRAM
- ENGINE COMPONENTS LOCATION
- ENGINE CONTROL AND ADJUSTMENT
- ENGINE REMOVAL
- ENGINE REFIT
- ENGINE TROUBLESHOOTING
- SPECIFIC ENGINE TOOLING
- REMOVAL
- REFIT
- SPECIFIC ENGINE TOOLING
l647461EN
(TCD/TD 3.6 L4 ENGINE)
10
ENGINE GENERAL CHARACTERISTICS AND
SPECIFICATIONS
pages
CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
POLLUTION MANAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INJECTION CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
BOSCH CP4.1 HIGH PRESSURE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
(11/05/2016)
10-01-M218EN
2
ENGINE GENERAL CHARACTERISTICS AND
SPECIFICATIONS
10
CHARACTERISTICS
⇒⇒ 4 cylinders in line
⇒⇒ Firing order from flywheel: 1, 3, 4, 2
⇒⇒ Anti-clockwise (viewed from flywheel)
⇒⇒ 3,6 ℓ cubic capacity
⇒⇒ Electronic management
⇒⇒ Direct injection
⇒⇒ Turbo (75cv)
⇒⇒ Turbo with cooler (100 hp and 120 hp)
⇒⇒ Compression ratio: 18:1
⇒⇒ Power rating 55.4 kW (75 hp), 74.4 kW (100 hp) and 90 kW (120 hp)
⇒⇒ Specific consumption: 210 and 220 g/kWh
⇒⇒ Maximum torque: 330 N.m (75 hp), 410 N.m (100 hp) and 480 N.m (120 hp) (at 1600 rpm)
⇒⇒ Dry engine weight: 270 kg
⇒⇒ Idle speed:
- Min rpm: 930 rpm
- nominal laden: 2200 rpm
- max. unladen: 2360 rpm
⇒⇒ Pre-heating and post-heating times:
10 and 140 s from -30 to -20°C
10 and 100 s at -10°C
5 and 50 s at 0°C
No pre-heating above 5°C
POLLUTION MANAGEMENT
The Stage 3B pollution standard is complied with by optimizing combustion to produce small amounts
of soot but which, in turn, produces large quantities of NOx.
Among other parameters, the EGR management is designed accordingly and the engine is therefore
equipped with a large exhaust gas recirculation cooler, thus reducing NOx levels.
This version does not have a throttle valve so as to allow more air to be supplied to the engine and thus
improve NOx management.
The remaining NOx is treated to 90 % by the catalytic converter.
There is no lambda probe as all the operating conditions are on the ECU map.
10-01-M218EN
(11/05/2016)
ENGINE GENERAL CHARACTERISTICS AND
SPECIFICATIONS
3
INJECTION CYCLE
10
1 - Fuel pre-injection 1
2 - Fuel pre-injection 2
3 - Fuel injection
Effects of fuel pre-injection
Pre-conditioning of the combustion chamber prior to main fuel injection
1. Reduces temperature of combustion
2. Reduces the main injection combustion delay
3. Reduces noise emissions (reduced peak combustion pressure)
The safety valve protects the fuel rail against excessive pressure by opening at approx. 1700 bar.
It remains pen and heats up until the engine and the fuel flow are stopped.
Over time, this heat may affect the hardening of the spring inside the valve.
For this reason, the engine is only allowed to run for period of 4 minutes, once the valve is open, and
the valve must be replaced after 50 openings.
Replace the valve before exceeding the number of openings or there is a risk of premature opening or leaks.
(11/05/2016)
10-01-M218EN
4
ENGINE GENERAL CHARACTERISTICS AND
SPECIFICATIONS
10
BOSCH CP4.1 HIGH PRESSURE PUMP
Synchronised with idle gear / crankshaft.
Approximately two strokes per crankshaft rotation.
Max. working pressure 1600 bar.
The high pressure pump is lubricated by the fuel. Its reliability can therefore be affected by fuel quality.
Excessive wear of the cam follower and of the bore with possible damage to the cam lobe is frequently
due to a poor quality of fuel.
4
Key:
1 - 2 lobe camshaft
2 - Piston type pump
3 - High pressure outlet
4 - MPROP (magnetic proportional valve)
5 - Low pressure inlet
6 - Discharge valve
3
5
2
If the MPROP is de-energised, a spring
pushes the fuel metering section upwards.
The passage from the fuel delivery pump to
the high pressure pump is completely open
and a large volume of fuel is delivered to the
high pressure pump.
10-01-M218EN
6
1
(11/05/2016)
10
ENGINE CIRCUITS FLOW DIAGRAM
pages
AIR INTAKE CIRCUIT AND EGR (EXHAUST GAS RECIRCULATION) . . . . . . . . . . . . . . . . . . . . . 2
LUBRICATION CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUEL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
(28/10/2014)
10-02-M218EN
2
ENGINE CIRCUITS FLOW DIAGRAM
10
AIR INTAKE CIRCUIT AND EGR (Exhaust Gas Recirculation)
Controls the flow of exhaust gases towards the intake.
A proportional actuator ensures accurate control of the EGR flow rate according to engine load,
temperature and other factors. This ensures optimum control of NOx emissions and particles. The one
way valves prevents boost air entering the EGR system.
Key:
1 - From air filter
8 - EGR Valve
9 - Cooling liquid supply
2 - Turbo
3 - Air turbo cooler (100 and 120 hp only)
10 - EGR cooler
4 - Cooled air temperature sensor (100 and 120 hp 11 - Cooling liquid return
12 - Non-return valves
only)
5 - Intake
13 - Gas cools
14 - To exhaust
6 - Exhaust
7 - Exhaust gas by-pass
4
3
9
1
10
12
8
7
13
11
2
6
5
14
10-02-M218EN
(28/10/2014)
ENGINE CIRCUITS FLOW DIAGRAM
3
The oil pressure and volume flow rate ensure lubrication of the engine and also, to a large extent, engine
cooling. The pressure relief valve opens at 9 bar and the maximum oil temperature in the sump is 125°C.
Key:
1 - Oil sump
2 - Oil pump
3 - Pressure relief valve
4 - Oil cooler
5 - By-pass valve
6 - Pressure control valve
7 - Oil filter
8 - Main oil gallery
9 - Camshaft bearing
10 - Crankshaft bearing
11 - Piston cooling nozzle
12 - Rocker arm
13 - Hydraulic tappets
14 - Turbo compressor
15 - Air compressor (optional)
12
14
15
11
8
13
5
4
9
7
10
6
3
2
1
4
7
6
2
3
6
8
(28/10/2014)
10-02-M218EN
10
LUBRICATION CIRCUIT
4
ENGINE CIRCUITS FLOW DIAGRAM
10
COOLING SYSTEM
The engine temperature is controlled by the ECU control unit (EMR 4) and depends on the required
performance. Exceeding the temperature limits will trigger the warning, power reduction and engine
shutdown stages. The maximum temperature difference across the radiator is 8°C. The maximum cooling
system pressure is 1,2 bar.
Key:
1 - Water pump
2 - Coolant enters the engine
3 - Cylinder tube / head cooling
4 - Lubricating oil radiator
5 - Exhaust return radiator
6 - Cab heating connection
7 - Temperature sensor
8 - Thermostat (opening 92°C, max 110°C)
9 - Radiator
10 - Expansion tank
6
10
9
7
5
4
8
3
2
1
10-02-M218EN
(28/10/2014)
ENGINE CIRCUITS FLOW DIAGRAM
5
FUEL CIRCUIT
10
Max. fuel supply. Pressure: 8 bar.
Regulated pressure fuel supply: 4 - 4,5 bar. Startup not allowed if P < 3,2 bar.
Fuel rail pressure, maximum service pressure: 1600 bar.
PRV (Pressure Relief Valve) on the fuel rail, opening pressure: 1700 bar.
Low Pressure:
Within the high pressure pump, the MPROP (Magnetic Proportional Electrovalve) controls the amount
of fuel delivered to the pump relative to the amount returned to the fuel tank.
High Pressure:
Fuel under high pressure is sent from the high pressure pump (Item 6) to the fuel rail (Item 7) where it
is available to all the injectors (Item 8).
Return:
The fuel return is generated by the opening of each injector (Item 8), of the MPROP (Item 6), and (in the
event of a malfunction) of the safety valve in the fuel rail (Item 7).
Key:
7 - High pressure fuel rail
1 - Fuel tank
8 - Injector
2 - Water separator / pre-filter
9 - One way valve
3 - Electrical fuel pump
4 - Fuel filter
10 - Return line
5 - Supply pressure sensor
11 - Tank return
6 - High pressure pump / FCU (Fuel Control Unit) 12 - ECU (Electronic Control Unit)
9
8
12
10
7
2
4
3
5
11
6
1
(28/10/2014)
10-02-M218EN
ENGINE CIRCUITS FLOW DIAGRAM
10
6
10-02-M218EN
(28/10/2014)
10
ENGINE COMPONENTS LOCATION
pages
ENGINE COMPONENTS (100 AND 120 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ENGINE COMPONENTS (75 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
WATER AND AIR COOLING SYSTEM (100 AND 120 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
WATER AND AIR COOLING SYSTEM (75 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
HYDRAULIC VENTILATION SYSTEM (100 AND 120 HP ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
HYDRAULIC VENTILATION SYSTEM (75 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DIESEL FUEL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
FUEL INJECTION CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
EGR (EXHAUST GAS RECIRCULATION) CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
(18/02/2015)
10-03-M218EN
2
ENGINE COMPONENTS LOCATION
10
ENGINE COMPONENTS (100 and 120 HP)
Key:
1 - Cooling water inlet
2 - Alternator belt
3 - Tensioning pulley
4 - Crankshaft sensor
5 - Ventilation pump
6 - Camshaft sensor
7 - Water pump
8 - Alternator
9 - EGR Valve
10 - Air supply to turbo
11 - EGR cooler
12 - Non-return valves
13 - Crankcase breather
14 - Oil filler plug
15 - Air supply to intake
16 - Fuel rail
17 - Fuel rail pressure sensor
18 - Intake air sensor
19 - Water temperature sensor
20 - Thermostat
21 - Cooling water outlet
22 - Fuel return
23 - Oil cooler
24 - Main connector
25 - Injection pump
26 - MPROP (magnetic proportional valve)
27 - Fuel intake
28 - Starter
29 - Oil filter
30 - Control cartridge
31 - Drain plug
32 - Boost relief valve
33 - Oil pressure sensor
34 - Engine ECU
34
Cooling
Air
Diesel
Electricity
Lubrication
EGR
12
10
11
9
13
17
14
15
16
18
8
22
19
23
7
20
28
21
24
26
27
6
5
25
4
2
29
30
31
10-03-M218EN
32
1
33
(18/02/2015)
ENGINE COMPONENTS LOCATION
3
ENGINE COMPONENTS (75 HP)
Key:
1 - Cooling water inlet
2 - Alternator belt
3 - Crankshaft sensor
4 - Oil pressure switch
5 - Camshaft sensor
6 - Water pump
7 - Alternator
8 - EGR Valve
9 - Air supply to turbo
10 - EGR cooler
11 - Non-return valves
12 - Crankcase breather
13 - Oil filler plug
14 - Intake manifold pressure sensor
15 - Fuel rail
16 - Fuel rail pressure sensor
17 - Intake air temperature sensor
10
18 - Water temperature sensor
19 - Thermostat
20 - Cooling water outlet
21 - Fuel return
22 - Oil cooler
23 - Main connector
24 - Injection pump
25 - MPROP (magnetic proportional valve)
26 - Fuel intake
27 - Starter
28 - Oil filter
29 - Control cartridge
30 - Drain plug
31 - Boost relief valve
32 - Oil pressure sensor
33 - Engine ECU
33
Cooling
Air
Diesel
Electricity
Lubrication
EGR
11
10
9
8
12
14
16
13
7
15 17
21
18
6
22
19
20
23
5
25
26
2
24
27
3
4
28
29
1
30
(18/02/2015)
32
31
10-03-M218EN
4
ENGINE COMPONENTS LOCATION
10
WATER AND AIR COOLING SYSTEM (100 and 120 HP)
Key:
1 - To water pump
2 - Boost pressure line
3 - Thermostat outlet
4 - Degassing line
5 - Bleeder (Behind high
pressure pump)
6 - Air filter
12 - Air cooler
7 - Clogging sensor
13 - Intake
8 - Air filter temperature sensor
9 - Turbo air intake
10 - Turbo air outlet
11 - Turbo air temperature sensor
2
4
3
5
1
11
12
9
13
7
8
10
6
10-03-M218EN
(18/02/2015)
ENGINE COMPONENTS LOCATION
5
WATER AND AIR COOLING SYSTEM (75 HP)
Key:
1 - To water pump
2 - Boost pressure line
3 - Thermostat outlet
4 - Degassing line
5 - Bleeder (Behind high
pressure pump)
2
10
6 - Air filter
7 - Clogging sensor
8 - Air filter temperature sensor
9 - Turbo air intake
10 - Intake
4
3
5
1
9
8
10
7
6
(18/02/2015)
10-03-M218EN
ENGINE COMPONENTS LOCATION
6
10
HYDRAULIC VENTILATION SYSTEM (100 and 120 HP )
Key:
1 - Oil supply
2 - Oil return
3 - Ventilation pump
4 - Fan motor
5 - Motor supply
6 - Drain
7 - Motor outlet
8 - Cooler
9 - Hydraulic oil temperature sensor
10 - Hydraulic oil compartment
11 - Transmission oil compartment
e 20 - Location
90°
9
MT
7
10
11
4
8
6
2
1
2
6
7
6
90°
4
6
4
7
1
5
3
2
1
6
9
10
11
8
MLT
2
7
1
6
4
5
3
10-03-M218EN
(18/02/2015)
ENGINE COMPONENTS LOCATION
7
HYDRAULIC VENTILATION SYSTEM (75 HP)
Key:
1 - Oil supply
2 - Oil return
3 - Ventilation pump
4 - Fan motor
5 - Motor supply
6 - Drain
10
7 - Motor outlet
8 - Cooler
9 - Hydraulic oil temperature sensor
10 - Hydraulic oil compartment
11 - Transmission oil compartment
e 20 - Location
90°
2
6
9
2
10
11
8
7
6
4
1
5
3
(18/02/2015)
10-03-M218EN
8
ENGINE COMPONENTS LOCATION
10
DIESEL FUEL CIRCUIT
Key:
1 - Fuel supply
2 - Fuel return
3 - Fuel gauge
4 - Fuel valve
5 - Pre-filter
6 - Water in diesel sensor
7 - Diesel pump
8 - Filter
9 - Pressure sensor
10 - Pressure test port (in place of the sensor)
1
2
3
9
7
5
8
4
6
10-03-M218EN
(18/02/2015)
10
ENGINE COMPONENTS LOCATION
9
FUEL INJECTION CIRCUIT
Key:
1 - Low pressure fuel supply
2 - High pressure pump
3 - MPROP (magnetic proportional valve)
4 - FCU (Fuel Control Unit) return
5 - High pressure fuel rail
6 - High pressure fuel line pressure sensor
10
7 - Pressure Relief Valve (PRV)
8 - PRV return
9 - Injector electrical connector
10 - High pressure fuel supply
11 - Injector return
Red circuit = 350 - 1800 bar
Green circuit = low pressure return
11
10
9
6
8
5
7
2
4
3
1
(18/02/2015)
10-03-M218EN
10
ENGINE COMPONENTS LOCATION
10
EGR (Exhaust Gas Recirculation) CIRCUIT
Key:
1 - Partial exhaust gas flow (not cooled)
2 - EGR valve, controller (electrical action)
3 - Cooling liquid return
4 - Exhaust gas return radiator (EGR)
5 - EGR radiator coolant supply line
6 - Partial exhaust gas flow (cooled)
7 - Intake
8 - Exhaust manifold
9 - Turbo attachment
10 - One-way valves
7
6
3
10
4
5
8
2
10-03-M218EN
1
9
(18/02/2015)
10
ENGINE CONTROL AND ADJUSTMENT
pages
PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
COMPONENT REMOVAL / REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– A – MOVABLE ENGINE COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– B – RADIATOR AND FAN MOTOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– C – RADIATOR AND FAN MOTOR REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– D – FAN HYDRAULIC MOTOR REMOVAL / REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
–– E – RADIATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
–– G – NEW ENGINE OIL DIPSTICK FITTING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 6
–– H – FIXED ENGINE COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
–– I – EXHAUST REMOVAL / REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
–– J – AIR-CONDITIONING BELT REMOVAL (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
–– K – AIR-CONDITIONING BELT REFIT (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
–– L – DRIVE BELT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
–– M – AIR-CONDITIONING COMPRESSOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
–– N – STARTER MOTOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
–– O – ALTERNATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
–– P – WATER PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
–– Q – TURBO REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
–– R – ENGINE SHOCK ABSORBER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
FAN DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
–– A – FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
–– B – PRINCIPLE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
–– C – SCHEMATIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
–– D – DESCRIPTION OF HYDRAULIC MOTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
–– E – CONDITIONS OF FAN CONTROL-RELATED COMPONENTS . . . . . . . . . . . . . . . . . . . . . 14
(10/11/2016)
10-04-M218EN
2
ENGINE CONTROL AND ADJUSTMENT
10
PREPARATION AND SAFETY INSTRUCTIONS
bb
Operate the battery cut-off no less than 30 seconds after turning off the ignition with the ignition
key.
Stabilise the machine on level ground.
Position the boom in the raised position and install the safety wedge.
COMPONENT REMOVAL / REFIT
A – MOVABLE ENGINE COVER REMOVAL
Unclip the strut from the cover (flat screwdriver) and support
the cover using a strap.
1
1
Undo the 4 screws of the 2 hinges (Item 1).
Remove the mobile cover.
B – RADIATOR AND FAN MOTOR REMOVAL
2
⇒⇒ Carry out the "MOVABLE ENGINE COVER REMOVAL"
operation e A
3
1
Drain the water and oil radiators.
Remove the water and air hoses (Fig. A (Item 1) and (Item 2)) .
Remove the expansion tank (2 nuts, 1 connector) and its support
bracket (3 screws).
Unscrew the bottom 2 silent blocks.
Unscrew the tie and the bracket (Fig. A (Item 3)).
Fig.A
6
1
7
Unscrew the oil hoses (Fig. B (Item 1) to (Item 4)).
Remove the turbo air supply pipe (Fig. B (Item 5)).
Disconnect the 3 sensors (Fig. B (Item 6) and (Item 7)).
2
3
4
Fig.B
10-04-M218EN
5
(10/11/2016)
ENGINE CONTROL AND ADJUSTMENT
3
Remove the fuse box support bracket.
Disconnect the cable harnesses (Fig. 1, (Item 1)) and the computer.
Remove the anti-recycling plate (Item 2).
Remove the cap (Item 3) and lift the radiator.
11
7
bb
10
Beware of the cable harness beneath the radiator.
C – RADIATOR AND FAN MOTOR REFIT
2
8
9
Fig.1
⇒⇒ Carry out the "MOVABLE ENGINE COVER REMOVAL"
operation e A
9
When carrying out a replacement, retain:
- the upper right hand silent block (Fig. 1, (Item 4)) and the
two lower silent blocks (Fig. 1, (Item 9)).
- the 2 (75°C) hydraulic temperature senors (Item 5)
and the (90°C) gear box temperature sensor (Item 6),
(25 N.m ± 15%).
- the turbo air temperature sensor (21 N.m ± 15%).
- the drain plug (Item 8), the anti-recycling plate (Item 2), the
cap (Item 3), the grommet (Item 11) and the cage nut (Item
10) on the top of the radiator.
bb
3
6
5
Fig.2
Attach the 3 silent blocs (Fig. 1, (Item 4) and (Item 9)), the tie (Fig.
1, (Item 7)) and the drain plug (Fig. 1, (Item 8)) to the radiator.
1
Attach the hydraulic hose to the radiator inlet (Fig. 3 (Item 1)).
2
Pass a sling through the hole at the cap (grommet) location
(Fig. 1 (Item 3)), refit the cap after installation.
Lower the radiator, being careful to avoid the turbo and
the computer,
Place the radiator and screw the silent blocks (Fig. 1 (Item 4)
and (Item 7)).
bb
Connect the hoses (Fig. 4, (Item 1) and (Item 2)) and the connectors
(Fig. 4, (Item 3) and (Item 4)) to the fan motor.
Fig.3
T
Gear
box
2
Attach the motor fuse box, pass the 2 sensor cables underneath.
Refit the cable harness grommet to the anti-recycling plate
(Fig. 1, (Item 1)).
Connect the sensors to the harness.
Refit the hydraulic hoses.
3
Refit the tie and the bracket.
1
T
4
Fig.4
(10/11/2016)
10-04-M218EN
10
1
4
3
ENGINE CONTROL AND ADJUSTMENT
4
3
10
1
4
2
Attach the engine water boost pressure line (Item 1) to the
holder under the expansion tank.
Connect hoses (Item 1 and Item 2).
Connect the water level sensor (Item 3).
Attach the expansion tank mounting flange (Item 4).
Fill the cooling water circuit with approx. 20 liters of water. Top
up the gear box oil and hydraulic oil levels.
Start-up and check the levels.
D – FAN HYDRAULIC MOTOR REMOVAL / REFIT
⇒⇒ Carry out the "MOVABLE ENGINE COVER REMOVAL"
operation e A
⇒⇒ Carry out the "RADIATOR AND FAN MOTOR REMOVAL"
operation e B
1
Lay the radiator flat, remove the grill, 4 screws.
Undo the nut securing the fan to the motor shaft.
2
2
10-04-M218EN
Detach the tapered fan motor shaft by hitting with a hammer
and a bronze drift punch (Item 1), taking care not to damage
the shaft. Recover the cotter and make sure to put it back in the
reinsert it in the fan slot,
Tightening of 45 N.m and 25 N.m couplings (10 mm hose).
When refitting: put back the washer and nut, tighten with torque
wrench to 40 N.m ±10%.
Be careful to place the grill in the correct direction so as to
use the appropriate hydraulic motor fastening holes (Item 2),
tightening torque 45N.m ±10%.
After refitting the fan motor on the grill, refit the fan grill, centering
the blades in the shroud.
(10/11/2016)
ENGINE CONTROL AND ADJUSTMENT
5
⇒⇒ Carry out the "MOVABLE ENGINE COVER REMOVAL"
operation e A
⇒⇒ Carry out the "RADIATOR AND FAN MOTOR REMOVAL"
operation e B
⇒⇒ Carry out the "FAN HYDRAULIC MOTOR REMOVAL /
REFIT" operated e D
Remove the shroud (Item 1) then detach the radiator by removing
the top and bottom plates (Item 2).
Change the faulty compartment.
2
2
2
1
2
(10/11/2016)
10-04-M218EN
10
E – RADIATOR REMOVAL
6
ENGINE CONTROL AND ADJUSTMENT
F – VENTILATION PUMP REMOVAL / REFIT
1
⇒⇒ Carry out the "ALTERNATOR REMOVAL" operation e L
10
2
Fastening screw (Item 1): 45 N.m ±20% with normal thread lock.
Wynns SG311 lubricant on pinion.
Hose couplings: 45 N.m (Item 2), 40 N.m (Item 3) ±10%.
3
G – NEW ENGINE OIL DIPSTICK FITTING
INSTRUCTIONS
1 - CUTTING THE NEW DIPSTICK
⇒⇒ Undo the 2 screws (Fig. 1, (Item 1)) and remove the
dipstick handle.
1
1
-5
50
18
⇒⇒ Cut the new dipstick guide (Fig. 1, (Item 2)) by 300mm,
as well as the dipstick (Fig. 1, (Item 3)).
2
3
Fig.1
2 - FITTING INSTRUCTIONS
⇒⇒ Mount the dipstick guide (Fig. 2, (Item 1)) in tight up
against the shoulder of the engine casing dipstick tube
(Fig 2, Item 2). Tighten the clamp (Fig. 2, (Item 3)) to 2 N.m.
1
3
2
⇒⇒ Fit the 2 guide retaining clamps (Fig. 3, (Item 1) and (Item
2)). Insert a washer in the small clamp (Fig. 3, (Item 2))
to avoid crushing the guide tube. Ensure that the guide
projects 40 mm as shown (Fig. 3, (Item 3)).
⇒⇒ Ensure that, when installed, the guide tube does not
interfere with the machine components.
Fig.2
40
3
2
⇒⇒ Insert the dipstick as far as it will go. Check that the
dipstick extends into the engine casing.
⇒⇒ Measure the excess length of dipstick and cut if required
to obtain the dimension of 18 mm (Fig. 1).
⇒⇒ Fit the handle on the dipstick, set the margin to 5 mm (Fig.
1) and tighten the 2 screws (Fig. 1, (Item 1)) to 2,5 N.m.
1
Fig.3
10-04-M218EN
(10/11/2016)
ENGINE CONTROL AND ADJUSTMENT
7
2
1
1
⇒⇒ Carry out the "MOVABLE ENGINE COVER REMOVAL"
operation e A
On the black protector, next to the boom, remove the 2 screws
(Item 1) and the 2 screws (Item 2).
2
Remove the 4 screws at the rear (Item 1).
2
Remove screw (Item 2) inside the housing (on the air filter holder).
I – EXHAUST REMOVAL / REFIT
1
⇒⇒ Carry out the "MOVABLE ENGINE COVER REMOVAL"
operation e A
⇒⇒ Carry out the "FIXED ENGINE COVER REMOVAL" operation
eH
2
2
1
bb
bb
Carefully mark the position of the exhaust relative to
the clamps and the compensator.
Undo the clamp on the pipe (Item 1), be sure to retain the seal.
Unscrew the 2 screws (Item 2) on the exhaust pipe clamp.
When, refitting, be careful not to place stress on
compensator, align the joints of the different items.
Tighten, the clamps to a torque of 12 N.m ±10%.
J – AIR-CONDITIONING BELT REMOVAL (option)
Remove the belt cover, 3 nuts (Item 1).
1
1
1
(10/11/2016)
10-04-M218EN
10
H – FIXED ENGINE COVER REMOVAL
8
ENGINE CONTROL AND ADJUSTMENT
2
Attach the special belt tool (Item 1) (e 10 - Specific engine
tooling) on the ribbed pulley (Item 2) and secure the tool with
the nut (Item 3).
4
Turn the pulley shaft (Item 4) to move the tool and lift the belt.
10
1
3
Pull the belt by hand to release it, continue turning and remove
the belt and the tool.
K – AIR-CONDITIONING BELT REFIT (option)
Attach the tool (Item 1) (e 10 - Specific engine tooling) on the
ribbed pulley (Item 2) and secure it with the nut (Item 3).
Place the belt on the pulley (Item 4) on the outside of the machine
and pass it just behind the nut (Item 3). Position it in the center
of the pulley (Item 2).
3
1
4
2
5
Turn the pulley (Item 5),install the belt and remove the tool.
Once the tool is removed, turn the pulleys a number of times
by hand to check that the new belt is properly positioned in
the grooves.
L – DRIVE BELT REMOVAL
2
1
⇒⇒ Carry out the "AIR-CONDITIONING BELT REMOVAL
(option)" operation e j
Move the tensioning roller upwards with the square drive of a
wrench (Item 1) and remove the belt (Item 2).
When changing the belt tensioner, put it back in the upper
right-hand position.
10-04-M218EN
(10/11/2016)
ENGINE CONTROL AND ADJUSTMENT
9
2
1
Drainig of the air-conditioning system must be carried
out in a ventilated space. Personal protection must be
worn: protective godggles and rubber gloves.
2
1
⇒⇒ Carry out the "AIR-CONDITIONING BELT REMOVAL
(option)" operation e j
1
Take off the rear grill, remove the 2 large screws on the right
(Item 1) and the two small screws on the left (Item 2).
2
2
bb
bb
Only operators who are certified to handle refrigerant
fluids may work on the air conditioning system, otherwise
please contact a specialist air-conditioning company.
Discharge the air-conditioning system (i air-conditioning
training course).
3
Disconnect connector X207 (Item 1).
Unscrew the 2 hoses (Item 2).
3
3
Undo the three screws (Item 3).
N – STARTER MOTOR REMOVAL
2
Take off the rear grill, remove the 2 large screws on the right
(Item 1) and the two small screws on the left (Item 2).
1
2
1
2
1
(10/11/2016)
Disconnect the X164 air inlet temperature sensor (Item 1),
Remove the hose from the air filter to the turbo (Item 2), unscrew
the 2 clamps, plug the engine ports.
10-04-M218EN
10
M – AIR-CONDITIONING COMPRESSOR REMOVAL
ENGINE CONTROL AND ADJUSTMENT
10
Unclip the pre-heating cable harness (Item 1) to gain access to
the starter.
1
Disconnect the connector on the starter motor (Item 2).
10
7
7
Unscrew the cable harnesses at the starter motor (Item 3): harness
to battery (Item 4), harness to alternator (Item 5), harness to
starter motor (Item 6).
7
2
Remove the 3 screws (Item 7), remove the starter motor via
the top.
6
3
4
5
O – ALTERNATOR REMOVAL
⇒⇒ Carry out the "DRIVE BELT REMOVAL" operation e L
1
Undo the two screws (Item 1).
Remove the alternator.
1
1
3
P – WATER PUMP REMOVAL
⇒⇒ Carry out the "DRIVE BELT REMOVAL" operation e L
2
10-04-M218EN
Disconnect the heating circuit outlet hose (Item 1) and the
return hose (Item 2).
Disconnect the engine water filling hose (Item 3).
(10/11/2016)
ENGINE CONTROL AND ADJUSTMENT
11
Q – TURBO REMOVAL
Loosen the turbo side air inlet hose clamp (Item 1), plug the
turbo inlet port.
3
Unscrew the 2 expansion tank mounting flange screws (Item 2).
Unscrew the boost hose clamp screw (Item 3).
1
3
Tilt the expansion tank forward
Remove the exhaust pipe elbow, unscrew the 2 clamps (Item 1
and Item 2), remove the seal (Item 3).
2
Tightening torque:
Item 1: 10 N.m ± 1 N.m
Item 2: 12 N.m ± 1 N.m
1
Loosen the turbo air output clamp (Item 1).
l 647461 (TCD 3.6 L4 ENGINE) - Turbocompressor
Removal - Refit
R – ENGINE SHOCK ABSORBER REMOVAL
1
Remove the transmission universal joint.
Unscrew the screws (Item 1, Item 2 and Item 3) in that order to
change the shock absorber components:
A - Damper
B - Seal
C - Ring
3
Tightening torque:
2
B
A
Screw no. 1: 35 N.m, 5/16-25
Screw no. 2 : 35 N.m with medium thread lock
Screw no. 3: 35 N.m with medium thread lock
C
1
(10/11/2016)
10-04-M218EN
10
2
12
ENGINE CONTROL AND ADJUSTMENT
FAN DRIVE
10
A – FUNCTION
The Fan Drive serves to adjust the speed of the engine cooling fan according to the various temperature
parameters.
The Fan Drive can temporarily reverse the direction of flow to unclog the engine cover air intake grills
(MLT version except MLT 732).
B – PRINCIPLE OF OPERATION
The Fan Drive is hydraulically driven by a motor and a fixed displacement pump, connected to the
engine's power take-off. The hydraulic flow therefore varies according to the engine speed, and thus
the maximum fan speed also. Control and reversal (MLT excepot MLT 732) are incorporated within the
hydraulic motor, as well as a relief valve and an anti-cavitation "freewheel" valve to ensure that the oil is
re-aspirated during engine shut-down, ensuring that the propeller rotation slows very gradually.
The control electrovalve serves to reduce the speed of rotation of the fan from its maximum speed.
The reversing electrovalve serves to change the fan's direction of rotation when it is powered by the
activation of the reversing switch and SPU control, performing an unblocking cycle.
In the event of a control system failure (sensors, continuity, electrovalves), the hydraulic drive is at
maximum power (coils not powered), this is the system's degraded mode.
FAN DRIVE REVERSAL for MLT versions (except MLT 732)
When it is activated in automatic mode, a reversal cycle will be
implemented every three minutes. It can also be activated at
any time for a single cycle, but an interval of three minutes is still
necessary between two cycles. Reversing can be deactivated;
the fan will then always turn in the same direction.
Engine water temperature for reversal to be enabled:
min.: 40 °C
/
maxi.: 104 °C
Max reverse speed ≈ 2000 rpm
Total time of reverse cycle ≈ 9 s
Time at maximum reverse speed ≈ 3 s
C – SCHEMATIC DIAGRAM
Key:
1 - Air filter temperature sensor
9 - Gear change electrovalve
2 - Engine coolant temperature sensor
10 - Fan drive reversal electrovalve for MLT versions
3 - Crankshaft speed sensor
(except MLT 732)
4 - Engine controller (ECU)
11 - Cooler
5 - Machine computer - SPU
12 - Hydraulic oil temperature sensor
6 - Dashboard module
13 - Transmission oil temperature sensor
7 - Fan drive reversal switch for MLT versions (except 14 - Boost air temperature sensor
MLT 732)
8 - Fan motor
10-04-M218EN
(10/11/2016)
ENGINE CONTROL AND ADJUSTMENT
13
7
12
11
X186
X164
4
X56
5
MT/MLT
X57
75°C
X247
90°C
X246
13
X252
X175
8
CAN
10
X174
2
X254
MLT
6
X912
9
14
3
X68
10
5
RP
M
x
10
0
X915
0
00
X245
15
00
20
25
00
0 30
X121
The analog signal from the boost air temperature sensor (14) arrives at the dashboard (6) on the printed
circuit to correct the signal and send it to the display module, that returns it via the CAN messaging
system to the SPU.
D – DESCRIPTION OF HYDRAULIC MOTORS
Key:
15 - Hydraulic control motor (BRV)
19 - From pump (P)
16 - Reversible hydraulic motor (BRVI)
20 - Return to tank (T)
17 - Fan direction reversal electrovalve (Y42) (On-Off) 21 - Motor drain (D)
18 - Fan speed control electrovalve (Y43) (PROP = 22 - Valve drain (D1)
23 - Anti-shock and anti-cavitation ("freewheel") valve
Proportional) and integral relief valve
24 - Anti-cavitation ("freewheel") valve
MLT (except MLT 732)
MT + MLT732
18
15
20
18
16
20
21
21
19
17
22
19
BRV
19.1 cm3/tr
P
BRVI
16.85cm3/tr
Y43
T
(10/11/2016)
D
24
D
P
Y43
Y42
23
T
D1
10-04-M218EN
10
1
ENGINE CONTROL AND ADJUSTMENT
14
0
60
40
30
1
50
20
0
REGULATION
TeE 0
mca
pret
rdae
tut
rem
dpi
fféer
raetu
ncr
e
75
Air
air
ambiant
50
The maximum temperature of the boost air depends o the ambient
temperature determined by the air filter temperature sensor (see
diagram opposite).
The closer we approach to the maximum allowable limit, the more
we increase the ventilation.
(°C) 80
Boost
air
Air suralimenté
Control electrovalve supply current management:
1 - Analog sensors: boost water and air;
2 - On-Off sensors (ventilation at maximum): hydraulic and
transmission oils
25
35
50
(°C)
Control is achieved by limiting the pressure of the hydraulic circuit, thus limiting the maximum fan speed.
While the pressure in the circuit has not reached that of the control electrovalve, the relationship between
the engine speed and the fan speed remains constant (see graph on next page, Slope A).
The maximum fan speed is limited at high engine speed by the control electrovalve which also serves
as a relief valve.
Graph of the fan speed against engine speed and control current
Oil temperatures below threshold limits (Hydraulic oil temperature = 70 °C).
Fan speed (rpm)
10
E – CONDITIONS OF FAN CONTROL-RELATED COMPONENTS
Engine speed (rpm)
The numerical values shown on the above graph are indicative and may vary and/or be changed.
10-04-M218EN
(10/11/2016)
ENGINE CONTROL AND ADJUSTMENT
15
n (Tr/min)
n+150
n-150
20
70
bb
10
Variation of fan speed with oil temperature
n
100
T huile (°C)
The computer will chose the most unfavorable temperature value between the engine coolant,
transmission oil, hydraulic oil and engine boost air temperature.
VALUE OF FAN SPEED CONTROL PARAMETERS
Engine coolant
temperature (°C)
Difference in
temperature
between the max.
authorised value
and the boost air
temperature
(°C)
Hydraulic oil
temperature (°C)
Transmission oil
temperature (°C)
Engine inlet
pressure (Bar)
Fan speed
(rpm)
Control
current (mA)
108
0
T ≥ 75 (contact
maintained up to T < 60)
T ≥ 90 (contact
maintained up to T < 75)
220
2280
0
500
700
90
5
108
1570
80
900
10
1100
15
1200
30
70
800
50
FAN SPEED
105
100
MAX.
1300
14
400
1400
MIN
Sensor and electrovalve electrical data sheets: e 80 - ELECTRICAL CHARACTERISTICS AND SPECIFICATIONS
(10/11/2016)
10-04-M218EN
ENGINE CONTROL AND ADJUSTMENT
10
16
10-04-M218EN
(10/11/2016)
10
ENGINE REMOVAL
pages
PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– A – GRILL AND DRAINING HATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– B – AIR AND WATER HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– C – HEATING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– D – LOWER HOSES AND FILTER SUPPORT BRACKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– E – ELECTRICITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– F – VENTILATION PUMP AND EXHAUST HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
–– G – SILENT BLOCS AND UNIVERSAL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
–– H – LIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
–– I – STANDARD ENGINE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
(27/11/2014)
10-06-M218EN
2
ENGINE REMOVAL
10
PREPARATION AND SAFETY INSTRUCTIONS
Stabilise the machine on level ground.
Perform several maneuvers in forward gear and reverse gear (wheels straight) in order to free the steering
and tyres of any stresses.
Position the boom in the raised position and install the safety wedge.
bb
Operate the battery cut-off no less than 30 seconds after turning off the ignition with the
ignition key.
Operate the fuel valve.
Place a tray under the engine.
The following operations must be performed:
e 10 - ENGINE CONTROL AND ADJUSTMENT:
⇒⇒ Movable engine cover removal
⇒⇒ Fixed engine cover removal
⇒⇒ Exhaust removal
⇒⇒ Air-conditioning belt and belt casing (option) removal
ENGINE REMOVAL
A – GRILL AND DRAINING HATCH
Take off the rear grill, remove the 2 large screws on the right
(Item 1) and the two small screws on the left (Item 2).
Remove the engine water draining hatch (center panel under
the housing), 2 screws.
Remove the plug and attach the drain hose.
2
1
2
1
B – AIR AND WATER HOSES
2
1
4
3
Disconnect the X164 air inlet temperature sensor (Item 1),
Remove the hose from the air filter to the turbo (Item 2), unscrew
the 2 clamps, plug the engine ports.
Remove the engine water outlet hose (Item 3), undo the 2
clamps and the support clamp (Item 4), plug the engine ports.
5
Unclip the degassing line, remove the cooled air hose from the
engine radiator (Item 5), undo the clamps, plug the engine ports.
Unscrew the upper 2 radiator silent blocks and keep it shifted
towards the front.
10-06-M218EN
(27/11/2014)
ENGINE REMOVAL
C – HEATING CIRCUIT
2
10
Disconnect the lower hose (Item 1).
Disconnect the upper hose (Item 2).
Disconnect the engine water filling hose (Item 3).
3
1
Near to the boom, remove the strut, 2 screws.
D – LOWER HOSES AND FILTER SUPPORT
BRACKETS
4
2
Disconnect the engine water return hose, loosen the clamp
and support clamp.
Disconnect the turbo air outlet hose, loosen the clamp.
On the diesel filter support bracket, disconnect the engine supply
hose, plug the opening on the filter, remove the 2 screws and
tilt the diesel filter support bracket backwards (Item 1).
On the air filter support bracket, loosen the engine oil gauge
dipstick clamp (Item 2).
Disconnect the water presence connector X178 (Item 3) and
clogging connector X166A and X166B (Item 4).
1
3
Remove the 3 screws (Item 1), hold the bracket in the backward
position with a sling.
Disconnect the engine connector X277.
1
Disconnect the diesel return.
1
1
E – ELECTRICITY
1
Disconnect the pre-heating cable harness (Item 1) X167.
(27/11/2014)
3
10-06-M218EN
4
ENGINE REMOVAL
Next to the starter, disconnect the starter relay connector X281
and the starter battery positive connector (Item 1).
10
Place the exhaust support half clamps towards the left to leave
a clear passage to the flywheel.
1
Remove the harness support plate (Item 3), 3 screws: ground
(Item 1), harness attachment (Item 2).
3
2
2
1
On the alternator, disconnect the excitation X59 and the starter
power supply.
F – VENTILATION PUMP AND EXHAUST HOSES
On the ventilation pump, disconnect the pump supply hose
and ventilation motor supply hose.
Remove the turbo outlet exhaust bend
G – SILENT BLOCS AND UNIVERSAL JOINT
Unscrew the 4 screws of the silent blocks (Item 1).
Unscrew the 4 screws of the universal joint by blocking motor
rotation
1
H – LIFTING
Install the M12 lifting ring close to,the flywheel (Item 1).
1
10-06-M218EN
(27/11/2014)
ENGINE REMOVAL
5
The suspension device must be adjustable to suit the engine
center of gravity.
10
Sling the engine.
Take out the engine.
I – STANDARD ENGINE REPLACEMENT
When replacing the engine:
1 - Remove the engine control unit in front of the cooler;
2 - The screws of the removed support brackets;
3 - Retain the following items from the removed engine, together
with their screws (e "Engine control and adjustment" for
tightening torques):
70 N.m ± 10%
+ Loctite 243
35 N.m ± 10%
H, 5/16-25
70 N.m ± 10%
+ Loctite 243
180 N.m ± 10%
+ Loctite 243
(27/11/2014)
10-06-M218EN
ENGINE REMOVAL
10
6
10-06-M218EN
(27/11/2014)
10
ENGINE REFIT
pages
PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ENGINE REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
POST REFIT ENGINE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
(06/09/2016)
10-07-M218EN
2
ENGINE REFIT
10
PREPARATION AND SAFETY INSTRUCTIONS
bb
Operate the battery cut-off no less than 30 seconds after turning off the ignition with the
ignition key.
Specific tooling: Jib crane (minimum 400 kg)
ENGINE REFIT
Position the engine.
Carry out the steps for removing the engine in the reverse order and observe the following instructions:
–– Set the height of the cylinder block screws as shown opposite, with a tightening torque of 110 N.m
±10%;
–– Refit the universal joint with new self-locking screws and a tightening torque of 79 N.m ±5%
POST REFIT ENGINE INSPECTION
–– Fill the hydraulic oil, gear box and coolant liquid tanks.
–– Operate the battery cut-off.
–– Put the key in the ignition and warm up the vehicle, top up the levels.
–– Test the engine for correct operation.
70 N.m ±10%
110 N.m ± 11 N.m
10-07-M218EN
(06/09/2016)
10
ENGINE TROUBLESHOOTING
pages
FAULT TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– ERROR INDICATOR LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
IGNITION SWITCHING TEST: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
START-UP CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
LACK OF POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INJECTION CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FAN DRIVE CHECK POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ENGINE ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
(11/10/2013)
10-08-M218EN
2
ENGINE TROUBLESHOOTING
FAULT TABLE
10
Fault
The engine
starts with
difficulty or
not at all
Cause
Measures
Fuel tank empty
Fill the fuel tank
Faulty electric fuel supply pump
Check
Clogged fuel intake line
Check
Temperature below startup temperature limit
Check
Cold start installation
Check/Replace
Incorrect engine oil SAE viscosity
Change lubrication oil
The fuel quality does not comply with the operating instructions
Change fuel
Battery is faulty or not charged
Check the battery
Wiring to starter loose or oxidised
Check the cables
Faulty starter motor or pinion will not mesh
Check the starter motor
Clogged air filter/ Faulty exhaust gas turbo-compressor
Check/Replace
Air in the fuel supply system
"Bleed fuel supply system"
Low compression pressure
Check compression pressure
Engine exhaust gas back-pressure too high
Check
Leaking injection line
Check the injection line
The engine will
not start and
the diagnostic
lamp is
flashing
The engine's electronic system prevents startup
Check the fault according to the error code,
eliminate the fault, if applicable
The engine
starts but runs
erratically or
stops
Engine exhaust gas back-pressure too high
Check
Low compression pressure
Check compression pressure
Cold start installation
Check/Replace
Air in the fuel supply system
Bleed
Fuel pre-filter clogged
Clean
The fuel quality does not comply with the operating instructions
Change fuel
Defective injector
Replace
Leaking injection line
Check the injection line
Gear changes
are possible
and the
diagnostic
indicator light
comes on
The engine electronic management system has detected a system error and
activated a replacement gear
Check the fault according to the error code,
eliminate the fault, if applicable
The engine is
too hot. The
temperature
warning
system is
tripped
Coolant bled pipe to expansion tank blocked
Clean
Incorrect engine oil SAE viscosity
Change lubrication oil
Faulty engine radiator
Check/Replace
Engine oil filter clogged on air or oil side
Replace
Engine oil level too high
Check oil level, empty if necessary
Oil level too low
Fill lubricating oil
Defective injector
Replace
Heat exchanger coolant dirty
Clean
Faulty coolant pump (V-belt broken or slack)
Check whether the belt is broken or has come off
Cooling liquid fault
Fill
Resistance in the cooling system is too high/Flow rate too low
Check the cooling system
Charging air line not air-tight
Check the air line
Charge air radiator clogged
Check/Clean
Clogged air filter/ Faulty exhaust gas turbo-compressor
Check/Replace
10-08-M218EN
(11/10/2013)
ENGINE TROUBLESHOOTING
Fault
Cause
Measures
Faulty air filter switch/Indicator lamp
Check/Replace
Faulty fan / torn or slack v-belt
Check the fan/the v-belt/replace if required
Engine exhaust gas back-pressure too high
Check
The engine
lacks power
Engine oil level too high
Check oil level, empty if necessary
Fuel suction temperature too high
Check the system
The fuel quality does not comply with the operating instructions
Change fuel
Clogged air filter/ Faulty exhaust gas turbo-compressor
Check/Replace
Faulty air filter switch/Indicator lamp
Check/Replace
Faulty fan / torn or slack v-belt
Check the fan/the v-belt/replace if required
Charging air line not air-tight
Check the air line
Charge air radiator clogged
Clean
Resistance in the cooling system is too high/Flow rate too low
Check the cooling system
Leaking injection line
Check the injection line
Defective injector
Replace
Leaking injection line
Check the injection line
Defective injector
Replace
Charging air line not air-tight
Check the air line
10
The engine is
too hot. The
temperature
warning
system is
tripped
"Not all engine
cylinders are
working"
Engine oil level too high
Check oil level, empty if necessary
No or too low
engine oil
pressure
Oil level too low
Fill lubricating oil
Engine angle too steep
Check engine position/Reduce inclination
Incorrect engine oil SAE viscosity
Change lubrication oil
Excessive
engine oil
consumption
Engine oil level too high
Check oil level, empty if necessary
Engine angle too steep
Check engine position/Reduce inclination
Drain crankshaft sump
Check/Replace
Oil i the
Engine used with insufficient load (< 20-30%) for a long period
exhaust system
Check the load factor
Engine
emitting blue
smoke
Engine oil level too high
Check oil level, empty if necessary
Engine angle too steep
Check engine position/Reduce inclination
Engine
emitting white
smoke
Temperature below startup temperature limit
Check
Cold start installation
Check/Replace
The fuel quality does not comply with the operating instructions
Change fuel
Defective injector
Replace
Clogged air filter/ Faulty exhaust gas turbo-compressor
Check/Replace
Faulty air filter switch/Indicator lamp
Check/Replace
Charging air line not air-tight
Check the air line
Defective injector
Replace
Engine exhaust
is black
Comment: Once all the faults have been repaired, the fault indicator will go off. For certain faults, it is
necessary to switch off the ignition and wait 30 s before switching it on again. In the event of a sensor
failure, the corresponding monitoring functions will be deactivated. Only the sensor failure is recorded
in the fault memory.
According to the configuration of the monitoring functions, the engine's electronic control system can
protect the engine in certain well-defined critical circumstances by ensuring that certain important limits
are not exceeded during operation and the correct operation of the system components. Depending
on the severity of a detected fault, the engine may continue running with restrictions, while the fault
indicator lamp remains on or flashes to indicate a severe system fault. In this event, the engine should
be switched off as soon as the interruption no longer presents any danger.
(11/10/2013)
3
10-08-M218EN
4
ENGINE TROUBLESHOOTING
Error indicator lamp
10
The error indicator lamp is installed at the driver's position. The fault light can issue the following signals:
Operating control
– Ignition working, fault indicator lamp comes on for approx. 2 seconds then goes off.
– No reaction when ignition switched on, check the fault indicator lamp.
The indicator lamp does not come on
– After testing the indicator lamps, an indicator lamp that is not lit indicates no faults and no anomalies
within the limits of the test.
Indicator lamp permanently lit
System error.
– Limited operation.
– When the indicator lamp is permanently lit, a monitored reading (e.g. coolant temperature, lubricating
oil pressure) is no longer within the acceptable range.
According to the type of error, the engine power may be reduced by the electronic controller to protect
the engine.
IGNITION SWITCHING TEST:
Preheating lamp, engine fault lamp and the special "engine stop" lamp come on.
START-UP CONDITIONS
If the engine fails to start, this could be due to:
–– The FNR switch being in the neutral position;
–– The ECU power supply.
–– The fuel pump. If the pressure is below 3,2 b, the engine will be prevented from starting. Disconnect
the sensor to make the system detect high default pressure. If the engine starts, check the fuel pump
and the fuel supply system;
–– Missing or incorrect engine speed sensor response. The engine injection system starts as soon as
sensor synchronization is confirmed, otherwise it has difficulty starting with only one sensor;
–– Insufficient fuel rail pressure at start-up;
–– The fuel supply pressure with the engine running is less than 4 b.
LACK OF POWER
If the engine lacks power, check:
–– The error codes;
–– That the fuel pump flow rate is OK. If pressure is low (P<=3,4 b) the engine indicator lamp will light;
–– That the fuel supply system is not obstructed or leaking;
–– That the circuits are not overheating.
10-08-M218EN
(11/10/2013)
ENGINE TROUBLESHOOTING
5
bb
Warning: the injector number in the error codes is equal to the firing order but different than
the cylinder number
FAN DRIVE CHECK POINTS
there are two main cases:
1 - The fan runs continuously at maximum speed: this may be due to an electrical system control fault
(degraded mode) or a sticking electrovalve;
2 - The fan does not reach the desired speed: this may be caused by a lack of hydraulic power (motor
or pump) or a sticking electrovalve.
The following tests will help direct the repairs:
Test conditions
Check to be performed
Correct value
Probable cause of failure
Test 0 : Preliminary
Engine cold
Take engine water, air filter (+17°C) and
boost air temperature sensor readings
with a diagnostic tool.
Start-up cold engine, water,
air, oil temperature sensor
readings < 40°C
Place a tachometer in from of the fan.
Ambient temperature
Change the sensors, otherwise check
harness continuity.
Test 1: Validation of non degraded mode function.
Fan speed
< 1000 rpm at all engine speeds.
Degraded mode: Check continuity of
harness, sensors, electrovalves.
Perform test 2.
Test 2: Validation of hydraulic and transmission oil control + validation of hydraulic circuit power.
Cold engine at max. rpm
Place a tachometer in from of the fan.
1- Shunt connector X246 then X247.
2- Disconnect X252
Fan speed
> 2000 rpm for each of the 3
connectors.
Check harness continuity between oil
temperature sensors and SPU terminal
X57-20.
For X252 : o Hydraulic control
Test 3: Validation of engine water control.
Hot engine (T>80 °C
opening of thermostat),
allow the engine to warm
up at min rpm.
Place a tachometer in from of the fan.
Accelerate to max. rpm
Fan speed
> 1200 rpm
Parameter readings:
1) 75 °C < water temperature < 85 °C
2) X252 driving current
Check continuity of harness and sensors.
Pressures in the system:
⇒⇒ Fan at max. speed, engine at max. rpm, oil cold:
200 b and 2300 rpm fan;
⇒⇒ Reversal cycle:
10 b minimum and approx. 110 b maximum during the blowing phase.
ENGINE ERROR CODES
o 80 - ELECTRICAL TROUBLESHOOTING
(11/10/2013)
10-08-M218EN
10
INJECTION CODE
ENGINE TROUBLESHOOTING
10
6
10-08-M218EN
(11/10/2013)
10
SPECIFIC ENGINE TOOLING
pages
FAN BELT FITTING TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ELECTRONIC TENSION METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ADDITIONAL ENGINE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
(21/11/2013)
10-09-M218EN
2
SPECIFIC ENGINE TOOLING
FAN BELT FITTING TOOL
10
Tool for facilitating elastic belt installation (Ref. 894113).
ELECTRONIC TENSION METER
Electronic tension meter (Ref 895692) for controlling belt tension.
ADDITIONAL ENGINE TOOLS
l 647461EN (TCD/TD6 3.6 L4 ENGINE) - SPECIFIC TOOLING
10-09-M218EN
(21/11/2013)
TRANSMISSION
20
- TRANSMISSION SCHEMATIC DIAGRAMS
- TRANSMISSION COMPONENTS LOCATION
- TRANSMISSION CONTROL AND
ADJUSTMENT
- TRANSMISSION REMOVAL
- TRANSMISSION TROUBLESHOOTING
- SPECIFIC TRANSMISSION TOOLING
- COMPONENT CONTROL AND ADJUSTMENT
- CHARACTERISTICS AND SPECIFICATIONS
- COMPONENT CONTROL AND ADJUSTMENT
- COMPONENT DIAGRAMS AND CROSS
SECTIONS
- TROUBLESHOOTING
- SPECIFIC TOOLING
l647058EN
(ANGLE GEAR BOX
15930-15932)
l647020EN
(COMPACT + MANUAL
GEAR BOX)
l6470ENEN
(POWERSHIFT PG 115
GEAR BOX)
20
TRANSMISSION SCHEMATIC DIAGRAMS
pages
TRANSMISSION DRIVE CHAIN / MANUAL GEAR RATIOS (COMPACT+) . . . . . . . . . . . . . . . . 2
TRANSMISSION DRIVE CHAIN / GEAR RATIOS (PG 115) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MANUAL TRANSMISSION OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
POWERSHIFT TRANSMISSION OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
(07/07/2016)
20-02-M218EN
2
TRANSMISSION SCHEMATIC DIAGRAMS
TRANSMISSION DRIVE CHAIN / MANUAL GEAR RATIOS (Compact+)
Front drive axle
Rear axle
Engine
20
Clockwise
Shuttle
Gearbox
Right angle
drive
Torque
converter
Transfer box
Forward gear
Gearbox
Z1
24 teeth
Z2
27 teeth
Z3
24 teeth
Z4
27 teeth
Z5
35 teeth
Z6
29 teeth
Z7
18 teeth
Z8
13 teeth
Z9
19 teeth
Z10
28 teeth
Z11
37 teeth
Z12
43 teeth
Z13
37 teeth
Z14
37 teeth
Right angle drive
Z20
23 teeth
Z21
23 teeth
Front and rear axles
Z22
11 teeth
Z23
35 teeth
Z24
70 teeth
Z25
14 teeth
Z26
27 teeth
Front drive axle
Rear axle
Gearbox
Gear box ratios
Transfer gear box
Converter
Right angle drive
20-02-M218EN
Gear ratio
final drive:
hub reduction:
Axle overall:
Shuttle ratio:
I
II
Forward gear
III
IV
I
II
Reverse gear
III
IV
Rear axle drive ratio
Torque
multiplication:
TCD3.6 engine
Ratio:
Z22/Z23 1/3,1818
Z25/(Z24+Z25) 1/6
1/19,09
Z2/Z4 1/1
(Z1*Z8)/(Z5*Z12) 1/4,824
(Z1*Z7)/(Z5*Z11) 1/2,998
(Z1*Z6)/(Z5*Z10) 1/1,408
(Z1*Z5)/(Z5*Z9) 1/0,792
(Z3*Z8)/(Z5*Z12) 1/4,8 24
(Z3*Z7)/(Z5*Z11) 1/2,998
(Z3*Z6)/(Z5*Z10) 1/1,408
(Z3*Z5)/(Z5*Z9) 1/0,792
Z13/Z14 1/1
1.991 to 1960 rpm
Z21/Z20 1/1
(07/07/2016)
TRANSMISSION SCHEMATIC DIAGRAMS
3
TRANSMISSION DRIVE CHAIN / GEAR RATIOS (PG 115)
Front drive axle
Rear axle
Engine
Clockwise
20
Shuttle
Gearbox
Right angle
drive
Torque
converter
Transfer gear
box
Forward gear
Gearbox
Z1
32 teeth
Z2
42 teeth
Z3
24 teeth
Z4
42 teeth
Z5
Z6
Z7
Z8
Z9
Z10
Z11
Z12
Z13
Z14
24 teeth
44 teeth
38 teeth
32 teeth
46 teeth
19 teeth
26 teeth
37 teeth
38 teeth
25 teeth
Z15
48 teeth
Z16
Z17
Z18
37 teeth
45 teeth
19 teeth
Right angle drive
Z20
23 teeth
Z21
23 teeth
Front and rear
axles
Z22
11 teeth
Z23
35 teeth
Z24
70 teeth
Z25
14 teeth
Z26
27 teeth
Front drive axle
Rear axle
final drive:
hub reduction:
Axle overall:
Shuttle ratio:
I
II
III
IV
V
VI
I
II
III
Forward gear
Gearbox
Gear box ratios
Reverse gear
Transfer gear
box
Converter
Right angle drive
(07/07/2016)
Gear ratio
Torque
multiplication:
Z22/Z23 1/3,1818
Z25/(Z24+Z25) 1/6
1/19,09
Z2/Z4 1/1
(Z3*Z10)/(Z9*Z15) 1/4,842
(Z1*Z10)/(Z7*Z15) 1/3,000
(Z3*Z8)/(Z9*Z13) 1/2,276
(Z1*Z8)/(Z7*Z13) 1/1,410
(Z5*Z6)/(Z9*Z11) 1/1,133 (1/1 : MLT 7)
(Z1*Z6)/(Z7*Z11) 1/0,702
(Z5*Z10)/(Z9*Z15) 1/4,842
(Z5*Z8)/(Z9*Z13) 1/2,276
(Z5*Z6)/(Z9*Z11) 1/1,33
Rear axle drive ratio
Z13/Z14 1/1
TCD3.6 engine
1.991 to 1960 rpm
Ratio:
Z21/Z20 1/1
20-02-M218EN
4
TRANSMISSION SCHEMATIC DIAGRAMS
MANUAL TRANSMISSION OPERATION OVERVIEW
X71
20
X01
X58
CAN
X03
X36
X20
X12
3
5
21
3
5
2
1
4
1
1
2
8
1
6
20A
F15
D
F30
25A
86
85
2
2
30
15A
C
15A
F23 F24 F25 F26 F27 F28 F29
5A
1
30
4
F14
5A
15A
F13
F22
B
10A
F12
10A
10A
F11
15A
F10
30A
85
X98
F9
1
F
1
F21
10A
A
K9
F8
15A
F20
5
E
86
7.5A
F19
F7
7.5A
F18
F6
7.5A
10A
F5
7.5A
F4
7.5A
F17
F3
I
H
8
86
86
30
85
87a
85
30
87
F16
F2
G
K4
1
K6
87a
87a
F1
7
3
5
4
1
2
3
5
K3
87
87a
87
K8
4
4
3
5
K2
87
K5
3
5
K7
2
1
4
1
K1
K0
1
X16
X17
X10
X09
X08
BV
M
Key:
: Direction of circulation of data (Input or Output)
BV : Gear box
M: Engine
X01: Transmission cut-off on gear lever
X03 : Seat sensor information
X08: Transmission fluid thermostat
X09: Forward electrovalve
X10: Reverse electrovalve
X12: Hand brake switch
X16: Rear right headlight
X17: Rear left headlight
X20: Reversing sound alarm
X36: JSM
X58: LLMI Safety module
X71: Transmission cut-off on brake pedal
X98: Transmission oil pressure switch
20-02-M218EN
(07/07/2016)
TRANSMISSION SCHEMATIC DIAGRAMS
Connectors
Driver presence
Forward/
reverse selector
authorization
Forward/reverse selector
Gear selection
Forward gear
Neutral
Reverse gear
X01
√
20
X03
√
X08
X09
√
X10
√
X12
√
X16
√
X17
√
X20
√
X36
√
X58
√
√
√
√
X71
√
X98
When changing the direction of travel, the lift truck should be
traveling at slow speed and not accelerating.
Comments
(07/07/2016)
5
Authorises
hydraulic
movements
and truck travel
movements.
Authorised if
driver presence
confirmed.
If the operator leaves the driving cab with forward or reverse
engaged, a continuous alarm will sound (X58). While this
alarm sounds, the operator can simply sit back in the seat and
continue advancing or reversing.
If the alarm becomes discontinuous (X58), the operator
must sit back in the seat, put the forward/reverse selector
in neutral (X36) and select forward or reverse if he wishes to
continue moving.
In order to
change gear, it is
necessary to cut
the transmission
by pressing the
button on the
lever or the neutral
of the forward/
reverse selector
or the brake pedal
(transmission cutoff mode).
20-02-M218EN
6
TRANSMISSION SCHEMATIC DIAGRAMS
POWERSHIFT TRANSMISSION OPERATION OVERVIEW
X71
X58
20
X36
X78
CAN
X03
X20
X16
X17
X12
X123
ECU
PS
X128
X194 X195 X196
X193
X197
X98
X198
X08
BV
X199
M
Key:
: Direction of circulation of data (Input or Output)
BV : Gear box
M: Engine
X03 : Seat sensor information
X08: Transmission fluid thermostat
X12: Hand brake switch
X16: Rear right headlight
X17: Rear left headlight
X20: Reversing sound alarm
X36: JSM
X58: LLMI Safety module
X71: Transmission cut-off on brake pedal
X78: Gear selection
X98: Transmission oil pressure switch
X123: Gear display
X128: 6th gear switch
X193: Speed sensor
20-02-M218EN
X194: Slow forward electrovalve
X195: Fast forward electrovalve
X196: Reverse electrovalve
X197: 1st gear electrovalve
X198 : 2nd gear electrovalve
X199 : 3rd gear electrovalve
(07/07/2016)
TRANSMISSION SCHEMATIC DIAGRAMS
Connectors
X03
Driver presence
Forward/
reverse selector
authorization
7
Forward/reverse selector
Gear selection
Forward gear
Neutral
Reverse gear
√
X08
X12
X16
√
X17
√
X20
√
X36
√
X58
√
20
√
√
√
X71
√
X78
√
√
X123
√
√
X128
√
X193
√
X194
√
X195
√
X98
X196
√
√
X197
√
√
X198
√
√
X199
√
√
When changing the direction of travel, the lift truck should be
traveling at slow speed and not accelerating.
Comments
(07/07/2016)
Authorises
hydraulic
movements
and truck travel
movements.
Authorised if
driver presence
confirmed.
If the operator leaves the driving cab with forward or reverse
engaged, a continuous alarm will sound (X58). While this
alarm sounds, the operator can simply sit back in the seat and
continue advancing or reversing.
If the alarm becomes discontinuous (X58), the operator
must sit back in the seat, put the forward/reverse selector
in neutral (X36) and select forward or reverse if he wishes to
continue moving.
In order to
change gear, it is
necessary to cut
the transmission
by pressing
neutral of the
forward/reverse
selector or the
brake pedal
(transmission cutoff mode).
20-02-M218EN
TRANSMISSION SCHEMATIC DIAGRAMS
20
8
20-02-M218EN
(07/07/2016)
20
TRANSMISSION COMPONENTS LOCATION
pages
MECHANICAL TRANSMISSION AND GEAR BOX COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
(26/06/2013)
20-03-M218EN
2
TRANSMISSION COMPONENTS LOCATION
20
MECHANICAL TRANSMISSION AND GEAR BOX COOLING
Key:
1 - Front drive axle
2 - Rear axle
3 - Drive axle universal joints
4 - Gear box C+
5 - Angle gear box
6 - Engine universal joint
7 - Cooler
8 - Temperature sensor
9 - Gearbox oil compartment
10 - Gear-box outlet hose
11 - Gear box inlet hose
12 - Gear box control unit (MLT PS)
1
12
ECU
8
PS
4
5
10
9
7
6
2
20-03-M218EN
3
11
(26/06/2013)
20
TRANSMISSION CONTROL AND ADJUSTMENT
pages
TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– MECHANICAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– ANGLE GEAR BOX OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
POWERSHIFT (PG 115) GEAR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– SHAFT AND CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
–– GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
–– OPERATING LOGIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
–– TRANSMISSION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
–– PRESSURE TEST PORT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
–– TABLE OF PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
–– ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
(06/09/2016)
20-04-M218EN
2
TRANSMISSION CONTROL AND
ADJUSTMENT
TIGHTENING TORQUE
MECHANICAL TRANSMISSION
20
70 N.m ± 10%
170 N.m ± 10%
37 N.m ± 10%
30 N.m ± 10%
41 N.m ± 10%
60 N.m ± 10%
70 N.m ± 10%
70 N.m ± 10%
1
2
3
17 N.m ± 10%
37 N.m ± 10%
37 N.m ± 10%
79 N.m ± 5%
4
7
6
79 N.m ± 5%
5
When connecting the converter (Item 1) with the flange (Item 2) and the washer (Item 3) ensure that it
is correctly centered and check the mounting of the screws on the angle gear box.
bb
Initially tighten the universal joint in the order shown, (4,6,5.7). Finish tightening to the
recommmended torque to apply uniform pressure.
ANGLE GEAR BOX OUTPUT SHAFT
New installation to be applied:
110 N.m ± 10%
Fit the thick washer by means of the 12-sided screw using a standard 12mm/12-sided socket to tighten
the screw.
20-04-M218EN
(06/09/2016)
TRANSMISSION CONTROL AND
ADJUSTMENT
MLT 634 120 PS
MLT 735 120 PS
MLT 741 120 PS
3
POWERSHIFT (PG 115) GEAR BOX
COMPONENTS
Key:
1 - Dip stick
2 - Main L.P. = 15 bar
3 - Converter L.P. = 6 bar
4 - Filling hole
5 - Control electrovalve unit
6 - Speed sensor
7 - Hand brake mechanism
8 - Transmission filter
9 - Cold start valve = 26 bar
1
2
FL
LP
LP
6
R
15
3
5
13
20
10 - Pump suction strainer
11 - Converter
12 - Transmission pump
13 - Electrovalve - clutch No. 1
14 - Electrovalve - clutch No. 2
15 - Electrovalve - clutch No. 3
FH
14
4
12
7
11
9
8
10
(06/09/2016)
20-04-M218EN
4
TRANSMISSION CONTROL AND
ADJUSTMENT
MLT 634 120 PS
MLT 735 120 PS
MLT 741 120 PS
20
SHAFT AND CLUTCH
FH for ward high
speed clutch
FL forward low speed
clutch
Clutch No. 1
Lay-shaft
Front axle output
shaft
Clutch No. 3
Clutch No. 2
Rear axle output shaft
GEARS
FL forward low speed
clutch
FH forward high speed
clutch
T7
T9
T8
Clutch No. 1
Clutch, reversing
T6
Clutch No. 2
T10
T4
Clutch No. 3
20-04-M218EN
(06/09/2016)
TRANSMISSION CONTROL AND
ADJUSTMENT
MLT 634 120 PS
MLT 735 120 PS
MLT 741 120 PS
5
OPERATING LOGIC
FORWARD gear
REVERSE gear
Maximum speed Clutch
Maximum speed
Clutch
FL+1
5,8
R+1
5,8
FH+1
9,4
R+2
12,4
FL+2
12,4
R+3
24
FH+2
19,7
FL+3
24.5
FH+3
38,1
1st
2nd
3rd
4th
5th
6th
20
Gears
TRANSMISSION SYSTEM
R
R
24
24
42
FH
42
42
FL
FH
24
32
46
44 38
3
37
26
2
42
FL
24
32
46
44 38
1
19
32
48
28
3
37
2
26
25
Forward
(06/09/2016)
1st gear
1
19
32
48
28
25
2nd gear
20-04-M218EN
6
TRANSMISSION CONTROL AND
ADJUSTMENT
MLT 634 120 PS
MLT 735 120 PS
MLT 741 120 PS
R
R
24
24
42
20
FH
42
42
FL
FH
24
32
46
44 38
3
37
2
26
42
FL
24
32
46
44 38
1
19
32
48
28
3
37
2
26
19
32
48
28
25
Forward
25
3rd gear
4th gear
R
R
24
24
42
FH
42
42
FL
FH
24
32
46
44 38
3
37
26
2
42
FL
24
32
46
44 38
1
19
32
48
28
3
37
2
26
25
Forward
20-04-M218EN
1
5th gear
1
19
32
48
28
25
6th gear
(06/09/2016)
TRANSMISSION CONTROL AND
ADJUSTMENT
MLT 634 120 PS
MLT 735 120 PS
MLT 741 120 PS
7
PRESSURE TEST PORT LOCATIONS
Key:
T1 - Converter pressure
T2 - Not used
T3 - Pump pressure
T4 - 3rd gear clutch pressure
T5 - Lubrication pressure
T6 - 1st gear clutch pressure
T5
(06/09/2016)
T7
20
T7 - Forward low speed FL pressure
T8 - Reverse gear clutch pressure
T9 - Forward high speed FH pressure
T10 - 2nd gear clutch pressure
T11 - Not used
T9
T11
T10
T4
T2
T1
T3
T8
T6
20-04-M218EN
8
TRANSMISSION CONTROL AND
ADJUSTMENT
MLT 634 120 PS
MLT 735 120 PS
MLT 741 120 PS
TABLE OF PRESSURES
Clutch 1
Clutch 2
Clutch 3
(T6)
(T10)
(T4)
0
14,75
0
0
14,25
0
14,75
0
0
14,25
0
0
0
15,75
0
4 Gear
0
14,25
0
0
15,75
0
5 Gear
14,25
0
0
0
0
15,75
6 Gear
0
14,25
0
0
0
15,75
REVERSE
FL forward low
speed clutch
(T7)
FH forward high
speed clutch
(T9)
Reverse clutch
(T8)
Clutch 1
Clutch 2
Clutch 3
(T6)
(T10)
(T4)
1st Gear
0
0
14,25
14,75
0
0
2 Gear
0
0
14,25
0
15,75
0
3rd Gear
0
0
14,25
0
0
15,75
FORWARD GEAR
FL forward low
speed clutch
(T7)
FH forward high
speed clutch
(T9)
Reverse clutch
(T8)
1st Gear
14,25
0
2 Gear
0
3 Gear
nd
20
rd
th
th
th
nd
Pump
(T3)
Converter (T1)
Lubrication
(T5)
15 to 18
5 to 8
0.75 to 1.25
ECU
The E.C.U. (Electronic Control Unit) is a transmission management controller.
It controls various gearbox functions:
–– Gear changes
–– Electrovalve wiring harness diagnostics
–– Input diagnostics
The E.C.U. power flow is as follows:
–– Data from
the shuttle lever
the hand brake/transmission cut-out
the speed sensor
Electrovalve power
supply
Output to
dashboard display
20-04-M218EN
(06/09/2016)
20
TRANSMISSION REMOVAL
pages
PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GEAR BOX REMOVAL (COMPACT +) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
(08/07/2016)
20-06-M218EN
2
TRANSMISSION REMOVAL
PREPARATION AND SAFETY INSTRUCTIONS
Stabilise the machine on level ground.
20
Position the boom in the raised position and install the safety wedge.
bb
Operate the battery cut-off no less than 30 seconds after turning off the ignition with the
ignition key.
Specific tooling:
–– Jib crane (min. 250 kg);
–– Hoists;
–– Wheeled container or pallet truck.
–– 2 x M12 lifting rings
GEAR BOX REMOVAL (COMPACT +)
Remove the plate, 4 screws (Item 1).
1
Place a 12 ℓ container under the gear box.
Drain the gear box (Item 1).
1
20-06-M218EN
(08/07/2016)
TRANSMISSION REMOVAL
3
Disconnect the front universal joint from the front drive axle
(Item 1), 4 self-locking screws to be replaced for reassembly.
20
1
Disconnect the rear universal joint from the rear box (Item 1),
4 self-locking screws to be replaced for reassembly.
Sling on the right hand side.
1
Remove the converter cover plate and undo the 6 attachment
screws (Item 1) by turning the universal joint with a wrench.
o 20 - SPECIFIC TRANSMISSION TOOLING
1
Unscrew the gear lever screws (Item 1).
1
(08/07/2016)
20-06-M218EN
4
TRANSMISSION REMOVAL
Loosen the adjustment screw (Item 1), remove the pin (Item 2)
and the spring (Item 3).
1
Change the spring if the loop is too twisted.
20
3
Remove the parking brake cable and clear it to the upper left
hand side.
2
Unscrew plug the cooling hose (M30x2,00).
Unscrew plug the cooling hose (M30x2,00).
Unscrew the 6 lower screws from the gear box to angle gear
box coupling housing (Item 1).
1
20-06-M218EN
(08/07/2016)
TRANSMISSION REMOVAL
5
Unscrew the 2 screws from the support bracket (Item 1).
20
1
1
Unscrew the 2 screws from the accumulator support (Item 1).
1
1
Unscrew the bolt from the priority valve support (Item 1), hold
it in the left.
1
Unscrew the clamp bracket to the right of the angle gear box
(Item 1).
1
(08/07/2016)
20-06-M218EN
6
TRANSMISSION REMOVAL
Undo the screw of the clamp on top of the gear box (Item 1).
20
1
Unscrew the 5 upper screws from the gear box to angle gear
box coupling housing (Item 1).
Leave the last connecting screw in place (Item 2).
Disconnect the electrovalves and the sensors X80 and X86.
1
2
Remove the two plugs on the M12 tapped holes (Item 1).
1
Place the two M12 rings.
Install a suitable lifting device (min. 250 kg), place it in tension.
Unscrew the bolt of the left-hand silent block (Item 1), change
the lock nut, then the four bracket screws (Item 2).
1
1
2
20-06-M218EN
(08/07/2016)
TRANSMISSION REMOVAL
7
Unscrew the bolt of the right-hand silent block (Item 1), change
the lock nut, then the four bracket screws (Item 2).
1
20
2
Unscrew the last screw from the gear box to angle gear box
coupling housing (Item 1).
Place a wheeled container or a pallet truck under the gear
box. Lower it, being careful of the harnesses, hoses or cables.
Move the gear box forward, being careful to ensure that the
converter comes away with the gear box, and taking care of
the electrovalve and sensor connections.
Lay the gear box in the container and pass it under the front axle.
1
Place the gear box on a suitable support and fit the new gear box.
3
4
3
Tighten the brake with the stop screw, unscrew the 8 screws
from the universal joint (Item 1).
Unscrew the 2 screws of the parking brake cable support (Item 2).
Undo the two couplings (Item 3).
1
2
Unscrew the screw of the gear lever return spring support (Item 4).
Remove the converter, tilting it to avoid loosing too much oil
(Item 1).
Clean the belt thoroughly to avoid diagnosing an oil leak.
2
If replacing the converter, fill it again before installation.
When refitting, fill the gear box with oil.
1
(08/07/2016)
20-06-M218EN
TRANSMISSION REMOVAL
20
8
20-06-M218EN
(08/07/2016)
20
TRANSMISSION TROUBLESHOOTING
pages
POWERSHIFT PG 115 6-SPEED TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– E.C.U. CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– OUTPUT CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– INPUT CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– START-UP DIAGNOSTICS/ERROR VERIFICATION FLOW CHART . . . . . . . . . . . . . . . . . . . . . 4
(08/07/2016)
20-08-M218EN
2
MLT 634 120 LSU PS
MLT 735 120 LSU PS
MLT 741 120 LSU PS
TRANSMISSION TROUBLESHOOTING
POWERSHIFT PG 115 6-SPEED TRANSMISSION
DESCRIPTION
20
Gear display
Gear selector
JSM
E.C.U. CONTROL
As soon as the ignition is switched on the ECU checks the output wiring (ECU to solenoid valves) and
input wiring (from shuttle control to ECU) in order to detect short circuits or breakages in the wiring loom.
The ECU first checks the output wiring and only checks the input wiring if the output wiring passes
testing.
ECU output wiring harness
When the ignition is switched on, if no problems are detected in the wiring looms the display shows
the number ‘‘8’’, and then the letter ‘‘n’’ corresponding to the neutral position on the shuttle control.
In the event of an output fault, the display shows the number :
- 6, 1, 8 ;
- or 6, 0, 2 ;
- or 6, 0, 1, 6, 8 ;
- then ‘‘E’’ (error) for 2 seconds before reverting to ‘‘n’’ .
It is possible to identify the defective harness by holding down the ‘‘-’’ button on the JSM gear selector,
then switching the ignition off, then on again. The display will then show the letter ‘‘E’’ followed by a
number indicating which harness is faulty.
20-08-M218EN
(08/07/2016)
MLT 634 120 LSU PS
MLT 735 120 LSU PS
MLT 741 120 LSU PS
TRANSMISSION TROUBLESHOOTING
3
OUTPUT CONTROL
Example:
Error codes:
ECU program fault (ROM)
20
then:
Low speed forward solenoid valve fault FL
High speed forward solenoid valve fault FH
Reverse gear solenoid valve fault
ECU memory fault (RAM)
No 1 solenoid valve fault
Fault on crawler solenoid valve
No 2 solenoid valve fault
No 3 solenoid valve fault
INPUT CONTROL
Procedure:
While holding the ‘‘-’’ button down on the JSM gear selector, switch the ignition back on.
Input diagnostic codes:
Transmission cut-off pin
Parking brake pin
Shuttle control reverse gear pin
Driver presence pin
Shuttle control forward gear pin
6th gear lock-out pin
Gear change up pin
Shuttle control neutral pin
5th gear locking switch
(08/07/2016)
20-08-M218EN
4
MLT 634 120 LSU PS
MLT 735 120 LSU PS
MLT 741 120 LSU PS
TRANSMISSION TROUBLESHOOTING
S TA R T- U P D I AG N O S T I C S / E R R O R
VERIFICATION FLOW CHART
Power up
Shiftdown
pressed?
Yes
Display version
number
No
20
Illuminate all
elements on
Display
Check ROM
Check RAM
ROM or RAM
error?
No
Check outputs,
Turning each on
for 90 ms and
checking not SC
or OC
Output error?
Display input state
Yes
Wait forever
Displaying 'E' and
repective Error:
'n' for nonvolatile(ROM),
'F' for RAM Failure
Yes
Alternate
displaying 'E' and
respective error:
'L,H,R,1,2,3'
No
Yes
Yes
Shiftdown
pressed?
Shiftdown
pressed?
No
No
Normal operation.
Display will not be
updated for 2secs
The software makes it possible to change from 5th to 6th at 19,5 kph:
MLT6 = Coef. 1340 Hz.
MLT 7 = Coef. 1520 Hz.
The software makes it possible to change down from 6th to 5th at 18,3 kph:
MLT6 = Coef. 1246 Hz.
MLT 7 = Coef. 1414 Hz.
20-08-M218EN
(08/07/2016)
20
SPECIFIC TRANSMISSION TOOLING
pages
BASIC MANOMETER SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DIGITAL MANOMETER SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GEAR BOX REMOVAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
(12/11/2014)
20-09-M218EN
2
SPECIFIC TRANSMISSION TOOLING
BASIC MANOMETER SET
20
This box contains all the components required for measuring
pressure on all Manitou products.
6
2
3
3
1
5
4
5
8
7
Basis gauge kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .549671
Consisting of:
1 2 3 4 5 6 7 8 -
1 gauge 1/9 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549882
1 gauge 0/40 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549883
2 gauge 0/60 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549884
1 gauge 0/400 bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549885
2 gauge 0/600 bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549886
4 standard hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549887
2 hoses for telehandler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549888
7 gauge tap connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549889
20-09-M218EN
(12/11/2014)
SPECIFIC TRANSMISSION TOOLING
3
DIGITAL MANOMETER SET
FUNCTIONS:
⇒ The upstream pressure temperature at +/- 2°C
⇒ The upstream temperature P1 with its mini and maxi (700 bar
in class 0.1)
⇒ Downstream pressure P2 with its min. and max. (700 bar
in class 0.1)
⇒ Differential pressure ΔP=P1-P
• Hold function: The user can freeze the screen display at any
time to take notes
• Unit function: The user can change the unit of measurement
at any time (bar, psi, kPa, mCe).
• Function Tare: Enables offset to zero
• Leak test function: Can measure a pressure variation over a
specified time
• Record function: A maximum of 16000 readings can be recorded.
The sampling period can be configured.
• Reset function: The 2 sensors are reset to zero
Digital Manometer kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .662187
Consisting of:
1 2 3 4 -
1 digital gauge ΔP HP 700 bar
1 measurement hose DN2 1215/1620, L = 1,5m, 630 bar
2 measurement hoses DN2 1620/1620, L = 1,5m, 630 bar
2 gauge adaptors 1620
(12/11/2014)
20-09-M218EN
20
• Gauge function: the display allows the following combinations:
4
SPECIFIC TRANSMISSION TOOLING
GEAR BOX REMOVAL TOOLS
20
PART NO.
DESIGNATION
479307
Hand press
479309
Input shaft and reverse lay shaft bearing puller
563390
4WD shaft bearing puller
563391
Output shaft front bearing puller
563392
Lay shaft and output shaft rear bearing puller
563394
Lay shaft front bearing puller
563393
Press for compressing the input shaft spring
563395
Feeler gauge set adapter
479307
Bearing puller
600743
Piston seal calibration ring
563390
Bearing puller for the font and rear bearings of the 4WD shaft and reverse lay shaft and input shaft front bearings
563392
Bearing puller for the front and rear bearings of the counter-shaft, the output shaft and the Crawler shaft
600744
Input shaft rear bearing puller
563394
Output and crawler shaft front bearing puller
600745
Press for compressing the clutch kit spring. (Adaptable to all shafts except the output shaft
600746
Press for compressing the clutch kit spring. (Adaptable to all shafts)
600747
Feeler gauge set adapter kit
600748
Feeler gauge set adapter
20-09-M218EN
(12/11/2014)
AXLE
- COMPONENT CONTROL AND ADJUSTMENT
- TROUBLESHOOTING
- SPECIFIC TOOLING
l 547983EN
(AXLE 212)
30
- AXLE CONTROL AND ADJUSTMENT
30
AXLE CONTROL AND ADJUSTMENT
pages
TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
(26/06/2013)
30-04-M218EN
2
AXLE CONTROL AND ADJUSTMENT
TIGHTENING TORQUE
AXLE
340 N.m ± 10%
30
340 N.m ± 10%
630 N.m ± 15%
630 N.m ± 15%
30-04-M218EN
(26/06/2013)
BRAKE
- BRAKE CHARACTERISTICS AND
SPECIFICATIONS
- BRAKE SCHEMATIC DIAGRAMS
- BRAKE COMPONENTS LOCATION
e 70 - HYDRAULICS
- BRAKE CONTROL AND ADJUSTMENT
40
- BRAKE REMOVAL
- BRAKE CONTROL AND ADJUSTMENT
- BRAKE TROUBLESHOOTING
- SPECIFIC BRAKE TOOLING
l 547983EN
(AXLE 212)
BRAKE CHARACTERISTICS AND SPECIFICATIONS
pages
40
SERVICE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
(19/02/2015)
40-01-M218EN
BRAKE CHARACTERISTICS AND
SPECIFICATIONS
2
SERVICE BRAKE
MLT (except MLT 732)
MT + MLT 732
Brake fluid L.H.M S8 214 B SHELL V=0,75 L
Brake fluid L.H.M S8 214 B SHELL V=0,75 L
Oil re
turn
Oil su
pply
Master cylinder ø31,75 mm
Displacement: 31.4 cm3
Master cylinder ø28,57 mm
Displacement: 20.2 cm3
193
24
5
61
40
58
Braking ratio:
193 / 58 = 3.327
Towards rear drive axle
(same as front drive axle)
Planetary reducer
R = 1/6
Oil bath disc brake:
Number of discs per wheel
4
Braking area per disc face
146.85 cm2
Total braking surface (front axle only)
2350 cm2
Total truck braking surface
4699 cm2
Recommended operating pressure
70 to 80 bar
Friction material
Dynamic friction coefficient
0,115
Static friction coefficient
0,095
Brand
DANA
Disc diameter
201,5 mm
Disc thickness
4,75 - 4,85 mm
Action radius
88 mm
Number of slave cylinders
1
Slave cylinder surface area
41.88 cm2
Wear compensation
Track width
40-01-M218EN
WELLMAN N°266
Auto
26,75 mm
(19/02/2015)
BRAKE CHARACTERISTICS AND
SPECIFICATIONS
PARKING BRAKE
3
Disc brake:
Number of discs per wheel
1
Braking area per disc face
30.8 cm2
Total braking area
61.6 cm2
Friction material
asbestos-free (CARLISLE
CORP.)
Dynamic friction coefficient
0,2
Static friction coefficient
0,4
Static application:
* Maximum permissible force at brake linkage (Fmax)
1,890 N
* Average friction radius (Ravg)
81 mm
(19/02/2015)
2,143 Nm
TURNER POWERTRAIN
Disc diameter
203.8 mm
Disc thickness
9.5 mm
Wear adjustment
mechanical
40-01-M218EN
40
* Max torque (Cmax= 0,014 x Fmax x Ravg)
Brand
BRAKE CHARACTERISTICS AND
SPECIFICATIONS
40
4
40-01-M218EN
(19/02/2015)
BRAKE COMPONENTS LOCATION
pages
(12/11/2013)
40
HYDRAULIC BRAKE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
40-03-M218EN
2
BRAKE COMPONENTS LOCATION
HYDRAULIC BRAKE
CIRCUIT
KEY
Item
BA
LS
Designation
Feed block + accumulator
Relief valve
MC
Master cylinder
PFQ
RLF
V1
VAFR
Brake fluid tank
Steering master cylinder
Trailer brake valve
Item
S
T
B
L
N
P
R
U
Designation
Trailer brake option
Tank
To braking system
V2
To steering column
Residual
Pressure
Brake fluid return
40
V
A
RLF
V1
V2
S
L
P
N
R
B
R
B
N
L
BA
MC
U
P
T
LS
P
VAFR
PFQ
40-03-M218EN
(12/11/2013)
BRAKE CONTROL AND ADJUSTMENT
SERVICE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ADJUSTING THE HEIGHT OF THE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
BLEEDING THE AXLE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
BLEEDING THE TRAILER BRAKING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CHECKING AND ADJUSTING THE PARKING BRAKE WITH THE LEVER . . . . . . . . . . . . . . . . . . . . . . 6
–– LIFT TRUCK WITH TRACTOR ROAD HOMOLOGATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
–– LIFT TRUCK WITHOUT TRACTOR ROAD HOMOLOGATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REMOVING THE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
–– REFITTING THE PARKING BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ADJUSTING THE PARKING BRAKE CALLIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
–– ADJUSTING THE CONNECTING ROD TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
–– ADJUST THE STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
–– ADJUST THE CABLE TENSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
(25/10/2017)
40-04-M218FR
40
pages
2
BRAKE CONTROL AND ADJUSTMENT
SERVICE BRAKE
ADJUSTING THE HEIGHT OF THE PEDAL
1 - BRAKE PEDAL
⇒⇒ Set the height of the brake pedal (Item A) 140 mm above the cab floor (without floor mats) by
means of the stop (Item B).
⇒⇒ Tighten the locknut (Item E).
⇒⇒ Adjust the pedal free play (Item A) (3 to 4 mm), by turning the push rod (Item C).
⇒⇒ Tighten the locknut (Item D).
40
2 - TRANSMISSION CUT-OFF SWITCH
⇒⇒ Pedal in its rest position (against stop Item B).
⇒⇒ Adjust the position of the switch (Item F) so that transmission cut-off activates when the pedal
is 125 mm from the cab floor (see diagram below).
B
C
D
A
40-04-M218FR
125 mm
140 mm
F
pedal free play
3 to 4 mm
garde de pédale
(0.11811 to
3 à 4 mm
0.15748 in)
E
(25/10/2017)
BRAKE CONTROL AND ADJUSTMENT
3
BLEEDING THE AXLE CIRCUIT
REQUIRED TOOLS: 1 brake bleeder (pressure 1 to 1,2 bar)
–– Raise the boom.
–– Remove the front cover plate (Item 1).
–– Remove the lower left hand dashboard casing (Item 2).
2
To the rear of the brake pedal, position the clevis on the hole
(Item L) at the end of the shaft, in the "Long" brake circuit bleeding
position.
L
–– Remove the brake fluid tank plug and fit the brake bleeder
adapter (Item 3).
3
–– Operate the bleeder.
(25/10/2017)
40-04-M218FR
40
1
4
BRAKE CONTROL AND ADJUSTMENT
–– Place a transparent hose on the left hand bleed screw (Item 5)
of the rear drive axle.
4
5
–– Loosen the bleed screw, then re-tighten it once the brake fluid
is flowing without air bubbles.
–– Repeat the operation on the right hand bleed screw (Item 6)
of the rear drive axle.
As a general rule, when bleeding the brake circuit start with the
most distant bleed screw and work towards the nearest.
40
–– Repeat also on the trailer bleed screw (Item 6). First remove
the boom rear cover plate and disconnect connector X18.
6
7
–– Repeat also on the right hand bleed screw (Item 7) of the front
drive axle, on the left hand bleed screw of the front drive axle
and bleed the master cylinder if necessary.
–– Top up the brake fluid tank level.
Oil to be used: e "CHARACTERISTICS" chapter in "00 GENERAL".
C
40-04-M218FR
When bleeding is complete fit the clevis (Item C) in the "short"
normal working position.
(25/10/2017)
BRAKE CONTROL AND ADJUSTMENT
5
BLEEDING THE TRAILER BRAKING CIRCUIT
REQUIRED TOOLS: 1 brake bleeder (pressure 1 to 1,2 bar)
y "40 - Specific tooling".
1 - Raise the boom.
2 - Remove the transmission cover plate (Item 1).
3 - Remove the lower left-hand dashboard cover (Item 2).
2
3
4 - Remove the brake fluid tank plug and fit the brake bleeder
adapter (Item 3).
5 - Place a transparent tube on the trailer brake valve bleed
screw (Item 4).
4
6 - Turn on the brake bleeder.
7 - Loosen the bleed screw, then re-tighten it once the brake
fluid is flowing without air bubbles.
8 - Top up the brake fluid tank level.
Fluid to be used: y "CHARACTERISTICS" in chapter "0 GENERAL".
(25/10/2017)
40-04-M218FR
40
1
6
BRAKE CONTROL AND ADJUSTMENT
PARKING BRAKE
CHECKING AND ADJUSTING THE PARKING BRAKE WITH THE LEVER
1
A
40
B
Lift truck with tractor road homologation
1 - Place the lift truck on level ground with the rated load in the transport position.
2 - Check braking by locking the parking brake (Item 1) in position A.
3 - Pull on the lift truck rear towing pin with a minimum force of 3,500 daN. The wheels of the lift truck
must not turn.
4 - Carry out adjustments if necessary:
- Progressively tighten the end of the lever (Item 1) and recheck braking.
- Repeat the operation until the correct braking adjustment is obtained.
Lift truck without tractor road homologation
1 - Place the lift truck on a slope of at least 15% with the rated load in the transport position.
2 - Check braking by locking the parking brake (Item 1) in position A.
⇒⇒ The adjustment is correct when the lift truck remains stationary on the slope.
3 - Carry out adjustments if necessary:
-D
epress the service brake pedal, unblock and release the parking brake (Item 1) in position B.
- Progressively tighten the end of the lever (Item 1) and recheck braking.
- Repeat the operation until the correct braking adjustment is obtained.
40-04-M218FR
(25/10/2017)
BRAKE CONTROL AND ADJUSTMENT
7
REMOVING THE PADS
4 - Place the lift truck on horizontal ground, with the parking brake off and in neutral.
5 - Chock the lift truck.
6 - Remove the parking brake cable (Item 1).
7 - Remove the upper calliper screw (Item 2).
8 - Swivel the calliper around the lower screw (Item 3).
1
2
9 - Compress the spring (Item 4) with two screwdrivers.
10 - Remove the pads (Item 5).
5
Refitting the parking brake pads
4
1 - Position the pads at the bottom of the housing.
2 - Check that the return spring is in position.
3 - Refit the pads by reversing the operations described in "REMOVING
THE PADS".
4 - Check and adjust the parking brake.
5
ADJUSTING THE PARKING BRAKE CALLIPER
1-1
Position truck on level, horizontal ground.
2
4
3
1
Key:
Cable stop (1)
Cable (2)
Connecting rod (3)
Spring (4)
Stop (5)
5
(25/10/2017)
40-04-M218FR
40
3
8
BRAKE CONTROL AND ADJUSTMENT
1-2
Adjusting the connecting rod travel
2
3
5 - Release handbrake
1
6 - Remove the handbrake cable (1) from the cable stop (2).
4
7 - Remove the pin and shaft (3) from the connecting rod (4).
1-3
8 - Remove the spring (1) from the support.
4
40
1
9 - Loosen the lock nut (2).
10 - Screw the stop (3) so that it is no longer in contact with the
connecting rod (4).
3
2
1-4
11 - Measure the distance between the connecting rod (1) and
the support (2).
2
1
1-5
12 - Put the brake pads in contact with the disc by pushing the
connecting rod by hand (1).
1
3
2
40-04-M218FR
13 - Once again measure the distance between the connecting
rod (2) and the support (3).
14 - The difference between the two measurements should be
12 mm ± 2 mm.
(25/10/2017)
BRAKE CONTROL AND ADJUSTMENT
9
1-6
15 - To reduce the difference between the two measurements:
A - Loosen the lock nut (1).
B - Tighten the nut (2) until 12 mm is obtained.
C - Tighten the lock nut (1) (60 N.m).
1
2
1-7
1 - Push the connecting rod (1) and bring the screw head (2) to
5 mm.
1
2
3
2 - Tighten the lock nut (3) (40 N.m).
1-8
Adjust the cable tension.
1 - Refit the shaft and pin (1).
1
2 - Reposition the spring (2).
2
1-9
1
3
6
2
3 - Tighten the nut (1) on the cable stop (2) to tension the cable (3).
4 - Loosen the connecting rod (4) slightly from the stop (5).
5 - Tighten the lock nut (6).
4
5
(25/10/2017)
40-04-M218FR
40
Adjust the stop
10
BRAKE CONTROL AND ADJUSTMENT
1 - 10
6 - Manoeuvre the handbrake several times.
7 - Check that the tension of the cable (1) is correct.
8 - Check that the connecting rod (2) is always slightly away from
the stop (3).
1
2
3
A
1 - 11
9 - Unscrew the end of the lever until the lever is locked in position A.
10 - Carry out the procedure "CHECKING AND ADJUSTING THE
PARKING BRAKE WITH THE LEVER".
40
B
40-04-M218FR
(25/10/2017)
BRAKE REMOVAL
pages
(08/11/2013)
40
MASTER CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
40-06-M218EN
2
BRAKE REMOVAL
MASTER CYLINDER REMOVAL
Unscrew the screw (Item 1), remove the casing.
Unscrew the hoses (Item 1), unscrew the 2 screws (Item 2),
remove the master cylinder.
1
1
1
1
40
1
2
2
40-06-M218EN
(08/11/2013)
BOOM
- BOOM CHARACTERISTICS AND
SPECIFICATIONS
- BOOM COMPONENTS LOCATION
- BOOM CONTROL AND ADJUSTMENT
50
- BOOM REMOVAL
BOOM CHARACTERISTICS AND SPECIFICATIONS
pages
DUPLEX BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
50
TRIPLEX BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
(01/02/2016)
50-01-M218EN
2
BOOM CHARACTERISTICS AND
SPECIFICATIONS
DUPLEX BOOM
Consisting of 2 elements:
- 1 fixed
- 1 moving
Boom weight:
50
- Weight of complete boom ≈ 1250 kg (6 meters), 1390 kg (7 meters).
TRIPLEX BOOM
Consisting of 3 elements:
- 1 fixed
- 2 moving
Boom weight:
- Weight of complete boom ≈ 1680 kg (9 meters), 1760 kg (10 meters).
50-01-M218EN
(01/02/2016)
BOOM COMPONENTS LOCATION
pages
LOCATION OF DUPLEX BOOM MAIN COMPONENTS (6 AND 7 M) . . . . . . . . . . . . . . . . . . . . . 2
50
LOCATION OF TRIPLEX BOOM MAIN COMPONENTS (9 AND 10 M) . . . . . . . . . . . . . . . . . . . 3
(01/02/2016)
50-03-M218EN
BOOM COMPONENTS LOCATION
2
LOCATION OF DUPLEX BOOM MAIN COMPONENTS (6 and 7 m)
Item
Designation
CSP
Counterbalance valve
T
Telescope (Boom head)
VI
Tilting cylinder
VT
Telescope cylinder
VT
T1
CSP
V1
Boom foot
50
V2
C
D
D
C
VI
B
A
B
CSP
A
C
A
D
B
50-03-M218EN
(01/02/2016)
BOOM COMPONENTS LOCATION
3
LOCATION OF TRIPLEX BOOM MAIN COMPONENTS (9 and 10 m)
Item
Designation
CSP
Counterbalance valve
CSPD
Double counterbalance valve
T1
Telescope 1
T2
Telescope 2 (Boom head)
VI
Tilting cylinder
VT1
Telescope cylinder 1
VT2
Telescope cylinder 2
1
3
2
V1
6
4
5
CSP
V2
V2
CSP
V1
Key to hoses
1 - Tilting V1
2 - Telescope V2
3 - Tilting V2
4 - Attachment 1
5 - Telescope V1
6 - Attachment 2
CSPD
50
V1
2
V2
5
2
2
5
6
1
4
3
6
5
4
1
3
1
6
2
5
6
1
4
3
4
5
3
2
VI
CSP
VT1
T2
CSPD
T1
VT2
CSP
(01/02/2016)
Boom foot
50-03-M218EN
BOOM COMPONENTS LOCATION
50
4
50-03-M218EN
(01/02/2016)
BOOM CONTROL AND ADJUSTMENT
pages
TIGHTENING TORQUES/GREASING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
TELESCOPE HEAD PAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
BOOM BASE PAD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
50
TELESCOPE CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REMOVING TELESCOPES T1+T2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TELESCOPE T2 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SHIM INSTALLATION AND GREASING AREA RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . 10
(13/12/2013)
50-04-M218EN
BOOM CONTROL AND ADJUSTMENT
2
TIGHTENING TORQUES/GREASING
Item
Designation
CSP
Counterbalance valve
T1
Telescope T1
VI
Tilting cylinder
VT
Telescope cylinder
- A.A -
Calage / Wedging
9 mini
Slide pad tightening torques
C1=15 N.m ±15%
C2=92 N.m ±15%
50
0 +0,5
- B.B -
Boom foot
A
T1
B
VI
CSP
A
VT
B
CSP
X
- Greasing inner boom
Grease the lower interior of the inner boom over length X (the area in which the inner cylinder slide pad
moves) using RETINAX HDM grease.
bb
Apply the correct slide pad tightening torques (see diagram). Apply "Loctite 243 Normal Thread
Lock" only to all fixings, studs/inserts and nuts/studs on the inside of the boom.
50-04-M218EN
(13/12/2013)
BOOM CONTROL AND ADJUSTMENT
3
TELESCOPE HEAD PAD REMOVAL
1
Locate the 4 plates and unscrew the 8 screws (10 mm wrench)
(Item 1).
Locate the shims.
Unscrew the 16 nuts: lock nut (17 mm wrench) and screw (6 mm
Allen key) (Item 2).
For the lower pads, raise the telescope,head in order to remove
them.
2
When reassembling, balance the shims.
BOOM BASE PAD REPLACEMENT
2
Remove the two side hose deflectors (Item 1).
Locate the shims.
Unscrew the 16 nuts: lock nut (17 mm wrench) and screw (6 mm
Allen key) (Item 2).
For the upper shims, extend the telescope approx. 300 mm, and
remove the telescope suspension option low boom position
sensor.
For the lower pads, lift the telescope head with a crowbar and
wedges.
TELESCOPE CYLINDER REMOVAL
Decompress all the hydraulic components (switch on the ignition
and operate the manipulator).
Extend the boom to expose the telescope cylinder head pin
(Item1).
Unclip the telescope cylinder head pin (Item 2), remove the
pin with a mallet.
Retract the cylinder.
1
Disconnect the hoses
Remove the boom rear casing, undo the 4 screws (Item 1), and
disconnect the light cable harness.
1
1
1
1
(13/12/2013)
50-04-M218EN
50
1
4
BOOM CONTROL AND ADJUSTMENT
Remove the rear left headlight support bracket (Item 1).
Unscrew the 6 boom base hoses (Item 2), and plug them.
2
1
50
1
Position the boom in such a way as to align the telescope cylinder
base pin with the opening (Item 1), remove the circlips from
both ends of the pin.
Remove the pin with a mallet.
Remove the cylinder.
50-04-M218EN
(13/12/2013)
BOOM CONTROL AND ADJUSTMENT
5
50
TRIPLEX BOOM COMPONENT REMOVAL
Key:
A - Telescope T1
B - Telescope T2
PREPARATION AND SAFETY INSTRUCTIONS
•
•
•
•
•
•
Stabilise the machine on level ground.
Fully retract the telescope.
If an attachment is mounted on the carriage, remove it.
Decompress all hydraulic elements.
Place the boom in the horizontal position with the carriage tilted fully upwards.
Deactivate battery power supply by means of the battery cut-off.
Specific tooling:
–– Floor crane or hoist + slings (1 000 kg min.).
–– Mallet.
–– Trestles.
(13/12/2013)
50-04-M218EN
6
BOOM CONTROL AND ADJUSTMENT
REMOVING TELESCOPES T1+T2
1
Remove the telescope cylinder circlip (Item 1)
50
Place a block between the telescope cylinder and the boom.
Remove the telescope cylinder pivot pin (Item 2).
2
Place a strap around the boom and pull out halfway (Item 3).
3
50-04-M218EN
(13/12/2013)
BOOM CONTROL AND ADJUSTMENT
7
Hold/Secure the boom (Item 4) at its center of gravity by
means of a strap (Item 5) and a lifting device (hoist) i "BOOM
CHARACTERISTICS AND SPECIFICATIONS".
5
4
Remove the U-clamp (Item 6) using a 13 mm wrench.
6
Dismantle then remove the six slide pads (Item 7).
7
7
7
50
7
7
8
(13/12/2013)
Fully remove the boom (Item 8).
50-04-M218EN
8
BOOM CONTROL AND ADJUSTMENT
10
11
Identify and unscrew the six hoses
- (x2) telescoping circuit (Item 9)
- (x2) tilting circuit (Item 10)
- (x2) attachments circuit (Item 11)
11
9
10
9
10
10
50
11
9
9
11
13
Set down the boom (Item 12) on trestles with the hoist + strap
(Item 13).
12
50-04-M218EN
(13/12/2013)
BOOM CONTROL AND ADJUSTMENT
9
TELESCOPE T2 REMOVAL
Perform i "TELESCOPES T1+T2 REMOVAL"
1
Remove the telescope cylinder circlip (Item 1)
2
50
Remove the telescope cylinder pivot pin (Item 2).
Place a strap around the boom and pull the boom head out
halfway (Item 3).
3
Hold/Secure the boom (Item 3) at its center by means of a strap
and a lifting device (hoist) i "BOOM CHARACTERISTICS AND
SPECIFICATIONS".
4
4
Dismantle then remove the six slide pads (Item 4).
4
4
4
4
Fully remove the boom head.
4
4
Set the boom head don on trestles.
(13/12/2013)
50-04-M218EN
10
BOOM CONTROL AND ADJUSTMENT
TRIPLEX BOOM COMPONENTS REFIT
bb
bb
Carry out the reverse procedure to that described above.
Follow the block assembly and greasing recommendations given below.
Apply "Loctite 243 normal thread lock" to all nut/screw interfaces situated only on the inside
of the boom.
SHIM INSTALLATION AND GREASING AREA RECOMMENDATIONS
1 - Grease the tube slip faces in the specified areas, the grease spread is 0,2 kg/m².
2 - Grease the slip face of each slide pad before installation.
50
3 - Install the slide pads in the following order: side pads, upper pads, lower pads.
4 - Finish adjusting the shimming system, at the upper part of the tubes by inserting slide pads while
complying with the operating clearances shown.
50-04-M218EN
(13/12/2013)
BOOM REMOVAL
pages
PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
50
BOOM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
(01/02/2016)
50-06-M218EN
BOOM REMOVAL
50
2
PREPARATION AND SAFETY INSTRUCTIONS
•
•
•
•
•
Stabilise the machine on level ground.
Fully retract the telescope.
If an attachment is mounted on the carriage, remove it.
Decompress all hydraulic elements.
Deactivate battery power supply by means of the battery cut-off (wait for 30 seconds after switching
off the ignition).
Weight of complete boom ≈ 1250 kg (6 meters), 1390 kg (7 meters), 1680 kg (9 meters), 1760 kg (10 meters).
Specific tooling:
–– Floor crane (minimum 2000 kg).
–– Hoists
–– Axle stand
–– Mallet
–– Slide hammer puller
50-06-M218EN
(01/02/2016)
BOOM REMOVAL
3
BOOM REMOVAL
Place a container under the vehicle beneath the boom foot
1
Raise the boom until the head pin of the lifting cylinder can
just be seen above the engine bonnet.
Sling the boom by the front ring (Item 1) using a suitable lifting
method.
Block the lifting cylinder, unscrew the lifting cylinder head pin
locking screw (17 mm wrench) (Item 1) and remove the pin with
a slide hammer puller (M12).
50
1
Unscrew the 6 boom foot hoses and plug them.
Block the compensating cylinder, unscrew the cylinder head
axle locking screw (17 mm wrench) (Item 1) and move the shaft
using a hub puller (M12).
1
Remove the boom rear casing, undo the 4 screws (Item 1), and
disconnect the light cable harness.
1
1
1
1
(01/02/2016)
50-06-M218EN
4
BOOM REMOVAL
Remove the angle sensor link rod (Circlips) (Item 1).
1
Disconnect the telescope retraction sensor (X134) (Item 2).
2
Remove the telescope suspension option telescope position
sensor (X226), unscrew the 2 screws (Item 1).
1
50
1
Unscrew the boom foot pivot pin locking screw (27 mm wrench)
(Item 1) and remove the pin. Recover the shim from the boom
foot.
1
Lift the boom and set it down on a suitable support.
When refitting, attach the 6 hoses to the boom in an orderly
fashion, they must not cross.
Check that they are not twisted before tightening.
Recalibrate the boom angle sensor and the strain gauge e 80
- "ELECTRICAL CONTROL AND ADJUSTMENT".
e 110 - "CRC OPTION: TELESCOPE SUSPENSION" to adjust the
telescope position sensor (X226).
50-06-M218EN
(01/02/2016)
HYDRAULICS
- HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS
- HYDRAULIC SCHEMATIC DIAGRAMS
- HYDRAULIC COMPONENTS LOCATION
- HYDRAULIC CONTROL AND ADJUSTMENT
- HYDRAULIC COMPONENTS REMOVAL
70
- HYDRAULIC SPECIFIC TOOLING
HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS
TECHNICAL DATA FOR HYDRAULIC COMPONENTS
pages
ACCUMULATOR BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
COUNTERBALANCE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SDM 140/4 DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SDM 140/2 DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DISTRIBUTOR SX 14 S (INLET ELEMENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DISTRIBUTOR SX 14 S (TILTING ELEMENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DISTRIBUTOR SX 14 S (CLOSING ELEMENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
DISTRIBUTOR SX 14 S (TELESCOPE - ATTACHMENT ELEMENTS) . . . . . . . . . . . . . . . . . . . . . . 25
POWER ASSISTED BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
CASAPPA MVP 60 PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
STEERING PUMP/STEERING UNIT OSPC 200 LS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
TILTING CUT-OFF VALVE (VCI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
FLOW DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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DISTRIBUTOR SX 14 S (LIFTING ELEMENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS
70
2
70-01-M218EN
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HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS
3
ACCUMULATOR BLOCK
Values for information purposes only.
1 - Role:
Provides a reserve of pressurized oil fir:
- Power assisted braking.
- Control valve control (depending on machine).
70
2 - Description:
P1/P2
WV
DM
T
DB
RV
SBO
U
: Pressure port
: Circuit selector
: Pressure reducer
: Tank return
: Pressure relief valve (45 bar)
: Non-return valve
: Membrane accumulator
: Service port
Notes : ____________________________________________________________________________________
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HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS
Values for information purposes only.
3 - Operation:
P1
U
Unit is supplied via P1.
P2 T
P1
U
Pressure reduced to 35 bar by pressure reducer, then
pressure stored in accumulator.
70
P2 T
P1
U
If the pressure reducer jams the pressure relief valve
opens (45 bar) to protect all components on exit U.
P2 T
4 - Fill in the table below:
P1
P2
10 b
270 b
50 b
0b
10 b
20 b
U
Commentary
Accumulator empty
45 b
35 b
Notes : ____________________________________________________________________________________
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HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS
5
COUNTERBALANCE VALVE
Values for information purposes only
Role:
– Insulates the cylinder in case of hose breakage.
V1
– Cylinder movement requires the starting of the I.C. engine.
– Limits max. pressure from impacts.
70
V2
1
C1
C2
3
2
1 - Temporization screws.
2 - By-pass valve.
4
V1
V2
3 - Slide with max. adjustment screw.
4 - One way valve.
Note:
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HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS
Values for information purposes only
C1
C2
V1
V2
C1
C2
V1
V2
70
Return control during cylinder descent.
When a position is secured, no component is able to exert sufficient pressure to open the valve.
Only a pressure peak due to an impact can open it.
C1
C2
V1
V2
When the cylinder is pushed, the supply (no-return valve to pass) and return are free.
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
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HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS
7
SDM 140/4 DISTRIBUTOR
Values for information purposes only.
Role:
- Limit maximum pressure.
- Direct the hydraulic flow to the receivers.
70
- Cut off hydraulic movements (VS).
- Limit shock pressure (Valve anti shock).
- Set the return flow in the neutral manipulator.
Notes : ____________________________________________________________________________________
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HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS
8
Values for information purposes only.
v
V4
V3
V2
T1
V1
PP
ET
EI
1. Tilt cut-off valve (VCI).
2. Boom descent valve (VRD).
3. Movement cut-off valve (VS).
4. Pressure limiter.
6
5
5. Anti-cavitation valve.
6. Anti-cavitation valve.
7. Valve slide
PP : Taking Pressure
6
5
1
P
T
2
3
MA
4
PP
A1 B1 V1
280 bar
3
V3 A2 B2
V A3 B3
A4 B4
A5 B5 T
200 bar
P
200 bar
70
EL
EA
D
280 bar
VS
4
260 bar
VCI
EE
EL
EI
V2
7
70-01-M218EN
2
T1
7
ET
EA
EA (O) EF
V4
1
7
7
7
(06/04/2017)
HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS
9
1 . Tilt cut-off valve (VCI) (12 V - 6 .8 Ω + freewheel diode on Pin 1)
200 bar
V3 A2 B2
280 bar
Permit or not the tilt function depending on
machine overload and machine software.
- When it is powered a 35 bar pressure is
applied to both sides of the spool, thereby
stopping any tilt movement.
- When unpowered, pressure can be applied
to one side or the other, thus allowing
movement.
VCI
EI
V4
2 . Boom flow control on descent valve (VRD) (12 V - 4 .7 Ω - 1 .5 A)
- Makes it possible to limit the descent speed
of the boom no matter what the load.
70
A1 B1 V1
280 bar
EL
V2 T1
3 . Safety valve (VS) (12 V - 6 .3 Ω + diode de roue libre sur Pin 1 et 2)
- The VS makes it possible to cut off all
hydraulic movements by directing the flow
divider pilot pressure to the tank.
P
VS
260 bar
EE
Notes : ____________________________________________________________________________________
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HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS
4 . Pressure limiter .
- The pressure relief valve makes it possible
to limit the internal pressure in the hydraulic
circuit, by diverting excess flow to the low
return.
P
VS
260 bar
EE
5 . Anti-cavitation valve .
A2 B2
V A3 B3
200 bar
200 bar
V3
70
280 bar
- The function of the anticavitation valve is to protect
the cylinder and hoses from
any excessive pressures.
VCI
EI
ET
V4
6 . Anti-cavitation valve .
V3
A2 B2
200 bar
A1 B1 V1
280 bar
280 bar
VCI
EL
EI
V2 T1
V4
Notes : ____________________________________________________________________________________
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HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS
11
7 . Valve slide .
V3 A2 B2
V A3 B3
A4 B4
A5 B5
200 bar
200 bar
A1 B1 V1
280 bar
280 bar
VCI
EL
EI
V2 T1
A
T
ET
EA
EA (O)
V4
1
B
LC
P
P
A
P
B
T
0
A
B
P
T
2
T
0
1
B
2
A
B
P
T
70
A
T
LC
P
P
A
T
T
1
B
LC
P
P
B
P
A
T
2
0
A
B
P
T
T
Notes : ____________________________________________________________________________________
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12
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SPECIFICATIONS
13
SDM 140/2 DISTRIBUTOR
Values for information purposes only
Role:
– Direct the hydraulic flow to the receiver.
– Limit shock pressure.
– Cancel various movements.
A2 B2
1
1
A3 B3 T
70
P
2
2
T1
P1
ESD
ESG
1 - Valve slide
2 - Plug
Note:
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HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS
Values for information purposes only
P
A2 B2
A3 B3 T
T1
P1
ESG
70
ESD
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HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS
15
DISTRIBUTOR SX 14 S (INLET ELEMENT)
Values for information purposes only.
Function:
- Divide the hydraulic flow, giving priority to steering.
- Limit maximum pressure.
- Reduce the LS pressure to zero when the control stick is
returned to the neutral position.
- Cut off hydraulic movements.
MA
1
2
A5
D
5
LS
M
1
3
4
70
VCI
b B1
D
A1
b B2
A2
A3
B3
B4
A4
b B5
DLS
b
b
P
2
Tdd
VS
a
LS
T
T
T
EE
3
B
A
B
T
EI
a
EA(O)
a
a
b
T
ET
T
EA
VRP
B
EF
EL
a
Pr
Tpr
4
1 - Priority Valve.
2 - Movement cut-off valve.
3 - Flow controller and filter.
4 - Pressure limiter.
5 - Non-Return Valve.
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
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HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS
Values for information purposes only.
LS
M
D
Hydraulic pressure arrives at P.
DLS
- The flow divider valve enables priority to be given to the steering
system when there is stand-by pressure equal to the spring. When
the orbitrol is not called for the pressure moves the slide and
applies the stand-by pressure from the pump to the valveblock
modules.
P
Tdd
VS
- The LS limiter enables the maximum circuit pressure to be limited
by limiting the pump pilot pressure. It pre-empts the action of
the pump DR slide and reduces rippling.
LS
T
EE
T
M
LS
- The regulator allows the LS pressure to fall to 0 when the control
stick returns to neutral.
D
70
DLS
- The VS enables all hydraulic movements to be cut off, directing
the divider pilot flow to the tank.
P
Tdd
VS
LS
T
EE
T
What is the function of the non-return valve?
How is the main pressure limited?
What is the exact calibration of the maximum pressure relief valve?
70-01-M218EN
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HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS
17
DISTRIBUTOR SX 14 S (TILTING ELEMENT)
Values for information purposes only.
Function:
- Direct the hydraulic flow to the receiver.
- Limit impact pressure.
- Enables all movement to be stopped.
MA
LS
M
2
A5
D
2
1
b B1
D
A1
3
1
4
70
VCI
b B2
A2
A3
B3
B4
A4
b B5
DLS
b
b
P
Tdd
VS
a
LS
T
T
T
EE
B
A
B
T
EI
3
a
4
EA(O)
a
a
b
T
ET
T
EA
VRP
B
EF
EL
a
Pr
Tpr
1 - Valve slide.
2 - Pressure balance.
3 - Pressure spike relief valve.
4 - Pressure spike relief valve.
Notes : ____________________________________________________________________________________
___________________________________________________________________________________________
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HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS
Values for information purposes only.
b B1
A1
- The hydraulic pressure arrives at the entry module with pump
stand-by pressure.
- The Pressure balance ensures communication between the main
pressure line through the valveblock to the receiver feed.
- It takes the receiver pressure and communicates it to the pump.
- There is a priority between the receiver feed and pressure
information transmission to avoid any rapid pressure increase
as a result of a delay in slide opening relative to pump control.
T
B
A
T
EI
a
70
Hydraulic control
(At “rest”)
b B1
A1
T
A
B
T
b B1
A1
T
A
B
EI
a
EI
a
Hydraulic control
(Setting “a”)
70-01-M218EN
T
Hydraulic control
(Setting “b”)
(06/04/2017)
HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS
19
DISTRIBUTOR SX 14 S (CLOSING ELEMENT)
Values for information purposes only.
Function:
– It contains a flushing valve whose function is to prevent
pressure spikes arising from the premature closing of
the main slide of one of the valveblock components
before the pump has returned to low.
T3
MA
Pr
r
VCI
LS
M
b B1
D
A1
b B2
A2
A3
B3
B4
A4
b B5
1
2
A5
D
3
4
1
DLS
b
70
Tp
b
P
Tdd
VS
a
LS
T
T
T
EE
B
A
B
T
EI
a
EA(O)
a
a
b
T
T
ET
EA
VRP
B
EF
EL
a
Pr
Tpr
1 - Flushing Valve.
Notes : ____________________________________________________________________________________
___________________________________________________________________________________________
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HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS
Values for information purposes only.
D
– The hydraulic pressure arrives at the entry module with pump
stand-by pressure.
EF
Tpr
70
Pr
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HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS
21
DISTRIBUTOR SX 14 S (LIFTING ELEMENT)
Values for information purposes only.
Function:
– Direct the hydraulic flow to the receiver.
– Limit impact pressure.
– Enables all movement to be stopped.
– Regulates pilot pressure as per machine overload.
VCI
1
2
A5
D
1
LS
M
b B1
D
A1
b B2
A2
A3
B3
B4
A4
b B5
3
4
DLS
b
b
P
Tdd
VS
a
LS
T
T
T
EE
B
A
B
T
EI
a
EA(O)
a
b
T
T
ET
EA
VRP
B
EF
EL
a
a
2
Pr
Tpr
3
1. Distribution slide (includes the pilot regulation valve VRP).
2. Pressure spike relief valve.
3 . Pressure balance.
Notes : ____________________________________________________________________________________
___________________________________________________________________________________________
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70
MA
22
HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS
Values for information purposes only.
Operating principles of the electro-hydraulic controller and VRP:
Jet at control valve inlet for descent
control
Hydraulic
controller
Control Valve
Pr
Valve slide
TPr
Pressure reduced
by SPU
The descent control is mixed, i.e. the hydraulic controller directly controls the slide in normal operation.
The pressure relief valve, on the other hand, can reduce the slide pilot pressure if the operator wishes
to reduce the flow sent to descent and thus the rate of descent.
70
Current/pressure reduction curve, VRP:
70-01-M218EN
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HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS
b B5
b
T
23
A5
VRP
– The hydraulic pressure arrives at the entry module with pump
stand-by pressure.
B
EL
a
Electro-hydraulic controller
(“Rest” state)
b B5
– It takes the receiver pressure and communicates it to the pump.
– There is a priority between the receiver feed and pressure
information transmission to avoid any rapid pressure increase
as a result of a delay in slide opening relative to pump control.
70
A5
– The Pressure balance ensures communication between the main
pressure line through the valveblock to the receiver feed.
b
T
VRP
B
EL
a
Electro-hydraulic controller
(Setting “b”)
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SPECIFICATIONS
70
24
70-01-M218EN
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HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS
25
DISTRIBUTOR SX 14 S (TELESCOPE - ATTACHMENT ELEMENTS)
Values for information purposes only.
EA
ET
Function:
- Direct the hydraulic flow to the receiver.
- Limit impact pressure.
- Enables all movement to be stopped.
EA
ET
VCI
1
LS
M
b B1
D
A1
b B2
1
2
A5
D
1
A2
A3
B3
B4
A4
b B5
3
4
DLS
b
b
P
Tdd
VS
a
LS
T
T
T
EE
B
A
B
T
EI
a
EA(O)
a
b
T
T
EA
ET
a
2
B
EF
EL
a
3
VRP
Pr
Tpr
2
1 - Valve slide.
2 - Pressure balance.
3 - Pressure spike relief valve.
Notes : ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
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70-01-M218EN
70
MA
26
HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS
Values for information purposes only.
Operating principles of the electro-hydraulic controller:
Pressure reduced
by SPU
Pr
Valve slide
TPr
A3
B3
b
B4
A4
- The hydraulic pressure arrives at the entry module
with pump stand-by pressure.
- The Pressure balance ensures communication between
the main pressure line through the valveblock to the
receiver feed.
b
- It takes the receiver pressure and communicates it
to the pump.
70
a
B
a
T
ET
EA
- There is a priority between the receiver feed and
pressure information transmission to avoid any rapid
pressure increase as a result of a delay in slide opening
relative to pump control.
Electro-hydraulic controller (“Rest” state)
A3
B3
b
B4
A4
b
a
B
b
a
B
T
EA
Electro-hydraulic controller (Setting “a”)
70-01-M218EN
B4
A4
b
a
ET
A3
B3
a
T
ET
EA
Electro-hydraulic controller (Setting “b”)
(06/04/2017)
HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS
27
POWER ASSISTED BRAKE MASTER CYLINDER
Values for information purposes only.
1 - Part :
- To send the pressure fluid in order to push the brake
pistion that will stop the wheels.
- To add the mechanical force (pedal) and the hydraulic
force in order to help the driver.
2 - Description :
P
N
B
R
70
L
R
N
L
B
PLNBR-
Assistance pressure
Pilot pressure (LS line)
Return to the tank line
Brake pressure
LHM tank
P
Notes : ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
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HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS
Values for information purposes only.
3 - Working :
Phase 1 (no action)
R
N
L
B
P
The pressure from the accumulator block arrives on P. The ball prevents the oil to pass because it is
maintained on its seat.
Pilot line (L) is connected to the tank return (N) because it does not use the master cylinder.
Phase 2 (the driver starts the action)
R
70
N
L
B
P
When the driver begins to push on the brake pedal, all components are in contact. In this case, the LS
line is cut (L).
The master cylinder is ready to send the pressure toward the brake with the assistance.
Phase 3 (during the action)
R
N
L
B
P
When the driver pushes completely the brake pedal, the piston moves and the ball does not stop the
oil. In this case, the pressure is sent to help the driver.
In the same time, the master cylinder sends a pilot pressure toward the flow divider to have the priority
on braking.
70-01-M218EN
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HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS
29
CASAPPA MVP 60 PUMP
Values for information purposes only.
1
2
3
1
3
7
5
8
70
2
6
4
7
1. PEC (Pressure Electronic Control).
2. Hydraulic flow regulator block + filter.
3 . Maximum displacement regulator.
4 . Minimum displacement regulator.
5 . High Pressure (B).
6 . Suction pressure (S).
7 . LS (X) line coupling. Includes filter and flow
limiter.
8 . Oil tank return.
X
B
4
1
M
P
2
(06/04/2017)
5
8 3
S
6
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30
HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS
Values for information purposes only.
CROSS-SECTIONAL VIEW
70
DESCRIPTION
– LS spring: 17 b
X
– Pressure limit: 315 b
Key:
B
1
P
M
1. PEC (Pressure Electronic Control).
2. Hydraulic flow regulator block + filter.
315b
17b
2
S
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
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HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS
31
Values for information purposes only.
FLOW ADJUSTMENT
Maintaining stand-by pressure.
Delta P = p(B) - p(X)
Delta P generated by weak flow passing through the pressure compensator i distributor.
If the Delta P increases, the pump’s displacement decreases.
Delta P
X
B
M
70
P
17b
S
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
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SPECIFICATIONS
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32
70-01-M218EN
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HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS
33
STEERING PUMP/STEERING UNIT OSPC 200 LS
Values for information purposes only.
T
P
Role:
L
– Direct and dose the flow in order to supply the steering
circuit.
R
– It is a rotating distributor.
LS
R
L
1. Secondary relief valve.
2. Distributor pump.
3. Main relief valve.
70
1
2
200 cm³/tr
3
LS
T
-P
-T
-R
-L
- LS
: Pressure.
: Tank return.
: Exit towards the right side.
: Exit towards the left side.
: Pilot line.
P
Note:
(06/04/2017)
70-01-M218EN
34
HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS
Values for information purposes only.
R
L
When the driver turns the steering wheel towards the right, he passes
the flow rate from P to R and sends pilot pressure towards the divisor
to get priority.
LS
T
P
R
L
When there is an impact on a wheel, the pressure increases in the line.
This pressure opens the valve which enables the resulting pressure to
be evacuated and therefore protects the hydraulic and mechanical
steering components.
70
LS
T
P
R
L
When the wheels are on full lock, the pressure in the steering circuit
rises. The LS line operates the relief valve and directs the flow to the
tank.
LS
T
70-01-M218EN
P
(06/04/2017)
HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS
35
TILTING CUT-OFF VALVE (VCI)
Values for information purposes only.
Function:
– To authorize or not crowding, taking into account machine
overload and machine software.
– When powered, 35 bar pressure is applied to each side
of the slide, giving rise to no crowding movement.
Maximum pressure (bar)
35
Maximum flowrate (L/min)
19
MA
1
VCI
LS
M
b B1
D
A1
b B2
A2
A3
B3
B4
A4
b B5
3
1
2
A5
D
4
DLS
b
b
P
Tdd
VS
a
LS
T
T
T
EE
B
A
B
T
EI
a
EA(O)
a
a
b
T
T
ET
EA
VRP
B
EF
EL
a
Pr
Tpr
1 - Crowding Cut-Off Valve (VCI)
Notes : ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(06/04/2017)
70-01-M218EN
70
– When unpowered, pressure can be applied to one side
or the other thus enabling movement.
HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS
70
36
70-01-M218EN
(06/04/2017)
HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS
37
FLOW DISTRIBUTOR
Values for information purposes only.
SPi
Role:
This valve sends hydraulic flow to reservoir in proportion
to the solenoid valve supply value.
70
EPi
C
SPi
B
EPi
A
Maximum pressure (bar) 345
345
Nominal flow rate (L/min)
105 l/mn
Resistance
10 Ω
Maximum current
1,2 A
(06/04/2017)
70-01-M218EN
38
HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS
Values for information purposes only.
C
B
If «SPi» is supplied at a maximum, the passage
from «A» to «C» is open to the maximum. That
corresponds to maximum flow.
SPi
EPi
A
A = Valve bank
B = TanK
C = Lifting cylinder.
70
C
B
=X%
SPi
If «SPi» is supplied at X %, the passage of «A» to «C»
is open at X % that corresponds to X % ofthe flow.
Pressure is thus greater upstream of «SPi».
«EPi» is opened and flow goes from the reservoir in
proportion to the solenoid valve supply.
EPi
A
70-01-M218EN
(06/04/2017)
HYDRAULIC SCHEMATIC DIAGRAMS
pages
MLT 634 + MLT 735 + MLT 741 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
MT 732 + MT 932 + MT 1030 EASY 75D ST3B S2 + MLT 732 . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
–– HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
–– KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
MT 1030 EASY 75D ST3B S1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
70
–– KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
–– HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
(31/08/2016)
70-02-M218EN
HYDRAULIC SCHEMATIC DIAGRAMS
70
2
70-02-M218EN
(31/08/2016)
HYDRAULIC SCHEMATIC DIAGRAMS
3
MLT 634 + MLT 735 + MLT 741
KEY
Designation
Position on
diagram
O27, G36
K10
AC
BRVI
Accumulator
Fan reverse control unit
Y42: Fan direction reversal EV
Y43: Fan control EV
CA
CSP
CR (O)
D
ET
EVAA (O)
EVP (O)
EVTDF (O)
EV (S1)
EV (S2)
FDAV
FDAR
FEMS
FR
M
MA
MC
N
REAR OPTION-1
REAR OPTION-2
REAR OPTION-3
REAR OPTION-4
REAR OPTION-5
REAR OPTION-6
Suction strainer
Counterbalance valve
Trailer hook (option)
Distributor
Attachment element
a (Y18): Neg. direction proportional EV
b (Y17): Pos. direction proportional EV
Attachment element (option)
Inlet element
Y20 : hydraulic cut-off EV (VS - safety valve)
Closing element
Tilting element
Lifting element
b (Y19): Lowering proportional EV
Telescope element
Rear attachment electrovalve (option)
Pilot electrovalve (option)
Telescope head electrovalve (option)
Electrovalve (solenoid 1)
Electrovalve (solenoid 2)
Front disc brake
Rear disc brake
EMS head filter
Return filter
Engine
Manipulator
Master cylinder
Level
Single-acting option (rear attachment plug)
Double-acting option (rear attachment plug)
Hydraulic hook option (rear attachment plug)
Double + single rear predisposition option (rear attachment plug)
2 double rear predispositions option (rear attachment plug)
Towing hook + double rear predisposition option (rear attachment plug)
REAR OPTION-7
Towing hook + single rear predisposition option (rear attachment plug)
A15
FRONT OPTION-1
FRONT OPTION-2
FRONT OPTION-3
Hydraulic locking option (front attachment connector)
Telescope head electrovalve option (front attachment connector)
Telescope head electrovalve and hydraulic locking option (front
attachment connector)
Hydraulic pump
Cooling circuit pump
Steering pump
Trailer brake connector integrated in the VAFR
Pressure test port
Pressure switch
Pressure sensitive switch (option)
Leakage return connector (option)
C33
C36
A38
EA
EA (O)
EE
EF
EI
EL
P
PCR
PD
PFR
PP
PRES
PRES (O)
PRF (O)
(31/08/2016)
S16
I31
C17, C19, C26
Q39
Q33
Characteristics
125 µm absolute
Q29
Q25
Q38
Q27
Q35
Q31
C16, C18, C21, C23
Q22
C37, C39
G35
I32
I2
I22
M39
Q18
15 µm absolute
I17
o 10 - ENGINE
O2,O40
A3
S11
C28
C27
C25
A23
A20
A18
G13
K15
C10
E4
O25
E12
G34
O12
70-02-M218EN
70
Item
4
HYDRAULIC SCHEMATIC DIAGRAMS
Item
R
Hydraulic tank
Position on
diagram
S11
RF
RLF
SC
SCFR
SD
Cooler
Brake fluid tank
Circuit selector
Trailer brake circuit selector
3 position steering selector
K14
C3
E8
E7
C9
VC
Compensating cylinder MLT 634 and MLT 735
I26
VI
Tilting cylinder
G26
VDAV
VDAR
VL
Front steering cylinder
Rear steering cylinder
Lifting cylinder
VT
Telescope cylinder
VAFR
VVT (O)
VAI (O)
VS
VRD
VASF
VCI
70
Designation
Trailer brake valve
Carriage locking cylinder (option)
Isolation valve (option)
Safety valve
Flow control valve
Telescope suspension valve:
E V (S1): Electrovalve (solenoid 1)
EV (S2): Electrovalve (solenoid 2)
Tilting cut-off valve
I4
I21
E35, G39
G30
E3
C34, A39
C33, C38
Q25
Q36
I35
Characteristics
Capacity 135 ℓ
Average level 110 ℓ
Steering reserve 12 ℓ
1: short steering
2: front wheel steering
3: crab steering
MLT 634: DE 100x50 C 310
MLT 735: DE 100x50 C 310
MLT 741: DE 110x55 C 310
MLT 634 : DE 120x60 C 445
MLT 735 : DE 130x65 C 380
MLT 741 : DE 140x70 C 388
MLT 634 : DE 130x70 C 720
MLT 735 : DE 140x70 C 720
MLT 741 : DE 150x70 C 716
MLT 634 : DE 70x50 C 2100
MLT 735 : DE 70x50 C 2700
MLT 741 : DE 75x55 C 2700
DE 60x45 C 183
O35
Note:
1 - The calibration pressures of the main relief valves, on the inlet elements, are given for maximum
engine speed.
2 - The calibration pressures of the secondary relief valves are given at an engine speed of 1000
rpm. (Disconnect the PEC from the hydraulic pump before setting the calibration pressures of the
secondary relief valves e 70 - HYDRAULIC CHARACTERISTICS AND SPECIFICATIONS: CASAPPA MVP
60 PUMP data sheet).
3 - The pressure relief valves should be adjusted at an oil temperature of 50 °C.
70-02-M218EN
(31/08/2016)
HYDRAULIC SCHEMATIC DIAGRAMS
HYDRAULIC DIAGRAM
MLT 634 + MLT 735 + MLT 741
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
A
39
40
41
42
A
OPTION AV-3
L
A B T
N
3 2
RLF
B1
AV
R
PD
C
OPTION AR-7
1
P
AR
T
Y
LS
N
E
V1
SCFR
VAFR
PFR
B
V1
V2
S
SC
P2
200 cm3/tr
V2
LS
C4
C4
C4
CR (O)
C2
C3
P
OPTION AR-4
PAAR (O)
C4
L
200b
200b
OPTION AR-5
PAAR (O)
PAAR (O)
PAAR (O)
1
2
3
OPTION AR-6
C2
C1
P1
CR (O)
C3
C1
PAAR (O)
C2
C3
C3
Y23
Y23
Y22
EVAA (O)
EVAA (O)
EVAA (O)
P2
P1
P2
PAAR (O)
VVT (O)
PAAV
P1
C4
PAAV
C3
C1
P2
P1
PAAV (O)
C2
PAAV
C3
C1
P2
P1
C
EVTDF (O)
EVTDF (O)
OPTION CRC
7.5 b
E
P
T
PAAV (O)
C2
C4
PAAV
Y23
P1
OPTION AR-1
PAAR (O)
C1
EVAA (O)
P2
OPTION AR-2
CR (O)
PAAR (O)
C2
C1
OPTION AR-3
PRES
140b
S
OPTION AV-2
OPTION AV-1
1
SD
P
2
3
VAI (O)
B
MC
VVT (O)
VAI (O)
1
5
VL
VI
VL
C2
300b
B
P
C1
VT
CSP
63 cm3/tr
V1
r=1
G
C2
PX
EV(S1)
30b
1.5 ℓ
AC
V2
C1
C2
335b
EV(S2)
VC
I
C1
LS S
FDAV
M
VDAV
BRVI
Y43
Y42
K
230b
PCR
V1
V2
RF
V2
C1
C2
CSP
70b
0.7 ℓ
13 b
K
BA
35b
75° C
V1
U
V2
45±5b
P1
T
FEMS
M
P
Ø1
Y7
1
VCI
2
4 bar
LS
D
b B1
EI
A1
b B2
EA(O)
6b
EVP (O)
5b
3
1
Y21
EA
R
2
EL
b B5
A5
EF
O
D
Y18 b
VS
4
aY16
LS
T
270b T
B
A
B
200 b
T
190b 280b
a
Middle level 110 ℓ
S
A4
4 bar
PRES (0) PRES (0)
Q
Tdd
T
CA
B4
4
P
Y20
N
A3
B3
ET
Y15 b
FR
Q
A2
3
4 bar
PRES (0)
M
DLS EE
T
MA
MA
PRF(O)
M
10 µm
0.32 ℓ
100 b
AC
PP
O
CSP
V2
r=1.04
21.14 cm3/tr
30b
V1
CSP
30b
T
VASF (O)
FDAR
V1
210b
I
30b+6/0
T
VDAR
P
16.85 cm3/tr
320b+15/0
C2
335b
a
T
VRD
aY17
23 b
b Y19
T
B
280 b
a Gicleur 0.8 mm
Nozzle 0.8 mm
Pr
Tpr
S
Steering reserve 12 ℓ
(31/08/2016)
70-02-M218EN
70
X
C1
1 2
ES.AR
3
ES.AV
G
PRES
HYDRAULIC SCHEMATIC DIAGRAMS
6
MT 732 + MT 932 + MT 1030 EASY 75D ST3B S2 + MLT 732
HYDRAULIC DIAGRAM
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
VT
A B T
B
3
MC
3 2
RLF
B1
1
AV
R
PD
CSP
C2
335b
C1
200b
1
2
31
32
33
34
35
36
37
39
C2
110b
V1
40
41
42
VVT (O)
OPTION AV-2
OPTION AV-1
VT1
PAAV (O)
V2
C4
PAAV
C1
CSPD
C2
300b
V1
140b
MT 732 + MLT 732
E
PAAV (O)
C2
C4
PAAV
C3
C1
P2
P1
PAAV (O)
C2
PAAV
C3
C1
P2
P1
C
EVTDF (O)
EVTDF (O)
200 cm3/tr
LS
A
OPTION AV-3
V2
CSP
30b
V1
L
200b
300b
T
38
VVT (O)
AR
3
P
30
315b +15
0
1
SD
C
2
29
VT2
A
C1
28
VAI (O)
2
VAI (O)
1
V2
MT 932
OPTION CRC
OPTION CRC
1er montage
2ème montage
P
E
VL
VL
VI
VL
P
LS
CF
C1
C2
300b
EF
C1
PX
V1
V2
PCR
VDAV
30b
1,5ℓ
17b
1ℓ
AC
AC
C1
M
T
VDAR
C2
335b
V2
30b
V1
V2
V2
21.14 cm3/tr
0.7 ℓ
13 b
160b
T
K
D
I
CSP
FDAR
(100CV)
PCR r=1.04
(75 CV)
VASF (O)
VASF (O)
V1
RF
K
BA
35b
(75 CV)
(100 CV)
70
30b +6
0
r=1
44 cm3/tr
P (100 CV)
19.09 cm3/tr
EV(S1)
VC
21.14 cm3/tr
S
BRV
G
C2
EV(S1)
320b +15
0
EV(S2)
(75CV)
FDAV
C2
CSP
8b
I
1 2
ES.AR
3
ES.AV
G
PRES
U
45±5b
P1
T
FCD
M
MA
P
M
10 µm
T
MA
MT 1030 Easy S2
1
2
4 bar
O
VSD
C1
C2
C1
100b CSPD 100b
280b
PRF(O)
Q
6b
5b
V1
V2
V1
VSS
B
R
N
CA
VSG
C2
280b
VSS
P
280 bar +15
0
10 ℓ/min
A1 B1
280 bar +15
0
V2
Steering reserve 12 ℓ
4
4 bar
4 bar
PRES (0) PRES (0)
O
D1 MT 1030 Easy S2
P
A3 B3 T
A2 B2
Q
VS
A
T1
P1
PP
S
V1 V3 A2 B2
200 bar +0
-5
50 ℓ/min
1200 tr/min
V A3 B3
A4 B4 T
10 ℓ/min
B
A
Middle level 110 ℓ
70-02-M218EN
200 bar +0
-5
50 ℓ/min
1200 tr/min
D
FR
PRES (0)
3
VRP
VCI
EE
260 bar +5
0
EL
90 ℓ/min
2100 tr/min
EI
V2
T1
ET
EA
EF
ESD
ESG
S
V4
(31/08/2016)
HYDRAULIC SCHEMATIC DIAGRAMS
KEY
7
MT 732 + MT 932 + MT 1030 EASY 75D ST3B S2 + MLT 732
Designation
AC
BA
BRV
CA
CSP
CSPD
D
EA / EE
EF / EI
EL / ET
D1
ESD / ESG
EVTDF (O)
FCD
FDAV
FDAR
FR
M
MA
MC
N
FRONT OPTION-1
FRONT OPTION-2
FRONT OPTION-3
P
PAAV
PAAV (O)
PCR
PD
PP
PRES
PRES (O)
PRF (O)
R
RF
RLF
SD
VASF
VC
VCI
VDAV
VDAR
VI
VL
VRP
VS
VSD / VSG
VT
VT1
VT2
VVT (O)
Accumulator
Accumulator block
Fan control unit
Suction strainer
Counterbalance valve
Double counterbalance valve
Distributor
Attachment element / Input element
Closing element / Tilting element
Lifting element / Telescope element
Distributor
RH stabiliser element / LH stabiliser element
Telescope head electrovalve (option)
Distributor control filter
Front disc brake
Rear disc brake
Return filter
Engine
Manipulator
Master cylinder
Level
Hydraulic locking option (front attachment connector)
Telescope head electrovalve option (front attachment connector)
Telescope head electrovalve and hydraulic locking option (front
attachment connector)
Hydraulic pump
Front attachment connector
Front attachment connector (option)
Cooling circuit pump
Steering pump
Pressure test port
Pressure switch
Pressure sensitive switch (option)
Leakage return connector (option)
Hydraulic tank
Cooler
Brake fluid tank
3 position steering selector
Telescope suspension valve:
Position on
diagram
G35, G38
K39
K12
S15
A26,C23,G26,I41
Q19
Q24
S31 / S25
S32 / S28
S26 / S30
Q33
S34 / S36
C37, C40
M39
I2
I22
Q15
I17
M2,M39
A3
S19
A33
A36
A39
G13
C35,C38,C40
C32,C38,C40
K16 / I13
C10
S24
G34
O37,O38,O39
Q10
S9
K14
C3
C9
E V (S1): Electrovalve (solenoid 1)
EV (S2): Electrovalve (solenoid 2)
Compensating cylinder
Tilting cut-off valve
Front steering cylinder
Rear steering cylinder
Tilting cylinder
Lifting cylinder
Pressure control valve
Safety valve
Right stabiliser valve / Left stabiliser valve
Telescope cylinder (MT / MLT 732)
External telescope cylinder (MT 932)
Internal telescope cylinder (MLT 932)
Carriage locking cylinder (option)
Characteristics
125 µm absolute
15 µm absolute
o 10 - ENGINE
100 HP / 75 HP
70
Item
Capacity 135 ℓ
Average level 110 ℓ
Steering reserve 12 ℓ
1: short steering
2: front wheel steering
3: crab steering
I33, I36
I25
S29
I4
I20
G26
E33, E36, G40
S27
Q25
O17 / O22
A22
C27
A27
C34, A40
DE 110x55 C 310
DE 120x60 C 416
DE 140x70 C 720
70x50 C 2700
DE 100x60 C 2600
DE 80x50 C 2600
DE 60x45 C 183
Note:
1 - The calibration pressures of the main relief valves, on the inlet elements, are given for maximum
engine speed.
2 - The calibration pressures of the secondary relief valves are for an engine speed of 1000 rpm.
3 - The pressure relief valves should be adjusted at an oil temperature of 50 °C.
(31/08/2016)
70-02-M218EN
8
HYDRAULIC SCHEMATIC DIAGRAMS
MT 1030 EASY 75D ST3B S1
KEY
Item
AC
BA
BRV
CA
CSP
CSPD
D
EA / EE
EF / EI
EL / ET
EVTDF (O)
FDAV
FDAR
FR
M
MC
N
P
PAAV(O)
PAAV (O) AV1
PAAV (O) AV2
PAAV (O) AV3
PAAV (O) AV4
PAAV (O) AV5
PAAV (O) AV6
PCR
PD
PFR(O)
PP
PRES
PRF (O)
70
R
RF
RLF
SCFR(O)
SD
VC
VDAV
VDAR
VI
VL
VS
VAI(O)
VAFR(O)
VRD
VT1
VT2
VVT (O)
Designation
Accumulator
Accumulator block
Fan control unit
Suction strainer
Counterbalance valve
Double counterbalance valve
Distributor
Attachment element / Input element
Closing element / Tilting element
Lifting element / Telescope element
Telescope head electrovalve (option)
Front disc brake
Rear disc brake
Return filter
Engine
Master cylinder
Level
Hydraulic pump
Front attachment connector (option)
Front attachment connector (option) Hydraulic locking
Front attachment connector (option) Telescope head electrovalve
Front attachment connector Telescope head electrovalve and hydraulic locking
Front attachment connector Single side-shift carriage (TSDL) and connectors
Front attachment connector (option) Telescope head electrovalve and TDSL
Front attachment connector (option) TDSL and hydraulic locking
Cooling circuit pump
Steering pump
Trailer brake connector integrated in the VAFR (option)
Pressure test port
Pressure switch
Leakage return connector (option)
Hydraulic tank
Cooler
Brake fluid tank
Trailer brake circuit selector (option)
3 position steering selector
Compensating cylinder
Front steering cylinder
Rear steering cylinder
Tilting cylinder
Lifting cylinder
Safety valve
Isolation valve (option)
Trailer brake valve (option)
Flow control valve
External telescope cylinder
Internal telescope cylinder
Carriage locking cylinder (option)
Position on
diagram
G36
K39
Characteristics
K12
S15
M28,G31, E38, I28
G38, M29
Q40
S26 / S27
S35 / S39
S33 / S37
C28 / C30
I2
I22
Q18
I20
A3
S12
G14
C23
C27
C29
C31
C34
C37
C39
I19 / I16
C12
E4
O25
G34
O12
S11
K16
C3
E7
C9
125 µm absolute
15 µm absolute
o 10 - ENGINE
100 HP / 75 HP
Capacity 135 ℓ
Average level 110 ℓ
Steering reserve 12 ℓ
1: short steering
2: front wheel steering
3: crab steering
DE 110x55 C 310
I31
I4
I22
G31
DE 120x60 C 416
G29
DE 140x70 C 720
Q25
C30, C32, C35, C40
E3
G24
G40
DE 100x60 C 2600
E40
DE 80x50 C 2600
C34, A40
DE 60x45 C 183
Note:
1 - The calibration pressures of the main relief valves, on the inlet elements, are given for maximum
engine speed.
2 - The calibration pressures of the secondary relief valves are for an engine speed of 1000 rpm.
3 - The pressure relief valves should be adjusted at an oil temperature of 50 °C.
70-02-M218EN
(31/08/2016)
HYDRAULIC SCHEMATIC DIAGRAMS
HYDRAULIC DIAGRAM
MT 1030 EASY 75D ST3B S1
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
A
30
31
32
33
34
35
OPTION AV-3
C
3
P
200b
L
200b
2
1
PD
VVT (O)
C2
C4
VAI (O)
PAAV (O)
R
AR
OPTION
P
200 cm3/tr
T
Y
VAFR
LS
N
E
PFR
B
V1
SCFR
S
C3
C1
P2
P1 EVTDF (O)
OPTION AV-4
C2
C4
C3
C1
P2
P1
39
VDL (O)
C4
VAI (O)
C2
EVTDF (O)
C3
C1
P2
P1
C4
VVT (O)
C
C2
C3
C1
P2
P1
VT2
140b
E
T
P
CSP
VL
C1
P
LS
CF
EF
C2
335b
8b
r=1
44 cm3/tr
(100CV)
PCR r=1.04
(75 CV)
P (100 CV)
19.09 cm3/tr
G
VDAR
V2
FDAR
C2
300b
VC
300b
V1
30b CSP
V1
V2
M
S
BRV
+15
0
VT1
C1
ES.AR
ES.AV
(75CV)
VDAV
315b
CSP
C1
3
C2
C2
300b
V1
PCR 21.14 cm /tr
C1
110b
V1 V2
G
FDAV
42
A
LS
V2
41
OPTION AV-6
VI
I
40
VDL (O)
VAI (O)
AV
OPTION AV-2
OPTION AV-1
PAAV (O)
SD
B1
1
1
38
VDL (O)
PAAV (O) PAAV (O)
3 2
RLF
2
3
PAAV (O) PAAV (O)
A B T
B
37
OPTION AV-5
VVT (O)
PAAV (O)
MC
36
PAAV (O)
VAI (O)
3
PAAV (O) PAAV (O)
2
VAI (O)
1
9
V2
I
T
D
RF
K
(75 CV)
(100 CV)
K
PRF(O)
VSD
C1
280b
M
V1
VSG
C2
C1
100b CSPD 100b
C2
280b
V2
V2
V1
M
PP
O
O
A1
P
A2
B1
A3
B2
B3
A4
B4
A5
FR
6b
Q
VRD
B5
280b
280b
A6
190b
B6
190b
T
D
A
EPI
5b
CVI
VS
B
A
B
NO
NF
B
A
NF
NF
B
A
NF
NF
B
A
NF
NF
B
A
NO
NF
B
A
NF
NF
Q
SPI
15 µm absolu
C
VRP
N
CA
125 µm
absolu
Niveau moyen: 104L
S
R
(31/08/2016)
250b
EE
Capacité 128 litres
EA
ESD
ESG
EL
EI
ET
S
EF
Réserve direction
70-02-M218EN
70
21.14 cm3/tr
160b
HYDRAULIC SCHEMATIC DIAGRAMS
70
10
70-02-M218EN
(31/08/2016)
HYDRAULIC COMPONENTS LOCATION
pages
KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
HYDRAULIC COMPONENT LOCATION (MLT EXCEPT MLT 732) . . . . . . . . . . . . . . . . . . . . . . . . 3
70
HYDRAULIC COMPONENT LOCATION (MT + MLT 732) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
(31/08/2016)
70-03-M218EN
2
HYDRAULIC COMPONENTS LOCATION
KEY
70
Item
Designation
Position on MLT diagram
(except MLT 732)
Position on MT + MLT 732
diagram
AC
Accumulator
Q26
BA
Accumulator block
Q24
O26
CSP
Counterbalance valve
M7
M6
D
Distributor
C4
C4
DM
Mechanical distributor
EA
Attachment element
C6
EE
Inlet element
E10
C6
EF
Closing element
E4
G7
I26
G5
EI
Tilting element
C8
E5
EL
Lifting element
C5
C5
ET
Telescope element
C7
D1
Distributor ( Mt 1030 Easy S2)
E5
A9
ESD
RH stabiliser element
E13
ESG
LH stabiliser element
E13
FA
ARGO filter
S22
I26
FR
Return filter
Q14
Q15
JSM
Manipulator
I26
L
Levers ( Mt 1030 Easy S1)
O
Orbitrol
O27
O27
P
Hydraulic pump
Q26
Q27/Q29
I26
G26
PP
Pressure test port
E10
C7
R
Hydraulic tank
Q22
Q23
K8
VC
Compensating cylinder
K8
VCI
Tilting cut-off valve
Q11
VI
Tilting cylinder
E28
E28
VL
Lifting cylinder
Q13
Q13
VS
Safety valve
C9
C8
VSD
Right stabiliser cylinder
I28
VSG
Left stabiliser cylinder
I26
VSS
Stabiliser safety valve
VT
Telescope cylinder (MLT except MLT 732)
K21
E26
VT1
External telescope cylinder (MT 932)
C20
VT2
Internal telescope cylinder (MT/MLT 732)
E26
70-03-M218EN
(31/08/2016)
HYDRAULIC COMPONENTS LOCATION
HYDRAULIC COMPONENT LOCATION (MLT except MLT 732)
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
D
C
EL
EA
ET
EI
VS
C
EE
VI
PP
E
3
VT
EF
E
G
G
I
I
K
K
VC
M
CSP
M
O
O
O
P
AC
BA
Q
VCI
FR
Q
R
VL
FA
S
S
(31/08/2016)
70-03-M218EN
70
JSM
HYDRAULIC COMPONENTS LOCATION
4
1
2
3
4
5
6
7
8
HYDRAULIC COMPONENT LOCATION (MT + MLT 732)
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
* MT 1030 Easy S2
D1*
A
C
PP
D
VS
C
EE
ESD
EL
E
A
VT1
ESG
VI
E
VT2
EI
ET
G
EA
G
L
EF
JSM
DM
70
I
I
FA
VSG*
VSD*
K
K
VC
CSP
M
M
O
O
O
VSS*
BA
P
P
Q
FR
VL
S
R
Q
100 CV
75 CV
S
70-03-M218EN
(31/08/2016)
HYDRAULIC CONTROL AND ADJUSTMENT
pages
DISTRIBUTOR CONTROL LOGIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OPERATING PRINCIPLES OF AGGRAVATING MOVEMENTS CUT-OFF . . . . . . . . . . . . . . . . . 4
SX 14 S DISTRIBUTOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
–– 1 - SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
–– 2 - TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
–– 3 - ESSENTIAL RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
–– 4 - REMOVAL AND REFITTING OF THE SX 14 S UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CASAPPA MVP 60 PUMP ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
–– PRESSURE TEST PORT VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
–– CASAPPA HYDRAULIC PUMP TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
(10/11/2016)
70-04-M218EN
70
–– 5 - SX 14 S UNIT REPAIR PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2
HYDRAULIC CONTROL AND ADJUSTMENT
DISTRIBUTOR CONTROL LOGIC
The JSM sends directional and proportional value data from rollers 1 and 2 to the SPU computer. The
computer converts these data into PWM control signals for the 4 coils controlling attachment and boom
movements.
A12
F N R
10
2
3
6
4
5
170
9
175
X36
168
2
R2
174
1
X36
D+ D-
173
X78
R1 D+ D-
BP5
Down
172
Up
7
1
11
8
12
EP27
CN1-B / X57
5
16
22
IN ANA 4
24
SPU
A3
170
171
IN TOR
14
IN ANA 3
OUTPWM 6
OUTPWM 5
29
CN1-B / X57
18
177
2
179
178
14
12
1
10
18
26
120 ohms
28
1
2
X57
14
9
17
25
34
11
Y18
ACCES -
2
Y15
12
11
10
9
8
7
1
SORTIE
TELES
2
X28
Y16
193
X29
1
2
3
4
5
6
177
177
1
6
192
176
X34
5
1
RENTREE
TELES
2
X105 193 noir
2
2
X105 192 noir
177
1
176
176
8
X105 194 noir
ACCES +
7
X87
194
179
179
1
Y17
70-04-M218EN
4
179
X35
3
X105 195 noir
178
178
X87
195
178
70
CN1-A / X56
176
7
13
19
26
OUTPWM 8
OUTPWM 7
CN1-A / X56
IN TOR 15
X56
1
8
14
20
12
11
10
9
8
7
EP26
168
169
169
1
2
3
4
5
6
(10/11/2016)
HYDRAULIC CONTROL AND ADJUSTMENT
3
JSM
70
SPU
Distributor SX14S
(10/11/2016)
70-04-M218EN
HYDRAULIC CONTROL AND ADJUSTMENT
4
OPERATING PRINCIPLES OF AGGRAVATING MOVEMENTS CUT-OFF
Movement cut-off is activated by the VRD/SPU or VCI at 105% gauge signal.
If the gauge signal indicates 112% the VS is also cut-off.
(These figures can change, depending on the boom angle)
The VS cut-off occurs 7 % after proportional cut-off to account for the possibility of the S.P.U. taking
longer to cut off the proportionals. The VS, therefore cuts off all movements at 112 %.
MA
1
VCI
LS
M
b B1
D
A1
b B2
A2
A3
B3
A4
B4
b B5
1
2
A5
D
3
4
DLS
2
b
b
P
Tdd
70
VS
a
LS
T
T
T
EE
B
A
B
T
EI
a
EA(O)
a
a
b
T
T
ET
EA
3
VRD
B
EF
EL
a
Pr
Tpr
1 - Tilting cut-off valve (VCI).
2 - Movement cut-off valve (VS).
3 - Flow distributor (VRD).
70-04-M218EN
(10/11/2016)
HYDRAULIC CONTROL AND ADJUSTMENT
5
70
SX 14 S DISTRIBUTOR REMOVAL
1 - SAFETY INSTRUCTIONS
Safety instructions and important notices which you must closely observe are shown in this chapter in
the following way:
bb
Instructions to be followed without fail to ensure your safety and avoid the risk of damage to
the equipment in the course of maintenance operations.
(10/11/2016)
70-04-M218EN
6
HYDRAULIC CONTROL AND ADJUSTMENT
2 - TROUBLESHOOTING
bb
Before carrying out any of the fault-finding procedures to detect the cause of the breakdown
or before removing the control block, it is essential to first carry out an examination of the
machine’s hydraulic circuit in order to eliminate any breakdown resulting from causes external
to the SX 14 S distributor unit.
Abnormal operation of the actuators connected to the control block.
Results observed
Probable cause
Additional checks
Lack of power at all
actuators
- LS pressure relief valve defective Measure pressure (see
- LS pressure relief valve out of
unit specifications)
adjustment
Lack of power on one
actuator only
- S econdary overpressure
limiter out of
adjustment
- S econdary pressure
relief valve jammed
"open" (return to tank)
70
- Incorrect slide stroke
- Adjustable hydraulic
control stop out of
adjustment
- Individual compensator
pressure blocked
Manual control: measure
slide stroke.
Direct electrical control:
check the coil resistance
(electric locks) (R: 2,5
Ohm at 25°C)
Failure to maintain
pressure
- Load hold check valve
faulty
- Excessive play between
the body and the slide
Steering abnormally hard Flow divider adjustment
problem
Excessive delay in
response to steering
70-04-M218EN
Flow Divider regulation
piston filter clogged
- Replace the LS pressure
relief valve (see section 5.1)
- Adjust the setting
-R
eset to design
pressure (see unit
specifications)
-R
eplace the secondary
pressure relief valve
(see section 5.5)
Change the body +
piston assembly
Lack of speed in one or all For SX 14 S fitted with
movements
“Open center” on the inlet
element: “Open center”
piston stuck in position P
towards T
Lack of speed in one
movement
Solutions
-C
ontrol piston sliding
freely
-C
ontrol piston jammed
- If stroke is incorrect,
change the body +
slide assembly. If the
resistance is incorrect
change the coil.
- Adjust the setting
- Replace body and
pressure compensator
assembly
-C
hange the body +
valve assembly
-C
hange the body +
slide assembly
-R
eplace control subsystem (see section
5.3)
-R
eplace body and
control sub-system
(see sections 5.7 and
5.3)
Change the filter
(10/11/2016)
HYDRAULIC CONTROL AND ADJUSTMENT
Results observed
Probable cause
Simultaneous movement
fault
- Individual compensator
orifice blocked
Additional checks
7
Solutions
- Remove and clean
individual compensator
(see section 5.7)
- Replace body and
pressure compensator
assembly
- Replace LS flow regulator
(see section 5.2)
- Individual compensator
pressure blocked
- LS line leakage
Abnormal machine operation.
Results observed
Probable cause
Additional checks
Engine remains under load - Flow regulator blocked
after slides have returned - R
egulator filter blocked
to neutral
Solutions
- Change the flow regulator
(see section 5.2)
- Change the filter
Abnormal control block operation.
Coupling fault
Probable cause
Additional checks
Solutions
- Mechanical defect
- Defective coil
- Check coil resistance (R: - Change the mechanical
16,5 Ohm at 20 °C)
lock
- If resistance is incorrect,
change the coil
Increased force on controls Control block assembly tie Check tightening torque Lo o s e n a n d a d j u s t t o
or slide return defective
rods too tight
tightening torque 42 ±
10% Nm.
Slide seals worn out
(10/11/2016)
bb
First free the
control block from
its fixing points
Replace the slide seals (see
section 5.6)
70-04-M218EN
70
Results observed
8
HYDRAULIC CONTROL AND ADJUSTMENT
Visually observable defects.
Results observed
Slide oil leaks
Probable cause
Defective slide seals
Oil leaks at pressure relief Defective seals
valves and plugs
Oil leakage between
elements
Defective seals between
elements
Hydraulic controller oil
leaks
- D efective seal between
unit and housing
- Defective adjustable stop
nut seal
Damaged joystick control
bellows
Additional checks
Solutions
Replace the slide seals (see
section 5.6)
Remove the pressure relief
valve or the plug and
replace the seals
R e m ove d i s t r i b u t i o n
modules and change seals
(see section 5.7)
Change the seal
Replace boot
3 - ESSENTIAL RULES
70
GENERAL NOTES CONCERNING THE CONNECTION OF THE DISTRIBUTION UNIT
–– When the block is removed all openings must be plugged immediately to avoid any contamination
of the hydraulic circuit.
–– When re-fitting the block remove the plastic plugs from openings just before re-making connections.
–– Do not tighten connectors to a torque greater than that specified in the assembly instructions.
–– Check the quality of the hydraulic oil and the filtration capacity during all maintenance or repair
operations.
–– The use of PTFE tape, hemp and jointing compound is forbidden.
–– Hydraulic lines and connections must be under not strain of any kind.
70-04-M218EN
(10/11/2016)
HYDRAULIC CONTROL AND ADJUSTMENT
9
4 - REMOVAL AND REFITTING OF THE SX 14 S UNIT
4.1 GENERAL GUIDANCE
bb
Before removing the SX 14 S control block it is essential to fully clean the unit and its surroundings
(Do not apply the output from a pressure washer directly to the unit).
It is essential that the hydraulic circuit is kept clean of all dirt or foreign objects. Use plastic
plugs on openings and pipes as soon as they are removed.
Wear protective clothing and use correct equipment to avoid any accident, particularly with
the fluid.
Use the lifting eye-bolts and appropriate maintenance equipment.
Place all the machine’s actuators attached to the control block in their rest positions (resting on
the ground, at the bottom of their movement etc.) to avoid any accident arising from unplanned
movements as a result of disconnecting the hydraulic circuit.
With the machine stopped: Release stored pressures by moving all the distribution slides.
4.2 SX 14 S UNIT REMOVAL
–– Fit a vacuum pump to the tank to limit oil leakage when connections are broken.
–– As soon as lines are disconnected from the control block, plug all openings.
–– Be sure to catch any escaped oil in an appropriate recipient.
–– Unscrew the mounting screws and remove the control block.
–– Ensure all mating faces are perfectly clean.
–– Check the mating face on the machine for flatness (Tolerance 0,5 mm).
–– Check the condition of all seals on line connectors.
–– Clean the block if it has been in prolonged storage.
–– Correctly offer the block up to the machine and fix it in place with bolts.
–– Connect the lines to the block as per the connecting diagram and the specified torques.
–– Ensure that hoses are deployed so that are not twisted or rubbing on anything.
–– When fitting has been correctly carried out, the control block can be put back into service:
⇒⇒ Decalibrate the LS relief valve before putting the machine into service.
⇒⇒ Keep one of the distributor lines activated after the hydraulic cylinder connected to it reaches
its end stop.
bb
On the distribution line in question, the value of the secondary pressure limiter must be greater
than that to be set with the LS limiter.
–– Adjust the maximum pressure measured at M. with the LS pressure limiter.
–– Retighten the locknut on the adjusting screw to torque: 20 ± 10% N.m.
(10/11/2016)
70-04-M218EN
70
4.3 SX 14 S UNIT REFIT
10
HYDRAULIC CONTROL AND ADJUSTMENT
5 - SX 14 S UNIT REPAIR PROCEDURES
5.1 CHANGING THE LS LIMITER
NOTE: There is no need to remove the control block from the
machine for this operation.
bb
Machine switched off:
- Place all actuators connected to the control block in
their rest position.
- Release all stored pressure by moving the distribution
slides.
NOTE: Catch any escaped oil in an appropriate container.
On the inlet element, unbolt the LS limiter (17 mm spanner).
Reassembly: tightening torque: see section 6.
5.2 CHANGING THE FLOW REGULATOR
NOTE: There is no need to remove the control block from the
machine for this operation.
bb
70
Machine switched off:
- Place all actuators connected to the control block in
their rest position.
- Release all stored pressure by moving the distribution
slides.
NOTE: Catch any escaped oil in an appropriate container.
On the inlet element, unbolt the LS limiter (22 mm spanner).
Reassembly: tightening torque: see section 6.
Filter removal and replacement
Using flat-nosed pliers, remove the filter from the regulator.
Filter
70-04-M218EN
bb
ake care not to damage the O-ring at the end of the
T
regulator.
(10/11/2016)
HYDRAULIC CONTROL AND ADJUSTMENT
11
5.3 REMOVAL OF FLOW DIVIDER CONTROL SUBASSEMBLY
NOTE: There is no need to remove the control block from the machine for this operation.
bb
achine switched off:
M
- Place all actuators connected to the control block in their rest position.
- Release all stored pressure by moving the distribution slides.
NOTE:
- Fit a vacuum pump to the fluid tank in order to limit any oil
leaks during this operation.
- Catch any oil leaks in an appropriate recipient.
- Unscrew the plug (12 mm Allen key).
- Remove the stop and the spring.
Reassembly: tightening torque: see section 6.
Selector kit
Ball
- Replace any defective parts.
- Replace the O-rings on the plugs.
- Reassembly is the reverse of removal.
O-rings
70
Sealing kit
Piston kit
5.4 FLUSHING VALVE REMOVAL
NOTE: There is no need to remove the control block from the machine for this operation.
bb
Machine switched off:
- Place all actuators connected to the control block in their
rest position.
- Release all stored pressure by moving the distribution
slides.
(10/11/2016)
70-04-M218EN
12
HYDRAULIC CONTROL AND ADJUSTMENT
Plug
O-ring seal
- On the output element, unscrew the flushing valve plug (12
mm Allen key).
Spring
Reassembly:
- Replace the plug O-ring.
- Tightening torque: see section 6.
Shims
Remove:
Piston
T3
- the shim,
- the spring,
- the ring,
- the piston.
- Reassembly is the reverse of removal.
5.5 SLIDE REMOVAL
NOTE: There is no need to remove the control block from
the machine for this operation.
bb
70
Machine switched off:
- Place all actuators connected to the control block
in their rest position.
- Release all stored pressure by moving the distribution
slides.
NOTE:
- Fit a vacuum pump to the fluid tank in order to limit any
oil leaks during this operation.
- Catch any oil leaks in an appropriate recipient.
- Remove the cover fixing screws (5 mm Allen key).
Reassembly: tightening torque: see section 6.
- Remove the cup and spring.
- Remove the O-ring from the cover.
- Extract the slide from the distribution element.
bb
Reassembly: grease new seals when fitting.
Slide fitting direction.
70-04-M218EN
(10/11/2016)
HYDRAULIC CONTROL AND ADJUSTMENT
13
5.6 CONTROL BLOCK REMOVAL/REASSEMBLY
Preliminary operations:
- Remove the control block from the machine (see section 4).
- Remove the 3 assembly nuts (13 mm socket).
Reassembly: tightening torque: see section 6.
- Remove the output element (1).
- S eparate the distribution elements (2) from the inlet
element (3).
- Replace the O-rings between the distribution elements,
the inlet element and the output element.
- If the inlet element is to be replaced, remove the tie rods.
- Reassembly is the reverse of removal. Ensure that tie rods
are torqued to the correct torque.
- B efore commencing, ensure that mating faces on the
elements are clean.
3
2
1
70
Individual pressure compensator removal
- Unscrew the plug (7 mm Allen key).
- Remove the compensator piston.
- Clean the piston's nozzle with compressed air.
- Check the condition of the bore.
Reassembly: replace the O-ring and the anti-extrusion ring
in the plug.
(10/11/2016)
70-04-M218EN
HYDRAULIC CONTROL AND ADJUSTMENT
14
100 N.m
12
42
N.m
T3
13
9
6
7
30-35 N.m
60 N.m
10 N.m
5
8
30-35 N.m
10 10 N.m
11
100 N.m
20 N.m
5 N.m
10 N.m
Loctite 542
4
3
5 N.m
1 N.m
10 N.m
1 45 N.m
20 N.m
20 N.m
Loctite 542
45 N.m
± 6 N.m
3,5 N.m
± 0,5 N.m
70
2
1 - Relief valve
2 - Flow regulator
3 - DLS/LS Selector
4 - Priority valve seat
5 - Priority valve plug
6 - Anti-shock valve
7 - Balance plug
70-04-M218EN
8 - Hydraulic control unit
9 - Return spring housing
10 - EMS module control piston
11 - EMS module
12 - Flushing valve plug
13 - Tie-bolt nuts
(10/11/2016)
HYDRAULIC CONTROL AND ADJUSTMENT
15
CASAPPA MVP 60 PUMP ADJUSTMENT
Supplementary explanations for the Casappa hydraulic pump:
70 - Hydraulic characteristics and specifications.
e 80
- Electrical characteristics and specifications.
PRESSURE TEST PORT VALUES
Delta P1 generated by weak flow passing through the distributor pressure compensator (Item 1).
Delta P2 generated by the flow passing through the limiter (Item 2). This delta P2 depends on the
distributor Delta P1.
The PLS pressure port must be mounted between the connector (Item 3) e "HYDRAULIC SPECIFIC
TOOLING - Casappa pressure test port connector" and the pump (Item 4) so that the delta P2 value can
be taken into account.
Example: Hydraulic control (Setting "b")
Values on diagram for information purposes only.
Delta P1
P
2
D EE
D
b B1
EI
A1
DLS
240b
M
1
P
70
b
LS
M
Ppompe
B
Delta P2
PLS
X
b
223b
240b
Tdd
VS
315b
700mA
223b
Y20
17b
S
IPEC
LS
T
270b T
T
B
A
T
190b 280b
a
3
Filter
Flow limiter
(10/11/2016)
4
70-04-M218EN
HYDRAULIC CONTROL AND ADJUSTMENT
16
IDLING SPEED (<1000 rpm)
IPEC
Minimum setting
Maximum setting
•
•
Twater < 60 °C
(Engine water sensor
voltage = 1,50 V)
Twater > 70°C
(Engine water sensor
voltage = 1,24V)
Distributor neutral
600 mA
Maximum movement
Distributor neutral
700 mA
Maximum movement
PLS
Ppump
0 bar
17 bar
223 bar
240 bar
0 bar
17 bar
206 bar
223 bar
The current at the PEC can reach 900 mA if the engine stalls. The pressure at pump exit will fall to 189 bar.
When cold the efficiency is reduced, we need more pressure to raise loads.
For 60 °C <; Twater < 70 °C, a slope is taken into account between 600 mA and 700 mA.
Current
Temp Limit
Cold Zone
Temp Limit
Hot Zone
COLD
ZONE
Current Min Hot Zone = Current Min Low Speed
Current Min Cold
Zone
HOT
ZONE
70
Engine Coolant Temperature [°C]
MAX. ENGINE SPEED (>1250 rpm)
IPEC
Distributor neutral
Minimum current
Ppump
0 bar
17 bar
271 bar *
253 bar, 288 bar max.
200 bar
217 bar
300 mA
Maximum movement
Maximum current
PLS
800 mA
If the engine stalls (< 800 rpm), the pump will control the pressure is such a way as to lower it to 217 bar.
* PEC pressure value, the pressure read will be that of the distributor LP (253 b).
70-04-M218EN
(10/11/2016)
HYDRAULIC CONTROL AND ADJUSTMENT
17
CHECKING STAND-BY PRESSURE
To carry out a quick check of flow regulator adjustment or if it is not possible to assemble the pressure
take-offs directly on the pump, a less precise measurement can be taken when the machine is at standby (no machine movements) at minimum rpm.
In these conditions, the pressure supplied can be more simply measured at the pressure take-off port
on the distributor block.
PP
X
D EE
B
D
EI
b B1
A1
T
A
DLS
Delta P2
P
LS
M
Delta P1
Pressure test port
M
P
Tdd
VS
Y20
S
T
LS
T
B
T
a
Acceptable Delta P range in standby condition: 17 - 20 bar
70
CHANGING THE STANDBY PRESSURE
To modify the LS regulation setting:
• Unscrew the LS regulator cap (1)
• Loosen the LS regulator locknut (2)
bb
Take care with the washer (3); it can be damaged in the course of this operation
• Tighten/loosen the LS regulation screw (4) to increase/reduce the Delta P adjustment.
• When the Delta P measured is within the acceptable range, tighten the LS regulator locknut (2).
• Re-affix the LS regulator cap (1).
¼ turn (90 °) on the flow regulator screw equates to approximately 3 bar change on the flow regulator.
1
4
3
(10/11/2016)
2
70-04-M218EN
18
HYDRAULIC CONTROL AND ADJUSTMENT
CASAPPA HYDRAULIC PUMP TIGHTENING TORQUES
in (Nm)
35
10
35
e Detail A
30
15
30
Detail A
70
20
30
2
30
130
30
50
25
15
70-04-M218EN
(10/11/2016)
HYDRAULIC CONTROL AND ADJUSTMENT
19
50
15
70
A-A
0,7-1
Bleed screw
15
AIR BLEED PROCEDURE
If necessary, residual air in the valve can be bled using the air bleed valve (cross-section AA).
The procedure is as follows:
• Loosen the air bleed screw in the adjustment screw by 2 turns.
• Pressurise the circuit to force out the air. Repeat several times if necessary.
• Tighten the air bleed screw, applying a tightening torque of 0,7-1 Nm.
(10/11/2016)
70-04-M218EN
HYDRAULIC CONTROL AND ADJUSTMENT
70
20
70-04-M218EN
(10/11/2016)
HYDRAULIC COMPONENTS REMOVAL
pages
DISTRIBUTOR REMOVEL (MLT EXCEPT MLT 732) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
70
HYDRAULIC PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
(08/07/2016)
70-06-M218EN
2
HYDRAULIC COMPONENTS REMOVAL
DISTRIBUTOR REMOVEL (MLT except MLT 732)
70
A
Key:
A - Hydraulic engine
PREPARATION AND SAFETY INSTRUCTIONS
–– Stabilise the machine on level ground.
–– Raise the boom and secure in position.
–– Deactivate battery power supply by means of the battery cut-off.
–– Before fully unscrewing a hose coupling, detach the hose from
the coupling to which it is attached to check that there is no
residual pressure in the circuit.
–– For the correct operation of the machine after repair, it is
recommended to plug all open sections of the hydraulic circuit
Specific tooling:
- Jib crane
70-06-M218EN
(08/07/2016)
HYDRAULIC COMPONENTS REMOVAL
3
Switch off the power supply.
Remove the protective casing (Item 1) and the flap (Item 2)
2
Placer a drain pan under the machine to collect the oil that will
drain from the distributor.
Depressurise the hydraulic circuit.
1
5
10
9
8
7
3
6
4
Remove the HP (Item 3), tank return (Item 4) and main LS hose
(Item 5).
Remove the fitting (Item 6)
Remove the hose (Item 7)
Remove the hose (Item 8)
Remove the hose (Item 9)
Remove the hose (Item 10) (according to option)
bb
Locate their positions to ensure they are correctly
reconnected
15
14
13
12
11
70
Remove the fitting (Item 11)
Remove the hose (Item 12)
Remove the hose (Item 13)
Remove the hose (Item 14)
Remove the hose (Item 15) (according to option)
bb
Locate their positions to ensure they are correctly
reconnected
19
19
18
18
16
17
(08/07/2016)
On the right of the distributor.
Remove the pressure test
port connector (Item 16)
Remove the hose (Item 17)
Remove the fitting (Item 18)
Remove the hose (Item 19)
bb
Locate their positions
to ensure they are
correctly reconnected
70-06-M218EN
4
HYDRAULIC COMPONENTS REMOVAL
(According to option) Remove the control hoses (Item 19) from
the lower part of the distributor.
Disconnect the connectors X29 and X34 (Item 20)
bb
Locate their positions to ensure they are correctly
reconnected
19
20
20
(According to option) disconnect the hose (Item 21) from the
electrovalve (Item 22).
22
21
70
Rear of the distributor:
Disconnect the hoses (Item 23) and remove the screws from
the valve support bracket (Item 24)
bb
Locate their positions to ensure they are correctly
reconnected
24
23
24
23
Cab interior:
Remove the screw (Item 25) and take off the casing (Item 26).
26
25
70-06-M218EN
(08/07/2016)
HYDRAULIC COMPONENTS REMOVAL
5
Remove the screws (Item
27) and tilt the SPU support
forward (Item 28).
28
27
30
30
(According to option), remove the cab hydraulic hook cable
(Item 29)
(According to option) Disconnect the two or three connectors
X28, X35, (X92) (Item 30)
30
bb
31
31
31
Locate their positions to ensure they are correctly
reconnected
31
31
(According to option) Disconnect the four or five control hoses
(Item 31) from the upper part of the distributor.
29
bb
Disconnect the safety valve connector (X23) (Item 32)
32
33
33
Remove the screw securing the distributor support bracket to
the frame (Item 33)
33
(08/07/2016)
70-06-M218EN
70
Locate their positions to ensure they are correctly
reconnected
6
HYDRAULIC COMPONENTS REMOVAL
Move the distributor to the side
(Item 34), remove the ground
wires (Item 35) and remove
the cables from the retaining
plates (Item 36) above and
below the distributor.
34
35
36
36
Sling the distributor and remove.
Place it is a suitable location for maintenance.
34
70
When refitting, preparer for the re-installation of the distributor
by placing the hoses in such a way that they will not be trapped
behind the distributor control heads after it is placed.
(According to option) When installing the hydraulic hook release
rod, ensure that the nut is correctly bearing on all threads.
70-06-M218EN
(08/07/2016)
HYDRAULIC COMPONENTS REMOVAL
7
HYDRAULIC PUMP REMOVAL
70
A
Key:
A - Hydraulic pump
PREPARATION AND SAFETY INSTRUCTIONS
–– Stabilise the machine on level ground.
–– Raise the boom and secure in position.
–– Deactivate battery power supply by means of the battery cut-off.
–– Place a drain pan under the vehicle.
Specific tooling:
- Jib crane
(08/07/2016)
70-06-M218EN
8
HYDRAULIC COMPONENTS REMOVAL
Remove the flap, 3 screws (Item 1)
1
1
1
Remove the clamp (Item 1), unscrew the 3 hoses (Item 2) and
disconnect connector X104 (Item 3).
2
2
3
2
1
70
Unscrew the 2 hoses (Item 1).
1
1
3
Unscrew the 2 hoses (Item 1).
Unscrew the 4 screws of the suction flange (Item 2), recover the
seal and hold it high.
1
1
Unscrew the tank return hose from the distributor (Item 3).
2
70-06-M218EN
(08/07/2016)
HYDRAULIC COMPONENTS REMOVAL
9
Unscrew the 4 pump fastening screws (Item 1).
1
1
1
1
Clearly identify the angle of the hose.
Unscrew the 4 screws from the hose connecting flange (Item 1).
When refitting, fill the pump with hydraulic fluid.
1
(08/07/2016)
70-06-M218EN
70
Sling the pump and lift out.
HYDRAULIC COMPONENTS REMOVAL
70
10
70-06-M218EN
(08/07/2016)
HYDRAULIC SPECIFIC TOOLING
pages
BASIC MANOMETER SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DIGITAL MANOMETER SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
70
CASAPPA PRESSURE TEST PORT CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
(08/11/2013)
70-09-M218EN
2
HYDRAULIC SPECIFIC TOOLING
BASIC MANOMETER SET
This box contains all the components required for measuring
pressure on all Manitou products.
6
2
3
3
4
5
70
1
5
8
7
Basis gauge kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .549671
Consisting of:
1 2 3 4 5 6 7 8 -
1 gauge 1/9 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549882
1 gauge 0/40 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549883
2 gauge 0/60 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549884
1 gauge 0/400 bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549885
2 gauge 0/600 bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549886
4 standard hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549887
2 hoses for telehandler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549888
7 gauge tap connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549889
70-09-M218EN
(08/11/2013)
HYDRAULIC SPECIFIC TOOLING
3
DIGITAL MANOMETER SET
FUNCTIONS:
• Gauge function: the display allows the following combinations:
⇒ The upstream pressure temperature at +/- 2°C
⇒ The upstream temperature P1 with its mini and maxi (700 bar
in class 0.1)
⇒ Downstream pressure P2 with its min. and max. (700 bar
in class 0.1)
⇒ Differential pressure ΔP=P1-P
• Hold function: The user can freeze the screen display at any
time to take notes
• Unit function: The user can change the unit of measurement
at any time (bar, psi, kPa, mCe).
• Function Tare: Enables offset to zero
• Leak test function: Can measure a pressure variation over a
specified time
70
• Record function: A maximum of 16000 readings can be recorded.
The sampling period can be configured.
• Reset function: The 2 sensors are reset to zero
Digital Manometer kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .662187
Consisting of:
1 2 3 4 -
1 digital gauge ΔP HP 700 bar
1 measurement hose DN2 1215/1620, L = 1,5m, 630 bar
2 measurement hoses DN2 1620/1620, L = 1,5m, 630 bar
2 gauge adaptors 1620
(08/11/2013)
70-09-M218EN
4
HYDRAULIC SPECIFIC TOOLING
CASAPPA PRESSURE TEST PORT CONNECTOR
70
Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .317397
70-09-M218EN
(08/11/2013)
ELECTRICITY
- ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
- ELECTRICAL SCHEMATIC DIAGRAMS
- ELECTRICAL COMPONENTS LOCATION
- ELECTRICAL CONTROL AND ADJUSTMENT
- ELECTRICAL COMPONENTS REMOVAL
- ELECTRICAL COMPONENTS REFIT
- ELECTRICAL TROUBLESHOOTING
80
- ELECTRICAL SPECIFIC TOOLING
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
pages
WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– FUSES AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– ELECTRICAL CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
OVERVIEW OF ELECTRICAL AND ELECTRONIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INPUTS/OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
–– MAIN ECU - SPU 25-15 - A3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
–– HYDRAULIC PUMP REFIT -A4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
–– ENGINE ECU - A19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
–– GEAR BOX ECU PG115 - A22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
80
DATA SHEETS FOR ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
(13/07/2016)
80-01-M218EN
2
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
WIRING
FUSES AND RELAYS
K17
X46
3
5
5A
K18
X95
5A
DETAILS ON THE HOLDER PLATE IN THE CAB
F32
F31
X47
X192
21 X48
3
5
4
2
2
1
86
25A
20A
86
X181
X187
1
6
15A
15A
15A
10A
15A
D
X37
F30
X188
C X39
1
80
B X40
7.5A
10A
10A
10A
F15
F23 F24 F25 F26 F27 F28 F29
7.5A
15A
F14
F22
5A
15A
F13
F21
7.5A
5A
F12
F11
15A
7.5A
F20
F10
7.5A
15A
F19
F9
10A
10A
F18
A X41
K9
F8
7.5A
15A
F17
F7
8
86
5A
7.5A
F16
5A
F6
1
30A
F5
30
2
F4
30
1
F
X180
85
87a
H
8
E
30
K6
5
X42
25A
30
85
86
85
87a
X45
I
X44
1
87a
85
4
1
K8
F3
G
87
F2
7
K4
87a
K7
X38
87
87
F1
4
3
5
87
3
5
2
3
5
K3
K2
K5
1
4
K1
2
1
2
1
4
3
5
K0
4
1
1
X190 X189
X191
Element
FUSES
80-01-M218EN
Item
Current
Designation
F1
7,5 A
LSU + AS OPTION
F2
15 A
REAR WORKING LIGHTS (STANDARD / OPTION)
F3
10 A
REAR WINDSCREEN WIPER + ROOF / SIDE WINDSCREEN WIPER
F4
15 A MAX.
F5
7,5 A
ROTATING BEACON LIGHT
F6
5A
WHEEL ALIGNMENTS + AS OPTION
F7
7,5 A
LLMI + OVERRIDE SWITCH + SENSORS + BLUE LIGHT OPTION (15 A)
F8
15 A
RELAYS K2/K3/K4 + TRANSMISSION CUT-OFF + JSM/FNR
F9
5A
DASHBOARD MODULE + INDICATOR LAMPS
ENGINE STOP EV OR ENGINE ECM
(13/07/2016)
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
FUSES
FUSES
RELAYS
(13/07/2016)
Item
Current
Designation
F10
10 A
HORN + STOP SWITCH
F11
15 A
WORKING LIGHT ON TELESCOPE (OPTION)
F12
10 A
INDICATOR LIGHTS
F13
30 A
VENTILATION
F14
25 A MAX.
F15
20 A
SPU
F16
5A
DIAGNOSTIC PLUG
F17
15 A MAX.
F18
15 A
FRONT WORKING LIGHTS (STANDARD/OPTION)
F19
15 A
REAR WINDSCREEN DEFROST (OPTION)
F20
10 A
PNEUMATIC SEAT + AS OPTION (OPTION)
F21
10 A
FRONT WINDSCREEN WIPER + FRONT WINDSCREEN WASHER
F22
10 A MAX.
F23
7,5 A
RIGHT SIDELIGHT + MODULE LIGHTING
F24
7,5 A
LEFT SIDELIGHT + REAR PLATE LIGHTING
F25
7,5 A
RIGHT INDICATOR LIGHTS
F26
7,5 A
LEFT INDICATOR LIGHTS
F27
15 A
DIPPED HEADLIGHT + ANTI-FOG LIGHT
F28
15 A
HEADLIGHTS
F29
15 A
WARNING + ROOF LIGHT + ANTI-THEFT + CLOCK +REV COUNTER
F30
25 A
LIGHT COMMUTATOR SWITCH
F31
5A
STARTER
F32
5A
DIAGNOSTIC PLUG + HYDRAULIC MOVEMENT CONTROL UNIT
CIGARETTE LIGHTER
FAN DRIVE + REAR HYDRAULICS + ANTI-THEFT (OPTION)
BOOM SUSPENSION +BOOM ELECTRICAL PRE-WIRING + EVDTF (OPTION)
K0
NOT USED
K1
NC TRANSMISSION CUT-OFF
K2
NO TRANSMISSION CUT-OFF (ONLY ON NON PS)
K3
REVERSE GEAR
K4
FORWARD GEAR (ONLY ON NON PS)
K5
BUZZER
K6
NOT USED
K7
FREE
K8
ANTI-START
K9
FLASHING UNIT
K17
MODULE SIGNAL LIGHTS
K18
NEUTRAL SAFETY (ONLY ON NON PS)
80
Element
3
80-01-M218EN
4
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
Element
Item
K11
Designation
Not used
Module
1
K12
Air-conditioning time delay relay
Pos. Wire N°
Colour
To
30
91
YELLOW
2
X112/1
85
181
BLACK
0,6
BF3 Mod.1 K12
86
90
GREY
0,6
X112/2
87
92
YELLOW
2
X112/3
30
45
YELLOW
2
BF3 Mod.5 F45
85
250
GREY
0,6
BF3 Mod.2 K6
180
BLACK
0,6
BF3 Mod.2 K1-85
181
BLACK
0,6
BF3 Mod.1 K11-85
58
GREY
0,6
BF3 Mod.2 K3
30
70
Yellow
F14
85
348
Black
K4/85
86
87
K1
Predisposition (10 / 20 A)
86
130
Grey
X112/4
87
131
Yellow
X112/5
30
85
K2
Front intermittent windscreen wiper relay (10/20 A)
Module 2
86
87
K3
Free
85
30
85
Front working light relay (10 / 20 A)
68
Yellow
Ep.11
345
Black
K6/85
346
Black
K5/85
171
Grey
X13/8
172
Grey
X112/12
163
Yellow
X11/7
164
Yellow
X25/4
343
Black
Ground M2
344
Black
K6/85
156
Yellow
F1
347
Black
K5/85
348
Black
K1/85
86
132
Grey
X112/6
87
134
Green
X15/3
87
134
Green
X15/4
80
K4
Comments
80-01-M218EN
(13/07/2016)
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
5
Element
FUSE
RELAYS
(13/07/2016)
Item
Current
F33
1A
Main display power supply via dashboard plate
F41
5A
Diagnostic plug
F45
10A
Diesel fuel relay
F46
30 A
Main fuse
F47
30 A
Main fuse
F48
30 A
Main fuse
F49
30 A
Main fuse
80
DETAILS OF MAIN AND OPTIONAL FUSES AND RELAYS
Designation
K10
Telescope suspension cut-off relay (illustration e110-C)
K11
Telescope suspension power supply relay (illustration e110-C)
K20
Starting relay (engine)
80-01-M218EN
6
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
ELECTRICAL CONNECTORS
Item
Diagram
B1
headlight
(X136)
1
Item
2
4
P14
(X142)
2
2
B1
cab
(X136)
Diagram
2
4
P15
(X143)
1
1
3
1
3
8
2
4
P1
(X27)
2
10
S12
(X150)
1
3
9
7
1
8
2
10
P2
(X26)
9
17
S16
(X153)
9
7
1
8
1
10
S54
(X152)
9
7
P4
(X140)
1
8
P5
(X141)
2
10
S115
(X149)
P6
(X154)
80
2
10
9
7
1
P7
(X148)
8
S139
(X151)
P9
(X147)
P10
(X144)
2
10
P8
(X139)
9
7
1
2
4
TUV1
1
3
TUV2
P11
(X138)
P12
(X145)
P13
(X146)
80-01-M218EN
X1
1
2
X2
(13/07/2016)
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
Item
Diagram
Item
Diagram
4
3
2
1
X3
X16
1
2
3
4
5 6
9
7
8
4
3
2
1
X17
X18
2
2
X9
5
6
7
X8
5
6
7
X4
7
1
1
1
2
3
4
2
X10
X19
1
8
7
6
5
1
X11
2
1
X20
2
X12
1
2
3
4
A
X21
C
X13
1
X22
3
2
80
6
5
4
B
2
1
1
X23
2
X14
6
5
4
3
X15
8
7
6
5
4
3
2
1
A
A
B
B
C
C
8
7
6
5
4
3
2
1
A1
B1
C1
X24
A
C
(13/07/2016)
2
A8
B8
C8
1
B
80-01-M218EN
8
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
Item
Diagram
A8
B8
C8
8
7
6
5
4
3
2
Item
A
B
B
C
C
8
7
6
5
4
3
2
A1
B1
C1
1
A
1
Diagram
X32
1
2
8
X24
Eng.
2
10
9
X33
7
1
1
X34
1
X25
2
2
1
X35
2
17
9
X26
10
1
X27
X36
1
2
3
4
5
6
12
11
10
9
8
7
2
4
1
3
1
X28
X37
80
2
1
1
X29
6
2
B
A
C
F
B
A
F
E
D
E
D
C
X38
X30
1
4
3
5
X31
A
C
X31
A/C
80-01-M218EN
B
X39
1
7
6
13
(13/07/2016)
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
Item
Item
Diagram
X46
X40
1
7
Diagram
2
4
1
3
5
6
13
1
2
X48
1
7
1
2
X47
X41
6
13
8
2
10
X42
9
X49
9
7
1
X50
X44
1
11
10
21
X51
8
2
10
7
8
7
6
5
1
1
3
X53
5
7
X45
Electric
plate
24
80
X45
Frame
9
X52
4
3
2
1
2
4
6
8
X54
4
2
(13/07/2016)
5
6
7
8
1
2
2
4
3
1
80-01-M218EN
10
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
Item
X55
Diagram
Item
5
6
7
8
9
Diagram
X70
1
2
10
1
X71
2
X56
X57
1
8
14
20
7
13
19
26
1
10
18
26
X72A
X72B
X73A
9
17
25
34
X73B
X74
X58
4
3
1
2
X75
80
X59
X76A
X60
X76B
8
2
10
X61
2
9
7
3
1
X77
6
5
26
X68
13
14
1
X78
1
4
2
1
X69
80-01-M218EN
1
3
2
4
(13/07/2016)
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
Item
Diagram
Item
Diagram
1
2
3
X79
4
5 6
9
7
8
X87
Distributor
1
2
3
4
MLT
1
2
3
4
5
6
MT
1
X80
11
2
8
7
6
5
7
9
8
12
11
10
X81
X82
X89
1
4
X90
1
4
3
6
2
1
3
6
4
2
X83
X91
3
1
2
X84
1
X92
2
1
2
X85
1
X93
2
MLT
1
2
3
4
X87
MT
(13/07/2016)
1
2
3
4
5
6
X95
80
1
2
4
1
8
7
6
5
3
5
12
11
10
9
8
7
X97
1
2
X98
80-01-M218EN
12
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
Item
Diagram
4
5
1
Item
3
2
1
2
3
4
5
6
X111
X99
X100
Diagram
6
5
4
4
3
X112
3
2
3
2
X102
8
X103
1
2
1
X113
1
6
5
4
2
10
12
11
10
9
8
7
X114
9
3
7
2
1
1
X104
1
X115
16
80
2
8
9
1
8
X105
2
10
X116
X105
Distributor
9
7
1
8
X106
2
X107
X110
80-01-M218EN
2
10
1
2
3
4
5
6
X117
1
9
7
1
12
11
10
9
8
7
(13/07/2016)
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
Item
Diagram
6
5
4
3
2
1
X118A
Item
7
8
9
13
Diagram
6
5
4
3
2
1
X124
10
11
12
7
8
9
10
11
12
8
2
10
X119
1
2
3
4
5
6
X124
PS
9
7
1
7
12
11
10
9
8
1
X127
2
8
1
2
3
4
5
6
X120
9
X128
7
8
7
12
11
10
9
1
2
3
4
5
6
X120
Eng.
2
10
1
12
11
10
9
8
7
1
X134
2
3
4
80
X135
X121
14
7
8
1
25
24
1
36
13
12
X122
X123
(13/07/2016)
X137
X158
4
3
D
C
A
B
J
H
E
F
G
X159
1
2
80-01-M218EN
14
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
Item
Diagram
Item
Diagram
X163A
X174
60
30
31
1
X163B
1 2
28
1
X164
2
3
7
28
4
5
X175
5
X165
6
29
51
73
28
6 73
50
72
1
2
94
94
X166A
X176
X166B
X178
X167
3
X168
2
2
1
X179
80
1
1
4
3
6
X169
8
2
10
X186
9
7
X170
1
X193
X194
X171
X195
X196
X197
X198
X172
X199
1
2
X201
X172
A/C
2
1
80-01-M218EN
(13/07/2016)
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
Item
X204
Diagram
Item
2
X255
A/C
Diagram
1
6
5
4
X205
2
3
X206
15
1
A
C
1
4
B
53
X277
X207
56
X208
60
62
1
2
X209
1
2
X280
X246
1
2
80
X245
1
2
X247
X281
1
3
1
2
2
X252
X253
X255
(13/07/2016)
1
3
1
2
2
4
X282
4
2
1
X283A
1
2
80-01-M218EN
16
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
Item
X283B
Diagram
2
X284A
1
2
3
4
5
6
X285
1
2
1
12
11
10
9
8
7
4
3
X286
1
2
1
3
4
80
X292
3
2
80-01-M218EN
(13/07/2016)
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
17
OVERVIEW OF ELECTRICAL AND ELECTRONIC SYSTEM
Key:
1 - Dashboard module
2 - Stability module
3 - Cab fuse box
4 - Gear box ECU (MLT PS) - A22
5 - Main ECU - SPU 25-15 - A3
6 - Diagnostic plug
7 - Hydraulic pump ECU - A4
8 - Engine fuse box
9 - Engine ECU - A19
10 - Strain gauge
CAN Bus
Hardwired connection
1
10
5
15
RPM
x
100
20
0
00
2
25
00
00
0 30
3
6
7
16
8
15
7
14
6
13
5
5
12
4
11
3
10
2
ECU
8
9
PS
4
9
1
80
10
EN15000 OPERATION:
Boom lowering control: VRP installed as part of the distributor raising/lowering system. Flow limiting
nozzle fitted to lowering pilot pressure distributor inlet to restrict flow.
Telescope extension control: SPU computer (signal is controlled).
Attachment +/- cut-off: SPU computer (signal is controlled).
Tilting +/- cut-off: VCI (Tilting cut-off valve) fitted externally on MLT (except MLT 732) and MLT PS,
internally on MT + MLT 732.
Dangerous movements cut-out: Activated by VRP/S.P.U. or VCI at 105% gauge signal, and if gauge signal
exceeds 120%, additional VS cut-out. (Percentages can change, depending on telescopic boom angle).
Operation is identical to the MLT T = 2 cut-out thresholds, depending on strain gauge signal.
(13/07/2016)
80-01-M218EN
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
18
INPUTS/OUTPUTS
MAIN ECU - SPU 25-15 - A3
Key :
APC : Post contact power
+BAT : Permanent supply
GND : Ground
NO : Normally Open
NC : Normally Close
S .P .U . : Safety Power Unit
A3
1
8
14
20
X56
80
Pin
N°
1
2
3
4
5
6
7
Type
Supply
Proportional output
Logic output
Logic output
Supply
8
Analog input
9
10
Logic input
Logic input
11
Logic input
12
13
14
15
Logic input
ECU wake-up input
Proportional output
Logic input
16
Logic input
17
18
19
20
21
22
23
24
Logic input
Analog input
Stabilized output
Ground
Stabilized output
Logic input
Logic input
Logic input
25
Analog input
26
Ground
80-01-M218EN
7
13
19
26
Active
Function on carriage
Remarks
state
APC
ECU supply
0V to 12V Attachment sense proportional electrovalve
Head boom electrovalve
GND
Not used
Security electrovalve (VS)
GND
Proportional electrovalve (Lowering)
+BAT
ECU supply
0.5V to Boom angle sensor lane 2
4.5V
GND
Not used
GND
Easy Connect System switch (NF)
Disabling «agravating» hydraulic movement cut-off
Support valid only for 1 min
APC
switch (NO)
APC
Neutral roller 1 contact (NO)
Telescoping
APC
ECU wake-up (NO)
Cut-off by emergency stop
0V to 12V Attachment sense proportional electrovalve
APC
Tilting neutralization switch (NO)
Hydraulic movement neutralisation switch
GND
(NO) (TÜV)
APC
Conductor presence seat contact (NO)
0V to 12V JSM roller 1 potentiometer
Telescoping
5V
Not used
GND
ECU ground
10V
Strain gauge supply - Attachment control selector control
GND
Forced operation switch (NO)
GND
Not used
APC
Not used
0.5V to Boom angle sensor lane 1
4.5V
GND
ECU ground
(13/07/2016)
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
19
MAIN ECU - SPU 25-15 - A3
Key :
APC : Post contact power
+BAT : Permanent supply
GND : Ground
NO : Normally Open
NC : Normally Close
S .P .U . : Safety Power Unit
A3
1
10
18
26
9
17
25
34
X57
Type
CAN 1 High
CAN 1 Low
Supply
Supply
Proportional output
Proportional output
Logic output
Supply
Supply
CAN 2 High
CAN 1 120 Ω
Logic input
Analog input
Logic input
Logic input
Analog input
Logic output
CAN 2 Low
Logic input
Logic input
Logic input
Logic input
Logic input
Logic input
Proportional output
LIN Interface
CAN 2 120 Ω
Ground
Proportional output
Logic output
Ground
Logic output
Logic output
Ground ECU
(13/07/2016)
Active
state
APC
APC
0V to 12V
0V to 12V
APC
APC
APC
APC
0V to 12V
APC
APC
0V to 12V
APC
GND
APC
GND
APC
APC
APC
0V to 12V
0V to 12V
APC
GND
APC
APC
Function on carriage
CAN H J1939
CAN L J1939
ECU supply
ECU supply
Telescope direction electrovalve power supply
Lowering proportional electrovalve power supply
Security electrovalve (VS)
ECU supply
ECU supply
CAN H - not used
Not used
JSM Switch 1 (NO)
Attachment flow selector
Ventilation control switch (NO)
Retracted telescope sensor (NO)
JSM roller 2 potentiometer
Control fan speed electrovalve
CAN L - not used
Lock attachment switch (NO)
Not used
Overload detection (NO)
Conductor presence seat contact (NF)
Retracted telescope sensor (NC)
neutral roller 2 contact (NO)
Lifting proportional electrovalve
Not used
Not used
Ground
Telescoping proportional electrovalve control output
Fan drive directional electovalve
Ground
Tilting neutralization electrovalve (VCI)
Forced operation activation lamp
ECU ground
Remarks
Cut-off by emergency stop
Cut-off by emergency stop
EV TDF
Attachment
80
Pin
N°
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
Attachment
CAN Shield
Analog sensor
80-01-M218EN
20
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
HYDRAULIC PUMP REFIT -A4
Key :
NC : not wired
GND : Ground
A4
X110
X111
X110
X111
80
PIN N°
X110-1
X110-2
X110-3
X110-4
X110-5
X110-6
X110-7
X110-8
X110-9
X110-10
X110-11
X110-12
X111-1
X111-2
X111-3
X111-4
X111-5
X111-6
X111-7
X111-8
X111-9
X111-10
X111-11
X111-12
Type
Supply
Rx
CAN L
CAN H
Tx
Ground
Digital output
Proportional output
80-01-M218EN
Actif state
APC
ECU supply
NC
NC
NC
RS232
CAN L J1939
CAN H J1939
RS232
NC
NC
NC
GND
Ground
Function on carriage
Remarque
Diagnostic connector
Diagnostic connector
ECU, CAN and RS232 shielding
NC
NC
NC
NC
NC
NC
NC
NC
GND
Régulation Pressure Proportional Electroval
NC
0V à 12V Régulation Pressure Proportional Electroval
NC
(13/07/2016)
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
21
ENGINE ECU - A19
A19
X174
PIN
N°
Designation
PIN
N°
Designation
2
Injector cylinder 3 supply
3
Injector cylinder 2 supply
32
Injector cylinder 3 return
4
Fuel metering electrovalve supply
33
Injector cylinder 1 return
5
Fuel metering electrovalve return
35
Preheating relay coil supply
37
Camshaft speed sensor signal 2
38
Crankshaft speed sensor shielding
39
Crankshaft speed sensor signal 2
40
Intake manifold pressure and temperature sensor ground
43
Intake manifold pressure sensor signal
16
Fuel rail pressure sensor supply
Injector cylinder 1 power supply
18
Injector cylinder 4 power supply
19
EGR valve supply
20
EGR valve ground
44
Oil pressure sensor signal
23
Glow plug validation supply
45
Preheating relay coil return
24
Intake manifold pressure and temperature sensor & oil pressure &
fuel supply pressure supply
46
Injector cylinder 2 return
25
Fuel rail pressure sensor ground
48
Injector cylinder 4 return
26
Fuel rail pressure sensor signal
27
Intake manifold temperature sensor signal
52
Camshaft speed sensor signal 1
28
Coolant liquid temperature sensor signal
53
Camshaft speed sensor ground
29
Coolant liquid temperature sensor & oil pressure & fuel supply
pressure ground
54
Crankshaft speed sensor signal 1
80
7
* If the data passes through the CAN, the PIN cannot be used. Check the electrical diagram e 80 - ELECTRICAL SCHEMATIC DIAGRAMS
(13/07/2016)
80-01-M218EN
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
22
ENGINE ECU - A19
A19
X175
80
PIN
N°
Designation
1
Battery +
2
Battery -
3
PIN
N°
Designation
57
Water in fuel sensor supply
Battery +
61
Fuel supply pressure signal
4
Battery -
62
Accelerator pedal sensors ground
5
Battery +
63
Position accelerator pedal sensors signal
6
Battery -
64
Water in fuel sensor ground
68
Neutral safety relay supply
71
Engine warning lamp
73
Start relay coil ground
15
Neutral safety relay Info
16
Accelerator pedal throttle sensor signal
26
Fuel pump ground
27
Oil pressure lamp
75
CAN High
28
Start relay coil supply
76
CAN Low
29
Lamp supply by engine ECU
79
Air filter temperature sensor signal
35
Ignition switch - Start info
82
EGR position sensor ground
44
EGR position sensor supply (+5V)
85
EGR position sensor signal
46
Accelerator pedal sensors supply
88
Ignition switch on info
48
Preheating lamp
90
Fuel pump supply
53
CAN Low
54
CAN High
93
Engine stop lamp
* If the data passes through the CAN, the PIN cannot be used. Check the electrical diagram e 80 - ELECTRICAL SCHEMATIC DIAGRAMS
80-01-M218EN
(13/07/2016)
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
23
GEAR BOX ECU PG115 - A22
Key :
NC : Wireless
A22
Type
Digital Input
Digital Input
Digital Input
Digital Input
Freq Input
Serial I/F
Display
Display
Output
0V Output
Supply
Output
Output
Display
Display
Serial I/F
Freq ground
Digital Input
Digital Input
Digital Input
Digital Input
Digital Input
Digital Input
Digital Input
Serial I/F
Output
Output
Output
Output
Output
Output
Output
Output
Supply
(13/07/2016)
Function on carriage
Direction F
Gear Up
NC
NC
NC
Enable 5F/3R
Speed Sense
Rx
Display Clk
Display 0V
Handbrake
Common
Supply 0V
NC
Reverse Alarm
Display +5V
Display Data
Tx
Speed Sense
Handbrake
Trans Dump
Enable 6F5F/3R
Gear Down
Direction R
NC
Operator Presence
Program enable
Solenoid L
Solenoid H
Solenoid R
Solenoid 1
Solenoid 2
Solenoid 3
NC
Eng. Start enable
Supply +12V
Comments
Switched High
Switched High
No operation
No operation / Optional CAN H
No operation / Optional CAN L
Switched High
<10kHz
TTL serial port for test
1.0A max. high side
Must be next to 0V supply
No operation
1.0A max. high side
TTL serial port for test
Switched Low
Switched Low
Switched High
Switched High
Switched High
No operation
Switched High
80
PIN N°
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
2.9A max. high side with diagnostics
2.9A max. high side with diagnostics
2.9A max. high side with diagnostics
2.9A max. high side with diagnostics
2.9A max. high side with diagnostics
2.9A max. high side with diagnostics
No operation
2.9A max. high side
Via ignition switch. Fused externally to 15A
80-01-M218EN
24
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
80
DATA SHEETS FOR ELECTRICAL COMPONENTS
Pages
DATA SHEETS FOR ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
A12
JSM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
B1
REVERSING SOUND ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
B2
HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
B4
WATER IN DIESEL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
B6
AIR FILTER CLOGGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
B7
HYDRAULIC FILTER PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
B9 - B10
WHEEL ALIGNMENT SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
B11
STOP PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
B20
STRAIN GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
B23
TELESCOPE ANGLE POTENTIOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
B31
75°C HYDRAULIC TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
B32
90°C TRANSMISSION TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . 32
B33
BOOST AIR INTAKE TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . 33
B46
AIR-CONDITIONING HIGH PRESSURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . 33
B48
ACCELERATOR PEDAL ANGLE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
B69
GEAR BOX OIL PRESSURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
B70
GEAR BOX OIL PRESSURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
B80
AIR INTAKE TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
B85
RADIATOR WATER LEVEL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
B86 / X914
FUEL AND ENGINE OIL PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
E15
ROTATING BEACON LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
P1
HOUR METER / REV COUNTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
P2
FUEL GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
P3
WATER TEMPERATURE INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
R2
FUEL LEVEL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
R11
MANUAL ACCELERATOR SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
S2
STARTER IGNITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
S4
WIPER COMMUTATOR SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
S5
LIGHT COMMUTATOR SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
S7
CIGARETTE LIGHTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
S11
BRAKE FLUID LEVEL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
S19
POWERSHIFT TRANSMISSION HAND BRAKE SWITCH . . . . . . . . . . . . . . . . . 42
S19
MECHANICAL TRANSMISSION HANDBRAKE SWITCH . . . . . . . . . . . . . . . . . 43
S34
TELESCOPE RETRACTED POSITION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . 43
S50
EMERGENCY STOP BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
X907
INTAKE MANIFOLD PRESSURE & TEMPERATURE SENSOR . . . . . . . . . . . . . .45
X915 - X916
CRANKSHAFT AND CAMSHAFT SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . 45
Y6
PEC (PRESSURE ELECTRONIC CONTROL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Y7
TILTING CUT-OFF EV / VCI (MLT except MLT 732) . . . . . . . . . . . . . . . . . . . . . 47
80-01-M218EN
(13/07/2016)
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
TILTING CUT-OFF EV / VCI (MT + MLT 732) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
TELESCOPE PROPORTIONAL EV (MLT except MLT 732) . . . . . . . . . . . . . . . . 48
ATTACHMENT PROPORTIONAL EV (MLT except MLT 732) . . . . . . . . . . . . . 48
TELESCOPE PROPORTIONAL EV (MT + MLT 732) . . . . . . . . . . . . . . . . . . . . . . 48
ATTACHMENT PROPORTIONAL EV (MT + MLT 732) . . . . . . . . . . . . . . . . . . . 48
TELESCOPE LOWERING PROPORTIONAL EV / VRD (MLT except MLT 732) . 49
TELESCOPE LOWERING PROPORTIONAL EV / VRD (MT + MLT 732) . . . . 49
HYDRAULIC CUT-OFF EV / VS (MLT except MLT 732) . . . . . . . . . . . . . . . . . . 50
HYDRAULIC CUT-OFF EV / VS (MT + MLT 732) . . . . . . . . . . . . . . . . . . . . . . . . 50
STABILIZER SAFETY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
FAN DRIVE REVERSAL ELECTROVALVE (MLT except MLT 732) . . . . . . . . . . 51
FAN DRIVE CONTROL ELECTROVALVE (MLT except MLT 732) . . . . . . . . . . 52
80
Y7
Y15 - Y16
Y17 - Y18
Y15 - Y16
Y17 - Y18
Y19
Y19
Y20
Y20
Y40-Y41
Y42
Y43
25
(13/07/2016)
80-01-M218EN
26
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
A12 JSM
X36 / X78
Signal Roller 2
8
Controlleur ground
9
BP1
10
BP2 Option
11
Forward gear
12
Reverse gear
12
Signal Roller 1
7
11
6
8
Roller 2 direction B (-)
1
Roller 2 direction A (+)
5
4
6
3
2
10
10
11
12
5
7
4
F
Roller 1 direction B (-)
9
BP1
+
3
R2
D+ D-
BP2
Roller 1 direction A (+)
R1
D+ D-
–
7
8
9
Power supply (+5V)
2
BP2
FNR
6
5
4
3
2
1
1
−
R2
Function
+
R1
PIN
N
R
(Joystick Switch and Move)
2
Function
Speed +
2
Speed –
2
1
1
1
BP1
PIN
Diagram
Correspondent connectors
12 pins connectors
PIN
Minimum
Current in potentiometer under 5 V ± 10%
Supply voltage
Outlet voltage
Note :
1
80
Outlet voltage
Maximum
1 mA
2 mA
5V
6-7
0.5 V
2-3-4-5
Rollers 1 or 2 direction (+) or (-)
2 pins connecteurs
Typical
PIN
2.5 V
4.5 V
0V
12 V
0 V = neutral rollers
12 V = direction validations (+) or (-)
BP (+ / -) appuyés
BP (+ / -) relâchés
1 (+)
0V
12 V
2 (-)
0V
12 V
Note : ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80-01-M218EN
(13/07/2016)
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
B1
REVERSING
AVERTISSEUR
SOUND
SONORE
ALARM
DE MARCHE ARRIÈRE
PIN
X20
Function
1
Power supply
2
Cab rear ground
27
1
2
Corresponding connector
Diagram
Typical
Voltage
12 V
Sound frequency
2800 Hz
Comments:
Sound cycle: 50% off 50% on, with 1,2 pulses per second
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
B2
HORN
X74
PIN
1
Function
Buzzer power supply
80
Corresponding connector
1
Diagram
Typique
Supply voltage
12 V
Resistance
2,17 Ω
Consumption
6,00 A
Nominal frequency
500 ± 20 Hz
Sound level
107 dB(A) / 13V
Note :
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(13/07/2016)
80-01-M218EN
28
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
B4
WATER
WATER IN
IN DIESEL
DIESEL SENSOR
SENSOR
X178
PIN
2
1
Function
1
Ground
2
Power supply
SENSING
2
Corresponding connector
1 MΩ
1
Diagram
Typical
Power supply
5V
Comments:
Contact signal: from 0,15 ℓ of water U < 2,60 V
Diesel fuel signal: U> 2,91 V
Tightening torque: 1,6 ± 0,3 N.m
Resistance in air and diesel fuel: R = 24 MΩ
Broken detection wires: R = 1 MΩ
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
B6
AIR FILTER CLOGGING
X166 A and B
80
PIN
Function
A
Clogging info
B
Ground
Corresponding connector
A
B
P
Diagram
PIN
Nominal depression
Voltage
Consumption
Typical
62 mbar ± 5%
B
Ground
25 mA
Note : contact closed = clogged filter
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80-01-M218EN
(13/07/2016)
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
B7
HYDRAULIC FILTER PRESSURE SWITCH
PIN
1
2
29
X22
Function
1
Oil pressure info
2
Rear cab ground
1
2
P
Corresponding connector
Diagram
Comments:
Type 1 negative logic input (ELN1)
Trigger value : 5 bars.
Filter bypass opening pressure of 6 bar.
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
WHEEL ALIGNMENT SENSOR
X15 / X21
PIN
A
C
B
Function
A
Ground
B
Signal
C
Power supply
_
+
80
B9 - B10
Corresponding connector
B
A
C
Diagram
PIN
Typical
Supply voltage
B
12 V
Direct current
A
10 mA
Outlet logic
Switch closed = wheels aligned
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(13/07/2016)
80-01-M218EN
30
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
B11 STOP PRESSURE SWITCH
X73 A and B
PIN
Function
A
12 V power supply
B
Stop Light Control
Corresponding connector
A
B
P
Diagram
Note :
- The Pressure switch contact closes at a pressure of 3 ± 0,4 bar in the braking circuit.
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
B20 STRAIN GAUGE
X99
Function
Power supply
3
Ground
4
CAN_H
5
CAN_L
Corresponding connector
R120
1
Black
2
Red
Shielding
CAN H
1
CAN L
PIN
3
2
80
4
5
1
5
4
2
3
Diagram
Typical
Supply voltage
12 V
Consumption
150 mA
Comments:
- CAN integrated terminal resistance 120 Ω.
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80-01-M218EN
(13/07/2016)
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
B23 TELESCOPE ANGLE POTENTIOMETER
X100
PIN
6
5
4
3
2
1
31
Function
1
Ground
2
12 V Power supply
3
Track 1 angle signal (0,5 to
4,5 V)
4
Ground
5
12 V Power supply
6
Track 2 angle signal (0,5 to
4,5 V)
Corresponding connector
2
3
+
S
1
0
5
+
6
S
4
0
Diagram
Typical
Supply voltage
12 V
Direct current
10 mA
Outlet voltage
See notes and diagrams
Load resistance
20 kΩ
Angular range
0° - 90°
Note :
Adjustment of the angle sensor and calibration (mini angle, max angle) are provided on each machine to 0 km.
Both procedures are detailed in the following chapter:
Voltage (V)
e Group 80 - Electrical control and adjustment
S1
S2
Centring of adjustment range
80
5V
4,5 V
S1
S2
0,5 V
-45°
0°
45°
Potentiometer angle (°)
Representation of a potentiometer track (the other track is of the same
value but reversed).
⇒ Black, the operating range of the potentiometer.
⇒ Red, range and setting values.
⇒ α represents the angle of the truck.
Adjusting the angle sensor is detailed in the following chapter:
e Group 80 - Electrical control and adjustment
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(13/07/2016)
80-01-M218EN
32
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
B31 75°C HYDRAULIC TEMPERATURE
TEMPERATURESENSOR
SENSOR
PIN
2
1
X247
Function
1
NO switch info output
2
Power supply
1
Corresponding connector
2
T
Diagram
Typical
Tolerance
± 3,5
Activation threshold
75 °C
Deactivation threshold
60 °C
Comments:
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
B32 90°C TRANSMISSION TEMPERATURE
TEMPERATURE SENSOR
SENSOR
PIN
80
2
1
X246
Function
1
NO switch info output
2
Power supply
1
Corresponding connector
2
T
Diagram
Typical
Tolerance
± 3,5
Activation threshold
90 °C
Deactivation threshold
75 °C
Comments:
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80-01-M218EN
(13/07/2016)
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
B33 BOOST AIR INTAKE TEMPERATURE SENSOR
1
PIN
X245
Function
1
2
1
2
1
Info
2
Ground
33
Corresponding connector
2
T
Diagram
Temperature (°C)
Typical (Ω)
Tolerance (Ω)
0
16232
± 894
20
6201
± 282
25
4966
± 221
30
4002
± 169
50
1793
± 57
60
1239
± 42
Comments:
Operating range: -40°C to 150 °C
Type: CTN
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
B46 AIR-CONDITIONING HIGH PRESSURE SENSOR
1
2
Corresponding connector
Function
1
Supply
2
Info
2
1
80
PIN
X204
HP
Diagram
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(13/07/2016)
80-01-M218EN
34
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
B48 ACCELERATOR PEDAL ANGLE SENSOR
X179
PIN
1
3
6
1
4
Function
1
Red
+
4
Green
S
2
Black
-
6
Blue
3
White
5
Yellow
Signal 1 power supply
2
Signal 1 ground
3
Signal 2 info
4
Signal 1 info
5
Signal 2 ground
6
Signal 2 power supply
+
-
+
IVS
Corresponding connector
-
Diagram
PIN
Supply voltage
1-6
Outlet voltage
3-4
Minimum
Typical
Maximum
5V
0,5 V
2,5 V
4,5 V
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
B69 GEAR BOX OIL PRESSURE SENSOR
X98
PIN
1
Function
Signal
80
Corresponding connector
P
Diagram
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80-01-M218EN
(13/07/2016)
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
B70 GEAR BOX OIL PRESSURE SENSOR
35
X8
PIN
Function
1
Signal info
Corresponding connector
T
Diagram
Temperature
Typical
25 °C
2000 Ω
70 °C
2800 Ω
100 °C
3400 Ω
120 °C
4000 Ω
Comments:
Normal operating temperature is between 70 and 120 °C
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
B80 AIR INTAKE TEMPERATURE SENSOR
X164
2
1
Function
1
Ground
2
Signal
Corresponding connector
1
(-)
2
(S)
T
Diagram
Nominal voltage
PIN
Minimum
Typical
Max
2
4.85 V
5V
5.15 V
Max. measurement current
Note :
Temperature range : -40 - 150 °C (130 °C Perm. temperature max.)
Type : NTC
1 mA
Resistance at -10 °C : 8.325 à10.572 kΩ
Resistance at 20 °C : 2.280 à 2.736 kΩ
Resistance at 80 °C : 0.288 à 0.359 kΩ
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(13/07/2016)
80-01-M218EN
80
PIN
36
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
B85 RADIATOR WATER LEVEL SENSOR
X168
PIN
1
2
Function
2
1
1
Engine signal computer
2
Engine ground
N
Corresponding connector
Diagram
Maximum
Current
0,5 A
Power
2W
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
B86 / X914 FUEL AND ENGINE OIL PRESSURE SWITCH
PIN
80
1
3
4
2
X282 / X914
Function
1
Power supply
2
Signal
1
2
(+)
(S)
P
3
4
Ground
4
(-)
Diagram
PIN
Min.
Typical
Max.
Supply voltage
1
4,5 V
5V
5,5 V
Voltage threshold
2
0,5 V
4,5 V
Comments:
Measured pressure range: 0 - 7 bar
Signal: 0,25 V ≤ Underpressure < 0,5 V ≤ Normal ≤ 4,5 V < Overpressure ≤ 4,75 V
Loss of ground: signal ≥ 4,8 V
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80-01-M218EN
(13/07/2016)
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
E15 ROTATING BEACON LIGHT
37
X145
PIN
A
Function
A
Power supply
B
Ground
B
M
Corresponding connector
Diagram
Typical
Supply voltage
12 V
Consumption
5A
Note :
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
HOUR METER / REV COUNTER
0
30
9
Analog input 1
11
Analog input 3
PIN
1
3
Function
15
0-5 V Power Supply
2
Satellite Bus
16
Rear lighting
2
3
Analog ground
17
After ignition
4
4
Satellite power supply
25
Analog ground
17
2
25
3
4
20
25
Diagram
Corresponding connector
PIN
Voltage
Consumption
Min.
Typical
Max.
8,5 V
12 V
32 V
150 mA
Comments:
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(13/07/2016)
80-01-M218EN
80
K-Line
16
15
30
25
2651
29
11
Alimentation
8
5
9
Satellite BUS
CAN L
15
10 RPMx100
100
20
8
4
Ignition
4
3
GND ANA
CAN H
2
llumination
3
1
K-Line
Ground
CAN Low
2
Battery
+ Battery (permanent)
0-5V DC input
15
RPM
x
1
Analog
Input 1
Analog input 3
10
9
14
1
Function
Ground
PIN
26
13
X68 / X69
CAN High
P1
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
FUEL GAUGE
X90
2
Ground
3
Power supply
4
Satellite Bus
5
Ground
6
Power supply
Corresponding connector
Voltage
3
4
5
6
Battery
Satellite Bus
2
Ground
3
6
1
1
Satellite BUS
1
4
Function
Battery
PIN
Ground
P2
Satellite BUS
38
Diagram
Min.
Typical
Max.
10 V
12 V
16 V
100 mA without back-lighting
150 mA with back-lighting
Consumption
Comments:
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
WATER TEMPERATURE INDICATOR
X89
80
3
6
1
Satellite Bus
2
Ground
3
Power supply
1
2
3
Battery
1
4
Function
Ground
PIN
Satellite BUS
P3
Corresponding connector
Diagram
Voltage
Consumption
Min.
Typical
Max.
10 V
12 V
16 V
Max
100 mA without rear lighting
150 mA with rear lighting
Note :
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80-01-M218EN
(13/07/2016)
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
R2
FUEL LEVEL SENSOR
39
X165
PIN
1
2
Function
1
Analog input
2
Ground
2
1
Corresponding connector
N
Diagram
Supply voltage
PIN
Min.
Typical
Max.
1
/
12 V
/
Comments:
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
R11 MANUAL ACCELERATOR SENSOR
X286
3
2
1
Function
3
Analogue signal
5
Ground
6
Power supply
80
PIN
Corresponding connector
s
0
3
+
2
1
Diagram
PIN
Supply voltage
6
Analogue signal
3
Minimum
Typical
Maximum
5V
0,5 V
4,5 V
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(13/07/2016)
80-01-M218EN
40
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
S2
STARTER IGNITION SWITCH
X54 / X55
PIN
4
2
6
7
8
9
3
1
5
10
Function
1
+ Battery
2
+ Battery
3
Un used
4
Shunt preload
5
+ After contact (+APC)
6
+ After contact (+APC)
7
Starter
8
Shunt preheating
9
Preheating control relay
10
Un used
OP
30
30
17
17
50a
19
19
54
15
58
1
2
3
4
7
8
9
5
6
10
Diagram
Corresponding connector
POS
Note :
Voltage drop : 300 mV
PIN
O P Maxi - 12 V
ITIO
N
7 (50a)
x
8 (19)
x
x
9 (19)
x
x
5 (54)
x
x
x
6 (15)
x
x
x
18 A / 1min
70 A / 3.5min
70 A / 3.5min
65 A / ∞
65 A / ∞
x
10 (58)
8A/∞
x -> PIN = 12 V
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
S4
WIPER COMMUTATOR SWITCH
X79 / X80
Function
F
80
2
1
0
0
PIN
1
2
3
4
5 6
9
7
8
1
2
1
Rear windscreen wiper and
windscreen washer power supply
2
Rear screen wiper control
3
Front windscreen wiper power supply
4
Rear screen washer
5
Front screen washer supply
6
Front screen washer control
7
Front screen wiper speed 1
8
Front screen wiper speed 2
9
Intermittent
5
1
Rear screen wiper parking
3
2
Front windscreen wiper parking
1
Corresponding connector
0
2
1
1
0
9
8
7
6
4
2
Diagram
Typical
Voltage
Consumption
12 V
As per outputs
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
80-01-M218EN
(13/07/2016)
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
S5
LIGHT COMMUTATOR
COMMUTATORSWITCH
SWITCH
X188
PIN
4
5 6
9
7
8
2
Function
4
1
Light power
supply
2
Dipped beam
headlights
3
Headlight
signal
0
1
2
3
41
3
9
56a
57/58
0
4
Main beam headlights
5
Horn
6
Horn power supply
7
Indicator lights
power supply
8
Right-hand
indicator light
9
Left-hand
indicator light
1
56b
54s
54d
R
0
L
2
8
49
6
5
7
L
30
1
31
Diagram
Corresponding connector
PIN
Min
Voltage
Consumption
Typical
Max
12 V
24 V
As per outputs
Note :
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
CIGARETTE LIGHTER
X32 / X91
PIN
1
2
Function
1
Power supply
2
Ground
3
Rear lighting
1
2
3
80
S7
Corresponding connector
Diagram
Voltage
Consumption
Minimum
Typical
Max
10,5 V
12 V
15 V
6A
10 A
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(13/07/2016)
80-01-M218EN
42
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
S11 BRAKE FLUID LEVEL SWITCH
X72
PIN
Function
1
Module A1 info (dashboard)
2
Cab Front Ground
A
N
Corresponding connector
B
Diagram
Note : contact closed = Level OK
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
S19 POWERSHIFT TRANSMISSION HAND BRAKE SWITCH
PIN
80
1
2
3
4
Function
1
ECU info output
2
Ground
3
Lamp output
4
Ground
Corresponding connector
X12
1
2
3
4
Diagram
PIN
Typical
Lamp power consumption
3
25 mA
ECU power consumption
1
6 mA
Comments:
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80-01-M218EN
(13/07/2016)
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
S19 MECHANICAL TRANSMISSION HANDBRAKE SWITCH
PIN
1
2
3
4
X12
1
Function
1
ECU info output
2
Ground
3
Lamp output
4
Ground
Corresponding connector
43
2
3
4
Diagram
PIN
Typical
LED power consumption
3
25 mA
SPU power consumption
1
6 mA
Comments:
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
S34 TELESCOPE RETRACTED POSITION SENSOR
2
3
Corresponding connector
4
PIN
Function
1
12 V power supply ignition
on
2
12 V power supply ignition
on
3
NC switch info output
4
NO switch info output
80
1
X134
1
4
3
2
Diagram
Note :
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(13/07/2016)
80-01-M218EN
44
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
S50 EMERGENCY STOP BUTTON
3
2
Corresponding connector
1
1
Power supply Battery +
2
Engine EV power supply
3
Power supply + after
ignition starting
4
Starter relay output
5
Engine EV output
6
SPU Power Supply
1
1
2
3
4
SPU
Function
EVM
PIN
DEM
6
5
4
X114
1
2
2
5
2
1
6
Diagram
Comments:
Notes: ____________________________________________________________________________________
80
___________________________________________________________________________________________
___________________________________________________________________________________________
80-01-M218EN
(13/07/2016)
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
45
X907 INTAKE MANIFOLD PRESSURE & TEMPERATURE SENSOR
PIN
Function
1
Ground
2
1
(-)
2
(S1)
3
(+)
4
(S2)
Temperature signal
3
T
Supply voltage
4
P
Pressure signal
Corresponding connector
Diagram
PIN
Minimum
Temperature Voltage level
2
0.5 V (-40°C)
Supply voltage
3
4.75 V
Note :
Pressure measuring range : 0.5 - 5 bar
Temperature measuring range : -40 - 130 °C
Type : CTN
Typical
Max
4.5 V (130°C)
5V
5.25 V
Température sensor measurement between pin 1 and 2
-40 °C = 44.400 kΩ ±7%
0 °C = 5.880 kΩ ±5%
25 °C = 2.010 kΩ ±4%
40 °C = 1.150 kΩ ±3%
80 °C = 0.315 kΩ ±2%
125 °C = 0.098 kΩ ±2%
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
X915 -AND
X916
X916 CRANKSHAFT
CRANKSHAFT
AND CAMSHAFT
AND CAMSHAFT
SPEEDSPEED
SENSOR
SENSOR
Function
1
Signal
2
Signal
1
2
Corresponding connector
(S1)
(S2)
N
S
Diagram
Signal
PIN
Typical
1 and 2
1.65 V
Note :
Measurement at 20 °C between pin 1 and 2 : 880 Ω ±10%
Measurement on crankshft turns at start-up speed : 1.65 V
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(13/07/2016)
80-01-M218EN
80
PIN
46
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
Y6
PEC (PRESSURE ELECTRONIC CONTROL)
PIN
X104
Function
1
PWM-OUT+
2
PWM-OUT-
1
2
Corresponding connector
Diagram
Typical
Resistance
Max.
6,2 Ω±7%)
Current
1,25A
Power
15 W
80
Comments:
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80-01-M218EN
(13/07/2016)
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
Y7
TILTING CUT-OFF EV / VCI (MLT except MLT 732)
PIN
1
2
X93
1
Function
1
Power supply
2
Ground
47
2
Corresponding connector
Diagram
Typical
Supply voltage
12 V
Coil resistance (at 20 °C)
4,2 Ω
Tolerance
10%
Consumption
1,5 A
Comments:
Electrovalve control is by current variation. Voltage is indicative only.
When cut-out is in effect, the VCI is no longer powered.
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
TILTING
TILTING CUT-OFF
CUT-OFF EV
EV //VCI
VCI(MT
(MT)+ MLT 732)
PIN
1
2
V
V3
1
Function
1
Power supply
2
Ground
2
80
Y7
V2
V4
T1
Corresponding connector
V1
Diagram
Typical
Supply voltage
12 V
Coil resistance (at 20 °C)
4,2 Ω
Tolerance
10%
Consumption
1,5 A
Comments:
Electrovalve control is by current variation. Voltage is indicative only.
When cut-out is in effect, the VCI is not powered.
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(13/07/2016)
80-01-M218EN
48
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
Y15 - Y16
Y17 - Y18
TELESCOPE PROPORTIONAL ELECTROVALVE
(MT)732)
EV (MLT except MLT
ATTACHMENT PROPORTIONAL
(MLT except MLT
732)
PROPORTIONALEV
ELECTROVALVE
(MT)
PIN
1
2
V
V3
1
Function
1
Power supply
2
Ground
X29 / X28
X35 / X34
2
V2
V4
T1
Corresponding connector
V1
Diagram
Min.
Max.
Supply voltage
0
6V
Consumption
0
1,5 A
Coil resistance (at 20 °C)
4,2 Ω
Tolerance
10%
Comments:
Electrovalve control is by current variation. Voltage is indicative only.
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(MT)
Y15 - Y16 TELESCOPE PROPORTIONAL ELECTROVALVE
EV (MT + MLT 732)
Y17 - Y18 ATTACHMENT PROPORTIONAL
(MT + MLT 732)
PROPORTIONALEV
ELECTROVALVE
(MT)
PIN
80
1
2
V
V3
1
Function
1
Power supply
2
Ground
X29 / X28
X35 / X34
2
V2
V4
T1
Corresponding connector
V1
Diagram
Min.
Max.
Supply voltage
0
6V
Consumption
0
1,5 A
Coil resistance (at 20 °C)
4,2 Ω
Tolerance
10%
Comments:
Electrovalve control is by current variation. Voltage is indicative only.
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80-01-M218EN
(13/07/2016)
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
49
Y19
Y19 TELESCOPE
PROPORTIONAL
LOWERING
EV ON BOOM
PROPORTIONAL
LOWERING /EV
VRD
/ VRD
(FLOW
(MLT
DISTRIBUTOR)
except MLT (MLT)
732) X92
PIN
1
2
1
Function
1
Power supply
2
Ground
2
Corresponding connector
Diagram
Min.
Max.
Supply voltage
0
6,9 V
Consumption
0
1,5 A
Coil resistance (at 20 °C)
3,5 Ω
Tolerance
10 %
Comments:
Electrovalve control is by current variation. Voltage is indicative only.
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
Y19
Y19 TELESCOPE
PROPORTIONAL
LOWERING
EV ON TELESCOPE
PROPORTIONAL
LOWERING
EV/ VRD
/ VRD
(FLOW
(MT +
DISTRIBUTOR)
MLT 732) (MT) X92
PIN
2
V
V3
1
Power supply
2
Ground
2
80
1
1
Function
V2
V4
T1
Corresponding connector
V1
Diagram
Min.
Max.
Supply voltage
0
6,9 V
Consumption
0
1,5 A
Coil resistance (at 20 °C)
3,5 Ω
Tolerance
10 %
Comments:
Electrovalve control is by current variation. Voltage is indicative only.
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(13/07/2016)
80-01-M218EN
50
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
Y20 HYDRAULIC CUT-OFF
CUT-OFF EV
EV // VS
VS (MLT
(SAFETY
except
VALVE)
MLT 732)
(MLT)
PIN
1
2
X23
1
Function
1
Power supply
2
Ground
2
Corresponding connector
Diagram
Typical
Supply voltage
12 V
Resistance (at 20°C)
9,6 Ω
Tolerance
10 %
Consumption
1,4 A
Comments:
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
Y20 HYDRAULIC CUT-OFF
CUT-OFF EV
EV // VS
VS (MT
(SAFETY
+ MLTVALVE)
732) (MT)
PIN
80
1
2
V
V3
X23
Function
1
Power supply
2
Ground
1
2
V2
V4
T1
Corresponding connector
V1
Diagram
Typical
Supply voltage
12 V
Resistance (at 20 °C)
9,6 Ω
Tolerance
10 %
Consumption
1,4 A
Comments:
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80-01-M218EN
(13/07/2016)
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
Y40-Y41
STABILIZER SAFETY VALVE
51
X84 / X85
PIN
Function
2
1
Power supply
1
2
Ground
1
2
Corresponding connector
Diagram
Typical
Supply voltage
12 V
Power
17 W
Coil resistance (at 20°C)
8.5 Ω
Remarks:
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
Y42 FAN DRIVE REVERSAL ELECTROVALVE
ELECTROVALVE(MLT except MLT 732)
2
1
Function
1
Power supply
2
Ground
2
1
80
PIN
X253
Corresponding connector
Diagram
Typical
Supply voltage
12 V
Coil resistance (at 20 °C)
5,8 Ω (8,6 Ω Hot)
Tolerance
10 %
Consumption
1,4 A
Comments:
Electrovalve control is by current variation. Voltage is indicative only.
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(13/07/2016)
80-01-M218EN
52
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
Y43 FAN DRIVE CONTROL
CONTROL ELECTROVALVE
ELECTROVALVE(MLT except MLT 732)
PIN
1
2
X252
Function
1
Power supply
2
Ground
2
1
Corresponding connector
Diagram
Min.
Supply voltage
Typical
0
7,2 V (at 65°)
Resistance (at 20 °C)
4,6 Ω
Tolerance
10 %
Consumption
Max.
1,2 A
Comments:
Notes: ____________________________________________________________________________________
80
___________________________________________________________________________________________
___________________________________________________________________________________________
80-01-M218EN
(13/07/2016)
ELECTRICAL SCHEMATIC DIAGRAMS
pages
ELECTRICAL DIAGRAM CODIFICATION EXAMPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CABLE IDENTIFICATION ON A WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
POSITION OF CONNECTORS ON DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
–– 1 – START-UP / CUSTOMER DIGICODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
–– 2 – CAN / ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
–– 3 – TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
–– 4 – HYDRAULIC MOVEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
–– 5 – SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
–– 6 – VENTILATION / AIR CONDITIONING / WIPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
–– 8 – LIGHTING / SIGNALING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
(26/07/2016)
80-02-M218EN
80
–– 7 – OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
ELECTRICAL SCHEMATIC DIAGRAMS
2
ELECTRICAL DIAGRAM CODIFICATION EXAMPLE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
t
Ba
1
2
III II I O P
17
17
50a
19
19
54
15
58
1
2
3
4
7
8
9
5
6
10
719
713
705
+ APC
669
30
769
X1
30
444
A
3
X151 5
6
71
13
7
2
269
11
4
5
666
11
EP6
F5
X201
5
4
6
1
369
X116
237
40
236
09
235
25
234
55
233
16
555
69
F3
469
719
EP7
12
8
1
71
Y40
421
Version Standard
10
9
MP 22
2
169
X162
420
A2
421
169
72
CN1-P2
BF2 / M3
Version H
02
CN2-P2
3
86
85
12
E
739
421
2
420
1
CAN A L
15
238
8
CAN A H
K21
87
C
F3
30
F4
4
7
X2
X150
BF1 / M1
19
1
-M
b
Ca - M2
ot 3
M -M
as
Ch
V
S2
Y16
X161
10
72
15
14
666
369
412
12
R
S25
N
JSM
46
87
17
86
16
CAN A L
CAN A H
420
1
Y15
X161
X38-7 X168
Sch. 8 Sch. 5
X166A
30
P
182
59
B06
8
179
82
1
172
34
7
178
49
5
176
88
4
175
87
6
177
19
174
86
1
X160
-
+
A12
412
183
3
+
B15
M
EP12
Sch.3
A1
9
M1
X76B
X166B
MP 12
X149
58
440
440
-
B16
88
59
2
173
85
S16
10
232
89
S15
9
180
56
X67
CN2-P1
80
K
47
569
11
12
F
76
89
13
42
8
I
90
41
9
EP5
77
Masse CAN A
91
11
58
CN1-P1
69
69
17
G
2
58
Option ETDF Version EP/RC
449
EP68
2
Y28
16
X148
Example of marking on cables and components on an electrical diagram
Key:
1 - Marking grid
2 - + Permanent
3 - + After ignition
4 - Grounds
5 - Wire N°
6 - Electrical connector
7 - Electrical connector name
8 - Electrical connector PIN N°
9 - Electrical component
80-02-M218EN
10 - Electrical component name
11 - Splice
12 - Version choice
13 - Other diagram reference
14 - CAN
15 - CAN Shielding
16 - Option
(26/07/2016)
ELECTRICAL SCHEMATIC DIAGRAMS
3
CABLE IDENTIFICATION ON A WIRING HARNESS
The electrical harnesses installed on the truck are composed of connectors.
In order to identify the connectors and their wires, each wire carried a marking.
X32/88/X64
Joins
Wire N°
X32 / 88 / X64
End points
X64
X32 / 88 / X64
80
X32
(26/07/2016)
80-02-M218EN
4
ELECTRICAL SCHEMATIC DIAGRAMS
80
POSITION OF CONNECTORS ON DIAGRAMS
Connectors
B+
M
W
X1
X2
X3
X4
X7
X8
X9
X10
X11
X12
X13
X14
X15
X16
X17
X18
X19
X20
X21
X22
X23
X24
X25
X26
X27
X28
X29
X30
X31
X32
X33
X34
X35
X36
X37
X38
X39
X40
X41
X42
X43
X44
X45
X46
X47
X48
X49
X50
X51
X52
X53
X54
X55
X56
X57
X58
80-02-M218EN
Diag. 1
√
√
√
Diag. 2
Diag. 3
Diag. 4
Diag. 5
Diag. 6
Diag. 7
Diag. 8
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
(26/07/2016)
ELECTRICAL SCHEMATIC DIAGRAMS
(26/07/2016)
Diag. 1
√
Diag. 2
Diag. 3
Diag. 4
Diag. 5
Diag. 6
Diag. 7
Diag. 8
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
80
Connectors
X59
X60
X61
X68
X69
X70
X71
X72A
X72B
X73A
X73B
X74
X75
X76A
X76B
X77
X78
X79
X80
X81
X82
X83
X84
X85
X87
X88
X89
X90
X91
X92
X93
X94
X95
X95E
X96
X97
X98
X99
X100
X101
X102
X103
X105
X106
X107
X108
X110
X112
X113
X114
X115
X116
X117
X118A
X118B
X118C
X119
X120
X121
X122
X123
X124
5
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
80-02-M218EN
80
6
ELECTRICAL SCHEMATIC DIAGRAMS
Connectors
X127
X128
X134
X135
X136
X137
X138A
X138B
X139A
X139B
X140
X141
X142
X143
X144
X146
X147
X149
X150
X151
X152
X153
X154A
X154B
X158
X159
X160
X163A
X163B
X164
X165
X166A
X166B
X167
X168
X169
X170
X171
X172
X174
X175
X176
X178
X179
X180
X181
X182
X183
X185
X186
X187
X188
X189
X190
X191
X192
X193
X194
X195
X196
X197
X198
80-02-M218EN
Diag. 1
Diag. 2
Diag. 3
√
√
Diag. 4
Diag. 5
Diag. 6
√
√
√
Diag. 7
Diag. 8
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
(26/07/2016)
ELECTRICAL SCHEMATIC DIAGRAMS
(26/07/2016)
Diag. 1
√
√
√
Diag. 2
√
Diag. 3
√
Diag. 4
√
Diag. 5
√
Diag. 6
Diag. 7
Diag. 8
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
Connectors
X284B
X285
X286
X287
X292
X292A
X292B
X292C
X293
X900
X901
X903
X904
X905
X906
X907
X912
X913
X914
X915
X916
X917
X918
X919
X920
Diag. 1
Diag. 2
Diag. 3
Diag. 4
Diag. 5
√
Diag. 6
Diag. 7
√
√
Diag. 8
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
80
Connectors
X199
X200A
X200B
X201
X202
X203
X204
X205
X206
X207
X208
X209
X210
X211
X216
X217
X218
X219
X220
X221
X222
X223
X224
X225
X226
X227
X228
X229
X230
X231
X232
X233
X234
X235A
X235B
X236
X238
X239A
X239B
X245
X246
X247
X250
X251
X252
X253
X254
X255
X256
X257
X258
X259
X260
X261
X273
X277
X280
X281
X282
X283A
X283B
X284A
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
7
√
√
√
√
√
√
√
80-02-M218EN
8
ELECTRICAL SCHEMATIC DIAGRAMS
ELECTRICAL DIAGRAMS
1 – START-UP / CUSTOMER DIGICODE
80
CONNECTORS
Item
Wiring harness type
Component
X24
Main - Engine
X40
Main
A15
X41
Main
A15
X42
Main
X44
X45
CONNECTORS
Designation
Position
Item
Wiring harness type
G6
X905
Deutz Harness
Injector cylinder 3
Start-up safety/wheel alignment/brake fluid tank/connector B on fuse plate
E15
X906
Deutz Harness
Injector cylinder 4
S38
Option and roof light power supply/connector A on fuse plate
C18
X912
Deutz Harness
Coolant temperature sensor
O38
A15
Fuse plate/connector H on fuse plate
E16
X915
Deutz Harness
Crankshaft speed sensor
M38
Main
A15
Relay/hydraulic movement cut-off/transmission cut-off/electrovalve/connector G
Main
A15
Fuse and relay plate power supply and ground/connector K on fuse plate
X46
Main
K17
X47
Main
F31
X54
Main
S2
Ignition switch (4 way)
C5
X55
Main
S2
Ignition switch (6 way)
C10
Item
X59
Engine
G2
Alternator L
G36
A15
Fuse plate and relay carrier
C17
X76A
Main
M1
Cab left-hand ground
C40 / E40
A19
Engine ECU
O29
X76B
Main
M1
Cab left-hand ground
E40 / C40
A22
Powershift transmission module
E32
X95
Main
K18
HELLA K18 mini relay plate (MT - MLT) (PS) (MT 1030 Easy)
E34
B+
Battery (+) / Battery cut-off connection
G37
Main harness/engine interface
Component
Designation
Position
Q38
C18
X917
Deutz Harness
Glow plug cylinder 1
I37
C13 / E19
X918
Deutz Harness
Glow plug cylinder 2
I37
HELLA K17 mini relay plate
E37
X919
Deutz Harness
Glow plug cylinder 3
I37
Starter atofuse fuse holder
E7
X920
Deutz Harness
Glow plug cylinder 4
I37
COMPONENTS
Designation
Position
X101
Power cable
M9
Frame ground cable/(-) battery
C40
G1
12 V - 110 Ah - 750 A Battery
A3
X102
Power cable
M9
ECU/frame ground cable
S40
G2
Alternator 14 V/100 A
G37
M
Alternator ground
G38
M1
Starter
I40
M2
Diesel pump
M12
S1
Battery cut-off
A2
X108
Main
M4
Front frame ground on cab bracket
C40
X114
Main
S50
Emergency stop
C29
X118A
Main
Anti-theft module predisposition
A20
X118C
Main
Anti-theft shunt
A20
X120
Main - Engine
Main harness/engine interface
K16
X122
Main
A22
Gear box ECU (MLT PS)
E32
X135
Option
M2
Option cab right-hand ground
C40
X137
Main
G1
Main display module and dashboard ground
A4
X159
Engine
S1
Battery cut-off
C1
X160
Power cable
M1
Cable + starter/alternator
I39
X163A
Engine
M2
Fuel pump power supply
M11
X163B
Engine
M2
Fuel pump ground
M13
X167
Engine
Glow plug conductor rail
I33
S2
Ignition switch
A7
S50
Emergency stop button
A29
W
Alternator W terminal
G37
Item
F4
F8
FUSES AND RELAYS
Designation
Current
7,5A/15A max Engine computer alarm + F50, X4-7 output option
Position
C17
15 A
Relays K2/K3/K4 + transmission cut-off + JSM/FNR
C17
F31
5A
Starter
E8
30 A
K22 relay electrovalve (starter control)
I3
X169
Power cable
M3
Engine unit ground on frame
E40
F45
X170
Engine
A19
Engine computer box ground
S29
F47
40 A
Engine ECU
G3
Main display power supply via dashboard plate
A2
F48
60 A
Preheating module
G3
80 A
Ignition switch
G3
Anti-start relay
E17
X171
Main
G1
X174
Engine
A19
Engine computer connector A1
M30
F49
X175
Engine
A19
Engine computer connector K1
K30
K8
X176
Power cable
M7
Engine unit ground to frame
E40
K18
Neutral start-up safety relay (main harness)
E35
X200A
Power cable
S1
Battery cut-off to (+) battery
A1
K21
70A
Engine computer power supply management relay
G8
X200B
Power cable
S1
Battery cut-off to general power supply
C1
K22
20/40A
Diode starter control relay
K40
X201
Engine
M5
Right center frame ground
I40
K23
Diesel fuel relay
I8
X277
Engine
A19
Engine harness/main harness interface
K35
X283A
Engine
Diesel pump harness interface
K11
Item
X283B
Engine
Diesel pump harness interface
K11
EP26E
E29
X292
Engine
Easy manager option interfgace to anti-start
C24
EP59
O24
X292A
Engine
Easy manager option interfgace to anti-start
C24
X292B
EP65
S33
Engine
Easy manager option interfgace to anti-start
A24
X292C
Engine
Easy manager option interfgace to anti-start
A26
EP70
K26
X900
Deutz Harness
Fuel metering valve
O38
X901
Deutz Harness
Fuel rail pressure sensor
O38
X903
Deutz Harness
Injector cylinder 1
Q38
X904
Deutz Harness
Injector cylinder 2
Q38
80-02-M218EN
SPLICES
Position
(26/07/2016)
ELECTRICAL SCHEMATIC DIAGRAMS
DIAGRAM 1 (Start-up / Customer Digicode)
8
9
10
11
12
14
15
16
17
18
19
20
33
34
35
36
37
38
39
18
13
C8
228
2
236
1
(H)
C1
3 30
1 86
X42
87 5
3
4
X292A
1
2
3
4
1
2
1
2
3
4
2
4
2
5
EP58
Sch. 7
X284A-9
Sch. 7
395
225
MLT & MT (PS) (MT 1030 Easy)
MLT & MT (PS)
MLT PS
X122
EP26E
X43-2
Sch. 3
226
X95
A22
2
X45
(K)
K18
1
5
4
5
87a
4
1
86
87
X120
228
X108
X169
3
X46
3
30
2
299 X76B
3
B5
B4
B1
B8
299
298
724 7 mm2
724
30
18
87
733
725
86
85
718 (T < 5°C) 7 mm2
B+
716
95 mm2
10A
12V 70A
X918
X167
X160
X920
718
I
B+ 30
X919
K23
87 734
X283B
1
747
2
X247-2
Sch. 5
20
X246-2
Sch. 5
744
2
EP70
720
719
734
1
Ignition/key data
Info ignition / clé 694
K22
88
X277
708
X163A
F41
Sch. 2
X163B
+
28
602
602
2
73
603
603
3
45
-
M2
M
info demarrage / clé
735
26
732
90
14
35
2.5 mm2 721
7 mm2
726
EP59
M1
15
751
X283A
752
12V 40A
50a
X175
ECM K1
228
85 735
732 86
M
3~
U
717
11
G2
L
35 mm2
726 7 mm2
K21
G
W
X59
X24-A6
Sch. 8
BF1/M2
14
X201
719
733 30
01
2.5 mm2 722 03
A19
ECM A1
2.5 mm2 723 05
Q
X170
S
E
222
85
X917
O
X176
13 3 mm2
16
C
X135
25 mm2
95 mm2
35
MLT & MT (PS)
10
69
EP12
Sch. 3
MLT PS
4 69
85 2
X101
95 mm2
298 X76A
X292
M10
ENGINE HARNESS
30
X923
1
K
50a
2 85
50 1
2
X174
725
35
716
23
717
38
601
601
1
54
621
621
21
39
615
615
15
28
624
624
24
5
620
620
20
CABLE 11
X915
EP KD
Sch. 5
M
1
(S1)
2
(S2)
X912 1
(-)
2
(S)
4
619
619
19
2
631
631
31
X901 1
26
625
625
25
2
07
632
632
32
3
33
662 1.5 mm2
662
62
X903 1
16
635 1.5 mm2
635
35
2
46
640 1.5 mm2
640
40
X904 1
3
641 1.5 mm2
641
41
2
32
638 1.5 mm2
638
38
X905 1
2
661 1.5 mm2
661
61
2
48
642 1.5 mm2
642
42
X906 1
18
637 1.5 mm2
637
37
2
02
702 2.5 mm2
703 2.5 mm2
06
704 2.5 mm2
EP65
701
7 mm2
T
X900 1
25
04
N
S
O
P
Q
701
S
X102
705 1 mm2
(26/07/2016)
A
X114
2 mm2
X192-7
Sch. 7
3 14
REVM
DEM
2
42
223
9
228
12
A8
13
11
MT1030 Easy
15
S50 1
1
3
EP04
Sch. 3
X4-7
Sch. 7
X44-9
Sch. 3 MLT & MT (PS)
(B)
X40
X292C
4
298
2
K8
197
226
3
41
299
1
12
10
(B)
X40
157
(G)
X44 16
F8
X192-7
Sch. 7
214
2
12 3 mm2
I
K
40
299
1
62
X61-5
Sch. 3
1
298
63
11
4
226
2
F4
8
227
64
(A)
X41 12
6
228
6
7
231
5
67
5
223
68
9
227
8
4
20
65
A15
X192-4
Sch. 7
5
499
7
15
30A
720
66
F31
8
F45
32
20
82
A1
11
10
715
F47
31
11 3 mm2
60A
13
30
20
64
13
11
12
63
10
82
X55
95 mm2
10 mm2 711
10 mm2 714
712
F48
29
227
10
10 3 mm2
80A
15
28
MT1030 Easy 209
58
6
X24
17
27
228
15
5
6
390
54
9
8
7
395
19
7
8
393
50a 19
4
X47
G
26
39
17
3
9
499
17
2
41
30
X48-1
Sch. 2
F49
25
14
30
1
(K)
X45
MLT PS
X54
F46-9
Sch. 6
BF1/M1
24
X292B
X118A
OP
X107-1 EP17
Sch. 2 Sch. 2
C
23
OPTION EASY MANAGER
X118C
713
22
S2
X200A
X200B
X159
21
225
G1
S1
E
13
225
265
7
2)
)
10
8) 69 )
s 10 X1 01 & X
as (X 3 ( X2 1
0
4
(
B)
Ch V M eu M M5 (X1
76
9
A ili u
/X
M ilie R M
6A )
M VD
X7 35
A b 1 ( X1
Ca M 2 (
GA R M or 76)
D ot X1
M 7(
M
95 mm2
6
233
A
5
X137
80-02-M218EN
80
4
-
236
3
X171 +
214
2
14
1
9
10
ELECTRICAL SCHEMATIC DIAGRAMS
2 – CAN / ECU
CONNECTORS
Item
Wiring harness type
X4
Main
X24
Main - Engine
X37
Main
X40
Main
X41
X44
Component
Designation
Item
Current
FUSES AND RELAYS
Designation
Position
Options power supply
E8
F1
10A MAX
Compensating cylinder isolation (7,5A)
C8
Main harness/engine interface
I10
F9
5A
Modules + dashboard indicator lamps + regeneration switch
C4
A15
Power connector/connector D on fuse plate
C4
F15
20 A
SPU
C5
A15
Start-up safety/wheel alignment/brake fluid tank/connector B on fuse plate
C3
F16
5 A/7,5 maxi
Diagnostic plug + fan control + air-conditioning option
C6
Main
A15
Option and roof light power supply/connector A on fuse plate
C6
F32
5A
Diagnostic plug + SPU + driver presence contact
A5
Main
A15
Relay/hydraulic movement cut-off/transmission cut-off/electrovalve/connector G
C8
F33
2A
VDO module clock power supply via dashboard plate
M12
X48
Main
F32
Autofuse plate for diagnostic plug
A4
X56
Main
A3
Safety Power Unit CN1-A
E24
X57
Main
A3
Safety Power Unit CN1-A
E28
X58
Main
A5
LLMI safety module
M31
X68
Main
P1
Main display module
Q15
X76A
Main
M1
Cab left-hand ground
M41/O41/Q41
X76B
Main
M1
Cab left-hand ground
E41/G41/I41
X99
Main
B20
Strain gauge
K26
X102
Power cable
M9
ECU/frame ground cable
S41
X107
Main
F33
Autofuse fuse support for VDO power supply/ST3B dashboard plate
M12
X110
Main
A4
Grey Casappa LSU ECU / A
A34
X114
Main
S50
Emergency stop
C13
X115
Main
Diagnostic plug
C35
X119
Main
S27
Override switch
M31
X121
Main
A2
Dashboard indicator lamps plate (14 way)
K12
X122
Main
A22
Gear box ECU (MLT PS)
Q24
X158
Engine
BF1
Engine diagnostic plug
S10
X170
Engine
A19
Engine computer box ground
S4
X175
Engine
A19
Engine computer connector K1
M6
X201
Engine
M5
Right center frame ground
S41
COMPONENTS
Designation
Item
80
Position
Item
SPLICES
Position
Item
SPLICES
Position
EP16
O20
EP38
E26
EP59
K5
EP17
O21
EP39
K31
EP61
O11
EP25
I27
EP40
K32
EP63
Q10
EP30
C39
EP41
K33
EP64
Q10
EP33
E38
EP43
A10
EP65
S9
EP35
G32
EP44
O9
EP96
M15
EP36
G33
EP45
O9
EP97
O15
G34
EP46
O8
EP98
O22
EP48
Q8
EP99
O21
EP37
CAN Network
PAD
Position
A2
Instrument panel
I13
A3
SPU module
C24
A4
LSU proportional pump ECU
A35
A5 /
LLMI
Longitudinal security module (LLMI)
O32
A15
Fuse plate and relay carrier
C3
A19
Engine ECU
O5
A22
Powershift transmission module
S25
B20
Strain gauge
M27
BF1
Engine fuse box - preheater power and relay
Q9
H12
Hour meter/rev counter module back lighting
Q19
L1
VDO inductor
O15
L2
VDO inductor
O22
P1
Hour meter/rev counter
Q15
R4
Resistance 120 ohm 1/2 W
O9
R7
Engine temperature sensor
K27
R9
Resistance 120 ohm 1/2 W
Q8
R10
Resistance 120 ohm 1/2 W
Q12
S50
Emergency stop button
C13
Y45
Ferrite
O17
Y46
Ferrite
O16
80-02-M218EN
Item
SPLICES
Position
SPU
LLMI
VCI
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
Diag.
Machine
CAN J1939
Diag.
Motor
ECU
Motor
VDO
Jauge
Vishay
(26/07/2016)
ELECTRICAL SCHEMATIC DIAGRAMS
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
189
8
7
6
CN1-A
1
SPU
E
257
CN1-B
28
1
181
EP38
EP33
X170
04
M10
06
H
X76A
300
X76A
544
X76A
543
X76A
695
X201
707
X201
701
X102
257
MLT PS
CABLE 1
302
4
CAN L
3
EP99
233
233
704 2.5 mm2
EP65
701
7 mm2
EP98
MLT PS
EP4
Sch. 3
X122
H12
36
18
A22
543
25
544
20
8
13
Q
12
705 1 mm2
(26/07/2016)
O
X137
Sch. 1
702 2.5 mm2
703 2.5 mm2
M
595
594
2
CAN H
31
79
1
30
80-02-M218EN
S
80
594
10
0 V output
G
H12
8
EP17
552
15
10 RPMx100
17
92
L2
Supply 0 V
B
710
709
706
707
P1
A
120 Ω
X119
K
EP40 EP41
35
GND
90
89
35
16
4
5
BF1
34
34
35
34
3
400
RX
ECM K1
02
2
92
30
X158
S
11
EP16
TX
Q
1
I
302
300
551
R9
120 Ω 1/2 W
X68
llumination
EP64
CAN Low
EP63
683
Ground
EP48
X76B
267
Y45
CAN High
685
682
Analog input 3
53
CAN L
EP46
580
684
Battery
75
CABLE 8 710
CAN H
R10
120 Ω 1/2 W
Y46
709
A19
EP61
695
301
557
R4
120 Ω 1/2 W
X76B
186
A5 / LLMI
301
Supply 12 V
O
691
EP45
24
689
K-Line
CABLE 6
L1
692
Ignition
689
EP44
301
76
CAN L
690
EP39
30
CABLE 9 - J1939
690
185
CABLE 2 - J1939
301
X58
EP97
54
693
CAN H
3
CABLE 9 - J1939
EP96
2
706
2
B20
91
723
2
399
05
1
G
491
5
R7
F33
722
CABLE 6 - CAN J1939
03
F41-5A
M
721
1
MT 1030 Easy
266
394
265
708
X107
BF1/ M1
X175
X76B
303
CABLE 10 595
4
EP28
Sch. 4
490
495 0.34 mm2
493
494
492
9
2.5 mm2 721
01
489
E
495
89
91
X284-3
Sch. 7
1
GND
10
0.34 mm2
ALIM 10V
EP59
X76B
305
ALIM 10V
2.5 mm2 722
X99
5
580
266
2.5 mm2 723
726
187
302
CABLE 4
1
267
8
OUT 8V
OUT 12V FILTRE
VBAT
X121
708
7 mm2
EP37
304
79
496
304
693
306
305
691
692
X171
Sch. 1 265
F47
Sch. 1 726
CABLE 1 - J1939
486
492
C7
A2
K
491
EP35
490
470
CABLE 7 - J1939
EP25
I
500
306
CABLE 7 - CAN J1939
C6
C
485
EP36
G
1
488
385
308
2
3
X284-2
Sch. 7
261
389
260
388
494
5
6
303
X284A-8
Sch. 7
493
CABLE 3 - J1939
C5
A
11
2
X284A-5
Sch. 7
X24
42
EP30 533
551
7
311
10
11
180
EP70
Sch. 1
12
486
14
307
310
16
24
13
552
526
CAN1-120
CAN1 H
GND CAN
GND
34
CABLE 5 261
61
498
8
260
5
X44-19
Sch. 6
12VC
9
noir 187
12VC
12VD
3
182
181
4
183
12VD
X57
21
120 ohms
CAN1 L
OUT SENSOR 10V
CN1-A
13
180
26
SPU
470
GND
IN W UP
20
61
GND
1
186
7
185
X56
12V Bat
12V P µC
498
6
189
X95-3
Sch. 4
12
188
379
5
41
X115
A3
2
1
497
17
155
164
X4
1
40
MLT PS
487
MT 1030 Easy
(G)
X44
39
CABLE 8
X114
( MLT732)
X41
7 (A)
3
183
182
497
2
488
X37
(D)
90
4
38
500
S50
520 MLT PS & MLT
Sch. 8
X40
(B)
X110
(A)
X285-1 X2
Sch. 3 Sch. 3
F1
F9
F15
F16
A15
C
188
2
F32
1
259
X48
37
A4
(MLT732)
EP43
2
62
A
X45
Sch. 1
MLT PS
& MLT
2
36
2)
)
10
8) 69 )
s 10 X1 01 & X
as (X 3 ( X2 1
0
4
(
B)
Ch V M eu M M5 (X1
76
A ili u M9
/X
M ilie R
6A )
M D
X7 35
AV b 1 ( X1
Ca A M 2 (
G RM
D
at
Vb
C
AP
X45-1
Sch.1 62
35
GND ECU
15
11
534
14
CAN L
13
ALIM ECU
12
520
11
CAN H
10
485
9
TX / RS 232
8
310
7
RX / RS 232
6
309
5
525
4
526
3
487
2
525
1
309
DIAGRAM 2 - CAN/ ECU
12
ELECTRICAL SCHEMATIC DIAGRAMS
3 – TRANSMISSION
CONNECTORS
80
Item
Wiring harness type
Component
Designation
Position
Item
COMPONENTS
Designation
Position
X1
Main
S21
Transmission cut-off on gear lever (MT - MLT)
Q10
A15
Fuse plate and relay carrier
A16
X2
Main
S46
Seat switch supply
K5
A17
FNR mechanical control handle
E16
X3
Main
S46
Seat sensor info
K6
A18
Transmission cut-off on distributor lever
S6
X7
Main
A18
Transmission cut-off on distributor lever / Preheat module
Q6
A22
Powershift transmission module
O34
X8
Main
B70
Transmission fluid thermostat (MLT PS: on PS gear box)
Q24
A23
PWS speed display
K40
X9
Main
Y3
Forward electrovalve (MT - MLT)
E30
B8
Steering fault pressure switch
C38
X10
Main
Y4
Reverse electrovalve (MT - MLT)
E28
B09
Front wheel alignment sensor
O19
X12
Main
S19
Handbrake switch
O14
B10
Rear wheel alignment sensor
O21
X15
Main
B9
Front wheel alignment
O18
B68
Frequency sensor on gear box
S39
X21
Main
B10
Rear wheel alignment
O20
B69
Transmission oil pressure sensor
S26
X36
Main
A12
JSM connector
G13
B70
Transmission oil temperature sensor
S24
X40
Main
A15
Start-up safety/wheel alignment/brake fluid tank/connector B on fuse plate
C18
E8
Wheel alignment indicator lamps
Q19
X42
Main
A15
Fuse plate/connector H on fuse plate
C33
H13
Front wheel alignment indicator lamp
Q20
X43
Main
A17
FNR mechanical control handle
G14
H14
Rear wheel alignment indicator lamp
Q22
X44
Main
A15
Relay/hydraulic movement cut-off/transmission cut-off/electrovalve/connector G
C19
S19
NO/NC hand brake sensor
O14
X45
Main
A15
Fuse and relay plate power supply and ground/connector K on fuse plate
C34
S20
NC brake pedal sensor
O8
X50
Main
H13
Front wheel alignment indicator
Q19
S21
NC gear lever switch
Q10
X51
Main
H14
Rear wheel alignment indicator
Q23
S30
Transmission cut-off switch
O4
X52
Main
S31
Wheel alignment switch
K22
S31
Wheel alignment switch
K22
X56
Main
A3
Safety Power Unit CN1-A
K10
S41
5 forward/3 reverse gear speed limitation switch
M36
X57
Main
A3
Safety Power Unit CN1-A
I13
S46
NO driver presence sensor
X61
Main
S30
Transmission cut-off switch
O4
S49
Transmission cut-off push button on distributor lever
S7
M5 / M7
X71
Main
S20
Transmission cut-off on brake pedal
O7
V4
1 A 1000 V diode - safety relay/forward gear
G25
X76A
Main
M1
Cab left-hand ground
E41
V5
1 A 1000 V diode - safety relay/reverse gear
G26
X76B
Main
M1
Cab left-hand ground
C41 / E41 / S41
V10
VISHAY SBYV28-200 diode
E31
X78
Main
B8
PS JSM connector (MLT PS)
G11
Y3
Forward electrovalve
G30
X81
Main
B8
Steering fault indicator lamp (MLT - MLT PS)
A38
Y4
Reverse electrovalve
G28
X82
Main
B8
Steering fault pressure switch (MLT - MLT PS)
A38
Y24
Powershift gear box electrovalve L
S36
X98
Main
B69
Transmission oil pressure switch (MLT PS: on PS gear box)
Q26
Y25
Powershift gear box electrovalve H
S35
X105
Main
M11
Distributor harness ground connection
I41
Y26
Powershift gear box electrovalve R
S33
X118A
Main
Anti-theft module predisposition
G5
Y27
Powershift gear box electrovalve 1
S31
X118C
Main
Anti-theft shunt
E5
Y28
Powershift gear box electrovalve 2
S29
X122
Main
A22
Gear box ECU (MLT PS)
M27
Y29
Powershift gear box electrovalve 3
S27
X123
Main
A23
Gear box display (MLT PS)
M37
X124
Main
Main harness/gear box interface (MLT PS)
Q28
X127
Main
X128
Main
S41
Item
FUSES AND RELAYS
Designation
Current
Position
TUV 6th gear shunt (MLT PS)
K33
F6
5A
Wheel alignments + option
A17
Trailer towing speed limitation switch (MLT PS)
M36
F8
15 A
Relays K2/K3/K4 + transmission cut-off + JSM/FNR
A17
X193
PS gear box
B68
Gear box speed sensor
Q38
K1
NC transmission cut-off relay
A19
X194
PS gear box
Y24
Low speed electrovalve (MLT PS)
Q36
K2
NO transmission cut-off relay
A23
X195
PS gear box
Y25
High speed electrovalve (MLT PS)
Q34
K3
Reverse gear relay
A26
X196
PS gear box
Y26
Reverse electrovalve (MLT PS)
Q33
K4
Forward gear relay
A28
X197
PS gear box
Y27
Gear 1 electrovalve (MLT PS)
Q31
X198
PS gear box
Y28
Gear 2 electrovalve (MLT PS)
Q29
X199
PS gear box
Y29
Gear 3 electrovalve (MLT PS)
Q27
Item
Position
Item
X285
Main
S46
Seat switch
K6
EP2
O17
EP24
I14
EP4
G10
EP31
K14
EP6
G25
EP95
K9
Position
EP7
G26
X287
Main
S46
Seat switch
K8
COMPONENTS
Designation
Item
A3
SPU module
K13
EP12
G25
A12
JSM (Joystick Switch and Move)
E13
EP23
I14
80-02-M218EN
SPLICES
SPLICES
Position
(26/07/2016)
ELECTRICAL SCHEMATIC DIAGRAMS
DIAGRAM 3 (Transmission)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
13
42
at
Vb
C
AP
A15
ri 0
st (X1
Di 11
M
6
5
4
X118C
9
5
7
6
8
4
X118A
X10
V10
542
MLT PS
(H)
X42
X45
(K)
X9
1
452 X76A
69
X81
X43
1
3
2
4
242
2
37
241
36
226
242
37
36
242
541
37
477
36
EP23
167
5
3
4
X12
1
45
2
S21
A18
3
2
29
1
2
1
X51
S19
MLT & MT (PS)
S19
MLT PS
H13
H14
X8
11
X98
6
1
2
X196
2
X195
1
X194
1
2
2
X193
556 556
M
17
Data display
0V Display
Input frequency < 10 kHz
12V Power Supply
5V Display
Clock display
Ground frequency
8
2
555 555
554 554
563
1
7
4
16
O
7
558
559
19
547
9
1
10
28
548
29
546
1
Electrovalve L
Electrovalve H
Electrovalve R
30
2
9
6F5F / 3R
5F / 3R
Electrovalve 1
X197
3
22
4
2
X123
A22
545
1
77F
6
Electrovalve H
Steering R
5
10
568
542
165
167
Steering F
15
31
549
X124
12
X199
24
32
X198
1
1
Electrovalve 2
Demultiplier
561
540
Steering R
23
Electrovalve 3
Hand brake
2
33
4
E8
Operator presence
Trans Dump
27
29
32
20
S41
X128
3
2
2
1
10
EP
+
_
T
P
B70
B69
Y28
Y27
EV2
Y29
EV3
Y26
EV1
EVR
Y25
EVH
Y24
EVL
1
Q
Resistance
47 Ohms / 5 W
2
+
71
X50
X38-6
Sch. 8
X38-2
Sch. 8
550
X38-5
Sch. 8
26
202
1
A
B10
48
X12
45
1
203
2
146
X1
206
1
139
3
28
B09
B
33
4
275
276
2
C
_
+
MLT & MT (PS)
X7
X21
A
202
B
MLT & MT (PS)
_
X11-2
Sch. 7
48
C
33
X15
46
47
262
MLT & MT (PS)
229
558
MLT PS
MLT PS
X38-5
Sch. 8
133
X186-10
Sch. 4
EP2
564
205
258
(MT 1030 Easy)
MLT & MT
Q
MT1030 Easy
565
MLT PS
MLT & MT (PS)
S20
113
452
41
77D
MLT & MT (PS)
1
203
10
X61
2
562
5 S30 6
X71
MLT PS
O
133
275
9
47
203
113
MLT PS
MLT & MT (PS)
113
8
227 MT 1030 Easy S1
383 MT 1030 Easy S2
49
2
MT1030 Easy
7
21
541
562
X122
9
553 553
MLT PS
566
561
K
7
560
146
146
EP31
X85-2
Sch. 4
556
133
49
1
1
0
567
563
1
77F
565
77E
X103-10
Sch. 7
MT 1030 Easy
139
A23
1
X52
M
77D
567
568
CN1-B
58
60/397
146
17
2
32
23
X127
10
134
IN TOR 2
CN1-A
17
S31
X105
MLT PS
9
5
148
15
1
OUT PWM 2
IN TOR 9
A3
SPU
1
0
28
77E
27
14
46
477
22
IN TOR 10
139
X56
MLT PS
60
60
S46
S46
X284A-12
Sch. 7
MLT & MT (PS) 206
3
MLT PS
1
392
EP95
X287
397 MT 1030 Easy
397
60
564
X3
476
X57
IN TOR 8
X285
2
X2
0
G
I
60
60
259
1
1
B8
X122-36
Sch. 2
X88-1
Sch. 4
K
P
MARCHE
AVANT
MLT & MT (PS)
MLT PS
MLT & MT (PS)
MLT PS
EP24 165
232 MT 1030 Easy
476
MLT PS 557
MT 1030 Easy
I
EP28
Sch. 4
Y3
MARCHE
ARRIERE
2
166
EP4
EP43
Sch. 2
EP26E
Sch. 1
MT 1030 Easy 231
X114-4
Sch. 1
Y4
X95-1
Sch. 1
E
(MLT732)
X82
EP12
5
276
MLT PS & MLT
V5
231
12
MLT PS
MLT PS 540
X114-2
Sch. 1
39
X41-12
Sch. 1
11
8
39
499
225
236
41
214
G
X42-1
Sch. 1
X36
2
1
197 X76B
11
258
X185
Sch. 8
312
1
X78
A
C
4
V10
2
1
V4
268
229
230
269
213
230
269
EP7
212
268
MLT PS
EP6
3
69
226
X95-3
Sch. 1
MLT & MT (PS) (MT 1030 Easy S1)
R
4
166
213
197
5
MLT & MT (PS) 167
MLT PS
16
5
MLT & MT (PS)
MLT & MT (PS)
A15-Timer
Sch. 8
3
MT 1030 Easy 232
1
MLT & MT (PS) 165
3
4
EP13
Sch. 8
R
N
1
5
MLT & MT (PS)
30
3
18
Down
F
86
30
1
205
197
10
3
MLT PS
B68
EP
S
S
S49
MT 1030 Easy
(26/07/2016)
80-02-M218EN
80
7
N
86
30
1
5
K4
MLT &
MT (PS)
313
8
3
2
5
87
2
K4 85
312
9
21
205
9
205
8
148
161
(B)
(G)
X40 X44
1
5
87
MLT & MT (PS) 212
F8
F6
58
8
86
3
2
85
MLT &
MT (PS)
)
F
Up
K3
5
87
6B
A12
Sch. 4
E
2
85
A17
A12
MLT PS
K2
5
30
1
X4-3
Sch. 7
A12
2
7
/X
6A )
X7 5
7
MT 1030 Easy
K2
4
87a
MLT PS
86
C
5
87
5)
2
85
G RM
D
K1
X45
Sch. 1
b 1 ( X13
Ca A M 2 (
A
14
ELECTRICAL SCHEMATIC DIAGRAMS
Item
X04
X28
X29
X32
X33
X34
X35
X36
80
X40
CONNECTORS
Wiring
Component
Designation
harnesstype
Main
Options power supply
Distributor
Y16
Telescope retraction electrovalve
Distributor
Y15
Telescope extension electrovalve
Main
S7
Cigarette lighter connector
Main
S33
Hydraulic movements neutralization switch
Distributor
Y18
Attachment minus direction electrovalve
Distributor
Y17
Attachment plus direction electrovalve
Main
A12
JSM connector
Start-up safety/wheel alignment/brake fluid tank/connector B
Main
A15
on fuse plate
X41
Main
A15
X44
Main
A15
X56
X57
Main
Main
A3
A3
Relay/hydraulic movement cut-off/transmission cut-off/
electrovalve/connector G
SPU CN1-A
SPU CN1-B
X76A
Main
M1
Cab left-hand ground
X76B
Main
M1
Cab left-hand ground
X84
X85
X87
X88
Main
Main
Main
Main
Y40
Y41
X92
Distributor
Y19
Left stabiliser electrovalve
Right stabiliser electrovalve
Distributor harness interface
Telescope head electrovalve switch
Proportional electrovalve on boom lowering/flow control
valve
Option and roof light power supply/connector A on fuse plate
4 – HYDRAULIC MOVEMENTS
Position
Item
I10
M30
M28
K37
I32
M27
M25
A32
X230
X231
X232
X233
X234
X250
X251
X252
X253
X254
X256
X257
X258
X259
X260
X261
CONNECTORS
Wiring
Component
Designation
harnesstype
Option
B12
NC reverse tilt movement detection pressure switch
Option
B13
NC boom lowering movement detection pressure switch
Option
B13
NC boom lowering movement detection pressure switch
Option
B14
NC forward tilt movement detection pressure switch
Option
B14
NC forward tilt movement detection pressure switch
Option
B50
Sensor B on attachment distributor
Option
B51
Sensor A on attachment distributor
Engine
Y43
Fan Drive control proportional EV
Engine
Fan Drive reversal electrovalve harness interface
Engine
Y42
Fan Drive reversal electrovalve
Option
B56
Sensor B on lifting distributor
Option
B57
Sensor A on lifting distributor
Option
B58
Sensor B on tilting distributor
Option
B59
Sensor A on tilting distributor
Option
B60
Sensor B on telescope distributor
Option
B61
Sensor A on telescope distributor
X273
Distributor
C8
C3
C5
E15
E27
M40 /
E40
M40 /
G40
K2
K4
I25
A31
M32
X93
Main
Y7
Tilting cut-off electrovalve/tilting cut-off valve
M36
X95E
X100
X105
X106
X111
X112
X113
X116
X117
X119
Main
Main
Main
Main
Main
Main
Main
Main
Main
Main
Main Engine
Main
Option
Main
Engine
Option
Option
Option
Option
Option
Option
Option
Option
Option
Option
Option
Option
Option
Option
Distributor
K12
B23
M11
M6
A4
S36
B21
S14
S28
S27
HELLA K12 mini relay plate (MT 1030 Easy)
EN 15000 boom angle sensor
Distributor harness ground connection
Rear frame ground
Black Casappa LSU ECU / B
Forced operation low pressure predisposition
Continue flow potentiometer predisposition
Easy connect system switch predisposition
Attachment locking switch predisposition
Override switch
G2
A22
O40
C40
I22
A15
A18
G37
I35
I39
Main harness/engine interface
G12
Telescope retraction sensor
Option cab right-hand ground
Fan reversal switch
Right center frame ground
Rear hydraulic selector switch
Rear hydraulic control switch
Rear hydraulic selector electrovalve
Rear hydraulic electrovalve 1 (+ direction)
Rear hydraulic electrovalve 2 (- direction)
Rear hydraulic predisposition
Telescope suspension switch
Telescope suspension electrovalve 1
Telescope suspension electrovalve 2
Telescope suspension valve pressure switch
Telescope position sensor
Telescope suspension cut-off relay
Telescope suspension power supply relay
NC reverse tilt movement detection pressure switch
Hydraulic cut-off electrovalve/safety valve
A27
S40
E11
K42
M11
O6
M10
Q3
Q5
K3
M22
Q16
Q14
O20
M16
Q17
Q20
M14
M34
X120
X134
X135
X186
X201
X216
X217
X218
X219
X220
X221
X222
X223
X224
X225
X226
X227
X228
X229
X23
80-02-M218EN
S34
M2
S40
M5
S22
S18
Y21
Y22
Y23
S23
Y10
Y11
B25
S24
K10
K11
B12
Y20
Item
A3
A4
A12
A15
B12
B13
B14
B21
B23
B25
B50
B51
B56
B57
B58
B59
B60
B61
BP5
R1
R2
S14
S18
S22
S23
S24
S27
S28
S33
S34
S36
S40
S48
V6
V7
V10
VCI
M11
Distributor harness ground connection
COMPONENTS
Designation
SPU module
LSU proportional pump ECU
JSM (Joystick Switch and Move)
Fuse plate and relay carrier
Reverse tilt/telescope suspension movement detection pressure switch
Lowering/telescope suspension movement detection pressure switch
Forward tilt/telescope suspension movement detection pressure switch
Continue flow potentiometer
Telescope Angle Potentiometer
Telescope suspension cylinder valve pressure switch
Sensor B on attachment distributor
Sensor A on attachment distributor
Sensor B on lifting distributor
Sensor A on lifting distributor
Sensor B on tilting distributor
Sensor A on tilting distributor
Sensor B on telescope distributor
Sensor A on telescope distributor
Horn press button
Signal resistances
Signal resistances
Easy connect system switch
Rear hydraulic control switch
Rear hydraulic selector switch
Telescope suspension switch
Telescope angle position senor
Override switch
Attachment locking switch
Movement neutralization switch
NO/NC retracted telescope position switch
Push button + continue flow indicator lamp
Fan reversal switch
Boom head electrovalve switch
Diode P600J 6A/600V - telescope suspension harness
Diode P600J 6A/600V - telescope suspension harness
VISHAY SBYV28-200 diode
Tilting cut-off valve
Position
M15
M15
M16
M17
M18
O24
O25
I12
I15
I15
O26
O29
O31
O33
O35
O37
O40 /
Q40
Position
E19
I21
A32
A3
O13
O15
O17
A18
A22
O20
O24
O25
O26
O29
O31
O33
O35
O37
A32
A33
A34
G37
O6
M11
M22
M16
I39
I35
I32
A27
A15
E11
A30
O18
O22
I2/I4
O36
Item
VRD
VS
Y6
Y7
Y10
Y11
Y15
Y16
Y17
Y18
COMPONENTS
Designation
Y20
Y21
Y22
Y23
Y40
Y41
Y42
Y43
Flow control valve
Safety valve
LSU Pump electrovalve
Tilting cut-off electrovalve/tilting cut-off valve
Telescope suspension electrovalve 1
Telescope suspension electrovalve 2
Telescope extend proportional electrovalve
Telescope retract proportional electrovalve
Attachment way+ proportional electrovalve
Attachment way- proportional electrovalve
Telescope lowering proportional electrovalve/flow distributor - priority flow control
valve
Hydraulic cut-off electrovalve/VS
Selection electrovalve
Rear hydraulic electrovalve 1
Rear hydraulic electrovalve 2
Left stabiliser electrovalve
Right stabiliser electrovalve
Fan Drive reversal
Fan Drive control
Item
Current
Y19
FUSES AND RELAYS
Designation
F7
7,5 A
F17
15 A Max.
F22
Telescope suspension + boom electrical predisposition + telescope head
10 A Max.
electrovalve
Position
O32
O34
K21
O36
Q16
Q14
O28
O30
O25
O27
O32
O34
O10
S3
S5
M2
M4
K14
K11
Position
LLMI + override switch + sensors + blue headlight opt (15A)
A5
Rear hydraulics + anti-theft + option
A3
A8
K10
Telescope suspension cut-off relay
S19
K11
Telescope suspension power supply relay
S21
K12
Stabiliser safety relay
G3
SPLICES
Item
Position
EP26
C33
EP27
C34
EP28
C17
EP29
C21
EP37E
M25
EP47
O16
EP49E
C26
EP69
I14
(26/07/2016)
ELECTRICAL SCHEMATIC DIAGRAMS
DIAGRAM 4 (hydraulic movements)
13
14
15
16
17
18
19
20
21
22
23
S36
26
27
28
B23
B21
29
30
S34
31
32
BP5
172
240
173
240
482
231
4
5
7
EP27
EP26
1
X106
467
466
CN1-B
24
30
X76A
132
479
1
0
9
G
234
10
8
1
9
1
0
1
X201
77C
X284-11
391
Sch. 7 MT 1030 Easy
(MT 1030
Easy)
1
0
478
456
9
I
9
11
S33 6
190
75B
S28 10
5
10
X33
5
X117
75A
218
S27
X119
77C
31
5
112
9
2
277
288
6
7
190
291
177
284
176
196
5
1
0
217
128
204
288
PS & MLT (MLT732)
740
217
286
2
234
1
292
234
12
8
42
7
10
X116
75C
MT 1030 Easy
234
292 MT 1030 Easy
234 MT + MLT 732
42
177
291 MT 1030 Easy
196
MT 1030 Easy
282
284 MT 1030 Easy
176
44
191
4
S14
5
ECS
10
30
480
101
X76B
X58-1
Sch. 2
K
2
283
S23 10
EP37E
S18 4
X217
X224
1
2
1
2
2
2
1
3
5
X228
2
1
3
1
2
1
2
X29
1
2
X28
2
X92
1
2
X23
1
A
B
MT 1030 Easy
B59
1
2
X93
B60
300
301
287
X260
2
MT 1030 Easy
B58
288
289
285
B
B57
1
1
MT 1030 Easy
MT 1030 Easy
B56
X259
2
X261
2
1
2
A
O
MT 1030 Easy
B61
264
194
179
X34
1
A
MT 1030 Easy
B51
X258
2
1
2
5
Q
Y6
X220
X227
X35
1
10
Y11
1
X223
noir
2
black
V6
195
EP47
9
X257
2
B
MT 1030 Easy
B50
V7
1
A
MT 1030 Easy
B25
black
1
3
B14
black
9
B13
P
noir
8
B12
noir
2
P
black
7
11
P
noir
1
X111
(B)
P
528
(MLT732)
PWM-OUT-
A4
527
MLT PS
& MLT
PWM-OUT+
B
O
X256
2
234
1
290
X251
2
44
1
191
X250
2
300
1
196
X225
299
X234
283
X232 X233
Y10
86
30
86
30
85
87
85
87
K10
K11
Y17
Y18
Y15
Y16
ACCES +
ACCES -
SORTIE
TELES
RENTREE
TELES
Y19
VRD
Y20
VS
Y7
VCI
X273
193
192
194
195
X135
S
Y22
(26/07/2016)
M
301
284
X230 X231
X105
293
264
black
noir
2
black
X222
287
193
6
177
3
293
X226
1
285
2
Y23
80-02-M218EN
S
80
9
292
8
192
2
176
7
291
1
2
290
0
1
289
S24
10
282
S22
X229
2
1
0
9
Y21
Q
E
19
456
25
288
16
UIN TOR 15
IN TOR 11
12
112
1
A
171
286
170
240
210
31
IN TOR 16
IN TOR 7
OUT PWM 10
23
20
234
6
42
MT 1030 Easy
736
OUT TOR 1
IN ANA 5
OUT PWM 1
OUT PWM 4
42
196
OUT PWM 6
177
169
3
X221
1
1
2
X32 2
X218
X219
21
A12
Sch. 3
X36
9
41
C
482
458
168
176
44
478
191
IN ANA 3
OUT PWM 5
IN TOR14
IN TOR 4
OUT LS 1-1
OUT LS 1-2
IN ANA 2
OUT PWM 8
179
297/479
Y42
Y43
noir
STAB
DROIT
2
32
7
2
X88
1
3
282
X254
2
44
1
178
2
178
739
738
737
1
X87
Y41
STAB
GAUCHE
0
484
483
375/481
481
467
284
169
465
464
OUT PWM 7
IN TOR 13 IN ANA 1
IN TOR 12
204
178
IN TOR 3
452
736
X253
2
299
179
382 noir
227 noir MT 1030 Easy S1
383 noir MT 1030 Easy S2
736
1
EP2
Sch. 3
1
EP69
X216
1
6
40
738
737
5
Y40
5
128
163
MT 1030 Easy S2
2
29
X4
9
6
X252
380
381
381
382 noir
1
11
D+ D-
39
MT 1030 Easy
15
33
D+ D-
38
1
6
191
1
X85
V10
5
13
R2
37
30
297 MT 1030 EasyS1
179
3
156
159
475
5
MT 1030 Easy
X84
V10
6
2
X57
18
1
EP4
Sch. 3
286
X120
X103-5
Sch. 7
I
K
14
12
R1
36
3
30
2
10
16
8
35
738
4
4
25
MLT & MT (MT 1030 Easy S1)
MLT & MT (MT 1030 Easy S1)
736
5
5
87a
85
A3
SPU
IN TOR 17
379
380
377
223
1
87
24
X61-10
Sch. 3
X46-3
Sch.8
86
454
291
CN1-A
22
34
2
IN TOR 6
241
210
3
463
376 MT 1030 Easy
481 (MLT & MT)
EP28
461
X56
10
132
77G
MT 1030 Easy S1
1
469
MT 1030 Easy
X43-5
MLT & MT (MT 1030 Easy) Sch. 3
459
4
MT 1030 Easy
EP49E
MT 1030 Easy
S40
453
E
K12
1
9
X186
2
4
484
(MT 1030 Easy S1)
0
5
G
6
IN TOR 5
455
MLT & MT
496
X99-3
Sch. 2
77G
1
1
X95E
5
465
469
483
1
IN TOR 18
EP29
3
464
468
468
457
2
466
1
457
3
458
459
2
2
X4-5
Sch. 2
X4-2
Sch. 7
X100
X113
4
462
460
13
156
12
380
155
17
3
377
(B)
3
X40
455
454
C
8
159
453
160
2
379
163
MT 1030 Easy 282
218
(A)
X41
(G)
X44
2
461
1
463
F22
F7
F1
F17
X112
33
A12
S48
A15
A
M
25
738
X45
Sch. 1
24
)
2)
8) 69 )
10
s 10 X 1 01 )
a s 4 ( X 3 ( ( X 2 06 & X
Ch V M eu M M5 (X1 101
)
6 X
A li
6B
u
(
i
M ie M 9
X7
l
R
i
/
M D M
A
R
AR D
76 5)
3)
AV b 1 (X 13
27
X
Ca A M 2 (
/X
G M ri 05
DR is t ( X 1
D 11
M
at
Vb
C
AP
MLT & MT (MT 1030 Easy)
277
12
IN TOR 13
11
170
10
241
9
IN ANA 4
8
175
7
171
6
168
5
174
4
42
3
286
2
178
1
15
16
ELECTRICAL SCHEMATIC DIAGRAMS
5 – SENSORS
CONNECTORS
Item
Wiring harness type
Component
X22
Main
B7
X24
Main - Engine
X40
Main
A15
COMPONENTS
Designation
Position
Item
Clogging hydraulic filter
I34
A2
Main harness/engine interface
M27
A3
SPU module
M19
Start-up safety/wheel alignment/brake fluid tank/connector B on fuse plate
C32
A7
Car radio
M29
Instrument panel
Position
M38
X56
Main
A3
SPU CN1-A
K39
A15
Fuse plate and relay carrier
A32
X57
Main
A3
SPU CN1-B
M19
A19
Engine ECU
C4
X68
Main
P1
Main display module
O28
B2
Horn
M33
X72A
Main
S11
Brake fluid level
E37
B4
Presence of water in diesel fuel
G14
X72B
Main
S11
Brake fluid level
E37
B6
Engine air filter clogging pressure switch
Q32
X73A
Main
B11
Stop switch
E32
B7
Hydraulic filter clogging pressure switch
I32
X73B
Main
B11
Stop switch
E34
B11
Stop switch pressure switch
G32
X76A
Main
M1
Cab left-hand ground
G41
B31
Hydraulic oil temperature
S21
X105
Main
M11
Distributor harness ground connection
I41
B32
Gear box oil temperature
S19
X120
Main - Engine
Main harness/engine interface
C7
B33
Boost air intake temperature sensor
Q22
X121
Main
A2
Dashboard indicator lamps plate (14 way)
M38
B48
Accelerator pedal potentiometer
E12
X164
Engine
B80
Air intake temperature sensor on hose
G10
B80
Air intake temperature sensor
G11
X165
Engine
R2
Fuel gauge
O25
B85
Radiator water level sensor
S31
X166A
Engine
B6
Air filter clogging info
O32
B86
Fuel pressure sensor (on fuel filter)
M17
X166B
Engine
B6
Air filter clogging ground
O34
P1
Hour meter/rev counter
O31
X168
Engine
B85
Radiator water level
S31
R2
Fuel level sensor (gauge)
Q26
X174
Engine
A19
Engine computer connector A1
I5
R11
Manual accelerator potentiometer
I36
X175
Engine
A19
Engine computer connector K1
C5
S11
Brake liquid level contact
E36
X178
Engine
B4
Presence of water in diesel fuel
G13
Y44
Ferrite
O28
X179
Main
B48
Accelerator pedal potentiometer
C10
Y47
Ferrite
O30
X201
Engine
M5
Right center frame ground
Q42
X245
Engine
B33
Boost air temperature sensor
O22
X246
80
Designation
Engine
B32
Transmission oil temperature sensor
S19
X247
Engine
Y37
Hydraulic oil temperature sensor
X277
Engine
A19
Engine harness/main harness interface
I11
X281
Engine
Engine side fuel filter pressure sensor extension
K14
X282
Engine
B86
Filter side fuel filter pressure sensor extension
K16
X286
Main
R11
Manual accelerator
K36
X907
Deutz Harness
Intake manifold pressure & temperature sensor
M14
X913
Deutz Harness
EGR valve position sensor & actuator
I14
X914
Deutz Harness
Oil pressure switch
O14
X916
Deutz Harness
Camshaft position sensor
K14
80-02-M218EN
S21
Item
Current
F10
10 A
FUSES AND RELAYS
Designation
Horn + stop switch
Position
A33
Item
SPLICES
Position
EP18
M29
EP21
C9
EP22
E8
EP66
O27
EP67
Q19
EP73
K9
EP KC
M14
EP KD
O13
(26/07/2016)
ELECTRICAL SCHEMATIC DIAGRAMS
DIAGRAM 5 (sensors)
1
2
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
X45
Sch. 1
41
42
2)
)
10
8) 69 )
s 10 X1 01 & X
as (X 3 ( X2 01
4
(
B)
Ch V M eu M M5 (X1
76
A ili u M9
/X
M ilie R
6A )
M D
X7 35
AV b 1 ( X1
Ca A M 2 (
G RM
D
at
Vb
C
AP
A15
F10
A
3
17
A
ENGINE HARNESS
5
46
669
1
669
EP21
675 1
Red
+
63
670
4
670
670 4
Green
S
62
671
2
671
EP22
676 2
672
S ANA U
3
-
Blue
B48
672 3
White
673 5
Yellow
674
X73A
-
57
700
700
2
64
699
699
1
X72B
B
P
B4
E
S11 N
43
X178
X73B
B11
56
ECM K1
X72A
A
+
IVS
E
672
X40-13
Sch. 8
-
Black
6
4
IVS
16
EP15
Sch. 8
+
57
0V
X179
SENSING
5V
X120
674
A19
C
X175
673
ECM K1
55
C
57
X40
(B)
X70-2
Sch. 6
56 X76A
G
G
X164
667
667
1
82
651
668
2
85
646
(-)
4
(S)
650
50
5
(5V)
609
9
613
13
3
3
4
4
628
628
28
X907 1
(-)
27
629
629
29
2
(S1)
24
622
622
22
3
(+)
43
623
623
23
44
626
626
26
EP KC
4
X914 1
O
2
627
627
27
EP KD
4
X24
P
A2
(-)
193
192
K
A2
A7
A3
B2
T
578
4
X121
6
M
A3
P
X57
20
X120
(+)
EP18 577
(S)
8
7
P
742
X165
(-)
X245
B33
Y44
1
EP66
1
2
2
X68
Y47
9
25
15
749
X166A
P1
R2
X201
X166B
N
EP70
Sch. 1
EP70
Sch. 1
Q
748
X247
T
T
B32
B31
747
X201
1
2
X168
748
2
16
1
746
744
743
X246
1
2
S
N
B85
(26/07/2016)
O
B6 P
T
EP67
S
194
17
B86
(S)
(S2)
3
29
X912-1
Sch. 1
Q
612
40
(+)
17
2
17
611
16
2
X282
X56
1
194
1
0-5V DC input
610
X38-7
Sch. 8
19
+
2
193
17
(S2)
X121-11
Sch. 8
0
3
576
M
2
X281 1
576
617
14
GND ANA
614
N
S
25
CABLE 10
X286
(S1)
25
614
1
25
613
s
X916
Analog Input 1
37
609
578
52
578
53
578
K
A3
26
646
R11
192
3
46
B7
579
51
652
P
M
577
(+)
25
EP73
(-)
2
I
X22
579
651
1
579
47
742
647
579
647
745
648
19
2
X913
Black
648
48
745
20
1
ENGINE HARNESS
MLT & MT (MT 1030 Easy S1)
X277
745
X174
I
X105
9
9
8
650
617
X38-7
Sch. 8
749
44
61
B80
80-02-M218EN
80
79
18
ELECTRICAL SCHEMATIC DIAGRAMS
6 – VENTILATION / AIR CONDITIONING / WIPERS
CONNECTORS
Item
Wiring harness type
X26
Main - Cab
X30
Main
X31
Main
X37
Main
X40
Main
X41
X44
Designation
COMPONENTS
Designation
Position
Item
M22
A8
Heating/ventilation panel
I6
Heating/ventilation
G2
A06
Air-conditioning module
O12
Air-conditioning option
M6
A15
Fuse plate and relay carrier
A2
A15
Power connector/connector D on fuse plate
C4
B46
High pressure air-conditioning sensor
O6
A15
Start-up safety/wheel alignment/brake fluid tank/connector B on fuse plate
C3
M3
Front windscreen wiper engine
I19
Main
A15
Option and roof light power supply/connector A on fuse plate
C6
M4
Rear windscreen wiper engine
S29
Main
A15
Relay/hydraulic movement cut-off/transmission cut-off/electrovalve/connector G
C7
M5
Roof windscreen wiper engine
S25
X45
Main
A15
Fuse and relay plate power supply and ground/connector K on fuse plate
A11
M6
Side windscreen wiper engine
S20
X70
Main
M7
Front windscreen washer pump
I16
M7
Front windscreen washer pump
I17
X72B
Main
S11
Brake fluid level
G39
M10
Air-conditioning compressor
S8
Upper cab harness interface
A8
Position
X76A
Main
M1
Cab left-hand ground
G41
M12
Air-conditioning fan 1
S10
X76B
Main
M1
Cab left-hand ground
M41
M13
Air-conditioning fan 2
S12
X77
Main
M3
Front windscreen wiper
I18
M16
Heating/ventilation fan
K5
X79
Main
S4
Wiper commutator switch
E16
R1
Preheating resistances
O8
X80
Main
S4
Wiping reset
E21
R3
Rear defrost
O31
X142
Cab
M4
Rear windscreen wiper
S28
S4
Wiper switch
C26
X143
Cab
M6
Side windscreen wiper
S19
S12
Revolving light switch
I4
X144
Cab
M5
Roof windscreen wiper option predisposition
S24
S16
Rear window defrost switch
O35
X149
Cab
S115
Roof/side windscreen wiper option switch predisposition
O16
S115
Roof/windscreen wiper switch
O16
X153
Cab
S16
Defrost switch
O35
X154A
Cab
R3
Rear defrost - power supply
O30
X154B
80
Component
Cab
X172
Main - Engine
X201
Engine
R3
M5
Rear defrost - ground
O30
Air-conditioning predisposition
M9
Right center frame ground
K41
X204
Option
B46
High pressure air-conditioning sensor
O6
X205
Option
A6
Air-conditioning module - power supply and control
O8
X206
Option
X207
Option
M10/M12/M13 Air-conditioning module - compressor and fan power supply
M10
Air-conditioning compressor
Q8
Q8
X208
Option
M12
Air-conditioning fan 1
Q10
X209
Option
M13
Air-conditioning fan 2
Q13
X255
Engine
Air-conditioning compressor power supply interface
Q8
80-02-M218EN
FUSES AND RELAYS
Designation
Item
Current
F3
10 A
Rear windscreen wiper + roof windscreen wiper
A5
F13
30 A
Fan
A4
F16
5 A/7,5 maxi
Diagnostic plug + fan control + air-conditioning option
A5
F19
15 A
Rear windscreen defrost
A6
F21
10 A
Front windscreen wiper + front windscreen washer
A3
F46
30 A
Air-conditioning/fan module option
K4
NO Heating/ventilation panel control relay
A8
K0
Item
Position
SPLICES
Position
EP45
O10
EP46
Q13
EP52
O29
EP57
Q25
(26/07/2016)
ELECTRICAL SCHEMATIC DIAGRAMS
DIAGRAM 6 (ventilation / air-conditioning / wipers)
2
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
X45 (K)
A15
4 69
K0 2
5
87
86
42
A
30
1
3
19
6
1
0
20
84
164
84
3 mm²
C
7
135
9
6
164
488
(D)
X37
80
1
85
(B)
X40
(G)
X44
(A)
10 X41
4
87a
F19
F16
F13
F21
85
0
7
2 mm2
151
X45
Sch. 1
41
2)
)
10
8) 69
)
s 10 X1 01 & X
as (X 3 ( 2 1
X
0
4
(
B)
Ch V M eu M M5 (X1
76
A ili u M9
/X
M ilie R
6A )
M D
X7 35
AV b 1 ( X1
Ca A M 2 (
G RM
D
at
Vb
C
AP
A
3
F3
1
19
S4
69
X76A
C
F
X115-1
Sch. 2
X79
1
2
3
4
5
6
7
8
X80
9
1
2
94
103
78
59
95
97
96
80
99
104
85
E
E
4 mm²
83
X76A
56
X76A
F
A8
X70
X77
2
2
3
0
1
4
1
2
M3 2
vit 1
M
1
I
-
2
S12
3
93
96
6
3
+perm
raz
I
X76A
1
M7
BP
78
93
95
E
94
D
59
C
153
151
B
43
A
154
X30
G
152
83
G
136
4 mm²
X72B
EP 3
Sch. 8
6
M16
K
K
BF1/M1
X159
Sch. 1
5 mm2
713
9
F46
5 mm2
12
727
5 mm2
5 mm2
5 mm2
728
X201
199 X76B
3
7
4
751
753
753
708
722
noir
716
1
0
1
5
9
S16
10
X153
O
751
noir
752
727
noir
713
EP57
Q
M12
3
1
2
3
1
2
3
727
724
713
X142
4
723
X144
4
721
X143
726
C
720
X209
712
2
725
1
718
2
719
1
716
X208
1
2
4
M13
4
+perm
S
raz
3
4
+perm
2
M6 vit
M
raz
3
vit
M
1
4
+perm
2
M5
raz
3
2
M4
M
1
S
vit
1
80-02-M218EN
80
201
199
200
708
709
710
709
710
754
714
711
715
R3
EP46
X207
M10
EP52
722
717
725
10
6
719
721
2
4 mm²
A
Blue
bleu
B
Green
vert
X255
C
Blue
bleu
X206
X149
RT7sec
Yellow/Green
jaune/vert
RT7sec
5
X154B
726
A06
R1
(26/07/2016)
135
X154A
9
8
X76B
752
0
X76B
201
M
750
B46
1
200
4
754
2
714
S115
6
12
noir
5
13
noir
4
11
9
750
8
noir
3
717
104
-
103
5
724
4
723
3
711
2
1
Q
2
noir
1
715
X205
718
EP45
2
HP
O
1
-
X26
99
2
-
1
-
X172
C
728
727
152
154
B
720
X204 1
A
Pink
rose
Purple
violet
X31
orange
Orange
M
153
30A
20
ELECTRICAL SCHEMATIC DIAGRAMS
7 – OPTIONS
80
CONNECTORS
COMPONENTS
Item
Wiring harness type
Name
Position
Item
X04
Main
0
Options power supply
Designation
O3
A1
Anti-theft unit
I19
X11
Main
S44
Pneumatic seat
Q10
A3
SPU module
E25
X27
Loudspeaker
Harness
0
Car radio/loudspeaker interface
A35
X37
Main
A15
Power connector/connector D on fuse plate
E3
X40
Main
A15
Start-up safety/wheel alignment/brake fluid tank/connector B on fuse plate
E6
X41
Main
A15
Option and roof light power supply/connector A on fuse plate
E3
X45
Main
A15
Fuse and relay plate power supply and ground/connector K on fuse plate
C33
X53
Main
A7
Car radio loudspeaker output
A35
X56
Main
A3
SPU CN1-A
E25
X76A
Main
M1
Cab left-hand ground
M41 / E41
X76B
Main
M1
Cab left-hand ground
S41
X94
Option
Y12
Telescope head electrovalve option
I25
X97
Main
S10
Telescope head electrical predisposition or telescope head electrovalve
G25
X103
Main
S29
Telescope head electrical connector or telescope head electrovalve switch predisposition
I30
X118A
Main
0
Anti-theft module predisposition
K9
X118B
Option
A1/A10
Anti-theft module
I16
X118B
Option
A1/A10
Anti-theft module
I15 / I16
X135
Option
M2
Option cab right-hand ground
K41
X138A
Cab
B28
Left loudspeaker power supply predisposition
C36
Designation
Position
A7
Car radio
A35
A10
Fintronic anti-start unit
I13
A11
Fintronic antenna
G13
A13
Digicode
G17
A14
Modclé
G20
A15
Fuse plate and relay carrier
C2
A25
Easy Manager option - ME 501-4
M24
A26
Easy Manager option keyboard
Q30
B27
Right loudspeaker
C37
B28
Left loudspeaker
C35
H36
Fintronic indicator lamp
G14
M15
Pneumatic seat compressor
Q11
R6
Preheat rod
O39
S10
Telescope head electrovalve reel
G25
S29
Telescope electrical connector/telescope head electrovalve switch
I29
S44
Pneumatic seat switch
S10
Y12
Telescope head electrovalve
I27
X138B
Cab
B28
Left loudspeaker ground predisposition
C35
X139A
Cab
B27
Right loudspeaker power supply predisposition
C38
X139B
Cab
B27
Right loudspeaker ground predisposition
C37
X192
Electric plate
A7
Car radio power supply
A33
X235A
Option
A13/A14
Digicode/modclé
G16
X235B
Option
A13/A14
Digicode/modclé
G16
F17
15 A Max.
FUSES AND RELAYS
Item
Current
Designation
F4
15 A
ECM wake-up + diag plug + diesel pump + temp sensors + opt X4 output
C4
F6
5A
Wheel alignments + AS option
C6
"Rear hydraulics + anti-theft
Fan Drive control as standard/Fan Drive optional on MT"
C4
Pneumatic seat + AS option
C5
Telescope suspension + boom electrical predisposition + boom head EV
C8
Warning + roof light + anti-theft + VDO clock module
C3
X236
Option
A11
FINTRONIC anti-start unit
G12
F20
10 A
X238
Option
R6
Preheat rod
O39
F22
10 A Max.
X239A
Option
A1
Digicode/modclé
I16
F29
15 A
X239B
Option
A1
Digicode/modclé
I16
X283
Option
A26
Keyboard
Q30
X284A
Option
A25
Easy Manager option
Q21
Item
Position on diagram
X284B
Option
A25
Easy Manager option
Q21
EP58
S23
X285
Main
S44
Pneumatic seat
O11
X287
Main
S44
Pneumatic seat
O12
80-02-M218EN
Position
SPLICES
(26/07/2016)
ELECTRICAL SCHEMATIC DIAGRAMS
DIAGRAM 7 (Options)
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
38
39
40
X45
Sch. 1
7
1
744
X27
8
F22
F6
7
X118-5
Sch. 1
8
X45
(K)
2
+
-
C
B27
4
69
69
X76A
216
156
(B)
X40
58
4
A
X139A
A3
SPU
X52-5
Sch. 3
E
X56 CN1-A
471 Black
noir
4
A11
X97
X186-5
Sch.4
A13
H36
2
1
A14
X236
472
S10
G
X235B
4
8
12
1
2
3
4
5
7
6
8
9
10
11
1
0
1
12
G
77B
F20
12
161
157
X4-1
Sch. 4
214
11
8
158
F4
F17
159
160
2
-
B28
42
472
X26A-10
Sch. 8
(A)
X41
MLT & MT (MT 1030 Easy) 453
F29
1
215
105
(D)
X37
4
X138A X139B
+
C
1
2
3
X138B
A15
X45
Sch. 1
2
253
X53
Black 254
noir
8
41
747
7
746
4
251
X45
Sch. 1
E
37
A7
X192
X45
Sch. 1
36
2)
)
10
8) 69 )
s 10 X1 01 & X
as (X 3 ( X2 01
4
(
B)
Ch V M eu M M5 (X1
76
A ili u M9
/X
M ilie R
6A )
M D
X7 35
AV b 1 ( X1
Ca A M 2 (
G RM
D
at
Vb
C
AP
A
3
Black 252
noir
2
745
1
21
7
9
X94 2
(+)
batt (+)
Battery
S29
1
or
X239B
12
I
9
10
4
6
3
5
8
7
11
2
10
X103
1
77B
X239A
5
4
3
2
1
12
11
10
9
8
7
6
5
4
3
2
1
214
225
X42-1
X41-12
Sch. 1
Sch. 1
EP04
X114-2
X114-4
Sch. 3
Sch. 1
Sch. 1
236
X61-5
Sch. 3
noir
12
11
10
9
8
7
6
5
4
3
2
1
X52-10
Sch. 3
X135
OPTION MT 1030 EASY 75D ST3B S1/S2
+ 5V
CAN L
Digital Output 1 (max 200mA)
Digital Input 3 (libre)
CAN H
Digital Input 4
2
O
Vert
R6
1
2
5
4
6
7
8
9
11
10
-
12
Marron
Noir
Bleu
Jaune
Gris
Bleu clair
Rose
Orange
Bleu
3
Infos transmises
via réseau CAN
+
3
OUT
A26
9
EP35
Sch. 2
EP36 X292-4
Sch. 2 Sch. 1
11
12
392
8
391
7
390
6
389
387
386
5
388
4
3
4
EP94
Sch. 8
S44
C
C
M15
M15
EP58
X115-1
Sch. 2
393
S44
X287 5
2
385
263
2
1
384
X284A
MT 1030 EASY
75D ST3B S1/S2
X293
1
262
2
Q
S
- BAT 0V
Noir
X284B
Rouge
Marron
X285
X222-2
Sch. 4
X11 1
3
Bleu
3
Blanc
4
X229
Sch. 4
+ BAT 12V
EP 2
Sch.3
6
Digital Input 2 (+APC)
156
475
3
394
8
Digital Input 1 (D+)
263
7
X238 1
262
2
161
158
263
157
211
160
X4
X119-1 EP95
Sch. 4 Sch. 3
Q
1 2 3
4 5 6
7 8 9
0 #
*
Trackunit
OPTION DUALID
(Key pad)
274
X76B
X292-1 X107-2
Sch. 1 Sch. 2
(26/07/2016)
K
M
Trackunit
ME 501-4
OPTION
A25
EASY MANAGER
Bus 1-wire
M
O
I
80-02-M218EN
S
80
K
211
6
X49-10
Sch. 8
215
7
39
8
41
9
499
10
216
X118A
11
131 noir
Y12
X118B X118B
12
134
5
475
Blocking
Blocage
(+) APC
NC C3
NC C2
Com C1
NC C1
Com C2
A1
Com C3
A10
Detection2 2
Détection
(-)
batt (-)
Battery
Detection1 1
Détection
X235A
22
ELECTRICAL SCHEMATIC DIAGRAMS
8 – LIGHTING / SIGNALING
80
CONNECTORS
Item
Wiring harness
type
X04
Main
X13
Main
Name
component
E2
CONNECTORS
Designation
Position
Item
Wiring harness
type
Name
component
Designation
Position
Options power supply
Q5
X186
Main
S40
Fan reversal switch
G20
Front right headlights
M15
X187
Electric plate
S13
Warning switch
A29
X14
Main
E1
Front left headlights
K14
X188
Electric plate
S5
Light commutator switch
C12
X16
Main
E4
Rear right headlights
M22
X189
Electric plate
V2
Awaiting stalk switch-plate TUV diode
A14
X17
Main
E3
Rear left headlights
M18
X190
Electric plate
V2
Awaiting plate-commutator switch TUV diode
A16
X18
Main
E7
License plate light
M32
X191
Electric plate
V2
Awaiting plate-working lights TUV diode
A17
X19
Main
Rear trailer connector interface
M25
X20
Main
B1
Reversing sound alarm (MLT - MLT PS)
M30
X24
Main - Engine
S15
X25
Main
X26
Main - Cab
X32
Main
S7
X37
Main
X38
Main
X39
X40
Main harness/engine interface
K8
X202
Option
Working lights on telescope option
O41
X203
Option
Upper cab harness interface
Q31
X210
Option
Cigarette lighter connector
M37
X211
Option
A15
Power connector/connector D on fuse plate
G11
X280
Option
A15
Fault indicator connector/connector I on fuse plate
G35
Main
A15
Lighting harness connector C on fuse plate
G12
Main
A15
Start-up safety/wheel alignment/brake fluid tank/connector B on fuse plate
G8
Item
X41
Main
A15
Option and roof light power supply/connector A on fuse plate
G6
A2
Instrument panel
G18
X44
Main
A15
Relay/hydraulic movement cut-off/transmission cut-off/electrovalve/connector G
G4
A4
LSU proportional pump ECU
I8
A6
Air-conditioning module
I8
A15
Fuse plate and relay carrier
C5
A19
Engine ECU
I4
B1
Reversing sound alarm
O30
B2
Horn
I35
E1
Front left headlights
K12
E2
Front right headlights
O16
E3
Rear left headlights
M18
E4
Rear right headlight
M22
E5
Left trailer lights
O26
E6
Right trailer lights
O29
E7
Rear license plate light
O32
E12
Front right working light
S17
E13
Front left working light
S16
E14
Roof light
S25
E15
Rotating beacon light
Q22
E16
Rear left working light
S22
E17
Rear right working light
S27
E18
Left telescope working light
Q39
E19
Right telescope working light
Q40
E20
Front left blue light
S2
E21
Front right blue light
S3
E22
Rear left blue light
S4
E23
Rear right blue light
S4
H1
Rear right and left fog light
O22
H2
Rear right and left position light
H3
Rear right and left stop light
H4
Rear left direction indicator light
O20
H5
Rear right and left reversing light
O19 / O24
H6
Rear right direction indicator light
O23
H7
Front right and left position lights
K13 / O17
H8
Right and left dipped beam light
K13 / O16
E18/E19
X45
Main
A15
Fuse and relay plate power supply and ground/connector K on fuse plate
C40
X46
Main
K17
HELLA K17 mini relay plate
K11
X49
Main
S32
Rear fog light switch
O35
X60
Main
Engine indicator lamp power supply interface
G20
X69
Main
P1
Main display to satellites module
Q12
X74
Main
B2
Horn
G34
X75
Main
V2
TUV sidelight control by working light on boom
A19
X76A
Main
M1
Cab left-hand ground
K41 / O41 / C41
X76B
Main
M1
Cab left-hand ground
K41 / M41
X83
Main
A2
Dashboard indicator lamps plate (4 way)
G18
X89
Main
P3
Engine water temperature module
Q14
X90
Main
P2
Fuel level module
Q6
X91
Main
S7
Cigarette lighter light
M39
X96
Main
E5/E6
Rear 7-pin socket electric connector (MT option)
M25
X106
Main
M6
Rear frame ground
K41 / M41 / O41
X120
Main - Engine
Main harness/engine interface
K6
X121
Main
A2
Dashboard indicator lamps plate (14 way)
I21
X135
Option
M2
Option cab right-hand ground
X136
Upper cab
X140
Upper cab
X141
K41 / S41
Lower cab/upper cab interconnection
Q17
E12
Front left working light option predisposition
S16
Upper cab
E13
Front right working light option predisposition
S17
X146
Cab
E16
Rear left working light
S23
X147
Cab
E17
Rear right working light
S27
X150
Cab
S12
Revolving light switch
S33
X151
Cab
S139
Front/rear working light switch
Q36
X152
Cab
S54
Telescope working light switch
S38
X175
Engine
A19
Engine computer connector K1
I5
X180
Electric plate
A15
Indicator lamp harness/connector E on fuse plate
G22
X181
Electric plate
A15
indicator lamp harness/connector F on fuse plate
G31
X182
Electric plate
A15
Power supply and engine indicator lamps on fuse plate
G21
X183
Electric plate
A2
Dashboard indicator lamps (16 way)
G21
X185
Electric plate
A2
Steering fault indicator
G28
80-02-M218EN
Blue headlight switch
S5
Aggravating movement cut-off power supply on non EN15000 version
Q2
E18
Left telescope working light
O39
E19
Right telescope working light
O41
S8
12 V socket option
M12
COMPONENTS
Designation
Position
O24
O20 / O23
(26/07/2016)
ELECTRICAL SCHEMATIC DIAGRAMS
COMPONENTS
Item
Designation
FUSES AND RELAYS
Position
Item
Current
Designation
Position
H9
Right and left main beam light
K13 / O16
F14
10 A
Cigarette lighter + option
C11
H10
Front right direction indicator light
O17
F18
15 A
Front working lights
C6
H11
Front left direction indicator light
K14
F23
7,5 A
Right sidelight + heating panel lighting/air-conditioning + indicator lamp
C15
H12
Hour meter/rev counter module back lighting
S11
F24
7,5 A
Left sidelight + rear number plate lighting
C14
H18
Engine water temperature module back-lighting
S8
F25
7,5 A
Right indicator lights
C17
H19
Red engine temperature indicator lamp
S14
F26
7,5 A
Left indicator lights
C16
H20
Steering fault
I19
F27
15 A
Dim lights + fog lights
C12
H21
Preheating indicator lamp
I20
F28
15 A
Headlights + indicator lamp
C13
H22
Engine pollution indicator lamp
I20
F29
15 A
Warning + roof light + anti-theft
C7
H23
Indicator lamp immediate engine fault stop
I28
F30
25 A
Light commutator switch
C12
H24
Transmission oil pressure indicator lamp
I23
K5
Machine fault alarm
C32
H25
Transmission oil temperature indicator lamp
I24
K9
Flashing / warning unit
C29
H26
Brake fluid level indicator lamp
I25
K17
Dashboard indicator lamps module LED test relay (main harness)
K9
H27
Parking brake indicator lamp
I26
H28
Battery charge indicator lamp
I27
H29
Engine oil pressure indicator lamp
I21
H30
Low radiator water level indicator lamp
I29
EP 3
K28
H31
Engine air filter clogging indicator lamp
I31
EP 50
Q18
H32
Right and left indicator lights lamp
I31
EP 51
Q17
H33
Side light indicator lamp
I32
EP 52
Q23
H34
Dipped beam headlights indicator lamp
I33
EP 53
Q23
H35
Main beam headlights indicator lamp
I34
EP 54
O26
H46
Fuel reserve indicator lamp
S8
EP 55
Q22
H47
Engine coolant temperature
S12
EP 56
Q20
P1
Hour meter/rev counter
Q10
EP 8
M27
P2
Fuel level module
S6
EP 9
K19
P3
Engine water temperature module
S14
EP10
K23
S05
Light commutator switch
A6
EP11
M23
S7
Cigarette lighter
O39
EP13
K22
SPLICES
Position
S8
12V socket
M13
EP14
M20
Revolving light switch
S32
EP15
M20
S13
Warning switch
A31
EP19
G9
S15
Blue headlight switch
S4
EP20
G9
S32
Rear fog light switch
M34
EP48
S3
S54
Telescope working light switch
Q38
EP49
S3
S139
Front and rear working light switch
Q33
EP74
I38
K23
EP75
I38
A15 / A18
EP94
I9
V1
Diode P600 J - reversing lights
V2
6A 300V diode - MATRA71887 AXB
V9
Diode P600 J - indicator lamp module relay
G9
V11
Diode
I38
80
Item
S12
FUSES AND RELAYS
Designation
Item
Current
F2
15 A
Rear working lights
C6
F5
7,5 A
Rotating beacon light
C7
Position
F7
7,5 A
LLMI + override switch + sensors + blue headlight opt (15A)
C18
F9
5A
Modules + dashboard indicator lamps + regeneration switch
C8
F10
10 A
Horn + stop switch
C9
F11
15 A
Working light on telescope/option
C8
F12
10 A
Right or left indicator lights
C19
(26/07/2016)
23
80-02-M218EN
ELECTRICAL SCHEMATIC DIAGRAMS
24
1
2
3
4
5
6
7
DIAGRAM 8 (lighting / signaling)
8
9
10
11
12
13
14
15
16
17
20
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
207
V2
sortie cadencée
X75
49
R
2
0
5
8
X187
S13
10
6
8
1
Yellow/Green
vert / jaune
0
L
2
3
54d
9
1
54s
G RM
D
0
56b
56a
57/58
30
31
L
5
S5
3
1
7
X188
C
X45
Sch. 1
(K)
X45
A15
X45
Sch. 1
F12
86
85 BUZZEUR
69 X76A
87
K9
87
Timer
3.5 sec ±0.5
F7
F25
F26
F23
F24
F28
F27
F30
F14
F10
F11
F9
F5
F2
F29
87a
FLASHING
UNIT
85
C
4
K5
F18
A
noir
1
7
6
42
2)
10
) 6) X
08 10 1 &
B)
76
/X
6A )
X7 5
4
+apc
+bat
A
41
3
AV b 1 ( X1
Ca A M 2 (
X191
V2
21
A RD R
A D
2
19
V2
s 1 X 0
as 4 (X 6 ( (X1
Ch V M R M M9
at
Vb
C
AP
X189
18
X190
V2
K4-5
Sch. 3
E
E
Fus Therm 2A
X38 (I)
3
4
11
12
H22
H29
IN TOR
H24
H25
H26
H27
H28
DZ1
11
X121
H23
H31 H32 H33
H30
14
123
X44-4
Sch. 3
X14
5
EP13
V1
EP10
239
247
30
114
246
255
115
4
3
2
1
3
1
7
6
5
5
4
X20
4
A
B
STOP
H1 H3 H6 H5
H2
E5
Left
trailer lights
feu rem GA
EP49
80-02-M218EN
H46
B1
STOP
Rightfeu
trailer
rem lights
DR
E7
2
1
0
729
H47
P3
E13
E12
77A
753
202
45
40
17
98
10
131
X103-10
Sch. 7
1
7
88
16
728
755
732
14
X26
2
3
736
7
728
102
5
207
87
6
86
162
105
739
15
+
1
-
749
C
X146
A
+
2
740
B
1
739
X148
742
M
1
-
E16
E14
S7
130 X76A
1
8
5
2
E17
X106
702
X25
O
X211
1
4
10
733
2
9
X151
E18
755
703
1
0
X147
2
X106
K
M
733
1
25
H12
2
S139
704
742
738
EP55
X145
741
A
10
756
748
X49
E6
702
EP53
743
Yellow
Black 706
705
B
S32
749
noir
X106
238
2
X210
743
707
759
704
E15
X141
740
237
102
0
1
7
2
1
2
E19
2
8
Q
9
9
S12
703
701
1
EP50
763
X140
762
H19
706
761
EP51
764
766
X89
761
3
EP56
765 jaune 765
2 mm2
766
21
Black
140 noir
Ground
Ground
2
Battery
Battery
1
20
30
H12
X69
141
22
Alimentation
4
Satellite BUS
70
3
Analog
Analog
GND
Ground
23
10 RPMx100
2
Satellite BUS
140
noir
21
Ground
Ground
Battery
Battery
Output
switch 2
22
141
Satellite BUS
Ground
Ground
Battery
Battery
Output
switch 1
15
5
P2
150
1
737
EP54
X135
X91
X32
9
X18
730
E20 E21 E22 E23
P1
H18
EP48
S
70
23
Satellite BUS
X202
10
6
2 mm2
EP52
701
1
1
0
1
100
1
101
2
5
STOP
730
731
149
162
163
128
S15
2
X136
4
Black
noir
5
99
144
247
2
198
106
H5 H4 H3 H1
X96
X106
758
5
E4
STOP
H2
6
6
X106
5
10
X150
S54
X152
757
6
758
10
759
X16
8
736
735
6
2
756
5
7
130
4
1
125
243
101 X76B
734
3
3
143
2
X19
737
1
117
77A
735
X17
255
5
116
4
120
108
107
3
123
2
EP15
118
1
4
124
X13
110
111
2
109
1
X30-B
SCh. 6
136
244
249
X73B
Sch. 5
198
209
EP14
144
EP8
248
EP11
731
X90
I
250
734
X203
EP74
100
EP3
145
249
EP9
250
1
E1H8 H9 H7 H11
256
3
X33-9
Sch. 4
5
EP75 19
V11
732
5
246
4
1
4
B2
X76B
X76A
111 X76A
124 X106
O
3
X22-1
Sch. 5
H35
H34
G
X98
Sch. 3
222
738
2
15
X12-3
Sch. 3
X40-10
Sch. 8
238
3
E2H8 H9 H7 H10
1
31
13
X8
X24-B2
Sch. 3 Sch. 5
DZ2
237
2
E3
9
A
X184
X74
753
239
5
4
87a
S8
1
6
3
X280
0
3
54
4
M
1
1
5
X24-A3
Sch. 5
222
3
Q
7
Tempo 3s
H21
2
D1
Tempo 1.5s
H20
K17
9
4
D2
1
X4
8
27
32
30
71
72
23
25
16
D4
1
3
31
34
5
noir 32
4
30
7
22
71
72
6
B
38
27
1
5
23
25
33
28
33
28
22
29
24
26
574
573
3
108
51
109
114
107
1
50
110
53
52
98
115
575
34
9
D3
4
X185
X81
Sch. 3
245
87
2
80
8
7
248
5
85
7
3
119
1
1
86
K
6
2
245
2
10
2
243
X46
4
125
X120
X284-1
Sch. 7
EP94 271
X24
3
6
244
MT1030 Easy
2
X183
122
18
1
X182
29
119
A6
A2
1
122
X59 18
Sch. 1
92
8
121
72
X60 X186
117
9
19
X181 (F)
5
8
145
72
19
A4
2
16
29
575
11
118
19
572
10
9
51
27
C2
C4
12
X95-2
Sch. 4
50
575
6
13
572
54
572
575
573
1
7
223
572
C3
224
ECM K1
71
573
574
74
48
A19
I
573
18
270
93
5
MT 1030 Easy
X175
4
X83
EP74 X95-2
Sch. 8 Sch. 1
EP20
(E)
X180
3
5
53
V9
4
X118-1
Sch. 7
EP19
X119-5
Sch. 4
1
209
224
754
55
73
X72A
Sch. 5
X73A
Sch. 5
EP29
Sch. 4
13
52
MT 1030 Easy
(C)
X39
(D)
X37
10
2 mm²
11
5
57
149
6
105
215
(B)
X40
13
5
87
3
MLT & MT (PS) (MT 1030 Easy)
X87-12
Sch. 4
G
1
143
(A)
X41
86
13
163
282
455
218
12
88
(G)
X44
S
X135
(26/07/2016)
ELECTRICAL COMPONENTS LOCATION
pages
KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– SPLICES AND FERRITES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2D LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
–– HARNESS ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
–– MAIN HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
–– CAB AND FRONT WORKING LIGHTS HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
–– ENGINE HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
–– ADDITIONAL HARNESSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
–– DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
–– AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3D LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
–– HARNESS ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
–– ENGINE HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
–– GROUNDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
(28/07/2016)
80-03-M218EN
80
–– PS GEAR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2
ELECTRICAL COMPONENTS LOCATION
KEY
CONNECTORS
Position on harness layout
80
Item
DESIGNATION
2D
AsseMain
mbly
Cab
3D
EnAddi-tional Assembly
gine
B+
BM
W
X1
X2
X3
X4
X7
X8
X9
X10
X11
X12
X13
X14
X15
X16
X17
X18
X19
X20
X20A
X20B
X21
X22
Battery (+) / Battery cut-off connection
Battery (-)/Frame connection
Alternator ground
Alternator W terminal
Transmission cut-off on gear lever (MT - MLT)
Seat switch supply
Seat sensor info
Options power supply
Transmission cut-off on distributor lever
Transmission fluid thermostat (MLT PS: on PS gear box)
Forward electrovalve (MT - MLT)
Reverse electrovalve (MT - MLT)
Pneumatic seat
Handbrake switch
Front right headlights
Front left headlights
Front wheel alignment
Rear right headlight
Rear left headlight
License plate light
Rear trailer connector interface
Reversing sound alarm (MLT - MLT PS)
Reversing sound alarm (MT)
Reversing sound alarm (MT)
Rear wheel alignment
Clogging hydraulic filter
X23
Hydraulic cut-off electrovalve/safety valve
K12
X24
X25
X26
X27
X28
X29
X30
X31
X32
X33
X34
X35
X36
X37
X38
X39
Main harness/engine interface
Working lights on telescope option
Upper cab harness interface
Car radio/loudspeaker interface
Telescope retraction electrovalve
Telescope extension electrovalve
Heating / ventilation
Air-conditioning option
Cigarette lighter connector
Hydraulic movements neutralization switch
Attachment minus direction electrovalve
Attachment plus direction electrovalve
JSM connector
Power connector/connector D on fuse plate
Fault indicator connector/connector I on fuse plate
Lighting harness connector C on fuse plate
Start-up safety/wheel alignment/brake fluid tank/connector B on
fuse plate
M23
I4
K19
K18
K12
K12
I18
I18
I18
I19
K12
K13
I20
I27
I27
K27
C27
M37
G26 I4
G27 K4
G23
I19
I19
K20
I6
E37
C37
G33
I27
K19
G32
X41
Option and roof light power supply/connector A on fuse plate
I27
K17
G31
X42
X43
Fuse plate/connector H on fuse plate
FNR mechanical control handle
Relay/hydraulic movement cut-off/transmission cut-off/
electrovalve/connector G
Fuse and relay plate power supply and ground/connector K on
fuse plate
I27
K15
E2
C31
I27
G19
C37
I27
M17
G40
X40
X44
X45
80-03-M218EN
Engine
Ground
connections
A26
A16
I21
E16
E16
I25
K21
K23
K22
E16
E17
Q29
E28
M34
Q5
G5
I3
I3
I4
C6
C17
C17
E6
E2
C22
C24
C24
C16
C18
C35
M3
E38
G39
O41
K38
O38
M37
G23
K-2
K-1
G23
K-3
K-3
I25
G22
G24
O0
K-4
S-4
S-3
Q-4
M11
M12
G36
G37
K2
K3
C14 / I7
/ O8
Q20
K12
Q-2
I6
I5
C10 / M13
E10 / K12
I22
I22
K22
K23
M20
I0
I1
I2
I4
G9 / M13
C9 / M12
(28/07/2016)
ELECTRICAL COMPONENTS LOCATION
3
Position on harness layout
DESIGNATION
AsseMain
mbly
X46
X47
X48
X49
X50
X51
X52
X53
X54
X55
X56
X57
X58
X59
X60
X61
X68
X69
X70
X71
X72A
X72B
X73A
X73B
X74
X75
X76A
X76B
X77
X78
X79
X80
X81
X82
X83
X84
X85
Support mini relay HELLA K17
Starter Atofuse plate
Autofuse plate for diagnostic plug
Rear fog light switch
Front wheel alignment indicator light
Rear wheel alignment lndicator light
Wheel alignment switch
Car radio loudspeaker output
Ignition switch (4 way)
Ignition switch (6 way)
SPU CN1-A
SPU CN1-B
LLMI safety module
Alternator L
Engine indicator lamp power supply interface
Transmission cut-off switch
Main display module
Main display to satellites module
Front windscreen washer pump
Transmission cut-off on brake pedal
Brake fluid level
Brake fluid level
Stop switch
Stop switch
Horn
TUV sidelight control by working light on boom
Cab left-hand ground
Cab left-hand ground
Front windscreen wiper
PS JSM connector (MLT PS)
Wiper commutator switch
Wiping reset
Steering fault indicator lamp (MLT - MLT PS)
Steering fault pressure switch (MLT - MLT PS)
Dashboard indicator lamps plate (4 way)
Left stabiliser electrovalve
Right stabiliser electrovalve
G28
G28
E28
I22
I22
I22
I22
I26
G24
G24
I13
I13
I24
G25
G25
I25
G25
X87
Distributor harness interface
K16
X88
X89
X90
X91
Boom head electrovalve switch
Engine water temperature module
Fuel level module
Cigarette lighter light
G25
G25
I19
X92
Proportional electrovalve on boom lowering/flow control valve
K13
X93
X94
X95
X96
Tilting cut-off electrovalve/tilting cut-off valve
Telescope head electrovalve option
HELLA K18 mini relay plate (MT - MLT)
Rear 7-pin socket electric connector (MT option)
Telescope head electrical predisposition or telescope head
electrovalve
Transmission oil pressure switch (MLT PS: on PS gear box)
Strain gauge
EN 15000 boom angle sensor
Frame ground cable/(-) battery
ECU/frame ground cable
Telescope head electrical connector or telescope head
electrovalve switch predisposition
LSU pump regulating electrovalve (MLT - MLT PS)
K11
G32
G28
G16
A34
I4
M37
Q-3
K20
I15
K3
K31
K30
C23
I31
K39
I25
M11
G7
K17
G31
K4
X97
X98
X99
X100
X101
X102
X103
X104
(28/07/2016)
E24
E24
E25
E26
E25
E25
K33
I26
E25
G25
G26
I20
I26
I26
I25
G24
G25
K27
K27
G16
I16
I16
M16
M15
M14
M14
K11
M10
M9
M31
M32
C4
Cab
3D
EnAddi-tional Assembly
gine
A32
A35
A36
G6
G8
G9
I7
E12
G4
G4
E-2
C-1
G10
K14
G7
G8
I7
G8
O8
M12
O10
O8
Q5
Q4
O4
O4
O4
O4
E38
S23
I4
I4
I5
I23
G5
G5
O14
I10
Q14
C34
C34
G31/
G31
E2
O12
O9
K22
Engine
E30 / K25
G3
G4
E4
E4
E5
E6
E8
G12
G3
G4
E10
I5
E10
G11
G10
G5
G10
I21
I21
G11 / O14
/ Q2
Ground
connections
C23
E23
80
Item
2D
K2
G9
G9
I2
C8 / I12
/ O5
E5 / K13
M-2
K12
I1
S-5
M32
I14
C1
C1
E31
E28
80-03-M218EN
4
ELECTRICAL COMPONENTS LOCATION
Position on harness layout
Item
AsseMain
mbly
X105
Distributor harness ground connection
K15
X106
Rear frame ground
M3
X107
Atofuse fuse support for VDO power supply/ST3B dashboard plate
X108
X110
X111
X112
X113
X114
X115
X116
X117
X118A
X118B
X118C
X119
Front frame ground on cab bracket
Pump ECU (gray - A) (MLT - MLT PS)
Pump ECU (black - A) (MLT - MLT PS)
Forced operation low pressure predisposition
Continue flow potentiometer predisposition
Emergency stop
Diagnostic plug
Easy connect system switch predisposition
Attachment locking switch predisposition
Anti-theft module predisposition
Anti-theft module
Anti-theft shunt
Override switch
Main harness / fan drive motor & accelerator potentiometer
interface
Dashboard indicator lamps plate (14 way)
Gear box ECU (MLT PS)
Gear box display (MLT PS)
Main harness/gear box interface (MLT PS)
TUV 6th gear shunt (MLT PS)
Trailer towing speed limitation switch (MLT PS)
Telescope retraction sensor
Option cab right-hand ground
Lower cab/upper cab interconnection
Main display module and dashboard ground
Left loudspeaker power supply predisposition
Left loudspeaker ground predisposition
Right loudspeaker power supply predisposition
Right loudspeaker ground predisposition
Front left working light option predisposition
Front right working light option predisposition
Rear windscreen wiper
Side windscreen wiper
Roof windscreen wiper option predisposition
Rotating beacon light - ground
Rotating beacon light - power supply
Rear left working light
Rear right working light
Roof light
Roof light ground
Roof light ground
Roof/side windscreen wiper option switch predisposition
Revolving light switch
Front/rear working light switch
Telescope working light switch
Defrost switch
Rear defrost - power supply
Rear defrost - ground
Engine diagnostic plug/Fuse box 1
Battery cut-off
Cable + starter/alternator
Fuel pump power supply
Fuel pump ground
Air intake temperature sensor on hose
Fuel gauge
X120
80
DESIGNATION
2D
X121
X122
X123
X124
X127
X128
X134
X135
X136
X137
X138A
X138B
X139A
X139B
X140
X141
X142
X143
X144
X145 A
X145B
X146
X147
X148A
X148B
X148C
X149
X150
X151
X152
X153
X154A
X154B
X158
X159
X160
X163A
X163B
X164
X165
80-03-M218EN
Cab
G31/
G28
I40
3D
EnAddi-tional Assembly
gine
C13 / I17
K2
/ S4
O-7
Engine
Ground
connections
I17
S8
G16
I27
I13
I14
I25
I25
G24
I14
I24
I19
O29
O30
E6
E6
C9
K28
C11
K24
A-2
C-3
E13
G13
G5
C-6
G4
I4
I24
C5
G10
M23
C29
K25
I24
K21
I24
I24
I3
O13
C15
C12
C19
C14
C13
O39
O17
K13
M6
S-5
G26
I16
I13
E13
E13
I13
I13
E23
E23
I11
I17
G18
G12
E11
I11
G13
G13
G13
I17
I18
I17
I18
I19
G11
G11
M23
O23
O14
O14
G22
E6
S15
S15
G15
I15
A39
C39
O19
G37
G25
E-7
C-6
E-2
E-2
A3
A4
G-4
G0
E4
Q27
Q16
I16
O12
O12
O12
G41
I41
K41
K41
M41
G20
G21
E-6
E-8
G-2
E-4
E-4
E-4
E0
E1
E2
E2
E3
E-7
E-5
I18
E28
E31
C31
M6
M6
O7
Q12
M9
M6
C20
A1
Q30 / S1
I1
K1
(28/07/2016)
ELECTRICAL COMPONENTS LOCATION
5
Position on harness layout
DESIGNATION
AsseMain
mbly
3D
X166A Air filter clogging info
X166B Air filter clogging ground
O14
O14
EnAddi-tional Assembly
gine
O9
O10
X167
O17
M13
M12
M22
M18
O25
G23
K14
M38
K21
Glow plug conductor rail
X168
X169
X170
X171
X172
X174
X175
X176
X178
X179
X180
X181
X182
X183
X184A
X184B
X185
Radiator water level
Engine unit ground on frame
Engine computer box ground
Main display power supply via dashboard plate
Air-conditioning predisposition
Engine computer connector A1
Engine computer connector K1
Engine unit ground to frame
Presence of water in diesel fuel
Accelerator pedal potentiometer
Indicator lamp harness/connector E on fuse plate
indicator lamp harness/connector F on fuse plate
Power supply and engine indicator lamps on fuse plate
Dashboard indicator lamps (16 way)
Battery charge indicator lamp interface
Battery charge indicator lamp interface
Steering fault indicator
Fan reversal switch (Main harness)/Engine indicator lamp power
X186
supply (Plate harness)
X187 Warning switch
X188 Light commutator switch
X189 Awaiting stalk switch-plate TUV diode
X190 Awaiting plate-commutator switch TUV diode
X191 Awaiting plate-working lights TUV diode
X192 Car radio power supply
X193 Gear box speed sensor
X194 Low speed electrovalve (MLT PS)
X195 High speed electrovalve (MLT PS)
X196 Reverse electrovalve (MLT PS)
X197 Gear 1 electrovalve (MLT PS)
X198 Gear 2 electrovalve (MLT PS)
X199 Gear 3 electrovalve (MLT PS)
X200A Battery cut-off to (+) battery
X200B Battery cut-off to general power supply
X200C Starter motor power supply on B+
X200D Alternator B+
X201 Right center frame ground
X202 Blue headlight switch
Aggravating movement cut-off power supply on non EN15000
X203
version
X204 High pressure air-conditioning sensor
X205 Air-conditioning module - power supply and control
X206
Air-conditioning module - compressor and fan power supply
X207
X208
X209
X210
X211
X216
X217
X218
X219
X220
X221
X222
Air-conditioning compressor
Air-conditioning fan 1
Air-conditioning fan 2
Left telescope working light
Right telescope working light
Rear hydraulic selector switch
Rear hydraulic control switch
Rear hydraulic selector electrovalve
Rear hydraulic electrovalve 1 (+ direction)
Rear hydraulic electrovalve 2 (- direction)
Rear hydraulic predisposition
Telescope suspension switch
(28/07/2016)
Cab
E29
M23
O24
O24
O22
Q37
O42
O15
S27
K9
K10
K20
K21
O11
A5
M22
M22
Q9
S13
M23
M23
Engine
Ground
connections
K1
M1
A41 / K31
/ G1
C1
I41
Q20
G25
I34
A26
E1
I25
I25
C41
Q28
S1
E37
E37
E40
E38
I25
M12
I31
I31
I31
I31
I31
I31
K19
K19
K19
K19
M19
M19
M19
Q23
Q24
S24
S23
M7
O23
G38
G36
G35
G35
G33
E37
K4
G4
K4
K8
I8
I11
G10
A1
A1
M20
G17
K12
I39 / G1
Q13
S10
80
Item
2D
M25
I39
E29
E25
O16
G9
E36
E39
80-03-M218EN
6
ELECTRICAL COMPONENTS LOCATION
Position on harness layout
80
Item
X223
X224
X225
X226
X227
X228
X229
X230
X231
X232
X233
X234
X235A
X235B
X236
X238
X239A
X239B
X245
X246
X247
X250
X251
X252
X253
X254
X255
X256
X257
X258
X259
X260
X261
X270
X271
X273
X275
X277
X280
X281
X282
X283A
X283B
X284
X285
X286
X292
X297
X900
X901
X902
X903
X904
X905
X906
X907
X908
X909
X910
DESIGNATION
Telescope suspension electrovalve 1
Telescope suspension electrovalve 2
Telescope suspension valve pressure switch
Telescope position sensor
Telescope suspension cut-off relay
Telescope suspension power supply relay
NC reverse tilt movement detection pressure switch
NC reverse tilt movement detection pressure switch
NC boom lowering movement detection pressure switch
NC boom lowering movement detection pressure switch
NC forward tilt movement detection pressure switch
NC forward tilt movement detection pressure switch
Digicode/modclé
Digicode/modclé
FINTRONIC anti-start unit
Preheat rod
Digicode/modclé
Digicode/modclé
Boost air temperature sensor
Transmission oil temperature sensor
Hydraulic oil temperature sensor
Sensor B on attachment distributor
Sensor A on attachment distributor
Fan Drive control proportional EV
Fan Drive reversal electrovalve harness interface
Fan Drive reversal electrovalve
Air-conditioning compressor power supply interface
Sensor B on lifting distributor
Sensor A on lifting distributor
Sensor B on tilting distributor
Sensor A on tilting distributor
Sensor B on telescope distributor
Sensor A on telescope distributor
Grounds
Grounds
Distributor harness ground connection
Grounds
Engine harness/main harness interface
12 V socket option
Engine side fuel filter pressure sensor extension
Filter side fuel filter pressure sensor extension
Diesel pump harness interface
Diesel pump harness interface
Easy Manager option
Seat switch
Manual accelerator option
Easy manager option interfgace to anti-start
Seat switch
Fuel metering valve
Fuel rail pressure sensor
Engine fuel temperature sensor
Injector cylinder 1
Injector cylinder 2
Injector cylinder 3
Injector cylinder 4
Intake manifold pressure & temperature sensor
Throttle valve position sensor & actuator
Exhaust gas pressure sensor
Exhaust gas temperature sensor
80-03-M218EN
2D
AsseMain
mbly
Q22
O23
O23
Cab
3D
EnAddi-tional Assembly
gine
Engine
I41
G38
G37
K25
A1
C1
K21
I19
K18
Ground
connections
O9
O9
O21
O21
K14
M16
M23
O23
M16
O16
Q23
Q10
Q10
Q10
S9
S8
S8
K11
M19
K15
C11
K14
Q15
I3
O13
O16
Q16
O15
G11
G6
K10
K10
O13
O16
S6 / O30
K25
C16
I11
K25
i19
C16
G15
I11
Q30
M30
K30
K33
K35
K38
M30
(28/07/2016)
ELECTRICAL COMPONENTS LOCATION
7
Position on harness layout
Item
X911
X912
X913
X914
X915
X916
X917
X918
X919
X920
X921
X922
DESIGNATION
2D
AsseMain
mbly
Wastegate valve regulator (turbo)
Coolant temperature sensor
EGR valve position sensor & actuator
Oil pressure switch
Crankshaft speed sensor
Camshaft position sensor
Glow plug cylinder 1
Glow plug cylinder 2
Glow plug cylinder 3
Glow plug cylinder 4
Intake manifold pressure sensor
Intake manifold temperature sensor
Cab
3D
EnAddi-tional Assembly
gine
Engine
Ground
connections
O30
K41
I31
S41
Q41
M30
K34
K37
K39
SPLICES AND FERRITES
Assembly
Main
K24
K23
K23
G27
G27
M11
M10
K21
M9
G27
K21
M9
M8
E15
E15
E14
G14
I14
E36
E36
E26
E37
G15
G26
E37
E38
O10
O10
O10
I14
I15
A6
A8
E24
G24
G30 / I30
G23 / E16
G24
G30 / I30
E28
O29
K28
I30
G30
G30
I30
E25
M8
M8
M8
EP1
EP2
EP2
EP3
EP4
EP6
EP7
EP8
EP9
EP10
EP11
EP12
EP13
EP14
EP15
EP16
EP17
EP18
EP19
EP20
EP21
EP22
EP23
EP24
EP25
EP26
EP27
EP28
EP29
EP30
EP33
EP34
EP35
EP36
EP37
EP38
EP39
EP40
EP41
EP44
EP45
(28/07/2016)
G27
G27
I13
I22
I22
K16
I21
I20
I16
K18
I14
I15
K15
I17
K17
K15
I21
O24
O24
Position on harness diagram
Distributor
Cab +
Engine
+ PS gear box Headlights
C32
C32
3D
80
Item
M40
M40
80-03-M218EN
8
ELECTRICAL COMPONENTS LOCATION
Item
Main
O23
O23
3D
E31
K24
O23
K24
O23
M23
K27
M22
Q24
O21
M23
M22
O21
O24
M22
O23
O22
M21
M23
I15
I15
O16
M40
K28
K28
I17
I17
E17
O10
O10
O10
O10
80
EP46
EP48
EP49
EP52
EP53
EP54
EP55
EP56
EP57
EP59
EP60
EP61
EP62
EP63
EP64
EP65
EP66
EP67
EP68
EP69
EP70
EP71
EP72
EP73
EP74
EP75
EP94
Y44
Y45
Y46
Y47
Assembly
Position on harness diagram
Distributor
Cab +
Engine
+ PS gear box Headlights
M39
M39
80-03-M218EN
(28/07/2016)
2D LOCATION
1
2
3
ELECTRICAL COMPONENTS LOCATION
HARNESS ASSEMBLY
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
9
42
Key
Main harness
A
A
Cab harness
Engine Harness
Distributor harness
PS gear box harness
C
Ground connection
X297
X146
Connection between harnesses
X285
X12
X11
X141
X3
X72B
X71
X138B
E
X73A
X73B
X145A
X76A
M1
X145B
X48
X76B
X17
X144
X148C
X25
X18
X97
X20
X111
Ep.30
X147
X99
X28
K
X35
V3
Ep.34 Ep.37
X23
MT
X273
Ep.28
M11
X87
X29
Ep.15
X106
Ep.14
Ep.11
Ep.9
X152
X292
X286
X32
X78
X1
X91
X30
X117
X36
X31
X33
Ep.27
Ep.58
X49
X116
X50
X128
X51
X127
X52
X123
Ep.25
X27
Ep.36
X193
X104
X22
M3
X61
X53
X4
X58
X112
Ep.95 Ep.4
G
K17 K18
I
G
K2
X45
K5
X44
F3
X37
F4
F5
K1
K3
K4
H
K9
F6
F7
F8
F9
F10
F11
F12
F13
F14
F15
D
F16
F17
F18
A
F19
F20
F21
F22
F23 F24 F25 F26 F27 F28 F29
B
X192
X187
K6
K8
K7
F1
X38
K0
C
X188
F30
X190
X40
X122
Ep.2
Ep.26
M9
X102
X195
X8
X196
X124
I
BF1
X41
X39
Ep.94
X10
X189
X191
X42
X113
Ep.43
X101
K
X74
X84
X9
X85
X15
Ep.66
X24
X198
M6
X75
X103
X119
Ep.3
X197
Ep.8
X80
X46
X98
X194
X92
X81
Ep.24
Ep.10
V1
Ep.13
Ep.29
X79
X186
Ep.38
X26
X77
X83
Ep.26
Ep.23
Ep.35
X105
X34
X21
X151
X136
X100
X93
X153
X143
Ep.33
Ep.71
Ep.72
X56
X150
X284A
X115
X137
X149
Ep.6
V4
Ep.12
Ep.7
V5
Ep.19
V9
Ep.20
F31
F32
X110
X57
X134
X90
X55
X139B
I
X89
X54
X154B
X19
X68
X114
X154A
X139A
X95
X60
X82
X148B
X142
X47
X118
X59
X148A
G
Splice
X14
X70
X120
X199
M5
X169
M
X255
Ep.69
X201
Ep.59
X172
Ep.70
M
X158
X270
M7
X168
X159
Ep.67
X247
X164
X178
X246
X167
Ep.65
X165
O
X166A
Ep.73
X166B
X281
X283A
O
X174
Ep.46
Ep.48
Ep.44
Ep.45
X253
X207
X252
X170
X175
M10
X282
X16
X277
Q
Q
X59
X245
S
(28/07/2016)
X13
Forward gear
S
80-03-M218EN
80
E
X72A
X140
X2
X138A
C
ELECTRICAL COMPONENTS LOCATION
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
X2
X179
EP21
50
50
EP22
X3
X285
X285
X285
X2
X11 X3
X8
M
LT
100
300
EP4
EP2
50
100
50
9
*
0
#
150
2
4
1
3
X31
D X37
EP75 V11EP74
6
i Cab harnesses
1
X30
100
1
A
X41
5
K
C
X39
B
X40
7
13
7
13
7
6
1
6
1
6
1
X32
X91
X33
X117
X186
X51 X50
3
5
30
Opt. EV - TDF
X115
A
4
2
2
2
1
4
4
F12
F13
F14
C
15A
15A
15A
F23 F24 F25 F26 F27 F28 F29
7.5A
F22
5A
Opt.
E
1
8
X192
1
6
ARG
EP30
D
X187
F30
Gris / A
noir / B
X110
X111
1
2
3
4
X190
X191
X183
80-03-M218EN
O
1
Q
X188
X182
X17
X134
AV
X83
X25
X19
F15
20A
F11
F21
B
M
25A
F10
10A
F9
X57
86
30A
86
F8
7.5A
F20
F7
1
15A
F19
F6
7.5A
F18
K9
15A
85
F5
30
X180
F
85
87a
30
F4
X56
Adhésif rouge
H
8
E
30
K6
7.5A
F17
F3
K
X20
Q
S
I
X100
86
85
87a
5A
F16
X70
86
85
X71
1
1
1
10A
X121
2
F2
K8
7.5A
X89
F1
X181
4
!?
K7
10A
X68
i Distributor harnesses
I
5
87
87a
87
3
5
10A
X90
EP97 / 99
Y44-Y45
Y46-Y47
G
87
30
X60 X69
X81
EP96 / 98
3
5
87a
45
X72B
K5
10A
EP16
T
P
F
7
K3 K4
K2
50
X72A
LS
X181
K1
2
1
1
2
4
50
EP17
B1
21
3
5
3
5
4
50
3
5
87
STOP
B2
X18
X184B X184A
or
EP18
B3
X97
8
X73A
X73B
B4
EP71
X284A X286 X292
1
EP39
A1
EP25 (MT 1030)
EP28 (MT 1030)
4
K0
EP40
A2
3
7
1
80
X61
6
X45
X49
EP41
X191
X99
A3
2
5
X52
TUV
M
X106
A4
1
Adhésif
rouge
X54
X103
ARD
X87
EP33
K17 + K18 - F32 + F31
X14
G
EP72
13
X75
X55
X16
H
X42
AVG
X22
X21
X104
EP34
V3
EP37
EP58
X53
EP36
EP35
EP37
EP28
EP25
3
-
50
X82
+
-
X76A
O
X27
+ Opt.
(F32)
I
EP14 EP15
Adhésif rouge
40
X78
7
X47
1
l
X38
(F31)
X48
X76B
5
(K18)
4
EP6 V4 EP12
EP7 V5
EP19 V9 EP20
X77
AV
E
50
250
X93
X36
X95
X107
100
EP8 EP9 EP11
X105
X87 (MT 1030)
X26
40
(K17)
3
Adhésif
jaune
50
(MT 1030)
50
X118
5
21
8
2
4
1
EP49
EP29
X105
10
7
G
X44
X46
EP10
V1
EP13
50
6
EP24
X45
EP38
40
5
EP23
500
100
30
4
42
X15
65
100
EP26
EP27
3
41
X74
1
2
40
X84
130
450
100
11
1
39
X171
EP26
EP94
(MT 1030)
EP3
EP95
50
X79
G
38
X137
X80
AV/AR
X120
X24
X9
50
50
EP43
X4
RAZ
X124
UE
ONIQ
ECTR E.C.U.
IT
EL
IER
BOIT ROL UN
CONT
NOEUD
N ° 2 4 7 174
X88
37
X85
MLT PS
PS
X122
0% 100%
X43
E
X98
1
2 12
3 11
4 10
9
75%
36
A
5
6 8
7
X113
50%
35
C
X112
N° 247175
34
X10
X116
25%
33
X13
X1
X7
32
AVD
ECS
C
31
X12
X127
X123
30
i PS gear box harnesses
Opt.
X128
X114
29
i Engine harnesses
X297
X119
X58
28
50
A
27
75
2
50
1
MAIN HARNESS
100
10
X189
ECU PP LSU
(Pump Casappa)
X75
S
(28/07/2016)
ELECTRICAL COMPONENTS LOCATION
CAB AND FRONT WORKING LIGHTS 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
X140
40
41
11
42
P4
A
A
B1
2
X136
1
EP1
EP2
C
X141
C
P5
E
E
P6
X154A
X154B
1
3
2
1
P10
X143
P15
G
3
4
1
2
X144
B1
4
2
X136
G
X139A
P8
X149 S115
X139B
2 4 6 8
1 3 5 7
EP2
X150 S12
P2
I
P9
X26
2 4 6 8
X147
I
1 3 5 7
EP3
i Main harnesses
X151
S139
2 4 6 8
EP4
EP11
K
EP13
EP8
1 3 5 7
EP5
X152 S54
EP12
K
2 4 6 8
EP7
X27
EP6
1 3 5 7
X153
i Main harnesses
EP1
EP10
M
S16
2 4 6 8
1 3 5 7
M
EP14
Option TUV (1)
TUV1
X148A
P7
X148B
X148C
O
1
2
3
4
Option TUV (2)
EP9
TUV2
X142
O
P14
EP15
P13
Q
X146
Q
X145A
X145B
P12
P11
X138B
X138A
S
S
(28/07/2016)
80-03-M218EN
80
P1
ELECTRICAL COMPONENTS LOCATION
12
1
2
3
4
5
6
7
8
ENGINE HARNESS
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
X159
C
C
E
E
X158
X247
X281
X246
X282
G
G
X168
X201
X207
X245
X277
I
I
X59
X178
K
K
80
X283B X283A
X252
X253
Black
M
X163B
M
X167
X170
X163A
X102
Red
X164
X166A
O
X255
X166B
O
X175
X120
X172
X174
X165
X24
Q
Q
S
S
80-03-M218EN
(28/07/2016)
ELECTRICAL COMPONENTS LOCATION
ADDITIONAL HARNESSES
1
2
3
4
5
6
7
8
9
A
11
12
13
14
15
16
17
MLT - MLT PS (sauf MLT 732)
18
19
20
21
22
23
24
25
26
PS GEAR BOX
AT
PL TAC
US H
DI ME
RE N
CT T
IO
N
DISTRIBUTOR
10
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
13
42
AIR CONDITIONING
A
STOP
X35
X92
C
X28
X273
C
X23
X105
2
C
1
6 1
A
B
5 2
4 3
X206
X205
X208
1
2
E
X93
E
X209
X8
X34
X194
AT
MI TAC
NU H
S D ME
IRE NT
CT
IO
N
i Main harnesses
X29
G
G
X199
X87
1 2
X204
i Main harnesses
STOP
MT + MLT 732
I
I
X198
X273
X197
X23
X105
X92
X195
X98
X93
K
X196
X193
K
X29
1
2
O
EV COUPURE
HYDRAULIQUE / VS
X87
X250
CAPTEUR B /DISTRIB ACCESSOIRE
X251
1
2
3
4
9
7
6
X256
EP37
8
5
10
X87
11
Q
150
12
CONNECTEUR INTERFACE
FAISCEAU PRINCIPAL
A
X92
2
X124
C
1
X34
M
X31
B
X23
1
2
2 1
1
3 1
0
4 1
9
O
EV PROPORTIONNEL
SUR DESCENTE FLECHE / VRP
X35
5
6 8
7
MT 1030 EASY
AT
AT
PL TAC
MIN TACH
US H
US ME
DI ME
DIR NT
RE NT
CT
EC
IO
TIO
N
N
M
X257
i Main harnesses
CAPTEUR A /DISTRIB ACCESSOIRE
CAPTEUR B /DISTRIB LEVAGE
CAPTEUR A /DISTRIB LEVAGE
i Main harnesses
X258
Q
X255
CAPTEUR B /DISTRIB INCLINAISON
X172
X259
MASSE FAISCEAU
DISTRIBUTEUR
X105
1
S
X260
X261
(28/07/2016)
CAPTEUR A /DISTRIB INCLINAISON
2
S
CAPTEUR B /DISTRIB TELESCOPE
CAPTEUR A /DISTRIB TELESCOPE
80-03-M218EN
80
X28
ELECTRICAL COMPONENTS LOCATION
14
3
4
5
6
7
8
9
10
11
12
13
14
15
16
rsion MLT -MLT
a ve
PS
pp
(sa
s
u
Ca
X110
X111
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
HARNESS ASSEMBLY
36
X46
37
38
X47
X48
X95
39
40
41
42
A
X140
)
732
LT
fM
A
2
ECU
Pu
m
p
1
3D LOCATION
X141
X44
3
5
I
X142
X76A
X76B
X147
G
X54
X55
X143
X292
X286
X32
X117
X114
X80
X90
X75
X83
X81
X50
4
2
4
1
2
2
1
30
20A
15A
15A
15A
7.5A
F23 F24 F25 F26 F27 F28 F29
B
1
6
X185
F15
C
D
X37
F30
E
25A
F12
F14
30A
5A
15A
F11
10A
F10
7.5A
F22
86
85
30
85
2
4
1
86
15A
F21
F9
1
86
F13
X183
X180
1
X192
X40
X187
X39
X14
X15
X189
X190
X188
G
X52
X61
X158
X26
X84
X13
X246
X102
X104
X175
X174
X120
X255
I
X170
X247
X168
X24
X172
X17
F20
F
E
X191
X1
X49
X12
X21
F8
X181
8
X45
X41
X85
X87
X3
F7
5
1
X112
X113
X105
X2
F19
A
X119
X58
X99
X11
F18
F6
X184
X89
X103
X51
X78
X36
F17
F5
H
X4
X27
X31
X297
X285
X59
X60
X68
X82
X33
X91
X30
X79
X116
X284A
X53
30
K9
7.5A
F16
X77
2
1
4
1
X70
X71
F4
8
85
87a
10A
X118
X72A
X72B
X139A
F3
K8
5A
X73A
X73B
X152
F2
10A
F1
X139B
X154B
K6
7.5A
X149
K7
4
1
2
1
87
3
5
X74
X136
X153
10A
X150
X148B
K5
G
K4
87a
C
X38
7
87
87a
86
85
X144
X151
X148A
X148C
E
K
3
5
87
X145B
I
3
5
87
X145A
X154A
K1
87a
X146
K0
K3
K2
X42
5A
X56
4
X138B
30
X57
3
5
X138A
X22
K
X245
X201
X167
X93
X164
X166
80
21
3
5
1
X115
7.5A
C
X165
X252
M
X59
M
X253
X106
X277
X283
X282
X163
X178
X16
O
O
X281
X207
X25
Q
X97
Q
X20
X19
X18
X134
X100
S
80-03-M218EN
S
(28/07/2016)
ELECTRICAL COMPONENTS LOCATION
ENGINE HARNESS
1
2
A
X200A
X159
X200B
C
X246
X247
X102
X101
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
B-
B+
X137
X171
27
28
29
30
31
32
33
34
35
36
37
38
39
42
A
X158
X176
X255
C
X59
X172
X200E
X24
E
M7
M3
M9
X120
G
41
X167
X168
E
40
15
M5
X201
X167
G
X170
i Main harnesses
X175
X164
X914
X169
X174
I
X201
I
X166A
M5
X245
X165
K
X59
X903 X167 X904 X918 X905 X919 X906 X920 X913
K
X200D
M
X901
M
X166B
X907
X283B
X912
O
X252
X283A
O
X277
X253
X900
Q
X163B
X163A
X200C
X160
S
X178
(28/07/2016)
X277
X281
X207
X282
X160
X916
X923
X915
Q
S
X281
80-03-M218EN
80
X917
ELECTRICAL COMPONENTS LOCATION
16
1
2
3
4
5
6
7
8
GROUNDS
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
90°
A
M1
X76A
X76B
C
E
40
41
42
A
C
M9
X101
X102
E
o Main harness
M2
X135
G
G
M4
X108
I
M11
X273
X105
I
p
o
d lo
un
Gro
M10
X170
K
o Engine harness
80
o Main harness
M5
X201
M
M
o Engine harness
O
M3
X169
Q
K
O
M7
X176
Q
o Main harness
S
M6
X106
S
80-03-M218EN
(28/07/2016)
ELECTRICAL CONTROL AND ADJUSTMENT
pages
MENU ARCHITECTURE - DASHBOARD DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
"BOOM ANGLE" ANGULAR SENSOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– ON-TRUCK ADJUSTMENT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TESTING THE LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE . . . . . . . . . . . 6
STRAIN GAUGE AND ANGLE SENSOR CALIBRATION (DEALER PROCEDURE) . . . . . . . . . . 7
STRAIN GAUGE RECALIBRATION (CLIENT PROCEDURE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
“AGGRAVATING” HYDRAULIC MOVEMENTS CUT-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
80
LED ILLUMINATION ACCORDING TO CHANGES IN GAUGE SIGNAL . . . . . . . . . . . . . . . . . . . 9
(23/04/2018)
80-04-M218EN
2
ELECTRICAL CONTROL AND ADJUSTMENT
MENU ARCHITECTURE - DASHBOARD DISPLAY
Initialization screen
Main screen
Press scroll button A to move between screens.
Initialization screen
A
Main screen
Long press on A
Setting the time
Long press on A
Reset to zero
Short press on A
Daily hour meter screen
Short press on A
ECU fault screen
Fault code display
Long press on A
e 80 - ELECTRICAL
TROUBLESHOOTING
Short press on A
Engine fault screen
Fault
code display
Occurrence
Long press on A
80
Short press on A
Instantaneous consumption screen
Occurrence
Short press on A
80-04-M218EN
(23/04/2018)
ELECTRICAL CONTROL AND ADJUSTMENT
3
"BOOM ANGLE" ANGULAR SENSOR ADJUSTMENT
OPERATION
The «boom angle» sensor transmits information to the computer about the actual position of the boom
in relation to the frame . The potentiometer and all the links fitted between the boom and the frame have
the same operating angle as the boom in relation to the frame actually in operation . The boom angle
potentiometer is fitted with two tracks (two sensors whose range of adjustment is between 0,5 volts
and 4,5 volts reversed one in relation to the other) . If the potentiometer is faulty, incorrectly connected
or badly adjusted, this leads to a fault on the overload indicator and hydraulic movement malfunction .
If there is a fault on the potentiometer, calibration is not possible .
The operating range must be centred in the acceptance range of the potentiometer (0,5 volts to 4,5 volts) .
To consult the electrical characteristics of the angular sensor:
e Group 80 - Electrical characteristics and specifications – data sheets for electrical components.
ON-TRUCK ADJUSTMENT PROCEDURE
Key:
A
C
Maxi
(23/04/2018)
b
80
A - Brake nut and bolt
B - Potentiometer pin
C - Link
B
The adjustment must be made without altering the length
of the link (Item C).
1 - Switch on the PAD and connect the VCI .
2 - Select «Diagnostic» and then confirm .
3 - Select your machine, and then confirm .
4 - Select the type of machine range and then confirm .
5 - Select the type of machine and then confirm .
6 - Switch on the ignition, start the machine and then confirm .
7 - If the truck is fitted with stabilisers, they must be placed on
the ground in order to increase the lifting angle .
8 - Place the boom in the top position .
80-04-M218EN
4
ELECTRICAL CONTROL AND ADJUSTMENT
9 - Select «Diagnostic global (tous les calculateurs)» and then confirm .
10 - Select «Calulateur central SPU» and then confirm .
11 - Select «Lecture paramètre» and then confirm . If there are any faults, refer to them and delete them .
12 - Select «Hydraulique» service and then confirm .
13 - Select «État des capteurs» and then confirm .
14 - Select «Capteur angle de flèche» and then confirm .
The PAD displays the voltages of each boom angle
potentiometer sensor .
15 - Loosen the brake nut and bolt (Item A) on the lever .
16 - Using a screwdriver, turn the potentiometer pin (Item B) to obtain the adjustment values defined
below .
Note: The adjustment is done by slightly turning the pin in the lever housing .
Adjustment values to be obtained:
80
Voltage
Mini
Maxi
0 .7 V
4 .3 V
17 - Then tighten the brake nut and bolt (Item A) .
18 - Place the boom in the down position (stabilizers retracted) .
Mini
19 - Check that the values are similar to those found in the top boom position and are within the
recommended adjustment range .
20 - Calibrate the boom angle sensor .
e Group 80 - Electrical control and adjustment - Strain gauge and angle sensor calibration.
80-04-M218EN
(23/04/2018)
ELECTRICAL CONTROL AND ADJUSTMENT
5
LONGITUDINAL STABILITY INDICATOR (LLMI)
ERROR CODES
The error codes are indicated by LEDs A3 to A7 on the warning device and
longitudinal stability limiter .
A7
A6
A5
A4
A3
ERROR CODES
A7
A6
LEDS
A5
A4
DESCRIPTIONS
A3
Regulating fault (fault detected during the test) .
Lowering regulating valve fault .
Safety valve cut-off fault (fault detected during the test) .
Safety valve fault .
Gauge calibration fault (fault detected during the test) .
Resetting the longitudinal stability limiter and warning device may resolve the problem .
(o : 3 - MAINTENANCE: G - OCCASIONAL MAINTENANCE)
Angle calibration fault (fault detected during the test) .
Inclination cut-off valve fault .
Strain gauge fault .
Jib angle sensor fault .
Telescope or attachment control fault .
Telescope retracted senor fault .
Computer earth output fault .
Aggravating hydraulic movement cut-off disable fault .
80
Fan drive valve fault .
Stability indicator fault .
Electronic handling controller fault .
Hydraulic control lever control setting fault .
Transmission cut-off output fault .
Electronic handling controller supply fault .
Telescope retracted sensor fault (fault detected during the test) .
Tilt cut-off valve fault (according to model)
Boom head solenoid valve fault . (OPTION)
Button fault, accessory hydraulic easy attachment (OPTION)
Electrovalve attachment hydraulic control and electrical jib provision fault button . (OPTION)
Forced operation indicator fault (OPTION)
Electric handling controller 10 V output fault .
Forced operation button fault (OPTION)
(23/04/2018)
80-04-M218EN
6
ELECTRICAL CONTROL AND ADJUSTMENT
TESTING THE LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE
– These tests are essential for checking the correct operation and adjustment of the different components of the device .
– Place the lift truck on fl at, level ground with the wheels straight .
b
Use the test button
only when instructed, following the guidance for a short press (less than 1 second)
or a long press (5 seconds).
In case of doubt during the test procedure, a clean exit can be made by a short press on the “BUCKET” MODE
or “SUSPENDED LOAD” buttons
.
Long press on the test button
STAGE 1
Short
press
the test
button .
1
- An audible beep .
- First green LED flashing .
- Test button lit .
- Place the lift truck without any
attachment, with the jib fully
retracted and raised .
- On stabilizers if fitted .
2
STAGE 2
1
- First green LED continuously lit .
- Second green LED flashing .
- Test button lit .
-- Lower the jib with the engine
running at full revs and the
hydraulic control at the maximum
setting . Calibrated speed until
movement is cut-off .
3
STAGE 3
2
80
1
- The first and second green LED’S
continuously lit .
- The third green LED flashing .
- Test button lit .
- Lower the jib until the movement is
cut-off .
- Try in the following order a reverse
tilt, a forward tilt (dumping) and a
telescope extension . None of these 3
movements should be possible .
- The fault indicator
- Press the button
STAGE 4
- The fault warning light remains
permanently on until the error is
repaired .
TEST OK
- One audible beep and progresses to
stage 2 .
TEST NOT OK
- Two audible beeps and lighting of
.
the fault warning light
- Exit test mode .
- Go to stage 4 .
Short
press
the test
button .
TEST OK
- One audible beep and progresses to
stage 3 .
TEST NOT OK
- Two audible beeps and lighting of
.
the fault warning light
- Exit test mode .
- Go to stage 4 .
Short
press
the test
button .
TEST OK
- Conformity of aggravating
movement cut-off .
- Exit test mode . All the LEDs will light
for 2 seconds and an audible beep
will be sounded .
TEST NOT OK
- Fault warning light comes on
- Exit test mode .
- Go to stage 4 .
.
and a beep indicate a fault .
briefly to view the error code .
- If there are several error codes, press the button
briefly several times to loop through
the error codes .
NOTE: A defective fuse can generate several error codes . If this is the case, check the fuses (see: 2 DESCRIPTION: 11 - FUSES AND RELAYS IN THE CAB)
Should there be the error code shown
A7
opposite, adjusting the longitudinal
stability limiter and warning device
A6
may solve the problem (see: 3 A4
MAINTENANCE: G - OCCASIONAL
MAINTENANCE) .
A3
- Consult your dealer, specifying the error codes(s) .
NOTE: For the stage 3 test, specify the non-conforming aggravating hydraulic movements, if
necessary .
80-04-M218EN
(23/04/2018)
ELECTRICAL CONTROL AND ADJUSTMENT
7
STRAIN GAUGE AND ANGLE SENSOR CALIBRATION (DEALER PROCEDURE)
Stability limit
light
Overload
indicator
Error light
BUCKET mode
switch
SUSPENDED
LOAD mode
indicator
Test button
Machine position: flat ground, wheels pointing forward, parking brake on, safe area .
RECORDING MINIMUM ANGLE:
- Press the “PARACHUTE” switch (activated for the next 10 seconds) .
STAGE - Before the end of the 10 seconds press at the same time the “SUSPENDED LOAD” and “TEST” buttons .
1
- Completely retract and lower the boom .
+
- Press the «TEST» button (short press) to record stage 1 .
RECORDING THE MAXIMUM ANGLE + MAXIMUM GAUGE STRAIN:
STAGE
- Completely raise and retract the boom, without accessories . (If applicable use the ground stabilizers)
2
- Press the «TEST» button (short press) to record stage 2 .
MEASURING THE TIME OF DESCENT FROM MAXIMUM TO MINIMUM ANGLE:
80
STAGE
- Lower the boom to its stop with the engine running at maximum revolutions (boom retracted) .
3
- Press the «TEST» button (short press) to record stage 3 .
STAGE
4
- Ensure that the boom is below 4° (boom retracted) .
- Press the «TEST» button (short press) to record stage 4 .
RECORDING MINIMUM GAUGE STRAIN:
t
- Activate the «PARACHUTE» switch to enable hydraulic movements .
STAGE
5
The boom must be below 4°.
- Extend the boom until the rear wheels leave the ground .
Wait several seconds for the machine to stabilize .
- Press the «TEST» button (short press) to record stage 5 .
t
After this calibration, check that movement cut-offs work correctly.
(23/04/2018)
80-04-M218EN
8
ELECTRICAL CONTROL AND ADJUSTMENT
STRAIN GAUGE RECALIBRATION (CLIENT PROCEDURE)
According to the use the telehandler is put to, the strain gauge may require to be periodically reset .
This operation can be carried out by the operator . The procedure is described below . Only the gauge is calibrated .
Main conditions:
– Have a load at equal to at least half the machine’s maximum capacity .
– The rear axle temperature must be below 50°C . If this temperature is exceeded the operator must not carry out the procedure .
– The procedure must be carried out on flat ground with all wheels facing the front .
Simultaneously press and hold down
STAGE 1
START
the «BUCKET» MODE
- Without attachments .
- Jib fully retracted and raised .
- On stabilizers if fitted .
STAGE 2
1
- An audible beep .
- First green LED flashing .
- Flashing test button .
and TEST
. buttons
- Two audible beeps will be sounded and all the LEDs will flash twice to confirm the start of the procedure .
- Without attachments .
- Stabilizers raised, if fitted .
- Carriage tilted fully backward .
- Jib fully retracted and in the down position a few centimeters off the ground .
/
80
- With the fork carrier or the bucket and a load (keep jib retracted to allow all other
hydraulic movements) .
- Jib fully retracted and in the down position a few centimeters off the ground .
2
STAGE 3
1
- First green led continuously
lit .
- Second green led flashing .
- Flashing test button .
STAGE 4
FINISH
b
/
Keep the load as close to the ground as possible throughout this operation.
- Hold down the disable the
«aggravating» hydraulic movement cut-off
button (indicator lamp lit), and extend the jib until the rear wheels are off the
ground .
NOTE: This stage consists of unloading the rear axle . It can be done using a jack
but without bearing on the rear axle . .
Short press
the test
button .
Short press
the test
button .
- Two audible
beeps will
be sounded
and all the
LEDs will
flash twice to
confirm the
end of the
procedure .
/
- After completing the resetting procedure, the telehandler is in an overloaded condition . Retract the
boom to restore the situation .
- All LEDs lit .
- A continuous audible beep
b
When the reset is completed, check the operation of the longitudinal stability limiter and warning device (see:
TESTING THE LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE (LLMC).
80-04-M218EN
(23/04/2018)
ELECTRICAL CONTROL AND ADJUSTMENT
9
“AGGRAVATING” HYDRAULIC MOVEMENTS CUT-OFF
Lift truck behaviour
Movement not restricted .
Gauge signal and speed of boom angle sensor monitored .
Rapid movements that may cause the lift truck to overturn are stopped pre-emptively .
Stopping a rapid movement suddenly could cause the lift truck to overturn .
Slow movements may lead to the lift truck's stability limit being reached .
Cut-off of all aggravating movements: boom extension and lowering .
Work zone
A - stability
B - Dynamic movement cut-off
C - stability limit
If the lift truck is not behaving normally:
=> Check the movement cut-off by referring to the load charts and inspecting the sensors .
A
B C
80
LED ILLUMINATION ACCORDING TO CHANGES IN GAUGE SIGNAL
Increasing value
of the gauge signal:
100% (L8)
92% (L7)
84% (L6)
76% (L5)
68% (L4)
60% (L3)
52% (L2)
0% (L1)
(23/04/2018)
80-04-M218EN
ELECTRICAL CONTROL AND ADJUSTMENT
80
10
80-04-M218EN
(23/04/2018)
ELECTRICAL COMPONENTS REMOVAL
pages
HYDRAULIC PUMP ECU REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPU REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GEAR BOX ECU REMOVAL (POWERSHIFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
80
ENGINE ECU REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
(06/11/2013)
80-06-M218EN
2
ELECTRICAL COMPONENTS REMOVAL
HYDRAULIC PUMP ECU REMOVAL
bb
Operate the battery cut-off no less than 30 seconds after turning off the ignition with the
ignition key.
Move the seat forward, open the rear glove box.
Remove the side cover, 1 screw (Item 1), lift up the cover from
the front and remove.
1
Remove the pump ECU, 2 screws and washers (Item 1).
1
80
1
SPU REMOVAL
bb
Operate the battery cut-off no less than 30 seconds after turning off the ignition with the
ignition key.
⇒⇒ The "HYDRAULIC PUMP ECU REMOVAL" operation must
be completed
1
2
1
80-06-M218EN
Remove the SPU, unscrew the 2 screws (Item 1), loosen screw
(Item 2).
Disconnect connectors X56 and X57.
(06/11/2013)
ELECTRICAL COMPONENTS REMOVAL
3
GEAR BOX ECU REMOVAL (POWERSHIFT)
bb
Operate the battery cut-off no less than 30 seconds after turning off the ignition with the
ignition key.
Remove the plate, 4 screws (Item 1).
1
Unscrew the 2 screws (Item 1) and disconnect the connector
(Item 2).
1
2
80
1
ENGINE ECU REMOVAL
bb
Operate the battery cut-off no less than 30 seconds after turning off the ignition with the
ignition key.
2
1
(06/11/2013)
Disconnect the 2 connectors, loosen the lock nuts then unscrew
the screws (Item 1).
When refitting: fully screw the AHC screws (Item 2) into
the silent block then screw the assembly onto the engine
housing by hand, screw the lock nut onto the screw
(Item 1) as far as it will go, position the ECU on the silent
blocks and screw the assembly as tightly as possible,
tighten the lock nuts.
Do not forget to connect the ground connector.
For replacement of software
e 80 - ELECTRICAL CONTROL AND ADJUSTMENT
bb
80-06-M218EN
ELECTRICAL COMPONENTS REMOVAL
80
4
80-06-M218EN
(06/11/2013)
ELECTRICAL COMPONENTS REFIT
pages
STRAIN GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– AXLE PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– CHARACTERISTICS OF PRODUCTS USED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– CHARACTERISTICS OF FASTENING SCREWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
–– ASSEMBLY PRECAUTIONS AND TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
954782) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
–– STRAIN GAUGE (
954783) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
80
–– STRAIN GAUGE (
(06/11/2013)
80-07-M218EN
2
ELECTRICAL COMPONENTS REFIT
STRAIN GAUGE
LOCATION
80
A
KEY:
A - Strain gage
b
PREPARATION AND SAFETY INSTRUCTIONS
⇒ The wheels must be aligned and the rear axle free from any load (tipped truck).
⇒ The contact surface must be perfectly clean.
⇒ Do not apply any Loctite to the screws.
⇒ Replace the gauge if faulty.
⇒ Store the gauge and axle at the same temperature.
⇒ Wear a mask and gloves when applying adhesive.
80-07-M218EN
(06/11/2013)
ELECTRICAL COMPONENTS REFIT
3
AXLE PREPARATION
1
The area in contact with the strain gauge (Item 1) has protective
painted film coating. Scrape this coating with a filling knife,
aiming to remove as much film as possible. Any remaining
adhesive traces can be removed with Soft Surface Cleaner
(aerosol degreaser).
Sand the area to be glued (Item 2) to roughen the surface and
achieve a good bond.
80
2
CHARACTERISTICS OF PRODUCTS USED
References
ACROBOND PU 284/30 (two-part polyurethane structural adhesive) ....................................273504
Mixer ...............................................................................................................................................................781596
Hand gun.......................................................................................................................................................781597
b
Handling time before start of polymerization and hardening phase is approx. 5 min.
If the product stays inside the mixer for more than 5 minutes, replace the mixer.
(06/11/2013)
80-07-M218EN
4
ELECTRICAL COMPONENTS REFIT
CHARACTERISTICS OF FASTENING SCREWS
The screws used are supplied with the strain gage.
e Refer to the spare parts catalog.
ASSEMBLY PRECAUTIONS AND TIGHTENING TORQUE
1
The two components (strain gauge and axle) must be
stored at the same temperature for at least four hours
before commencing assembly.
The strain gauge must be assembled with an axle that is
free from any load.
For this:
1 - Lift the rear axle off the ground with a suitable hydraulic
jack (Item 1).
1
2
2 - Secure the machine by placing a two suitable stands
(Item 2), one on either side of the frame.
2
80
2
3
80-07-M218EN
3 - Remove the jack to fully unload the rear axle.
(06/11/2013)
ELECTRICAL COMPONENTS REFIT
STRAIN GAUGE (
5
954782)
STEP 1:
Using a gun, apply the two-part mixture to the axle by placing
4 daubs of adhesive as shown opposite (Item 1).
b
1
Wear a mask and gloves when using this product.
STEP 2:
Place two M10x40 screws on the strain gauge and then place
the assembly on the axle.
Take care not to place adhesive on the central part
of the gage.
b
Area free of glue
80
STEP 3:
The two M10 screws should be tightened progressively, as follows:
– Tighten screw No. 1 to a torque of 34 N.m
– Tighten screw No. 2 to a torque of 34 N.m
– Tighten screw No. 1 to the rated torque C = 67 N.m ± 5%
– Tighten screw No. 2 to the rated torque C = 67 N.m ± 5%
STEP 4:
Next, install the plastic casing (Item 1) and secure it with
the two M4x10 pan-head screws.
1
(06/11/2013)
b
Do not apply grease to the tops of the M10x40
screws, as it is incompatible with the adhesive.
80-07-M218EN
6
ELECTRICAL COMPONENTS REFIT
STRAIN GAUGE (
954783)
STEP 1:
– Note the month/year of the gauge and enter into the lift
truck date sheet.
STEP 2:
– Apply glue to the grooves of the strain gauge (a total of
8 daubs of glue).
80
STEP 3:
– Position the strain gauge and attach with the screws. The
two M10 screws should be tightened gradually, as follows:
⇒ Tighten screw No. 1 to a torque of 34 N.m
⇒ Tighten screw No. 2 to a torque of 34 N.m
⇒ Tighten screw No. 1 to the rated torque C = 67 N.m ± 5%
⇒ Tighten screw No. 2 to the rated torque C = 67 N.m ± 5%
80-07-M218EN
(06/11/2013)
ELECTRICAL COMPONENTS REFIT
7
Strain gauge impact loading procedure:
H = 275mm
Ground = 860g
1 - Let fall hammer (o schema) 5 times on the screw n°1,
axle center side.
2 - Let fall hammer (o schema) 5 times on the screw n°2,
axle wheel side.
3 - Let fall hammer again (o schema) 2 times on the screw
n°1, axle center side.
Rear axle
STEP 4:
2
– Place a red mark on the heads of the screws, the gauge
and the axle.
– Fit the protective casing.
– Attach the protective casing with the two screws and
the washers.
– After having checked the red marks, apply a green mark
to the heads of the screws.
(06/11/2013)
80-07-M218EN
80
1
ELECTRICAL COMPONENTS REFIT
80
8
80-07-M218EN
(06/11/2013)
ELECTRICAL TROUBLESHOOTING
pages
NAVIGATION MENU DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPU 25-15 - A3 ERROR CODES LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ENGINE ECU ERROR CODES LIST (DTC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HYDRAULIC PUMP ERROR CODES LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
LONGITUDINAL STABILITY INDICATOR (LLMI) ERROR CODE LIST . . . . . . . . . . . . . . . . . . . . 32
80
GEAR BOX ERROR CODE LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
(31/08/2016)
80-08-M218EN
2
ELECTRICAL TROUBLESHOOTING
NAVIGATION MENU DISPLAY
Press on the scroll button (A) under the display to move between screens.
SPU fault screen and falut number
Fault code display
Long press on A
Short press on A
Fault code display
Engine fault screen and falut number
Long press on A
SPU 25-15 - A3 ERROR CODES LIST
A3
SPU 25-15
PAD code
80
Hexadecimal
010203
010204
010303
010304
010603
010604
010605
010703
010704
010705
011203
011204
011205
011303
011304
011305
012103
012104
012105
012303
012304
012305
012503
012504
012505
013103
013104
013105
Code on
machine
screen
Decimal
SPN
FMI
520450
03
520450
04
520451
03
520451
04
520454
03
520454
04
520454
05
520455
03
520455
04
520455
05
520466
03
520466
04
520466
05
520467
03
520467
04
520467
05
520481
03
520481
04
520481
05
520483
03
520483
04
520483
05
520485
03
520485
04
520485
05
520497
03
520497
04
520497
05
80-08-M218EN
COMPONENT
Sensors power supply output
Sensors power supply output
Forced operation button indicator lamp
Forced operation button indicator lamp
Telescope head electrovalve output
Telescope head electrovalve output
Telescope head electrovalve output
Levelling authorization output
Levelling authorization output
Levelling authorization output
Lifting cut-off electrovalve output
Lifting cut-off electrovalve output
Lifting cut-off electrovalve output
Transmission authorization output
Transmission authorization output
Transmission authorization output
Safety electrovalve output 2
Safety electrovalve output 2
Safety electrovalve output 2
Cut-off electrovalve output
Cut-off electrovalve output
Cut-off electrovalve output
Telescope extension electrovalve output
Telescope extension electrovalve output
Telescope extension electrovalve output
Tilting neutralization electrovalve output
Tilting neutralization electrovalve output
Tilting neutralization electrovalve output
CHARACTERISATION DESCRIPTION
Signal voltage too high: + battery short circuit
Signal voltage too low: ground short circuit
Signal voltage too high: + battery short circuit
Signal voltage too low: ground short circuit
Signal voltage too high: + battery short circuit
Signal voltage too low: ground short circuit
Circuit impedance too high: open circuit
Signal voltage too high: + battery short circuit
Signal voltage too low: ground short circuit
Circuit impedance too high: open circuit
Signal voltage too high: + battery short circuit
Signal voltage too low: ground short circuit
Circuit impedance too high: open circuit
Signal voltage too high: + battery short circuit
Signal voltage too low: ground short circuit
Circuit impedance too high: open circuit
Signal voltage too high: + battery short circuit
Signal voltage too low: ground short circuit
Circuit impedance too high: open circuit
Signal voltage too high: + battery short circuit
Signal voltage too low: ground short circuit
Circuit impedance too high: open circuit
Signal voltage too high: + battery short circuit
Signal voltage too low: ground short circuit
Circuit impedance too high: open circuit
Signal voltage too high: + battery short circuit
Signal voltage too low: ground short circuit
Circuit impedance too high: open circuit
(31/08/2016)
ELECTRICAL TROUBLESHOOTING
3
SPU 25-15
Hexadecimal
01330D
520499
13
013403
013404
013405
013507
013603
013604
013605
013707
014503
014504
014505
014603
014604
014605
014703
014704
014705
014803
014804
014805
014903
014904
014905
020102
020402
020502
021007
021402
021602
02160C
021702
022202
022402
022602
022609
022610
022612
022700
022701
022702
022709
02270A
022713
520500
520500
520500
520501
520502
520502
520502
520503
520517
520517
520517
520518
520518
520518
520519
520519
520519
520520
520520
520520
520521
520521
520521
520705
520708
520709
520720
520724
520726
520726
520727
520738
520740
520742
520742
520742
520742
520743
520743
520743
520743
520743
520743
03
04
05
07
03
04
05
07
03
04
05
03
04
05
03
04
05
03
04
05
03
04
05
02
02
02
07
02
02
12
02
02
02
02
09
16
18
00
01
02
09
10
19
02320D
520754
13
024102
024110
024113
024202
024210
024213
024302
024402
024A05
031101
041609
520769
520769
520769
520770
520770
520770
520771
520772
520778
520977
521238
02
16
19
02
16
19
02
02
05
01
09
(31/08/2016)
COMPONENT
CHARACTERISATION DESCRIPTION
Out of range signal value defined by the calibration: Calibration
not carried out or carried out incorrectly
Safety electrovalve output
Signal voltage too high: + battery short circuit
Safety electrovalve output
Signal voltage too low: ground short circuit
Safety electrovalve output
Circuit impedance too high: open circuit
Safety electrovalve operation error
Faulty actuator (mechanical problem)
Control electrovalve output
Signal voltage too high: + battery short circuit
Control electrovalve output
Signal voltage too low: ground short circuit
Control electrovalve output
Circuit impedance too high: open circuit
Control electrovalve operation error
Faulty actuator (mechanical problem)
Telescope retraction electrovalve output
Signal voltage too high: + battery short circuit
Telescope retraction electrovalve output
Signal voltage too low: ground short circuit
Telescope retraction electrovalve output
Circuit impedance too high: open circuit
Attachment line A control electrovalve output
Signal voltage too high: + battery short circuit
Attachment line A control electrovalve output
Signal voltage too low: ground short circuit
Attachment line A control electrovalve output
Circuit impedance too high: open circuit
Attachment line B control electrovalve output
Signal voltage too high: + battery short circuit
Attachment line B control electrovalve output
Signal voltage too low: ground short circuit
Attachment line B control electrovalve output
Circuit impedance too high: open circuit
Fan rotation direction reversal electrovalve output Signal voltage too high: + battery short circuit
Fan rotation direction reversal electrovalve output Signal voltage too low: ground short circuit
Fan rotation direction reversal electrovalve output Circuit impedance too high: open circuit
Fan speed control electrovalve output
Signal voltage too high: + battery short circuit
Fan speed control electrovalve output
Signal voltage too low: ground short circuit
Fan speed control electrovalve output
Circuit impedance too high: open circuit
Forced operation button
Erratic signal value
Telescope head electrovalve activation button
Erratic signal value
Attachment line decompression button
Erratic signal value
Retracted telescope not detected
Faulty actuator (mechanical problem)
JSM FNR selector
Erratic signal value
Longitudinal stability display
Erratic signal value
Longitudinal stability display
Faulty sensor or actuator
Aggravating movements contact 1
Erratic signal value
Override button
Erratic signal value
Retracted telescope sensor
Erratic signal value
Boom lifting angle sensor
Erratic signal value
Boom lifting angle sensor
Information not available on the CAN bus
Boom lifting angle sensor
Upper sensor signal value at normal value
Boom lifting angle sensor
Lower sensor signal value at normal value
Strain gauges
Upper sensor signal value at normal value
Strain gauges
Lower sensor signal value at normal value
Strain gauges
Erratic signal value
Strain gauges
Information not available on the CAN bus
Strain gauges
Abnormal signal value variation for correct operation
Strain gauges
Transmitted signal value on CAN bus invalid
Out of range signal value defined by the calibration: Calibration
Boom angle sensor calibration error
not carried out or carried out incorrectly
Telescope roller sensor
Erratic signal value
Telescope roller sensor
Upper sensor signal value at normal value
Telescope roller sensor
Lower sensor signal value at normal value
Attachment roller sensor
Erratic signal value
Attachment roller sensor
Upper sensor signal value at normal value
Attachment roller sensor
Lower sensor signal value at normal value
Tilting movement slide contact
Erratic signal value
Attachment movement slide contact
Erratic signal value
Air intake temperature sensor
Circuit impedance too high: open circuit
ECU power supply voltage
Lower sensor signal value at normal value
Longitudinal stability display
Information not available on the CAN bus
Strain gauge calibration error
80-08-M218EN
80
PAD code
Code on
machine
screen
Decimal
SPN
FMI
4
ELECTRICAL TROUBLESHOOTING
SPU 25-15
PAD code
Hexadecimal
044009
044B09
044D09
051500
05150C
022810
022812
Code on
machine
screen
Decimal
SPN
FMI
521280
09
521291
09
521293
09
521493
00
521493
12
520744
16
520744
18
COMPONENT
CAN bus fault
VDO dashboard fault
Casappa computer fault
Computer
Computer
Throttle manual senseur fault
Throttle manual senseur fault
CHARACTERISATION DESCRIPTION
Information not available on the CAN bus
Information not available on the CAN bus
Information not available on the CAN bus
Upper sensor signal value at normal value
Faulty sensor or actuator
Upper sensor signal value at normal value
Lower sensor signal value at normal value
ENGINE ECU ERROR CODES LIST (DTC)
80
KWP
SPN
code
38 523925
FMI
3
Engine ECU
fault
PROBLEMS
ACTION
code
731 Short circuit on battery
Check the wiring harness and the charge value
Short circuit on battery: error on the SCR
Check the wiring harness and the charge value on the pins: A04,
733
Heating relay/Valve message.
A05
The error detection limit is a limit within the ECU.
Check the wiring harness and the charge value on the pins A01,
167 Short circuit on relay of grounding actuator 2
K74, K91 and/or reflash the ECU.
If the error persists, replace the ECU.
The error detection limit is a limit within the ECU.
Check the wiring harness and the charge value on the pins A88,
731 Short circuit on relay of grounding actuator 3
K57.
If the error persists, replace the ECU.
40
523927
3
42
523924
4
43
523925
4
44
523926
4
732
The error light indicator is permanently on.
Short circuit on relay of grounding actuator 4
45
168
3
318
Error signal on the battery voltage: high signal
range.
Check the wiring harness and the alternator connected to it.
Alarm: the error light indicator is permanently on
46
168
4
47
168
2
73
523912
4
84
639
14
271
Fault on BusOff-Status Can bus
85
1231
14
271
Fault on BusOff-Status Can bus
86
1235
14
271
CAN-Bus 2 = engine bus BusOff-Status
80-08-M218EN
Error signal on the battery voltage: low signal
range.
High voltage on the battery: fault signal limit
318
exceeded
Error on the gas valve, High voltage, or short
7-2-2
circuit to power supply source
318
The error detection limit is a limit within the ECU.
Check the wiring harness and the charge value on the pins A90.
If the error persists, replace the ECU.
Check the wiring harness and the alternator connected to it.
Check the wiring harness and the alternator connected to it.
The gross voltage value is above the minimum limit. Check the
throttle valve.
Check the wiring of CAN bus A and replace or repair if necessary. Check if CAN bus B has a resistance of 120 ohm. - The error margin
is a fault limit within the ECU
Check the wiring of CAN bus B and replace or repair if necessary. Check if CAN bus B has a resistance of 120 ohm. - The error margin
is a fault limit within the ECU.
Check the wiring of CAN bus C and replace or repair if necessary. Check if CAN bus C has a resistance of 120 ohm. - The error margin
is a fault limit within the ECU.
(31/08/2016)
ELECTRICAL TROUBLESHOOTING
5
Engine ECU
FMI
fault
code
SPN
PROBLEMS
88
102
2
223
Boost air pressure above the alarm threshold.
89
102
2
223
Boost air pressure above the shutdown limit.
93
110
1
225
Check the low physical range on the cooling
temperature.
96
110
3
225
Error on the cooling temperature sensor; Signal Check the sensor and replace if necessary, check the cable
value above the normal range.
connection and, if necessary, repair or replace it.
ACTION
Check the waste gate system and replace TC is necessary,
Check if all of the CAC channels are clean, check the air supply
circuits if necessary.
Check the waste gate system and replace TC is necessary,
Check if all of the CAC channels are clean, check the air supply
circuits if necessary.
Check the wiring harnesses and the coolant temperature sensor
connected to it.
97
110
4
225
Check the sensor and replace if necessary, check the cable
Error on the cooling temperature sensor; Signal connection and, if necessary, repair or replace it.
value below the normal range.
Measure the voltage on the coolant liquid temperature sensor and
replace the wiring harness if necessary.
98
110
0
232
High cooling temperature; alarm signal limit
exceeded
99
110
0
232
Clean the radiator, check the fan drive, check the coolant level,
Cooling temperature; system reaction launched check the whole cooling system, check that the thermostat is
working correctly, check the water pump.
101
111
1
235
Shutdown request
Coolant liquid level too low
121
1109
2
341
Engine stop request ignored
The error detection limit is a limit within the ECU.
Check the memory errors for additional error codes in order to
determine the initial cause.
Depending on the additional errors, look for other information in
the section entitled "Actions for repairing the error".
Clean the radiator, check the fan drive, check the coolant liquid
level, check the whole cooling system, check that the thermostat is
working correctly, check the water pump.
Check the coolant level, inspect the condition of the cooling
system in case of leaks and, if necessary, repair it, check the sensors
and the wiring.
Depending on the error, the engine will need shutting down.
122
523698
11
591
Engine stop request originating from the
supervision and control function
129
3224
2
596
DLC error on the CAN’s NOX sensor.
The error detection limit is a limit within the ECU.
Check the Nox sensor and the CAN-BUS wiring.
130
3224
9
597
Time exceeded error on the NOX sensor of the
CAN-Receive-Frame AT1IG1Vol
Check the NOX sensor and check that it is connected properly.
133
523938
9
766
Time exceeded error (BAM to packet) for CAN.
Check the NOX sensor and check that it is connected properly.
134
523939
9
766
Broadcast of calibration message for upstream
NOx sensor has failed.
Check the NOX sensor and check that it is connected properly.
135
138
139
523940
3234
3234
9
2
9
766
114
117
Time exceeded error on CAN
DLC error on the CAN’s Nox
Time exceeded error on CAN
140
523941
9
141
523942
9
142
523943
9
167
168
169
523704
523935
523936
12
12
12
Check the NOX sensor and check that it is connected properly.
Check the downstream NOX sensor and check that it is connected properly.
Check the downstream NOX sensor and check that it is connected properly.
Check the downstream NOX sensor and check that it is connected
767 Time exceeded error (BAM to packet) on CAN
properly.
Calibration message 1: message 1 of NOx sensor Check the downstream NOX sensor and check that it is connected
767
after the catalytic converter has failed.
properly.
Time exceeded error (PCK2PCK) on CANCheck the downstream NOX sensor and check that it is connected
767
Receive-Frame AT1OGCVol2.
properly.
6-1-5 Time exceeded error on CAN-messages
Check the wiring harness and the client’s CAN nodes.
763 Time exceeded error on CAN-messages
Check the wiring harness and the client’s CAN nodes.
764 Time exceeded error on CAN-messages
Check the wiring harness and the client’s CAN nodes.
171
523212
9
3-3-3 Time exceeded error on CAN messages
Check the connection of the CAN Bus (programming of the Bus,
polarity, short circuits, power supply circuit interruptions), test the
reception protocol, check the whole range of CAN functions.
179
523240
9
527
Time exceeded error on CAN-message
FunModCtl; Control function mode
Check the connection of the CAN Bus (programming of the Bus,
polarity, short circuits, power supply circuit interruptions), test the
reception protocol, check the whole range of CAN functions.
198
523216
9
281
282
523766
523767
283
284
9
9
Time exceeded error on CAN; preheat control,
engine control
1-1-8 Time exceeded error on CAN-message
1-1-8 Time exceeded error on CAN-message
No detailed info
No detailed info
523768
9
1-1-9 Time exceeded error on CAN-message Active
No detailed info
523769
9
1-1-9 Time exceeded error on CAN-message Passive
No detailed info
(31/08/2016)
3-3-7
Check the wiring harness and the client’s devices/equipment.
80-08-M218EN
80
KWP
code
6
ELECTRICAL TROUBLESHOOTING
Engine ECU
KWP
code
291
523776
FMI
9
119
PROBLEMS
Time exceeded error on CAN-message active
523777
9
119
293
523778
9
1-1-8
294
523779
9
1-1-8
300
523605
9
1-1-8
301
523606
9
1-1-9
305
898
9
118
306
520
9
No engine braking
1-1-9 Time exceeded error on CAN-message; control
signal
360
523982
0
737
High battery voltage
361
523982
1
737
Low battery voltage
362
523090
2
329
brake pre-selection switch
630
12
281
ACTION
The error detection limit is a limit within the ECU.
Check the connection of the CAN Bus (programming of the Bus,
polarity, short circuits, power supply circuit interruptions), test the
reception protocol, check the whole range of CAN functions.
Check the connection of the CAN Bus (programming of the Bus,
polarity, short circuits, power supply circuit interruptions), test the
Time exceeded error on CAN-message setpoint
reception protocol, check the whole range of CAN functions, check
the actuators.
Check the connection of the CAN Bus (programming of the Bus,
polarity, short circuits, power supply circuit interruptions), test the
No engine braking
reception protocol, check the whole range of CAN functions, check
Time exceeded error on CANthe actuators.
Check the connection of the CAN Bus (programming of the Bus,
polarity, short circuits, power supply circuit interruptions), test the
Passive time exceeded error on CAN-message
reception protocol, check the whole range of CAN functions, check
the actuators.
Time exceeded error on CAN-message
No detailed info
Time exceeded error on CAN-message;
No detailed info
Postpone
292
376
80
SPN
fault
code
Check the connection of the CAN Bus (programming of the Bus,
Time exceeded error on CAN-message; setpoint polarity, short circuits, power supply circuit interruptions), test the
reception protocol, check the whole range of CAN functions.
Check the connection of the CAN Bus (programming of the Bus,
polarity, short circuits, power supply circuit interruptions), test the
reception protocol, check the whole range of CAN functions.
Check wiring, alternator and wires and repair, or replace if
necessary.
Check wiring, alternator and wires and repair, or replace if
necessary.
The error detection limit is a limit within the ECU.
Check the wiring and the switches.
If the error persists, change the ECU.
EEPROM memory access error (delete)
The error detection limit is a limit within the ECU.
There are no solutions for resolving this error/failure. In each new
reset phase, the debounce level is rest.
If it is not programmed, the EEPROM is faulty --> If the ECU is faulty,
reprogram the ECU or replace if necessary.
377
630
12
281
EEPROM memory access error (read)
The error detection limit is a limit within the ECU.
There are no solutions for resolving this error/failure. In each new
reset phase, the debounce level is rest.
If it is not programmed, the EEPROM is faulty --> If the ECU is faulty,
reprogram the ECU or replace if necessary.
378
630
12
281
EEPROM memory access error (write)
The error detection limit is a limit within the ECU.
If it is not programmed, the EEPROM is faulty --> If the ECU is faulty,
reprogram the ECU or replace if necessary.
381
411
4
693
Physical scale (measured) low for the EGR
differential pressure
Check the wiring harness and the EGR connected to it.
387
523612
12
555
389
190
0
214
390
190
11
214
391
190
14
214
417
171
3
312
418
171
4
312
80-08-M218EN
The error detection limit is a limit within the ECU.
Important: sequence error, check what the error is in the memory,
in case there are other errors.
Engine speed above the authorized limit
Check the parameters of the running gear with regard to
(FOC-Level 1)
overspeed.
Engine speed above the authorized limit
Check the parameters of the running gear with regard to
(FOC-Level 2)
overspeed.
Engine speed above the authorized limit
Check the parameters of the running gear with regard to
(Overrun mode)
overspeed.
Check the wiring diagram. If the temperature sensor environment
Error on the SCR system’s ambient temperature
is not working, check the sensor and replace if necessary, check
sensor; air inlet temperature on the DPF system;
that the wires are connected correctly and repair or replace them
high signal range
if necessary.
Check the wiring diagram. If the temperature sensor environment
Error on the SCR system’s ambient temperature
is not working, check the sensor and replace if necessary, check
sensor; air inlet temperature on the DPF system;
that the wires are connected correctly and repair or replace them
low signal range
if necessary.
ECU software error; injection interruption
(31/08/2016)
ELECTRICAL TROUBLESHOOTING
7
Engine ECU
419
420
SPN
190
190
FMI
8
12
fault
code
Camshaft speed sensor fault
212
Camshaft sensor detection: out of range,
disrupted signal, no signal
The error detection limit is a limit within the ECU. This is caused by
a faulty signal or no signal from the camshaft.
Check the position of the incremental gear, clean it or reposition
it if necessary, check the correct location of the sensors. Check the
sensor on the camshaft and its wiring.
Offset angle between crankshaft and camshaft
sensor too great.
212
190
2
213
422
190
8
212
190
12
ACTION
The error detection limit is a limit within the ECU. This is caused by
a faulty signal from the camshaft.
Check the position of the incremental gear, clean it or reposition
it if necessary, check the correct location of the sensors. Check the
sensor on the camshaft and its wiring.
421
423
PROBLEMS
212
The error detection limit is a limit within the ECU. This is caused by
an offset between the crankshaft and the camshaft.
Check the position of the incremental gear, clean it or reposition it
if necessary, check the correct location of the sensors.
Check the sensor on the camshaft and its wiring.
The error detection limit is a limit within the ECU. This is caused by
a faulty signal originating from the camshaft. Check the position of
Crankshaft sensor detection: out of limit, signal
the incremental gear, clean it or reposition it if necessary, check the
lost, signal disrupted
correct location of the sensors. Check the sensor on the camshaft
and its wiring.
Speed detection; out of limit, signal lost,
Crankshaft speed sensor; no more signal
The error detection limit is a limit within the ECU. This is caused by
a faulty signal or no signal from the crankshaft.
Check the position of the incremental gear, clean it or reposition
it if necessary, check the correct location of the sensors on the
crankshaft and its wiring.
464
97
3
228
Water in diesel sensor error; high signal range
Check the wiring and the presence of water on the diesel sensor.
Check the wiring, if the water level on the diesel sensor is not
working, check the sensor and replace if necessary,
Check the connecting wire and repair or replace it if necessary.
465
97
4
228
Water in diesel sensor error; low signal
Check the wiring, the sensor and the ECU.
472
94
3
216
Diesel pressure sensor error; high signal
473
94
4
216
Diesel pressure sensor error; low range signal
474
94
1
216
low diesel pressure; alarm limit exceeded
543
676
11
263
Error on the cold start assist relay.
544
676
11
263
Error on the open cold start assist relay.
545
729
5
263
Error on the open cold start assist relay
547
729
12
263
Check that the relay is working properly and replace it if necessary.
Temperature error on the cold start assist relay. Check the temperature value around the cold start relay under the
worst-case operating conditions.
549
729
3
263
Incoming air heating device; short circuit on the The error detection limit is a limit within the ECU. Electrical error,
battery
check the wiring of the air inlet preheater.
551
729
4
263
Incoming air heating device; short circuit on
power circuit ground
The error detection limit is a limit within the ECU. Electrical error,
check the wiring of the air inlet preheater.
559
523895
13
1-5-8
Check if there is an IMA code missing from
injector 1 (following the firing order).
The error detection limit is a limit within the ECU. Check the
adjustment value of the injector (IMA). This can be checked using
SERDIA.
560
523896
13
1-5-8
Check if there is an IMA code missing from
injector 2 (following the firing order).
The error detection limit is a limit within the ECU. Check the set of
parameters and flash the correct adjustment value for the injector
(IMA). This can be checked using SERDIA.
561
523897
13
1-5-8
Check if there is an IMA code missing from
injector 3 (following the firing order).
562
523898
13
1-5-8
Check if there is an IMA code missing from
injector 4 (following the firing order).
(31/08/2016)
Check the wiring and check that the sensor is working properly,
check the sensor and replace if necessary, check that the wire is
connected correctly and repair or replace it if necessary
Check the wiring and check that the sensor is working properly,
check the sensor and replace if necessary, check that the wire is
connected correctly and repair or replace it if necessary
Check the low diesel pressure measuring device (diesel feed pump,
relay, fuses, wiring and sensor) and repair or replace if necessary.
The error detection limit is a limit within the ECU.
Check the wiring harness, replace the relay.
The error detection limit is a limit within the ECU.
Check the wiring harness, replace the relay.
The error detection limit is a limit within the ECU. Electrical error,
check the wiring.
The error detection limit is a limit within the ECU. Check the
adjustment value of the injector (IMA). This can be checked using
SERDIA.
The error detection limit is a limit within the ECU. Check the
adjustment value of the injector (IMA). This can be checked using
SERDIA.
80-08-M218EN
80
KWP
code
8
ELECTRICAL TROUBLESHOOTING
80
Engine ECU
KWP
code
SPN
FMI
fault
code
563
523899
13
1-5-8
Check if there is an IMA code missing from
injector 5 (following the firing order).
564
523900
13
1-5-8
Check if there is an IMA code missing from
injector 6 (following the firing order).
565
523350
4
151
Injector in cylinder row 1; short-circuited
566
523352
4
152
Injector in cylinder row 2; short-circuited
567
523354
12
153
Fault on the output of the injector’s power stage
568
651
5
154
Injector 1 (following the firing order);
interruption of the electrical connection
569
652
5
155
Injector 2 (following the firing order);
interruption of the electrical connection
570
653
5
156
Injector 3 (following the firing order);
interruption of the electrical connection
571
654
5
161
Injector 4 (following the firing order);
interruption of the electrical connection
572
655
5
162
Injector 5 (following the firing order);
interruption of the electrical connection
573
656
5
163
Injector 6 (following the firing order);
interruption of the electrical connection
580
651
3
154
Injector 1 (following the firing order); shortcircuited
581
652
3
155
Injector 2 (following the firing order); shortcircuited
582
653
3
156
Injector 3 (following the firing order); shortcircuited
583
654
3
161
Injector 4 (following the firing order); shortcircuited
The error detection limit is a limit within the ECU. Check the wiring
harness and the injectors and repair them or replace them if
necessary. Use the SERDIA injector test for the diagnosis.
584
655
3
162
Injector 5 (following the firing order); shortcircuited
The error detection limit is a limit within the ECU. Check the wiring
harness and the injectors and repair them or replace them if
necessary. Use the SERDIA injector test for the diagnosis.
585
656
3
163
Injector 6 (following the firing order); shortcircuited
The error detection limit is a limit within the ECU. Check the wiring
harness and the injectors and repair them or replace them if
necessary. Use the SERDIA injector test for the diagnosis.
592
523615
5
135
Measuring device (on diesel circuits), circuit
open
593
523615
12
135
594
523615
3
135
80-08-M218EN
PROBLEMS
ACTION
The error detection limit is a limit within the ECU. Check the
adjustment value of the injector (IMA). This can be checked using
SERDIA.
The error detection limit is a limit within the ECU.
Check the adjustment value of the injector (IMA). This can be
checked using SERDIA.
The error detection limit is a limit within the ECU.
Check the wiring harness and the injectors and repair them or
replace them if necessary.
The error detection limit is a limit within the ECU.
Check the wiring harness and the injectors and repair them or
replace them if necessary.
The error detection limit is a limit within the ECU.
If the error cannot be corrected, replace the ECU.
The error detection limit is a limit within the ECU.
Check the wiring harness and the injectors and repair them or
replace them if necessary.
The error detection limit is a limit within the ECU.
Check the wiring harness and the injectors and repair them or
replace them if necessary.
The error detection limit is a limit within the ECU.
Check the wiring harness and the injectors and repair them or
replace them if necessary.
The error detection limit is a limit within the ECU.
Check the wiring harness and the injectors and repair them or
replace them if necessary.
The error detection limit is a limit within the ECU.
Check the wiring harness and the injectors and repair them or
replace them if necessary.
The error detection limit is a limit within the ECU.
Check the wiring harness and the injectors and repair them or
replace them if necessary.
The error detection limit is a limit within the ECU.
Check the wiring harness and the injectors and repair them or
replace them if necessary. Use the SERDIA injector test for the
diagnosis.
The error detection limit is a limit within the ECU.
Check the wiring harness and the injectors and repair them or
replace them if necessary. Use the SERDIA injector test for the
diagnosis.
The error detection limit is a limit within the ECU.
Check the wiring harness and the injectors and repair them or
replace them if necessary. Use the SERDIA injector test for the
diagnosis.
The error detection limit is a limit within the ECU.
Check the wiring harness and the measuring device, and repair
them or replace them if necessary.
The error detection limit is a limit within the ECU.
Check the wiring harness and the measuring device, and repair
Measuring device (on diesel circuits); excessive them or replace them if necessary.
temperature on the power circuit; battery short Check that the measuring device is working correctly and replace
circuit
it if necessary.
Check the temperature on the measuring deice and modify its
installation in the event of overheating.
The error detection limit is a limit within the ECU.
Measuring device (on diesel circuits), battery
Check the wiring harness and the measuring device, and repair
short circuit
them or replace them if necessary.
(31/08/2016)
ELECTRICAL TROUBLESHOOTING
9
Engine ECU
KWP
code
SPN
FMI
fault
code
595
523615
4
135
596
523615
3
135
597
523615
4
135
604
1323
12
2-4-1
605
1324
12
2-4-1
606
1325
12
2-4-1
607
1326
12
2-4-1
608
1327
12
2-4-1
609
1328
12
2-4-1
610
1322
12
2-4-1
612
523612
12
555
613
523612
12
555
ECU has reported an internal software error
The error detection limit is a limit within the ECU.
Check the wiring and check the actuators connected to the
sensors. If the error does not disappear, replace the ECU.
614
523612
12
555
ECU has reported an internal software error
The error detection limit is a limit within the ECU. Check the wiring
and check the actuators connected to the sensors.
If the error does not disappear, replace the ECU.
615
523612
12
555
ECU has reported an internal software error
616
523612
12
555
ECU has reported an internal software error
617
523612
12
555
ECU has reported an internal software error
618
523612
12
555
ECU has reported an internal software error
619
523612
12
555
Injection system; electrical failures on the
injectors
620
523612
12
555
ECU has reported an internal software error
621
523612
12
555
ECU has reported an internal software error
623
523612
12
555
ECU has reported an internal software error
624
523612
12
555
ECU has reported an internal software error
625
523612
12
555
ECU has reported an internal software error
627
523612
12
555
ECU has reported an internal software error
628
523612
12
555
ECU has reported an internal software error
629
523612
12
555
Diagnosis fault, check to report the accelerator
pedal position error
630
523612
12
555
Diagnosis fault, check to report the engine
speed error
631
523612
12
555
Injection firing time consistency error
632
523612
12
555
Firing angle start consistency error
633
523612
12
555
Control diagnosis of the fault, report the error
caused by ZFC non-plausibility
634
523612
12
555
Fault diagnosis check report normal mode
The error detection limit is a limit within the ECU.
request because of an error in the Pol2 quantity If the error does not disappear, replace the ECU.
(31/08/2016)
PROBLEMS
ACTION
The error detection limit is a limit within the ECU. If the error does
not disappear, replace the ECU.
The error detection limit is a limit within the ECU.
If the error does not disappear, replace the ECU.
The error detection limit is a limit within the ECU.
If the error does not disappear, replace the ECU.
The error detection limit is a limit within the ECU.
If the error does not disappear, replace the ECU.
The error detection limit is a limit within the ECU.
If the error does not disappear, replace the ECU.
The error detection limit is a limit within the ECU.
If the error does not disappear, replace the ECU.
The error detection limit is a limit within the ECU.
If the error does not disappear, replace the ECU.
The error detection limit is a limit within the ECU.
If the error does not disappear, replace the ECU.
The error detection limit is a limit within the ECU.
If the error does not disappear, replace the ECU.
The error detection limit is a limit within the ECU.
If the error does not disappear, replace the ECU.
The error detection limit is a limit within the ECU.
If the error does not disappear, replace the ECU.
The error detection limit is a limit within the ECU.
If the error does not disappear, replace the ECU.
The error detection limit is a limit within the ECU.
Check the pedal, repair or replace it. Check the wiring.
If the error does not disappear, replace the ECU.
The error detection limit is a limit within the ECU.
If the error does not disappear, replace the ECU.
The error detection limit is a limit within the ECU.
If the error does not disappear, replace the ECU.
The error detection limit is a limit within the ECU.
If the error does not disappear, replace the ECU.
The error detection limit is a limit within the ECU.
If the error does not disappear, replace the ECU.
80-08-M218EN
80
The error detection limit is a limit within the ECU.
Measuring device (on diesel circuits), grounding
Check the wiring harness and the measuring device, and repair
short circuit
them or replace them if necessary.
The error detection limit is a limit within the ECU.
Measuring device (on diesel circuits), battery
Check the wiring harness and the measuring device, and repair
short circuit
them or replace them if necessary.
The error detection limit is a limit within the ECU.
Measuring device (on diesel circuits), grounding
Check the wiring harness and the measuring device, and repair
short circuit
them or replace them if necessary.
Excessive firing failures identified on cylinder 1
Not used
(following the firing order)
Excessive firing failures identified on cylinder 2
Not used
(following the firing order)
Excessive firing failures identified on cylinder 3
Not used
(following the firing order)
Excessive firing failures identified on cylinder 4
Not used
(following the firing order)
Excessive firing failures identified on cylinder 5
Not used
(following the firing order)
Excessive firing failures identified on cylinder 6
Not used
(following the firing order)
Excessive firing failures identified on more than
Not used
one cylinder
Detection of surveillance within the ECU has
The error detection limit is a limit within the ECU.
reported the error
If the error does not disappear, replace the ECU.
10
ELECTRICAL TROUBLESHOOTING
Engine ECU
FMI
fault
code
SPN
PROBLEMS
635
523612
12
555
Fault diagnosis to report the ICO request error
because of an error in the shutdown Pol2
636
523612
12
555
Fault diagnosis, check to report the
The error detection limit is a limit within the ECU.
international organization request error because
If the error does not disappear, replace the ECU.
of an error in the Pol3 efficiency factor
637
523612
12
555
Internal ECU monitoring detection reported
error
638
523612
12
555
639
523612
12
555
640
523612
12
555
641
523612
12
555
642
523612
12
555
643
523612
12
555
644
646
523612
523612
3
4
555
555
714
523612
12
555
715
523612
12
555
716
523612
12
555
717
523612
12
555
732
100
3
224
Oil pressure error; low range test signal
733
100
4
224
Oil pressure error; high range test signal
736
100
1
231
Low oil pressure; alarm limit exceeded
The error detection limit is a limit within the ECU.
Check the oil level, oil leaks from the engine, measure the external
oil pressure to check the validity of the sensor measurement.
737
100
1
231
Low oil pressure; engine stop limit exceeded
The error detection limit is a limit within the ECU.
Check the oil level, oil leaks from the engine, measure the external
oil pressure to check the validity of the sensor measurement.
The error detection limit is a limit within the ECU.
If the error does not disappear, replace the ECU.
Path limitation diagnosis restricted by level 2
ECU surveillance.
The error detection limit is a limit within the ECU.
If the error does not disappear, replace the ECU.
Overvoltage observed on power supply
Undervoltage observed on power supply
Fault control diagnosis to report active WDA
because of query/response communication
errors
Error in active ABE report as a result of
undervoltage detection
Error in active ABE report as a result of
overvoltage detection
Fault control diagnosis to report active WDA/
ABE for unknown reason
The error detection limit is a limit within the ECU.
The error detection limit is a limit within the ECU.
747
1237
2
145
Forcing (override) switch; consistency error.
750
107
3
1-3-6
Error on the air filter’s differential pressure
sensor; battery short circuit
751
107
0
1-3-6
Error on the air filter’s differential pressure
sensor; grounding short circuit
752
107
0
136
Air filter differential pressure: ground short
circuit
772
102
2
223
Downstream pressure of the boost air coolant,
consistency error
80-08-M218EN
ACTION
The error detection limit is a limit within the ECU.
If the error does not disappear, replace the ECU.
The error detection limit is a limit within the ECU.
Monitoring of fuel quantity check
If the error does not disappear, replace the ECU.
The error detection limit is a limit within the ECU.
Fault control diagnosis to report the plausibility
Check the measuring device or the cable.
error
Check the pressure on the rail. Check the rail system and check for
In the pressure control on the rail
leaks.
Control diagnosis of the fault to report the
The error detection limit is a limit within the ECU.
plausibility error when comparing the torques If the error does not disappear, replace the ECU.
Travel limitation diagnosis restricted by level 2 The error detection limit is a limit within the ECU.
ECU surveillance
If the error does not disappear, replace the ECU.
Travel limitation diagnosis restricted by level 2 The error detection limit is a limit within the ECU.
ECU surveillance
If the error does not disappear, replace the ECU.
80
KWP
code
The error detection limit is a limit within the ECU.
Reset the software.
The error detection limit is a limit within the ECU.
Reset the software.
The error detection limit is a limit within the ECU.
Reset the software.
The error detection limit is a limit within the ECU.
Reset the software.
Check the batteries and wiring,
Check the wiring. If the sensor is not working properly, check it and
replace it if necessary,
check that the wire is connected correctly and repair or replace it if
necessary.
The gross measurement of the Oil_uRawPSwmp value exceeds
Oil_SRCPSwmp.uMin_C
Check the wiring. If the sensor is not working properly, check it and
replace it if necessary, check that the wire is connected correctly
and repair or replace it if necessary.
No detailed info!
If you have pressed the Block button for less than the maximum
reasonable time.
Check the wiring. If the sensor is not working properly, check the
switch and replace it if necessary, check that the wire is connected
correctly and repair or replace it if necessary.
If the signal PAirFltD_uRaw is below the authorized limit PAirFltD_
uSRCMax_C, a measurement amplitude breach signal is reset after
debouncing repair.
No detailed info
If the signal PAirFltD_uRaw is below the authorized limit PAirFltD_
uSRCMax_C, a measurement amplitude breach signal is reset after
debouncing repair.
No detailed info.
Check the air filter and clean it or replace it if necessary, check the
wiring, check the sensor and replace if necessary, check that the
wire is connected correctly and repair or replace it if necessary
Replace the boost pressure sensor
Replace the ECU
(31/08/2016)
ELECTRICAL TROUBLESHOOTING
11
Engine ECU
SPN
FMI
fault
code
PROBLEMS
Check for major leaks throughout the engine air inlet system,
particularly from the compressor to the air intake manifold.
Check the air filter.
Replace the boost air pressure sensor.
ACTION
774
102
1
223
Downstream pressure of the boost air coolant,
pressure below the low physical limit
776
102
3
223
Downstream pressure of the boost air coolant,
battery short circuit or open circuit
Check the wiring, if the boost air pressure/temperature sensor is
not working, check the sensor and replace if necessary, check that
the wire is connected and repair or replace it if necessary.
777
102
4
223
Downstream pressure of the boost air coolant,
grounding short circuit
Check the wiring, if the boost air pressure/temperature sensor is
not working, check the sensor and replace if necessary, check that
the wire is connected and repair or replace it if necessary.
693
The error detection limit is a limit within the ECU.
EGR valve blocked open
Problem on the actuator of the EGR valve
Problem with the EGR coolant (check cooling water intake)
Venturi module differential pressure on the EGR
Problem with EGR valve
circuit above the high physical limit
throttle valve blocked in closed position => check gas inlet
Exhaust pressure too high => check the exhaust pressure
Check the Nox sensor upstream of the SCR catalytic converter
Problem with venturi DP (differential pressure) sensor
693
The error detection limit is a limit within the ECU.
Venturi module differential pressure on the EGR Check that the differential pressure sensor is assembled correctly
circuit below the low physical limit
on the venturi tube
Change the differential pressure sensor if it is broken.
791
792
411
411
0
1
The error detection limit is a limit within the ECU.
EGR valve blocked open or closed (mechanical blockage)
EGR pipework blocked by a metal plate placed at the seal
downstream of the EGR valve.
Problem on the actuator of the EGR valve
Problem with the EGR coolant (check cooling water intake)
Problem with EGR valve
Gas inlet blocked in closed position => check the gas inlet
Exhaust pressure too high => check the exhaust pressure
Check the Nox sensor upstream of the SCR catalytic converter
Fault on the venturi DP (differential pressure) sensor
793
411
11
693
Check if consistency fault on deviation of the
desired and actual mass flow on the EGR, the
second mentioned is calculated from the EGR
differential pressure sensor.
795
411
3
693
Error on the differential pressure sensor of the
venturi module (EGR), low control signal
796
411
4
693
Error on the differential pressure sensor of the
venturi module (EGR), high control signal.
825
523009
9
253
The pressure retaining valve (PRV) has reached
the authorized cycle limit.
Check the wiring, if the boost differential pressure sensor of the
EGR is not working, check the sensor and replace if necessary,
check that the wire is connected and repair or replace it if
necessary.
Check the wiring, if the boost differential pressure sensor of the
EGR is not working, check the sensor and replace if necessary,
check that the wire is connected and repair or replace it if
necessary.
Replace the pressure relief valve (PRV) and reset the fault using
Serdia.
826
523470
2
146
The pressure retaining valve (PRV) is forced to
open, apply an increase in pressure.
The error detection limit is a limit within the ECU.
Reset the fault and, if it reappears, check the injection system.
827
523470
2
146
The pressure retaining valve (PRV) is forced to
open, apply an increase in pressure.
Reset the fault and, if it reappears, check the injection system.
146
The pressure retaining valve (PRV) is forced to
open.
Conditions achieved for stopping the engine.
The error detection limit is a limit within the ECU.
Check the PRV opening counter and replace the PRV if necessary,
check the relevance of the rail’s pressure sensor value and replace
it if necessary,
check the FCU and replace it if necessary.
146
The pressure retaining valve (PRV) is forced to
open.
Alarm conditions achieved.
The error detection limit is a limit within the ECU.
Check the PRV opening counter and replace the PRV if necessary,
check the relevance of the pressure sensor value on the rail and
replace it if necessary,
check the FCU and replace it if necessary.
828
829
523470
523470
(31/08/2016)
12
12
80-08-M218EN
80
KWP
code
12
ELECTRICAL TROUBLESHOOTING
Engine ECU
KWP
code
FMI
PROBLEMS
523470
14
146
831
523470
11
146
832
523470
11
146
833
523009
10
The pressure retaining valve (PRV) opening
2-5-3 time has passed, to ensure monitoring of its
condition
856
523613
0
134
857
523613
0
134
859
523613
523613
0
0
134
Device for measuring pressure on the rail,
minimum pressure value on the rail exceeded
Negative deviation on rail pressure
(RailMeUn22).
The error detection limit is a limit within the ECU.
(A) check the back-pressure
(B) check that the injector is working correctly using SerDia
(C) replace the components if necessary (measuring device,
injector)
862
523613
0
134
864
523613
2
134
876
523470
7
146
877
157
3
147
878
157
4
147
523720
80-08-M218EN
8
The error detection limit is a limit within the ECU.
(A) check for leaks
(B) check the pressure on the main diesel circuit
(C) replace the components, check the sensor and replace it if
necessary, check the diesel circuit and repair it if necessary
The error detection limit is a limit within the ECU.
Device for measuring pressure on the rail,
(A) check for leaks
pressure drop on the rail.
(B) check the pressure on the main diesel circuit
Maximum positive pressure deviation on the rail
(C) replace the components, check the sensor and replace it if
exceeded.
necessary, check the diesel circuit and repair it if necessary
Device for measuring pressure on the rail,
positive deviation on the speed limiter
The error detection limit is a limit within the ECU.
(A) check the back-pressure
(B) check that the injector is working correctly using SerDia
(C) replace the components if necessary (measuring device,
injector)
134
926
Replace the pressure relief valve (PRV) and reset the fault using
Serdia.
Device for measuring pressure on the rail,
pressure deviation on the rail (RailMeUn2).
Leak detected on the rail system (RailMeUn10).
1
8
The error detection limit is a limit within the ECU.
Check the PRV and replace it if necessary.
134
523613
523720
Pressure on the rail outside tolerance limits.
At this stage, the PRV can no longer be opened
by a pressure shock.
The error detection limit is a limit within the ECU.
Device for measuring pressure on the rail
(A) check the back-pressure
Maximum positive pressure deviation on the rail (B) check that the injector is working correctly using SerDia
exceeded on the measuring device (RailMeUn1). (C) replace the components if necessary (measuring device,
injector)
861
925
ACTION
The error detection limit is a limit within the ECU.
Only after resetting the ECU.
Check the PRV opening counter and replace it if necessary,
Open the pressure retaining valve (PRV)
check the relevance of the rail’s pressure sensor value and replace
it if necessary,
check the FCU and replace it if necessary.
The error detection limit is a limit within the ECU.
Pressure retaining valve (PRV) error; pressure on
Check the rail pressure, check the relevance of the pressure sensor
the rail outside tolerance limits.
value on the rail, check the FCU.
830
858
80
SPN
fault
code
(A) check the back-pressure
(B) check the overpressure valve and the measuring device.
(C) replace the components if necessary
The error detection limit is a limit within the ECU.
Device for measuring pressure on the rail,
(A) check the back-pressure
setting point for the measuring device in forced
(B) check the overpressure valve and the measuring device
mode inconsistent.
(C) replace the components if necessary
(A) check the overpressure valve on the rail and replace it if
necessary,
maximum pressure on the rail exceeded (PRV). (B) check the high-pressure pumps, the overpressure valves and
the measuring device,
(C) replace the components if necessary
Error on the pressure sensor on the rail.
Check the wiring, check the pressure sensor on the rail and replace
Voltage sensor voltage exceeds the upper
if necessary, check that the wire is connected and repair or replace it
authorized limit.
if necessary.
Error on the pressure sensor on the rail.
Check the wiring, check the rail pressure sensor and replace if
Voltage sensor voltage below the lower
necessary, check that the wire is connected and repair or replace it if
authorized limit.
necessary.
Device for measuring pressure on the rail,
maximum pressure on the rail exceeded.
148
DEF supply module heating temperature; duty
cycle in invalid mode.
If the duty cycle of the SCR supply module heating is outside the
default value zone
check the supply module and replace it if necessary.
Check the wiring.
148
DEF supply module heating temperature; duty
cycle in non-valid mode.
If the duty cycle of the SCR supply module heating is inside the
validity range,
check the supply module and replace it if necessary.
Check the wiring.
(31/08/2016)
ELECTRICAL TROUBLESHOOTING
13
Engine ECU
FMI
fault
code
SPN
PROBLEMS
927
523721
11
689
Temperature measurement on the urea supply
module unavailable.
928
523722
8
929
523722
8
930
523721
8
931
523721
8
932
29
3
935
91
3
937
29
4
The error detection limit is a limit within the ECU.
No load shedding possible during the current duty cycle
check the supply module and replace it if necessary. Check the
wiring.
The duration of reception of the signal PWM SCR is within the
range of values specified, from 150 ms to 250 ms
Check the supply module and replace it if necessary
Check the wiring.
The error detection limit is a limit within the ECU.
If a signal followed by temperature signal information is received
and if a temperature signal for both pieces of information is
Fault detected on the PWM signal of the DEF
691
supply module.
received one after the other.
Check the supply module and replace it if necessary.
Check the wiring.
DEF supply module temperature; duty cycle
Check the supply module and replace it if necessary.
689
non-valid mode.
Check the wiring.
If the duty cycle received from the supply module SCR_rSMT
is within the validity range (SCR_rSMTVld-Min_C <= SCR_rSMT
Urea supply module temperature; duty cycle in <= SCR_rSMTVldMax_C), OR in a default value zone (SCR_
689
non-valid mode.
rSMFailMin_C <=SCR_rSMT <= SCR_rSMFailMax_C), check the
supply module and replace it if necessary.
Check the wiring.
If the signal is below the acceptable limit APP_uRawSRCHiHTLIS_C,
the signal for breach of the range of correct values is reset after the
repair (debouncing).
Switch of the unladen operation mode manual
1-2-6
If the CCP is active (CCP_stActive = 1) and the value read in the
validation lever; battery short circuit
EEPROM memory is correct, the signal is below the APP limit, a
signal for breach of the range of authorized values is reset after
debouncing.
Check the wiring, check the accelerator pedal sensor and replace it
if necessary, check the wire connection and repair it or replace it if
Acceleration pedal sensor error.
necessary.
2-2-6
high signal.
If the value of the signal is below the correct limit APP_
uRaw1SRCHigh_C, the signal for breach of the range of authorized
values is reset after debouncing.
691
1-2-6
PWM signal of the DEF supply module; time
outside validity limits.
Switch of the unladen operation mode manual
validation lever; ground short circuit
Acceleration pedal sensor error.
The signal is below the authorized range.
940
91
4
2-2-6
943
3532
3
1-2-7 DEF tank level sensor error; high signal range.
945
3532
4
1-2-7 DEF tank level sensor error; low signal range
946
1079
13
282
Fault on power supply voltage sensor 1.
947
1080
13
282
Fault on power supply voltage sensor 2.
948
523601
13
282
Fault on power supply voltage sensor 3.
(31/08/2016)
ACTION
If the signal value exceeds the acceptable limit APP_
uRawSRCHiHTLIS_C, the signal for breach of the authorized range
is reset after debouncing.
If the CCP is active (CCP_stActive = 1) and the value read in
the EEPROM memory is correct, the signal exceeds the APP_
uHTLISCCPLo[1] limit value, a signal for breach of the range of
authorized values is reset after debouncing.
Check the wiring, check the accelerator pedal sensor and replace it
if necessary, check the wire connection and repair it or replace it if
necessary.
If the signal is above the acceptable limit APP_uRaw1SRCLow_C,
the signal for breach of the range of authorized values is reset after
repair.
Check the DEF tank sensor, check the wiring
The gross voltage value SCR_uRawUTnkLvl is below SCR_
SRCUTnkLvl.uMax_C.
The gross voltage value SCR_uRawUTnkLvl is above SCR_
SRCUTnkLvl.uMin_C
Check the DEF tank sensor, check the wiring.
Check the wiring of external components, check that the voltages
are compliant and correct them if necessary,
check the connection of the cables and repair them or replace
them if necessary,
If the error cannot be corrected, replace the ECU.
Check the wiring of external components, check that the voltages
are compliant and correct them if necessary,
check the connection of the cables and repair them or replace
them if necessary,
If the error cannot be corrected, replace the ECU.
Check the wiring of external components, check that the voltages
are compliant and correct them if necessary,
check the connection of the cables and repair them or replace
them if necessary,
If the error cannot be corrected, replace the ECU.
80-08-M218EN
80
KWP
code
14
ELECTRICAL TROUBLESHOOTING
Engine ECU
KWP
code
SPN
FMI
fault
code
956
677
3
512
Power side start relay.
battery short circuit.
The error detection limit is a limit within the ECU.
Check the wiring, operate the relay and replace it if necessary,
check the wiring connection and repair it or replace it if necessary.
957
677
4
512
Power side start relay, ground short circuit.
The error detection limit is a limit within the ECU.
Check the wiring, operate the relay and replace it if necessary,
check the wiring connection and repair it or replace it if necessary.
958
677
5
512
Control side start relay, error due to absence of
charge.
The error detection limit is a limit within the ECU.
Check the wiring, operate the relay and replace it if necessary,
check the wiring connection and repair it or replace it if necessary.
959
677
12
512
Increase in temperature on the power stage of
the start relay.
The error detection limit is a limit within the ECU.
Check the wiring, operate the relay and replace it if necessary,
check the wiring connection and repair it or replace it if necessary.
960
677
3
512
Control side start relay, battery short circuit.
The error detection limit is a limit within the ECU.
Check the wiring, operate the relay and replace it if necessary,
check the wiring connection and repair it or replace it if necessary.
PROBLEMS
961
677
4
512
Control side start relay, ground short circuit.
973
974
523612
523612
14
14
555
555
Softwarereset CPU SWReset_0
Softwarereset CPU SWReset_1
975
523612
14
555
Softwarereset CPU SWReset_2
976
91
11
2-2-6
Consistency error between APP1 and APP2 or
APP1 and operating switch idling (unladen)
ACTION
The error detection limit is a limit within the ECU.
Check the wiring, operate the relay and replace it if necessary,
check the wiring connection on the terminal and repair it or
replace it if necessary.
The error detection limit is a limit within the ECU.
The error detection limit is a limit within the ECU.
The error detection limit is a limit within the ECU.
If possible, perform a software reset. Replace the ECU.
The error detection limit is a limit within the ECU.
Check the wiring, check the accelerator pedal sensor and replace it
if necessary,
check the wiring connection and repair it or replace it if necessary,
If the duration of PWM APP_tiPWMPer is between APP_
tiSRCLoPWMPer_C and APP_tiSRCHiPWMPer_C.
29
2
980
523550
12
515
Terminal 50 (excitation time of the starter has
been used for too long)
The error detection limit is a limit within the ECU.
Check the wiring, check whether the sensor is working, check the
starter switcher and replace it if necessary,
check the wiring connection and repair it or replace it if necessary.
992
105
1
128
Temperature of the boost air coolant
downstream.
Temperature below the authorized physical
limit.
Is the temperature below -40 °C?
If so, change the sensor.
994
105
3
128
Electrical fault on the boost air temperature.
Physical value of the signal above the normal
range (SRC).
995
105
4
128
Electrical fault on the boost air temperature.
Physical value of the signal below the normal
range.
80
978
Consistency error between the sensor and the
idling operating switch (unladen), accelerator
pedal detection.
1-2-6
In the case of a manual gas knob with an idling
operating switch (unladen), fault on the idling
contact.
The error detection limit is a limit within the ECU.
The accelerator pedal must have plausibly detected the full load
and the unladen value at least once.
The raw signal of the sensor Air_uRawTCACDs (voltage) > Air_
SRCTCACDs.uMin_C.
Check the CAC sensor and replace if necessary, check that the wire
is connected correctly and repair or replace it if necessary.
The signal of the sensor Air_uRawTCACDs (voltage) is below
Air_SRCTCACDs.uMin_C.
Check the CAC sensor and replace if necessary, check that the wire
is connected correctly and repair or replace it if necessary.
996
105
0
233
Boost air coolant temperature. Reaction of the
Check and clean the CAC system. Check if the fan is working,
system launched.
Check that the ventilation is working by measuring the
High boost air coolant temperature. Alarm level
temperature.
exceeded.
997
105
0
233
Check and clean the CAC system. Check if the fan is working,
Low boost air coolant temperature. Engine stop
Check that the ventilation is working by measuring the
level exceeded.
temperature.
1007
412
3
682
1008
412
4
682
80-08-M218EN
Electrical fault on the EGR coolant temperature
downstream
High signal range.
Electrical fault on the EGR coolant temperature
downstream
Low signal range.
Check the wiring harness to the TEGr sensor.
Replace the TEGR sensor.
Check the wiring harness to the TEGr sensor.
Replace the TEGR sensor.
(31/08/2016)
ELECTRICAL TROUBLESHOOTING
15
Engine ECU
SPN
1011 523960
FMI
0
fault
code
771
1012 523960
1
771
1014
5763
6
594
1015 520521
5
594
1016
5763
7
594
1022
5763
6
1023
5763
5
1024
5763
3
1025
5763
4
1036
4768
2
PROBLEMS
High value for EGR coolant temperature
downstream.
EGR valve blocked open.
Fault on the actuator of the EGR valve
Fault with the EGR coolant (check cooling water).
Fault on EGR valve
Gas inlet blocked in closed position
Exhaust pressure too high
Check the Nox sensor upstream of the SCR catalytic converter
Fault on venturi DP (differential pressure) sensor.
Low value for EGR coolant temperature
downstream.
EGR valve blocked open.
Fault on the actuator of the EGR valve
Fault with the EGR coolant (check cooling water).
Fault on EGR valve
Gas inlet blocked in closed position
Exhaust pressure too high
Check the Nox sensor upstream of the SCR catalytic converter
Fault on venturi DP (differential pressure) sensor.
Error on the EGR valve actuator or the throttle
valve.
High signal range.
Error on the EGR valve actuator or the throttle
valve; Physical value of the signal below the
normal range.
Check the wiring and repair it or replace it if necessary, check the
actuator using a SERDIA test of the EGR and replace it if necessary.
Check the wiring and repair it or replace it if necessary, check the
actuator using a SERDIA test of the EGR and replace it if necessary.
The error detection limit is a limit within the ECU.
Position of the EGR valve actuator or the throttle
Error detection limit, a deviation is only visible from a value > 7%.
valve not consistent
Troubleshoot with SERDIA 2010, use Diagnostic EGR.
Error on the EGR valve actuator or the throttle
5-9-4 valve; Physical value of the signal above the
normal range
Error on the EGR valve actuator or the throttle
5-9-4 valve; Physical value of the signal below the
normal range
Position error on the EGR valve sensor actuator
or the throttle valve.
594
Physical value of the signal above the normal
range.
Position error on the EGR valve actuator sensor
or the throttle valve.
594
Physical value of the signal below the normal
range.
683
ACTION
Consistency error with the temperature
upstream of the DOC.
Check the wiring, check if fault on the actuator, check the actuator
and replace if necessary, check the connecting wire and repair or
replace it if necessary.
Check the wiring, check the connecting wire and repair it or
replace it if necessary, check the actuator with the SERDIA 2010
test of the EGR and replace it if necessary.
Check the wiring, check if fault on the actuator, check the actuator
and replace if necessary, check the connecting wire and repair or
replace it if necessary.
Check the wiring, check if fault on the actuator, check the actuator
and replace if necessary, check the connecting wire and repair or
replace it if necessary.
Check the ambient temperature => is its value plausible?
Has the DOC sensor upstream been fitted on the exhaust line?
Has the T sensor upstream of the DOC been fitted in its correct
position upstream of the DOC (and not upstream of the SCR or
downstream of the DOC)?
Check the T sensor upstream of the DOC
Check the other T sensors in the EAT system (do Exh_tOxiCatDs &
UCatUsT_tFlt_mp display plausible values?) Check that there are
not errors on these.
Check the engine's air circuit: EGR valve, gas inlet,
Check the turbo and each of the pipes for leaks and correct
Temperature upstream of the DOC exceeds the
operation
engine stop limit
Check the injectors: is an injector blocked?
Change the temperature sensor upstream of the DOC
Check the engine's air circuits: EGR valve, gas inlet, leaks and
Temperature upstream of the DOC exceeds the correct operation of the turbo and all of the pipes
high alarm limit
Check the injectors: is an injector blocked?
Change the temperature sensor upstream of the DOC
1039
4765
0
683
1040
4765
0
683
1044
4768
3
683
Electrical fault on the exhaust gas temperature
upstream (DOC); Physical value of the signal
above the normal range.
Check the wiring harness of the temperature sensor upstream of
the DOC
Change the temperature sensor upstream of the DOC
1045
4768
4
683
Electrical fault on the exhaust gas temperature
upstream (DOC); Physical value of the signal
below the normal range.
Check the wiring harness of the temperature sensor upstream of
the DOC
Change the temperature sensor upstream of the DOC.
(31/08/2016)
80-08-M218EN
80
KWP
code
16
ELECTRICAL TROUBLESHOOTING
Engine ECU
80
KWP
code
SPN
FMI
fault
code
PROBLEMS
ACTION
1069
4360
0
668
Exhaust gas temperature upstream of the SCRCat exceeds the high physical limit
Check the temperature deviations along the DOC (Exh_tOxiCatDsExh_TOxiCatUs).
If so, the engine emits too much carbon monoxide => check the
injectors: is an injector blocked?
=> check the EGR valve
If the T deviation is too great between the exhausts coming out of
the engine (too hot) => check the engine’s air intake circuits: EGR
valve, gas inlet, leaks and correct operation of the turbo and all of
the pipes
If this error occurred during standstill, the origin of the error could
be burnt soot resulting in an exothermic reaction in the DPF
(which is not supposed to happen) => Remove the DPF for visual
inspection
change the temperature sensor upstream of the SCR.
1070
4360
1
668
Exhaust gas temperature measured before the
SCR-Cat < low physical limit
Cold start and ambient temperature < the limit? Poor detection
Check the wiring harness to the sensor UCatUsT
Change the sensor UCatUsT
1072
4361
3
668
1073
4361
4
668
1075
3361
6
677
1077
3361
3
677
1078
3361
3
677
1079
3361
4
677
1080
3361
4
677
1090
4345
5
674
1092
4345
3
674
1093
4345
4
674
1094
4343
5
673
1096
4343
3
673
1097
4343
4
673
1098 523718
5
676
1100 523718
3
676
1101 523718
4
676
1102
4341
5
675
1104
4341
3
675
1105
4341
4
675
80-08-M218EN
Error on the temperature sensor upstream of
Check the sensor
the SCR catalytic converter; Physical signal value Check the wiring
above the normal range
Replace the UCatUsT sensor
Error on the temperature sensor upstream of
Check the sensor
the SCR catalytic converter; Physical signal value Check the wiring
below the normal range
Replace the UCatUsT sensor
DEF dosing valve; power too high at the end of Check the wiring
injection
Check the DEF injection valve
The error detection limit is a limit within the ECU.
DEF dosing valve; battery short circuit
See if a substitution function needs anticipating
Check the wiring
The error detection limit is a limit within the ECU.
DEF dosing valve; battery short circuit
Check the wiring
Urea dosing valve; short circuit on ground or
Check the wiring
control circuit
The error detection limit is a limit within the ECU.
DEF dosing valve; power side short circuit
Check the wiring
The error detection limit is a limit within the ECU.
DEF return circuit on the SCR heater; circuit
Check the wiring
open
Check the heating element
The error detection limit is a limit within the ECU.
DEF return circuit on the SCR heater; battery
Check the wiring
short circuit
Check the heating element
The error detection limit is a limit within the ECU.
DEF return circuit on the SCR heater; ground
Check the wiring
short circuit
Check the heating element
The error detection limit is a limit within the ECU.
Primary side pressure circuit DEF heating relay
Check the wiring
SCR; circuit open
Check the heating element
The error detection limit is a limit within the ECU.
Pressurized DEF circuit on the SCR heater
Check the wiring
-Pressure circuit DEF; battery short circuit
Check the heating element
The error detection limit is a limit within the ECU.
Pressurized DEF circuit on the SCR heater
Check the wiring
-Pressure circuit DEF; ground short circuit
Check the heating element
The error detection limit is a limit within the ECU.
Main relay of the primary side pressure circuit
Test the main relay of the SCR
SCR; circuit open
Check the wiring and replace the relay if necessary
The error detection limit is a limit within the ECU.
SCR main relay; battery short circuit
Check the wiring
Check the main SCR relay
The error detection limit is a limit within the ECU.
Check the wiring
SCR main relay; ground short circuit
Check the main SCR relay
The error detection limit is a limit within the ECU.
SCR-DEF heating relay main circuit open
Check the wiring harness,
Check the power supply circuit
The error detection limit is a limit within the ECU.
SCR-DEF heating main circuit; battery short
Check the wiring harness,
circuit
Check the power supply circuit
The error detection limit is a limit within the ECU.
SCR-DEF heating main circuit; ground short
Check the wiring harness,
circuit
Check the power supply circuit
(31/08/2016)
ELECTRICAL TROUBLESHOOTING
17
Engine ECU
SPN
FMI
fault
code
1106 523719
5
672
SCR-DEF heating relay main module open
1108 523719
3
672
SCR-DEF heating relay main module; battery
short circuit
1109 523719
4
672
SCR-DEF heating main module; ground short
circuit
1110
4366
5
671
SCR tank heating valve main circuit open
1112
4366
3
671
SCR tank heating valve; short circuit on the
battery
1113
4366
4
671
SCR tank heating valve; short circuit on the
ground
1117 523632
11
666
Pump engine unavailable
1118
4375
5
666
PROBLEMS
Urea pump engine; circuit open
ACTION
The error detection limit is a limit within the ECU.
Check the wiring
Check the connections, replace the power supply module if
necessary
The error detection limit is a limit within the ECU.
Check the wiring
Check the connections, replace the power supply module if
necessary
The error detection limit is a limit within the ECU.
Check the wiring
Check the connections, replace the power supply module if
necessary
The error detection limit is a limit within the ECU.
Check the wiring
Check the connections, replace the urea tank heating valve if
necessary
The error detection limit is a limit within the ECU.
Check the wiring
Check the connections, replace the urea tank heating valve if
necessary
The error detection limit is a limit within the ECU.
Check the wiring
Check the connections, replace the urea tank heating valve if
necessary
The error detection limit is a limit within the ECU.
The error detection limit is a limit within the ECU.
The hardware detects a load on the outlet power stage of the PWM
for the urea pump actuator module.
Check the wiring
Check the urea supply module pump
The error detection limit is a limit within the ECU.
The hardware detects that there are no short circuits to the battery
on the outlet power stage of the PWM for the urea pump actuator
Urea pump engine; battery short circuit
module.
Check the wiring
Check the urea supply module pump
The error detection limit is a limit within the ECU.
The hardware detects a short circuit with ground fault on the
outlet power stage of the PWM for the urea pump actuator
module.
Urea pump engine; ground short circuit
This error is reset by moving to bit 1 the measuring point UPmpMot_stPrevTstRslt_mp
Check the wiring
Check the urea supply module pump
Check the urea pump
DEF supply module pressure, DEF pressure
Check the supply module pressure sensor
above the normal range
Clean the urea pump (filter)
Check the urea pump
DEF supply module pressure sensor; weak signal Check the supply module pressure sensor
Clean the urea pump (filter)
Error on the urea pump pressure sensor above Check the wiring
the normal range
Check the urea supply module pressure sensor
1120
4375
3
666
1121
4375
4
666
1122
4334
0
665
1123
4334
1
665
1127 523632
3
665
1128 523632
4
665
Urea pump pressure sensor error; Physical signal Check the wiring
value below the normal range
Check the urea supply module pressure sensor
1129
4376
5
667
Reversible SCR valve; open load
1131
4376
3
667
Reversible SCR valve; battery short circuit
1132
4376
4
667
Reversible SCR valve; ground short circuit
(31/08/2016)
The error detection limit is a limit within the ECU.
Check the wiring
Check the urea supply module
The error detection limit is a limit within the ECU.
Check the wiring
Check the urea supply module
The error detection limit is a limit within the ECU.
Check the wiring
Check the urea supply module
80-08-M218EN
80
KWP
code
18
ELECTRICAL TROUBLESHOOTING
Engine ECU
KWP
code
1135
80
1136
SPN
3031
3031
FMI
0
1
fault
code
669
669
PROBLEMS
DEF tank, DEF temperature above the physical
limit
DEF tank, DEF temperature below the physical
limit
1138
4365
3
6-6-9
Urea tank temperature sensor error: battery
short circuit
1139
4365
4
6-6-9
Urea tank temperature sensor error: ground
short circuit.
1157
97
12
228
Water in the diesel level prefilter; maximum
value exceeded
1170 523612
12
555
ECU software internal error
1180
168
0
318
Battery voltage too high
1181
168
1
318
Battery voltage too low
1183
172
1
226
Air intake filter sensor: out of range
1222
190
14
2-1-2
Crankshaft and camshaft speed sensor signal
unavailable on the CAN
1223
5763
5
594
Operate the EGR valve or the throttle valve;
circuit open
1224
5763
6
594
Operate the EGR valve or the throttle valve;
current too strong
1226
5763
3
594
Operate the EGR valve or the throttle valve;
battery short circuit
1227
5763
3
594
Operate the EGR valve or the throttle valve;
battery short circuit
80-08-M218EN
ACTION
Section: CANBUS sensor:
Check if the temperature or the urea tank is really very high?
Check the CANBus message on the urea tank temperature sensor
DEF Com_dRxSCR2Byt2
Compare it with Com_dRxSCR1Byt1 (is the urea temperature the
same if it is measured with a good quality sensor?)
Does tank reheating work continuously?
Check the wiring of the DEF quality sensor
Section: analog DEF T and level sensor:
Check if the temperature of the urea tank is really hot?
Check the urea tank temperature SCR_tSensUTnkT
Compare this urea tank temperature with EnvT_t or SCR_tSMT (is it
the same as the urea temperature in the supply module?)
Does tank reheating work continuously?
Check the wiring of the analog DEF T and level sensors
Section: CANBUS sensor:
Check the ambient temperature EnvT_t => close to -40 °C? If so,
the error risk is plausible
Check the CANBus message - message from the urea tank
temperature DEF: Com_dRxSCR2Byt2
Compare it with Com_dRxSCR1Byt1 (is the urea temperature the
same if it is measured on a good quality sensor?)
Check the wiring of the DEF quality sensor
Check the quality sensor (DEF)
Section: analog DEF T and level sensor:
Check the temperature in the urea tank: is it really cold?
Check the ambient temperature EnvT_t => close to -40 °C? If so,
the error risk is plausible
Check the temperature in the urea tank: SCR_tSensUTnkT
Check the wiring of the analog DEF T and level sensor
Check the analog DEF T and level sensor
The error detection limit is a limit within the ECU.
The raw voltage value measured SCR_uRawUTnkT remains below
SCR_SRCUTnkT.uMax_C.
Check the wiring.
The error detection limit is a limit within the ECU.
The raw voltage value measured SCR_uRawUTnkT is above SCR_
SRCUTnkT.uMin_C.
Check the wiring.
Measure the voltage on the water in diesel level sensor and change
the wiring harness if necessary.
The error detection limit is a limit within the ECU.
Reflash the ECU. If the error persists, replace the ECU.
Check the alternator, the alternator regulator, and replace it if
necessary, check the wiring and the voltage on the alternator
Check the alternator, the wiring, the contact resistance, the
protection fuses, the excessive consumption on the electrical
system, check the battery and replace it if necessary, check the
battery terminals and replace it if necessary
Cold start temperature and ambient temperature < the limit
Check the wiring harness to the sensor AFST
Change the sensor AFST
The error detection limit is a limit within the ECU.
Check the wiring, check the wires and repair them or replace them
if necessary.
The error detection limit is a limit within the ECU.
Check the wiring, the components and the ECU
Check the repairs using SerDia 2010 Use Case
The error detection limit is a limit within the ECU.
Check the wiring, the components and the ECU
Check the repairs using SerDia 2010 Use Case
The error detection limit is a limit within the ECU.
Check the wiring, the components and the ECU
Check the repairs using SerDia 2010 Use Case
The error detection limit is a limit within the ECU.
Check the wiring, the components and the ECU
Check the repairs using SerDia 2010 Use Case
(31/08/2016)
ELECTRICAL TROUBLESHOOTING
19
Engine ECU
SPN
FMI
fault
code
1228
5763
4
594
1229
5763
4
594
1230
5763
6
5-9-4
1231
5763
11
5-9-4
1232
5763
4
5-9-4
1239 523984
3
788
1241 523986
4
176
1242 523987
4
791
1337
2797
4
565
1338
2798
4
566
1339
2797
4
565
1340
2798
4
566
1381
164
2
839
1398
1136
0
681
1423
5763
0
5-9-4
1424
5763
1
5-9-4
1425
172
1434 524050
1435 524051
(31/08/2016)
PROBLEMS
ACTION
The error detection limit is a limit within the ECU.
Check the wiring, the components and the ECU
Check the repairs using SerDia 2010 Use Case
The error detection limit is a limit within the ECU.
Operate the EGR valve or the throttle valve;
Check the wiring, the components and the ECU
battery short circuit
Check the repairs using SerDia 2010 Use Case
Operate the EGR valve or the throttle valve;
The error detection limit is a limit within the ECU.
overload due to short circuit
Check the wiring and the components
Increase in power stage temperature due to
The error detection limit is a limit within the ECU.
current being too strong.
Check the wiring and the components
The error detection limit is a limit within the ECU.
Voltage below the low limit.
Check the wiring and the components
The error detection limit is a limit within the ECU.
UB6; battery short circuit, error on actuator relay Check the wiring, the components and the ECU.
Check the wiring, the components and the ECU.
The error detection limit is a limit within the ECU.
SCR heating relay; ground short circuit
Check the wiring, the components and the ECU.
The error detection limit is a limit within the ECU.
UB6; ground short circuit, error on actuator relay
Check the wiring, the components and the ECU.
The error detection limit is a limit within the ECU.
Time exceeded on the ground short
Check the wiring, the components and the ECU
circuit diagnosis on Cyl. Bank 0;_
Note: the injector in question must be determined following the
IVDiaShCirGndToutBnk_0
firing order
The error detection limit is a limit within the ECU.
Time exceeded on the ground short
Check the wiring, the components and the ECU
circuit diagnosis on Cyl. Bank 1;_
Note: the injector in question must be determined following the
IVDiaShCirGndToutBnk_1
firing order
Check the wiring, the components and the ECU
Injector diagnosis; short circuit on the ground of
Note: the injector in question must be determined following the
cylinder row 0
firing order
Check the wiring, the components and the ECU
Injector diagnosis; short circuit on the ground of
Note: the injector in question must be determined following the
cylinder row 1
firing order
The error detection limit is a limit within the ECU.
Operation in rail pressure security mode is not
Reset the fault and, if it reappears, check the ECU and the injection
executed correctly ()
device
Out of range on ECU temperature
Close the heating air circuits, replace the ECU
Alarm limit reached on an EGR air intake internal The mass air flow rate AFS_dm is greater than or equal to AFS_
actuator error
PhysRng.Max_C
Engine stop limit reached on an EGR air intake
not used
internal actuator error
Operate the EGR valve or the throttle valve;
ground short circuit
Max. limit temperature value reached in the air
filter casing
0
226
11
11
8-3-6 CAN; not used
8-3-7 CAN; not used
Check the external conditions:
is the temperature > the limit on the engine’s air intake circuit?
For example: on the finishers, does the engine absorb the air taken
in on the hot asphalt?
Is the sensor placed on a dirty air filter shroud situated over the
engine cover under hot environmental conditions, or idling or
other equivalent conditions?
=> if so, use the application team to check and adapt to these limit
conditions
if not, check the sensor and the wiring harness
Change the sensor
Not used
Not used
80-08-M218EN
80
KWP
code
20
ELECTRICAL TROUBLESHOOTING
Engine ECU
KWP
code
80
1455
SPN
3711
FMI
fault
code
PROBLEMS
Temperature too low or too high during an
established regime main cycle
12
711
1505 524057
2
Diesel supply pump, inadequate supply
8-4-3
pressure
1533 524074
9
246
1534 524075
11
247
1535 524076
9
248
1536 524077
11
249
1537 524078
9
255
80-08-M218EN
ACTION
Check if the temperature upstream of the DOC Exh_tSensOxiCatUs
remains in the limits of those of the standstill: > 450 °C? If not:
=> Check the engine air circuit: EGR valve, gas inlet, correct
operation and leaks on the turbo and all of the circuits
Check if the temperature deviations along the DOC by Exh_
tSensOxiCatDs - Exh_tSensOxiCatUs are inside those of the
established standstill regime: < 100 °C? If not:
Check the exhaust circuits downstream of the turbo (search for oil
leaks)
check the injectors: is an injector blocked?
Too much carbon monoxide in the exhausts? White smoke (when
the EAT system is hot, and not during cold start)?
Check the engine's air intake: EGR valve, gas inlet, correct operation
and leaks on the turbo and all of the circuits
Check the exhaust gas temperature sensors in the EAT system: T
upstream of the DOCC, T downstream of the DOC, and T upstream
of the SCR catalytic converter
These three temperatures can have an influence on Phy_tPfWgh
The error detection limit is a limit within the ECU.
Check if the pressure is too low on the diesel circuit (diesel supply
pump, relay, fuse, wiring, sensor), and repair them or replace them
if necessary.
The error detection limit is a limit within the ECU.
Check the NOx sensor downstream of the SCR catalytic converter:
does it contain water? Shake the sensor after disassembling it => if
NOx sensor downstream of the SCR-CAT,
there is water inside, replace the sensor.
internal sensor open
Check the sensor assembly position, and try to assess if water
condensation has formed and built up.
Check the wiring harness.
Replace the sensor
The error detection limit is a limit within the ECU.
Check the NOx sensor downstream of the SCR catalytic converter:
does it contain water? Shake the sensor after disassembling it => if
there is water inside, replace the sensor.
NOx sensor downstream of the SCR-CAT,
Check the sensor assembly position, and try to assess if water
internal sensor short circuit
condensation has formed and built up. Replace it otherwise, if this
is critical and if it is feasible.
Check the wiring harness.
Replace the sensor
The error detection limit is a limit within the ECU.
Check the NOx sensor downstream of the SCR catalytic converter:
does it contain water? Shake the sensor after disassembling it => if
NOx sensor downstream of the SCR-CAT,
there is water inside, replace the sensor.
internal sensor open
Check the sensor assembly position, and try to assess if water
condensation has formed and built up.
Check the wiring harness.
Replace the sensor
The error detection limit is a limit within the ECU.
Check the NOx sensor downstream of the SCR catalytic converter:
does it contain water? Shake the sensor after disassembling it => if
NOx sensor upstream of the SCR-CAT, internal there is water inside, replace the sensor.
Check the sensor assembly position, and try to assess if water
sensor short circuit
condensation has formed and built up.
Check the wiring harness.
Replace the sensor
Check if the NOx sensor downstream of the SCR catalytic converter is
physically fitted inside the exhaust line.
Check the lambda values of the NOx sensor downstream of the SCR catalytic
converter for the idling speed: ComRxSCR_rCanLamDs_mp > the limit?
Compare it with ComRxSCR_rCanLamUs_mp. The values must be almost
Nox sensor downstream of the SCR-CAT, lambda identical
value above the normal high limit
Check the CANBus of the NOx sensor downstream of the SCR catalytic
converter
Check the NOx sensor downstream of the SCR catalytic converter’s
wiring circuit
Check the NOx sensor downstream of the SCR catalytic converter itself
Replace the NOx sensor downstream of the SCR catalytic converter
(31/08/2016)
ELECTRICAL TROUBLESHOOTING
21
Engine ECU
SPN
FMI
fault
code
PROBLEMS
ACTION
Compare with ComRxSCR_rCanLamUs_mp. ComRxSCR_rCanLamDs_
mp must be almost identical!
If the value is almost identical, check the engine air circuit: EGR valve,
gas inlet, correct operation and leaks on the turbo and all of the circuits.
Check the engine injection circuit: is an injector blocked?
Nox sensor downstream of the SCR-CAT, lambda If the lambda value measured upstream of the SCR is greater
value below the normal low limit
(ComRxSCR_rCanLamUs_mp): diesel in the urea tank?
Check the CANBus of the NOx sensor downstream of the SCR catalytic
converter
Check the NOx sensor downstream of the SCR catalytic converter wiring
Check the NOx sensor downstream of the SCR catalytic converter itself
Replace the NOx sensor downstream of the SCR catalytic converter
Check if the NOx sensor upstream of the SCR catalytic converter is physically
fitted inside the exhaust line.
Check the lambda values of the NOx sensor upstream of the SCR catalytic
converter at idling speed, compare it with ComRxSCR_rCanLamUs_mp < the
limit?
Nox sensor upstream of the SCR-CAT, lambda
Compare it with ComRxSCR_rCanLamDs_mp. The values must be almost
value above the normal high limit
identical
Check the CANBus of the NOx sensor upstream of the SCR catalytic converter
Check the NOx sensor upstream of the SCR catalytic converter’s wiring
Check the NOx sensor upstream of the SCR catalytic converter itself
Replace the NOx sensor upstream of the SCR catalytic converter
Check the engine air circuit: EGR valve, gas inlet, correct operation and
leaks on the turbo and all of the circuits.
Check the engine injection circuit. Is an injector blocked?
Nox sensor upstream of the SCR-CAT, lambda
Check the CANBus of the NOx sensor upstream of the SCR catalytic
value below the normal low limit
converter
Check the NOx sensor upstream of the SCR catalytic converter wiring
Check the NOx sensor upstream of the SCR catalytic converter itself
Replace the NOx sensor upstream of the SCR catalytic converter
Check the CANBus of the NOx sensor downstream of the SCR catalytic
converter
Nox sensor downstream of the SCR-CAT, lambda
Check the NOx sensor downstream of the SCR catalytic converter wiring
value below the minimum value
Check the NOx sensor downstream of the SCR catalytic converter itself
Replace the NOx sensor downstream of the SCR catalytic converter
Check the CANBus of the NOx sensor upstream of the SCR catalytic
converter
Nox sensor upstream of the SCR-CAT, lambda
Check the NOx sensor upstream of the SCR catalytic converter wiring
value below the normal low limit
Check the NOx sensor upstream of the SCR catalytic converter itself
Replace the NOx sensor upstream of the SCR catalytic converter
1538 524079
9
256
1539 524080
9
257
1540 524081
9
258
1542 524083
9
261
1544 524085
9
912
1555 524063
5
869
SCR reheating return circuit; circuit open
Check the wiring and the components
1556 524063
5
869
Main SCR relay could be not connected
Check the wiring and the components
1557 524063
5
869
Pressurized SCR reheating circuit; circuit open
Check the wiring and the components
1558 524063
3
869
Main SCR relay; battery short circuit
1559 524063
4
869
The main SCR relay on the reheating valve,
ground short circuit.
Check the wiring and the components
Disconnect the reheating valve connector then reset/clear the
fault.
If the fault is still present, you then have to check the wiring to the
control unit pin.
If the error has disappeared, you must check the wiring via the
relay, and of course the reheating cables and relays too.
1560 524063
5
869
The main relay of the suction line is not
connected
Check the wiring and the components
1561 524063
5
869
SCR reheating supply module; circuit open
Check the wiring and the components
1562 524063
5
869
SCR reheating tank; circuit open
Check the wiring and the components
(31/08/2016)
80-08-M218EN
80
KWP
code
22
ELECTRICAL TROUBLESHOOTING
Engine ECU
KWP
code
SPN
80
1565 524065
FMI
0
fault
code
892
PROBLEMS
ACTION
Pressure sensor upstream of the SCR-CAT,
pressure above the physical limit
Check if there has been any crystallization in the exhaust circuit,
upstream of the SCR and downstream of the urea injector.
Check that the exhaust circuits are connected correctly to the
pressure sensor upstream of the SCR catalytic converter: presence
of siphons? Water in the pipes? Water in the sensor?
Check if the exhaust outlet circuits are free from obstacles
(downstream of the SCR catalytic converter)
Check the wiring of the pressure sensor upstream of the SCR
catalytic converter
Check the pressure sensor upstream of the SCR catalytic converter:
If the sensor is no longer connected to the vehicle frame => check
that the sensor is free
Is the sensor subjected to major vibrations at low and high idling
speeds? => try to eliminate these vibrations
Change the pressure sensor upstream of the SCR catalytic
converter
Calculate to check if the engine's exhaust flow (by volume) is
within plausible EDC limits: SCR_dvolSCRUs? If not:
Check the T sensor upstream of the SCR catalytic converter, check
the whole engine air circuit: EGR valve, gas inlet, correct operation
and risks of leaks on the turbo and all of the circuits
Check the SCR catalytic converter: if it is broken, change the SCR
catalytic converter
1566 524065
1
892
Pressure sensor upstream of the SCR-CAT,
pressure below the normal low limit
Check the correct connections from the exhaust circuits up to the
pressure sensor upstream of the SCR catalytic converter and check
for leaks
Check the electrical connectors: 4h pin open? / use of a new type of
connector? It is possible that there has been a pressure exchange
inside the electrical connector to its outside environment
Check the exhaust circuits: check that there are no leaks upstream
of the SCR catalytic converter
Check the wiring of the pressure sensor upstream of the SCR
catalytic converter
Change the pressure sensor upstream of the SCR catalytic
converter
Calculate to check if the engine's exhaust flow from the engine (by
volume) inside the EDC: SCR_dvolSCRUs is correct. If not:
Check the T sensor upstream of the SCR catalytic converter, check
the whole engine air circuit: EGR valve, gas inlet, correct operation
and risks of leaks on the turbo and all of the circuits
Check the SCR catalytic converter: if it is broken, change the SCR
catalytic converter
1569 524065
3
892
Pressure sensor upstream of the SCR-CAT;
battery short circuit or circuit open
Check the pressure sensor wiring upstream of the SCR catalytic converter.
Check the pressure sensor upstream of the SCR catalytic converter.
Replace the pressure sensor upstream of the SCR catalytic converter
1570 524065
4
892
Pressure sensor upstream of the SCR-CAT;
ground short circuit
Check the pressure sensor wiring upstream of the SCR catalytic converter.
Check the pressure sensor upstream of the SCR catalytic converter.
Replace the pressure sensor upstream of the SCR catalytic converter
DEF supply module, reheating temperature
above the normal upper limit
Compare SCR_tSMT with SCR_tSMHtrT. Are the two values the
same?
Check the temperature of the urea tank (SCR_tAdapUTnkT). If
it is very hot (> 70 °C), does reheating of the urea tank operate
continuously?
Does the pump no longer stop running? Check the wiring of the
supply module
Compare SCR_tSMT with SCR_tSMHtrT. Do the two display
different values or is the temperature of the urea tank (SCR_
tAdapUTnkT) cold?
Replace the urea pump unit
Fault on the supply module temperature sensor
Fault on the supply module heating
Fault on the supply module heating
DEF supply module, reheating temperature
below the normal lower limit
Check if the ambient temperature EnvT_t is < the limit.
Compare SCR_tSMT with SCR_tSMHtrT
Check the wiring of the supply module reheating module
Replace the urea pump unit
Fault on the supply module reheating temperature sensor
Fault on the supply module
1581 524067
1582 524067
80-08-M218EN
0
1
894
894
(31/08/2016)
ELECTRICAL TROUBLESHOOTING
23
Engine ECU
SPN
1585 524067
FMI
0
fault
code
894
PROBLEMS
ACTION
DEF supply module, reheating temperature
above the normal upper limit
Compare SCR_tSMT with SCR_tSMHtrT. Are the two values the
same?
Check the temperature of the urea tank (SCR_tAdapUTnkT). If
it is very hot (> 70 °C), does reheating of the urea tank operate
continuously?
Does the pump no longer stop running? Check the wiring of the
supply module
Compare SCR_tSMT with SCR_tSMHtrT. Do the two display
different values or is the temperature of the urea tank (SCR_
tAdapUTnkT) cold?
Replace the urea pump unit
Fault on the supply module temperature sensor
Fault on the supply module heating
Fault on the supply module heating
Check if the ambient temperature EnvT_t is < the limit.
Compare SCR_tSMT with SCR_tSMHtrT
Check the wiring of the supply module reheating module
Replace the urea pump unit
Fault on the supply module reheating temperature sensor
Fault on the supply module
1586 524067
1
894
DEF supply module, reheating temperature
above the normal upper limit
1593
1761
0
129
DEF tank, DEF level above the normal high limit Check the level sensor and the gauge float
1594
1761
1
129
DEF tank, DEF level below the normal low limit
Check the level sensor and the gauge float
Error on pressure sensor upstream of the SCRCAT
Check the electrical connector: 4h pin open? Has a new type of
connector been used?
It is possible that there has been a pressure exchange between the
inside of the electrical connector and its outside environment.
Is there water in the sensor?
Is the sensor frozen?
Check the wiring of the pressure sensor upstream of the SCR
catalytic converter
Change the pressure sensor upstream of the SCR catalytic
converter
Check the pressure sensor inlet (Air_pCACDs)
Check the ambient pressure sensor (EnvP_p)
1598 524065
1639 524147
2
13
892
966
Check that the assumption that the circuits, the pump or the tank
are frozen can be discounted.
Check that there is urea in the urea tank.
Check the urea circuits:
Are all the circuits connected? Have the circuits been connected
correctly?
Is the suction circuit blocked?
Are there any leaks? Not just a urea leak to the outside but also an
air leak in the circuits, especially in the suction circuit
Apply the standard pressure test process:
Is the urea pump working? => check the wiring harness and the
PWM signal of the pump
Does the urea pressure increase?
SCR system, generation of pressure towards the Has the DFC already been checked and repaired?
If none of this has given results at this stage:
top is not possible
Check the urea pressure sensor: at ignition and for SCR system
status = 0 (Init check), SCR_pAbsAdapUPmpP should be the same
as EnvP_p. If this is not achieved, then the sensor is working!
Check the reversible valve => see DFC_SCRCoRevVlvBlk
Check the pump’s filter; is there dirt inside?
Suspect components:
Urea pump faulty (broken)
Reversible valve permanently open
Urea suction circuit; return circuit broken, or bad connection
(inversion)
Fault on PWM power stage
Pump pressure valve faulty (broken)
1646 524063
12
869
1647 524063
12
8-6-9 DEF tank, defrost time too long
(31/08/2016)
DEF supply module, defrost time too long
Check:
the environment temperature sensor
the temperature sensor of the SCR supply module
electrical heating of the SCR supply module
Check the wiring and the components.
80-08-M218EN
80
KWP
code
24
ELECTRICAL TROUBLESHOOTING
Engine ECU
80
KWP
code
SPN
FMI
fault
code
PROBLEMS
ACTION
Check the urea level => if it is empty, top up with urea
Check the DEF level sensor.
If there is urea in the tank, move the level sensor float; this must
move freely. When the body of the sensor is lifted up, then
SCRUTnk_rVol_mp must change.
Change the DEF level sensor if the value does not change or if it is
not realistic.
Check the urea level => if it is empty, top up with urea
Check the DEF level sensor.
If there is urea in the tank, move the level sensor float; this must
move freely. When the body of the sensor is lifted up, then
SCRUTnk_rVol_mp must change.
Change the DEF level sensor if the value does not change or if it is
not realistic.
Check the wiring and the components.
The error detection limit is a limit within the ECU.
Check CANBUS EAT Control Receive Message, PGN65348.
CM1 Module Customer Receive Message.
Check the wiring of the CAN Bus (programming of the Bus, polarity,
short circuits, power supply interruptions), test the reception
protocol, check the CAN functional range.
Check the wiring of the CAN Bus (programming of the Bus, polarity,
short circuits, power supply interruptions), test the reception
protocol, check the CAN functional range.
Check the wiring of the CAN Bus (programming of the Bus, polarity,
short circuits, power supply interruptions), test the reception
protocol, check the CAN functional range.
Replace the wheel speed sensor
The error detection limit is a limit within the ECU.
Check the EGR actuator and check that the EGR is not mechanically
blocked and is clean.
Check that the valve moves freely. If this is blocked, change the
EGR valve.
The error detection limit is a limit within the ECU.
Check the other components of the CAN bus. If no message is sent,
repair the wiring.
If it is OK, change the EGR actuator.
The error detection limit is a limit within the ECU.
Start Serdia Usecase to reset the EGR actuator.
Check the EGR valve and the assembly position. If it is OK, change
the EGR actuator.
The error detection limit is a limit within the ECU.
Replace the EGR actuator.
The error detection limit is a limit within the ECU.
Start Serdia Use case to reset the EGR actuator.
Check the battery voltage. Check if the EGR is blocked or if it would
not turn silently.
If everything is OK, change the EGR actuator.
1655
1761
14
138
DEF tank, DEF level below the first alarm limit
1656
1761
14
138
DEF tank, DEF level below the second alarm
limit
1666 524100
9
924
Time exceeded error on CAN-message.
1676 524104
9
928
Time exceeded error on CAN-message.
1683 524121
9
9-4-5 Time exceeded error on CAN-message
1687 524125
9
9-4-9 Time exceeded error on CAN-message
1705 524156
9
972
Time exceeded error on CAN-message.
1752
2791
7
415
EGR actuator, actuator blocked
1753
2791
2
415
EGR actuator, CAN error
1754
2791
13
415
EGR actuator, EOL calibration error
1755
2791
12
415
EGR actuator, internal electrical fault
1756
2791
13
415
EGR actuator fault
1757
2791
6
415
Current on the EGR actuator beyond the
maximum limit
1758
2791
3
415
1759
2791
4
415
1760
2791
13
415
1761
2791
7
415
EGR actuator, broken spring detected
1762
2791
16
415
EGR actuator, temperature too high.
Leave the EGR actuator to cool and check how much heat builds
up during the worst-case scenarios.
1763
2791
0
415
EGR actuator, temperature high and becoming
critical
Leave the EGR actuator to cool and check how much heat builds
up during the worst-case scenarios.
80-08-M218EN
Power voltage of the EGR actuator beyond the
maximum limit value
Power voltage of the EGR actuator below its
minimum limit value
EGR actuator, learning process outside
authorized range
Check the voltage of the battery.
Check the voltage of the battery.
The error detection limit is a limit within the ECU.
Start Serdia Usecase to reset the EGR actuator.
The error detection limit is a limit within the ECU.
Replace the EGR actuator.
(31/08/2016)
ELECTRICAL TROUBLESHOOTING
25
Engine ECU
KWP
code
SPN
1827 524141
1857 523612
1858 524147
FMI
7
12
7
fault
code
PROBLEMS
ACTION
Check the electrical connections on the urea injector:
- wiring harness
- connector
Perform the injection test with SERDIA Use case. If this shows a
fault:
- remove the urea injector from the exhaust circuit:
- check if there has been any direct crystallization on the nozzle
and on the injector plate
- rinse it thoroughly with water
- put the urea injector back in place, then perform the injection test
with SERDIA use-case
If the error persists, change the urea injector.
192
DEF dosing valve, dosing valve blocked
555
The error detection limit is a limit within the ECU.
Check if there are other errors that are still active, and repair them
Engine starter, consistency error for the starting Check all of the starting conditions required on the engine, for
conditions
example neutral switch
Check the engine speed during starting. If it is too slow, check the
battery voltage, then check if there is no starter malfunction.
966
SCR system, reversible valve blocked
Perform the SERDIA Use-case injection test task to check that the
urea injector is working correctly.
Perform the SERDIA Use-case pressure test task to check that the
circuits are filled with urea and that the supply module is working
properly.
Perform the SERDIA unladen operation test task. The urea pump
pressure SCR_pAbsAdapUPmpP must fall below the urea pump
pressure before the reversible valve is opened.
Observe SCR_pAbsAdapUPmpP & SCR_stURevVlv (0 = closed, 1 =
open) & SCR_rDycUdosVlv
The error is corrected each time, after the empty status (64) of the
SCR system has finished correctly => with a debounce time of 30 s.
1859 524175
(31/08/2016)
0
993
SCR-CAT, Nox emissions higher than the
maximum limit permitted
- Check the DEF level in the tank; this should be higher than 12%.
- Check the quality of the DEF ComRxSCR_rAdBlu, which should be
greater than 32.5%. If it is below 24, the tank contains diluted urea
or even water => change the tank liquid with DEF of the correct
quality
- Check the DEF supply module: perform a pressure test => Replace
the supply module
- Check DEF dosing valve => test the injector => clean the injector
with water => Redo the injector test => Replacer the injector
- Check the NOx sensor downstream of the SCR catalytic converter:
check the wiring and the sensor itself. With the engine and the
EAT system hot (SCRT_tCatAvrgExhGs > 250 °C) and at established
speed, check the values measured on the Nox sensor: on
ComRxSCR_stNOxRdyUs & ComRxSCR_stNOxRdyDs, ComRxSCR_
rNOxUs must be > ComRxSCR_rNOxDs. ComRxSCR_rNOxDs must
be < 100 ppm for operation at established speed => change the
NOx sensor downstream of the SCR catalytic converter
- Check the engine’s air circuits: dp sensor venturi, EGR coolant
circuit, EGR valve, gas inlet, leaks and correct operation of the turbo
and the circuits. Are the EGR circuits blocked?
- Check the engine speed sensors: are the sensors on the camshaft
and the crankshaft faulty?
- Check the injection system: is the calculation of the engine torque
correct?
Change the SCR catalytic converter
Change the DOC
80-08-M218EN
80
If the error persists, change the supply module.
26
ELECTRICAL TROUBLESHOOTING
Engine ECU
KWP
code
SPN
1863 524177
FMI
7
fault
code
995
PROBLEMS
SCR system, DEF suction circuit clogged or
blocked
ACTION
Check that the DEF circuits, the pump and the tank have not
frozen.
Check the DEF level in the tank.
Check the DEF circuits:
Are all of the DEF circuits connected?
Is the suction circuit blocked?
Are there any leaks? Not just urea to the outside, but also air leaks
into the circuits, especially the suction circuit!
Perform the pressure test with SERDIA usecase:
Is the DEF pump working? => check the wiring harness and the
PWM signal for the pump.
Does the urea pressure increase?
Have all of the errors already been dealt with?
If nothing has got to the bottom of the problem at this stage:
Check the urea pressure sensor: upon ignition and for the SCR
system status = 0 (Init check), SCR_pAbsAdapUPmpP must be the
same as EnvP_p. Then the sensor is good!
Check the DEF pump filter: is there any dirt inside?
Suspect components:
suction line
Problem with PWM Powerstage with a default value that does not
result in an increase in pressure
Fault on the DEF pump pressure sensor
The DEF pump filter has dirt in it
7
996
80
1864 524178
Check that the DEF circuits, the pump and the tank have not
frozen.
Check the DEF level in the tank.
Check the DEF circuits:
Are all of the DEF circuits connected?
Is the suction circuit blocked?
Are there any leaks? Not just urea to the outside, but also air leaks
into the circuits, especially the suction circuit!
Perform the pressure test with SERDIA usecase:
Is the DEF pump working? => check the wiring harness and the
PWM signal for the pump.
Does the urea pressure increase?
Have all of the errors already been dealt with?
SCR system, DEF pressure outside of limit values If nothing has got to the bottom of the problem at this stage:
Check the urea pressure sensor: upon ignition and for the SCR
system status = 0 (Init check), SCR_pAbsAdapUPmpP must be the
same as EnvP_p. Then the sensor is good!
- Check the reversible valve
- Check the DEF pump filter: is there any dirt inside?
Suspect components:
Broken DEF pump
Reversible valve permanently open
DEF suction circuit, return circuit broken or inversion of circuit
connections
PWM Powerstage fault
broken DEF pump sensor
1865
4360
80-08-M218EN
2
668
Exhaust temperature sensor error upstream of
the SCR,
Check if the temperature sensor upstream of the SCR catalytic
converter is physically fitted in the exhaust circuit
If the cold start conditions can be guaranteed (= engine stopped
for at least 8 hours), compare the values EnvT_t, EngDa_tEng,
Exh_TOxiCatUs, Exh_tOxiCatDs and SCR_tSensUCatUsT at ignition,
without starting the engine; are they all identical?
Compare the values Exh_TOxiCatUs, Exh_tOxiCatDs and SCR_
tSensUCatUsT after 15 min of operation at constant speed (fixed
point): do they show similar values? (with a tolerance of 30K). Are
the ambient temperature (EnvT_t) and cooling water temperature
(EngDa_tEng) plausible?
Is the sensor blocked with urea crystals? Remove the urea injector
and visually inspect the temperature sensor upstream of the SCR
catalytic converter
Check the sensor wiring
Then put the sensor back in place
(31/08/2016)
ELECTRICAL TROUBLESHOOTING
27
Engine ECU
1866
SPN
4334
1867 524067
FMI
2
2
fault
code
665
894
PROBLEMS
ACTION
DEF supply module pressure error
Check the environment pressure sensor (EnvP_p) => is the value
plausible?
Can you stop the engine, then restart it right away? => Then shut
down again. Wait until the ECU afterrun has finished, then restart
the engine
Is the return circuit free of blocked? Does the urea pump pressure
display values < 1,000 hPa in the SCR emptying state (64)?
Check the revision valve => Does the pressure on the urea pump
show values < 1,000 hPa in the SCR emptying state (64)? =>
change the supply module
Fault on the supply module pressure sensor => change the supply
module
DEF supply module temperature error
Compare SCR_tSMT with SCR_tSMHtrT, EnvT_t and CEngTds_t and
SCR_tAdapUTnkT => Are they all the same? If not:
Has the machine been transported from a cold environment to a
hot one or vice versa without running the engine, for example in
the workshop?
Fault on the environment temperature sensor
Fault on the coolant temperature sensor
Fault on the supply module temperature sensor
Problem with the supply module (broken?) => replace the supply
module
1868 524067
2
894
DEF supply module temperature error
Compare SCR_tSMT with SCR_tSMHtrT, EnvT_t and CEngTds_t and
SCR_tAdapUTnkT => Are they all the same? If not:
Has the machine been transported from a cold environment to a
hot one or vice versa without running the engine, for example in
the workshop?
Fault on the environment temperature sensor
Fault on the coolant temperature sensor
Fault on the supply module temperature sensor
Problem with the supply module (broken?) => replace the supply
module
1874 524152
2
971
Urea quality sensor; message on the CAN
Check the electrical connections on the urea quality sensor
Check the engine CAN bus
Check the urea quality sensor itself
change the urea quality sensor
997
Level and temperature of the urea tank on the
CAN bus, time exceeded message on the CAN
Check the electrical connections of the equipment suction sensor
(level and temperature sensor built into the tank)
Check the engine CAN bus
Check the level sensor itself
Change the suction unit
138
DEF tank, DEF level below the third alarm limit
value
Check DEF level => if it is empty, refill it
Check the DEF level sensor
If there is urea in the tank, detach the sensor, and move it. The float
must move freely if the body of the sensor is lifted up.
The value of SCRUTnk_rVol_mp must change
Compare SCRUTnk_rVol_mp with:
1 = SCR_rawUTnkLvl
2 = SCR_rAdapUtnkLvl
3 = SCRUTnk_rActTnkVol *SCRUTnk_facVolPer_mp
In the event of malfunction, replace the DEF level sensor.
683
Check that all of the exhaust gas temperature sensors in the EAT
system are fitted correctly: on the exhaust circuits, and in the right
place,
Check the position of the sensor upstream of the SCR, which could
have been fitted in the wrong position.
If the cold start conditions can be guaranteed (= engine stopped
Exhaust gas temperature sensor error upstream for at least 8 hours), compare the values EnvT_t, EngDa_tEng,
and downstream of the DOC
Exh_TOxiCatUs, Exh_tOxiCatDs and SCR_tSensUCatUsT at ignition,
without starting the engine. Are all of these values identical? Then
the sensor itself is good.
Check for leaks from the exhaust pipes.
Check the sensor wiring.
Replace the sensors
Check the DOC => is it still physically intact?
1875 524153
1880
1881
1761
4768
(31/08/2016)
2
14
2
80-08-M218EN
80
KWP
code
28
ELECTRICAL TROUBLESHOOTING
Engine ECU
KWP
code
SPN
1891 524190
1892 524191
14
14
8
1894 524194
80-08-M218EN
8
PROBLEMS
ACTION
Limitation level 1 active
Check the DEF level in the tank. If there is no DEF, top up to the
upper limit level.
Check the quality of the DEF in the tank. If it is filled with an
unsuitable liquid, refill the tank with the right DEF.
Check if there are any other errors that could originate from
hardware malfunction.
Limitation level 2 active
The error detection limit is a limit within the ECU.
Check the DEF level in the tank. If there is none left, top up to the
level above the security level limit.
Check the quality of the DEF in the tank.
Check if there are any other falsification or fault hardware errors
275
The stop time in regeneration mode exceeds
the long limit threshold. Vehicle was in stop
mode for too long or too often.
Change the oil and reset the counter.
Study the standstill mode statistics => see maintenance manual:
Standstill operation or operation often interrupted by the driver/
with engine stoppage? => Put the engine in standstill and instruct
the operator
Standstill operation often required due to the soot load => Check
the DPF differential pressure sensor
Standstill operation does not manage to reach the desired
temperature level:
Check the engine's air circuits: are the gas inlet, EGR valve and
turbo OK?
Are there any leaks in the engine’s air intake or exhaust circuits?
Check the temperature sensors in the exhausts: upstream and
downstream of the DOC
If the DPF soot load level allows:
Put the engine in established speed and check the temperature
reached upstream and downstream of the DOC: T upstream of the
DOC in the region of 480-550 °C? Downstream of the DOC, after 25
minutes at established speed, is the main 590 °C cycle achieved?
Are the temperature traces stable and regular?
Is the temperature downstream of the DOC higher than that
upstream of the DOC, but with a difference that does not exceed
100K?
Very little difference (< 10K after 25 min at established speed of
the main phase, 590 °C downstream of the DOC not reached) =>
change the DOC
A lot of difference (>100K, after 25 min at established speed of the
main phase 590 °C downstream of the DOC exceeded?) => check
the engine's injection device and its air circuits
276
Study the standstill mode statistics => see maintenance manual:
Standstill operation or operation often interrupted by the driver/
with engine stoppage? => Put the engine in standstill and instruct
the operator
Standstill operation often required due to the soot load => Check
the DPF differential pressure sensor
Standstill operation does not manage to reach the desired
temperature level:
Check the engine's air circuits: are the gas inlet, EGR valve and
turbo OK?
Are there any leaks in the engine’s air intake or exhaust circuits?
Check the temperature sensors in the exhausts: upstream and
The stop time in regeneration mode exceeds
downstream of the DOC
the short limit. Vehicle was in a short time lapse If the DPF soot load level allows:
in stop mode for too long or too often.
Put the engine in established speed and check the temperature
Change the oil and reset the counter.
reached upstream and downstream of the DOC: T upstream of the
DOC in the region of 480-550 °C? Downstream of the DOC, after 25
minutes at established speed, is the main 590 °C cycle achieved?
Are the temperature traces stable and regular?
Is the temperature downstream of the DOC higher than that
upstream of the DOC, but with a difference that does not exceed
100K?
Very little difference (< 10K after 25 min at established speed of
the main phase, 590 °C downstream of the DOC not reached) =>
change the DOC
A lot of difference (>100K, after 25 min at established speed of the
main phase 590 °C downstream of the DOC exceeded?) => check
the engine's injection device and its air circuits
272
273
80
1893 524193
FMI
fault
code
(31/08/2016)
ELECTRICAL TROUBLESHOOTING
29
Engine ECU
KWP
code
1895
1896
SPN
3519
3520
FMI
12
3
fault
code
PROBLEMS
ACTION
Check if the temperature sensor signal is plausible. If the signal is
inconsistent, replace the tank suction unit.
Check if the signal is consistent for CAN bus communications. If the
signal is inconsistent, replace the tank suction unit.
Check operation of the heating valve and the correct layout of the
pipes. The coolant flow passing through the reheating valve must
be observed in the direction of the arrow.
Of all of the actions above are OK, check the actual temperature in
the DEF tank during the most severe operating cycles, and improve
installation of the DEF tank.
277
DEF tank temperature too high
278
"The error detection limit is a limit within the ECU.
DEF quality sensor; battery short circuit or circuit Check the ECU wiring harnesses up to the DEF tank suction unit
open
Check the communications on the CAN bus. If the signal is
degraded, replace the suction unit."
"The error detection limit is a limit within the ECU.
Check the ECU wiring harnesses up to the DEF tank suction unit
Check the communications on the CAN bus. If the signal is
degraded, replace the suction unit."
1897
3520
4
278
DEF quality sensor; ground short circuit
1898
3519
3
277
Check the ECU wiring harnesses up to the DEF tank suction unit
DEF quality sensor, internal temperature sensor
Check the communications on the CAN bus. If the signal is
short circuit on battery or circuit open
degraded, replace the suction unit.
1899
3519
4
277
Check the ECU wiring harnesses up to the DEF tank suction unit
DEF quality sensor, internal temperature sensor
Check the communications on the CAN bus. If the signal is
short circuit on ground
degraded, replace the DEF tank suction unit.
1900 524195
14
279
Stoppage request caused by crystallization
being ignored for too long
If crystallization is clearly visible, then regeneration in standstill
mode must be performed.
Has the engine been operated at low load for long periods? If so,
this could be the cause of the crystallization.
Are the NOx sensors working properly? Compare ComRxSCR_
rNOxUs to ComRxSCR_rNOxDs with ComRxSCR_stNOxRdyUs =
1 & ComRxSCR_stNOxRdyDs = 1 engine warm and EAT system,
SCRT_tCatAvrgExhGs_mp > 250 °C, SCR_stStatus = ""Dosing"" = 8):
the NOx level measured upstream of the SCR catalytic converter
must be higher than downstream of the SCR.
Run the engine unladen and wait until the SCR system reaches
""stand-by"" status (no dosing), SCRT_tCatAvrgExhGs_mp < 225 °C:
ComRxSCR_rNOxUs = ComRxSCR_rNOxDs
Clean the urea injector: rinse it thoroughly with water
Check the EGR circuits: differential pressure sensor on the venturi
tube, correct operation and leaks on the EGR coolant, EGR valve,
gas inlet. Are there any EGR coolant water leaks from the exhaust?
Check the leaks from the air circuits.
Check the turbo
If no crystallization is visible in the mixing circuit:
Check the exhaust pressure sensor upstream of the SCR catalytic
converter of SCR (SCR_pSensUCatUsP): tube, water in the sensor?
Check the environment pressure sensor (EnvP_p): is the value
plausible?
Check the exhaust temperature sensor upstream of the SCR
catalytic converter (SCR_tSensUCatUsT): is the value plausible,
compared with Exh_tOxiCatUs & Exh_tOxiCatDs, for example when
the engine is running unladen for 20 minutes?
=> Run the engine at established speed to get rid of the
crystallization and reset the DFC
(31/08/2016)
80-08-M218EN
80
Remove the urea injector from the exhaust circuit and visually
inspect the injector and the exhaust circuit to see if there has been
any urea crystallization upstream of the SCR catalytic converter:
30
ELECTRICAL TROUBLESHOOTING
Engine ECU
80
KWP
code
SPN
FMI
fault
code
PROBLEMS
ACTION
1904
3520
2
First check that the tank contains urea of known quality
Check the urea level in the tank: add urea until the level reaches at
least 10 cm above the sensor.
Check that the urea is not frozen and that enough urea is in liquid
form
Check the sensor: are the temperature and the level of the urea
tank displayed? Change/redo the levels if you refill with urea.
Check the electrical connections
DE quality sensor, poor DEF quality detected or
Check the CAN bus
2-7-8
DEF measurement impossible.
A new quality control will be done if topping up of the urea has
been detected or if a quality evaluation was triggered with no
conclusion: to launch a quality measurement: top up with urea up
to at least 10% of the volume of the tank.
Wait until the quality evaluation has been launched, which can
take up to 30 minutes => then check the value. This should be
around 33%
Change the quality sensor
1907
3520
13
278
Urea quality not valid on UQS
Check the quality of the DEF and/or that of the DEF quality sensor
1908
3519
13
277
Temperature value not valid on UQS
Check the temperature of the system and/or the DEF quality sensor
1911
3532
3
127
DEF level on UQS outside the maximum range
Check the quality of the DEF and/or that of the DEF quality sensor.
1912
3532
4
127
Quality on UQS outside the minimum range
Check the quality of the DEF and/or that of the DEF quality sensor.
1914
4365
3
669
DEF quality sensor, tank temperature; battery
short circuit or circuit open
Check the wiring harness and the DEF quality sensor
1915
4365
4
6-6-9
DEF quality sensor; tank temperature; ground
short circuit
Check the wiring harness and the DEF quality sensor
1917
3936
14
2-8-6 Stop request ignored for too long.
1918
3936
14
2-8-6
1921
51
5
5-9-4
1922
51
6
1924
1925
51
51
3
3
Open circuit on the electrical harness of the
throttle valve
Threshold exceeded on the throttle valve
5-9-4
control current
5-9-4 Battery short circuit of the throttle valve (A02)
5-9-4 Battery short circuit of the throttle valve (A67)
1926
51
4
5-9-4 Ground short circuit of the throttle valve (A02)
1927
51
4
5-9-4 Ground short circuit of the throttle valve (A67)
1931
51
7
1935
51
3
1936
51
4
Position of the throttle valve outside plausible
5-9-4 range (deviation greater than 7% compared to
the setpoint value)
Battery short circuit or open circuit of the
5-9-4
throttle valve
5-9-4 Ground short circuit of the throttle valve
1939 524198
11
3-1-3
Reduction in power caused by post-treatment
system component failure (master ECU)
1940 524199
11
3-1-3
Reduction in power caused by attempted
falsification on the SCR system (master ECU)
1941 524200
11
3-1-3
1942 524201
11
Reduction in power caused by too small a
quantity of DEF (master ECU)
3-1-3 DEF level error (master ECU)
1943 524202
11
3-1-3 DEF temperature error (master ECU)
1944 524203
11
3-1-3 DEF level error (master ECU)
Power reduction following too long without
having launched the required regeneration
1945 524204
11
3-1-3 DEF system bleed error (master ECU)
1946 524205
11
3-1-3 SCR system shutdown (master ECU)
1947 524206
11
3-1-3 DEF injection deactivation (master ECU)
80-08-M218EN
Put the engine in stop mode. If the DPF soot load level is too high,
call the maintenance team to put the engine in stop mode.
If the DPF soot load level is too high, remove the DPF => replace
the DPF.
(31/08/2016)
ELECTRICAL TROUBLESHOOTING
31
Engine ECU
KWP
code
SPN
FMI
fault
code
1948 524207
11
3-1-3 Regeneration inhibition (master ECU)
1949 524208
11
3-1-3 Power reduction level 1 (master ECU)
1950 524209
11
3-1-3 Power reduction level 2 (master ECU)
1951 524210
11
3-1-3 DEF concentration fault (master ECU)
PROBLEMS
1952 524211
11
3-1-3 DEF quality error (master ECU)
1953 524212
11
3-1-3 DEF quality sensor error (master ECU)
1954 524213
11
3-1-3 DEF temperature sensor error (master ECU)
1971 524230
11
3-1-5
Reduction in power caused by post-treatment
system component failure (slave ECU)
1972 524231
11
3-1-5
Reduction in power caused by attempted
falsification on the SCR system (slave ECU)
1973 524232
11
3-1-5
1974 524233
1975 524234
1976 524235
11
11
11
Power reduction following poor DEF quality
(slave ECU)
3-1-5 DEF level error (slave ECU)
3-1-5 DEF temperature error (slave ECU)
3-1-5 DEF level error (slave ECU)
1977 524236
11
3-1-5 SCR system bleed error (slave ECU)
1978 524237
11
3-1-5 SCR system stop error (slave ECU)
11
3-1-5 DEF injection deactivation (slave ECU)
11
3-1-5 Regeneration inhibition (slave ECU)
1981 524240
11
3-1-5 Power reduction level 1 (slave ECU)
1982 524241
11
3-1-5 Power reduction level 2 (slave ECU)
1983 524242
11
3-1-5 DEF concentration error (slave ECU)
1984 524243
11
3-1-5 DEF quality error (slave ECU)
1985 524244
11
3-1-5 DEF quality sensor error (slave ECU)
1986 524245
11
3-1-5 DEF temperature sensor error (slave ECU)
80
1979 524238
1980 524239
ACTION
(31/08/2016)
80-08-M218EN
32
ELECTRICAL TROUBLESHOOTING
HYDRAULIC PUMP ERROR CODES LIST
COMPONENT
Internal memory fault
Battery voltage
CAN bus fault
Pump electrovalve outlet
ECU configuration
Pump electrovalve outlet
PROBLEM
Circuit fault
Circuit fault
Circuit fault
Circuit fault
Configuration error
Power supply circuit fault
LONGITUDINAL STABILITY INDICATOR (LLMI) ERROR CODE LIST
i Chapter 80: "ELECTRICAL CONTROL AND ADJUSTMENT"
GEAR BOX ERROR CODE LIST
80
i Chapter 20 : "TRANSMISSION TROUBLESHOOTING"
80-08-M218EN
(31/08/2016)
ELECTRICAL SPECIFIC TOOLING
pages
SOLUTION 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– DIAGNOSTIC CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– DIAGNOSTIC CASE: ENGINE ST3B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– CONNECTION TO TRUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SOLUTION 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
–– DIAGNOSTIC CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
–– CONNECTION TO TRUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
BREAKOUT BOX KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
80
ELECTROVALVE ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
(18/02/2016)
80-09-M218EN
2
ELECTRICAL SPECIFIC TOOLING
SOLUTION 1
80
DIAGNOSTIC CASE
1 - PAD (ensemble PC durcis + valise) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plus fournis
2 - Stylets (lot de 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745368
3 - VCI (Interface Communication Véhicule / PAD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745439
4 - Câble Diag OBD Manitou . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745245
5 - Câble portable VCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745244
6 - Câble Diag RC2 / RC4 Manitou . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745246
7 - Batterie LI-ION 7,4V / 9,6AH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745367
8 - Cordon secteur norme CE L : 3m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745247
9 - Bloc Alimentation Diag 3G 60W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745251
10 - Câble alimentation prise allume cigare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745240
11 - Câble pince batterie noir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745242
12 - Câble pince batterie rouge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745241
13 - Câble alimentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745243
14 - Station d’accueil (charge batterie) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745236
15 - Desserte d’atelier (ensemble desserte + station) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745235
80-09-M218EN
(18/02/2016)
ELECTRICAL SPECIFIC TOOLING
3
DIAGNOSTIC CASE: ENGINE ST3B
2
1
3
Engine box fitness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .894942
Consisting of:
1 - Communication box EDL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 894937
2 - Electric Cable OBD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 894940
3 - Electric Cable USB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 894938
CONNECTION TO TRUCK
CASE 1
PAD
VCI
CÂBLE DIAG OBD
80
REF . 745245
Note: The cable Ref. 745245 can diagnose the entire machine except the engine.
CASE 2
PAD
CÂBLE USB
USB
REF . 894938
REF . 894937
EDL
CÂBLE DIAG OBD
REF . 894940
Note: The case Ref. 894 942 is used to diagnose the engine.
(18/02/2016)
80-09-M218EN
4
ELECTRICAL SPECIFIC TOOLING
SOLUTION 2
80
DIAGNOSTIC CASE
Diagnostic case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .947349
Diagnostic case (Specific for Russia) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .947350
Consisting of:
1 - Tablet (with accessories and cables). . . . . . . . . . . . .895845 / 947351 (Specific for Russia)
2 - Digitizer Touch Pen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947208
3 - Tether . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947355
4 - VCI (Vehicle Communication Interface / PAD) (with cable USB et OBD) . . . . . . . 895986
5 - OBD diag cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947201
6 - USB/Ethernet cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947202
7 - Battery (6 cellules : 8h) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947206
8 - AC Adaptor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947353
9 - Case (not shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947345
Sold separately :
10 - Docking station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947354
11 - Legacy diag cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947204
12 - Battery (9 cellules : 17h) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947207
80-09-M218EN
(18/02/2016)
ELECTRICAL SPECIFIC TOOLING
5
CONNECTION TO TRUCK
CASE 1
PAD
VCI
CÂBLE DIAG OBD
RÉF . 947201
80
Note: The cable Ref. 947201 can diagnose the entire machine.
(18/02/2016)
80-09-M218EN
6
ELECTRICAL SPECIFIC TOOLING
BREAKOUT BOX KIT
Breakout box kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 785503
Consisting of:
80
1 - 1 breakout box (DT connectors) ..........................................................................................785504
2 - 1 breakout box (DTM connectors) ......................................................................................785505
ELECTROVALVE ADAPTER
1 - Solenoid adapter.......................................................................................................................662196
80-09-M218EN
(18/02/2016)
OPTIONS - ATTACHMENTS
pages
MACHINE OPTION CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1
FORCED OPERATION OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1
CRC OPTION: TELESCOPE SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C1
E.C.S. OPTION (EASY CONNECTING SYSTEM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D1
MANUAL ACCELERATOR OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E1
110
AIR-CONDITIONING OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F1
MACHINE OPTION CONFIGURATION
SOFTWARE INSTALLATION FOR ADDING OPTIONS
Fitting the options below requires extra installations via the diagnostic PAD tool.
bb
You must have a VPN connection via the RJ45 network port and a BLUE smart card.
i Technical specifications: 1920)
(
–– FORCED OPERATION OPTION
–– ECS (EASY CONNECTING SYSTEM) ATTACHMENT LINE DEPRESSURIZATION OPTION
–– TELESCOPE HEAD ELECTROVALVE OPTION
110
–– ATTACHMENT LINE LOCKING
(13/11/2013)
110-M218A-EN
MACHINE CONFIGURATION
110
A2
110-M218A-EN
(13/11/2013)
FORCED OPERATION OPTION
pages
FORCED OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3
–– CONTINUOUS HYDRAULIC MOVEMENT OF THE ATTACHMENT . . . . . . . . . . . . . . . . . . . . B3
FORCED OPERATION SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4
110
–– ELECTRIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4
(13/11/2013)
110-M218B-EN
B2
FORCED OPERATION OPTION
2
1
X113
X112
1 - Safety hydraulic movement
2 - Potentiometer
Item
X112
Item
Wire N°
Colour
Section
(mm2)
To
1
460
BLACK
0,6
EP28
2
461
GREY
0,6
X56/22
3
463
GREY
0,6
X57/33
4
462
BLACK
0,6
EP28
Pos
Wire N°
Colour
Section
(mm2)
To
1
457
GREY
0,6
EP29
2
459
BLACK
0,6
EP28
3
458
GREY
0,6
X57/13
4
3
1
2
3
2
1
110
X113
Pos
110-M218B-EN
(13/11/2013)
FORCED OPERATION OPTION
B3
FORCED OPERATION
bb
his OPTION must only be used with an attachment requiring continuous hydraulic movement,
T
such as brush, supply bucket, mixer, spray… It is strictly forbidden in handling operations and
in all other cases (winch, crane boom, crane boom with winch, hook, etc.).
CONTINUOUS HYDRAULIC MOVEMENT OF THE ATTACHMENT
–– Check that potentiometer C is set to 0%.
–– Switch button A to the front or the back (depending on the
type of attachment), press button B and release button A. The
red indicator 1 flashes to indicate that it is in operation.
A
–– Set the required flow rate using potentiometer C.
–– To stop continuous hydraulic movement of the attachment,
move switch A forwards or backwards or press button B.
Indicator 1 goes out.
–– Set potentiometer C to 0%.
bb
ever leave the driver's cab without resetting potentiometer
N
C to 0%. Before starting the lift truck, make sure the
potentiometer is set to 0%.
B
C
NOTE: I f the operator leaves the driver's cab, the continuous
hydraulic movement will automatically stop and must be
restarted.
110
1
(13/11/2013)
110-M218B-EN
B4
FORCED OPERATION OPTION
FORCED OPERATION SCHEMATIC
ELECTRIC
3
EP28 459
X113
457
X44-13
EP29
21E 455
469
483
484
458
CN1-A / X56
A3
13
SPU
IN ANA 5
IN TOR
3
22
210
241
210
461
noir
noir 496
1
31
33
CN1-B / X57
AGND
noir 462
2
463
461
4
OUTPWM
10
3
457
2
noir 459
1
463
noir 460
X112
458
B21
S36
110
CN1-B / X57
110-M218B-EN
(13/11/2013)
CRC OPTION: TELESCOPE SUSPENSION
pages
OPERATING PRINCIPLES OF THE “CRC” KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C2
–– OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C2
TELESCOPE SUSPENSION VALVE (VASF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3
SCHEMATIC DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C6
–– HYDRAULIC SCHEMATIC DIAGRAMS FOR LSU TELEHANDLER . . . . . . . . . . . . . . . . . . . . . C6
–– ELECTRICAL SCHEMATIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C7
OPERATING LOGIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C8
CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C9
–– HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C9
–– ELECTRIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C10
COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C11
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C12
110
–– POSITION CONTACT SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C12
(13/11/2013)
110-M218C-EN
C2
CRC OPTION: TELESCOPE SUSPENSION
OPERATING PRINCIPLES OF THE “CRC” KIT
The telescope suspension dampens shaking of the lift truck on
rough ground (e.g. handling straw in a field).
A1
A
Applications are:
–– 70%: movements on road and in fields.
–– 30%: others, floating for mucking out animal housing, snow
clearing.
A2
Maximum effectiveness: 1500 kg (or 3 bigballers)
–– Driving comfort
–– Less stress on components
–– Optimised safety
OPERATION
–– Set the forks or attachment down on the ground and raise the front wheels by a few centimeters only.
–– Push switch A to position A1, the indicator lamp will come on indicating that telescope suspension
is enabled.
–– Push switch A to position A2, the indicator lamp will go out indicating that telescope suspension is
disabled.
bb
elescope suspension is enabled up to a lift height of 3 meters above ground level (measured to
T
the fork carriage pivot pin) with the boom retracted. When you operate beyond this height or
perform another hydraulic movement (tilting, telescoping, attachment), telescope suspension
is immediately disabled and the indicator lamp A goes out.
110
When the engine is off, telescope suspension is automatically deactivated.
110-M218C-EN
(13/11/2013)
CRC OPTION: TELESCOPE SUSPENSION
C3
110
TELESCOPE SUSPENSION VALVE (VASF)
(13/11/2013)
110-M218C-EN
C4
CRC OPTION: TELESCOPE SUSPENSION
Pilot pressure: 110 bar
Safety valve setting 320 bar 0/+15 bar
Operating pressure: 30 bar 0/+6 bar
Safety valve setting 32,5 bar
OPTION CRC
VL
1 2
C1
3
PRES
PX
C2
EV(S1)
30b
1.5 L
The purpose of the parachute valve is to avoid
a load being dropped should a break occur
in the connection between the valve and the
accumulator.
Electrovalves S1 and S2 should be excited when
the vehicle exceeds 3 kph in order to enable the
suspension function via the accumulator.
AC
EV(S2)
300b
110
T
110-M218C-EN
V1
V2
VASF (O)
PORTS
V1-V2 = M22x1,5
T = M16x1,5
ACC. = M18x1,5
PX = G1/4
C1-C2 = Ø 11,5
(13/11/2013)
CRC OPTION: TELESCOPE SUSPENSION
TELESCOPE SUSPENSION VALVE PRESSURE SWITCH
C5
B25
PIN
Function
1
Switch
2
Supply relay
X225
1
2
2
1
P
Corresponding connector
PIN
Diagram
Min.
Typical
Max.
Supply voltage
12 V
42 V
Consumption
6 mA
Comment:
- The Pressure switch contact opens at 7,5 ± 0,7 bar.
Notes: _____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
PRESSURE SWITCH
B12-B13-B14
PIN
Function
1
Power supply
2
Switch
X229
X230
X231
X233
X232
P
P
P
X234
Diagram
PIN
Min.
Typical
Max.
Supply voltage
12 V
42 V
Consumption
3,5 A
Notes: _____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(13/11/2013)
110-M218C-EN
110
Comment:
- The Pressure switch contact closes at a pressure of 3 ± 0,4 bar in the braking circuit.
C6
CRC OPTION: TELESCOPE SUSPENSION
SCHEMATIC DIAGRAMS
HYDRAULIC SCHEMATIC DIAGRAMS FOR LSU TELEHANDLER
OPTION CRC
VL
1 2
C1
3
PRES
X
PX
B
L L1 L2
EV(S1)
30b
1.5 L
P
M
63 cm3/tr
C2
AC
EV(S2)
S
300b
T
V1
V2
VASF (O)
C1
C2
CSP
70b
V1
V2
Key:
AC
- Accumulator
CSP
- Counterbalance valve
EL
- Lifting element
EV (S1) - Electrovalve (solenoid 1)
EV (S2) - Electrovalve (solenoid 2)
M
- Perkins diesel engine
P
- Equipment pump
PRES - Pressure switch
VASF - Telescope suspension valve (option)
VL
- Lifting cylinder
VRP
- Pressure distributor
b B5 A5
VRP
b
T
B
280 b
EL
110
a
110-M218C-EN
(13/11/2013)
CRC OPTION: TELESCOPE SUSPENSION
C7
ELECTRICAL SCHEMATIC DIAGRAM
1 0 2
1
7 2
X226
1
6
3
10
X233
X232
X230
X231
P
P
B12
X234
X225
P
B13
1
noir
SWF 525 212
+
SWF 586 373 S12
X229
2
P
B25
B14
9
8
noir
2
X222
S23
S24
V7
1
2
3
4
5
6
7
8
2
9
Y10
2
noir
X227 2
1
3
5
X228 2
1
3
5
86
30
86
30
85
87
85
87
K10
K11
Cab ground
Frame ground
X135
noir
Y11
1
noir
X223
noir
noir
X04
1
noir
X224
noir
V6
Key:
Reverse tilt/Telescope suspension mvts detection pressure switch
Lowering/Telescope suspension mvts detection pressure switch
Forward tilt/Telescope suspension mvts detection pressure switch
Telescope suspension cylinder valve pressure switch
Telescope suspension cut-off relay
Telescope suspension power supply relay
Telescope suspension switch
Telescope position sensor
Diode P600J 6A/600V- Telescope suspension harness
Diode P600J 6A/600V- Telescope suspension harness
Telescope suspension electovalve 1
Telescope suspension electovalve 2
(13/11/2013)
110
B12:
B13:
B14:
B25 :
K10 :
K11 :
S23 :
S24 :
V6 :
V7 :
Y10 :
Y11 :
110-M218C-EN
C8
CRC OPTION: TELESCOPE SUSPENSION
OPERATING LOGIC
Te l e s c o p e s u s p e n s i o n
schematic diagram
Engine running
no hydraulic
movements K10=1
Press switch S1 to switch
suspension on
Boom lowered
to ground S2=0
Boom raised S2=1
Telescope suspension not
switched on
Boom lowered to ground S2=0
Telescope suspension
activated
K11=1
EV (S1) EV (S2) power
supply + indicator lamp
Hydraulic movement: Lowering,
forward tilt, reverse tilt K10=0
(K11=1)
pivot pin height TS > 3m
from ground S10=0
EV (S1) EV (S2) cut-off +
indicator lamp
Hydraulic movement
stop
K10=1 (K11=1)
pivot pin height TS < 3m
from ground S10=1
(normal operation)
engine off
110
Press switch S1:
Suspension off
Power cut-off K10=0
K11=0
Telescope suspension
in stop position
110-M218C-EN
(13/11/2013)
CRC OPTION: TELESCOPE SUSPENSION
C9
CIRCUITS
HYDRAULIC CIRCUIT
EV(
S2)
VASF
Px
VT
EV(
S1)
Key:
AC:
Accumulator
P:
Pump
T:
Tank
VASF: Telescope suspension valve
VT:
Telescope cylinder
AC
P
L1
0
29
110
T
(13/11/2013)
110-M218C-EN
C10
CRC OPTION: TELESCOPE SUSPENSION
ELECTRIC CIRCUIT
X233
3
5
1
4
2
1
4
2
3
5
K0
3
5
3
5
X234
I
1
4
2
1
4
2
1
4
2
3
5
K1
K2
K3
K4
H
G
87a
85
86
87a
30
K6
86
85
30
F8
F9
F10 F11 F12
5A
15A
10A
F7
5A
7.5A
F13
F6
15A
F5
MA
F
86
K9
10A
F4
7.5A
1
4
2
F3
7.5A
F2
F14
F15
D
A
15A
15A
7.5A
15A
7.5A
7.5A
7.5A
10A
10A
10A
F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 F28 F29
25A
F30
10A
S23
K8
30
87
F1
87a
87a
K7
E
85
87
30A
K5
3
5
86
87
30
85
87
C
B
T
4
K10
K11
X227
X228
P
3
1
2
(F17)
X4-6
X222
1
5
5
3
3
3
5
7
2
4
1
2
3
4
5
6
7
8
9
6
8
1
4
2
1
4
2
9 10
X135
MLT1035
X232
S24
X231
m
bl
2
1
X230
X226
X229
MLT6-7
X223
S24
Y10
X224
X225
Y11 B25
Key:
110
B25:
MA:
S23:
S24:
Y10:
Y11:
110-M218C-EN
Telescope suspension cylinder valve pressure switch
Manipulator
Telescope suspension switch
Telescope position sensor
Telescope suspension electovalve 1
Telescope suspension electovalve 2
(13/11/2013)
CRC OPTION: TELESCOPE SUSPENSION
C11
COMPONENT LOCATION
1
K1
2
K1
0
K1
T
4
1
2
K1
1
2
0
K1
110
K1
P
3
(13/11/2013)
110-M218C-EN
CRC OPTION: TELESCOPE SUSPENSION
C12
ADJUSTMENTS
POSITION CONTACT SETTING
–– Position the boom as indicated (Fig. A). The
fork carriage pivot pin should be at least 3
meters off the ground.
3m
–– Adjust the position contact 1 (Fig. B) so that
it trips in this configuration.
–– To check the setting, press switch 4 (Fig. C).
The switch indicator light should come on. It
should go out when you position the boom
above the indicated height (Fig. A).
Fig. A
–– Adjust if necessary.
–– Refit the boom rear cover plate.
1
Fig. B
4
110
Fig. C
110-M218C-EN
(13/11/2013)
E.C.S. OPTION (EASY CONNECTING SYSTEM)
pages
ATTACHMENT LINE DEPRESSURIZATION (E.C.S OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2
–– OPERATING PRINCIPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2
SCHEMATIC DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3
110
–– ELECTRIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3
(13/11/2013)
110-M218D-EN
D2
E.C.S. OPTION (EASY CONNECTING
SYSTEM)
ATTACHMENT LINE DEPRESSURIZATION (E.C.S OPTION)
OPERATING PRINCIPLE
A
S14
A
S14
X116
X129
X116
MLT 1035
MLT 6-7
MLT 731
For easy connection and disconnection of hydraulic attachments.
- Press the push-button A for two seconds to release the pressure from the attachment circuit.
- Connect or disconnect the rapid connectors of the hydraulic attachment.
Item
Wire N°
Colour
Section
(mm2)
To
1
479
GREY
0,6
X56/10
75C
BLACK
0,6
X116/10
480
BLACK
0,6
X76B
9
277
GREY
0,6
X117/9
10
75C
BLACK
0,6
X116/5
5
8
2
7
1
110
X116
Pos
110-M218D-EN
(13/11/2013)
E.C.S OPTION
(EASY CONNECTING SYSTEM)
D3
SCHEMATIC DIAGRAMS
ELECTRIC
CN1-A / X56
IN TOR IN TOR
13
3
22
A3
SPU
479
23
A3: SPU module
ECS
277
278 35C X129-9
1
9
5
10
75C
noir
Cab ground
Frame ground
110
X76B 480 noir
SWF 525 010
+
SWF 586 373 S17
35B 279 noir
0
1
X116
X129-10
S14
479
S14: E C S s w i t c h ( A t t a c h m e n t l i n e
depressurization)
(13/11/2013)
110-M218D-EN
E.C.S. OPTION (EASY CONNECTING
SYSTEM)
110
D4
110-M218D-EN
(13/11/2013)
MANUAL ACCELERATOR OPTION
pages
LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OPERATING PRINCIPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
110
USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
(02/12/2014)
110-E-M218EN
2
MANUAL ACCELERATOR OPTION
LAYOUT
1
X286
A3
1
A2
GND ANA
2
192
+
3
193
X286
0
194
s
OUTPUT 5V
WIRING DIAGRAM
OPTION
R11
EP18 577
576
578
576
15
25
GND ANA
X68
194
Y47
0-5V DC input
The main ECU (A3) provides a stable 5V supply, the engine
indicator plate (A2) provides an analog ground. The
input, pin 15, of the rev-counter dial (P1) receives the
potentiometer setpoint (R11) and transmits it to the other
ECUs via the CAN bus.
6
X121
577
193
OPERATING PRINCIPLE
192
19
X56
P1
USE
bb
110
The engine speed regulator cannot under any circumstances be used while driving on the road.
Turn the button (Item 1) to increase or reduce the engine speed, and thus control the hydraulic flow
within the attachment circuit.
View the rev. counter to adjust the engine speed.
Return the engine to idle before switching off the lift truck's ignition.
110-E-M218EN
(02/12/2014)
AIR-CONDITIONING OPTION
pages
OPERATING PRINCIPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OPERATION DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DESCRIPTION OF COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
AIR CONDITIONING SYSTEM COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ASSEMBLY INSTRUCTIONS FOR AIR-CONDITIONING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . 6
SAFETY MEASURES FOR HANDLING R134A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REFRIGERANT FLUID LOAD FOR THE AIR-CONDITIONING CIRCUIT . . . . . . . . . . . . . . . . . . 6
CHARGING METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FUNCTIONAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ANTI-ICING SAFETY MONITORING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
110
AIR-CONDITIONING INSPECTION FORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
(03/12/2014)
110-F-M218EN
2
AIR-CONDITIONING OPTION
OPERATING PRINCIPLE
Electromagnetic
clutch
Alternator
Compressor
Engine
Low pressure
steam circuit
High pressure
steam circuit
External
air
Axial fan
Condenser
Hot air
discharge
Drier Filter
Binary pressure
switch
Warm air
Indicator lamp
Filters
High pressure
liquid circuit
Centrifugal fan
(Turbine)
Pressure reducing valve
Low pressure
liquid circuit
Evaporator
Thermostat
110
Condensate out
Diffusion of
cold air
CABINTERIOR
110-F-M218EN
(03/12/2014)
AIR-CONDITIONING OPTION
3
OPERATION DESCRIPTION
The air-conditioning system reduces the atmospheric pressure in the cab interior by extracting and
dispersing the heat to the exterior.
This heat exchange is possible thanks to the use of a refrigerant fluid, R134a whose properties are to
obtain very low temperature at low pressures by dilating it and inversely high temperatures at average
pressure by compressing it.
The use of the properties of this fluid is done following the closed circuit cycle whose principle is:
Phase 1: compression
The fluid in the gaseous state at low pressure and at low temperature is drawn in and compressed by
the compressor which sends it at high pressure and high temperature to the condenser.
Phase 2: condensation
The fluid passes through the condenser to transmit its heat to the outside of the vehicle, by means of
the fan.
As it passes through the condenser the fluid liquefies while maintaining a high temperature and pressure.
It is then filtered in a drier (or desiccator).
Phase 3: expansion
The fluid enters a pressure reducing valve (or expansion valve) so as to lower its pressure and temperature
considerably while remaining in liquid state.
Phase 4: evaporation
The fluid passes through the evaporator to absorb the cab interior heat and vaporises while maintaining
a low temperature and pressure.
In this way, the cab interior air propelled by the fan motor cools and releases its moisture when in
contact with the evaporator. The condensation of the air is then drained and evacuated to the outside
of the vehicle.
110
The high and low pressures in the system are monitored by a HP and LP pressure switch attached directly
on the drier filter.
It has the following safety functions:
⇒⇒ Complete shutdown of the air-conditioning system if the pressure is lower than 2 bars or greater
than 27 bars.
(03/12/2014)
110-F-M218EN
4
AIR-CONDITIONING OPTION
DESCRIPTION OF COMPONENTS
Compressor
The compressor circulates the fluid through the circuit, drawing it in as a low pressure and low
temperature gas from the evaporator and sending it to the condenser as a high pressure, high
temperature gas.
Condenser
The condenser is a thermal exchanger that transmits the heat recuperated from the evaporator
to the outside air by means of the fan and causes the condensation of the fluid at high pressure.
Drier filter
The filter is the main protective component in the system. It performs the following functions:
- Filtering any solid particles carried by the fluid that could damage the compressor or
obstruct the reducing valve, for example.
- Dehumidifying the fluid and the oil to protect all the components to protect all parts of
the circuit from corrosive substances and freezing moisture at the outlet of the pressure
reducing valve.
- Storing the fluid in liquid state and thus constituting a buffer tank to compensate for
pressure variations. It therefore helps to absorb pressure differences generated by the
compressor.
The "binary" pressure switch
Mounted to the drier filter, the pressure switch is the system's safety device that is sensitive to
pressure variations. It protects the system against both excessively low pressures and excessively
high pressures by directly controlling the compressor clutch:
- Acts against low pressures (below 2 bars) due to a lack of refrigerant, a leak or a downstream
circuit blockage.
- Acts against high pressures (greater than 27 bars) due to incorrect compressor cooling,
an excess of refrigerant or an upstream circuit blockage.
Pressure reducing valve
The pressure reducing valve is mounted on the evaporator inlet. By expansion, it lowers the
pressure and thus the temperature of the fluid in such a way as to cool the air passing through the
evaporator. It adjusts the flow to calibrate the quantity of fluid in such a way that it is completely
vaporised at the evaporator outlet.
110
Evaporator
The evaporator is a heat exchanger fitted with a pressure reducing valve and a fan. The fan
draws air across the cold evaporator fins. As the air passes across the fins the moisture it contains
condenses and the air leaves the evaporator cooled. This heat exchange allows the coolant to
evaporate at low pressure.
Anti-frost thermostat
The electric thermostat is connected to a sensor located between two evaporator fins. Temperature
variations in the evaporator lead to changes in the resistance of the potentiometer in the preset
thermostat and this controls the compressor clutch relay.
110-F-M218EN
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AIR-CONDITIONING OPTION
5
AIR CONDITIONING SYSTEM COMPONENT LOCATION
Connector
u
cea
ais
n F al
exio rincip
n
n
P
Co
HP Pressure
switch
X31
tion
Fixa
ceau
fais
avecoteur
m
Receiver-drier
Condenser
X255
X172
ec
n av r
tio oteu
nnec m
Co ceau
fais
LPconnector
Evaporator
HPconnector
110
Compressor
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AIR-CONDITIONING OPTION
ASSEMBLY INSTRUCTIONS FOR AIR-CONDITIONING CIRCUIT
bb
Only operators who are certified to handle refrigerant fluids may work on the air conditioning
system, otherwise please contact a specialist air-conditioning company.
Carry out the assembly operations in a dry and dust free area. Use PAG ISO 100 SP 20 oil for the lubrication
of all seals and seal surfaces before assembly.
Location
Hose module
internal diameter
external
diameter
coupling thread
Between compressor and condenser
Module 8
10 mm
20,5 mm
3/4˝-16 UNF
Between drier filter and reducing valve
Module 6
8 mm
18 mm
5/8˝-18 UNF
Between evaporator and compressor
Module 10
13 mm
23,5 mm
7/8˝-14 UNF
To evaporator:
–– Tightening torque on Module 10: 25 Nm, 22mm wrench and + 25/26mm counter-wrench on expansion
valve
–– Tightening torque on Module 6: 16 Nm, 16/17mm wrench and + 25/26mm counter-wrench on
expansion valve
SAFETY MEASURES FOR HANDLING R134a
1 - Individual protection: protective goggles and rubber gloves.
2 - Perform the operations in a ventilated space.
3 - First aid: After inhalation, breath clean air, give oxygen or perform mouth-to-mouth resuscitation
according to the degree of urgency (medication contraindication). Consult a doctor. In the event
of contact with the eyes, rinse thoroughly for 15 minutes and see a doctor. In the event of contact
with the skin, rinse thoroughly and remove contaminated clothing.
4 - Storage conditions: keep R134a in a sealed container in a dry, cool and well ventilated place.
5 - Handling: only in ventilated areas.
6 - Measures to take in case of accident: wear a self-contained breathing apparatus in the event that
R134a is exposed to fire.
110
REFRIGERANT FLUID LOAD FOR THE AIR-CONDITIONING CIRCUIT
Refrigerant fluid:
Charging equipment:
Quantity of fluid:
110-F-M218EN
R134a
Charging station
950 gr ± 50 gr and 135ml of PAG SP20 oil.
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AIR-CONDITIONING OPTION
7
CHARGING METHOD
bb
Only operators who are certified to handle refrigerant fluids may work on the air conditioning
system, otherwise please contact a specialist air-conditioning company.
Prior to using the charging station, refer to the instruction booklet for the device.
Initial refrigerant charging (duration 56 min)
1 - Station-to-circuit connection phase (about 1 minute).
2 - Refrigerant circuit evacuation phase (minimum duration 45 minutes).
⇒⇒ Achieve a vacuum at a pressure of -0,75 bar in 10 minutes maximum,
⇒⇒ Maintain the vacuum at a pressure of –0.99 bar maximum for dehumidifying in 30 minutes
minimum,
⇒⇒ Check leaks within 5 minutes.
3 - Charging operation (maximum duration 10 minutes).
Refrigerant charging after servicing and repair (duration 90 min)
1 - Preparation phase (about 15 minutes).
⇒⇒ Connect up circuit station,
⇒⇒ Run vehicle engine at between 800 and 1200 rpm,
⇒⇒ Simultaneously, run the ventilation fan at maximum speed "II",
⇒⇒ Turn off vehicle ignition after 10 to 15 minutes.
2 - Recovery phase (15 minutes maximum). Its aim is to recover and recycle the gas, oil and any
impurities present in the circuit. Launch the fluid recovery cycle on the station.
3 - Waiting phase of 3 to 4 minutes to enable any micro freezing of oil and humidity to be recuperated.
4 - Recovered oil discharge phase (about 1 minute).
5 - Phases 1, 2 and 3 can be redone if pressure build-up is observed during phases 2 and 3.
6 - Refrigerant circuit evacuation phase (minimum duration 45 minutes).
⇒⇒ Achieve a vacuum at a pressure of -0,75 bar in 10 minutes maximum,
⇒⇒ Maintain the vacuum at a pressure of –0.99 bar maximum for dehumidifying in 30 minutes
minimum,
⇒⇒ Checking leaks within 5 minutes maximum.
7 - Charging phase (maximum 10 minutes).
Fluid top-up (duration 15 min) vehicle engine running
bb
The R134a fluid, in free air is a colorless and odorless gas, heavier than air, that may be dangerous
for human beings in certain conditions. Always recover the refrigerant fluid using the charging
station.
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110-F-M218EN
110
1 - Preparation phase (about 10 minutes).
⇒⇒ Connect up circuit station,
⇒⇒ Run vehicle engine at between 800 and 1200 rpm,
⇒⇒ Simultaneously, run the ventilation fan at maximum speed "II"
2 - Additional charging phase (about 5 minutes).
8
AIR-CONDITIONING OPTION
FUNCTIONAL CHECKS
The following checks are carried out with the vehicle engine running.
1. Heating control
Use the switch to set the heater fan to speed "II".
Ensure the air-conditioning switch is in its "off" position.
110
Check the increase in temperature between the minimum hot position
and the maximum hot position.
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2. Air-conditioning adjustments
• Connect the charging station
• Start up the vehicle engine
• Switch on the air-conditioning as follows:
Use control switch to select speed "I" for air diffusion.
Turn the air-conditioning control to maximum.
Using the manual control, adjust the temperature to the minimum warm
position.
110
–– Open the 2 diffuser outlets.
–– Adjust the engine to idle speed (about 800 rpm)
–– Wait 5 minutes minimum for the circuit to stabilise.
–– Check that the LP and HP circuit pressures between two compressor cut-offs are between:
⇒⇒ 0,5 bar and 2 bar in LP,
⇒⇒ 6 bar and 20 bar in HP.
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AIR-CONDITIONING OPTION
ANTI-ICING SAFETY MONITORING
–– Connect the charging station
–– Start up the vehicle engine
–– Switch on the air-conditioning as follows:
Use control switch to select speed "I" for air diffusion.
Turn the air-conditioning control to maximum.
The compressor activates, then the condenser fans 7 seconds later.
Using the manual control, adjust the temperature to the minimum
warm position.
110
–– Close all diffuser outlets.
–– Adjust the engine to idle speed (about 800 rpm)
–– Check that the LP and HP circuit pressures are between:
⇒⇒ 0,5 bar and 2 bar in LP,
⇒⇒ 6 bar and 20 bar in HP.
–– Check that the compressor is cut-off after a few minutes:
⇒⇒ LP ≥ 3 bar,
⇒⇒ HP ≤ 5 bar.
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AIR-CONDITIONING INSPECTION FORM
–– With the engine at min. revs, ventilation speed set to "I", air-conditioning in operation and set to
minimum heating position.
–– Check the output air temperature and note:
Machine No.
Temperature
External
Air output
Pressures
BP
HP
Compressor
cut-off
110
Date
(03/12/2014)
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AIR-CONDITIONING OPTION
110
12
110-F-M218EN
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