647583EN (28/09/2018)

MT 1435 EASY 75D ST3B S1

MT 1440 EASY 75D ST3B S1
MT 1840 EASY 75D ST3B S1

REPAIR MANUAL
 647583EN
2

DATE OF ISSUE OBSERVATION

15 / 05 / 2016 - 1st ISSUE

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

28 / 09 / 2018 - Partial update : GR85-06 and GR110

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.
 647583EN 3

HOW TO USE THIS REPAIR MANUAL ?

1GENERAL CHARACTERISTICS AND SAFETY 2

00

00
GENERAL, CHARACTERISTICS AND SAFETY

10
ENGINE

20
TRANSMISSION - GENERAL INSTRUCTIONS AND SAFETY NOTICE

30
AXLE

40
BRAKE
60

55

50
BOOM
70

HYDRAULIC
80

ELECTRICITY
85

DRIVER’S CAB
90

FRAME - BODYWORK
110

OPTIONS - ATTACHMENTS

3 4 GENERAL INSTRUCTIONS AND SAFETY

4 NOTICE
00

00

RULES FOR MAINTENANCE

Do not carry out any work on the machine unless you have followed
a suitable training course and have the knowledge required for it.

Make sure you have taken into consideration all the indicator plates
on the machine and in the instruction manual.

GENERAL INSTRUCTIONS AND SAFETY NOTICE

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

when operations have to be done before the machine has had
time to cool down.
pages

PREAMBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
MAINTENANCE POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
RULES FOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Before carrying out any operation on an electrically powered

1
component, activate the battery cut-off.
2 If the telehandler does not have a battery isolation device, disconnect
the battery connecters then re-assemble them.

Before carrying out any welding operations, think about

disconnecting computers.
ECU

A machine operating in a contaminated environment should be

specifically equipped. Moreover, local safety notices deal with
maintenance and repair work on such machines.

00-M173EN (29/09/2011)
(29/09/2011) 00-M173EN

l547982 : See the repair manual N° 547982.

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

GENERAL

00
ENGINE

10
TRANSMISSION

20
AXLE

30
BRAKE

40
BOOM

50
HYDRAULICS

70
ELECTRICITY
80
DRIVER'S CAB
85

FRAME - BODY
90
110

OPTIONS - ATTACHMENTS
 GENERAL CHARACTERISTICS AND SAFETY

00
- GENERAL INSTRUCTIONS AND SAFETY
NOTICE

- GENERAL CHARACTERISTICS AND

SPECIFICATIONS

- GENERAL LOCATION

- GENERAL CONTROL AND ADJUSTMENT

 00
GENERAL
GENERALINSTRUCTIONS
INSTRUCTIONSAND
ANDSAFETY
SAFETYNOTICE
NOTICE

pages

PREAMBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
MAINTENANCE POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
RULES FOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

(08/03/2016) 00-00-M257EN
 2 CONSIGNES ET SÉCURITÉS GÉNÉRALES
00

PREAMBLE

This chapter deals with the general instructions and safety notice during inspection and maintenance
work.
Other instructions and warnings are indicated in each chapter concerned.

In order to reduce accident risks, make sure to:

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

 This manual should be found in all trucks.
– Please follow all safety instructions.
– Use the appropriate tools for any work to be performed.
– Use original Manitou spare parts.

Any non-compliance increases the risk of accidents occurring which may lead to causing grievous bodily
harm and even death.

An efficient, dependable and profitable combination will be formed if the operator follows the safety
manual correctly and the machine is serviced properly.

When you see this symbol:

It means: Warning! Be careful! Your safety, somebody else’s or the safety of the lift truck itself
is at risk.

The manufacturer cannot predict all possible risky situations. Consequently, the safety instructions
given in the safety manual are not exhaustive.
At any time, as an operator, you must envisage, within reason, the possible risk to yourself, to others or
to the lift truck itself when you repair, service or drive it.

Manitou cannot be held responsible for the use of any lifting devices, tools or operating methods other
than those specified.

00-00-M257EN (08/03/2016)
 CONSIGNES ET SÉCURITÉS GÉNÉRALES 3

00
MAINTENANCE POSITION

2 4

1 3

Before any intervention:

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

2 - Turn off the engine and remove the ignition key.
3 - Let the machine cool down.
4 - Take all the pressure out of the circuits concerned.

(08/03/2016) 00-00-M257EN
 4 CONSIGNES ET SÉCURITÉS GÉNÉRALES
00

RULES FOR MAINTENANCE

Do not carry out any work on the machine unless you have followed
a suitable training course and have the knowledge required for it.

Make sure you have taken into consideration all the indicator plates
on the machine and in the instruction manual.

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

when operations have to be done before the machine has had
time to cool down.

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.

If the telehandler does not have a battery isolating switch, disconnect

the battery terminals then gather them.

b Before carrying out any welding operations, think of

disconnecting computers.

ECU

A machine operating in a contaminated environment should be

specifically equipped. Moreover, local safety notices deal with
maintenance and repair work on such machines.

00-00-M257EN (08/03/2016)
 CONSIGNES ET SÉCURITÉS GÉNÉRALES 5

00
Never step on a part of the machine that has not been designed for it.

Never wear clothes, jewelry or objects that could get caught during
work and cause accidents.

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

other protection required for the work to be carried out.

When carrying out maintenance operations near a mobile object,

make sure it is securitized.

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

liquids, solids, gases that are harmful to the environment, make
sure the necessary precautions are taken to avoid contaminating
the environment.

(08/03/2016) 00-00-M257EN
 6 CONSIGNES ET SÉCURITÉS GÉNÉRALES
00

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

the equipment used is suitable for at least the load for which it
is subjected by the component and that it meets the national
standards for lifting devices.

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

sturdy enough to support the load, that its lifting capacity is sufficient
and that it is correctly placed and positioned under the machine.

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

in the machine.

Never control any leaks using a hand.

max.

min.

MAX Never adjust a component to over the maximum capacity indicated

by the manufacturer.

MIN
00-00-M257EN (08/03/2016)
 00
GENERAL CHARACTERISTICS AND SPECIFICATIONS

pages

MT 1435 - MT 1440 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– CHARACTERISTICS AND FLUIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
MT 1840 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– CHARACTERISTICS AND FLUIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

(03/08/2016) 00-01-M257EN
 GENERAL CHARACTERISTICS AND
2 SPECIFICATIONS MT 1435 - MT 1440
00

CHARACTERISTICS AND FLUIDS

Designation Value Designation Type Residual

Fuel tank EN590 / ASTM D975 140 ℓ
Truck weight with forks 10,855 kg
Engine oil MANITOU GOLD 7.5 ℓ
Boom weight 2,500 kg Cooling system Cooling liquid (protection -35°) 17 ℓ
Ground Gearbox MANITOU Automatic transmission oil 21.1 ℓ
FRONT (MLT) 5,305 kg
distribution Hydraulic tank MANITOU ISO VG 46 Hydraulic oil 135 ℓ
per axle with Brake system MANITOU Mineral brake fluid 1ℓ
forks REAR (MLT) 5,550 kg
Air-conditioning system R134A gas 950 g ±50
Pulling force 7,450 daN Axle differential Special MANITOU oil for immersed brakes 7.2 ℓ
Wheel reduction gear MANITOU SAE80W90 Mechanical transmission oil 0.75 ℓ

D1
C1

W2

U2
U1
DIMENSIONS

N
Item Value
A mm 1,200

P2

P3
B mm 3,070

G2
G1
Y

C mm 1,905
C1 mm 1,790 D2
L
Z

D mm 6,135 C B I
D1 mm 6,020 A D
D2 mm 4,859 E
E mm 7,335
F mm 1,960 W3
F1 mm 1,960 J
G mm 384
G1 mm 367
G2 mm 380
G3 mm 355
I mm 1,160
J mm 892
K mm 1,040
L mm 50
N mm 1,855
O mm 125
P2 ° 34
P3 ° 33
R mm 3,779
S mm 8,626 F1
G3

F
T mm 4,183
W
U1 mm 2,452
U2 mm 2,640 W1
V mm 5,468
V1 mm 1,285
V2 mm 3,986
W mm 2,374
W1 mm 3,793
W2 mm 1,134
W3 mm 2,422
Y ° 12
V

Z ° 114
K

V2
O

T
V1

S
00-01-M257EN (03/08/2016)
 GENERAL CHARACTERISTICS AND
MT 1840 SPECIFICATIONS 3

00
CHARACTERISTICS AND FLUIDS

Designation Value Designation Type Residual

Fuel tank EN590 / ASTM D975 140 ℓ
Truck weight with forks 11,710 kg
Engine oil MANITOU GOLD 7.5 ℓ
Boom weight 3,120 kg Cooling system Cooling liquid (protection -35°) 17 ℓ
Ground Gearbox MANITOU Automatic transmission oil 21.1 ℓ
FRONT (MLT) 5,510 kg
distribution Hydraulic tank MANITOU ISO VG 46 Hydraulic oil 135 ℓ
per axle with Brake system MANITOU Mineral brake fluid 1ℓ
forks REAR (MLT) 6,200 kg
Air-conditioning system R134A gas 950 g ±50
Pulling force 7,950 daN Axle differential Special MANITOU oil for immersed brakes 7.2 ℓ
Wheel reduction gear MANITOU SAE80W90 Mechanical transmission oil 0.75 ℓ

D1
C1

W2

U2
U1
DIMENSIONS

N
Item Value
A mm 1,200

P2
mm 3,070

P3
B

G2
G1
Y

C mm 2,044
C1 mm 1,929 D2
L
Z

D mm 6,274 C B I
D1 mm 6,159 A D
D2 mm 4,894 E
E mm 7,474
F mm 1,960
W3
F1 mm 1,960
G mm 437 J
G1 mm 420
G2 mm 433
G3 mm 302
I mm 1,160
J mm 892
K mm 1,040
L mm 50
N mm 1,908
O mm 125
P2 ° 37
P3 ° 34
R mm 3,779
S mm 8,788
T mm 4,307 F1
G3

F
U1 mm 2,505
D1 W
U2 mm 2,693
V mm 5,592 C1 W1
V1 mm 1,285
V2 mm 4,009
W mm 2,420
W1 mm 3,793 W2
W2 mm 1,134
W3 mm 2,422
Y ° 12
U2
U1

Z ° 114
N
P2

P3
G2
G1
Y

D2
L
Z

C B I
A D
E

(03/08/2016) 00-01-M257EN
 GENERAL CHARACTERISTICS AND
4 SPECIFICATIONS
00

00-01-M257EN (03/08/2016)
 00
GENERAL LOCATION

pages

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

(03/08/2016) 00-03-M257EN
 2 GENERAL LOCATION
00

LOCATION OF NAME AND IDENTIFICATION PLATE

Key:
1 - Manufacturer's plate 6 - Cab
2 - Engine 7 - Boom
3 - Gearbox 8 - Frame
4 - Front axle 9 - Attachment manufacturer's plate
5 - Rear axle

MANITOU BF 44158 ANCENIS CEDEX FRANCE

MODELE MODELLO SERIE SERIE
MODEL MODELO SERIES SERIE

Année de fabrication Anno di fabbricazione Année modèle Anno modello

Year of manufacture Año de fabricación Model year Año modelo

N° de série N° di serie
Puissance ISO/TR14396
Serial Nr N° de serie
Power ISO/TR14396
Potenza ISO/TR14396
Potencia ISO/TR14396

Masse à vide Massa a vuoto

1
kW
Unladen mass Masa en vacio

5 kg Capacité nominale
Rated capacity
Capacità nominale
P.T.R.A. P.T.C.A.
Capacidad nominal
Authorized gross vehicle weight P.T.R.A.

daN kg

Effort de traction Sforzo di trazione Effort vertical maxi. (sur crochet de remorquage)
Drag strain Esfuerzo de tracción Maximum vertical force (on trailer hook)
Sforzo verticale massimo (sul gancia di traino)
daN Esfuerzo vertical máximo (sobre gancho de remolque)

Pression des pneumatiques (Bar) daN

Tyres pressure (Bar)
Pressione dei pneumatici (Bar)
Presión de los neumáticos (Bar) N° d'homologation
Homologation Nr
Avant Anteriore Arrière Posteriore N° di omologazione
Front Adelante Rear Trasero N° de homologación

N°295449

2
7

MANITOU BF
44158 ANCENIS CEDEX
FRANCE

MODELE

N° dans la série

Année fabrication

2 Masse à vide
kg
9
C d G / Tablier
A vide / En charge : mm

Cap. Nominale

Pression de service

AVERTISSEMENT : RESPECTEZ
LA CAPACITE DE L'ENSEMBLE
"CHARIOT ET EQUIPEMENT"

N°207701

3 4

00-03-M257EN (03/08/2016)
 00
GENERAL CONTROL AND ADJUSTMENT

pages

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

(03/08/2016) 00-04-M257EN
 2 GENERAL CONTROL AND ADJUSTMENT
00

STANDARD TIGHTENING TORQUES

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

1 - Tightening torque in N.m (±20%) for screw / nut connection (NF E 25-030-1):
Ø x “coarse” pitch Grade 8.8 Grade 10.9 Ø x “fine” pitch Grade 8.8 Grade 10.9
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
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

b
M36 x 4 2068 3037 - - -
For hexagon screws with flanges (NF E 25-030-1) :
Apply an increased torque of +10%.

b Where washers are used, the following coefficient is to be applied (FD E 25-502) :
- Plate : +0%
- Smooth tapered washer (CL): +5%
- Spring (or Grower) washer without jaws (W) : +10%
- Conical, internal teeth (CDJ-JZC) : +15%.

2 - Tightening torque in N.m (±20%) for screw / nut connection (with marking) :

4 5 6 7 8
4T 6T 8T
------------ ------------ ------------

5T 7T 11
Ø x Pitch (flange : 4 .8T) (flange : 6 .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)
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)

b
M16 x 1 .5 113 (120) 137 172 (170) 226 265 (270) (360) (400)

use the upper class where spring (or Grower) washers are used.

00-04-M257EN (03/08/2016)
 ENGINE

10
- ENGINE CHARACTERISTICS AND
SPECIFICATIONS

- ENGINE CIRCUITS FLOW DIAGRAM

- ENGINE COMPONENTS LOCATION

- ENGINE CONTROL AND ADJUSTMENT

- ENGINE REMOVAL

- ENGINE TROUBLESHOOTING

- SPECIFIC ENGINE TOOLING

- CHARACTERISTICS AND SPECIFICATIONS

l647461EN
- CONTROL AND ADJUSTMENT
(ENGINE TCD/TD 3.6 L4)
- SPECIFIC TOOLING
 10
ENGINE GENERAL CHARACTERISTICS
AND SPECIFICATIONS

pages

CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
POLLUTION MANAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INJECTION CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
BOSCH CP4.1 HIGH PRESSURE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

(03/09/2016) 10-01-M257EN
 ENGINE GENERAL CHARACTERISTICS AND
2 SPECIFICATIONS

CHARACTERISTICS

⇒⇒ 4 cylinders in line
⇒⇒ Firing order from flywheel: 1, 3, 4, 2
10

⇒⇒ Anti-clockwise (viewed from flywheel)

⇒⇒ 3.6 ℓ cubic capacity
⇒⇒ Electronic management
⇒⇒ Direct injection
⇒⇒ Turbo
⇒⇒ Compression ratio: 18:1
⇒⇒ Power rating 55.4 kW (75 hp)
⇒⇒ Specific consumption: 210 and 220 g/kWh
⇒⇒ Maximum torque: 330 Nm
⇒⇒ Dry engine weight: 270 kg
⇒⇒ Idle speed: - Min rpm: 930 rpm
- nominal laden: 2,200 rpm
- max. unladen: 2,360 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-M257EN (03/09/2016)
 ENGINE GENERAL CHARACTERISTICS AND
SPECIFICATIONS 3

INJECTION CYCLE

1 - Fuel pre-injection 1
2 - Fuel pre-injection 2

10
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. 1,700 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.

(03/09/2016) 10-01-M257EN
 ENGINE GENERAL CHARACTERISTICS AND
4 SPECIFICATIONS

BOSCH CP4.1 HIGH PRESSURE PUMP

Synchronized with idle gear / crankshaft.

Approximately two strokes per crankshaft rotation.
10

Max. working pressure 1,600 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 3
2 - Piston type pump
5
3 - High pressure outlet
4 - MPROP (magnetic proportional valve)
5 - Low pressure inlet
6 - Discharge valve
2

6
If the MPROP is de-energized, 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. 1

10-01-M257EN (03/09/2016)
 10
ENGINE CIRCUITS FLOW DIAGRAM

pages

AIR INTAKE CIRCUIT AND EGR (EXHAUST GAS RECIRCULATION) . . . . . . . . . . . . . . . . . . . . . 2

LUBRICATION CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUEL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

(03/09/2016) 10-02-M257EN
 2 ENGINE CIRCUITS FLOW DIAGRAM

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,
10

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 7 - Cooling liquid supply
2 - Turbo 8 - EGR cooler
3 - Intake 9 - Cooling liquid return
4 - Exhaust 10 - One way valves
5 - Exhaust gas bypass 11 - Gas cools
6 - EGR Valve 12 - To exhaust

1 7
8
10 11
6

5
9
2
3
4

12Z

10-02-M257EN (03/09/2016)
 ENGINE CIRCUITS FLOW DIAGRAM 3

LUBRICATION CIRCUIT

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.

10
Key:
1 - Oil sump 9 - Camshaft bearing
2 - Oil pump 10 - Crankshaft bearing
3 - Pressure relief valve 11 - Piston cooling nozzle
4 - Oil cooler 12 - Rocker arm
5 - Bypass valve 13 - Hydraulic tappets
6 - Pressure control valve 14 - Turbo compressor
7 - Oil filter 15 - Air compressor (optional)
8 - Main oil gallery
12

14

15

11
8

13
5

4
9

7
10

6 3 2

7
6
2

3 6

(03/09/2016) 10-02-M257EN
 4 ENGINE CIRCUITS FLOW DIAGRAM

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
10

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 6 - Cab heating connection
2 - Coolant enters the engine 7 - Temperature sensor
3 - Cylinder tube / head cooling 8 - Thermostat (opening 92 °C, max. 110 °C)
4 - Lubricating oil radiator 9 - Radiator
5 - Exhaust return radiator 10 - Expansion tank

6
10

9
7
8

5 4 3

2
1

10-02-M257EN (03/09/2016)
 ENGINE CIRCUITS FLOW DIAGRAM 5

FUEL CIRCUIT

Max. fuel supply. Pressure: 8 bar.

Regulated pressure fuel supply: 4 - 4.5 bar. Startup not allowed if P < 3.2 bar.

10
Fuel rail pressure, maximum service pressure: 1,600 bar.
PRV (Pressure Relief Valve) on the fuel rail, opening pressure: 1,700 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:
1 - Fuel tank 11 - Return to tank
2 - Water separator / pre-filter 12 - ECU (Electronic Control Unit)
3 - Electrical fuel pump
4 - Fuel filter
5 - Supply pressure sensor
6 - High pressure pump / FCU (Fuel Control Unit)
7 - High pressure fuel rail
8 - Injector
9 - One way valve
10 - Return line

12 8

10

2
4 5
11

3 6

(03/09/2016) 10-02-M257EN
 6 ENGINE CIRCUITS FLOW DIAGRAM
10

10-02-M257EN (03/09/2016)
 10
ENGINE COMPONENTS LOCATION

pages

ENGINE ELEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
WATER COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
AIR INTAKE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
HYDRAULIC VENTILATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DIESEL FUEL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FUEL INJECTION CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
EGR (EXHAUST GAS RECIRCULATION) CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

(03/09/2016) 10-03-M257EN
 2 ENGINE COMPONENTS LOCATION

ENGINE ELEMENTS

Key:
1 - Cooling water inlet 18 - Water temperature sensor
10

2 - Alternator belt 19 - Thermostat

3 - Crankshaft sensor 20 - Cooling water outlet
4 - Engine oil pressure switch 21 - Fuel return
5 - Camshaft sensor 22 - Oil cooler
6 - Water pump 23 - Main connector
7 - Alternator 24 - Injection pump
8 - EGR Valve 25 - MPROP (magnetic proportional valve)
9 - Air supply to turbo 26 - Fuel intake
10 - EGR cooler 27 - Starter
11 - One way valves 28 - Oil filter
12 - Crankcase breather 29 - Control cartridge
13 - Oil filler plug 30 - Drain plug
14 - Intake air pressure sensor 31 - Pressure relief valve
15 - Fuel rail 32 - Oil pressure sensor
16 - Fuel rail pressure sensor 33 - Engine ECU
17 - Intake air temperature sensor
33
Cooling
Air 11
Diesel
Electricity
Lubrication 10 9
EGR
12 8

14
16
13

7
15 17

21 18
6
22
19
20

23 25 5

26
2
27 24
3

28
29

32
30 31

10-03-M257EN (03/09/2016)
 ENGINE COMPONENTS LOCATION 3

WATER COOLING SYSTEM

Key:
1 - Expansion tank 6 - Bleeder (Behind high pressure pump)

10
2 - To water pump 7 - Breather
3 - Boost pressure line
4 - Thermostat outlet
5 - Degassing line

3
4

AIR INTAKE CIRCUIT

Key:
1 - Air filter
2 - Air inlet
5
3 - Clogging sensor
4 - Turbo air intake
5 - Intake
4

(03/09/2016) 10-03-M257EN
 4 ENGINE COMPONENTS LOCATION

HYDRAULIC VENTILATION SYSTEM

Key:
A - Gearbox Hot transmission oil
10

B - Engine fan Cooled transmission oil

C - Cooler Hot hydraulic oil
D - Hydraulic tank Cooled hydraulic oil

PMV
C

10-03-M257EN (03/09/2016)
 ENGINE COMPONENTS LOCATION 5

DIESEL FUEL CIRCUIT

Key:
1 - Fuel supply 6 - Water in diesel sensor

10
2 - Fuel return 7 - Diesel pump
3 - Fuel gauge 8 - Filter
4 - Fuel tank 9 - Pressure sensor
5 - Pre-filter 10 - Pressure test port (in place of the sensor)

4
3

9
5 10

(03/09/2016) 10-03-M257EN
 6 ENGINE COMPONENTS LOCATION

FUEL INJECTION CIRCUIT

Key:
1 - Low pressure fuel supply 7 -  ressure Relief Valve (PRV)
P
10

2 - High pressure pump 8 - PRV return

3 - MPROP (magnetic proportional valve) 9 - Injector electrical connector
4 - FCU (Fuel Control Unit) return 10 - High pressure fuel supply
5 - High pressure fuel rail 11 - Injector return
6 - High pressure fuel line pressure sensor

Red circuit = 350 - 1,800 bar

Green circuit = low pressure return

11

10 9

6
8

5 7

10-03-M257EN (03/09/2016)
 ENGINE COMPONENTS LOCATION 7

EGR (Exhaust Gas Recirculation) CIRCUIT

Key:
1 - Partial exhaust gas flow (not cooled) 6 - Partial exhaust gas flow (cooled)

10
2 - EGR valve, controller (electrical action) 7 - Intake
3 - Cooling liquid return 8 - Exhaust manifold
4 - Exhaust gas return radiator (EGR) 9 - Turbo attachment
5 - EGR radiator coolant supply line 10 - One way valves

10

8
2 1
9

(03/09/2016) 10-03-M257EN
 8 ENGINE COMPONENTS LOCATION
10

10-03-M257EN (03/09/2016)
 10
ENGINE CONTROL AND ADJUSTMENT

pages

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

VENTILATION MANAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– A – FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– B – PRINCIPLE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– C – SCHEMATIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– C – HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
–– E – CONDITIONS OF VENTILATION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

(05/31/2016) 10-04-M257EN
 2 ENGINE CONTROL AND ADJUSTMENT

ENGINE TIGHTENING TORQUES

F
10

230 N.m
110 N.m

110 N.m

230 N.m

230 N.m

110 N.m

110 N.m 230 N.m Tolérance ± 10%

Vue F

110 N.m ± 10%

230 N.m ± 10%

10-04-M257EN (05/31/2016)
 ENGINE CONTROL AND ADJUSTMENT 3

VENTILATION MANAGEMENT

A – FUNCTION

10
Ventilation management serves to control activation of the engine cooling fan according to various
temperature parameters.

B – PRINCIPLE OF OPERATION

The fan is hydraulically driven by an engine and a fixed displacement pump, connected to the hydraulic
pump. The hydraulic flow therefore varies according to the engine speed, and thus the maximum fan
speed also. The electrovalve is incorporated within the hydraulic engine, with a relief valve and an anti-
cavitation "freewheel" valve. To ensure that the oil is re-aspirated during engine shut-down, the propeller
rotation slows very gradually.
In the event of a control system failure (sensors, continuity, electrovalves), the hydraulic drive is active
by default (coils not powered), this is the system's degraded mode.

C – SCHEMATIC DIAGRAM

Key:
1 - Engine coolant temperature sensor 5 - Fan engine
2 - Crankshaft speed sensor 6 - Pilot electrovalve
3 - Engine ECU 7 - Cooler
4 - Machine ECU

4
X149
3

X148 X290
6
CAN
X175
X174
5
1

X912

X915

(05/31/2016) 10-04-M257EN
 4 ENGINE CONTROL AND ADJUSTMENT

C – HYDRAULIC DIAGRAM
10

E – CONDITIONS OF VENTILATION CONTROL

Fan cut-off electrovalve supply current management:

1 - Engine coolant temperature sent by CAN
2 - Engine speed sent by CAN

Pilot control line

The fan is activated by an ON/OFF electrovalve. The fan speed is therefore at maximum (approx.
1,800 rpm) or stopped.
The maximum fan speed is limited at high engine speed by the relief valve.

If engine speed < 1,500 rpm and engine coolant temperature > 90 °C, the fan is activated.
If engine speed > 1,500 rpm and engine coolant temperature > 100 °C, the fan is activated.
If engine coolant temperature < 80 °C, the fan is turned off (electrovalve powered).

Variation of fan speed with oil temperature

n (Tr/min)

n+150
n

n-150
20 70 100
T huile (°C)
10-04-M257EN (05/31/2016)
 10
ENGINE REMOVAL

pages

PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

STARTER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DRIVE BELT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ALTERNATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FAN ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ENGINE ECU REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
–– REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CATALYTIC CONVERTER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
–– REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
COOLER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

(04/14/2016) 10-06-M257EN
 2 ENGINE REMOVAL

PREPARATION AND SAFETY INSTRUCTIONS

Stabilize the machine on level ground.

Maneuver the machine a number of times in forward and reverse (wheels straight) in order to release
10

any stresses acting on the steering and tires.

Raise the boom up again to mid-height and install the safety wedge.

bb
Deactivate battery power supply by means of the battery cut-off.
Operate the battery cut-off no less than 30 seconds after turning off the ignition with the
ignition key.

Open the engine covers.

To remove the engine, turn the front and rear wheels to the right:

Specific tooling:

- Pallet truck
- Jib crane (minimum 1,000 kg)

10-06-M257EN (04/14/2016)
 ENGINE REMOVAL 3

STARTER REMOVAL
1
2

Disconnect the excitation (Item 1) and the battery + (Item 2).

3
Undo the two screws (Item 3) and remove the starter.

10
3

DRIVE BELT REMOVAL

1 Remove the belt cover (Item 1).

Slacken the belt using the alternator adjustment screw:

l 647461 (TD 3.6 L4 engine).

ALTERNATOR REMOVAL

2
Perform the operation "10 - DRIVE BELT REMOVAL".

Disconnect the 2 cables (Item 1)

Remove the alternator. Remove the 2 screws (Item 2):

l 647461 (TD 3.6 L4 engine).

1

FAN ENGINE REMOVAL

2
Fixed casing:
Perform the operation "10 - COOLER REMOVAL"

Option to open lower cover:

Remove the cable from the hook (Item 1) and remove the lower
cover.
1
Remove the support pad (Item 2).

(04/14/2016) 10-06-M257EN
 4 ENGINE REMOVAL

Disconnect the hoses on the fan engine (Item 1).

Remove the protective grille (Item 2).
10

Undo the central nut from the propeller, and ease off using a
bronze jay to take off the propeller.

Remove the fan engine and mark the position of the threading
1 used (Item 1).

ENGINE ECU REMOVAL

Disconnect the 2 connectors by lifting up the locking tabs

(Item 1). Pay attention to the ground cable.

Remove the ECU.

Refit

Use the SERDIA software for pairing.

1

CATALYTIC CONVERTER REMOVAL

1 Undo the clamps (Item 1) and keep the seals.

2
Undo the flanges (Item 2) and remove the circlips and axles
2 (Item 3).
3 Remove the catalytic converter.

3
1 Refit

Pay attention to the refitting direction, making sure to position

the internal protective grille of the catalytic converter on the
engine exhaust outlet side.
Be careful not to place stress on the compensator, and align the
joints of the different items. Tighten the clamps to a torque of
12 Nm ±10%.
10-06-M257EN (04/14/2016)
 ENGINE REMOVAL 5

COOLER REMOVAL

Fixed casing:
Turn the front and rear wheels to the right:

10
Remove the deflector (Item 1).

Remove the screw (Item 1).

2
Remove the screws (Item 2).
2
Remove the engine housing.
2
Remove the fan’s protective grille and move it away from the
2 1 cooler.

Option to open lower cover:

Perform the operation "10 - FAN ENGINE REMOVAL".

All casing types:

Drain the coolant radiator.
Disconnect the coolant outlet hose on the engine. Disconnect
the lower hoses.

1 Disconnect the minimum coolant level wiring harness (Item 1)

(X258) and alternator controller (X179).

(04/14/2016) 10-06-M257EN
 6 ENGINE REMOVAL

1
Remove the 3 screws from the coolant tank mounting (Item 1).

2 Position the coolant tank on the engine.

Remove the rubber plug from the cooler lifting hole (Item 2).
10

Disconnect the two hoses (Item 1) and the air hose (Item 2).

2 Disconnect the 2 coolant hoses.

Sling the cooler through the hole provided for this purpose.
Remove the 2 cooler retaining screws on the frame.

Take out the cooler and pay attention to the engine ECU.
1

ENGINE REMOVAL

Turn the front and rear wheels to the right:

1
Remove the deflector (Item 1).

Fixed casing:
Perform the operation "10 - COOLER REMOVAL".

1 Option to open lower cover:

1
Remove the screws (Item 1).
1
Remove the engine housing.
Drain the coolant radiator.
1 Perform the operation "10 - CATALYTIC CONVERTER REMOVAL"
and the engine exhaust pipe.
1
Perform the operation "10 - FAN ENGINE REMOVAL".

10-06-M257EN (04/14/2016)
 ENGINE REMOVAL 7

1 Disconnect the minimum coolant level wiring harness (Item 1)

(X258) and alternator controller (X179).

Disconnect the filling hose (Item 2).

10
3 Remove the air supply hose (Item 3).

1
Remove the 3 screws from the coolant tank mounting (Item 1).

Disconnect the 2 coolant hoses on the top of the cooler.

Remove the expansion tank.

1

All casing types:

Disconnect the engine harness: X277 (Item 1), X281 (Item 2),
X257 (Item 3), X282 (Item 4), X61 (Item 5) and X283 (Item 6).
3
Disconnect the diesel supply and return.
4
8 Disconnect the heating hoses and its attachments (Item 7).

Remove the dipstick attachment (Item 8).

6 1
5
On the engine wheel, remove the harness attachment.
2

7
7

Disconnect the ground (Item 1).

1 Disconnect the ground under the turbo (X122).

Remove the heating hose mounting (Item 2).

Run the engine harness towards the cooler.

(04/14/2016) 10-06-M257EN
 8 ENGINE REMOVAL

Put a lifting ring M12 on the engine wheel in the place of the
harness mounting (Item 1).
10

Disconnect the engine from the gearbox and unscrew the four
attachment screws (Item 1).
Turn the engine shaft to reach the attachment screws one by one.

Remove the hose attachment (Item 1) on the engine mounting

rear arm.

The suspension device must

be adjustable to suit the
engine center of gravity.

Sling the engine.

10-06-M257EN (04/14/2016)
 ENGINE REMOVAL 9

Undo the front and rear silent blocks (Item 1) and the top screw
2 (Item 2).

3 Undo the three screws (Item 2).

3

10
1

Remove the cover plate (Item 1).

1 1
Remove the screws (Item 1).
1 1

1 1
Remove the shorter screws (Item 2).

1 1 Take out the engine.

1 1

2 2

(04/14/2016) 10-06-M257EN
 10 ENGINE REMOVAL
10

10-06-M257EN (04/14/2016)
 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 CHECK POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ENGINE ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

(06/01/2016) 10-08-M257EN
 2 ENGINE TROUBLESHOOTING

FAULT TABLE

Fault Cause Measures

The engine Fuel tank empty Fill the fuel tank
10

starts with
Faulty electric fuel supply pump Check
difficulty or
not at all 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 oxidized Check the cables
Faulty starter engine or pinion will not mesh Check the starter engine
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 The engine's electronic system prevents startup Check the fault according to the error code,
not start and eliminate the fault, if applicable
the diagnostic
lamp is
flashing
The engine Engine exhaust gas back-pressure too high Check
starts but runs
Low compression pressure Check compression pressure
erratically or
stops 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 The engine electronic management system has detected a system error and Check the fault according to the error code,
are possible activated a replacement gear eliminate the fault, if applicable
and the
diagnostic
indicator light
comes on

The engine is Coolant bled pipe to expansion tank blocked Clean

too hot. The
temperature
Incorrect engine oil SAE viscosity Change lubrication oil
warning
system is Faulty engine radiator Check/Replace
tripped 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-M257EN (06/01/2016)
 ENGINE TROUBLESHOOTING 3

Fault Cause Measures

The engine Faulty air filter switch/Indicator lamp Check/Replace
is too hot.
Faulty fan / torn or slack v-belt Check the fan/the v-belt/replace if required
The temperature
warning system
is tripped Engine exhaust gas back-pressure too high Check

10
The engine Engine oil level too high Check oil level, empty if necessary
lacks power
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
"Not all engine Leaking injection line Check the injection line
cylinders are
Defective injector Replace
working"
Charging air line not air-tight Check the air line
Engine oil level too high Check oil level, empty if necessary
No or too low Oil level too low Fill lubricating oil
engine oil
Engine angle too steep Check engine position/Reduce inclination
pressure

Incorrect engine oil SAE viscosity Change lubrication oil

Excessive Engine oil level too high Check oil level, empty if necessary
engine oil
Engine angle too steep Check engine position/Reduce inclination
consumption
Drain crankshaft sump Check/Replace
Oil i the Engine used with insufficient load (< 20-30%) for a long period Check the load factor
exhaust system

Engine Engine oil level too high Check oil level, empty if necessary
emitting blue
Engine angle too steep Check engine position/Reduce inclination
smoke

Engine Temperature below startup temperature limit Check

emitting white
Cold start installation Check/Replace
smoke
The fuel quality does not comply with the operating instructions Change fuel
Defective injector Replace
Engine exhaust Clogged air filter/ Faulty exhaust gas turbo-compressor Check/Replace
is black
Faulty air filter switch/Indicator lamp Check/Replace
Charging air line not air-tight Check the air line
Defective injector Replace

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.
(06/01/2016) 10-08-M257EN
 4 ENGINE TROUBLESHOOTING

Error indicator lamp

The error indicator lamp is installed at the driver's position. The fault light can issue the following signals:
Operating control
10

– 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-M257EN (06/01/2016)
 ENGINE TROUBLESHOOTING 5

INJECTION CODE

bb Warning: the injector number in the error codes is equal to the firing order but different than

10
the cylinder number

FAN CHECK POINTS

There are two main cases:

1 - The fan runs continuously at maximum speed (approx. 1,800 rpm): this may be due to an electrical
system control fault (degraded mode) or a sticking electrovalve;
2 - The fan does not reach maximum speed: this may be caused by a lack of hydraulic power (engine
or pump) or a sticking electrovalve.

ENGINE ERROR CODES

o 80 - ELECTRICAL TROUBLESHOOTING

(06/01/2016) 10-08-M257EN
 6 ENGINE TROUBLESHOOTING
10

10-08-M257EN (06/01/2016)
 10
SPECIFIC ENGINE TOOLING

pages

ELECTRONIC TENSION METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

ADDITIONAL ENGINE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

(06/01/2016) 10-09-M257EN
 2 SPECIFIC ENGINE TOOLING

ELECTRONIC TENSION METER

Electronic tension meter (Ref 895692) for controlling belt tension.
10

ADDITIONAL ENGINE TOOLS

l 647461EN (TCD/TD 3.6 L4 ENGINE) - SPECIFIC TOOLING

10-09-M257EN (06/01/2016)
 TRANSMISSION

- TRANSMISSION SCHEMATIC DIAGRAMS

20
- TRANSMISSION COMPONENTS LOCATION

- TRANSMISSION CONTROL AND

ADJUSTMENT

- TRANSMISSION REMOVAL

- SPECIFIC TRANSMISSION TOOLING

- CHARACTERISTICS AND SPECIFICATIONS

- FLOW DIAGRAMS AND SCHEMATIC l547982

DIAGRAMS
(Gearbox
- TROUBLESHOOTING Series PSR09)

- SPECIFIC TOOLING
 TRANSMISSION SCHEMATIC DIAGRAMS

20
pages
MECHANICAL TRANSMISSION (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– DRIVE TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– OPERATION OVERVIEW (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– GEARBOX PORT LOCATIONS (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
–– NEUTRAL (STANDARD) SCHEMATIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
–– FORWARD GEAR (STANDARD) SCHEMATIC LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
–– REVERSE GEAR (STANDARD) SCHEMATIC LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

(06/27/2016) 20-02-M257EN
 2 TRANSMISSION SCHEMATIC DIAGRAMS

MECHANICAL TRANSMISSION (STANDARD)

DRIVE TRAIN

Front axle Rear axle

Clockwise
20

Engine

Torque converter

Z4 Z3
Z2 Z2

Z1

Z5 Z6 Z7 Z8 Z9 Z23

Z22

Z10 Z11 Z12 Z13

Gearbox

Forward gear

Z24 Z25 Z26

Gearbox Standard axle

Gear Number of teeth Gear Number of teeth
Z1 45 Z22 9
Z2 47 Z23 34
Z3 37 Z24 70
Z4 37 Z25 14
Z5 71 Z26 27
Z6 23
Z7 32
Z8 46
Z9 71
Axle option 35 km/h
Z10 49
Gear Number of teeth
Z11 43
Z22 12
Z12 33
Z23 35
Z13 30
Z24 70
Z25 14
Z26 27

20-02-M257EN (06/27/2016)
 TRANSMISSION SCHEMATIC DIAGRAMS 3

OPERATION OVERVIEW (STANDARD)

ECU
ECU
PAD Manimux
X138 Engine
Cluster
30
20
X100
10

X45 X181
1
0
1/2

R
H

3
C
0
6
2
9
5
1
8
4

NF

20
CAN A

CAN B

X60
X121
X38
X67

X32
ECU
Manimux
X52 NO
Power 1

X133

X56 X57 X58

X55 X62
X54 X92
X53
Gearbox

Key:

M: Engine X133: ON/OFF negative brake pressure switch

X32: Rear right headlight X138: Emergency stop
X38: Reversing buzzer X181: Accelerator pedal potentiometer
X45: Door switch (NC)
X52: Door switch (NO)
X53: Forward gear electrovalve
X54: Reverse gear electrovalve
X55: Forward gear sensor
X56: Reverse gear sensor
X57: Forward clutch pressure
X58: Box temperature sensor
X60: Gear lever transmission cut-off
X62: Gearbox output speed sensor
X67: JSM lever control
X92: Negative brake electrovalve control
X121: Seat

(06/27/2016) 20-02-M257EN
 4 TRANSMISSION SCHEMATIC DIAGRAMS

Forward/ Forward/reverse selector

Connectors Driver presence reverse selector Gear selection
authorization Forward gear Neutral Reverse gear

X32 √

X38 √

X45 √ √
20

X52 √ √

X53 √

X54 √

X55 √

X56 √

X57 √ √ √

X58 √ √ √

X60 √ √ √ √

X62 √ √

X67 √ √

X92 √

X121 √ √

X133 √

X138 √ √ √ √ √ √

X181 √ √ √
Indicator light Indicator light
Indicator light C1
A1 flashes then B1 flashes then
comes on and the
remains steady the remains steady the
parking brake is
moment you press moment you press
applied (negative
on the accelerator on the accelerator
brake)
pedal pedal

A1

In order to
C1
change gear,
Authorizes
it is necessary
hydraulic Authorized if
to cut the
Comments movements driver presence B1 transmission
and truck travel confirmed
by pressing the
movements
button on the
Reversal of direction is permitted below 11 km/h. Above this lever
speed the gear selection is forced to neutral.

Order + activation Neutral Order without

activation

20-02-M257EN (06/27/2016)
 TRANSMISSION SCHEMATIC DIAGRAMS 5

GEARBOX PORT LOCATIONS (STANDARD)

46
37
45

12
31

20
16

11
13 32

Components
Item Designation
11 Coolant inlet
12 Coolant outlet
13 Oil filter inlet
16 Oil filter outlet
31 Main pressure test port
32 Lubrication pressure test port
37 Converter pressure test port
45 Clutch reverse gear pressure test port
46 Forward clutch pressure test port

(06/27/2016) 20-02-M257EN
 6 TRANSMISSION SCHEMATIC DIAGRAMS

NEUTRAL (STANDARD) SCHEMATIC DIAGRAM

RETURN

CONVERTER PRESSURE

REGULATED PRESSURE
20

37 32

Cooler Lubrication

Hose Hose
Relief valve
valve: 8.5 bar

Relief valve
valve: 18 - 22 bar

31

STANDARD MODULATION VALVE

Forward / Reverse / Neutral Gear Selector

Modulation
valve

Analog
pressure
Pressure switch switch X55

Modulation
valve
Hose
BYPASS VALVE
3.44 / 3.94 bar

Analog
Filter pressure
switch X56

45 46

Hose

REVERSE Gear FORWARD Gear

Pump

Suction strainer

Breather

Oil tank

20-02-M257EN (06/27/2016)
 TRANSMISSION SCHEMATIC DIAGRAMS 7

FORWARD GEAR (STANDARD) SCHEMATIC LAYOUT

RETURN

CONVERTER PRESSURE

REGULATED PRESSURE

20
Torque converter
37 32

Cooler Lubrication

Hose Hose
Relief valve
valve: 8.5 bar

Relief valve
valve: 18 - 22 bar

31

STANDARD MODULATION VALVE

Forward / Reverse / Neutral Gear Selector

Modulation
valve

Analog
pressure
Pressure switch switch X55

Modulation
valve
Hose
BYPASS VALVE
3.44 / 3.94 bar

Pressure
Filter switch
analog
X56
45 46

Hose

REVERSE Gear FORWARD Gear

Pump

Suction strainer

Breather

Oil tank

(06/27/2016) 20-02-M257EN
 8 TRANSMISSION SCHEMATIC DIAGRAMS

REVERSE GEAR (STANDARD) SCHEMATIC LAYOUT

RETURN

CONVERTER PRESSURE

REGULATED PRESSURE
20

Converter
37 torque 32

Cooler Lubrication

Hose Hose
Relief valve
valve: 8.5 bar

Relief valve
valve: 18 - 22 bar

31

STANDARD MODULATION VALVE

Forward / Reverse / Neutral Gear Selector

Valve
Modulation

Pressure
switch
Pressure switch analog
X55

Valve
Modulation
Hose
BYPASS VALVE
3.44 / 3.94 bar

Pressure
Filter switch
analog
X56
45 46

Hose

REVERSE Gear FORWARD Gear

Pump

Suction strainer

Breather

Oil tank

20-02-M257EN (06/27/2016)
 TRANSMISSION COMPONENTS LOCATION

20
pages

TRANSMISSION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

(04/15/2016) 20-03-M257EN
 2 TRANSMISSION COMPONENTS LOCATION

TRANSMISSION SYSTEM
20

Rear axle

Gearbox

Filter
Gearbox
Front drive axle

20-03-M257EN (04/15/2016)
 TRANSMISSION COMPONENTS LOCATION 3

COOLING SYSTEM

Cooler 20

Gearbox

(04/15/2016) 20-03-M257EN
 4 TRANSMISSION COMPONENTS LOCATION
20

20-03-M257EN (04/15/2016)
 TRANSMISSION CONTROL AND ADJUSTMENT

20
pages

LOCATION: PRESSURE TEST PORTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

PRESSURE TEST PORT VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TRANSMISSION ASSEMBLY TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
BLOCKING 4TH GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

(06/17/2016) 20-04-M257EN
 2 TRANSMISSION CONTROL AND ADJUSTMENT

LOCATION: PRESSURE TEST PORTS

20

PP-45
X56 PP-46

PP-37 X55
PP-31

PP-32

20-04-M257EN (06/17/2016)
 TRANSMISSION CONTROL AND ADJUSTMENT 3

PRESSURE TEST PORT VALUES

No. of pressure test Values (bar)

Element Correspondence
ports Min. Max.

PP-31 Main pressure 19 20.5

20
PP-32 Lubricating pressure 1.5 6

Converter inlet
Gearbox PP-37 3.5 12
pressure

Forward Gear clutch

PP-45 pressure 0/1 19
(=X55)

Reverse Motion clutch

PP-46 pressure 0/1 19
(=X56)

Note:

Two pressure switches connected to X55 and X56 on the electrovalve enable the Forward Motion clutch
pressure (PP-45) and Reverse Motion clutch pressure (PP-46) to be displayed on the Pad tool.

TRANSMISSION ASSEMBLY TIGHTENING TORQUES

40 N.m ± 10%

100 N.m ± 10%

32 N.m ± 10%

(06/17/2016) 20-04-M257EN
 4 TRANSMISSION CONTROL AND ADJUSTMENT

BLOCKING 4TH GEAR

–– Remove cap 1.
20

–– Insert screw 2.

bb Observe tightening torque: 11 N.m so as to break screw head.

20-04-M257EN (06/17/2016)
 TRANSMISSION REMOVAL

20
pages

PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

GEARBOX REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

(05/27/2016) 20-06-M257EN
 6 TRANSMISSION REMOVAL

PREPARATION AND SAFETY INSTRUCTIONS

Stabilize the machine on level ground.

Maneuver the machine a number of times in forward and reverse (wheels straight) in order to release
any stresses acting on the steering and tires.

Raise the boom up again to mid-height and install the safety wedge.

bb
20

Deactivate battery power supply by means of the battery cut-off.

Operate the battery cut-off no less than 30 seconds after turning off the ignition with the
ignition key.

Open the engine covers.

To remove the engine and gearbox, turn the front and rear wheels to the right:

Specific tooling:

- Pallet truck
- Hoist.
- Jib crane (minimum 1,000 kg)

20-06-M257EN (05/27/2016)
 TRANSMISSION REMOVAL 7

GEARBOX REMOVAL
1
1 Support the gearbox with a pallet truck.

Then perform operation "10 - ENGINE REMOVAL" without

removing the retaining screws from the gearbox.

In the cab, disconnect connector X121 from the seat (pneumatic

20
seat option) and remove the seat mounting.

Remove the 2 hydraulic pump fastening screws (Item 1).

2
In the boom, mark the gearbox connectors (Item 1), X58 (Item 2),
1
5 X62 (Item 3).

4 Remove the wiring bracket (Item 4).

Disconnect the gearbox cooler hose.

1 1

1 Mark the position of the gear lever and remove it (Item 5).

1
1
3

On the back of the gearbox, remove the hose mounting screws

(Item 1).

Remove the universal joint spacers (Item 2), making sure to hold
the bearing cages in place.
1
2
Disconnect the gearbox cooler hose.
1
2

On the front of the gearbox, remove the hose mounting (Item 1),
on the gearbox mounting.

Remove the universal joint spacers (Item 2), making sure to hold
1 the bearing cages in place.

Disconnect the 2 hoses towards the filter.

2 2

Perform the operation "40 - PARKING BRAKE REMOVAL".

3

(05/27/2016) 20-06-M257EN
 8 TRANSMISSION REMOVAL

Under the gearbox, loosen the lower screw of the mounting

(Item 1).

Remove the lower screw (Item 2).

2

Disengage the hydraulic pump.

Remove the engine-gearbox assembly carefully.

20

1 1 Remove the screws (Item 1).

1 1

Remove the shorter screws (Item 2).

1 1

1 1
Disconnect the gearbox.

1 1
For the refit, perform the removal operations in reverse order,
2 2 tightening to the specified torques, and top up if necessary.

20-06-M257EN (05/27/2016)
 SPECIFIC TRANSMISSION TOOLING

20
pages

BASIC MANOMETER SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

DIGITAL MANOMETER SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
50 MM MACHINED SOCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

(03/08/2016) 20-09-M257EN
 2 SPECIFIC TRANSMISSION TOOLING

BASIC MANOMETER SET

This box contains all the components required for measuring

pressure on all Manitou products.
20

2 3 5

1 3 4 5

Basis gauge kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .549671

Consisting of:

1 - 1 gauge 1/9 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549882

2 - 1 gauge 0/40 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549883
3 - 2 gauge 0/60 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549884
4 - 1 gauge 0/400 bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549885
5 - 2 gauge 0/600 bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549886
6 - 4 standard hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549887
7 - 2 hoses for telehandler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549888
8 - 7 gauge tap connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549889

20-09-M257EN (03/08/2016)
 SPECIFIC TRANSMISSION 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

20
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 - 1 digital gauge ΔP HP 700 bar

2 - 1 measurement hose DN2 1215/1620, L = 1,5m, 630 bar
3 - 2 measurement hoses DN2 1620/1620, L = 1,5m, 630 bar
4 - 2 gauge adaptors 1620

(03/08/2016) 20-09-M257EN
 4 SPECIFIC TRANSMISSION TOOLING

50 MM MACHINED SOCKET

Socket 50 machined to an outer diameter of 65 mm which is used to dismantle the flanges connecting
the transmission shaft to the gearbox.
20

Ø 65

20-09-M257EN (03/08/2016)
 AXLE

- AXLE CONTROL AND ADJUSTMENT a

l 547983EN
- AXLE TROUBLESHOOTING
(Axle type 212)
- SPECIFIC AXLE TOOLING

30
 BRAKE

- BRAKE CHARACTERISTICS AND

SPECIFICATIONS

- BRAKE SCHEMATIC DIAGRAMS i70 - HYDRAULICS

- BRAKE COMPONENTS LOCATION i70 - HYDRAULICS
- BRAKE CONTROL AND ADJUSTMENT

- BRAKE REMOVAL

40
- SPECIFIC BRAKE TOOLING

- BRAKE CONTROL AND ADJUSTMENT

l547983EN
- BRAKE TROUBLESHOOTING
(AXLE 212)
- SPECIFIC BRAKE TOOLING
 BRAKE CHARACTERISTICS AND SPECIFICATIONS

pages

SERVICE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

40
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

(03/08/2016) 40-01-M257EN
 BRAKE CHARACTERISTICS
2 AND SPECIFICATIONS

SERVICE BRAKE

Liquide de frein LHMS

LHMS brake fluid

MAX

Vers pont arrière

263 Towards rear drive axle
(same as front (Idem
drive axle)
pont avant)
ilel
Oi
Hu
Epicycloidal
Réducteur Èpicycloïdale
step-down
R= 1/6 gear
R = 1/6
76
Maitre-cylindre
Master cylinder
Ø31.74 mm
Cylindrée: 31.65 cm3
Ø 31,75 mm
Cyl.: 30.9 cm³
40

Oil bath disc brake:

Number of discs per wheel front / rear 4/3
Braking area per disc face 146.85 cm2
Recommended operating pressure 70 to 80 bar
Friction material Paper N266
Disc diameter 201.5 mm
Disc thickness 4.75 - 4.85 mm
Action radius 88 mm
Number of slave cylinders 1
Wear compensation Auto
Track width 26.75 mm

40-01-M257EN (03/08/2016)
 BRAKE CHARACTERISTICS
AND SPECIFICATIONS 3

PARKING BRAKE

Block
Power supply + Accumulator
BLOC ALIM+ACCU

40
U1

Disc brake on gearbox

Number of discs 1
Braking area per disc face 51.1 cm2
Total braking area 102.2 cm2
Friction materials asbestos-free
(new: brake pad clearance = 0.5 mm
Play
run-in: brake pad clearance = 0.25 to 0.38 mm)
Disc diameter 290 mm
Disc thickness 10 mm
Wear adjustment mechanical

(03/08/2016) 40-01-M257EN
 BRAKE CHARACTERISTICS
4 AND SPECIFICATIONS
40

40-01-M257EN (03/08/2016)
 BRAKE CONTROL AND ADJUSTMENT

pages

SERVICE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

40
–– PEDAL SYSTEM STOP ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– BLEEDING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– BLEEDING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
–– FREEWHEEL AND TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

(03/08/2016) 40-04-M257EN
 2 BRAKE CONTROL AND ADJUSTMENT

SERVICE BRAKE

PEDAL SYSTEM STOP ADJUSTMENT

Brake pedal (Item 1):

–– Use the stop (Item 2) to set the brake pedal (Item 1) to a height of 120 mm above the cab floor
(without floor mat).

–– Tighten the lock nut (Item 3).

–– Adjust the brake pedal free travel (2 to 3 mm clearance at the end of the pedal), unblock the stop-
bolt (Item 4) and turn the push-button (Item 5).

–– Tighten the lock nut (Item 4).

40

Brake pedal position

at rest

1
120

40-04-M257EN (03/08/2016)
 BRAKE CONTROL AND ADJUSTMENT 3

BLEEDING PROCEDURE

Location:

FDar
MC
RLF
VP
VP

40
VP

VP FDav

Key:

FDar: Rear brake disc

FDav: Front brake disc
MC: Master cylinder
RLF: Brake fluid tank
VP: Bleed screw

Open the front cover (Item 1).

(03/08/2016) 40-04-M257EN
 4 BRAKE CONTROL AND ADJUSTMENT

The oil tank should be lifted before bleeding. This is done by

removing the tank and placing it on the support provided (Item 2).

4 Use a bleeder (Item 3): Pressure between 1 and 1.2 bar.

Fit the brake bleeder adapter (Item 4) to the tank.

40

Place a transparent recovery hose onto the front right bleed

screw (Item VP).

Operate the bleeder.

VP

Loosen the bleed screw, then re-tighten it once the brake fluid
is flowing without air bubbles.

Repeat the operation for the 3 front and rear axle bleed screws.

Top up brake fluid level (Shell LHM S fluid).

40-04-M257EN (03/08/2016)
 BRAKE CONTROL AND ADJUSTMENT 5

PARKING BRAKE
ADJUSTMENT PROCEDURE

– Apply hydraulic pressure to the brake (min . 80 bar) .

– Remove the cap (Item 1) and completely undo the adjusting screw (Item 2) .
– Undo the locknut (Item 4) and adjust the pad A clearance to 0 .3 mm using the adjusting screw (Item 3) .
– Retighten the locknut (Item 4) .
– Adjust the clearance from pad B to 0 .3 mm using the adjusting screw (Item 2) .
– Refit the cap (Item 1) .
– Check that the brake linings are free .
– Lower the hydraulic pressure .

b If the total maximum clearance exceeds 2.5 mm, the parking brake needs to be adjusted.

40
6
A B

4
5

6 1 +1 +1
0,3 0 0,3 0

When refitting the parking brake, tighten both screws (Item 5)

by applying a rotation of 1 .5 to 2 turns in order to compress the
washers (Item 6) by about 1 .5 to 2 .0 mm .
5
5

6 6

(03/08/2016) 40-04-M257EN
 6 BRAKE CONTROL AND ADJUSTMENT

BLEEDING PROCEDURE

bb Place on level ground.

Chock the front and rear wheels.

–– Start the truck to charge the accumulator.

–– Stop the truck.

–– Switch the ignition on again.

–– Connect up cable (Part no. 265865) between parking brake electrovalve (Item 1) and cigarette lighter.

–– Open the bleed screw (Item 2).

–– Close the bleed screw (Item 2) when flow is constant (no air bubbles).

–– Remove the cable (Part no. 265865).

40

90°

40-04-M257EN (03/08/2016)
 BRAKE CONTROL AND ADJUSTMENT 7

FREEWHEEL AND TOWING

bb This maneuver is dangerous. Carefully chock up forklift

truck before towing since the parking brake system is
inoperative.

Place the forward/reverse selection lever and gear lever in neutral.

1 Chock up the lift truck.

Remove the cap (Item 1).

Undo the screw (Item 2) with a socket wrench (Item 3) to release

the brake disc. Leave a minimum 5 mm clearance between the
disc (Item 4) and the brake pads (Item 5).

40
Put the towing device in place.

Remove the chocks.

Switch on the hazard warning lights.

3 bb Do not tow truck at a speed greater than 6 km/h. Maximum

towing distance: 5 km.

5 5

2.5 mm 2.5 mm

(03/08/2016) 40-04-M257EN
 8 BRAKE CONTROL AND ADJUSTMENT
40

40-04-M257EN (03/08/2016)
 BRAKE REMOVAL

pages

PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

40
–– BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– PARKING BRAKE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

(03/08/2016) 40-06-M257EN
 2 BRAKE REMOVAL

PARKING BRAKE

2
1

BRAKE PADS

Remove the cap (Item 3) from parking brake.

40

Unscrew the brake pads (Item 2) by undoing the adjusting screw

(Item 4).
6

Undo the long screw (Item 5).

4

Remove the brake pads.

6 PARKING BRAKE UNIT

Unscrew the two side screws (Item 6).

Remove the parking brake unit (Item 1).

40-06-M257EN (03/08/2016)
 SPECIFIC BRAKE TOOLING

pages

HYDRAULIC BRAKE BLEED VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

40
PARKING BRAKE BLEEDER HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

(03/08/2016) 40-09-M257EN
 2 SPECIFIC BRAKE TOOLING

HYDRAULIC BRAKE BLEED VALVE

Bleed valve supplied with all the components required for

bleeding the hydraulic brake circuits of Manitou products.
Operating instructions included.
40

MANITOU Reference

HYDRAULIC BRAKE BLEED KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .554019

SPARE PARTS:
– TOP MANOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 719980
– BOTTOM MANOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 719981
– Membrane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 661913
– HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 661914

PARKING BRAKE BLEEDER HARNESS

1000

MANITOU Reference

PARKING BRAKE BLEED HARNESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .265865

40-09-M257EN (03/08/2016)
 BOOM

- BOOM CHARACTERISTICS AND

SPECIFICATIONS

- BOOM SCHEMATIC DIAGRAMS

- BOOM COMPONENTS LOCATION

- BOOM CONTROL AND ADJUSTMENT

- SPECIFIC BOOM TOOLING

50
 BOOM CHARACTERISTICS AND SPECIFICATIONS

pages

TRIPLEX (MT 14 METERS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

QUADRUPLEX (MT 18 METERS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

50

(03/08/2016) 50-01-M257EN
 BOOM CHARACTERISTICS AND
2 SPECIFICATIONS

TRIPLEX (MT 14 METERS)

Consisting of 3 components:

- 1 fixed
- 2 moving

Deployment:

Deployment of Triplex boom controlled simultaneously.

⇒⇒ T1 and T2 extend at the same time.

Machines equipped with Triplex boom:

- MT 1435
- MT 1440

Boom weight:

- Approx. 2,710 kg
50

50-01-M257EN (03/08/2016)
 BOOM CHARACTERISTICS AND
SPECIFICATIONS 3

QUADRUPLEX (MT 18 METERS)

Consisting of 4 components:

- 1 fixed
- 3 moving

Deployment:

Quadruplex boom deployment controlled simultaneously.

⇒⇒ T1, T2 and T3 extend at same time.

Machines equipped with Quadruplex boom:

- MT 1840

Boom weight:

- Approx. 3,092 kg

50

(03/08/2016) 50-01-M257EN
 BOOM CHARACTERISTICS AND
4 SPECIFICATIONS
50

50-01-M257EN (03/08/2016)
 BOOM SCHEMATIC DIAGRAMS

pages

CHAIN BOOM OPERATING MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

50

(03/08/2016) 50-02-M257EN
 2 BOOM SCHEMATIC DIAGRAMS
50

50-02-M257EN (03/08/2016)
 BOOM SCHEMATIC DIAGRAMS 3
CHAIN BOOM OPERATING MECHANISM

DIAGRAM OF HYDRAULIC CIRCUIT AT BOOM INTERMEDIATE POSITION

Hydraulic hoses (bottom layer)

Hydraulic hoses (top layer)

SCHEMATIC DIAGRAM OF CHAINS AT BOOM INTERMEDIATE POSITION T2 extend chain

T3 extend chain

50
T2 retract chain

Telescope T2 T3 retract chain

Telescope T3

Telescope T1

Boom foot

(03/08/2016) 50-02-M257EN
 4 BOOM SCHEMATIC DIAGRAMS
50

50-02-M257EN (03/08/2016)
 BOOM COMPONENTS LOCATION

pages

INDEX OF COMPONENT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

TX BOOM MAIN COMPONENT LOCATION (3 ELEMENTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
QX BOOM MAIN COMPONENT LOCATION (4 ELEMENTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

50

(03/08/2016) 50-03-M257EN
 2 BOOM COMPONENTS LOCATION

INDEX OF COMPONENT CODES

pages

- TX boom main component location................................................................................. 3

Item Designation
CSD Double safety valve
CSP Counterbalance valve
T1 Telescope 1
T2 Telescope 2
VT1 Telescope cylinder 1
VT2 Telescope cylinder 2
X134 Retracted boom sensor

pages

- QX boom main component location................................................................................ 4

50

Item Designation
CSD Double safety valve
VT Telescope cylinder
B67 Intermediate boom extend sensor 1
B68 Intermediate boom extend sensor 2
S34 Retracted boom sensor
X134 Retracted boom sensor
X202 Intermediate boom extend sensor 2
X203 Intermediate boom extend sensor 1

50-03-M257EN (03/08/2016)
 BOOM COMPONENTS LOCATION 3
TX BOOM MAIN COMPONENT LOCATION (3 ELEMENTS)

CSD

CSD

VT2

T2

50
VT1
T1

CSP

X134

(03/08/2016) 50-03-M257EN
 4 BOOM COMPONENTS LOCATION
QX BOOM MAIN COMPONENT LOCATION (4 ELEMENTS)

VT
50

X134 / S34

X203
CSD X202

B67
B68

50-03-M257EN (03/08/2016)
 BOOM CONTROL AND ADJUSTMENT

pages

PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHECKING BOOM CHAIN WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
–– OUTER CHAINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

50
–– INNER CHAINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DISMANTLING CHAIN BOOM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
–– GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
–– STAGES INVOLVED FOR CHANGING CHAINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
–– "HYDRAULIC KIT" REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
–– "TELESCOPE T2 + T3 ASSEMBLY" REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
–– "TELESCOPE T3" REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
REASSEMBLING CHAIN BOOM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
–– GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
–– "TELESCOPE T3" REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
–– "TELESCOPE T2 + T3 ASSEMBLY" REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
–– CHAIN TENSION PRESETS DURING REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
–– CHECKING AND SETTING CHAIN TENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
–– "HYDRAULIC KIT" REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

(03/08/2016) 50-04-M257EN
 2 BOOM CONTROL AND ADJUSTMENT

PREPARATION AND SAFETY INSTRUCTIONS

• Stabilize the machine on level ground.

• Deactivate battery power supply by means of the battery cut-off.
• Decompress all hydraulic components.

Weight of complete boom = approx. 3,092 kg

Specific tooling:

–– Lifting system (Hoist + strap)

–– Mallet

–– Crowbar

–– Wooden chock

–– Rope
50

–– Trestles

–– Channel lever e 50 "Specific tools"

–– Hose routing support tool e 50 "Specific tools"

–– Hose tension adjustment gauge e 50 "Specific tools"

–– Chain checking gauge e 50 "Specific tools"

50-04-M257EN (03/08/2016)
 BOOM CONTROL AND ADJUSTMENT 3

IMPORTANT INFORMATION

bb Check internal chain wear during the dismantling procedure.

"Checking boom chain wear".

bb When changing a chain, replace the pair and measure the difference in length between the chains.

bb Where dismantling and reassembly are performed without changing the chain (worn chains
not replaced with new ones), measure the presetting dimensions on the machine (Items 7 & 8)
before the start of dismantling. These dimensions will be useful for presetting the chain tensions
when reassembling.
"Chain tension presets"

Example of preset

50
6

4 1

7 3

XLeft hand chain

5
6

XRight hand chain

Key:

1 Chain 6 Counternut
2 Chain tensioner 7 Dimension to read on left chain tensioner before
3 Boom dismantling.
4 Belleville washers 8 Dimension to read on right chain tensioner before
5 Nut dismantling.
(03/08/2016) 50-04-M257EN
 4 BOOM CONTROL AND ADJUSTMENT

CHECKING BOOM CHAIN WEAR

OUTER CHAINS

Chain wear occurs at a number of locations:

• On the joints, which leads to elongation of the chain.

• On the edge of link plates through contact with the pulleys.
• On the face of the plates and the extended pins through contact with the pulley flanges.
• On the alignment of the flats of the extended pins.

CHAIN ELONGATION

We recommend that you perform this operation using the chain checking gauge.

e 50 - "Specific boom tooling"

–– Set the lift truck on its stabilizers, with the boom horizontal.
–– Fully extend the telescopes and continue operating the control for a few moments to properly tension
the chains.
–– As the chain will likely wear unevenly over its length, divide the chain into 4 equal sections and check
50

with the gauge at the center of each section.

T2 extend chain T3 extend chain

25.4 mm x 9 = 228.6 mm 19.05 mm x 12 = 228.6 mm

25.4 mm 19.05 mm

= = = = = = = =

bb If the dimension is greater than the maximum dimension (228.6 mm +2% = 233.2 mm), replace
the pair of chains.

50-04-M257EN (03/08/2016)
 BOOM CONTROL AND ADJUSTMENT 5

PLATE EDGE WEAR

As for chain elongation, perform a check in the middle of each equal section using a caliper gauge.

15.5 mm
24 mm

T2 extend chain T3 extend chain

bb If the dimension is less than the minimum dimension (24 mm - 2% = 23.5 mm and 15.5 mm -2%
= 15.2 mm), replace the pair of chains.

EXTENDED PIN WEAR

As for chain elongation, perform a check in the middle of each equal section using a caliper gauge.
42,25 mm
53,6 mm

50
T2 extend chain T3 extend chain

bb If the dimension is less than the minimum dimension (53.6 mm - 2% = 52.5 mm and
42.25 mm -2% = 41.4 mm), replace the pair of chains.

–– In addition to wear, the high pressures between the side of the plates and the pulleys may force out
material, causing the joints to seize. Replace the pair of chains in this case also.

ALIGNMENT OF EXTENDED PIN FLATS

Check the chains over their entire length.

–– High friction between the plates and the extended pins may cause the pins to turn within the outer
plates and thus come out of their housing.

NOT OK OK

bb If the flats are not aligned in the longitudinal direction of the chain, replace the pair of chains.

(03/08/2016) 50-04-M257EN
 6 BOOM CONTROL AND ADJUSTMENT

INNER CHAINS

The telescopes need to be dismantled to check the boom inner chains.

e "Dismantling chain boom components".

Chain wear occurs at a number of locations:

• On the joints, which leads to elongation of the chain.

• On the edge of link plates through contact with the pulleys.
• On the face of the plates and the extended pins through contact with the pulley flanges.
• On the alignment of the flats of the extended pins.

CHAIN ELONGATION

We recommend that you perform this operation using the chain checking gauge.

e 50 - "Specific boom tooling"

–– As the chain will likely wear unevenly over its length, divide the chain into 4 equal sections and check
with the gauge at the center of each section.
50

19.05 mm x 12 = 228.6 mm

19.05 mm

bb If the dimension is greater than the maximum dimension (228.6 mm +2% = 233.2 mm), replace
the pair of chains.

PLATE EDGE WEAR

As for chain elongation, perform a check in the middle of each equal section using a caliper gauge.
15.5 mm

bb If the dimension is less than the minimum dimension (15.5 mm - 2% = 15.2 mm), replace the
chain or pair of chains.

50-04-M257EN (03/08/2016)
 BOOM CONTROL AND ADJUSTMENT 7

EXTENDED PIN WEAR

As for chain elongation, perform a check in the middle of each equal section using a caliper gauge.

42.25 mm

bb If the dimension is less than the minimum dimension (42.25 mm - 2% = 41.4 mm), replace the
chain or pair of chains.

–– In addition to wear, the high pressures between the side of the plates and the pulleys may force out
material, causing the joints to seize. Replace the pair of chains in this case also.

ALIGNMENT OF EXTENDED PIN FLATS

Check the chains over their entire length.

–– High friction between the plates and the extended pins may cause the pins to turn within the outer
plates and thus come out of their housing.

50
NOT OK OK

bb If the flats are not aligned in the longitudinal direction of the chain, replace the chain or pair
of chains.

(03/08/2016) 50-04-M257EN
 8 BOOM CONTROL AND ADJUSTMENT

DISMANTLING CHAIN BOOM COMPONENTS

50

GENERAL INFORMATION

In order better to understand chain boom operation and dismantling procedure:

o 50 "Boom schematic diagram"

The "chain boom component dismantling" operation is broken down into a number of stages:

• "Hydraulic kit" removal

• "Telescope T2 + T3 assembly" removal

⇒⇒ The "Hydraulic kit removal" operation must be completed

• "Telescope T3" removal

⇒⇒ The "Hydraulic kit removal" and "Telescope T2 + T3 assembly" operations must be completed

These various stages are detailed below in this chapter.

50-04-M257EN (03/08/2016)
 BOOM CONTROL AND ADJUSTMENT 9

STAGES INVOLVED FOR CHANGING CHAINS

50
The table below shows the various actions to be taken according to the chains to be replaced.

Chain designation Action to be taken

Extend T2
Extract T2+T3 assembly.
Retract T3

Extract T1+T2+T3+ hydraulic kit assembly.

Comment:
Retract T2

It is not obligatory to remove the hydraulic kit to change the "Retract

T2" chain

Extend T3 Extract T2+T3 assembly, the extract T3.

(03/08/2016) 50-04-M257EN
 10 BOOM CONTROL AND ADJUSTMENT
50

5 "HYDRAULIC KIT" REMOVAL

1

Remove protection cover (Item 1) by undoing the 4 screws

(Item 2).
2
5

Undo the 2 screws (Item 3) from the "attachment hydraulic

4 tube support bracket" (Item 4) on the right hand side of the
3 boom head.

3 Take out two hydraulic tube clamps (Item 5).

Undo the two screws (Item 6) that hold the bracket (Item 7)
supporting the two hydraulic tubes on the left side of the
6
boom head.

7
6

50-04-M257EN (03/08/2016)
 BOOM CONTROL AND ADJUSTMENT 11

Disconnect the electrical connector (Item 8).

Undo the boom head stop (Item 12).

12 Place an oil container under boom head.

Pull the set of five hydraulic tubes (Item 13) to the outside of the
13
13 boom head then unscrew using 27 mm and 30 mm wrenches.
13
13
13 Then use stoppers to plug the hydraulic connections to prevent
any flow of oil.

50
Pull on the set of five hydraulic hoses (Item 14) to pull out the
clamp (Item 15).

15

14

Undo the two screws (Item 16) of the clamp.

Remove the clamp (Item 15).

Reposition the hydraulic hosing pieces (Item 14) in boom head

15
so that they do not become caught when the hydraulic kit is
extracted.

16

14

(03/08/2016) 50-04-M257EN
 12 BOOM CONTROL AND ADJUSTMENT

Unscrew and remove the rear cover (Item 17) attached to frame
(6 screws).

17

Remove the "hose guide" (Item 18) by unscrewing the 2 screws

(Item 19) on either side.

18

19 19
50

Unscrew pulley axle greasing nipple (Item 20).

20

Unscrew the two stops (Item 21) positioned on the "spring

supports" (Item 22).
21
22 21 22
Using a 22 mm socket wrench (Item 24), turn the screw (Item 23)
23
on each side in a clockwise direction to slacken the hose tensioning
23
24 system.

50-04-M257EN (03/08/2016)
 BOOM CONTROL AND ADJUSTMENT 13

Using the special "channel lever" (Item 25), pull the channel
(Item 26) to slacken the hoses (Item 27).

26

25

27

Undo the right hand side "pulley support bracket" (Item 28) by
removing the 3 screws (Item 29) with a 15 mm wrench.

29

29

29

50
28

Firstly, remove only the "pulley support bracket" (Item 28) on

28
the right hand side.

Remove the right hand pulley (Item 30) from its axle (Item 31).

Do the same for the central pulley (Item 32).

31
Then remove the left hand pulley (Item 33) together with its
axle (Item 31).
33 32 30

Undo the left hand side "pulley support bracket" (Item 34) by
removing the 3 screws (Item 35) with a 15 mm wrench.
35

35

35

34

(03/08/2016) 50-04-M257EN
 14 BOOM CONTROL AND ADJUSTMENT

If possible use the "channel lever" (Item 25) to push the channel
(Item 26) so as to gain better accessibility for undoing the two
screws of the "spring supports"
26

25

Using a 13 mm wrench, undo the two screws (Item 36) of the

right hand side "spring support" (Item 37).
37
Repeat the operation on the left hand side "spring support".
36
36
50

Attach electrical harness (Item 38) with a tie (Item 39) to prevent
it being damaged when the hydraulic kit (Item 40) is extracted.
39
38
Pull the "hydraulic kit" assembly (Item 40) out by about 50 cm
so as to gain access for disconnecting the five hoses and
40
disconnecting electrical connector.

Place an oil container under hoses.

42
Disconnect five hoses (Item 41) using 27 mm and 30 m wrenches.

Plug the hose ends with stoppers (Item 42).

41
41
41 Disconnect the electrical connector (Item 43).
41
43
41

50-04-M257EN (03/08/2016)
 BOOM CONTROL AND ADJUSTMENT 15

Use a rope (Item 44) to tie the hoses against the truck so that
they do not hamper hydraulic kit extraction.

44

Pull the "hydraulic kit" assembly (Item 45) out by about 1 meter.
47

Also pull out the hoses (Item 46) above it to assist extraction.
46

Place the sling and hoist (Item 47) to support the assembly
during extraction.
45

50
Pull out the "hydraulic kit" assembly (Item 45), checking that
46
hoses (Item 46) come with it.

Set down the "hydraulic kit" assembly (Item 45) on two trestles
(Item 48).
48
45

48

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 16 BOOM CONTROL AND ADJUSTMENT

"TELESCOPE T2 + T3 ASSEMBLY" REMOVAL

4
⇒⇒ The "Hydraulic kit removal" operation must be completed.

5
Using a 24 mm wrench, undo the nuts and locknuts (Items 1 & 2)
3 of the "T3 extend chain tensioners" (Item 3) attached to telescope
2
T1 (Item 4).
1
5
3 Remove the Belleville washers (Item 5).
50

Remove the two chain tensioners (Item 3) on telescope T3.

Using a 36 mm wrench, undo the nuts and locknuts (Items 6 & 7)

of the "T2 extend chain tensioners" (Item 8) attached to boom
foot (Item 9).
9
10
6
Remove the Belleville washers (Item 10).

Remove the two chain tensioners (Item 8) on telescope T2.

10
8
7
6

Remove the two "T2 extend chain tensioners" (Item 8)

by removing the pins and cotter pins (Items 9 & 10).

9
10

50-04-M257EN (03/08/2016)
 BOOM CONTROL AND ADJUSTMENT 17

Undo the screw (Item 11) of the axle pin that holds the chain
rollers (Item 12) in place on telescope T1 (Item 4).
12

12

11

Use a tube and a mallet (Item 13) to free the roller axle pin (Item 14).

Remove the two rollers and their wedges.

13

14

50
Remove the circlip (Item 17) from the cylinder pin (Item 18).

17

18

Use 15 mm wrench to remove the four screws (Item 19) from the
20
telescope cylinder (Item 20) screws (Item 19) then remove the
19
fixing brackets (Item 21).
19
21
19

19
21

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 18 BOOM CONTROL AND ADJUSTMENT

Using a sling and hoist (Item 22), gently lift the cylinder (Item 23)
whilst pulling out cylinder pin (Item 24).
22

23

Use a tube and mallet (Item 25) to free the pin from its housing.

25

24
50

Raise cylinder sufficiently to gain access to the four nuts (Item 26).
23
Place a wooden chock (Item 27) between the cylinder (Item 23)
and the boom foot (Item 28).

27

28

Undo the four nuts (Item 26) of the "T2 retract chain tensioners"
(Item 29) without removing them.

26
29
26 26
26
29

50-04-M257EN (03/08/2016)
 BOOM CONTROL AND ADJUSTMENT 19

Undo the four screws (Item 30) of the "T2 retract chain blades"
(Item 31) attached to the back of telescope T2.
30 31
30 30
30

Remove the two nuts (Item 32) from the "T3 retract chain tensioner"
(Item 33) attached to the front of telescope T1.

32

32

33

50
35 Remove the left hand and upper pads (Item 35) + shims (Item 36) +
35 screws and nuts (Item 37) from the base of telescope T2 (Item 34).

36 This operation gives increased clearance to facilitate the extraction

36
34
of the T2 + T3 assembly.

36 37 37

37
37

37 37
35

Remove the brush seal (Item 38) at the bottom of the boom foot
(Item 39).
41

Remove all brush seals (Item 40) from telescope T1 (Item 41).
39
40

38

(03/08/2016) 50-04-M257EN
 20 BOOM CONTROL AND ADJUSTMENT

Separate the "T3 retract chain" (Item 42) from its tensioner
(Item 43) by removing the cotter pin (Item 44) and the pin
(Item 45).

45

44
43

42

Place a rope (Item 46) around the links at the end of the chain.

This operation is necessary so that the chain can be tensioned

during T2 + T3 assembly extraction to avoid any possible kinking.

46
50

Use a crowbar (Item 47) to slightly offset the T2+T3 assembly

(Item 48) from telescope T1 (Item 49).

49

47

48

50
Using a 19 mm socket wrench, undo the sixteen nuts (Item 50) of
the slide pads on telescope T1 (Item 49). Then undo the screws
and remove the pads + shims.
50 50

50 49

50-04-M257EN (03/08/2016)
 BOOM CONTROL AND ADJUSTMENT 21

51
Use the sling and hoist (Item 51) to pull out the "telescope T2
+ T3" assembly (Item 52) pulling on the "T3 retract chain" with
the rope (Item 53).

bb
52

Check that the "T3 retract chain" remains in tension during

T2 + T3 assembly extraction.

53

Pull on the "telescope T2 + T3" assembly but do not pull it out

completely.

Place a container (Item 54) to receive the "T3 retract chain"

(Item 55).

55

54

50
Position temporary shims (Item 56) between telescope T1 (Item 57)
and T2 (Item 58).
58

This will hold the boom straight and avoid crushing the "T3
retract chain" when moving the sling to the center of gravity of
57
the T2 + T3 assembly.

56 56

Reposition the sling (Item 59) at the center of gravity of the

"Telescope T2+T3" assembly to ensure it remains balanced when
removed.

Remove the temporary shims.

59
Completely remove the "telescope T2+T3" assembly and set it
down on two trestles.

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 22 BOOM CONTROL AND ADJUSTMENT
50

"TELESCOPE T3" REMOVAL

5 5

6
3 6 ⇒⇒ The "Hydraulic kit removal" and "Telescope T2 + T3 assembly
removal" operations must be completed.

7
Remove the left hand and upper slide pads (Item 5) + shims
7 7 (Item 6) + screws and nuts (Item 7) from the base of telescope
7
T3 (Item 3).
6

7
5
This operation gives increased clearance to facilitate the extraction
7
of telescope T3.

Undo the two nuts (Item 8) of the "pad support bracket" (Item 9).

Remove the support bracket.

10
10
9
8 Unscrew the two nuts (Item 10) of the "T3 retract chain blade"
8 (Item 11) attached to the back of telescope T3.
11

Remove the blade.

50-04-M257EN (03/08/2016)
 BOOM CONTROL AND ADJUSTMENT 23

Remove all the brush seals (Item 12) from telescope T2 (Item 13).

13 12

Remove the screw (Item 14) from the axle pin (Item 15) of the
rollers (Item 16).

15 Remove the axle pin (Item 15) then the rollers (Item 16).

16 14

50
Undo the sixteen nuts of the slide pads on telescope T2 (Item 17).
17

18 Then undo the screws (Item 18) and remove the pads + shims
19
18 (Item 19).
19

18
19
18

Using a sling and hoist (Item 20), gently lift telescope T3 (Item 21)
then remove the shims located between T2 and T3.
20

21

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 24 BOOM CONTROL AND ADJUSTMENT

Pull on telescope T3 (Item 21) but do not pull it out completely.

20 Place a wooden chock (Item 22) under the boom head.

This operation stabilizes the boom while the sling is moved to
the center of gravity of telescope T3.

Reposition the sling (Item 20) at the center of gravity of telescope

T3 to ensure it remains balanced during removal.
21
Fully remove telescope T3 and set it down.

22
50

50-04-M257EN (03/08/2016)
 BOOM CONTROL AND ADJUSTMENT 25

REASSEMBLING CHAIN BOOM COMPONENTS

50
GENERAL INFORMATION

In order to better understand chain boom operation and reassembly procedure:

e 50 "Boom schematic diagram"

The "chain boom component reassembly" operation is broken down into a number of stages:

• "Telescope T3" refit

• "Telescope T2 + T3 assembly" refit
⇒⇒ The "Telescope T3 refit" operation must be completed
• "Hydraulic kit" refit
⇒⇒ The "Telescope T3 refit" and "Telescope T2 + T3 assembly refit" operations must be completed

These various stages are detailed below in this chapter.

bb During the reassembly procedure:

- Grease the slip face of each slide pad before installation
- Grease the telescope sliding faces.

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 26 BOOM CONTROL AND ADJUSTMENT

"TELESCOPE T3" REFIT

bb Apply "Loctite 243 normal thread lock" to all screw/

insert and nut/screw connections located only on the
inside of the boom.

Refit all the slide pads (Item 1) at the bottom of telescope T3

(Item 2).

Place shims (Item 3) only on the underside of telescope T3 (Item 2).

50

Using a sling and hoist, insert telescope T3 into telescope T2 (Item

4) without fully inserting it. Leave a clearance of about 30 cm.

2 Use a crowbar to push the bottom of telescope T3 (Item 2)

against the bottom right hand side of telescope T2 (Item 4).

Measure the clearance "J1" between the two telescopes on left

1
hand side. Divide this value by 2 to determine the thickness of
3
3 the shim to be inserted on each side of telescope T3.
4
1
Shim thickness = J1/2
1

Insert a shim on either side of telescope T3.

5 Determine the clearance "J2" between the upper pad (Item 5)

6 J2 and the top of telescope T3.

Insert a shim (Item 6) under each pad (Item 5) to take up this

clearance (between 0 and 0.5 mm).

J1

50-04-M257EN (03/08/2016)
 BOOM CONTROL AND ADJUSTMENT 27

Insert the two pads (Item 7) and two shims (Item 8) into the top
of telescope T2 (Item 4).
Secure them by tightening their rods and nuts.

9 Insert the four side pads + rods (Item 9) on each side of telescope
4 T2.
9 J3
Insert the two pads + shims + rods on the top of telescope T2.
7
8
Use a crowbar (Item 10) to push telescope T3 (Item 2) against
10 2 the right hand side of telescope T2 (Item 4).

Measure the clearance "J3" between the two telescopes on the

left hand side. Divide this value by 2 to determine the thickness
of the shim to be inserted on each side of telescope T2.

Shim thickness = J3/2

Insert a shim (Item 11) on either side of telescope T2.

11
Total clearance between 0 and 0.5 mm.

50
Determine the clearance "J4" between the upper pad and the
13 shim (Item 13).

Insert a shim (Item 14) to take up this clearance.

14

J4
Tighten the rods and nuts of each pad according to the specified
tightening torques.

Observe the tightening torques and assembly recommendations.

9 mini

C1=15 N.m +- 15%

C1 = 15 N.m ± 15%
C2=92 N.m +- 15% C2 = 92 N.m ± 15%
Wedging

Fully insert telescope T3 into telescope T2.

0 +- 0,5

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 28 BOOM CONTROL AND ADJUSTMENT

Attach the "T3 retract chain blade" (Item 15). Tighten the two
screws (Item 16) to a torque of 95 N.m.

bb Bring the heel of the chain plate tightly against the

seating before tightening the fastening screws.

Refit the "pad support bracket" (Item 17) then tighten its two
nuts + washers (Item 18).

17 16 Apply "Loctite 243 normal threadlock" to the fasteners.

15

18 18
16
50

22
22 Refit all the slide pads (Item 22) at the bottom of telescope T2
(Item 23).

Place shims (Item 24) only on the underside of telescope T2

23
(Item 23).

24
22
22

24 22

50-04-M257EN (03/08/2016)
 BOOM CONTROL AND ADJUSTMENT 29

"TELESCOPE T2 + T3 ASSEMBLY" REFIT

1
⇒⇒ The "Telescope T3 refit" operation must be completed

Using a sling and hoist (Item 1), insert the "telescope T2 + T3"
assembly (Item 2) into telescope T1 (Item 3).
During this operation, check that the "T3 retract chain" feeds in
smoothly and remains in tension.
Place the "T2 extend chains" on the center of T2 to ensure that
2 they do not slide to the side.

50
Position temporary shims (Item 4) between telescope T1 (Item 3)
and telescope T2 (Item 5).
5
This will hold the boom straight and avoid crushing the "T3
retract chain" (Item 6) when moving the sling (Item 1) to the
4 boom head position.
4

3
1

1 Reposition the sling (Item 1) at the head of the boom then insert
the "telescope T2 + T3" assembly into telescope T1 (Item 3).

Comment: Do not insert the T2 + T3 assembly fully into T1. Leave

3 about 30 cm clearance.

Lift the T2 + T3 assembly and remove the temporary shims (Item 4).

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 30 BOOM CONTROL AND ADJUSTMENT

Insert 2 slide pads (Item 7) + 2 shims (Item 8) between telescopes

T1 (Item 3) and T2 (Item 5).
3
5

Tighten their rods + locating rings + nuts.

bb Apply "Loctite 243 normal thread lock" to all screw/

insert and nut/screw connections located only on the
inside of the boom.
50

Observe the tightening torques and assembly recommendations.

9 mini

C1=15 N.m +- 15%

C2=92 N.m +- 15% C1 = 15 N.m ± 15%

C2 = 92 N.m ± 15%
Wedging

0 +- 0,5

Insert the 2 slide pads (Item 9) + rods (Item 10) to the left hand
11 side of telescope T1 (Item 11).
10
9 Repeat the operation on the right hand side of telescope T1.
10

10

9
10

50-04-M257EN (03/08/2016)
 BOOM CONTROL AND ADJUSTMENT 31

Insert the 2 slide pads (Item 12) + shims (Item 13) at the top of
telescope T1 (Item 11).

11

13

12

Use a crowbar to push the head of telescope T2 against the right

hand side of telescope T1.

Measure the clearance "J1" between the two telescopes on left

hand side. Divide this value by 2 to determine the thickness of
the shim to be inserted on either side of telescope T1.
J1
Shim thickness = J1/2

Insert a shim on either side of telescope T1.

Total clearance between 0 and 0.5 mm.

50
Determine the clearance "J2" between the shim (Item 13) and
14
13 J2 the underside of telescope T1.

15 Insert shims (Item 14) on each slide pad to take up this clearance.
15
Tighten all the nuts of the slide pads (Item 15) to recommended
torque.
15

C1 = 15 N.m ± 15%
15
C2 = 92 N.m ± 15%

Attach the "T3 retract chain" (Item 16) to its tensioner (Item 17)
by refitting the pin and its cotter pin (Item 18).
17

Then fully insert the "telescope T2 + T3" assembly into telescope T1.
16 18

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 32 BOOM CONTROL AND ADJUSTMENT

Use a crowbar to push the bottom of telescope T2 against the

20
bottom right hand side of telescope T1.
20
Measure the clearance "J3" between the two telescopes on the
left hand side. Divide this value by 2 to determine the thickness
T1 of the shim to be inserted on each side of telescope T2.
21
21
J4
T2 Shim thickness = J3/2
19 J3
Insert a shim (Item 19) on either side of telescope T2.

Find the "J4" clearance between upper pad (Item 20) and T2
telescope upper side.

Insert a shim (Item 21) to each pad (Item 20) to take up this
22 clearance.
22
Tighten their rods + locating rings + nuts (Item 22).

22
bb Apply "Loctite 243 normal thread lock" to all screw/
insert and nut/screw connections located only on the
inside of the boom.
50

Observe the tightening torques and assembly recommendations.

9 mini

C1=15 N.m +- 15%

C2=92 N.m +- 15% C1 = 15 N.m ± 15%

C2 = 92 N.m ± 15%
Wedging

0 +- 0,5

Insert the "T2 + T3" assembly fully into T1.

Attach the two "T2 retract chain plates" (Item 23) to the foot of
telescope T2 (Item 24) by tightening the 4 screws (Item 25) to
a torque of 95 N.m.

Apply "Loctite 243 normal threadlock" to the fasteners.

24
bb Bring the heel of the chain plate tightly against the
seating before tightening the fastening screws.

23

25 23

50-04-M257EN (03/08/2016)
 BOOM CONTROL AND ADJUSTMENT 33

Before repositioning the two rollers (Item 26) on telescope T1,

temporarily place a rag (Item 27) between telescope T2 (Item
28) and telescope T1 (Item 29) to prevent the washer falling into
29 the boom.
27

28

26

Place the roller (Item 26) and its washer (Item 30).
26

30

50
Insert the "roller axle pin" (Item 31). Remove the rag and place
it on the other side.

31
Repeat the operation for the second roller.
29
Once the second roller and its washer are in place, use a mallet
to fully insert the "roller axle pin" (Item 31).

Remove the rag then screw and tighten the axle pin locking
screw on telescope T1 (Item 29).

Place the rollers (Item 32) on telescope T2 (Item 33) then insert
their axle pins (Item 34).
33
32
Screw and tighten the pin locking screw (Item 34) on T2 telescope.
34

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 34 BOOM CONTROL AND ADJUSTMENT

Attach the two "T2 extend chain tensioners" (Item 35) with pins
and cotter pins (Item 36).

36
35

36
35

Fit the "T3 extend chain tensioners" (Item 37) on telescope T2

(Item 38).

39
Insert the Belleville washers (Item 39) then the nuts (Item 40).
40

37

40 Pre-set the tension of the "T2 retract chains" so as to obtain

39 dimension X1.
37 38

e "Chain tension presets during reassembly"

50

41

Using a sling and hoist (Item 41), refit the cylinder (Item 42) on
42
telescope T1 (Item 43).

Use a mallet to insert its hinge pin in telescope T1 (Item 43)

43
then fit its circlip.

Refit and tighten the plates (Item 44) on either side of the cylinder
(Item 42) by tightening the 4 screws (Item 45).
45

45

45
44
44

45

50-04-M257EN (03/08/2016)
 BOOM CONTROL AND ADJUSTMENT 35

Fit the "T2 extend chain tensioners" (Item 46) on telescope T1.

Insert the Belleville washers (Item 47) then the nuts (Item 48).

bb
48

Pay attention to the stacking direction of the Belleville

washers (Item 47).
47

46

50

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 36 BOOM CONTROL AND ADJUSTMENT

CHAIN TENSION PRESETS DURING REASSEMBLY

STEP 1: "T2 RETRACT CHAIN" PRESETS

Set the dimension "X1" by turning the nut (Item 1).

1
With no worn chain replacement:
50

X1Left = Dimension read on "left chain tensioner" before

dismantling.
X1Right
X1Right = D imension read on "right chain tensioner"
1
before dismantling.

With worn chain replacement with new:

X1Left
1) Measure the difference in length (ΔL) between the
chains.

ΔL
2) Position the "left chain tensioner" at:

X1Left = 65 mm.

3) Position the "right chain tensioner" at:

X1Right = 65 mm + ΔL ⇒ if LRight chain < LLeft chain

X1Right = 65 mm + ΔL ⇒ if LRight chain > LLeft chain

50-04-M257EN (03/08/2016)
 BOOM CONTROL AND ADJUSTMENT 37

STEP 2: "T3 RETRACT CHAINS" PRE-SETTING

Set the dimension "X2" by turning the nut (Item 2).

2

With no worn chain replacement:

X2 = dimension measured on machine before dismantling.

X2
With worn chain replacement with new:

X2 = 90 mm.

STEP 3: "T2 EXTEND CHAIN" PRESETS

Before tightening the nuts (Item 3), protect the cylinder rod
(Item 8).
3
Set the dimension "X3" by turning the nut (Item 3).

With no worn chain replacement:

50
X3 = dimension measured on machine before dismantling.
X3Left
With worn chain replacement with new:

X3 = 40 mm.
3

STEP 4: "T3 EXTEND CHAIN" PRESETS

X3Right

Set the dimension "X4" by turning nut (Item 4).

With no worn chain replacement:

4
X4 = dimension measured on machine before dismantling.

With worn chain replacement with new:

X4 = 55 mm.
X4Left
Carry out a full boom extend/retract cycle.

When the boom is extended, the "extend chains" should quickly

become taut and the retract chains should become a little slack.
4

When the boom is retracted, the "extend chains" should become

X4Right
a little slack and the retract chains should quickly become taut.

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 38 BOOM CONTROL AND ADJUSTMENT

CHECKING AND SETTING CHAIN TENSIONS

The procedure is carried out with boom in horizontal position and in 2 situations:

⇒⇒ During the boom component reassembly procedure

or
⇒⇒ Periodic inspection

T3 Underside of chain

Top of T1

107 -010
T2
H2
Bottom
chain
Top of T2
T1
75 -10
0

H1
50

1) Fully extend the boom then retract it by a total of 200 mm.

2) Monitor "extend chains" slack:

⇒⇒ H1 = 75 0
-10
mm

⇒⇒ H2 = 107 0
-10
mm

bb
Turn their nuts to obtain dimensions "H1" and "H2".

The distance to the underside of the left and right chains must be the same to within 2 mm.

3) Fully retract the telescopes with care.

4) C
 heck that the telescopes are at the mechanical stop.
If they are not, measure the following clearances:

⇒⇒ Clearance between T1 and T2 (Item 6)

⇒⇒ Clearance between T2 and T3 (Item 7)

bb
6

Acceptable clearance = less than 3 mm

T3 T2
T1
7
50-04-M257EN 6 (03/08/2016)
 BOOM CONTROL AND ADJUSTMENT 39

Where clearance is greater than 3 mm, carry out the following procedure:

No Clearance T1/T2 ≤ Clearance Clearance T1/T2 > Clearance No

T2/T3 T2/T3
Yes Yes

Slacken the T2 extend chain by the value of Slacken the T3 retract chain by the difference
clearance T1/T2 between clearances T1/T2 and T2/T3

Tighten the T2 retract chains by the value of Slacken the T2 extend chain by the value of
clearance T1/T2 clearance T1/T2

Tighten the T2 retract chains by the value of

clearance T1/T2

Tighten the T3 extend chains by the difference

between clearances T1/T2 and T2/T3

Carefully retract the boom

No No
Clearance T1/T2 is zero

50
Yes

Measure clearance between T2/T3

No No
Clearance T2/T3 > 3 mm Clearance T2/T3 ≤ 3 mm

Yes Yes

Slacken the T3 extend chains by the

value of the clearance

Tighten the T3 retract chain by the

value of the clearance

Fully extend the boom then retract it by

approx. 200 mm
Checking tension of extend chains

Tighten the T2 extend chains:

0
dimension 107 -10 mm above T1
If chains are too taut
⇒ chain failure.
Tighten the T3 extend chains:
0
dimension 75 -10 mm above T2

Carefully extend and retract the boom

End of No Yes
procedure Clearance > 3 mm
(03/08/2016) 50-04-M257EN
 40 BOOM CONTROL AND ADJUSTMENT

Note: Where there is a difference in tensioner length on a pair of chains, this difference should be
maintained, do not set the tensioners to the same dimension.

5) Tighten the locknuts of each "chain tensioner" once all chain tensions have been set. Tighten the
locknuts to a torque of:

C = 85 N.m

6) Refit the cotter pins on each "chain tensioner".

50

50-04-M257EN (03/08/2016)
 BOOM CONTROL AND ADJUSTMENT 41

"HYDRAULIC KIT" REFIT

⇒⇒ The "Telescope T3 refit" operation must be completed

Place the special "Hose routing support" tool (Item 1) inside

1
telescope T3. This tool assists the insertion of hoses into the
hose channel.

Using a sling and hoist, position the "Hydraulic kit" at rear of truck.

50
Apply a layer of grease to the channel within the pad support
areas between channel and pads attached onto telescope T3.

Feed the hoses and the electrical harness (Item 2) into the channel
by sliding them over the special tool (Item 1).

Insert the "Hydraulic kit" approximately 20 cm into the boom.

Remove the special tool (Item 1).

Insert "Hydraulic kit" by inclining it so that it passes over the

"T3 retract chain".
2

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 42 BOOM CONTROL AND ADJUSTMENT

Connect the hoses and the electrical connector (Item 3) at the

foot of the boom.

3
bb Place an oil container to recover any flow of oil from
the hoses.

Fully insert "Hydraulic kit" into the boom.

Attach the "spring support bracket" (Item 4) onto telescope

T2 (Item 5), by tightening the two screws (Item 6) on each side
of telescope T2. Apply "Loctite 243 normal threadlock" to the
fasteners.

bb
6 6
4
The "Spring support" should be fixed in a hight position
in the holes as shown in the photograph.
5
50

9 Attach the "left hand pulley support bracket" (Item 7) onto

telescope T1 (Item 8). Apply "Loctite 243 normal threadlock"
to the three screws (Item 9) then tighten them.
7
9

10 Pre-assemble two pulleys (Item 10) with the axle pin (Item 11).
10

11

50-04-M257EN (03/08/2016)
 BOOM CONTROL AND ADJUSTMENT 43

Position the "pulley + axle pin" assembly (Item 12) with hoses
(Item 13).

Then insert the third pulley onto the axle pin.

13
12

Attach the "right hand pulley support bracket" (Item 14) onto
telescope T1 (Item 8). Apply "Loctite 243 normal threadlock"
to the three screws (Item 15) then tighten them.
8

15

15
15

14

50
Screw in the grease nipple (Item 16).

Refit the "hose guide" (Item 17). Tighten the two screws (Item 18)
on each side. Apply "Loctite 243 normal threadlock".
18

16
17

18

HOSE TENSION ADJUSTMENT

19
19
Loosen the 2 nuts (Item 19).

(03/08/2016) 50-04-M257EN
 44 BOOM CONTROL AND ADJUSTMENT

Use the special "hose tension adjustment gauge" tool (Item 20)
to set the two "spring supports" (Item 21) to 120 mm by turning
the nuts (Item 19).

–– Clockwise rotation = reduce dimension

–– Anti-clockwise rotation = increase dimension
22
22 21
21
19
19 Tighten the stop screw (Item 22) on each "spring support".
20
Remove the special tool.

Refit the hoses at the top of the boom.

Connect up hoses and reconnect electrical connector.

Refit brush seals blades on the telescopes.

Perform a complete boom extend/retract test to test the correct

rolling out of the hosing. Carry out operation twice.

Carry out same test under load.

50

50-04-M257EN (03/08/2016)
 SPECIFIC BOOM TOOLING

pages

CHANNEL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
HOSE ROUTING SUPPORT TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
HOSE TENSION ADJUSTMENT GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CHAIN CHECKING GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

50

(03/08/2016) 50-09-M257EN
 2 SPECIFIC BOOM TOOLING

CHANNEL LEVER

90°
50

690 mm

100 mm

50-09-M257EN (03/08/2016)
 SPECIFIC BOOM TOOLING 3

HOSE ROUTING SUPPORT TOOL

630
mm

45 mm

120°

mm
170

50
600 mm

70 mm
124 mm

(03/08/2016) 50-09-M257EN
 4 SPECIFIC BOOM TOOLING

HOSE TENSION ADJUSTMENT GAUGE

60 m
m
30 m
m

mm
120
50

CHAIN CHECKING GAUGE

CHAIN CHECKING GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161583

50-09-M257EN (03/08/2016)
 HYDRAULIC

- HYDRAULIC CHARACTERISTICS AND

SPECIFICATIONS

- HYDRAULIC SCHEMATIC DIAGRAMS

- HYDRAULIC COMPONENTS LOCATION

- HYDRAULIC CONTROL AND ADJUSTMENT

- HYDRAULIC COMPONENTS REMOVAL

- HYDRAULIC COMPONENTS REFIT

- HYDRAULIC SPECIFIC TOOLING

70
 HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS

–– PRIORITY FLOW DIVIDER (DDP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

–– BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
–– STEERING PUMP OSPC 200 LS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
–– PILOT SAFETY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
–– LEVELING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
–– STABILIZER COUNTERBALANCE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
–– DOUBLE TELESCOPE COUNTERBALANCE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

70
–– COMPLETE ELECTROVALVE (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
–– COMPENSATING ISOLATION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
–– TX TELESCOPE DOUBLE COUNTERBALANCE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
–– FLOW DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
–– SD 8/7 DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

(06/20/2016) 70-01-M257EN
 HYDRAULIC CHARACTERISTICS AND
2 SPECIFICATIONS

PRIORITY FLOW DIVIDER (DDP)

Values for information purposes only.

Role:

EF
- Supply for several receptors from only one pump .
- Maintaining priority for steering and brake power supply .
CF

LS
70

1
LS CF EF
DDP
1 - Calibrated connection .
2 2 - Strainer .
3 3 - Spring slide .

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
70-01-M257EN (06/20/2016)
 HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS 3

Values for information purposes only.

LS CF EF
EF
CF

LS

Once the engine has started, the pump outputs in a line crossing the priority flow divisor .

The pressure increases until it compresses the spring, which changes the position of the slide .

This slide position change causes direct line connections with the valve .

LS CF EF
EF
CF

70
LS

The steering and the master-cylinder are priorities . It is impossible to maneuver the valve .

As soon as the steering orbitrol or the master-cylinder are subject to stress, this information is given to
the priority flow divisor .

This information causes a change in the position of the slide, so as to supply the steering and braking
with power in priority .

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________

(06/20/2016) 70-01-M257EN
 HYDRAULIC CHARACTERISTICS AND
4 SPECIFICATIONS

BRAKE MASTER CYLINDER

Values for information purposes only.

R
B
Role:

- Send pressurized liquid to push the brake piston to block

N
L1
the wheels .

- Cumulate a mechanical (pedal) and hydraulic force to

P
help the driver .

N P
A

A
R B
70

L1

L
C

A-A

B L1 L -P : Power pressure .
N
RLF -L : LS pressure (Signal line) .
- L1 : LS direction pressure .
-N : Return to tank .
R -B : Braking pressure .
-R : Connexion RLF .
- RLF : LHM tank .

P
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

70-01-M257EN (06/20/2016)
 HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS 5
Values for information purposes only.

L1 P
N
1 B L1 L
N
RLF

Pressure from the block accumulator arrives on P . The ball (1) prevents oil from passing beca
held on its seat .
The pilot line is connected to the tank return because the master cylinder is not used, there
connected to N .

L1 P
N
B L1 L
N
RLF

70
P

When the driver starts to press on the pedal, all components are in contact with each other . In t
the return tank is switched off from the LS line (L) .
The master cylinder is ready to send pressure to the brakes using the power system .

L1 P
N
3 2 B L1 L
N
1 RLF

4 P

The driver presses fully down on the pedal . With the movement of the slide (2), the needle (3)
the ball (1) to enable pressure to be sent onto the power piston (4) .
The master-cylinder sends pilot pressure to the flow divisor to give priority to braking .
(06/20/2016) 70-01-M257EN

Notes: ______________________________________________________________________________
 HYDRAULIC CHARACTERISTICS AND
6 SPECIFICATIONS

STEERING PUMP OSPC 200 LS

Values for information purposes only.

T
P
Role:
L
– Direct and dose the flow in order to supply the steering
R circuit .

– It is a rotating distributor .

LS

R L
1 . Secondary relief valve .

2 . Distributor pump .
1
3 . Main relief valve .
70

2
200 cm³/tr

3 -P : Pressure .
-T : Tank return .
LS -R : Exit towards the right side .
-L : Exit towards the left side .
- LS : Pilot line .

T P

Note:

70-01-M257EN (06/20/2016)
 HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS 7

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 .
LS

T P

R L

70
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 P

(06/20/2016) 70-01-M257EN
 HYDRAULIC CHARACTERISTICS AND
8 SPECIFICATIONS

PILOT SAFETY 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 .

V2
70

C1 C2
1 3 1 - Temporization screws .

2 2 - By-pass valve .
4
3 - Slide with max . adjustment screw .

4 - One way valve .

V1 V2

Note:

70-01-M257EN (06/20/2016)
 HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS 9

Values for information purposes only

C1 C2

V1 V2

Return control during cylinder descent .

C1 C2

V1 V2

70
When a position is secured, no component is able to exert sufficient pressure to open the valve .

Only a pressure peak due to an impact can open it .

C1 C2

V1 V2

When the cylinder is pushed, the supply (no-return valve to pass) and return are free .

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(06/20/2016) 70-01-M257EN
 HYDRAULIC CHARACTERISTICS AND
10 SPECIFICATIONS

LEVELING VALVE
Values for information purposes only.

Role :
V2

- Insulates the tilt cylinder in case of hose breakage .

V1

2 C2 C1 2 1 - Non-return valve .
2 - Balancing valve .
1 1

V2 V1
70

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

70-01-M257EN (06/20/2016)
 HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS 11

STABILIZER COUNTERBALANCE VALVE

Values for information purposes only.

Role :
2
M

- Insulates the stabilizers cylinder in case of hose breakage .

C1

C2

V1

M1

V2

C2 1 - Non-return valve .
C1 M1 2 - Balancing valve .
2
1 M2

70
2
V1 V2

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

Maximum pressure (bar) 350

Maximum flowrate (L/min) 60

(06/20/2016) 70-01-M257EN
 HYDRAULIC CHARACTERISTICS AND
12 SPECIFICATIONS

DOUBLE TELESCOPE COUNTERBALANCE VALVE

Values for information purposes only.

Role :

C1
- Insulates the cylinder in case of hose breakage .
C2
- Cylinder movement requires the starting of the I .C .
engine .
V1
- Limits max . pressure due to impacts .
V2
70

C1 C2
300b 1 1 300b 1 - Balancing valve .
2 - By-pass ring .
3 - Temporization screws .
2 2

3
V1 3 V2

Maximum pressure (bar) 350

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
70-01-M257EN (06/20/2016)
 HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS 13

COMPLETE ELECTROVALVE (OPTION)

Values for information purposes only.

P1
P2 C2

C3

C1

C4

C4 C2
2 Key :

C3 C1 1 - Non - return valve

2 - Valve

70
1 1
P2 P1

Maximum pressure (bar) 310

Maximum flowrate (L/min) 90

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

(06/20/2016) 70-01-M257EN
 HYDRAULIC CHARACTERISTICS AND
14 SPECIFICATIONS

COMPENSATING ISOLATION VALVE

Values for information purposes only.

Role :

- Insulate the compensating cylinder in case of hose breakage .

V2
C2

Pil

1 - Non-return valve .
2 - Balancing valve .
2
Pil
C2 V2

320b +20
70

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
70-01-M257EN (06/20/2016)
 HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS 15

TX
TXTELESCOPE DOUBLE
TELESCOPING COUNTERBALANCE
DOUBLE SAFETY VALVE VALVE bf2,3
Values for information purposes only.

Role :

- Isolates cylinder in case of hose rupture .

- Imposes IC engine start to authorise cylinder movement .

- Limits max . pressure from impacts .

70
C1 C2
300b 300b 2
1 1 1 - Balancing valve
2
2 - By-pass ring
110b
3 - Time delay screw
3

3
V1 V2

Maximum pressure (bar) 350

V1 -> C1 = 150 l/min
Nominal flow rate (L/min)
V2 -> C2 = 250 l/min

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(06/20/2016)
(19/01/2011) 70-01-M257EN
F70-3-0035EN
 HYDRAULIC CHARACTERISTICS AND
16 SPECIFICATIONS

FLOW DISTRIBUTOR
Values for information purposes only.

SPi
Role:

This valve sends hydraulic flow to reservoir in proportion

to the solenoid valve supply value .

EPi
70

SPi
B
EPi
A

Maximum pressure (bar) 345 345

Nominal flow rate (L/min) 105 l/mn
Resistance 10 Ω
Maximum current 1,2 A

70-01-M257EN (06/20/2016)
 HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS 17

Values for information purposes only.

C
If «SPi» is supplied at a maximum, the passage
from «A» to «C» is open to the maximum . That
corresponds to maximum flow .

B SPi

EPi

A
A = Valve bank
B = TanK
C = Lifting cylinder .

C =X%
If «SPi» is supplied at X %, the passage of «A» to «C»
is open at X % that corresponds to X % ofthe flow .
Pressure is thus greater upstream of «SPi» .

70
«EPi» is opened and flow goes from the reservoir in
B SPi
proportion to the solenoid valve supply .

EPi

(06/20/2016) 70-01-M257EN
 HYDRAULIC CHARACTERISTICS AND
18 SPECIFICATIONS

SD 8/7 DISTRIBUTOR
Values indicative only

Role:

- Limit maximum pressure .

- Direct the hydraulic flow to the receivers .

- Cut off hydraulic movements (VS) .

- Limit shock pressure .

- To return the flow when the manipulator is in neutral .

M
L B7 A7 B6 A6 B5 A5 B4 A4 B3 A3 B2 A2 B1 A1
70

200 bar 280 bar 280 bar

12 VDC
T1 NO NF NF NF NO
A A A A A

V
B B B B B VS
NF NF NF NF NF P
T

270 bar ± 5 bar

180 bar

ES ET1 EA EI EL ESG ESD ECD EE

Note:

70-01-M257EN (06/20/2016)
 HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS 19

INLET ELEMENT (EE) AND OUTLET ELEMENT (ES)

The spool is in neutral .

T1

The flow passes through the safety valve and returns to the tank .
12 VDC

VS
P
T

270 bar ± 5 bar

M
EE

The spool moves under the effect of a pilot pressure on the coil . T1

12 VDC
The flow passes through the safety valve and returns to the tank .
VS
P
T

70
270 bar ± 5 bar

EE

P1 The flow passes through all the distributor elements before collecting
to be sent to the tank .
T1

T P

180 bar

ES
(06/20/2016) 70-01-M257EN
 HYDRAULIC CHARACTERISTICS AND
20 SPECIFICATIONS

TILTING COMPONENT (EI)

B5 A5

200 bar 280 bar

The spool is in neutral .

A The flow passes through the spool and returns to the tank .
B

T P

T1

EI
B5 A5

The spool moves downwards when operated by the driver .

200 bar 280 bar
P1
The flow is directed to A5 and the pressure on the tilting movement
increases . A
B
T P
70

T1

EI
B5 A5

200 bar 280 bar The spool moves upwards when operated by the driver .
A
The flow is directed to B5 and the pressure on the tilting movement
B
increases .

T P

T1

EI
70-01-M257EN (06/20/2016)
 HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS 21

LIFTING ELEMENT (EL)

B4 A4

280 bar
P1 The spool is in neutral .
NF
A The flow passes through the spool and returns to the tank .
B
NF
T P

T1

EL

B4 A4

The spool moves downwards when operated by the driver .

280 bar
P1
The flow is directed to A4 and the pressure on the lowering movement
increases . A
B
T P

70
T1

EL

B4 A4

The spool moves upwards when operated by the driver .

280 bar
P1
A The flow is directed to B4 and the pressure on the lifting movement
B increases .

T P

T1

EL
(06/20/2016) 70-01-M257EN
 HYDRAULIC CHARACTERISTICS AND
22 SPECIFICATIONS

LEFT AND RIGHT STABILISER ELEMENTS (ESG AND ESD)

B3 A3

The spool is in neutral .

P1

A The flow passes through the spool and returns to the tank .
B

T P

T1

ESG

B3 A3

The spool moves downwards when operated by the driver .

P1
The flow is directed to A3 and the pressure on the stabiliser upward
movement increases . A
B

T P
70

T1

ESG

B3 A3

The spool moves upwards when operated by the driver .

P1
The flow is directed to B3 and the pressure on the stabiliser lowering
A
movement increases .
B

T P

T1

ESG
70-01-M257EN (06/20/2016)
 HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS 23

SLOPE CORRECTOR ELEMENT (ECD)

B1 A1

P1
The spool is in neutral .

A The flow passes through the spool and returns to the tank .
B

T P

T1

ECD

B1 A1

The spool moves downwards when operated by the driver .

P1
The flow is directed to A1 and the pressure on the sloping movement
increases .
A
B
T P

70
T1

ECD

B1 A1

The spool moves downwards when operated by the driver .

P1
A The flow is directed to B1 and the pressure on the sloping movement
B increases .

T P

T1

ECD
(06/20/2016) 70-01-M257EN
 HYDRAULIC CHARACTERISTICS AND
24 SPECIFICATIONS

ATTACHMENT ELEMENT (EA)

B6 A6

The spool is in neutral .

P1

The flow passes through the spool and returns to the tank .

T P

T1

EA

B6 A6

The spool moves downwards under the effect of a pilot pressure .

The flow is directed to A6 and the pressure on the attachment movement P1

increases .

T P
70

T1

B6 A6 EA

The spool moves downwards under the effect of a pilot pressure .

P1

The flow is directed to B6 and the pressure on the attachment

movement increases .

T P

T1

EA
70-01-M257EN (06/20/2016)
 HYDRAULIC SCHEMATIC DIAGRAMS

pages

KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
–– MT 1435 EASY 75D ST3B S1 / MT 1440 EASY 75D ST3B S1 . . . . . . . . . . . . . . . . . . . . . . . . . 5
–– MT 1840 EASY 75D ST3B S1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

70

(06/09/2016) 70-02-M257EN
 2 HYDRAULIC SCHEMATIC DIAGRAMS
70

70-02-M257EN (06/09/2016)
 HYDRAULIC SCHEMATIC DIAGRAMS 3

KEY

Position on diagram
Item Designation Characteristics (Options)
MT 1435 _ MT 1440 MT 1840
AC Accumulator I3 / M3
BA Feed block + accumulator K1
BE Sealing plug S17
BR Breather plug Q16
CA Suction strainer S11
CAR One way valve I17 / I32
CPD Double counterbalance valve K36 / K41 / M39
CSD Double safety valve K19
CSP Counterbalance valve I19 / E30 / K35 E30 / K35
D1 Distributor Q21
EE - Main input element S38
EE2 - Input element 2 S21
ET1 - Telescope element 1 S27
ET2 - Telescope element 2 S24
EA - Attachment element S28
EL - Lifting element S31
EI - Tilting element S30
ECD(O) - Leveling element S36 OPTION
Esd - Right stabilizer section S35
Esg - Left stabilizer section S33
ES - Output element S25
3-position steering distributor
- Position 1: short steering
D3 C10
- Position 2: front wheel steering

70
- Position 3: crab position
EVAA(O) Rear attachment electrovalve E27 OPTION
EVTF(O) Telescope head electrovalve E24 OPTION
F Filter S6
FDar Rear disc brake E16
FDav Front disc brake E2
FP Negative brake G5 With clogging indicator
FR Return filter Q14 With clogging indicator
Engine
- Min RPM 850 rpm (±10)
M Q6 / Q12
- Nominal rpm loaded 2,200 rpm
- Max rpm unladen 2350 rpm
MC Master cylinder C7
MR Cooler engine K11
MRR(O) Adjusted cooler engine M11 OPTION
N Level S8
P Hydraulic pump Q11
PAAV(O) Front attachment connector A24 / E19 / G19 / A26 / A32 OPTION
PAAR(O) Rear attachment connector C29 OPTION
PD Steering pump E10
Pp Pressure test port S41 / G37 / G35 / A7 / Q20 / M5 / M3 / K6 / M2
PRES Pressure switch A1
PRF(O) Leakage return connector G19 OPTION
R Hydraulic tank S19
(06/09/2016) 70-02-M257EN
 4 HYDRAULIC SCHEMATIC DIAGRAMS

Position on diagram
Item Designation Characteristics (Options)
MT 1435 _ MT 1440 MT 1840
RDU Unidirectional flow reducer G5
RF Oil cooler I15
RLF Brake fluid tank C6
MR Cooling engine K12
VAI(O) Insulation valve C22 / A30 / A24 OPTION
VC Compensating cylinder I36 SIZE 110x55 C 485
VCD (O) Leveling cylinder M40 OPTION - DE 120x55 C 158
VDV Fan discharge valve K12
VDar Rear steering cylinder E14
VDav Front steering cylinder E4
VDF Brake valve E7
VI Tilting cylinder E31 SIZE 150x75 C 355
VIC Compensating isolation valve I34
VL Lifting cylinder I34 SIZE 170x85 C1100
VRD Flow reduction valve M34
VS Safety valve Q38
VSD Right hand stabilizer cylinder I41 SIZE 125x60 C 486
VSG Left hand stabilizer cylinder I36 SIZE 125x60 C 486
VT Telescope cylinder I22 SIZE 115x75 C3730
VT1 Telescope cylinder 1 K22 SIZE 120x65 C3766
VT2 Telescope cylinder 2 I22 SIZE 100x60 C3834
VTSDL(O) Single side-shift carriage cylinder A19 / A34 OPTION
VVT(O) Carriage Locking Cylinder C19 / A28 / A22 DE 60x45 C 183 - OPTION

Note:
70

• The calibration pressures of the main relief valves on the inlet elements are given for maximum
engine speed.
• The calibration pressures of the secondary relief valves are at an engine speed of 1,000 rpm.
• The pressure relief valves should be adjusted at an oil temperature of 50 °C.

70-02-M257EN (06/09/2016)
 HYDRAULIC SCHEMATIC DIAGRAMS 5
HYDRAULIC DIAGRAM
MT 1435 EASY 75D ST3B S1 / MT 1440 EASY 75D ST3B S1
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

PRES O F
3b ±0.124b < 2.41b > 3b 2
NO 3 1

A Pp-5 PAAV(O) PAAV(O) PAAV(O) A

b AV AR VVT(O) (2 PRISES) (2 PRISES) VVT(O) (2 PRISES) VTSDL(O)
VTSDL(O)
3 2 1
B L N
1 2 3 4
VAI(O) 3 4

VAI(O)
A B T
D3
3 2 1

C RLF MC P P
VVT(O) C4 C1 C3 C2 C
PAAR(O)
(1 ou 2 PRISES)
VAI(O)

PONT ARRIERE
PONT AVANT

FDav VDav R L VDar 2

x
PD 200b 200b FDar
C4
2 C3
PAAV(O) C2
E
250/125 cm3/tr
(2 PRISES) 1
C1 EVAA(O) VI E
VDF
x 2 EVTF(O)
P A
LS 140b
Standard C1 C2
x 1
CSP2 320b +20
0

T P
B PAAV(O) P2 P1 110b
(2 PRISES)
P2 P1 V1 V2
20cm3
G C2 G
b Pp-7
PRF(O) Pil
Pp-6
B

32
b
RDU V2

0b
+2
0
0
75 Microns VIC O F
12 l/mn
CAR < 36.2b > 50b

VC PRES
(TETE)
50b ±2b
Ø1 VT2 0b NO
A
NO
A
I RF CAR I
A C1 C2 VL VSG VSD
D +20
160b 3b 320b
AC
0

0,32l 19cm³ /tr

50b P T
CSP1
b
110b

Pmv Pp-1 V1 V2
C1 C2 C1 C2 C2 C1
BA

70
conjonction : 123b
MR (PIED) 370b +20
0 100b 280b M 280b 100b M
disconjonction : 145b
EV
K VT1 K
FT
RV1
U1 110b CSP3 CPD1 CPD2
0.5b V1 V2 V1 V2 V2 V1
PRES-1 VDV C1 C2
Beta 13.2 (2) =200

90b ±6b
A
RV2
57b ±4b 180b
+15b
NO
X290
Y65
CSD 300b 300b
0.5b
45b ±3b O F
B C
110b
< 90b > 110b
VCD(O)
VRD
Ppv Pd Pp-d U2 Pp-2 T
M 13 b
B M
b b
0,7 l V1 V2
AC A
CPD3
(O) C2 C1
350b 350b

V2 V1
O Ø1 O

L P2 B8 A8 T1 T B7 A7 B6 A6 B5 A5 B4 A4 B3 A3 B2 A2 B1 A1 P
D 200b 280b 210b

FR Pp-9
2b
LS CF EF 160b
Q P 2.5b
b
VS PRES Q
BR M2 B
NO
B
NF
B
NF
B
NF
B
NO 33b ±1b
16µm F O
8b 300 l/mn
135 l/mn V A A A A A NF < 33b > 40b

M 0.03b
NF NF NF NF NF

M
27.3 cm3/tr 45 cm3/tr BE VS 2 180b
Pp-8
17.1 cm3/tr
b
CA 270b
N
S 135µm 160 L/mn
S
R
EE2 ET2 ES ET1 EA EI EL Esg Esd ECD (O) EE

(06/09/2016) 70-02-M257EN
 6 HYDRAULIC SCHEMATIC DIAGRAMS
MT 1840 EASY 75D ST3B S1

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

PRES O F
3b ±0.124b < 2.41b > 3b 2
NO 3 1

A Pp-5 PAAV(O) PAAV(O) PAAV(O) A

b AV AR VVT(O) (2 PRISES) (2 PRISES) VVT(O) (2 PRISES) VTSDL(O)
VTSDL(O)
3 2 1
B L N
1 2 3 4
VAI(O) 3 4

VAI(O)
A B T
D3
3 2 1

C RLF MC P P
VVT(O) C4 C1 C3 C2 C
PAAR(O)
(1 ou 2 PRISES)
VAI(O)

PONT ARRIERE
PONT AVANT

FDav VDav R L VDar 2

x
FDar
PD 200b 200b
C4
2 C3
PAAV(O) C2
E
250/125 cm3/tr
(2 PRISES) 1
C1 EVAA(O) VI E
VDF
x 2 EVTF(O)
P A
LS 140b
Standard C1 C2
x 1
CSP2 320b +20
0

T P
B PAAV(O) P2 P1 110b
(2 PRISES)
P2 P1 V1 V2
FP 20cm3
G C2 G
b Pp-7
PRF(O) Pil
Pp-6
B

32
b
RDU V2

0b
+2
0
0
75 Microns VIC O F
12 l/mn
CAR < 36.2b > 50b

VC PRES
0b 50b ±2b
NO NO
Ø 0.6
A A
I RF CAR I
A VL VSG VSD
D
160b 3b
AC
0,32l 19cm³ /tr VT
50b b
P T

Pmv Pp-1
C1 C2 C1 C2 C2 C1
BA
70

conjonction : 123b
MR 370b +20
0 100b 280b M 280b 100b M
disconjonction : 145b
EV
K K
FT
RV1
U1 110b CSP3 CPD1 CPD2
0.5b V1 V2 V1 V2 V2 V1
PRES-1 VDV C1 C2
Beta 13.2 (2) =200

A
RV2
57b ±4b 180b
90b ±6b
NO
X290 CSD
+15b Y65 300b 300b
0.5b
45b ±3b O F
B C
< 90b > 110b
VCD(O)
VRD
Ppv Pd Pp-d U2 Pp-2 T
M 13 b
B M
b b
0,7 l V2 V1
AC A
CPD3
(O) C2 C1
350b 350b

V2 V1
O Ø1 O

P2 A8 B8 T1 T B7 A7 B6 A6 B5 A5 B4 A4 B3 A3 B2 A2 B1 A1 P
D 200b 280b 210b

FR
2b
LS CF EF
Q P 2.5b 180b
VS PRES Q
BR Pp-9 B
NO
B
NF
B
NF
B
NF
B
NO 33b ±1b
16µm F O
8b 300 l/mn
135 l/mn b A A A A A NF < 33b > 40b
NF NF NF NF NF
M 210b
0.03b M2 M
27.3 cm3/tr 45 cm3/tr BE VS 2
Pp-8
17.1 cm3/tr
b
CA 270b
N
S 135µm 160 L/mn
S
R
EE2 ET2 ES ET1 EA EI EL Esg Esd ECD(O) EE
L V
70-02-M257EN (06/09/2016)
 HYDRAULIC COMPONENTS LOCATION

pages

KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– MT 1435 EASY 75D ST3B S1 / MT 1440 EASY 75D ST3B S1 . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– MT 1840 EASY 75D ST3B S1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

70

(03/08/2016) 70-03-M257EN
 2 HYDRAULIC COMPONENTS LOCATION

KEY

MT1435 Electric code

Item Designation MT1840
MT1440 equivalence
BA POWER SUPPLY BLOCK + ACCUMULATORS X X
CA SUCTION STRAINER X X
CPD 1 (O) DOUBLE PILOT VALVE (Leveling cylinder) X X
CPD 2 DOUBLE PILOT VALVE (right hand and left hand stabilizer cylinders) X X
CSD DOUBLE COUNTERBALANCE VALVE (VT) X
CSD DOUBLE COUNTERBALANCE VALVE (VT1) X
CSP1 COUNTERBALANCE VALVE (VT2) X
CSP2 COUNTERBALANCE VALVE (tilting cylinder) X X
CSP3 COUNTERBALANCE VALVE (Lifting cylinder) X X
D 9-ELEMENT DISTRIBUTOR X X
D3 3-POSITION STEERING DISTRIBUTOR X X
FR RETURN FILTER X X
JSM HYDRAULIC CONTROL LEVER X X
MC MASTER CYLINDER X X
P HYDRAULIC PUMP X X
PD STEERING PUMP X X
R HYDRAULIC TANK X X
RLF BRAKE FLUID TANK X X
VC COMPENSATING CYLINDER X X
VCD (O) LEVELING CYLINDER X X
Vdar REAR STEERING CYLINDER X X
Vdav FRONT STEERING CYLINDER X X
VDF BRAKE VALVE X X
VI TILTING CYLINDER X X
70

VIC COMPENSATING ISOLATION VALVE X X

VL LIFTING CYLINDER X X
VRD FLOW REGULATION VALVE X X
VSD RIGHT HAND STABILIZER CYLINDER X X
VSG LEFT HAND STABILIZER CYLINDER X X
VT TELESCOPE CYLINDER X
VT1 TELESCOPE CYLINDER 1 X
VT2 TELESCOPE CYLINDER 2 X

70-03-M257EN (03/08/2016)
LOCATION HYDRAULIC COMPONENTS LOCATION 3

MT 1435 EASY 75D ST3B S1 / MT 1440 EASY 75D ST3B S1

VIC VT1 D3
VC CSD FR
JSM
D

CSP1 PD

VT2 RLF

VRD
MC

VL
VSG

70
CPD2

Vdar

CSP3 VI
P
CA
VDF
BA
VCD (O)
CPD1 (O)
Vdav VSD CSP2
(03/08/2016) 70-03-M257EN
 4 HYDRAULIC COMPONENTS LOCATION MT 1840 EASY 75D ST3B S1

CSD VC VIC VT D3
FR
JSM

PD
VRD

RLF

MC

VSG
70

VL
CPD2
Vdar
CSP3
VI
P
CA
VDF
CSP2
BA
VCD (O)
CPD1 (O)

Vdav
VSD
70-03-M257EN (03/08/2016)
 HYDRAULIC CONTROL AND ADJUSTMENT

pages

PRESSURE TEST PORTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

–– VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– PRESSURE TEST PORT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
BLEEDING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
–– COMPENSATING, TILTING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
–– MAIN DISTRIBUTOR (MT 1435 - MT 1440) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
–– MAIN DISTRIBUTOR (MT 1840) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

70

(03/08/2016) 70-04-M257EN
 2 HYDRAULIC CONTROL AND ADJUSTMENT

PRESSURE TEST PORTS

VALUES
Values (bar)
Element No. of pressure test ports Correspondence
Min. Max.

Steering circuit
PP-d 8 / 10 140 / 160
pressure

Parking brake
Accu. Block PP-1 125 160/180
circuit pressure

Brake assistance
PP-2 31 35
circuit pressure

Brake Master Braking circuit

PP-5 0 80
Cylinder pressure

PP-6 Tilt-up pressure 3 280

Compensating
cylinder
PP-7 Tilt-down pressure 0 190/210

PP-8 Valve pressure 0 270

Mechanical
distributor
70

Telescope extend
PP-9 0 160
pressure

70-04-M257EN (03/08/2016)
 HYDRAULIC CONTROL AND ADJUSTMENT 3
PRESSURE TEST PORT LOCATION

PP-5
90°

180°

PP-9

PP-d

PP-2
PP-1

PP-8

PP-7
70

PP-6
180°

(03/08/2016) 70-04-M257EN
 4 HYDRAULIC CONTROL AND ADJUSTMENT

BLEEDING PROCEDURES

COMPENSATING, TILTING CIRCUIT

–– Loosen upper nut (Item 1) on isolation valve (Item 2).

–– Release the air.

–– Retighten the nut (Item 1).

2
70

70-04-M257EN (03/08/2016)
 HYDRAULIC CONTROL AND ADJUSTMENT 5

TIGHTENING TORQUES
MAIN DISTRIBUTOR (MT 1435 - MT 1440)

Item Distributor / Connector (N.m)

A1
A2 60
A3
A4 60
A5
60
A6
A7 60

P2 B1
B2 60
B8
V B3
B4 60
B7 B5
B6 60
B5 B6
P1 B4
S1 B3 A7 B7 60
S2 B2 A6
B1 A5 B8 60
S4 M A4
S3 A3 M - M2 35
A2 P1 - P2 100
A1
M2 S1 - S4 30
T1
T1 100
V 35

MAIN DISTRIBUTOR (MT 1840)

70
Item Distributor / Connector (N.m)

A1
A2 60
A3
A4 60
M2
A5
60
A6
A7 60
P2
B1
B8
V B2 60
B3
B4 60
B7 B5
B6 60
B5 B6
P1 B4
S1 B3 A7 B7 60
S2 B2 A6
B1 A5 B8 60
S4 M A4
S3 A3 M - M2 35
A2
A1 P1 - P2 100

T1 S1 - S4 30
T1 100
V 35

(03/08/2016) 70-04-M257EN
 6 HYDRAULIC CONTROL AND ADJUSTMENT
70

70-04-M257EN (03/08/2016)
 HYDRAULIC COMPONENTS REMOVAL

pages

OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
MECHANICALLY CONTROLLED DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

70

(03/08/2016) 70-06-M257EN
 2 HYDRAULIC COMPONENTS REMOVAL

OIL TANK
70

PREPARATION AND SAFETY INSTRUCTIONS

Drain the oil tank before removing it.

For this:
⇒⇒ Retract all cylinders to force out the oil.
⇒⇒ Remove the drain screw

Special tool:

⇒⇒ Pallet truck (500 kg)

70-06-M257EN (03/08/2016)
 HYDRAULIC COMPONENTS REMOVAL 3

2
1

Disconnect the oil tank hoses indicated in zones 1 and 2.

Disconnect the return filter hose (Item 3).

Undo the three screws (Item 4).

70

(03/08/2016) 70-06-M257EN
 4 HYDRAULIC COMPONENTS REMOVAL

Undo the screw (Item 5).

Undo the two screws (Item 6).

6
6

Place a pallet truck under the oil tank (Item 7).

70

Remove all screws.

Take out the oil tank (Item 7).

70-06-M257EN (03/08/2016)
 HYDRAULIC COMPONENTS REMOVAL 5

MECHANICALLY CONTROLLED DISTRIBUTOR

70

PREPARATION AND SAFETY INSTRUCTIONS

–– Stabilize the machine on level ground.

–– Raise the boom and secure it in position (anti-drop - strut).
–– Decompress all hydraulic components before dismantling.
–– Deactivate battery power supply by means of the battery cut-off.

(03/08/2016) 70-06-M257EN
 6 HYDRAULIC COMPONENTS REMOVAL

Remove the 2 protective covers by unscrewing the 9 screws

(Item 1).

1 1

2
Undo the six push-pull rivets inside the bellows (Item 2).
Disconnect the electrical connector from the JSM (Item 4).
Undo the locknut (Item 3) on each lever.
Unscrew the levers then remove the bellows and its belt.
4

6
Remove mechanical valve side panel (Item 5) by undoing its four
70

screws (Item 6).

5

Identify and disconnect the electrical connectors.

23
X1

7
X6

6
X7 2
X7

X8
0
X7 X 1
8 79
X8 X
4 77 X7
X8 X
83
X8 X 2
6 81
X8
5 5
X7

70-06-M257EN (03/08/2016)
 HYDRAULIC COMPONENTS REMOVAL 7

Identify and disconnect hydraulic hoses.

Remove the emergency stop from its support bracket by

undoing the two screws (Item 7) and disconnecting the
electrical connector.
7
7

Undo the three fastening screws (Item 9) attaching the valve

70
8 assembly and distributor support bracket (Item 8).
Lift and remove the assembly from inside the cab.

(03/08/2016) 70-06-M257EN
 8 HYDRAULIC COMPONENTS REMOVAL
70

70-06-M257EN (03/08/2016)
 HYDRAULIC COMPONENTS REFIT

pages

OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
MECHANICALLY CONTROLLED DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

70

(03/08/2016) 70-07-M257EN
 2 HYDRAULIC COMPONENTS REFIT

OIL TANK
70

PREPARATION AND SAFETY INSTRUCTIONS

The oil tank is drained.

Special tool:

⇒⇒ Pallet truck (500 kg)

70-07-M257EN (03/08/2016)
 HYDRAULIC COMPONENTS REFIT 3

Position the oil tank (Item 1) on truck using a pallet truck.

Attach the oil tank (Item 1) onto the truck with 6 screws
(Items 2, 3 & 4).
2
2

70
3

4 1

(03/08/2016) 70-07-M257EN
 4 HYDRAULIC COMPONENTS REFIT

Connect the hose (Item 5) to the return filter (Item 6).

8
7
70

Connect the oil tank hoses identified in zones 7 and 8.

Top up the oil level.

Oil quantity = 111 L (mean level)

70-07-M257EN (03/08/2016)
 HYDRAULIC COMPONENTS REFIT 5

MECHANICALLY CONTROLLED DISTRIBUTOR

70

PREPARATION AND SAFETY INSTRUCTIONS

–– The machine is stabilized on level ground.

–– The boom is raised and secured in position (anti-drop – strut).
–– All the hydraulic elements are decompressed.
–– Deactivate battery power supply by means of the battery cut-off.

(03/08/2016) 70-07-M257EN
 6 HYDRAULIC COMPONENTS REFIT

Attach the distributor + support bracket assembly (Item 1) to

the frame with the three fastening screws (Item 2).

Attach the emergency stop (Item 3) to the cab with the two
fastening screws (Item 4).
Connect its electrical connector.
4
4

Connect the hydraulic hoses to the distributor.

70

70-07-M257EN (03/08/2016)
 HYDRAULIC COMPONENTS REFIT 7

Connect the electrical connectors.

23
X1

7
X6

6
X7 2
X7

X8
0
X7 X 1
8 79
X8 X
4 77 X7
X8 X
2 83
X8 X
6 81
X8
5 5
X7

Attach the side panel (Item 5) to the cab with its four fastening
6
screws (Item 6).

7
Refit the bellows assembly (Item 7) + levers (Item 8) + JSM (Item 9).
Tighten the locknut on each lever.

70
Connect the electrical connector of the JSM (Item 9).
Click six push-pull rivets inside the bellows (Item 7).
9

Refit the 2 protection covers, securing them in place with the

9 fastening screws (Item 10).

10

10 10

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 8 HYDRAULIC COMPONENTS REFIT
70

70-07-M257EN (03/08/2016)
 HYDRAULIC SPECIFIC TOOLING

pages

BASIC MANOMETER SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

DIGITAL MANOMETER SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

70

(03/08/2016) 70-09-M257EN
 2 HYDRAULIC SPECIFIC TOOLING

BASIC MANOMETER SET

This box contains all the components required for measuring

pressure on all Manitou products .

2 3 5

1 3 4 5
70

Basis gauge kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .549671

Consisting of:

1 - 1 gauge 1/9 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549882

2 - 1 gauge 0/40 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549883
3 - 2 gauge 0/60 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549884
4 - 1 gauge 0/400 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549885
5 - 2 gauge 0/600 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549886
6 - 4 standard hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549887
7 - 2 hoses for telehandler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549888
8 - 7 gauge tap connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549889

70-09-M257EN (03/08/2016)
 HYDRAULIC SPECIFIC TOOLING 3

DIGITAL MANOMETER SET

:SNOITCNUF
FUNCTIONS:
:snoitanibmoc gniwollof eht swolla yalpsid eht :noitcnuf eguaG •
• Gauge function: the display allows the following combinations:
C°2 -/+ ta erutarepmet erusserp maertspu ehT ⇒
rab 007( ixam dna inim sti htiw⇒1PThe
erutupstream
arepmet mpressure
aertspu etemperature
hT ⇒ at +/- 2°C
⇒ The upstream temperature
)1 .0 ssalc ni P1 with its mini and maxi (700 bar
rab 007( .xam dna .nim sti htiw in
2Pclass
erus0 .1)
s er p m a er t s n w o D ⇒
⇒ Downstream pressure
)1 .0 ssalcP2 ni with its min . and max . (700 bar
in class 0 .1)
P-1P=PΔ erusserp laitnereffiD ⇒
⇒ Differential pressure ΔP=P1-P
yna ta yalpsid neercs eht ezeerf nac resu ehT :noitcnuf dloH •
• Hold function: sThe
etonuser
ekacan
t ot efreeze
mit the screen display at any
time to take notes
tnemerusaem fo tinu eht egnahc nac resu ehT :noitcnuf tinU •
• Unit .)efunction:
Cm ,aPk ,isThe
p ,rauser can
b( em it ychange
na ta the unit of measurement
at any time (bar, psi, kPa, mCe) .
orez ot tesffo selbanE :eraT noitcnuF •
• Function Tare: Enables offset to zero
a r ev o n o i t a i r a v er u s s er p a er u s a e m n a C : n o i t c n u f t s e t k a eL •
• Leak test function:eCan mit dmeasure
efiiceps a pressure variation over a
specified time
.dedrocer eb nac sgnidaer 00061 fo mumixam A :noitcnuf droceR •
.de•rugRecord function:
finoc eb nac doirAep
maximum
gnilpmasofe16000
hT readings can be recorded .
The sampling period can be configured .
orez ot teser era srosnes 2 ehT :noitcnuf teseR •

70
• Reset function: The 2 sensors are reset to zero

781266 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . tik retemonaM lati

Digital Manometer kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .662187
: fo gnitsis
Consisting of:
rab 007 PH PΔ eguag latigid 1
1 - 1 digital gauge ΔP HP 700 bar rab 036 ,m5,1 = L ,0261/5121 2ND esoh tnemerusaem 1
2 - 1 measurement hose DN2 1215/1620, L = 1,5m,
rab 03630
6 ,mbar
5,1 = L ,0261/0261 2ND sesoh tnemerusaem 2
3 - 2 measurement hoses DN2 1620/1620, L = 1,5m, 630 bar 0261 srotpada eguag 2
4 - 2 gauge adaptors 1620

(03/08/2016) 70-09-M257EN
 4 HYDRAULIC SPECIFIC TOOLING
70

70-09-M257EN (03/08/2016)
 ELECTRICITY

- ELECTRICAL CHARACTERISTICS AND

SPECIFICATIONS

- ELECTRICAL SCHEMATIC DIAGRAMS

- ELECTRICAL COMPONENTS LOCATION

- ELECTRICAL CONTROL AND ADJUSTMENT

- ELECTRICAL COMPONENTS REMOVAL

- ELECTRICAL TROUBLESHOOTING

- ELECTRICAL SPECIFIC TOOLING

80
 ELECTRICAL CHARACTERISTICS
AND SPECIFICATIONS

pages

FUSES AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

–– SHUNT BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ECU INPUTS/OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
–– ENGINE ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
–– MANIMUX CLUSTER MC ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
–– MANIMUX POWER MP1 ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
–– MANIMUX POWER MP2 ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
–– OPTIONS ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DATA SHEETS FOR ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

80

(04/20/2016) 80-01-M257EN
 ELECTRICAL CHARACTERISTICS
2 AND SPECIFICATIONS
FUSES AND RELAYS

DETAILS OF ENGINE COMPARTMENT RELAYS AND FUSES (BF1)

Module 2 DETAIL BOITE FUSIBLE

BF1

Module 1

F56

7.5A F55

25A F54
5A
K21

F66
F59

F58

F57

2A
5A
40A F53
K23
60A F52

30A F51

BF1 Fuses and relays

Element Item Designation Comments

F51

F52 Preheating module K21 (60 A)

F53 Engine ECM power supply (30 A)

Module 2 F54 Engine diagnostic plug power supply (5 A)

F55 Diesel pump relay power supply K23 (20 A)

80

F56 Not used

F57 Not used
F58 Not used
F59 Not used
F66 Easy Manager power supply (2 A) (OPTION)

K21 Preheater relay (70 A)

Module 1

K23 Diesel pump relay (20/40 A)

80-01-M257EN (04/20/2016)
 ELECTRICAL CHARACTERISTICS
AND SPECIFICATIONS 3

CAB FUSE AND RELAY DETAILS (BF3)

Module 5

Module 4
Module 3 6 F46
30 A 15 A 2A
30

87
30

87

15 A 7.5 A 2A
86 87a 85 86 87a 85

5 5A 15 A 10 A
K3 K6
Module 2
F45

15 A 15 A 15 A 2A 30 30

4 F44 40 A 87 87
2A 7.5 A 15 A /25 A 15 A
0

Module 1
2A 2A 15 A 2A
3 F43 50 A 86 87a 85 86 87a 85

2A 15 A 15 A 20 A K2 K5
2 F42 40 A 5A 2A 10 A 15 A
30 30

87 87
7.5 A 3A 15 A 7.5 A
1 F41
5A 3A 10 A 15A / 20 A 86 87a 85 86 87a 85

F31 F21 F11 F1 K1 K4

Barrette D

Barrette A
Barrette C

Barrette B
MODULE 5 MODULE 4 MODULE 3 MODULE 2 MODULE 1

Fuses and relays BF3

Element Item Designation Comments

K11 Not used

Module
1
K12 Not used

K1 Starter safety relay (10/20 A)

K2 Front windscreen wiper intermittent relay (10 / 20 A)

K3 Air-conditioning fan engine relay (10/20 A)

Module 2
K4 Not used

80
K5 Ventilation / heating relay (10/20 A)

K6 Air-conditioning compressor control relay (10/20 A)

(04/20/2016) 80-01-M257EN
 ELECTRICAL CHARACTERISTICS
4 AND SPECIFICATIONS

Fuses and relays BF3

Element Item Designation Comments
F1 Engine oil vapor reheating relay K4 (3 A)
F2 Rear hydraulic two way electrovalve (7.5 A)
F3 S35 circuit breaker power supply (Max 15 A)
F4 Heating / Ventilation (2 A)
S19 override movement forcing circuit breaker / Driver
F5
presence seat switch power supply (2 A)
S36 circuit breaker power supply / Boom head electrical
F6
connector option (Max. 15 A)

F7 Digicode cluster / Client start-up antique option (2 A)

F8 Pneumatic seat (15 A)

F9 Ignition switch position 1 (Cluster wake-up) (2A)
F10 Car radio / + APC (2A)
Module 3
F11 Cigarette lighter (10 A)

Front windscreen wiper / windscreen washer fluid /

F12
Intermittence relay K2 (15A)

F13 Rear windscreen wiper / Rear windscreen washer (10 A)

F14 SPU power supply (X112-10 and X112-12) (Max. 15 A)
F15 S37 circuit breaker power supply (Max. 15A)
Telescope working light power supply S42 and cab
F16
option S43 (15 A / 25 A)
F17 Rear working lights S38 (15A)
F18 Rear windscreen defrost S39 (Max. 15A)
F19 Roof windscreen wiper / windscreen washer S40 (7.5 A)
F20 Electric window winder (20 A)

F21 Roof light / Door switch / Seat switch (3A)

F22 Cluster Power Supply (3A)

F23 Radio control battery charger (2A)
F24 Front windscreen wiper engine auto return (15A)
F25 Client immobilizer + permanent (2 A)
F26 Car radio + permanent (7.5A)
Rear windscreen wiper engine auto return / Roof and
F27
80

side option (15A)

F28 Diagnostic plug (5 A)

Module 4 F29 Air-conditioning compressor relay K6 (7.5 A)

F30 Ventilation / heating (20 A)
F31 Engine ECU wake-up (5 A)
F32 Side windscreen wiper / Windscreen washer S41 (7.5 A)
F33 Diagnostic plug (5 A)
F34 Inclinometer (2 A)
F35 Access console (2A)
F37 APC 120 electronic inching version (15A)
F38 Free
F39 Free
F40 Free
F41 Free
F42 Manipower 2 (40 A)
F43 Ignition switch (50 A)
Module 5 F44 Manipower 1 (40 A)
K3 air-conditioning fan engine + K12 air-conditioning
F45
time delay relay (30 A)
F46 Free
80-01-M257EN (04/20/2016)
 BF3/M3

BF3/M4

(04/20/2016)
A
F1

C
F21
Item
Towards X201 Towards X2/5
SHUNT BAR

Shunt bar B
Shunt bar C
Shunt bar A

Shunt bar D
F22 F2

F23 F3

F24 F4

F25 F5

F26 F6

F27 F7

F28 F8

F29 F9

F30 F10
Towards X201 Towards X2/6
F31 F11
Towards bar B Towards X2/5
F32 F12
Towards bar D
F33 F13

F34 F14

F35 F15

F36 F16

F37 F17

F38 F18

F39 F19

F40 F20
AND SPECIFICATIONS
ELECTRICAL CHARACTERISTICS

Towards D3 Towards X2/6

80-01-M257EN
D
B
5

80
 ELECTRICAL CHARACTERISTICS
6 AND SPECIFICATIONS

CONNECTORS
Item Diagram
S17 1 12
2 6
11
S18 X16 3 10 X31 5
4 9 4
S19 5 8 1
6 7 2
3
S35

S36
X20 6
S37 X32 5
4
1
2
3
X21 1
X1
4 2
6
2 1 X33 5
3 4
1
X22 2
5 3
6
7 X34
X2 8
9
10 1 12 6
2 11
X23 X35 5
3 10
Cab 4 9 4
X6 5 8 1
6 7 2
X9 3
X10

1 1 12
2 6
2 X23 11
3 10 X36 5
X11 3 Engine 4 9 4
7 5 8 1
4 8 6 7 2
5 6 9 3

X12 1 6
X25 5 X37
2 4 2
1
31 2 1
1 3
80

X13 X38 1
X26 1
2 2
40
10 X39
3 X27 1
2
1 2
4
7
X14 4
3
5
8 X28 X40 2
9 1
6 1
2 5
6
6 2 7
5 1 8
4 7 3
X15 3 8 X29
9
2 6
10
1 5
11 4
12 X45

X30

80-01-M257EN (04/20/2016)
 ELECTRICAL CHARACTERISTICS
AND SPECIFICATIONS 7

Item Diagram

X60 1
X72
X46 1 2 1
2 4
2 3

X61

X47 X73

X48 1 X62 1
2 X75 1

2 2
X49 1
2

X63
X50
X76
2

X52 X64 X77

2 X78
1 X79
X80
X81
X53 1 X82
X65 3
2 X83 A
2 B
1 X84
X85
X54 1 X86
2 X66 3
2 4
1 X88 3
1
2
X55 1 12
2 11
B X67 3
A 10
C 4 9
5 8 X91 1
6 7
2

80
X56

B
A
X68 X92 1
C
1
2 2

X57
2 1 2
A
23
X69 4
1 3
C X93
5 6
B
8
7

X58
X70
2

1 2
1 24

2 3
4
X59 4 X94
5 6
1
X71 8
3 1 7
2 4
3

(04/20/2016) 80-01-M257EN
 ELECTRICAL CHARACTERISTICS
8 AND SPECIFICATIONS

Item Diagram

X140 3
X116 1
4 2
X95 2
3 1
1 4
3
2

6
5
4 4 7
X96 X118 8
3 3
1 9
2
2 10
1
11
12 X148
(CN1)

6 X119
X100 5
4 X120
1
2
3

X101 6
X121 5
X102 4
X103 1
1 2
X104 3
X105 2
X106
X122
X107
2 X149
4 (CN2 )
X108
1
3 X123 1
2
X109 1
2
X110
Cab 4
X124
X110 3
1 X153
Frame
2
X111
3
X154 1
Cab 4 2
X111 6 1 X130
5 7 X155 2
Frame 12 8 1
X112 11 9
10 X131
80

Cab 18 17 16 15 14 13 2
X112 X166 1
Frame
X132
2

X114 2
1 X133
2 4 1 1
3 X173
2

4
3
X134
1
2 4
3
1

X174
9

60
X115
30
8

4 31
X138
16

3 1
1
1 2
2 28
1
2
3 7

28
4

X175
5 29
6 51

73

5 28

6 73
X139 3
50
72

94

2 94
1

80-01-M257EN (04/20/2016)
 ELECTRICAL CHARACTERISTICS
AND SPECIFICATIONS 9

Item Diagram

6
X176
X287 5
4
1
D 2
C
A 3
B
X178 J E
H
F
G
X289 2
1

X179
1
X293 2

X201

X204
X294
X205 2

1
X254 1
2
6
X296 5
4
X257 1
2
3

6
X258 X297 5
2 4
1
1 2
3

X260 1 1
2 8
X300
14 7
20 13
X263 19
26

X269 1

80
10
X301 18 9
1 26 17
4 53
60 25
X277 34
56
62

X281 1

3
4
2

1
3
X282
4
2

X283
2 1
D

(04/20/2016) 80-01-M257EN
 ELECTRICAL CHARACTERISTICS
10 AND SPECIFICATIONS

ECU INPUTS/OUTPUTS

ENGINE ECU

A13
A19

X174
PIN PIN
Designation Designation
N° N°
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
7 Fuel rail pressure sensor supply
37 Camshaft speed sensor signal 2
16 Injector cylinder 1 power supply 38 Crankshaft speed sensor shielding
39 Crankshaft speed sensor signal 2
18 Injector cylinder 4 power supply 40 Intake manifold pressure and temperature sensor ground
19 EGR valve supply
20 EGR valve ground 43 Intake manifold pressure sensor signal
44 Oil pressure sensor signal
23 Glow plug validation supply 45 Preheating relay coil return
Intake manifold pressure and temperature sensor & oil pressure & 46 Injector cylinder 2 return
24
80

fuel supply pressure supply

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
Coolant liquid temperature sensor & oil pressure & fuel supply 54 Crankshaft speed sensor signal 1
29
pressure ground

* If the data passes through the CAN, the PIN cannot be used . Check the electrical diagram e 80 - ELECTRICAL SCHEMATIC DIAGRAMS

80-01-M257EN (04/20/2016)
 ELECTRICAL CHARACTERISTICS
AND SPECIFICATIONS 11

A13
A19

X175

PIN PIN
Designation Designation
N° N°
1 Battery + 57 Water in fuel sensor supply
2 Battery -
3 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
15 Neutral safety relay Info 71 Engine warning lamp
16 Accelerator pedal throttle sensor signal
73 Start relay coil ground
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)

80
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

(04/20/2016) 80-01-M257EN
 ELECTRICAL CHARACTERISTICS
12 AND SPECIFICATIONS

MANIMUX CLUSTER MC ECU

Key:
ALIM: Supply INANA: Analog Input OUTANA: Analog output
EJ: Gauge inlet INTOR: Logic Input OUTOR: Logic Output
GND: Ground LSS: Output safety line WK: Wake up

A9

Cluste
r
X14 (CN104)

X13 (CN105)

PIN TYPE Designation PIN TYPE Designation

X13 (CN105) X14 (CN104)
1 CAN H Manimux CAN High 1 POWER SUPPLY Commutator switch power supply (+BAT)
2 CAN H Manimux CAN High 2 INTOR Position light
3 CAN CAN ground 3 INTOR Dipped beam headlight
4 EL Start key position 1 4 INTOR Headlight
5 INTOR D+ alternator excitation 5 INTOR Horn
6 OUTOR Fuel electrovalve control relay command re-read 6 POWER SUPPLY Commutator switch power supply (+BAT)
7 OUTOR Intermittent wiper relay command re-read 7 POWER SUPPLY Commutator switch power supply (APC)
8 OUTOR Intermittent wiper relay command re-read 8 INTOR Right indicator light
9 GND CLUSTER Ground 9 INTOR Left indicator light
10 POWER SUPPLY Manimux Cluster power supply (+BAT)
11 CAN L Manimux CAN Low
12 CAN L Manimux CAN Low
13 CAN CAN ground
16 OUTOR Fuel electrovalve control relay command re-read
17 INTOR Ignition key in preheat position
80

18 INTOR OVERRIDE switch

19 GND Reserve ground
20 POWER SUPPLY Manimux Cluster power supply (+BAT)
21 EL Cab emergency stop push-button
22 GND Reserve ground
24 WK Manimux Power Wake-up
25 EL Flashing bicolour anti-theft LED
26 EL Flashing bicolour anti-theft LED
27 INANA Fuel level gauge
28 INTOR Front windscreen wiper intermittent
29 INTOR Anti-theft
30 INTOR Ignition key in start position
31 INTOR Pressure switch on master cylinder
32 GND CLUSTER Ground
33 EST Spare
34 INTOR Engine air filter clogged
35 INTOR Low brake fluid level
36 INTOR Engine oil pressure switch
37 INANA Spare
38 LSS Output inhibition
39 INTOR Door opening contact
40 INTOR Engine water thermoswitch

80-01-M257EN (04/20/2016)
 ELECTRICAL CHARACTERISTICS
AND SPECIFICATIONS 13

MANIMUX POWER MP1 ECU

Key:
ALIM: Supply GND: Ground OUTANA: Proportional Output
EFC: Current frequency input INANA: Analog Input OUTOR : Logic Output
ER: Wake-up Input INTOR: Logic Input

A1
(CN1-P1)

MP
1
X148/CN1-P1

PIN TYPE Designation PIN TYPE Designation

2 OUTANA Gear box pressure sensor power supply voltage 50 INANA Boom angle 1 sensor
3 OUTANA Gear box pressure sensor power supply voltage 51 INANA Analogue left-hand stabiliser pressure sensor
4 INTOR Load limiter input (Australia) 52 EFC Speed sensor
5 INTOR Accelerator NC contact 53 INTOR Right stabilizer pressure switch 2
6 INTOR NO contact on door 54 INTOR Left-hand stabiliser pressure switch 2
7 INTOR Lifting electrovalve slide position l+ contact B 55 INTOR Direction assistance pressure switch
9 INTOR Lowering electrovalve slide position L- contact A 56 INTOR Joystick push button 1
10 INTOR Tilting electrovalve slide position contact B 57 INTOR Telescope working light switch (TUV)
11 CAN CAN A ground 58 INTOR Push button “+”
14 CAN CAN B ground 59 INTOR Forward gear selection
15 GND Power supply ground 60 INTOR Hydraulic filter clogging contact
16 VBAT Manimux Power 12V battery voltage 61 OUTANA Walvoil safety valve 1 and 2 electrovalve current
17 VBAT Manimux Power 12V battery voltage 62 OUTANA Forward electrovalve current
19 INANA Joystick telescope roller (R1) 63 OUTANA Reverse electrovalve current
20 INANA Reverse motion pressure sensor 64 OUTANA Trailer stop light current
Analogue accelerator pedal (PSRO9I at stage 3A) 65 OUTOR
21 INANA
Analogue right-hand stabiliser pressure sensor 66 OUTANA RD L Walvoil electrovalve current
22 POWER SUPPLY Gear box speed sensor power supply 67 OUTANA Auxiliary proportional electrovalve direction 1 H Walvoil
23 INTOR Right stabiliser pressure switch 1 68 OUTANA Auxiliary proportional electrovalve direction 2 H Walvoil
24 INTOR Left-hand stabiliser pressure switch 1

80
69 OUTANA Proportional electrovalve telescope extended H Walvoil
25 INTOR Presence of water in diesel fuel 70 OUTANA Proportional electrovalve telescope retracted H-Walvoil
26 INTOR Accelerator NO contact 71 CAN A Manimux CAN High
27 INTOR NO contact on seat 72 CAN A Manimux CAN Low
Push button ‘-’ (Hydrostatic) 73 CAN B CAN Truck high
29 INTOR
Declutch push button
74 CAN B Machine CAN low
30 INTOR Reverse gear selection
75 GND Power supply ground
31 OUTOR CAN gauge power supply
76 VBAT Manimux Power 12V battery voltage
32 OUTANA Gear box pressure sensor power supply voltage
77 VBAT Manimux Power 12V battery voltage
34 OUTANA Roller power supply voltage
78 GND
36 OUTANA Walvoil RD electrovalve
79 INANA Forward motion pressure sensor
37 OUTANA Auxiliary proportional electrovalve direction 1 L Walvoil
80 INANA Boom angle 2 sensor
38 OUTANA Auxiliary proportional electrovalve direction 2 L Walvoil
81 INANA
39 OUTANA Walvoil L telescope extend proportional electrovalve
82 GND Ground JSM roller + contact
40 OUTANA Walvoil L telescope retract proportional electrovalve
83 INTOR Boom retracted NO contactor 1
41 CAN A Manimux CAN High
84 INTOR Boom retracted NC contactor 2
42 CAN A Manimux CAN Low
85 INTOR Joystick telescope roller extension (R1)
43 CAN B CAN Truck high
86 INTOR Joystick telescope roller retraction (R1)
44 CAN B Machine CAN low
87 INTOR Joystick attachment roller plus direction (R2)
45 GND Power supply ground
88 INTOR Joystick attachment roller minus direction (R2)
46 VBAT Manimux Power 12V battery voltage
89 INTOR Joystick push button 2
47 VBAT Manimux Power 12V battery voltage
90 ER Power wake-up
48 GND Boom angle 1 & 2 sensor ground
49 INANA Joystick attachment roller (R2)
(04/20/2016) 80-01-M257EN
 ELECTRICAL CHARACTERISTICS
14 AND SPECIFICATIONS

Key:
ALIM: Supply GND: Ground LSS: Output safety line
EFC: Current frequency input INANA: Analog Input OUTANA: Proportional Output
ER: Wake-up Input INTOR: Logic Input OUTOR : Logic Output

A1
(CN2-P1)

X149/CN2-P1
MP
1

PIN TYPE Designation PIN TYPE Designation

1 OUTANA Accelerator pedal power supply voltage 53 OUTOR Cab lighting control
2 OUTANA Accelerator pedal power supply voltage 54 OUTOR Fan by-pass relay control
3 INTOR Leveling slide position contact B 57 INTOR Cooling liquid low level
4 INTOR Right-hand stabiliser lowered slide position contact A 58 GND Movement safety electrovalve ground (S58)
5 INTOR Left-hand stabiliser lowered slide position contact A 59 OUTANA Front right working light
8 INANA Boom inductive sensor at chain 2 60 OUTANA Right dipped beam headlight
9 INANA Parking brake pressure switch 61 OUTANA Right main beam headlight
10 INANA Gearbox oil temperature (PSR09) 62 OUTANA Rotating beacon light
11 INANA Front wheel alignment sensor 63 OUTANA Left dipped beam headlight
13 GND Front wheel alignment sensor ground 64 INTOR Right-hand stabiliser raised slide position contact A
14 OUTANA Front left position light 65 OUTANA Trailer right indicator light
15 OUTANA Rear left position light + registration number plate light (TUV) 66 OUTANA Trailer reverse lights
16 OUTANA Front right position light 67 OUTANA Trailer fog lights
17 OUTANA Rear right position light 68 OUTANA Trailer left indicator light
18 OUTOR Rear wheel alignment sensors power supply 69 OUTANA
19 OUTOR Gear box temperature sensor power supply 70 OUTANA Parking brake electrovalve current
80

20 OUTOR Parking brake pressure switch power supply 71 INANA

21 OUTOR Boom angle sensor power supply (20 mA) 72 OUTANA Right-hand stop light current
22 INTOR Chain boom voltage sensor 73 OUTANA Rear left indicator light
24 INANA Output safety line signal (LSS) Reverse light
74 OUTANA
27 INTOR Gear box oil pressure switch Reversing buzzer
28 INTOR Pressure switch on Walvoil distributor (VS) 75 OUTANA Reverse light current
29 INTOR Braking assistance circuit pressure switch (TUV) 76 OUTANA Trailer rear right position light option
30 INTOR Platform overload information P1 77 OUTANA Telescope head electrovalve
31 OUTANA Left main beam headlight current 78 OUTANA Rear right indicator light
32 GND Rear wheel alignment sensor ground 79 OUTANA Rear fog light
33 INTOR Leveling slide position contact A 80 OUTOR Chain boom inductive sensor power supply
34 INTOR Left-hand stabiliser raised slide position contact B 81 INTOR Seat NC contact
39 INANA Boom inductive sensor at chain 1 82 OUTOR
40 OUTANA Parking brake electrovalve current 83 OUTOR Negative brake control 1
41 INANA Rear wheel alignment sensor 84 OUTOR APC120 computer unit micro supply
42 OUTANA Right-hand stop light current 87 OUTANA Front left working light
43 OUTANA Front left indicator light 88 INTOR Tilting electrovalve slide position contact A
44 OUTANA Reverse lights current 89 OUTANA Front right working light
45 OUTANA Left-hand side lights current 90 OUTANA Horn
46 OUTANA Right-hand side lights current
48 OUTANA Front right indicator light
49 OUTOR Front wheel alignment sensor power supply
50 OUTOR Chain boom inductive sensor power supply

80-01-M257EN (04/20/2016)
 ELECTRICAL CHARACTERISTICS
AND SPECIFICATIONS 15

MANIMUX POWER MP2 ECU

Key:
ALIM: Supply GND: Ground LSS: Output safety line
EFC: Current frequency input INANA: Analog Input OUTOR: Logic Output
ER: Wake-up Input INTOR: Logic Input OUTANA: Proportional Output

A2
(CN1-P2)

MP
2
X150/CN1-P2
PIN TYPE Designation PIN TYPE Designation
1 OUTOR 47 VBAT Manimux Power 12V battery voltage
Longitudinal electro-proportional manipulator block 49 INANA Joystick raise
2 OUTANA
power supply voltage 50 INANA Joystick tilt-down or hydraulic function direction 2
Longitudinal electro-proportional manipulator block 53 INTOR
3 OUTANA
power supply voltage
54 INTOR
Platform hydraulic request source selection
4 INTOR 55 INTOR Intermediate Inductive sensor 2 (platform option)
(platform option)
56 INTOR Tilting proportional electrovalve status
5 INTOR Radio control hydraulic request source selection (option) 57 INTOR Telescope proportional electrovalve status
6 INTOR Rescue button (platform option) 58 INTOR
59 INTOR
60 INTOR
11 CAN CAN A ground 61 OUTANA Left rear axle locking electrovalve current

62 OUTANA Boom descent movement discharge electrovalve current

15 GND Power supply ground
63 OUTANA
16 VBAT Manimux Power 12V battery voltage
64 OUTANA Right rear axle locking electrovalve current
17 VBAT Manimux Power 12V battery voltage
65 OUTOR Deflector electrovalve voltage
19 INANA Joystick tilt-up or hydraulic function direction 1
66 SPWM
20 INANA Tilt meter X signal
67 SPWM
21 INANA Inclinometer Y signal

80
71 CAN A Manimux CAN High
23 INTOR
69 SPWM
24 INTOR
72 CAN A Manimux CAN Low
25 INTOR
Platform intermediate extension inductive sensor
73 CAN B
26 INTOR
Lifting proportional electrovalve status
27 INTOR
Auxiliary proportional electrovalve status
75 GND Power supply ground
29 INTOR
Hydrostatic engaged gear sensor
76 VBAT Manimux Power 12V battery voltage
30 INTOR
Rescue key contact (platform option)
77 VBAT Manimux Power 12V battery voltage
31 OUTOR
Lifting electrovalve power supply voltage
80 INANA Joystick lower
Longitudinal electro-proportional manipulator block
32 OUTANA 83 INTOR
power supply voltage
Transversal electro-proportional manipulator block 84 INTOR
34 OUTANA 85 INTOR Telescope suspension pressure switch 1
power supply voltage
35 OUTOR Telescope electrovalve power supply voltage 86 INTOR Telescope suspension pressure switch 2
36 SPWM Fan regulation L 87 INTOR
88 INTOR
CAN A 89 INTOR
41 Manimux CAN High
(H) 90 ER Power wake-up
CAN A
42 Manimux CAN Low
(L)

45 GND Power supply ground

46 VBAT Manimux Power 12V battery voltage

(04/20/2016) 80-01-M257EN
 ELECTRICAL CHARACTERISTICS
16 AND SPECIFICATIONS

Key:
ER: Wake-up Input INTOR: Logic Input OUTOR : Logic Output
GND: Ground LSS: Output safety line
INANA: Analog Input OUTANA: Proportional Output

A2
(CN2-P2)

X151/CN2-P2
MP
2

PIN TYPE Designation PIN TYPE Designation

1 OUTANA 55 GND Telescope suspension electrovalve 1 ground
Air admission temperature probe power supply 56 OUTANA Danfoss tilting electrovalve
2 OUTANA
(Fan option) 58 GND Telescope suspension solenoid valve 2 ground
14 OUTANA 59 OUTANA
15 OUTANA 65 OUTANA Telescope suspension electrovalve 1
16 OUTANA 66 OUTANA Hydrostatic high speed electrovalve current
17 OUTANA 67 OUTANA Telescope suspension electrovalve 2
18 OUTOR Intermediate sensor power supply voltage 68 OUTANA Hydrostatic low speed electrovalve current
19 OUTOR 69 OUTANA Hydrostatic motion direction electrovalve current
20 OUTOR 70 OUTANA Danfoss load-shedding electrovalve current
21 OUTOR 72 OUTANA Danfoss right outrigger electrovalve current
23 OUTOR 73 OUTANA Danfoss levelling electrovalve current
24 LSS Output safety line signal 75 OUTANA Danfoss left outrigger electrovalve current
26 OUTANA Danfoss auxiliary electrovalve 76 OUTANA
40 OUTANA Danfoss load-shedding electrovalve current 77 OUTANA
42 OUTANA Danfoss right outrigger electrovalve current 78 OUTANA
43 OUTANA Danfoss levelling electrovalve current
80

79 OUTANA
44 OUTANA Danfoss left outrigger electrovalve current 80 OUTOR
45 OUTANA
82 OUTOR Platform/radio control engine speed relay control voltage
46 OUTANA
48 OUTANA 83 OUTOR Tilting electrovalve power supply voltage
49 OUTOR Intermediate sensor power supply voltage 84 OUTOR
50 OUTOR 85 OUTANA Danfoss telescope electrovalve
51 OUTOR 86 OUTANA Danfoss lifting electrovalve
53 OUTOR Auxiliary electrovalve power supply voltage 87 OUTANA
89 OUTANA
54 OUTOR Platform/radio control start relay control voltage
90 OUTANA Hydrostatic low speed electrovalve current

80-01-M257EN (04/20/2016)
 ELECTRICAL CHARACTERISTICS
AND SPECIFICATIONS 17

OPTIONS ECU

Key :
APC : Post contact power NO : Normally Open
+BAT : Permanent supply NC : Normally Close
GND : Ground S .P .U . : Safety Power Unit

A19 /
SPU 25/15

1 1
10 8
18 9 14 7
26 17 20 13
X301 / CN1-B
25 19
X300 / CN1-A 34 26
X301 / CN1-B X300 / CN1-A

Pin
Type Active state Function on carriage Remarks
N°
X300 / CN1-A
1 Power supply APC Power supply (APC) To F14
3
Log output GND Electro-pump unit relays
4
7 Power supply +BAT Power supply (APC) To F23
13 ECU wake-up input APC ECU wake-up To F14
19 Stabilized output 5V Stop & Go accumulator pressure sensor power supply
20 Ground GND ECU ground
25 Analog input 0,5V to 4,5V Stop & Go accumulator pressure sensor signal
26 Ground GND ECU ground
X301 / CN1-B
1 CAN 1 High CAN H J1939
2 CAN 1 Low CAN L J1939
3
Supply APC ECU supply To F14
4

80
5 Proportional output 0V à 12V Fan speed control electrovalve
6 Logic output 12V Stop & Go starter safety relay Cuts ignition key starter signal
7 Logic output 12V Stop & Go accumulator charge electrovalve
13 Analog input 0V à 12V Air temperature sensor Fan control
14 Logic input 12 V Stop & Go stop/start switch (NO)
16 Analog input 0V à 12V Hydraulic oil temperature sensor Fan control
17 Logic output 12V Stop & Go hydraulic starter electrovalve
21 Logic input GND Cover switch (NO)
26 LIN Interface Battery charge sensor
28 CAN Ground CAN Ground CAN Shield
30 Logic output 12V Engine starter relay
31 Ground GND ECU ground
34 Ground GND ECU ground

(04/20/2016) 80-01-M257EN
 ELECTRICAL CHARACTERISTICS
18 AND SPECIFICATIONS

DATA SHEETS FOR ELECTRICAL COMPONENTS

Item
Designation Pages
Electric

Anti-theft output 19
A12 Joystick JSM 20
B1 Reversing buzzer 21
B2 Horn 21
B6 Air filter switch 22
B7 Hydraulic filter switch 22
B8 Master cylinder pressure switch 23
B9 + B10 Wheel alignment sensor 23
B11 + B12 Valve position sensor (BV pressure) 24
B13 Transmission oil pressure switch (mechanical version) 24
B14 Transmission speed sensor 25
B22 Mechanical distributor pressure switch contact 25
B23 Boom angle sensor 26
B24 Transmission oil thermo switch 27
B34 Water in fuel filter sensor 27
B35 to B44 Walvoil slide position 28
B48 Accelerator pedal angle sensor 28
D+ Alternator input 29
W Alternator rotation sensor 30
E15 Rotating beacon light 30
R2 Fuel level gauge 31
S2 Starter ignition switch 31
S9 NC door opening switch 32
80

S10 NO door opening switch 32

S11 Brake fluid switch 33
S14 Transmission cut-off switch 33
S34 Boom retracted switch 34
Y3+Y4 Forward and reverse electrovalve 34
Y9+Y16 VS electrovalve (Mechanical version) 35
Y50 VRD electrovalve (Mechanical version) 35
Y65 Fan discharge valve 36

80-01-M257EN (04/20/2016)
 ELECTRICAL CHARACTERISTICS
AND SPECIFICATIONS 19

Anti-theft output X118

PIN Function
1 Power supply + Battery
2 Power Supply + Post contact
3 Plug
4 Manimux info Power Supply 12 11 10 9 8 7 6 4 5 3 2 1

6
5 5 Starter solenoid inlet
4 7
8 6 Emergency stop outlet
3
9 Engine electrovalve relay
2 7
10 inlet
1
11
12 8 Starter outlet
Diagram
9 Anti-theft/Cluster info
10 LED Cluster Inlet/Outlet
11 LED Cluster Inlet/Outlet
12 Cab Ground M1
Corresponding connector

PIN Minimum Typical Maximum

Manimux current 4 mA 6 mA /

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

80

(04/20/2016) 80-01-M257EN
 ELECTRICAL CHARACTERISTICS
20 AND SPECIFICATIONS

A12 Joystick JSM X67

(Joystick Switch and Move)

R
PIN Function

N
F
1 Power or ground supply
R1 2 Roller 1 direction A (+)

12
11
3 Roller 1 direction B (-)
R2
4 Roller 2 direction A (+)

−
6

+
5 5 Roller 2 direction B (-)

8
4 7

1
3 8 6 Signal Roller 1
9

7
FNR 2
– 10 7 Signal Roller 2
1

5
11
8 Power or ground supply

D+ D-
BP2 12

4
R2
+ 9 BP1

6
BP1

3
10 BP2 Option

D+ D-
R1

2
11 Forward

BP2

10
12 Reverse

9
PIN Function

BP1
1 1 Speed +

2
2
2 Speed –

1
Correspondent connectors Diagram

12 pins connectors PIN Mini Typical Maxi

Current ± 10% 1 mA 2 mA
Potentiometers Supply voltage 1 5V
under 5 V (10% à
90%) 6-7 0 .5 V 2 .5 V 4 .5 V
Outlet voltage
2-3-4-5 0V 5V

Current ± 10% 1 mA 2 mA
Potentiometers Supply voltage 1 12 V
under 12 V (25% à
75%) 6-7 3V 6V 9V
Outlet voltage
2-3-4-5 0V 12 V

2 pins connectors PIN Mini Maxi

80

1 0V 5 ou 12 V
Outlet voltage
2 0V 5 ou 12 V

Note : ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

80-01-M257EN (04/20/2016)
 ELECTRICAL CHARACTERISTICS
AND SPECIFICATIONS 21

B1 Reversing buzzer X38

PIN Function 1 2

1 1 Buzzer power supply

2 2 Rear cab ground

Corresponding connector

Diagram

PIN Minimum Typical Maximum

Resistance (10%) 19,5 Ω 21,7 Ω
Average current 0,60 A 0,75 A
Voltage 12 V

Notes: ____________________________________________________________________________________
B2 Horn X39
___________________________________________________________________________________________
___________________________________________________________________________________________
PIN Function

1 Buzzer power supply

Corresponding connector

80
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: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(04/20/2016) 80-01-M257EN
 ELECTRICAL CHARACTERISTICS
22 AND SPECIFICATIONS

B6 Air filter switch X20

PIN Function A B

A Clogging info

B Ground

Corresponding connector
P

Diagram

PIN Typical
Nominal depression 62 mbar ± 5%

Voltage B Ground

Consumption 25 mA
Note : contact closed = clogged filter

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

B7 Hydraulic filter switch X21

PIN Function

1 2
1 1 Oil pressure info

2 2 Frame ground M2
80

Corresponding connector
P

Diagram

PIN Minimum Typical

Manimux current 1 4 mA 6 mA

Voltage threshold U < 2V = 0 U > 6,5V = 1 Umax = 16V

Inlet type Type 1 negative logic inlet (ELN1)

Note :

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80-01-M257EN (04/20/2016)
 ELECTRICAL CHARACTERISTICS
AND SPECIFICATIONS 23

B8 Master cylinder pressure switch X64

PIN Function

1 2
1 Pressure information
2
2 M1 Cab ground
1
Corresponding connector P

Diagram

PIN Minimum Typical

Manimux current 1 4 mA 6 mA

Voltage threshold U < 2V = 0 U > 6,5V = 1 Umax = 16V

Inlet type Type 1 negative logic inlet (ELN1)

Note :

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

B9 + B10 Wheel alignment sensor X65-X66

PIN Function

1 Ground
3
2 2 Signal _ +
1

80
3 Power supply
Corresponding connector

3 2 1

Diagram

PIN Typical
Supply voltage 12 V

Direct current 10 mA

Outlet logic Switch closed = wheels aligned

Type of outlet PNP at Vbat

Note :

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(04/20/2016) 80-01-M257EN
 ELECTRICAL CHARACTERISTICS
24 AND SPECIFICATIONS

B11 + B12 Valve position sensor (BV pressure) X55-X56

PIN Function

A Manimux ground B

B 5V Power Supply C
B
A
C Analogue forward and A
C reverse motion pressure
signal
Corresponding connector

Diagram

PIN Minimum Typical Max

Supply voltage / 5V /

Power supply current / / 7 mA

Output voltage 0,5 V 2,5 V 4,5 V

Load resistance 20 000 Ω / /

Note :

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

B13 Transmission oil pressure switch (mechanical version) X57

PIN Function
1 2
1 Pressure switch info
2
2 Frame ground M2
80

1
Corresponding connector
P

Diagram

PIN Minimum Typical Max

Manimux current 1 4 mA 6 mA /

Voltage threshold U < 2V = 0 U > 6,5V = 1 Umax = 16V

Type of input Type 1 negative logic input (ELN1)

Note :

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80-01-M257EN (04/20/2016)
 ELECTRICAL CHARACTERISTICS
AND SPECIFICATIONS 25

B14 Transmission speed sensor X62

PIN Function

1 Sensor power supply

1
c
Manimux and Econ .B
2
2 frequency signal
Corresponding connector

2 1

Diagram

PIN Minimum Typical Max

Supply voltage 12 V

Average current 10,5 mA

Low level current 7 mA

High level current 14 mA

Teeth frequency 0 Hz 25 000 Hz

Note :
- Frequency info + Manimux Power 1 power supply in standard Mechanical version .
- Frequency info + Inching version Econ .B power supply .

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________

B22 Mechanical distributor pressure switch contact X76

PIN Function

1 Valve pressure info 1 2

2
2 M1 chassis ground

80
1
Corresponding connector
P

Diagram

PIN Minimum Typical

Manimux current 1 4 mA 6 mA

Voltage threshold U < 2V = 0 U > 6,5V = 1 Umax = 16V

Inlet type Type 1 negative logic inlet (ELN1)

Note :

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(04/20/2016) 80-01-M257EN
 ELECTRICAL CHARACTERISTICS
26 AND SPECIFICATIONS

B23 Boom angle sensor X100

PIN Function
1 Ground
2 12 V Power Supply

Track 1 angle signal

3
6 (0 .5 to 4 .5V)
5
4 2 3 1 5 6 4
1
4 Ground
2 + S 0 + S 0
3 5 12 V Power Supply

Track 2 angle signal

6
(4 .5 to 0 .5 V)
Diagram
Corresponding connector

Typical
Supply voltage 12 V

Direct current 10 mA

Output voltage See notes and diagrams

Load resistance 20 kΩ

Angular range 0° - 90°

Remarks:
An adjustment of the angle sensor and a calibration (min . angle, max . angle) are required on each
machine, after each new calibration .
These two procedures are detailed in the following chapter:
e Group 80 - Electrical control and adjustment
Voltage (V)

S1 S2 Centering of the adjustment range

5V
4,5 V
80

S1

S2

0,5 V

-45° 0° 45°
Potentiometer angle (°)

Representation of a track of the potentiometer (the other track is of

the same value but inverted) .
⇒ In black the operating range of the potentiometer .
⇒ In red, the range and the setting options .
⇒ α represents the working angle of the cart .

The angular sensor setting is detailed in the following chapter:

e Group 80 - Electrical control and adjustment

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80-01-M257EN (04/20/2016)
 ELECTRICAL CHARACTERISTICS
AND SPECIFICATIONS 27

B24 Transmission oil thermo switch X58

PIN Function
1 2

1 Signal info

2 Signal ground

Corresponding connector
T

Diagram

PIN Minimum Typical Max

Manimux current 4 mA 6 mA /
Note :

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

B34 Water in fuel filter sensor X61

PIN Function

Presence of water in diesel 1 2 3

1
fuel

2 Engine ground

80
3
2
1
3 Power supply

Corresponding connector

Diagram

PIN Min. Typical Max.

Supply voltage / 12 - 24 V /
Remarks:

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

(04/20/2016) 80-01-M257EN
 ELECTRICAL CHARACTERISTICS
28 AND SPECIFICATIONS

B35 to B44 Walvoil slide position X77-X78-

X81 → X84-X86 X78-X85

PIN Function NC NO
A (1) Contact info 1 2 1 2

A
B B (2) Frame Ground M1

Corresponding connector

Diagram

PIN Minimum Typical Max

Manimux current 4 mA 6 mA /

Voltage threshold U < 2V = 0 U > 6,5V = 1 Umax = 16V

Type of input Type 1 negative logic input (ELN1)

Note :

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

B48 Accelerator pedal angle sensor X181

PIN Function 1 Red +

1 Signal 1 power supply +
4 Green S
2 Signal 1 ground
-
3 Signal 2 info 2 Black -
1
80

3 4 4 Signal 1 info
6
6 Blue
5 Signal 2 ground +
3
6 Signal 2 power supply White
IVS

Corresponding connector
5
Yellow -

Diagram

PIN Minimum Typical Maximum

Supply voltage 1-6 5V
Outlet voltage 3-4 0,5 V 2,5 V 4,5 V

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80-01-M257EN (04/20/2016)
 ELECTRICAL CHARACTERISTICS
AND SPECIFICATIONS 29

B74 Radiator minimum water level sensor X258

PIN Function
1 2
1 Engine signal computer
1
2 2 Engine ground

Corresponding connector
N

Diagram

PIN Minimum Typical Maximum

Current / / 0,5 A
Power / / 10 W

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

D+ Alternator input

PIN Function

Battery charge indicator

D+
lamp G

80
3~
M
U D+
Corresponding connector
G2

Diagram

PIN Min. Typical Max.

Power consumed 0.8 W 1.2 W 1.4 W
Engine running: D+ = 12V
Output logic
Engine not running: D+ = 0V

Notes: _____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(04/20/2016) 80-01-M257EN
 ELECTRICAL CHARACTERISTICS
30 AND SPECIFICATIONS

W Alternator rotation sensor

PIN Function

Alternator frequency
W
(Engine rpm)
G
Corresponding connector
3~
M
U

G2 W

Diagram

PIN Min. Typical Max.

Frequency W 100 Hz / 1,000 Hz

High level voltage W VBAT-1 V / /

Low level voltage W / / 1V

Note:
- Info W on Cluster with ratio between alternator F and engine rpm.

Notes: _____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

E15 Rotating beacon light X6

PIN Function

1 Power supply
2

2 Ground M
80

Corresponding connector

Diagram

Typical
Voltage 12 V
Resistance (10%) 2,82 Ω
Current 5A

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80-01-M257EN (04/20/2016)
 ELECTRICAL CHARACTERISTICS
AND SPECIFICATIONS 31

R2 Fuel level gauge X63

PIN Function 1

1 Fuel level info

Corresponding connector

Diagram

PIN Typical
Supply voltage 1 12 V
Empty tank resistance 1 345 Ω
Full tank resistance 1 2Ω
Inlet type Analogue inlet

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

S2 Starter ignition switch X1-X2

PIN Function
1 + Battery
2 + Battery
4 3 Un used

80
2 1
3 4 Shunt preload
OP
5 + After contact (+APC) 30 30 17 17 50a 19 19 54 15 58

1 2 3 4 7 8 9 5 6 10

6 + After contact (+APC)

5 7 Starter
6
7 8 Shunt preheating
8 Diagram
9 9 Preheating control relay
10
10 Un used
Corresponding connector

POS

Note : PIN
ITIO
N O P Maxi - 12 V
Voltage drop : 300 mV 7 (50a) x 18 A / 1min

8 (19) x x 70 A / 3.5min

9 (19) x x 70 A / 3.5min

5 (54) x x x 65 A / ∞

6 (15) x x x 65 A / ∞

10 (58) x 8A/∞

x -> PIN = 12 V
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(04/20/2016) 80-01-M257EN
 ELECTRICAL CHARACTERISTICS
32 AND SPECIFICATIONS

S9 NC door opening switch X48

PIN Function
1 2

1 Cluster alert info

2 +12V Power supply

Corresponding connector

Diagram

PIN Minimum Typical Maximum

Manimux current 4 mA 6 mA /
Manimux Voltage U < 2V = 0 U > 6,5V = 1 Umax = 16V
Inlet type Type 1 positive logic inlet (ELP1)

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

S10 NO door opening switch X52

PIN Function 1 2

1 Driver presence info

2 Cab Ground M2
80

Corresponding connector

Diagram

PIN Minimum Typical Maximum

Manimux current 4 mA 6 mA /
Voltage threshold U < 2V = 0 U > 6,5V = 1 Umax = 16V
Inlet type Type 1 negative logic inlet (ELN1)

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80-01-M257EN (04/20/2016)
 ELECTRICAL CHARACTERISTICS
AND SPECIFICATIONS 33

S11 Brake fluid switch X22

PIN Function A

1 Module A1 info (dashboard)

2 Cab Front Ground

N
Corresponding connector

Diagram

Note : contact closed = Level OK

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

S14 Transmission cut-off switch X60

PIN Function

1 Declutch info 2
1
2 2 Frame Ground M1 1

80
Corresponding connector
S14

Diagram

PIN Minimum Typical Max

Manimux current 1 4 mA 6 mA /

Voltage threshold U < 2V = 0 U > 6,5V = 1 Umax = 16V

Type of input Type 1 negative logic input (ELN1)

Note :

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(04/20/2016) 80-01-M257EN
 ELECTRICAL CHARACTERISTICS
34 AND SPECIFICATIONS

S34 Boom retracted switch X134

PIN Function
1 NO Switch 1 4 3 2

2 NC Switch
1
2 4 3 M3 Chassis Ground
3
4 M3 Chassis Ground
Corresponding connector

Diagram

PIN Minimum Typical Maximum

Supply current 4 mA 6 mA /

Note :
When the boom is retracted, the NO switch is closed and the NC switch is open .

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

Y3+Y4 Forward and reverse electrovalve X53-X54

PIN Function

1 Power supply
1 2

2 2 Frame ground M2
80

1
Corresponding connector

Diagram

PIN Minimum Typical Max

Voltage 1 / 12 V /

Current / 2,3 A /

Resistance / 6,3 Ω /
Note :
- Measurements taken at 20°C

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80-01-M257EN (04/20/2016)
 ELECTRICAL CHARACTERISTICS
AND SPECIFICATIONS 35

Y9+Y16 VS electrovalve (Mechanical version) X75-X123

PIN Function

1 Power output MP1

1
2 2 MP1 ground

Corresponding connector

2 1 2 1

Diagram

PIN Minimum Typical Max

Resistance / 6,8 Ω /

Current / 1,76 A /
Note :

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

Y50 VRD electrovalve (Mechanical version) X260

PIN Function

1 Power supply
1
2 2 Frame ground

80
Corresponding connector

1 2

Diagram

PIN Minimum Typical Max

Resistance

Current

Note :

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(04/20/2016) 80-01-M257EN
 ELECTRICAL CHARACTERISTICS
36 AND SPECIFICATIONS

Y65 Fan discharge valve X290

PIN Function

1 12 V

2 1 2 Ground

Corresponding connector

Diagram

PIN Minimum Typical Max

Voltage 1 12 V

Current 1 .2 A 1 .7 A

Resistance 7 .2 Ω

Power 20 W
Note :

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80

80-01-M257EN (04/20/2016)
 ELECTRICAL SCHEMATIC DIAGRAMS

pages

CODES ON THE ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

CABLE IDENTIFICATION ON A WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MULTIPLEXING OF THE MANIMUX SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– POSITION OF CONNECTORS BY DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
–– 1 – CUSTOMER ENGINE START / DIGICODE / EMERGENCY STOP BUTTON . . . . . . . . . . 6
–– 2 – CAN H-L / OBD PLUG (DIAGNOSTIC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
–– 3 – TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
–– 4 – HYDRAULIC MOVEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
–– 5 – SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
–– 6 – LIGHTING AND SIGNALING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
–– 7 – LIGHTING AND SIGNALING / CAR RADIO OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
–– 8 – HEATING + AIR-CONDITIONING OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
–– 9 – REAR HYDRAULIC TWO WAY / TDF ELECTRIC SOCKET / OIL HEATER . . . . . . . . . . . . 20

80
–– 10 – TDF EV / PNEUMATIC SEAT OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
–– 11 – FAN REGULATION OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

(05/12/2016) 80-02-M257EN
 2 ELECTRICAL SCHEMATIC DIAGRAMS

CODES ON THE ELECTRICAL DIAGRAMS

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
S2
V

M -M
Ca - M2
Ch
Ba

ot 3
1

b
as
t

-M
1
2
III II I O P
A 4
30 30 17 17 50a 19 19 54 15 58
7
3 X1 1 2 3 4 7 8 9 5 6 10 X2
X151 5

769

669

444
719
713
705
+ APC 6
71 739

X150
BF1 / M1 02
Version H
238
F3 8 3

CN2-P2
11 237 40
421 2

K21
C F4 15
13 7 2
269 EP6 236 09
12 169 1

8
30
87

5 666
4
Y40
11 25
12 235 169
72 X162
85

86

421
234 55 420
Version Standard
4
5 369
F5 6 1 233 16 A2 10
X201 X116 MP 22 9 421 2
555 69

420 1

BF2 / M3
CN1-P2
CAN A H

E CAN A L X161 Y16

F3 469
EP7
719
71 72 10

15
14
666

412
369

G 13 412 2
12 11 41 42
1
69
58
569 EP12 420
69
CN1-P1

Masse CAN A

CAN A H

CAN A L

Sch.3
59
X161 Y15
77
91

90 76

89 47 X38-7 X168
EP5 M1
Sch. 8 Sch. 5 9 X76B
88 46

I
17

87 17 9
X166A X166B
R 16
86
S25 N
12 183 30 P
F

11 182 59
A1 B06
8 82
179
JSM 1 34 MP 12
172

K 7 178 49

X149
5 176 88 58
440 440
B16
80

4 175 87
CN2-P1

Option ETDF Version EP/RC

+

6 177 19

B15 3 174 86 58
449 2 Y28
-

EP68
16
+

2 173 85 1

S16 10 232 89
X160
M
A12 S15 9 180 56

X67 X148

Example of marking on cables and components on an electrical diagram

Key:

1 - Marking grid
2 - + Permanent 10 - Electrical component name
3 - + After ignition 11 - Splice
4 - Grounds 12 - Version choice
5 - Wire N° 13 - Other diagram reference
6 - Electrical connector 14 - CAN
7 - Electrical connector name 15 - CAN Shielding
8 - Electrical connector PIN N° 16 - Option
9 - Electrical component
80-02-M257EN (05/12/2016)
 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° End points X64

X32 / 88 / X64 X32 / 88 / X64

X32

MULTIPLEXING OF THE MANIMUX SYSTEM

ECU
CALC.

Control
BUS CAN

ECU

e.g. Pressure switch e.g. electrovalve

80
P
Module

Acquisition/Input Processing Action/Output

ECU: Electronic Control Unit

The ECUs share their data via the CAN BUS network.
Each operator request (command) is processed by an ECU.
For this request to be activated, the machine position (via sensors, pressure switches, etc.) is recognized
and exchanged through the Manimux system.
After analysis, the system authorizes or forbids the activation of the receiver (e.g.: electrovalve).

(05/12/2016) 80-02-M257EN
 4 ELECTRICAL SCHEMATIC DIAGRAMS

POSITION OF CONNECTORS BY DIAGRAM

Part No. Diag. 1 Diag. 2 Diag. 3 Diag. 4 Diag. 5 Diag. 6 Diag. 7 Diag. 8 Diag. 9 Diag. 10 Diag. 11
C1.1 Q4
C1.2 M33
C2.1 Q12
C2.2 M29
C3.1 O20
C3.2 O12
C4.1 Q18
C4.2 Q27
C5.1 Q14
C5.2 Q32
C6.1 M11
C6.2 Q31
C7.1 Q7
C8.1 O11
X1 C5
X2 C10
X6 G32
X9 G1
X10 G1
X11 E26
X11 C25
X12 E34
X13 G7 C5 I8
X13 C28 C21
X14 G3
X15 G22 G31 M26 A27/O22
X16 C24 E20 K29
X20 C5
X21 I25
X22 E14
X23 C5/G6 K20 C28
X23 G18 G12 M36
X25 K36
X25 C26
X26 G23
X27 Q18
X28 Q20
X29 M13
X30 O36
80

X31 Q30
X32 Q34
X33 M9
X34 Q33
X35 Q22
X36 Q26
X37 Q38
X38 Q37
X39 M38
X40 O33
X43 Q16
X45 E6
X46 Q12
X47 Q14
X48 M11
X49 M10
X50 C24
X52 M40
X53 M5
X54 K5
X55 G6
X56 E6
X57 G37
X58 G39

80-02-M257EN (05/12/2016)
 ELECTRICAL SCHEMATIC DIAGRAMS 5

Part No. Diag. 1 Diag. 2 Diag. 3 Diag. 4 Diag. 5 Diag. 6 Diag. 7 Diag. 8 Diag. 9 Diag. 10 Diag. 11
Part No. Diag. 1 Diag. 2 Diag. 3 Diag. 4 Diag. 5 Diag. 6 Diag. 7 Diag. 8 Diag. 9 Diag. 10 Diag. 11
X59 G14
X60 I5 X148 G40 S3 S10 E26 M30 E36
X61 I11 X149 G31 C3 S10 E38 M22 M34 G12 K10
X62 I5 G34 X163A M11
X63 C14 X163B M13
X64 E15 X166 Q10
X65 C32 X173 G27 E19
X66 C34 X174 M30 M4
X67 M7 S6 X175 K30 G16 G4
X68 C16 G14 X176 K8
X68 I14 X178 M26
X69 M3 X179 G38
X70 C38 X181 G9
X71 O15 X201 C4 A5 A3 C4 G7 C9 M8
X72 Q15 X204 G18
X73 C14 X205 G20
X75 M15 X254 K14
X76 C31 X257 I33
X77 O31 X258 Q25
X78 O33 X260 K15
X79 O35 X263 K33
X80 A20 X268 S29
X81 A26 X270 I39
X82 A28 X277 K35 M9
X83 A22 X283A K11
X84 A24 X283B K11
X85 A29 X284 S8 E7
X86 A31 X285 A2
X87 G29 X286 A4
X88 I32 X289 M14
X91 O11 X290 G16 O12
X92 C10 X291 E6
X93 A16 X292 G6
X94 A23 X293 M14
X95 M24 X294 E38
X96 I29 X295 E39
X97 G26 X296 Q30
X97.1 K26 X297 Q34
X100 I39 X300 Q8
X101 Q25 X301 E8
X102 Q22 X302 C8 / C17
X103 X900 O38

80
Q29
X104 Q27 X901 O38
X105 O29 X903 Q38
X106 K36 X904 Q38
X107 Q10 X905 Q38
X108 Q4 X906 S38
X109 G37 X907 Q13
X110 O14 M14 I12 X912 O38
X112 A16 I10 M27 I35 X913 M13
X115 M4 X914 Q13
X116 A7 X915 M38
X118 C26 X916 O13
X118A A17 X917 I37
X118C A17 X918 I37
X121 C7/E7 Q6/O7/O4 X919 I37
G40 K41 X920 I37
X122
S41
X123 S15
X124 O38
X130 O37
X131 O38
X132 I34
X133 C36
X134 I29
X138 C24
(05/12/2016) 80-02-M257EN
 6 ELECTRICAL SCHEMATIC DIAGRAMS
1 – CUSTOMER ENGINE START / DIGICODE / EMERGENCY STOP BUTTON

CONNECTORS COMPONENTS
Wiring harness Name Position on Hydraulic Position on Hydraulic
Item Designation Item Designation
type component diagram correspondence diagram correspondence
Main X1 S2 Ignition switch (4 way) C5 M4 Alternator ground G40
Main X2 S2 Ignition switch (6 way) C10 S1 Battery cut-off A7
Main X9 Engine fuse box supply G1 S2 Ignition switch A7
Main X10 Cab fuse box supply G1 S50 Emergency stop button A24
X13 A9 Cluster C28 W Alternator W terminal G39
Main - Engine X23 Main harness/engine interface G18
FUSES AND RELAYS
Main X118A Anti-theft module predisposition A17 Position on
Item Current Designation
Main X118C Anti-theft shunt A17 diagram
Option X122 M4 Engine ground G40 K41 S41 F7 2A Anti-theft (Customer anti-start Option) C13

Main X138 S50 Emergency stop C24 F31 5A ECU alert engine F13

Engine X163A M2 Fuel pump power supply M11 F43 50 A Ignition switch C5

Engine X163B M2 Fuel pump ground M13 F52 60 A Preheater relay K21 G3

Engine X174 A13 Engine ECU connector A1 M30 F53 40 A Engine ECU I3

Engine X175 A13 Engine ECU connector K1 K30 F54 5A Engine diagnostic connector power supply I3

Engine X179 G2 Alternator L G38 F55 20 A Diesel pump relay K23 I3

Main X201 BF3 BF3 cab fuse box C4 F66 2A Easy Manager option A3

Engine X257 Glow plug conductor rail I33 K1 10/20 A Starter safety relay E21

Engine X268 A13 Engine ECU box ground S29 K21 70A Preheater relay I8

Power cable X270 M1 + starter I39 K22 20/40 A Diode starter control relay K40

Engine X277 A19 Engine harness/main harness interface K35 K23 20/40 A Diesel fuel relay K8

Engine X283A Diesel pump harness interface K11 SPLICES

Engine X283B Diesel pump harness interface K11 Item Position on diagram
Power cable X285 G1 + battery A2 EP5 C30
Power cable X286 G1 - Battery A4 EP20 E36
Engine X291 Easy manager option interface to battery E6 EP21 E38
Engine X292 Easy manager option interface to anti-start G6 EP55 E7
Deutz Harness X900 Fuel metering valve O38 EP59 A4
Deutz Harness X901 Fuel rail pressure sensor O38 EP75
80

O24
Deutz Harness X903 Injector cylinder 1 Q38 EP95 S32
Deutz Harness X904 Injector cylinder 2 Q38
Deutz Harness X905 Injector cylinder 3 Q38
Deutz Harness X906 Injector cylinder 4 S38
Deutz Harness X912 Coolant temperature sensor O38
Deutz Harness X915 Crankshaft speed sensor M38
Deutz Harness X917 Glow plug cylinder 1 I37
Deutz Harness X918 Glow plug cylinder 2 I37
Deutz Harness X919 Glow plug cylinder 3 I37
Deutz Harness X920 Glow plug cylinder 4 I37

COMPONENTS
Position on Hydraulic
Item Designation
diagram correspondence
A9 Cluster C28
A13 Engine ECU O29
G1 12 V - 110 Ah - 750 A Battery A4
G2 Alternator 14 V/100 A G39
M1 Starter I40
M2 Diesel pump M13
80-02-M257EN (05/12/2016)
 ELECTRICAL SCHEMATIC DIAGRAMS 7
DIAGRAM 1 – CUSTOMER ENGINE START / DIGICODE / EMERGENCY STOP BUTTON
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
X285 + - X286 S1

Ch M 5 (
95 mm2

AV R M
as 3 (X X__
A

s __ _)
Ca 1 (X X__
50 mm2
95 mm2

G1

391
25 mm2

M 2 ( or 22)
b __ _)

_)
S2

M ot X1
A A

M 4(

_)
M
F66-2A EP59
434 X118C 4 8 6 7 5 9
S50 1 2 1 2
OP X118A
X138
30 30 17 17 50a 19 19 54 15 58 BF3/M3
4 5 6 7 8 9
1 2 3 4
A9 35 mm2 M3

12

349

46

119

123
120
X1 1 2 3 4 7 8 9 5 6 10 X2 A F7 12 X122

119

243

184
66

134
95 mm2
11

65
F X118-11
69 Sch. 2
X13 21 29 30

123

122
134
F
C BF3/M5 60 70 B
184 M1
C
X201 F43 3 61 F
67
94
F F K4-85 EP5
68 358 X112-5

179
Sch. 10

94

121
Sch. 10
72
73

120
391 K1 M1
434
85 87 87a
35 mm2
BF3/M4
X291 1 2
68 D F31 46
2 5 4

M3
BF3/M4-C
Sch. 2 F
1 3

E 391 240
F 86 30
E
X284-4 X112-4

120
93
434

389 Sch. 2 Sch. 10 240 241 M2

EP55 X284-3 EP20 EP21
349 Sch. 2
X284-9
299

Sch. 2 EP56
321
65

Sch. 2
X292 1 2 3 4

121
243

49
X23 8 9 11

X9
2 mm2 719 X122

694

14

18
G X10 G
W
X179
18
G2 M4
7 mm2 711

X122
BF1/M1 L
714
720

3~
F52 724 7 mm2 U
7 mm2

15 16
3 mm2

B+
60A
BF1/M2

35 mm2
715

K21 95 mm2
13
F53 14 726 7 mm2 724 30
87
30A
718 (T < 5°C) 7 mm2
X918
I 717 X257 X270 I
2
F55 5 733 725 86 85 716 X920
718
B+ 30 50a
20A
X917
715

12V 70A
F54 X919
4 1 706 M1
5A
K23 X175
733 30 ECM K1 X122
87 734 15
228
X178-A X122
734

Sch. 2
719

68
732 86 85 735 228
K22
K K
X283A 1 2
info demarrage / clé 14 35
ENGINE HARNESS 30 50a
X277
12V 40A
Info ignition / clé 694 88 X923
X283B 1 2 28
602 602 2 1 2 85 50 1

73 3
603 603 2
752

751

X174
X163A X163B 45
725
35
+ - 716

80
M2
23 717
M 38 1 M
601 601
54 21
X915
26 621 621 1 (S1)
735
N
90
39
615
CABLE 11 615 15 2 (S2) S
732

EP KD X912 1 (-)
Sch. 5
28 24 2 T
624 624 (S)

5
620 620 20 X900 1

O 2.5 mm2 721 01 4

619 619
19 2 O
7 mm2 726
EP75
2.5 mm2 722 03
A13 25
631 631
31 X901 1

2.5 mm2 723 05 26 25 2

625 625 P
07 32 3
632 632

33 662 1.5 mm2 662

62 X903 1

ECM A1
16 35 2
635 1.5 mm2 635

46 640 1.5 mm2 640

40 X904 1
Q Q
3 41 2
641 1.5 mm2 641

32 638 1.5 mm2 638 38 X905 1

2 61 2
661 1.5 mm2 661

48 642 1.5 mm2 642 42 X906 1

18 37 2
637 1.5 mm2 637

02
702 2.5 mm2
S X268 S
04
703 2.5 mm2 701 X122
06
704 2.5 mm2 701 7 mm2 705 X122
EP95
EP82 695 705 1 mm2
Sch. 2

(05/12/2016) 80-02-M257EN
 8 ELECTRICAL SCHEMATIC DIAGRAMS
2 – CAN H-L / OBD PLUG (DIAGNOSTIC)

SPLICES

CONNECTORS Item Position on diagram

Wiring harness Name Position on Hydraulic Ep.5 E35

Item Designation
type component diagram correspondence
Ep.15 O13
Cab 1 X 13 A9 Cluster G7
Ep.16 K7
Frame/Cab 1 X110 Frame/cab Interface O14
Ep.28 I36
Frame/Cab 1 X112 Frame/cab Interface A16
Cab 1 X115 OBD diagnostic plug M4 Ep.29 O14

Frame X116 Manimux Power supply engine/frame interface A7 Ep.56 Q8

Frame X148 A1 Manimux Power CN1-P1 G40 Ep.64 M15
Frame X149 A1 Manimux Power CN2-P1 G31 Ep.65 M16
Frame/Engine X173 Frame/Engine Interface G27 Ep.67 I35
Engine X175 A13 Engine ECU G16 Ep.68 I34
Engine X178 BF1 Engine diagnostic plug M26 Ep.69 I35
Cab X201 BF3/M5 Cab BF3 fuse box A5
Ep.76 K22
Frame X263 B50 Vishay CAN gauge (pre-equipment) K33
Ep.77 K22
Cab 1 X284 Easy Manager option S8
Ep.78 K25
Ep.79 K25
Ep.80 G23
Ep.81 I23
Ep.82 G24
COMPONENTS
Ep.96 M20
Hydraulic Ep.97 M20
Item Designation Position on diagram
correspondence
Ep.98 M22
A1 Manimux Power MP12 G33
A9 Manimux Cluster MC4 G5 CAN Network
A 13 Engine ECU G15
B 50 Vishay CAN gauge M23
PAD tool
D3 Diode D3 C33
Engine ECU
R4 120 Ω 1/2 W resistor I23
R10 120 Ω 1/2 W resistor K22
R12 120 Ω 1/2 W resistor K26

Manimux
80

Cluster
FUSES AND RELAYS DIAG.
Engine
Item Designation Position on diagram diagnostic
plug Manimux
F9 Ignition switch position 1 (CLUSTER alert) E5 Power MP12
VCI
F22 Cluster power supply A14
F23 RC Battery charger A14
CAN B
F28 OBD diagnostic plug +VBat (5A) C14
CAN A
F33 OBD diagnostic plug +APC (5A) C14
F44 MANIPOWER 12 40A C6

(Standard version)

Key:

- CAN A: CAN Manimux (Cluster ⇔ Power12)

- CAN B: CAN Truck (Power12 ⇔ Econ.B 120 and Engine ECM)

80-02-M257EN (05/12/2016)
 ELECTRICAL SCHEMATIC DIAGRAMS 9
DIAGRAM 2 - CAN H-L / OBD PLUG (DIAGNOSTIC)
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

Ca

Ch M2
Ca M1

Bo ssis
b
b
a
ite M1
5
-1

M
54

2
AP t
Ba
C

Key:
V

A
72
BF3 / M5 BF3 / M4 36
A
73
73 C F22 - CAN A: CAN Manimux (Cluster ⇔ Power2) 35 mm²

X201 35 X112 - CAN B: CAN Truck (MP12 ⇔ Vishay Can Gauge ⇔ A13)
F23
- A: Power supply
18
37 37
X116
F44
442 2
442 72
F28
42 - M: Ground
441 1 441
68
F33
48
- LSS: Output safety line

240
D3
240 241 241
X2
C Sch. 1 C
67
68
70

66

69

154-155
B A
190-191-192
F9

442

BF3 / M3 441
E E
14

EP 5
EP17 388

01 34 X173
X175
154

155

190

191

192
266

CN1-P1 / X148

86
X258/1
35

36

87

88

89

90

91
206

28
29 284
5 4 10 20 9 32 X13 46 Sch. 5 4
CN2-P1 / X149 16 17 46 47 76 77 15 45 75

695 X268
G A
05
36 Ep.82 Sch. 1 G
M A M

CLUSTER A13 03 693 923

2
A1 / MP 12

693
35 71 24

R 120 ohm
A9 / MC4 54
690 692
284 57

3
CAN H

High CAN A
High CAN A
Ep.80

Low CAN A

Low CAN A
L H
76
689

1
3 11 1 24 38 Ep.81 691 8 31 44 43 14 74 73 90 11 42 41 71 72

CAN L
143

107

Black

96

48
448

447
EP 69
449

I R4
EP 28 I
120 Ω 1/2 W
LSS
42 EP 67

CAN B
CAN A

48 EP 68
1

CAN A
CAN B
16 Wake-up line
CAN H 75 684 682
Ep.76

120 Ω 1/2 W
14
Ep.78 X263 3 2 5 4 1

R12
53 685 683
6 CAN A CAN L Ep.77 Ep.79

CAN B
K K

709

710
5 186 185
EP 16 R10
11 120 Ω 1/2 W

CAN B
3
BF1 R
393

B50
J 1939

J 1939
392

F54-1
Sch. 1
X115
CAN B

707
706

709

710

80
CAN B
A B C D E F G H J
M X178 M

12 383 EP 64
J 1939

CAN B J 1939 11
384 EP 65 CAN B
107
9 71 LSS

382
X302-2
Sch. 12
7
381
X302-1 Wake-up line
45

O EP 15 187 8 95 EP 29 O
6

CAN A 5 CAN A

X110 185

X23-11 49 206
Sch. 1 EP56

Q Q

X291-2 S19-1
Sch. 1 Sch. 4
EP55 X292-4 EP54
Sch. 1 Sch. 1 Sch. 5

394
387

388

389

391

392

394

393

321

395

396

S X284 S
1 2 3 4 5 6 7 8 9 10 11 12

(05/12/2016) 80-02-M257EN
 10 ELECTRICAL SCHEMATIC DIAGRAMS
3 – TRANSMISSION
DIAGRAM 3 – TRANSMISSION
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
CONNECTORS

M Ma
M se C se C
as s
as h ab
se as M
Ch s is 1
Wiring harness Name Position on Hydraulic

as M
s is 2
Item Designation

M
type component diagram correspondence

1
A
Frame X 53 Y3 Forward electrovalve M5
Frame X 54 Y4 Reverse electrovalve K5
Frame X55 B11 Forward gear sensor G6
Frame X56 B12 Reverse gear sensor E6 CN2-P1 / X149
Frame X60 S14 Gear lever transmission cut-off I5 70
223 223 8 2

83

X 62
7
Frame B14 Gearbox output speed sensor I5 222 222 1

C EP90

X92 Y13
Frame X 67 A12 JSM connector M7
Frame X 92 Y13 Negative brake electrovalve control C10
Frame X148 A1 Manimux Power CN1-P1 S3
Frame X149 A1 Manimux Power CN2-P1 C3

E X56
3 B
98

B12
20 C
99

18 A
100

X55
2 B
105

B11
79 C
106
G
78 A
107

X60
29
170 1

171 2
S14
COMPONENTS
I
Hydraulic X62
Item Designation Position on diagram
correspondence 52
102 102 2

22 c
101 101
A1
1
Manimux Power MP1 M2
B14
A12 JSM (Joystick Switch and move) M11
B11 Forward motion pressure sensor G8 X54
B12 Reverse motion pressure sensor E8 K 104 2

63
103 103 1

B14 Gearbox output speed sensor I9 Y4

B15 Roller 1 on JSM O12
A1 / MP 12
80

B16 Roller 2 on JSM O12 X53

110 2

S14 Gear lever switch I8 62

109 109 1

S15 BP1 contact on JSM (leveling or right/left stabilizers) M10 Y3

M
S16 BP2 contact on JSM (Only with EVTF option) M10 X67
56
180
9
S15
A12 / JSM
S25 FNR contact on JSM Q11 89 10
S16
232

Y3 Forward gear electrovalve M9 85

173 2

B15
Y4 Reverse electrovalve K9 86
174
3

19 6
177
Y13 Parking brake electrovalve C11

B16
87 4
175
O 88 5
176

49 7
178

34 1
172

82 8
179

59 11
182

30 12
183
F
N S25
Q R

SPLICES

Item Position on diagram 5

26

Ep.90 C7 CN1-P1 / X148

S

80-02-M257EN (05/12/2016)
 ELECTRICAL SCHEMATIC DIAGRAMS 11
4 – HYDRAULIC MOVEMENT
DIAGRAM 4 – HYDRAULIC MOVEMENT
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
CONNECTORS

M
M eC
M se assi
5

as
as h
as Ch s M
-1

se as 2
54
AP at

Ch s is
B
C
V

as M
Wiring harness Name Position on Hydraulic

s is 2
Item Designation

M
type component diagram correspondence

3
A
Engine/Cab 1 X23 Engine/cab interface G12
Frame X 67 A12 JSM connector S6
Frame X71 Output A on telescope and attachment O15
Frame X72 Output B on telescope and attachment Q15
Frame X75 Y9 Movement safety EV1 M15
Frame/Cab 1 X112 Frame / cab interface I10 C
Frame X123 Y16 Safety electrovalve S15
Frame X148 A1 Manimux Power CN1-P1 S10
Frame X149 A1 Manimux Power CN2-P1 S10
Frame X260 Y50 Flow regulation electrovalve connector K15
Engine X290 Y65 Engine fan regulation G16
E

Sch. 6 175 174

K6-B5
COMPONENTS
2
307

Hydraulic 279
5
279
1

Item Designation Position on diagram

correspondence G X23 X290 Y65
K3 85 87 87a

A1 Manimux Power MP1 O9 2 5 4

A12 JSM (Joystick Switch and Move) S2

1 3

B15 Telescope roller on JSM Q3 86 30

B16 Accessory roller on JSM Q3

276

278
S15 BP1 contact on JSM (leveling or right/left stabilizers) S3 276 3 276

I X112
S16 BP2 contact on JSM (Only with EVTF option) S3
S25 FNR contact on JSM O3 BF3 / M4
F29
Y5 Extension telescope proportional electrovalve Q17 278

Y6 Telescope retraction proportional electrovalve O17

Y7 Attachment proportional electrovalve direction 1 O17
Y8 Attachment proportional electrovalve direction 2 O17 K
Y9 Safety valve 1/distributor M17 Y50
1

Y16 Safety valve 2/distributor S17 138

2
139
Y50 Flow regulation valve K16

80
X260
Y65 Engine fan regulation electrovalve G17
36 2
138 542

M
66 1
139 540

X75 Y9
FUSES AND RELAYS 68
149 149 4

38 3
148 148

Item Designation Position on diagram 70

Y8
2
145 145

F9
40
Engine fan regulation (3 A) I4
1

A1 / MP 12
144 144

O X71 Y6
K3 Engine fan regulation relay (10/20 A) G8
67
R 147 147
4

S25 N 37 3
146 146
F 12 183 30

11 182 59
69
Y7
2
143 143
8 82
179
39 1
142 142
1 172 34

X72 Y5
SPLICES 7 178 49

Q 5 176 88
75
192

45
191
4 175 87

Item Position on diagram

B16

15
190
6 177 19
61
241

Ep.25 S13
3 86
174
CN1-P1 / X148
B15

540
2 173 85

Ep.26 S13 10 232 89 54

276 EP25
541
2

1
539
S16 9 180 56 58
240 EP26

CN2-P1 / X149 X123 Y16

542
S S15
A12 / JSM X67

(05/12/2016) 80-02-M257EN
 12 ELECTRICAL SCHEMATIC DIAGRAMS
5 – SENSORS
CONNECTORS COMPONENTS
Wiring harness Name Position on
Item Designation Item Designation Position on diagram
type component diagram
Cab 1 X 13 A9 Cluster C5 A1 Manimux Power MP1 E31
Engine X 20 B6 Air filter clogging C5 A9 Manimux Cluster MC2 C9
Frame X 21 B7 Hydraulic filter sensor I25 A13 Engine ECU G3
Cab 1 X 22 S11 Brake fluid level E14 B6 Engine air filter clogging pressure switch E5
Engine/Cab 1 X 23 Engine/cab interface C5/G6 B7 Hydraulic filter clogging pressure switch K25
Cab 1 X 45 S9 Door switch closed/cluster NF (wake-up) E6 B8 Brake master cylinder pressure switch E15
Cab 1 X 52 S10 Door switch closed/Manimux Power NO M40 B9 Front wheel alignment sensor C33
Frame X57 B13 TRANSMISSION OIL PRESSURE SWITCH G37 B10 Rear wheel alignment sensor C35
Frame X58 B24 Temperature sensor BOX (2 contacts on MX) G39 B13 Transmission oil pressure switch G37
Engine X61 B34 Presence of water in diesel fuel I11 B14 Gearbox output speed sensor G35
Frame X 62 B14 Gearbox output speed sensor G34 B17 Servo brake circuit fault pressure switch E39
Cab 1 X 63 R2 Fuel gauge C14 B18 Right-hand stabilizer pressure switch 1 I29
Cab 1 X 64 B8 Master cylinder pressure switch E15 SPLICES B19 Right-hand stabilizer pressure switch 2 K32
Frame X 65 B9 Front wheel alignment C32 Item Position on diagram B20 Left-hand stabilizer pressure switch 1 K29
Frame X 66 B10 Rear wheel alignment C34 EP3 G8 B21 Left-hand stabilizer pressure switch 2 I25
Frame X 70 B17 Assist brake circuit pressure switch C38 EP4 G8 B22 Safety valve/distributor hydraulic cut-out pressure switch E31
Cab 1 X 73 R2 Fuel gauge C14 Ep.20 G39 B23 Boom angle sensor I37
Frame X76 B22 Safety valve/distributor pressure switch C31 Ep.61 M34 (MT1840) B24 Gearbox oil temperature sensor G32
Frame X77 B36 Boom lifting NC sensor O31 EP74 M8 B29 Negative brake fault pressure switch C36
Frame X78 B35 Boom lowering NC sensor O33 Ep.91 G38 B30 Servo steering circuit fault pressure switch K34
Frame X79 B37 Tilting NO sensor O35 EP KC Q11 B34 Water in diesel sensor I13
Frame X80 B38 Tilting NC sensor A20 EP KD S10 B35 Boom lowering NC sensor Q33
Frame X81 B42 Right stabilizer raising NC sensor A26 B36 Boom lifting NC sensor Q31
Frame X82 B41 Right stabilizer lowering NC sensor A28 B37 Tilting NO sensor Q35
Frame X83 B40 Left stabilizer raising NC sensor A22 B38 Tilting NC sensor A21
Frame X84 B39 Left stabilizer lowering NC sensor A24 B39 Left stabilizer lowering NC sensor A24
Frame X85 B43 Leveling NO sensor A29 B40 Left stabilizer raising NC sensor A22
Frame X86 B44 Leveling NC sensor A31 B41 Right stabilizer lowering NC sensor A28
Frame X 87 B18 Right stabilizer down pressure switch G29 B42 Right stabilizer raising NC sensor A26
Frame X 88 B19 Right stabilizer high pressure switch I32 B43 Leveling NO sensor A29
Frame X 96 B20 Left stabilizer low pressure switch I29 B44 Leveling NC sensor A31
Frame X 97 B21 Left stabilizer high pressure switch G26 B48 Accelerator pedal angular sensor G10
Frame X100 B23 Boom angle sensor I39 B54 QX boom extension inductive sensor C1 Q37
Cab 1 X121 Seat driver presence connector C7/E7 B55 QX boom extension inductive sensor C2 Q38
Frame X124 C1 and C2 QX boom inductive sensor connector O38 B74 Mini-radiator water level sensor S25
QX Boom X130 B54 Inductive sensor inner C1 QX boom O37 B80 Air intake temperature transmitter K9
80

QX Boom X131 B55 Inductive sensor inner C2 QX boom O38 R2 Fuel level sensor C14
Frame X132 B30 Servo steering circuit fault pressure switch I34 R13 2.4 kOhm resistor K10
Frame X133 B29 ON/OFF negative brake pressure switch C36 S9 Closed cab door switch on cluster NC (wake-up) E5
Frame X134 S34 Retracted boom sensor I29 S10 Closed cab door switch on power NO M38
Frame X148 A1 Manimux Power CN1-P1 E26 S11 Brake liquid level contact E14
Frame X149 A1 Manimux Power CN2-P1 E38 S17 Not used G16
Frame/Engine X173 Frame/Engine Interface E19 S34 Retracted boom sensor K28
Engine X174 A13 Engine ECU connector A1 M4
Engine X175 A13 Engine ECU connector K1 G4
FUSES AND RELAYS
Engine X176 B80 Air intake temperature sensor K8
Engine X277 A13 Engine harness/main harness interface M9 Item Designation Position on diagram
Cab X181 B48 Accelerator pedal potentiometer G9 F21 Roof light, door switch and seat switch C3
Cab X201 BF3 Cab BF3 fuse box A3
Engine X258 B74 Mini-radiator water level sensor Q25
Cab X284 Easy Manager option E7
Deutz Harness X907 Intake manifold pressure & temperature sensor Q13
Deutz Harness X913 EGR valve position sensor & actuator M13
Deutz Harness X914 Oil pressure switch Q13
Deutz Harness X916 Camshaft position sensor O13

80-02-M257EN (05/12/2016)
 ELECTRICAL SCHEMATIC DIAGRAMS 13
DIAGRAM 5 – SENSORS

1 t
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

M se C ass M2
M Mas Ca
M e C Ca M1
Ba

as h is
as se b
as h b
X84 X81 X82 X86 X111

160

158

164

162
X83 X85

151

161

159

165

163

167
150
X80
14 13

166
15
V

168

169

se as M
s
as

Ch sis 1
se

as M2
1 2 1 2 1 2 1 2 1 2 1 2 1 2

sis
25 mm²

114

113

112

M
A A

1
X201 X139 3 2 1

CLUSTER
72

73

A9 / MC2 B38 B40 B39 B42 B41 B43 B44

BF3 / M4
F21

X13 34 36 40 39 36 40 27 35 31 6

138
62

63

139

135

137
118
53

X23 X63 B9 B10

34

184

185
7 B4 B6

C X76 B29 C
1 2
P
749

X70
17

X20 X121 1
_ + _ +

225
2
R2
X65 X66 X133
B6

224
N
X73 X173 P 3 2 1 3 2 1 1 2 1

16
B17

114
B22

115

113
4

227
84
85

83
P

229
P
Siège

284

272

150

160

158

164

162

168

166

184
47

31

32
135
81 57 49 11 32 18 41 9 20 29

139
3 13

156
2 80 6 37 88 34 5 4 64 33 28

X121 3 2
X22 1 X64 1 2
81
CN2-P1 / X149
E E
248

S11 B8
27

A1 / MP12
396
118

34

12 80 6
X284 N P

S9
1 2

X45 CN1-P1 / X148

X22 2

167
64
60 54 84 83 24 23 53 7 9 10 55 22 52 80 48 50 21 10 19 27
X175

159
156

221

108

111
202

101

102

230
127

226
154

152
38

37

156
125

22

21

20
ECM K1 X23 X181 167
46 1 168
669 1 27 140 Red S18-10
EP3 +
X62 2 1 1

112
5V 2

A13

62

63
1 2
+

123

124
X87
145

129

130
63
G S ANA U
670 4 144 144 4 Green S 1 7 10 X97 X58 X57 G
2 3 2 1
3 1
-
62 671 2 26 141 2 Black
EP4 -
0V

B48 S17 B14 P

322

16 6
672 3 25 145 Blue T
B13

EP20
EP91
IVS 3 9
+ c
S17
B24

137
3
25 White P
P

64
IVS

B21 B18

80
5
322 Yellow -
X110
ECM K1

18

22
24

23

21
19

18
X100

106
4 6 5 1 3 2

202

203

226

228
127

128

126

125
X134 X96 X88

37
38

39

40
I I
X61 B34 X21 1 2 2 3 4 1 3 2 1 1 2 3
X132 1 2

57 700 700 2
SENSING

64 699 699 1 B23

P P P P

B7 B20 B19 B30

S34
X176 X176
79 667 667 1 1

82 651 668 2 B80 2 R13

K K
85 646
44
650
61
617

X174 X277

106

163
X913 X52 1 2

80
20 48
648 648 1 (-)

19 47 M

31
S10
647 647 (+)
M 2
M

EP61
51 3
651 652 (-)
EP74
46 4
646 (S)

50 5
650 (5V)

53 9
609 609 Only MT1840

271

272
X916

270

32
52
613 613 13 1 (S1) 1 2 4 3
X124
37 CABLE 10 14 2
N
S
614 614 (S2) + +

O X281 X282 O
1 610 1
(+)
B87 X77 X78 X79

156

157

154

155

152

153
17 2 2
617 611 (S) 1 2 1 2 1 2 1 2 1 2

P
3 3
X130 X131
4 612 4
(-) S S

C1 C2
40
628 628 28 X907 1 (-) + +

27
629 629
29 2 (S1)
T B36 B35 B37 B54 B55
748

748
24 22 3
622 622
16
(+)
Q EP KC Q
P 1 2
43 23
623 623 4 (S2) X258
X914 1
(+)
44 26 2
626 626 (S)
P
3 N

29 27 4
627 627
EP KD (-)
B74
S S
X912-1
Sch. 1

(05/12/2016) 80-02-M257EN
 14 ELECTRICAL SCHEMATIC DIAGRAMS
6 – LIGHTING AND SIGNALING

CONNECTORS COMPONENTS

Wiring harness Name Position on Hydraulic Hydraulic

Item Designation Item Designation Position on diagram
type component diagram correspondence correspondence
Cab 2 X6 E15 Rotating beacon light G32 M7 Front windscreen washer pump S18
Cab 1 X 11 S4 Wiper stalk switch E26 M8 Rear windscreen washer pump S20
Cab 1 X 12 Wiping reset E34 M9 Window up engine S17
Cab 1 X 13 A9 Cluster I8 M11 Rotating beacon light engine G35
Cluster X 14 S5 Light commutator switch G3 S4 Wiper commutator switch A39
Cab 1 X 15 High/low cab interface G22 S5 Light commutator switch E10
Cab 1 X 16 High/low cab interface C24 S6 Window up switch S4
Cab 1 X 25 M3 Front windscreen wiper K36 S7 Cigarette lighter S15
Cab 2 X 27 M7 Front windscreen washer pump Q18
Cab 2 X 28 M8 Rear windscreen washer pump Q20
Frame X 31 E3 Rear left headlight Q30
Frame X 32 E4 Rear right headlight Q34
Cab 2 X 33 Front L/R working headlight link M9
Frame X 35 E1 Front left headlight Q22
FUSES AND RELAYS
Frame X 36 E2 Front right headlight Q26
Frame X 38 B1 Reverse buzzer Q37
Item Designation Position on diagram
Frame X 39 B2 Main horn M38
Cab 2 X 43 M9 Window up engine Q16 F11 Cigarette lighter (10A) I3
Cab 1 X 46 S7 Cigarette lighter Q12 F12 Front windscreen wiper and windscreen washer (15A) I4
Cab 1 X 47 S7 Cigarette lighter light Q14 F13 Rear windscreen wiper and windscreen washer (10A) I4
Option X 48 E12 Front right working light M11 F20 Electric window up I5
Option X 49 E13 Front left working light M10 F21 Roof light and door contact A14
Cab 2 X 50 E14 Roof light C24 F24 Front auto return windscreen wiper engine+ Vbat (15A) C14
Cab 2 X 59 M4 Rear windscreen wiper engine G14
F27 Side + roof + rear windscreen wiper engine + Vbat (10/-15A) C14
Cab 1 X 68 Roof switch supply C16
F45 BF3 Power supply (cab) (40A) A5
Cab 1 X 69 S6 Window wind up M3
K2 Front windscreen wiper intermittent relay K33
Frame/Cab 1 X110 Frame/cab Interface M14
K3 Air-conditioning fan engine relay K31
Frame X149 A1 Manimux Power CN2-P1 M22
K6 Air-conditioning compressor control relay K31
Engine X201 BF1/M1 Engine compartment fusebox BF1 C4
Frame X296 E3 Left-hand tail light (option) Q30
80

Frame X297 E4 Rear right headlight (option) Q34

COMPONENTS

Hydraulic
Item Designation Position on diagram
correspondence
A1 Manimux Power MP1 M28
A9 Manimux Cluster MC2 G5
B1 Reversing sound alarm Q38
SPLICES
B2 Main horn M38
D2 Diode D2 G36 Item Position on diagram
E1 Front left headlight Q23
Ep.1 Q5
E2 Front right headlight Q26
E3 Rear left sidelight with fog light Q30 Ep.2 Q6 - O31

E4 Rear right headlight with reverse light Q34 Ep.10 C17

E12 Front right working light O10 Ep.11 K28
E13 Front left working light O11 Ep.36 O35
E14 Roof light E24
E15 Rotating beacon light G36
M3 Front windscreen wiper engine K37
M4 Rear windscreen wiper engine G15

80-02-M257EN (05/12/2016)
 ELECTRICAL SCHEMATIC DIAGRAMS 15
DIAGRAM 6 - LIGHTING AND SIGNALING

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
5
-1
54

M se C
AP t

M
Ba
C

as h
as
V

se as
M has s M
M se C M3
as sis 2
as a
C si

se b
Ca M1
b
M
A A

2
BF3 / M4 S4
X201 F21
0 1
0
73 33

33
78
F24
X16 5 6

72
38

X107-1

29

30
44

F27
X68 Sch. 8
F

41 1
46 45 X108-1
C EP 10 C

43

30 + BAT
29
X50
57/58 56a 56b 54s 54d 49 A C B

1 L 0 R
0 2 S8

X11
S5
1 2 3 4 5 6 7 8 9
X12
E 1 2
E
E14
30 L 31

131
19

129

130
236

127

18

128
117

116

132
43

24

25
X59 1 3 2 4

X14 X15
1 2 3 4 5 6 7 8 9
1
24 116

1 2
25 2 117

G
+perm
M4 vit
G
raz
M 26 3 97
E15
CLUSTER 3

132
28
27 4 98
A9 / MC2 4
X6 1 2
28 5 99 D2
M11

239
8 28
X13
131
136

I I
BF3 / M3
67

70

239

130

153
133
6
BF3 / M2

38
F11

F12

F13

F20

17
2 X25
K6 K2 2 5 4
3 6 1 5 4 2

85 87 87a

175
3 M3 2
16

17

19

32

+perm vit 1
86 30
K 2 2
K
K3 1 3
1
raz
M
-

174

233
136
6

6
23
17 233
EP 11

80
100

78

97

98

99

X33 3 4 1 2
X110 B2
M 1 10 13 14 15
M
A1 / MP 12
63

72

75

76

77
165

101
32

X69
1 2 1 2
CN2-P1 / X149
A B C
X49 X48 62 59 87 69 46 63 31 14 43 60 61 16 48 15 79 72 73 78 42 17 74 90 X39
62

noir

69

211
122
132

133

134

135

116
119

121
120

14
52
77

76

75

72

63

54

56

16

13

11
E12 E13

EP2

211

56
55

54
58

EP36
O X31 4 2 3 5 1 6
10
O

16

13

11

12
9
X32 6 5 3 1 2 4
62
EP1

EP2

131

132

133

134

135

X297

118

119

120

121

122
X296

10
101

17
X35 1 2 3 4 5 6
X36 1 2 3 4 5 6 4 2 3 5 1 6 6 5 3 1 2 4
X38 1 2
100

128

166
noir

127

160

161
71

X43 X27 X28

16

Q X46 1 X47
2 1 1 2 1 2
Q
noir

1 2
63

64

STOP STOP

H8 H9 H7 H11 H8 H9 H7 H10 H2 H1 H3 H4 H6 H3 H2 H5

0
1 7 2 8 10 M M M
1 2
noir

E1 E2 E3 E4 B1

noir
noir
S7 M9 M7 M8
S6 3 4 9
69
71

S S

(05/12/2016) 80-02-M257EN
 16 ELECTRICAL SCHEMATIC DIAGRAMS
7 – LIGHTING AND SIGNALING / CAR RADIO OPTIONS

CONNECTORS COMPONENTS

Wiring harness Name Position on Hydraulic Hydraulic

Item Designation Item Designation Position on diagram
type component diagram correspondence correspondence
Cab 1 X 15 High/low cab interface G31 S40 Roof windscreen wiper switch O11
Cab 1 X 16 High/low cab interface E20 S41 Side windscreen wiper switch O6
Cab 2 X 26 M14 Top & side glass wash pump G23 S42 Telescope working light switch I37
Option X 34 E5/E6 Trailer headlight Q33
Frame X 37 E7 Rear number plate light Q38
Frame X 40 Trailer socket O33
Cab 1 X 68 Roof switch supply G14
Cab 1 X 93 A7 Car radio supply A16
FUSES AND RELAYS
Cab 1 X 94 Loudspeakers A23
Cab 2 X101 E17 Rear right working light Q25 Item Designation Position on diagram
Cab 2 X102 E16 Rear left working light Q22
BF3/M3
Option X103 E19 Right telescope working light Q29
F10 Car radio + Post contact (2A) C5
Option X104 E18 Left telescope working light Q27
Frame X105 Boom working light (predisposition connector option) O29 F11 Cigarette lighter (10A) C6

Cab 2 X107 M5 Cab roof windscreen wiper engine Q10 F12 Front windscreen wiper and windscreen washer (15A) C6
Cab 2 X108 M6 Side windscreen wiper engine Q4 F16 S42 and S43 switch supply (15A max.) C7
Frame/Cab 1 X112 Frame/cab Interface M27 F17 Rear working light (15 A) C7
Frame X148 A1 Manimux Power CN1-P1 M30 F18 Rear windscreen defrost (10A) C8
Frame X149 A1 Manimux Power CN2-P1 M34 F19 Roof windscreen wiper and windscreen washer (7.5A) C9
Engine X201 BF3 BF3 cab fuse box G7 BF3/M4
Cab 2 X204 B27 Right loudspeaker G18
F26 +V bat car radio (7.5 A) G11
Cab 2 X205 B28 Left loudspeaker G20
F27 Side + roof + rear windscreen wiper engine + Vbat (10/15A) G11
F32 + Post contact side windscreen wiper and windscreen washer (7.5A) G11

COMPONENTS

Hydraulic
Item Designation Position on diagram
80

correspondence
A1 Manimux Power MP1 M37 Splices
A7 Car radio A20
B27 Right loudspeaker I19 Item Position on diagram
B28 Left loudspeaker I20
Ep.10 Q4
D3 Diode D3 C33
Ep.11 I36
E5 Left trailer light S33
Ep.35 O37
E6 Right trailer light S37
Ep.73 O29
E7 Rear number plate light S38
E16 Rear left working light S22
E17 Rear right working light S24
E18 Left telescope working light S27
E19 Right telescope working light S29
M5 Roof windscreen wiper engine Q11
M6 Side windscreen wiper engine Q6
M14 Roof and side windscreen washer pump I24
R3 Rear windscreen defrost Q17
S38 Rear working light switch O23
S39 Rear window defrost switch O18

80-02-M257EN (05/12/2016)
 ELECTRICAL SCHEMATIC DIAGRAMS 17
DIAGRAM 7 - LIGHTING AND SIGNALING/CAR RADIO OPTIONS
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

5
-1
54
AP t

M Ma Ca
Ba
C

as sse b
V

se C M
as

C h ab 2
se

as M
A7

sis 1
M
A A

3
X93 X94
A B
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8

151
15

40

74

75

76

77
67 68

69
66

70
D3
240 241
C C
F10

F11

F12

F16

F17

F18

F19
BF3 / M3
28

31
15

30
29

74

75

76

77

81
X16 1 2 3 4 9
34 83
E 7 E

20

21

22

23

36
8
55 29
9
57 30

BF3 / M4 59
10
47
240
68
F32 47
11
61 31
X201
F26

158
12
X204 X205

81
21
40

20

22

23
73
1 2 1 2 X26 1 2 X15
G X68 G
72

F27

34
41 1 46

28 2 47 M 1 0 1 7 2 8 9

B27 B28 M14 5

S42 6 10

S42

48 50

I I
49 S43-5
Sch. 10

48
EP11
47

K K

5 4

42
60 38 39
A1 / MP 12

80
83
58 41 40
59

61

M 14
CN1-P1 / X148 CN2-P1 / X149 M
X112

536
2 7 10 2 7 10 0 1 9
1 1 1 0 1 9
0 0 1
2 2 57 64 68 75 67 66 76 65 15

537

249
S41 S40 S39 S38

52
5 4 9 5 4 9 5 10 5 10

EP35
S41 S40 S39 S38
57

56

50
37

toit
53

EP73
lateral 55 54

36 37
O O

538

256

245

243

247

244

249

250

248

246
X105 1 2
X40 3 1 5 2 7 8 6 4

X59-1
Sch. 7
43

EP 10 X34 3 1 7 2 6 5 4

noir
51

50
44

X103
45

41

52
53
42

X108 X107 X104 X37

Q 1 3 2 4 1 3 2 4 1 2 1 2 2 1
Q
40

39

X102 1 2 1 2
X101

1 2 1 2
38

M6 vit M5 vit
+perm +perm

raz
M
raz
M R3
E18 E19
STOP STOP

3 3
- -
4 4
E16 E17
E5 E6 E7
S S

(05/12/2016) 80-02-M257EN
 18 ELECTRICAL SCHEMATIC DIAGRAMS
8 – HEATING + AIR-CONDITIONING OPTION

CONNECTORS FUSES AND RELAYS

Wiring harness Name Position on

Item Designation Item Designation Position on diagram
type component diagram
Air-conditioning C1.1 A8 Heating/ventilation control button Q4 F4 Heating / Ventilation (2 A) G3
Air-conditioning C2.1 M16 Heating blower fan engine Q12 F30 +V bat air-conditioning fan engine (25A) C3
Air-conditioning C3.1 B52 Frost protection thermostat O20 Compressor and air-conditioning fan engine power supply
F45 E3
Air-conditioning C4.1 K14 Air-conditioning compressor control relay Q18 (30 A)
Air-conditioning C5.1 R14 Fan speed Q14 K5 Ventilation/heating relay C6
Air-conditioning/ K14 Air-conditioning compressor control relay Q18
C6.1 HVAC Air-conditioning control harness link/Cab 1 M11
Cab 1
Air-conditioning C7.1 A8 Heating/ventilation control button Q7
Splices
Air-conditioning C8.1 S13 Air-conditioning control switch O11
Cab 2/Air-
C1.2 COND Air-conditioning condenser fan M33 Item Position on diagram
conditioning
Cab 2/Air- Ep.10 Q4
C2.2 COND Cab/air-conditioning condenser harness link M29
conditioning
Electronic air-conditioning condenser fan management Ep.11 I36
Air-conditioning C3.2 A25 O12
module Ep.35 O37
Air-conditioning C4.2 B46 Air-conditioning high and low pressure switch Q27 Ep.73 O29
Air-conditioning C5.2 M13 Air-conditioning fan engine 2 Q32 SP1.1 M10
Air-conditioning/
C6.2 M12 Air-conditioning fan engine 1 Q31 SP2.1 Q12
Cab 1
SP5.1 O13
Cab 1/Cab 2 X 15 High/low cab interface M26
SP6.1 O13
Cab 1 X 16 High/low cab interface K29
SP1.2 M29
Engine/Cab 1 X 23 Cab/engine interface M36
SP75.2 M31
Cab 1 X 29 A8 Heating/ventilation control M13
SP76.2 M28
Engine X 30 M10 Air-conditioning compressor O36
SP77.2 M30
Cab 1/Air-
X 95 Cab/air-conditioning condenser harness link M28
conditioning SP78.2 M29
Cab 1 X97.1 Air-conditioning condenser management module power supply K26 SP81.2 M33
Frame/Cab 1 X110 Frame/cab Interface I12 SP82.2 M33
Frame X149 A1 Manimux Power CN2-P1 G12
SP83.2 M32
Engine X290 Fan regulation M33
SP84.2 M32

COMPONENTS
80

Item Designation Position on diagram

A1 Manimux Power MP1 G12

A8 Heating/ventilation control button Q5
A25 Electronic air-conditioning condenser fan management module O33
B46 Air-conditioning high and low pressure switch sensor S27
B52 Frost protection thermostat Q20
COND Air-conditioning condenser unit M28
H12 Heating panel light lamp Q4
HVAC Heating/air-conditioning fan control unit M3
M10 Air-conditioning compressor Q37
M12 Air-conditioning fan engine 1 Q30
M13 Air-conditioning fan engine 2 Q32
M16 Heating blower fan engine Q12
S12 Heating speed control switch Q7
R14 Fan speed Q15
S13 Heater speed control switch Q10

80-02-M257EN (05/12/2016)
 ELECTRICAL SCHEMATIC DIAGRAMS 19
DIAGRAM 8 – HEATING + AIR-CONDITIONING OPTION
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

M - M se M âss
M
M -M
M - M se C

M Ma e C teu rr
4
/5

2 as o is
5
4 as
3 as h

1 ss hâ r
- s
-M e s
15

as Cab sis a
C
+ t

se in v
AP
Ba

Ca e
V

bi
ne
A A

a
K4
K2 Sch.9
Sch.9

178
BF3/M2

177

6
K5 85 87

2 5 4

BF3 / M4
1 3

C 86 30 C
X201
F30
141
55

Sch.1 141

X201 BF3 / M5
Sch.1 F45 447

446

E E

X2 BF3 / M3
Sch.1
66
F4 55

69

A1
G G
45
X149
64

X110
64

2
102

I I

K K

126
80

79

52

81
X16 8 7 12 11 9

X97.1

32

31

67

66
2
447 69

446
1
68 SP76

X15 SP81

SP84

SP83
SP78

SP77

SP75

SP82

80
4
33

M X95 1 2 3 4 1 2 3 4 X290 M
152

102

126

X29
79

80
6

1 2 3 4 5 6 C2 C1
C6
COND

52
HVAC SP2 10 X23
SP1 SP5
SP1

rouge

rouge
jaune
noir

noir

750
C3 10 7 9 5 6

SP6

(+)

GND

SIGNAL
SERIE
(+)

GND

750
X30
O PCB RELAIS A25 O

PARLELLE

FAN A (+)
FAN B (+)

FAN A (-)
SP2

FAN B (-)
1 2 3 C3
C8

MP
1 2 3
C
C7 C2 C5 8 1 2 4 3
510 Ohms

C1 2 1 E F A B
C4
R

2 4 1 3
1 3 T
A
1 3 M10
H12
2160C

jaune

jaune

jaune

jaune
MTS

rouge

rouge
1

noir

noir
0

303
2 B ON 4 1 3 2 1 2 1 2
Q 2 5 4
C6 C5
Q
S12 3
K14 OFF C4
+ - + -
2 4
A8 C 1.16 Ohm 0.31 Ohm 5
4 0.57 Ohm 10C 3.50C
S13 M16 R14
D B52
M12 M13
MP
14-17
bars
HP LP
22-28 2-2.1
B46 bars bars
FAN B FAN A
S S
52

(05/12/2016) 80-02-M257EN
 20 ELECTRICAL SCHEMATIC DIAGRAMS
9 – REAR HYDRAULIC TWO WAY / TDF ELECTRIC SOCKET / OIL HEATER

CONNECTORS FUSES AND RELAYS

Wiring harness Name Position on Hydraulic

Item Designation Item Designation Position on diagram
type component diagram correspondence
Cab 1 X11 S4 Wiper stalk switch C25 BF3/M3
Cab 1 X13 A9 Cluster C21 F1 K4 predisposition relay C8
Cab 1/Cab 2 X 15 High/low cab interface A27/O22 F3 S35 circuit breaker power supply C8
Engine/Cab 1 X 23 Cab/engine interface C28 F5 Switch predisposition C9
Cab 1 X25 M3 Front windscreen wiper C26
F6 Boom head electrical connector C10
Cab 1/Cab 2 X68 Roof switch supply I14
F12 Front windscreen wiper and screenwash C12
Frame X106 Boom electrical connector (option) K36
F14 K1 predisposition relay C13
Frame X109 Y14 Rear hydraulic two way EV G37
F15 S36 and S37 switch supply C13
Frame/Cab 1 X112 Frame/cab Interface I35
Cab 1 X118 Customer digicode C26 F16 S42 and S43 switch supply C14

Frame X148 A1 Manimux Power CN1 - P1 E36 BF3/M4

Engine X201 BF3 BF3 cab fuse box M8 F31 + Post contact safety engine starter, relay K5 O11
X294 Frame harness - oil vapor heater link E38 F35 ORH console (2A) Q13
X295 Engine oil vapor heater E39 F37 Power supply +APC 120 (Option) (15 A) Q14
BF3/M2
K1 Standby E24
K2 Front windscreen wiper intermittent relay E25
K4 Standby E28

K5 Stop electrovalve relay, diesel supply pump, cold starter electrovalve E29

BF3/M1
K11 Standby C29
COMPONENTS

Hydraulic
Item Designation Position on diagram
correspondence
A1 Manimux Power MP1 E37
A9 Manimux Cluster MC2 A22
D3 Diode D3 O36
R5 Engine oil vapor heater E40
S18 Hydraulic two way EV switch K28
S19 Override Switch K30
80

S35 Option switch M25

S36 Option switch M28
S37 Option switch M30
S38 Rear working light switch S27
S39 Rear window defrost switch S26
S40 Roof windscreen wiper switch S24 SPLICES
S41 Roof windscreen wiper switch S23
S42 Telescope working light switch Q23 Item Position on diagram
S43 Option switch Q26
Ep.11 G12
Y14 Rear two way hydraulic electrovalve I37
Ep.11 O20

80-02-M257EN (05/12/2016)
 ELECTRICAL SCHEMATIC DIAGRAMS 21
DIAGRAM 9 – REAR HYDRAULIC TWO WAY / TDF ELECTRIC SOCKET / OIL HEATER
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

5
-1
54

M Ma e C
C

as ss ab
AP

se e M
M
as

Ch Cab 1
s

as M
sis 2
M
A A

3
181
180

CLUSTER

90

92
X15
BF3 K11
1 5 4 1
K12
5 4

A9 / MC2
6

X11 X25 X118 X23 M1 86 87 87a

69

67

68

70
7 4 6 4

66

115
A B X13 36 40 8 6 18 6
85 30

136

137
2 3 3

87
2

129

133

141
F10

F11

F12

F14

F15

F16

F20

52

181

91
F1

F2

F3

F5

F6
C C
BF3/M3

28
4
1

9
7

18

22
EP. 5

360
359
94
X11-5
Sch. 7 Sch. 1 91
A1 / MP12

1
90

129
133
176

2
92

180
177
X302-8 X148

3
174

52
175 93 93 65
Sch. 12
E X302-9 E

549
179 178

4
358 358
BF3 M2

141
Sch. 12

115

96

5
95 549
K1 2 5 4
K2 2 5 4
K3 2 5 4
K4 2 5 4
K5 2 5 4
K6 2 5 R5

6
85 87 87a 85 87 87a 85 87 87a 85 87 87a
96 550 550

7
85 551
86 30 86 30 86 30 86 30 X302-10

8
86 374
1 3 1 3 1 3 1 3 1 3 1 3
Sch. 12 X294 X295
X118-8 X302-7

9
17

137
1
136

233

95
359 359

93

46
120
Sch. 12

10
Sch. 1 88
EP11

X302-6

11
360 360
Sch. 12 X302-11
G G

12
82 251
Sch. 12
236

13
83

251

252
14
84
X11-3 1 2
Sch. 7

15
20
X109

16
23

X302-4

17
37 361
Sch. 12

18
Y14

X112
I I

395 Sch. 11
28

X68 X284/11

86

87
2 168 169

0 1 10 1 10
47

253

254
1 1 0

X106 1 2

K 5 S18 9 5 S19 9 K
S18 S19
3 8

80
85
88

82
170 171 172
M M
0 1 10 0 1 10 1 10
1 1 1 0
47

S35 S36 S37

EP11

5 9 5 9 5 9
84

X15 S35 S36 S37

8

S42-5 48
4 5 9 10 22 27
174
168

170

Sch. 8
35

O
D3 O
240 241
240
68

35

D
F31

F35

F37

F40

9 0 1 9
1
5A

BF3/M4
S42 5 S43
46

23

20

Q Q
10
S42 S43
51
49

9 9 9 9

S41 S40 S39 S38

S S

(05/12/2016) 80-02-M257EN
 22 ELECTRICAL SCHEMATIC DIAGRAMS
10 – TDF EV / PNEUMATIC SEAT OPTIONS
DIAGRAM 10 – TDF EV / PNEUMATIC SEAT OPTION
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

5
-1

M se
M
54

as Ca
CONNECTORS

as

se b
C
AP

Ch M2
as
sis
Wiring harness Name Position on Hydraulic

M
3
Item Designation A
type component diagram correspondence
Frame X 91 Telescope head electrovalve O11
Cab 1 X121 M15 Pneumatic seat pump Q6/O7/O4
Frame X149 A1 Manimux Power CN2-P1 K10
Option X166 Y12 Telescope head electrovalve connector Q10
C

COMPONENTS
G
Hydraulic
Item Designation Position on diagram
correspondence
A1 Manimux Power MP12 K12
M15 Pneumatic seat pump S4
S44 Pneumatic seat switch Q4
Y12 Boom head electrovalve S10 I

66
K BF3 / M3
A1 / MP 12

F8
CN2-P1 / X149
80

13
77

3
FUSES AND RELAYS
M

Item Designation Position on diagram

BF3/M3
EVTDF
F8 Pneumatic seat (10A) K4

4
O
1 2
X91

162

13
X121 5 4

S44

Q
C X166 1 2

M15
Y12

80-02-M257EN (05/12/2016)
 ELECTRICAL SCHEMATIC DIAGRAMS 23
11 – FAN REGULATION OPTION
DIAGRAM 11 – FAN REGULATION OPTION
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
CONNECTORS

M
as
s
Wiring harness Name Position on Hydraulic

e
Ch
Item Designation

as
type component diagram correspondence

iss
M
5
A
Option X254 Y61 Fan regulator valve K14
Option X289 B78 Hydraulic oil temperature sensor M14
Option X293 B79 Fan regulation air temperature sensor M14 EP 65
Sch. 2
Option X300 A19 SPU 25/15 - CN1-A Q8 EP 64 X112-10 X112-5 X109-1 X302
Sch. 10 Sch. 10
Option X301 A19 SPU 25/15 - CN1-B E8 Sch. 2
X112-18 X112-12 X112-4 X112-9
Sch. 10
1 2 3 4 5 6 7 8 9 10 11 12

Frame/Option X302 Option link C8 / C17 Sch. 10 Sch. 10 Sch. 10 Sch. 10

C
1 mm2

381

382

361

360

359

358

374

251
93
COMPONENTS 1 2 3 4 5 6 7 8 9 10 11 12
X302

Hydraulic
Item Designation Position on diagram CN1-B X301
correspondence
A19 SPU 25/15 ECU G8 E

B78 Hydraulic oil temperature sensor M17

B7
B79 Air intake temperature sensor O17
R10 510 ohm 1/2 W - 1% resistor K12

B14
374

B17
R11 510 ohm 1/2 W - 1% resistor M12
V7 Vishay 1A diode 1N4004 G6 V7

B34
A19 SPU 25/15
353

B30
358
Y61
372
Fan speed control electrovalve I17 G EP 47 EP 48

B31
352 350 350
EP 45

B6
93

B26
B4
371
436

B3
360 370
EP 42

B21
B28
I

2
SPLICES 436

B1
CAN B H

B5
435

1
435

B2
Item Position on diagram
CAN B L
Y61
X254
EP41 K7
EP42 I6

B16
392 438

EP44 O12 K

2
438
EP45 G12

A13
R10
363

EP47 G5

1
437
EP 55

A1
359 362
EP 41
EP48 G7

80
X289

A7
EP53 M11
361
B78

T
EP54 M13

B13
440
391

388
EP55 K13 M

2
440

R11
439

1
EP 53 EP 54

388
X293
B79

T
A26
349 346
EP 44

A20
348

A19
Alim

A25
Entr9e

A6
A5
Q

CN1-A X300

(05/12/2016) 80-02-M257EN
 24 ELECTRICAL SCHEMATIC DIAGRAMS
80

80-02-M257EN (05/12/2016)
 ELECTRICAL COMPONENTS LOCATION

pages

KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– GROUNDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
–– DIODES AND SPLICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2D LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
–– HARNESS ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
–– FRAME HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
–– CAB HARNESSES 1 AND 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
–– ENGINE HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3D LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
–– FRAME HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
–– CAB HARNESS 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

80
–– CAB HARNESS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
–– ENGINE HARNESSES 1 - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

(04/22/2016) 80-03-M257EN
 2 ELECTRICAL COMPONENTS LOCATION
MT 1435 / 1440 / 1840
KEY
CONNECTORS

Wiring harness Position on harness layout

Item Designation Comments
type Assembly Frame Cab Engine
Engine B+ Alternator power supply Q21
Cab 2 S6 Window up switch G21 E18
Cab 2 S8 Roof light control switch
Cab 1 S17 Option switch I23 C18
Cab 1 S18 Hydraulic two way EV switch I23 C18
Cab 1 S19 Override Switch I24 A19
Cab 1 S35 Option switch I25 A22
Cab 1 S36 Boom head electrical connector switch (option) I24 C23
Cab 1 S37 Option switch I24 C23
Cab 2 S38 Rear working light switch E11 I4
Cab 2 S39 Rear window defrost switch E11 I4
Cab 2 S40 Roof windscreen wiper switch E9 I4
Cab 2 S41 Side windscreen wiper switch E10 I4
Cab 2 S42 Telescope working light switch E12 G5
Cab 2 S43 Option switch E13 G5
Engine W Alternator Q18 I7
Cab 1 X1 Ignition switch (4 way) I29 O29
Cab 1 X2 Ignition switch (6 way) I29 O30
Cab 2 X6 Rotating beacon light A11 C14
Engine X10 Power supply terminal block O26 O35
Cab 1 X11 Wiper commutator switch I29 K34
Cab 1 X12 Wiping reset I30 K36
Cab 1 X13 Manimux cluster K33 M34/S39
Cluster X14 Light commutator switch Q37
Cab 1 X15 Cab high/low connection I24 G13
Cab 2 X15A Cab high/low connection C15 E13
Cab 1 X16 Cab high/low connection G24 G11
Cab 2 X16A Cab high/low connection C15 E11
Engine X20 Air filter clogging Q15 G3
Frame X21 Hydraulic filter sensor I16 E27
Cab 1 X22 Brake fluid level I27 K26
Engine/Cab 1 X23 Cab/engine connection O24 Q28
Cab 1 X25 Front windscreen wiper G27 K28
Cab 1 X26 Top & side glass wash pump G30 I23
Cab 1 X27 Front windscreen washer pump G29 I23
Cab 1 X28 Rear glass wash pump I29 K23
Cab 1 X29 Heating I28 K32
Engine X30 Air-conditioning compressor Q15 I3
Frame X31 Rear left headlight I5 C11
Frame X32 Rear right headlight Q5 I5
Cab 2 X33 Left/Right front working light connection C17 C14
Frame X35 Front left headlight I40 I36
Frame X36 Front right headlight Q40 K36
Frame X37 Rear license plate light M4 E4
Frame X38 Reverse buzzer O3 I9
Frame X39 Horn M36 I29
80

Frame X40 Trailer socket M5 E3

Engine X42 Cold start system thermo switch (KSB) Q20 I11
Cab 2 X43 Window up engine G22 E17
Cab 1 X45 Door switch closed/cluster NF (wake-up) G21 I10
Cab X46 Cigarette lighter I20 C28
Cab X47 Cigarette lighter light I20 C28
X48 Front right working light Option on UK truck
X49 Front left working light Option on UK truck
Cab 2 X50 Roof light A10 C11
Cab 1 X52 Door switch closed/Manimux Power NO G20 I10
Frame X53 Forward electrovalve M18 M14
Frame X54 Reverse electrovalve M17 M12
Frame X55 Forward motion pressure sensor O18 M14
Frame X56 Reverse motion pressure sensor M20 K15
Frame X57 Front clutch pressure M18 K13
Frame X58 Gearbox temperature sensor O16 M12
Cab 2 X59 Rear windscreen wiper engine A6 A5
Frame X60 Gear lever transmission cut-off M17 K12
Engine X61 Fuel water level sensor Q16 E14
Frame X62 Gearbox output speed sensor M21 K16
Cab 1 X63 Fuel gauge I28 I24
Cab 1 X64 Master cylinder pressure switch G28 I25
Frame X65 Front wheel alignment sensor M32 I27
Frame X66 Rear wheel alignment sensor M12 O11
Frame X67 JSM connector K23 Q38/M26
Cab 1 X68 Roof switch supply I24 G12
Cab 2 X68A Roof switch supply A15 E12
Cab 1 X69 Cab/window control connection G23 G14
Cab 2 X69A Cab/window winder connection G23 G17
Frame X70 Assist brake circuit pressure switch M30 Q20
80-03-M257EN (04/22/2016)
 ELECTRICAL COMPONENTS LOCATION 3

Wiring harness Position on harness layout

Item Designation Comments
type Assembly Frame Cab Engine
Frame X71 Output A on telescope and attachment K25 Q26/O31
Frame X72 Output B on telescope and attachment K26 Q26/M31
Cab 1 X73 Fuel gauge I30 I23
Frame X75 Movement safety electrovalve 1 K22 Q37/O28
Frame X76 Safety valve/distributor pressure switch K24 S37/M26
Frame X77 Boom lifting NC sensor K22 Q30/O29
Frame X78 Boom lowering NC sensor K22 Q29/M29
Frame X79 Tilting NO sensor K23 Q28/O30
Frame X80 Tilting NC sensor K24 Q28/M30
Frame X81 Right stabilizer raising NC sensor K18 Q33/O29
Frame X82 Right stabilizer lowering NC sensor K19 Q33/O29
Frame X83 Left stabilizer raising NC sensor K20 Q31/O29
Frame X84 Left stabilizer lowering NC sensor K21 Q31/O29
Frame X85 Leveling N0 sensor K17 Q34/O28
Frame X86 Leveling NC sensor K17 Q34/O28
Frame X87 Right stabilizer down pressure switch Q38 M36
Frame X88 Right stabilizer high pressure switch Q37 M37
Frame X91 Boom head electrovalve (option) M2 A5
Frame X92 Parking brake electrovalve M30 O21
Cab 1 X93 Car radio supply I32 K38
Cab 1 X94 Loudspeakers I32 M38
Cab 2 X95 Cab / air-conditioning condenser harness E8 E2
connection
Frame X96 Left stabilizer high pressure switch I38 I37
Frame X97 Left stabilizer low pressure switch I37 I36
Cab 1 X97.1 Cab / air-conditioning condenser harness E6 G25
connection
Frame X100 Boom angle sensor O2 G10
Cab 2 X101 Rear right working light E6 E5
Cab 2 X102 Rear left working light A7 A13
Frame X105 Boom working light (predisposition connector option) M2 A7
Frame X106 Boom electric socket (predisposition option) M2 A8 Option
Cab 2 X107 Cab roof windscreen wiper engine E10 G6
Cab 2 X108 Side windscreen wiper engine E14 I2
Frame X109 Rear hydraulic two way EV M6 E17
Frame/Cab X110 Frame/cab connection G16 E33 K8
Frame/Cab X111 Frame/cab connection G16 M8
Frame/Cab X112 Frame/cab connection G16 E33 M8
Cab X114 Accelerator switch I27 K30
Cab X115 OBD diagnostic plug I22 G26
Frame/Cab X116 Frame/cab connection O22 O15 K22
Cab X118 Customer digicode I28 O32
Cab X121 Pneumatic seat pump I21 E27
Engine X122 Engine ground
Frame X123 Safety electrovalve K27 Q25
Frame X124 Tires/telescoping position sensors K2 A9
Frame X132 Servo steering circuit fault pressure switch M30 Q21
(Deutschland)
Frame X133 ON/OFF negative brake pressure switch M31 Q21
Frame X134 Retracted boom sensor M2 A4
Cab 1 X138 Emergency stop I27 M30

80
Cab 1 X139 Pedal potentiometers I27 K30
Cab 1 X140 Resistance shunt I22 G27
Frame X148 Manimux Power 1 (MP1) I12 A20
Frame X149 Manimux Power 1 (MP1) I14 A22
Frame X150 Manimux Power 2 (MP2)
Frame X151 Manimux Power 2 (MP2)
Option X153 Air-conditioning fan engine connector 1 Option on UK truck
Option X154 Air-conditioning fan engine connector 2 Option on UK truck
Option X155 Air-conditioning connector on condenser Option on UK truck
Option X166 Telescope head electrovalve connector Option
Frame/Engine 1 X173 Frame/engine connection O25
Engine X174 Engine ECU O25 M34
Engine X175 Engine ECU O26 M35
Engine X176 Air intake temperature sensor
Engine X178 Diagnostic plug
Engine X179 Alternator + connection
Engine X201 BF3 cab fuse box Q20 K14
Cab 2 X204 Right loudspeaker C6 A2
Cab 2 X205 Left loudspeaker A6 A7
Option X254 Fan regulation valve (O)
Engine X257 Glow plug power supply Q15 M16
Engine X258 Radiator minimum water level sensor O23 E15
Frame X260 Flow regulation electrovalve M3 G7
Frame X263 Vishay CAN gauge I10 C18
Engine X268 ECU ground O27 M30
Engine X283 Diesel pump harness (X269) Q16 C13
Engine X281 Diesel filter sensor (filter) Q15
Engine X282 Diesel filter sensor (engine) Q16
Cab 1 X284 Easy manager (O) I31 M31
Option X287 fan regulation (O)
(04/22/2016) 80-03-M257EN
 4 ELECTRICAL COMPONENTS LOCATION

Wiring harness Position on harness layout

Item Designation Comments
type Assembly Frame Cab Engine
Option X289 Hydraulic oil temperature sensor
Engine X290 Fan regulation Q22 O27
Option X291 Easy manager BAT +/- (option)
Cab 1 X292 Easy manager anti-start (option) I31 M31
Option X293 Fan regulation air temperature sensor (option)
Option X294 Oil vapor heater/frame connection (option)
Option X295 Engine oil vapor heater (option)
Option X296 Rear left headlight
Option X297 Rear right headlight
Engine 2 X900 Fuel metering valve Q18
Engine 2 X901 Fuel rail pressure sensor Q18
Engine 2 X902 Engine fuel temperature sensor Q18
Engine 2 X903 Injector cylinder 1
Engine 2 X904 Injector cylinder 2
Engine 2 X905 Injector cylinder 3
Engine 2 X906 Injector cylinder 4
Engine 2 X907 Intake manifold pressure & temperature sensor Q18

Engine 2 X908 Throttle valve position sensor & actuator Q18

Engine 2 X909 Exhaust gas pressure sensor Q17
Engine 2 X910 Exhaust gas temperature sensor Q17
See "Engine harness" 3D location
Engine 2 X911 Wastegate valve regulator (turbo) Q17
Engine 2 X912 Coolant temperature sensor Q17
Engine 2 X913 EGR valve position sensor & actuator Q17
Engine 2 X914 Oil pressure switch Q17
Engine 2 X915 Crankshaft speed sensor Q17
Engine 2 X916 Camshaft speed sensor Q17
Engine 2 X917 Glow plug cylinder 1 Q18
Engine 2 X918 Glow plug cylinder 2 Q19
Engine 2 X919 Glow plug cylinder 3 Q19
Engine 2 X920 Glow plug cylinder 4 Q19
Engine 2 X921 Intake manifold pressure sensor
Engine 2 X922 Intake manifold temperature sensor

GROUNDS

Wiring harness Position on harness layout

Item Designation Comments
type Assembly Frame Cab Engine
Engine Engine ground M4 Engine ground M4 Q22 I21
Frame M1 AV frame ground M1 AV frame ground K28 M22
Cab 1 M1 AV Cab ground M1 AV Cab ground I29 M34
Frame M2 mid-frame ground M2 mid-frame ground M22 M17
Cab 1 M2 rear cab ground M2 rear cab ground I20 K14
Frame M3 rear frame ground M3 rear frame ground M5 E13
Cab 2 X011 Cab ground M2 A15 C10

DIODES AND SPLICES

80

Wiring harness Position on harness layout

Item Designation Comments
type Assembly Frame Cab Engine
Cab 1 D2 Diode D2 I30 K34
Cab 1 D3 Diode D3 I19 K14
Cab 1 EP.1 Splice I19 K21
Engine EP.1 Splice Q23 G25
Cab 2 EP.1 Splice C8 A5
Cab 2 EP.1 Splice G21 G18
Cab 2 EP.2 Splice G22 G18
Cab 2 EP.2 Splice A8 A11
Cab 2 EP.3 Splice A8 A10
Cab 2 EP.4 Splice C8 C3
Frame EP.5 Splice M13 G21
Cab 1 EP.5 Splice I27 M31
Cab 2 EP.5 Splice C9 E3
Cab 2 EP.6 Splice C8 C3
Cab 2 EP.7 Splice C8 C4
Cab 2 EP.8 Splice C8 A3
Cab 1 EP.9 Splice O29 O25
Cab 2 EP.9 Splice C8 A3
Cab 2 EP.10 Splice A9 A11
Cab 1 EP.11 Splice I18 M18
Cab 2 EP.11 Splice C10 E3
Cab 1 EP.15 Splice G16 K9
Cab 1 EP.16 Splice I21 G25
Cab 1 EP.17 Splice K32 M32
Frame EP.20 Splice O2 G8
Frame EP.25 Splice M28 O24
Frame EP.26 Splice M28 Q24
Frame EP.29 Splice G15 E30
80-03-M257EN (04/22/2016)
 ELECTRICAL COMPONENTS LOCATION 5

Wiring harness Position on harness layout

Item Designation Comments
type Assembly Frame Cab Engine
Cab 1 EP.56 Splice K31 M31
Frame EP.61 Splice M2 C7
Frame EP.64 Splice I15 E30
Frame EP.65 Splice G15 E31
Frame EP.73 Splice K5 E12
Frame EP.90 Splice M30 O21
Frame EP.91 Splice O2 G8

80

(04/22/2016) 80-03-M257EN
 6 ELECTRICAL COMPONENTS LOCATION
80

80-03-M257EN (04/22/2016)
2D LOCATION ELECTRICAL COMPONENTS LOCATION 7
HARNESS ASSEMBLY

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

Cab View 2 X50

Key:
X102 Ep.10
A X011A Frame Harness A
X010 Ep.2 X011
Cab Harness 1
X205 Ep.3 X68A

X59 X6
X16A Cab Harness 2
Ep.1
X15A Engine Harness
Ep.9
C Engine Harness 2 C
Ep.8 X33
Ep.7
Ep.4 Connection between harnesses
Ep.6 X33
Ep.5 Ep.11
X204 Splice

X95
X107

X101
E E
X108
S40 S43
S41 S42
S39 S38
X97.1
X43

S6
G Ep.1 Ep.2 X69A G
X110 Ep.15 X25 X64 X27
X52 X45
X112 X15 X26
Ep.65
Ep.64 X116 X69
Module M5 X22 X63 X73 X28
X148 / CN1-P1

X149 / CN2-P1
X16 X97
Manimux X111
Power 1 Ep.29 Module M4 D3 X96
Masse Cab M2 X139 X181 X29 X11 X12 X94
BF3 S17 X68
X31 Module M3 S18 X35
I X302 X46 X121 X115 S19 D2 I
X263 X93
Module M2 Masse Cab M1
X47 S35 X138
X118 X284
X1
Module M1 S36
30

Ep.16 Ep.5
20
10
X10
0

X292
1
0

X2
1/2

X21
R

S37
OK

Ep.11 X

Ep.1 X13
Ep.5 X201 Ep.56 Ep.17
X67 X76
X75
K K

Ep.73 X85 X86 X81 X82 X83 X84 X77 X78 X79 X80 X71 X72 X123 Masse Chassis M1
X106
X132
X70 X133
X105

X91 Ep.61 X39

X109 Ep.26 Ep.25

80
X124 Masse Chassis
M3 X60 X57 X56
X134 X92
M M
X66 X62 Ep.90
X65
X40 X54
Masse Boite
X38 X53 M2
X37 Ep.91
X100 X23
X58
Ep.20 X294
X55
X260 X173 X10
O X174 X175 O
Ep.77
Ep.76
X268
Ep.74 Ep.95
X257
X277 Ep.75
Module Module
X910
X258 BF1 M2 M1
X900 X176
X32 X911 X20 X36
X282
Q X281
X912
X901 X917 X290
X178 Q
X122 X87
X902 X918
X61 X913
X30 X907
X914 X919 X88
X283 X179
X908
X915 X920 L
X909
X916

S S
Forward gear

(04/22/2016) 80-03-M257EN
 8 ELECTRICAL COMPONENTS LOCATION
FRAME HARNESS

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

Ep 28 Key:
Ep. 67
Ep. 68 PVC 6X7 sheath
A Opt. EV Opt. A

X149
Opt. Manimux
Ep. 69

X148
Slotted ringed sheath
ARG ARD
X134 X91 X105 X106 X124 X31 X32
X263 Ringed non-slotted sheath

Splice
C C
100

Ep.61 200 X116 Cab harness

Masse Chassis M3 50 50 50
Ep.35 Ep.36 Ep.73
X110 Cab harness

Ep.5
Opt.
X37
50 50 50 Ep.29 Ep.64 Ep.65
E X109 E
X21 X302
X40 Cab harness
X112

X260
100

70

G G
X100
Ep.20 Ep.91

X38
X96
X97
I I

X35
X65 AVG
X39

X57
K X56 K
X60
X36
AVD
X62 n/mn

X54
23
X1 X87
80

X53 7 X88
X6

M 6 M
X7
X58 Masse Chassis M2 2
X55 Masse Chassis M1 X7

X80
X78 X7
9 1
X84 X
77 X7
80 X82 X
83
X86 X
81
X85
5
250 X7

O O
X66
Ep.90 X92 Ep.25
X173 X294
X123
50 X72 X80 X78 X84 X82 X86
X70 X133
X79 X77 X83 X81 X85
X132 X75
Ep.26
Engine harness X71
Q Q

X67

S X76 S

80-03-M257EN (04/22/2016)
 ELECTRICAL COMPONENTS LOCATION 9
CAB HARNESSES 1 AND 2

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

Cab 2 Cab 1
Ep.1 Ep.3 Ep.2
Key:
X010
A X59 A
X204 X102 Opt.
Ep.9 Ep.10 Opt. ARG Diode
+ AR S19 S35
-
M
X205
Splice
Ep.8 + Opt.
-
S18 S36
X50
Ep.7
Opt.
Opt. S17 S37
C C
X33 Opt. AVD X46
Ep.4 Opt. AVG

X6 X47

Ep.6

X011 M
X011A
X43
E E
Ep.5 X101
Opt. ARD + X16A X68A X15A
-
X95 S6 Pn
X121
Ep.11 Cab additional harness
Ep.1

Ep.2
80

X107 M X97.1 X16 X68 X15 X115

Toit Diagn
Ep.16
G G
S43 Opt.

S42

S38 Opt. ARD X69 X69A

Opt. ARG X73 X63
S39
AV X27 X64
X108 S41 Latéral Window winder additional harness
I I
S40 Toit
Latéral NF X45 Toit +
X26
M (Wake-up) Latéral

NO X52
Stop X29
AR X28
X22 X139
X25
Masse Cab M2 RAZ
Speed AV/AR AV/AR
60 X11 X12
K Frame harness X110 AV
X181
X93 ALIM AUTO K
D3
Ep.1 M
D2
100

50
Ep.15
50 50
Opt. EASY MANAGER Masse Cab M1
Frame harness X111 X94 HP AUTO

80
Ep.11
X138 X284
Frame harness X112 X292
M M
Ep.56 Ep.17
30

X201
20
X100

1
10
0
1/2

X13
R
OK

50 50
Frame harness X116

Ep.5
X118
200 1 2 3
4 5 6

O MO 7 8 9
O
DU * 0 #

LE X1 X2
MO 5
DU 4 6
LE
MO 4
DU MODULE 5 MODULE 4 MODULE 3 MODULE 2 MODULE 1
LE
MO 3
DU BF3
LE
MO 2
DU
LE
Q 1 Q

X291 X23 X14

Rear axle X13

S Light commutator switch S

0
Engine harness

(04/22/2016) 80-03-M257EN
 10 ELECTRICAL COMPONENTS LOCATION
ENGINE HARNESS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

Key:
A A
Cab harness
Diode
Splice

X23

C C

X283

X281

X61

X282
E E

Cab harness X173

X30
G G

Ep.74
Engine harness X277

50

50
Ep.75

50
Ep.95
X122 X258
I I

30 60
min.

K23
Ep.78 Ep.79

K21
20
5
Ep.76
X178

30
K X176 K
Ep.77

100
X257

Ep.82
X268
80

Ep.80
Ep.81
M M
X175
X174

X290 X20

X10

X179
REGUL.

O O

Q Q

S S

80-03-M257EN (04/22/2016)
3D LOCATION ELECTRICAL COMPONENTS LOCATION 11
FRAME HARNESS

Cab Ground X78 X80

X82 X84
X86 X148

X123
P1
CN1

X79 MA
NIM
UX

X67 X128 X263

X77 Frame Ground CN2
P1

Frame Ground X83 M3 X149

X76 M1
X81
X75 X85 X109
X72
X71
X35
X92

X133
X132 X124

X70 X39 X97

X91
X106
X105 X134
X32 X31

X96 X100
X38
X36 X260
X302

X40 X116
X88
X87 X37 X21

X112
X110

80
X66
Frame Ground X62
M2
X53

X60 X56 X57

X55

X62
X173
X55

(04/22/2016) 80-03-M257EN
 12 ELECTRICAL COMPONENTS LOCATION
CAB HARNESS 1

5
S3 36
S 37
S

7
S1 8
X4
6 S1 9
S1
7
X4

"A"

X140

A 21
X1
15
X1 X116
X110
Masse Cab M2
X112
X111

X69
X15
X68
X16
NF
X45
NO
X52

90°

X1
3

X13

X1

Anti-theft
shunt X2

X118
X29
X11
X12
X93 Masse
80

X94 Cab M1

"B" X1
39

X22 X138

81
X1

ss
rne
Ha ating
He

X64

X27 X28
X26

X23

X25
B

X73
X63

Engine harness

80-03-M257EN (04/22/2016)
 ELECTRICAL COMPONENTS LOCATION 13
CAB HARNESS 2

X95 X101
"F"
X204
X107
X102
S38 à S43 X010 X59
X108

F
X205

X50

X33 X6

S6 1A

80
01
1-X
X43 X01

X15A
X68A
X16A

X69A

(04/22/2016) 80-03-M257EN
 14 ELECTRICAL COMPONENTS LOCATION
ENGINE HARNESSES 1 - 2

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
X268

A A

X20
X257
C C
X174
X175

E E
X277
X258
X10 X178

X30 X176
G G
X281

I I

X282
X283
X61
K K
X903 X257 X904 X918 X905 X919 X906 X920 X913

X917
X901
80

M M
X179 X907
X270
X173
X912
O O
X10 X277
B-
B+ X900
Q Q
X916

X122 X915
X923
S S
X281

80-03-M257EN (04/22/2016)
 ELECTRICAL CONTROL AND ADJUSTMENT

pages

CLUSTER MENU ARCHITECTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

CALIBRATION MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
–– STEP 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
–– STEP 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
–– STEP 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
–– STEP 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
–– STEP 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
–– STEP 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REPLACEMENT OF ECUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
"BOOM ANGLE" ANGULAR SENSOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
–– OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
–– ON-TRUCK ADJUSTMENT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

80

(23/04/2018) 80-04-M257EN
 2 ELECTRICAL CONTROL AND ADJUSTMENT
80

80-04-M257EN (23/04/2018)
 ELECTRICAL CONTROL AND ADJUSTMENT 3
CLUSTER MENU ARCHITECTURE
Key:
RST H: Partial hour meter reset PARK: Parking brake configuration CFLOW: Forced motion configuration LLMC: Movement shut-down inhibition authorization
PASS: Degraded mode UNIT: Machine speed unit DIGI1: Anti-theft type configuration DIGI2: Manitou anti-theft code
CUST: Customer code DTC: Error code (Data Trouble Code) IDENT: Identification OUTOR: Digital output
INTOR: Digital input OUTANA: Analogue output INANA: Analogue input

Info
Accessible only when engine is stopped

< INFO CLOCK LCD OPT DIAG XPERT >

Press OK to Press OK to
Enter Customer Code Enter Diag Mode
If DTC

If maintenance ENTERING
is needed CUSTOMER < IDENT OUTOR INTOR OUTANA INANA FAIL >
/ ADMIN CODE
Check + Correct Code
No DTC
Maintenance MC MC MC MC MC MC DISPLAY
HOUR BACKL RST H NEXT
DISPLAY DISPLAY DISPLAY DISPLAY DISPLAY CONTEXT
DISPLAY RST H - DTC N°
- Software N° Input/output Input/output Input/output Input/output - DTC State
OPTION - DTC Date
- Hour ENTERING BACK LIGHT state table state table state table state table
- Activate / Deactivate - DTC Hour
- Date HOUR CONTROL MP1 MP1 MP1 MP1 MP1 - DTC Name
MC PARK DISPLAY
DISPLAY DISPLAY DISPLAY DISPLAY DISPLAY MP1
NEXT
DISPLAY PARK CONTEXT
- Software N° Input/output Input/output Input/output Input/output
next OPTION
state table state table state table state table - DTC N°
context - Automatic / Manual MP2 MP2 MP2 MP2 MP2
- DTC State
- DTC Date
- No fault CFLOW - DTC Hour
or DISPLAY DISPLAY DISPLAY DISPLAY DISPLAY - DTC Name
- DTC N° "Present" CFLOW
- DTC State "Present" - Software N° Input/output Input/output Input/output Input/output
MP2 DISPLAY
OPTION NEXT
- DTC Date "Present" state table state table state table state table
CONTEXT
- DTC Hour "Present" - Activate / Deactivate S/N - DTC N°
- DTC Name "Present"
DATE CONTR LLMC - DTC State
DISPLAY - DTC Date
MP1 LLMC - DTC Hour
- Machine N° - DTC Name
DISPLAY OPTION
ENTERING CONTRAST ENG DISPLAY
next - Activate / Deactivate
DATE CONTROL NEXT
context PASS CONTEXT

- No fault - DTC N° “Present”

or BY-PASS - DTC State “Present”
- DTC N° "Present" MODE OPTION - DTC Name “Present”

80
- DTC State "Present" - Activate / Deactivate
- DTC Date "Present"
Press OK to
- DTC Hour "Present" UNIT Enter Xpert Mode
- DTC Name "Present"

UNIT OPTION
MP2
DISPLAY - Km/h / Mph < RESET ADMIN ERASE CALIB >
next DIGI1
FORM
context HOURM Press OK to Press OK to SECU
DIGICODE Enter Admin Code Enter Admin Code
- No fault OPTION If RSTH is activated COMFIRM Press OK to Enter Calibration
or RESET
- DTC N° "Present"
ENTERING - Activate / Deactivate Menu > Option Security Procedure
Calibration Mode
- DTC State "Present" FORM + Correct Code ENTERING ENTERING Manual repair
DIGI2 ADMINISTRATION ADMINISTRATION 80 – Control
- DTC Date "Present" CODE CODE and Adjustment
- DTC Hour "Present"
If RSTH is deactivated ENTRY CODE
- DTC Name "Present" 1 - 24 DD/MM/YYYY ENTERING Menu > Option CLIENT + Correct Code + Correct Code ENTERING
2 - 12 MM/DD/YYYY ANTI-THEFT CODE ADMINISTRATION
3 - 12 DD/MM/YYYY Press OK to change CODE + Correct Code
ENG 4 - 24 MM/DD/YYYY
MAINT Admin Code
MC
GAUGE
DISPLAY CUST COMFIRM Press OK to Erase
RESET Erase Failures Failures
next Press OK for Gauge Recelibration
ENTERING Fast Procedure
context ENTERING
ENTERING Calibration Mode
CUSTOMER CODE CUSTOMER /
- No fault ADMIN CODE + Correct Code NEW CODES MP1 Operator's manual
or Press OK to Erase
- DTC N° "Present" Erase Failures Failures ENTERING
- DTC State "Present" OIL CUSTOMER CODE + Correct Code
- DTC Name "Present"
Accessible only when COMFIRM
engine is stopped RESET MP2 BOOM
Press OK to Enter Calibration
Press OK to Erase
Press OK to reset Erase Failures Failures Boom Calibration Mode Procedure
Engine Oil Maintenance Manual repair
80 – Control
and Adjustment
ENTERING
ADMINISTRATION
(23/04/2018) CODE
80-04-M257EN
+ Correct Code
 4 ELECTRICAL CONTROL AND ADJUSTMENT

CALIBRATION MENU STEP 2

CALIB

This procedure allows this operation to be easily performed. Fully extend the stabilizers
then press

–– Provide a fork carrier or a bucket and a load corresponding to at least half the lift truck's rated capacity. 1/7 Fully set down the stabilizers and confirm .
–– Carry out calibration preferably with fork lift truck cold (before use), or ensure that rear axle temperature CALIB

is not greater than 50 °C. Complety lower the boom

on the frame

Lower boom fully with telescopes fully retracted and confirm .

then press

–– Place the lift truck on flat, level ground with the wheels straight. 2/7

bb
CALIB
CALIB
Lift the boom to max position,
fully retract the boom

Raise the boom fully with telescopes fully retracted and confirm .
Calibration incomplete or failed then press

Scrupulously follow the boom positioning instructions. If the screen is displayed, 3/7

this indicates a failure to obey an instruction, a cancellation request or a late response.

STEP 3

STEP 1 CALIB

Wait…
Calibration in progress

Calibration in progress...
Press button to display the menu screen with the time and date. Scroll horizontally using the
buttons to bring up the XPRT menu on the screen and vertically using the buttons to
reach the SECU "boom angle and strain gauge calibration" sub-menu. STEP 4
Confirm with . ADMIN
CALIB

00__ Lower the boom at full engine

Key in ADMIN code and confirm .

speed then press

4/7 Lower the boom with the engine running at full revs and the hydraulic control at the

maximum setting and confirm .

CALIB
Completly lower the boom
on the frame

If instructed, fully lower boom and confirm .

then press
4/7

CALIB

< INFO CLOCK LCD OPT DIAG XPERT >

80

Rise stabilizers,
then press

5/7 Fully raise stabilizers and confirm .

Press OK to
Enter Xpert Mode

OK

< RESET ADMIN ERASE CALIB >

SECU
Press OK to Enter
Security
Calibration Mode

OK

ENTER CODE
ADMIN OK + right code

GAUGE

STEP 2
80-04-M257EN (23/04/2018)
 ELECTRICAL CONTROL AND ADJUSTMENT 5

STEP 5

bb Always keep the load as close to the ground as possible during this operation.

/
With the fork carriage or the bucket and a load. Boom fully retracted and lowered to approximately
20 centimeters from the ground.
CALIB
Use override switch to
extend the boom until rear
axle is lifted then wait 5s
and press
6/7

/
 old down the disable the "aggravating" hydraulic movement cut-off button
H (indicator lamp lit),
and telescope the boom until the rear wheels leave the ground.

Wait 5 seconds and confirm .

STEP 6

CALIB

Retract the boom then

press to store
new calibration
7/7

Retract the telescopes to restore the situation, then press the button to record the new parameters.

80

(23/04/2018) 80-04-M257EN
 6 ELECTRICAL CONTROL AND ADJUSTMENT

REPLACEMENT OF ECUS
The ECU replacement procedure can be found in the "Diagnostic" menu of the PAD, under "ECU
replacement".
80

80-04-M257EN (23/04/2018)
 ELECTRICAL CONTROL AND ADJUSTMENT 7

"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
A - Brake nut and bolt
B B - Potentiometer pin
C - Link

b 80
C

The adjustment must be made without altering the length

of the link (Item C).

1 - Start machine .
Maxi
2 - If the truck is fitted with stabilisers, they must be placed on
the ground in order to increase the lifting angle .

3 - Place the boom in the top position .

(23/04/2018) 80-04-M257EN
 8 ELECTRICAL CONTROL AND ADJUSTMENT

The voltages of each boom angle potentiometer sensor can be viewed on the Cluster screen .

To ascertain the method of displaying these values, please refer to the following chapter:

e Group 80 - Electrical troubleshooting - Input/output conditions.

ANA05 = 04,05 V Example of the values display on the Cluster.

ANA06 = 00,95 V
ANA07 = 00,00 V
ANA08 = 00,00 V
2/5

4 - Loosen the brake nut and bolt (Item A) on the lever .

5 - Using a screwdriver, turn the potentiometer pin (Item B) to obtain the adjustment values defined
below .

Note: The adjustment is done by slightly turning the pin in the lever housing .

Adjustment values to be obtained:

Mini Maxi
Voltage 0 .7 V 4 .3 V

6 - Then tighten the brake nut and bolt (Item A) .

80

7 - Place the boom in the down position (stabilizers retracted) .

Mini

8 - Check that the values are similar to those found in the top boom position and are within the
recommended adjustment range .

9 - Calibrate the boom angle sensor .

e Group 80 - Electrical control and adjustment - Boom angle and strain gauge calibration

80-04-M257EN (23/04/2018)
 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

80

(03/10/2016) 80-07-M257EN
 2 ELECTRICAL COMPONENTS REFIT

STRAIN GAUGE

LOCATION

A
80

KEY:
A - Strain gage

b PREPARATION AND SAFETY INSTRUCTIONS

⇒ The wheels must be aligned and the rear axle free from any load (tipped truck) .
⇒ The contact surface must be perfectly clean .
⇒ Do not apply any Loctite to the screws .
⇒ Replace the gauge if faulty .
⇒ Store the gauge and axle at the same temperature .
⇒ Wear a mask and gloves when applying adhesive .

80-07-M257EN (03/10/2016)
 ELECTRICAL COMPONENTS REFIT 3

AXLE PREPARATION

The area in contact with the strain gauge (Item 1) has protective
painted film coating . Scrape this coating with a filling knife,
aiming to remove as much film as possible . Any remaining
1
adhesive traces can be removed with Soft Surface Cleaner
(aerosol degreaser) .

Sand the area to be glued (Item 2) to roughen the surface and

achieve a good bond .

80
CHARACTERISTICS OF PRODUCTS USED
References
ACROBOND PU 284/30 (two-part polyurethane structural adhesive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .273504
Mixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .781596
Hand gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .781597

b
Handling time before start of polymerization and hardening phase is approx . 5 min .

If the product stays inside the mixer for more than 5 minutes, replace the mixer.

(03/10/2016) 80-07-M257EN
 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
1 jack (Item 1) .

2 - Secure the machine by placing a two suitable stands

(Item 2), one on either side of the frame .

2
80

3 3 - Remove the jack to fully unload the rear axle .

80-07-M257EN (03/10/2016)
 ELECTRICAL COMPONENTS REFIT 5

STEP 1:

– Note the month/year of the gauge and enter into the lift
truck date sheet .

STEP 2:

– Apply glue to the grooves of the strain gauge (a total of

8 daubs of glue) .

STEP 3:

80
– Position the strain gauge and attach with the screws . The
two M10 screws should be tightened gradually, as follows:

⇒ Tighten screw No . 1 to a torque of 34 N .m

⇒ Tighten screw No . 2 to a torque of 34 N .m
⇒ Tighten screw No . 1 to the rated torque C = 67 N .m ± 5%
⇒ Tighten screw No . 2 to the rated torque C = 67 N .m ± 5%

(03/10/2016) 80-07-M257EN
 6 ELECTRICAL COMPONENTS REFIT

Strain gauge impact loading procedure:

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,

H = 275mm
axle wheel side .
3 - Let fall hammer again (o schema) 2 times on the screw
n°1, axle center side .

Rear axle

STEP 4:

1 2
– Place a red mark on the heads of the screws, the gauge
and the axle .

– Fit the protective casing .

80

– Attach the protective casing with the two screws and

the washers .

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

to the heads of the screws .

80-07-M257EN (03/10/2016)
 ELECTRICAL TROUBLESHOOTING

pages

INPUT/OUTPUT STATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– CODE READING PRINCIPLE (EXAMPLE FOR OUTOR AND INTOR) . . . . . . . . . . . . . . . . . . 2
–– "OUTOR" CODE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– "INTOR" CODES DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
–– "OUTANA" CODES DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
–– "INANA" CODES DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ERROR CODES (DTC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
–– MC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
–– MP1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
–– MP2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
–– ENG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

80

(05/25/2016) 80-08-M257EN
 2 ELECTRICAL TROUBLESHOOTING

INPUT/OUTPUT STATES

CODE READING PRINCIPLE (Example for OUTOR and INTOR)

< INFO CLOCK LCD OPT DIAG XPERT >

Press OK to
Enter Diag Mode

OK

< IDENT OUTOR INTOR OUTANA INANA ERROR >

Screen display example

MC

0000 0001
MP1 0101 1010
1001 1111
1101 0100 1/2

MP2

Component description Line Column PIN Page State Consequence

0 Seat occupied
Seat NC contact 2 3 X149-81 1/2
1 Seat empty

Conclusion:

The MP1 computer unit detects in X148/06 that the door is open .
80

< IDENT OUTOR INTOR OUTANA INANA ERROR >

Screen display example

MC

ANA01 = 2,52 A
MP1
ANA02 = 2,53 A
ANA03 = 1,02 A
ANA04 = 2,52 A
1/8

MP2

Component description Line Column PIN Page

Right flashing current 3 1 X149-65 1/8

80-08-M257EN (05/25/2016)
 ELECTRICAL TROUBLESHOOTING 3

"OUTOR" CODE DESCRIPTION

< INFO CLOCK LCD OPT DIAG XPERT >

Press OK to
Enter Diag Mode

OK

< IDENT OUTOR INTOR OUTANA INANA ERROR >

MC Component description Line Column PIN Page State Consequence

0 Not powered
Fuel electrovalve running relay control re-read 1 1 X13-6/16 1/1
1 Powered
0 Not powered
Intermittent wiper relay control re-read 1 2 X13-7/8 1/1
MP1 1 Powered

MP2

80

(05/25/2016) 80-08-M257EN
 4 ELECTRICAL TROUBLESHOOTING

< IDENT OUTOR INTOR OUTANA INANA ERROR >

MC

MP1 Component description Line Column PIN Page State Consequence

/ 1 1 X148-01 1/1
0
CAN gauge power supply 1 2 X148-31 1/1
1
MP2 / 1 3 X148-35 1/1
1 4 X148-65 1/1
0
APC120 computer unit micro supply 1 5 X149-84 1/1
1
1 6 X149-82 1/1
Derivation ventilation control relay 1 7 X149-54 1/1
/ 1 8 X149-23 1/1
0 Activated
Negative brake control 1 2 1 X149-83 1/1
1 Deactivated
0 Deactivated
Cab lighting control 2 2 X149-53 1/1
1 Activated
0 Powered
Wheel alignment sensor power supply voltage 2 3 X149-18/49 1/1
1 Not powered
Box temperature sensor power supply voltage 0 Powered
Parking brake pressure switch power supply voltage 2 4 X149-19/20/50/80 1/1
Chain boom sensor power supply voltage 1 Not powered
0 Not powered
Boom angle sensor power supply voltage 2 5 X149-21 1/1
1 Powered
0 Not Powered
2 6 X149-51 1/1
1 Powered
80

80-08-M257EN (05/25/2016)
 ELECTRICAL TROUBLESHOOTING 5

< IDENT OUTOR INTOR OUTANA INANA ERROR >

MC

MP1

MP2 Component description Line Column PIN Page State Consequence

1 1 X150-01 1/1
0 Not powered
Lifting electrovalve power supply voltage 1 2 X150-31 1/1
1 Powered
0 Not powered
Telescope electrovalve power supply voltage 1 3 X150-35 1/1
1 Powered
0
Deflector electrovalve voltage 1 4 X150-65 1/1
1
/ 1 5 X151-84 1/1
0 OK
Basket/remote control engine speed relay control voltage 1 6 X151-82 1/1
1 Not OK
0 OK
Basket/remote control start relay control voltage 1 7 X151-54 1/1
1 Not OK
/ 1 8 X151-23 1/1
0 Not powered
Tilting electrovalve power supply voltage 2 1 X151-83 1/1
1 Powered
0 Not powered
Auxiliary electrovalve power supply voltage 2 2 X151-53 1/1
1 Powered
0 Not powered
Intermediate sensor power supply voltage 2 3 X151-18/49 1/1
1 Powered
/ 2 4 X151-19/20/50/80 1/1
/ 2 5 X151-21 1/1
/ 2 6 X151-51 1/1

80

(05/25/2016) 80-08-M257EN
 6 ELECTRICAL TROUBLESHOOTING

"INTOR" CODES DESCRIPTION

< INFO CLOCK LCD OPT DIAG XPERT >

Press OK to
Enter Diag Mode

OK

< IDENT OUTOR INTOR OUTANA INANA ERROR >

MC Component description Line Column PIN Page State Consequence

0 Not clogged filter
Engine air filter clogging 1 1 X13-34 1/1
1 Clogged filter
0 Normal level
Brake fluid low level 1 2 X13-35 1/1
1 Low level
MP1 0 Pressure not low
Engine oil pressure switch 1 3 X13-36 1/1
1 Pressure low
0 Temperature normal
Coolant temperature sensor 1 4 X13-40 1/1
1 Temprerature high
0 Brake not pressed
MP2 Master cylinder pressure switch 1 5 X13-31 1/1
1 Brake pressed
0 Closed door
Door open contact 1 6 X13-39 1/1
1 Open door
0
External anti-theft 1 7 X13-29 1/1
1
0 Not starting
Ignition key in position 3 (start) 1 8 X13-30 1/1
1 Starting
0 Inactive
Side light switch 2 1 X14-02 1/1
1 Lighting request
0 Inactive
Horn control switch 2 2 X14-05 1/1
1 Horn request
0 Inactive
Right flashing switch 2 3 X14-08 1/1
1 Lighting request
0 Inactive
80

Left flashing switch 2 4 X14-09 1/1

1 Lighting request
0 Inactive
Headlights switch 2 5 X14-04 1/1
1 Lighting request
0 Inactive
Dipped headlights switch 2 6 X14-03 1/1
1 Lighting request
0 Inactive
Front windscreen wiper intermittent commutator switch 2 7 X13-28 1/1
1 Wiping request
0 Not preheating
Ignition key in position 2 (preheating) 2 8 X13-17 1/1
1 Preheating
0 Inactive
Override switch 3 1 X13-18 1/1
1 Override request
0 Charging
D+ alternator excitation 3 2 X13-05 1/1
1 Not charging

80-08-M257EN (05/25/2016)
 ELECTRICAL TROUBLESHOOTING 7

< IDENT OUTOR INTOR OUTANA INANA ERROR >

MC

Component description Line Column PIN Page State Consequence

MP1
0 Not down
Right stabilisator pressure switch 1 1 1 X148-23 1/2
1 Down
0 Not down
Right stabilisator pressure switch 2 1 2 X148-53 1/2
1 Down
MP2
0 Not down
Left stabilisator pressure switch 1 1 3 X148-24 1/2
1 Down
0 Not down
Left stabilisator pressure switch 2 1 4 X148-54 1/2
1 Down
0 No water
Water in fuel 1 5 X148-25 1/2
1 Water
0 Pressure OK
Steering assistance pressure switch 1 6 X148-55 1/2
1 Pressure low
0 Pedal pressed
Throttle NO switch 1 7 X148-26 1/2
1 Pedal not pressed
0 Inactive
Joystick BP1 1 8 X148-56 1/2
1 Active
0 Seat empty
Seat NO contact 2 1 X148-27 1/2
1 Seat occupied
0 Inactive
Telescope working light switch (TUV option) 2 2 X148-57 1/2
1 Lighting request
0 Seat occupied
Seat NC contact 2 3 X149-81 1/2
1 Seat empty
0 Not stretched
stretched chain boom sensor 2 4 X149-22 1/2
1 Stretched
0 Boom extended
NO retract boom sensor 2 5 X148-83 1/2
1 Return boom
0 Return boom
NC retract boom sensor 2 6 X148-84 1/2
1 Boom extended
0 Inactive
Positive (+) steering R1 joystick 2 7 X148-85 1/2
1 Movment request

80
0 Inactive
Negative (-) steering R1 joystick 2 8 X148-86 1/2
1 Movment request
0 Inactive
Positive (+) steering R2 joystick 3 1 X148-87 1/2
1 Movment request
0 Inactive
Negative (-) steering R2 joystick 3 2 X148-88 1/2
1 Movment request
0 Inactive
Joystick BP2 3 3 X148-89 1/2
1 Active
0 Inactive
Joystick Bp+ 3 4 X148-58 1/2
1 Request
BP Declutch 0 Inoperative (BP-)
3 5 X148-29 1/2
Joystick Bp- 1 Active (Declutch)
0 No request
Joystick Forward 3 6 X148-59 1/2
1 Request
0
Joystick Reverse 3 7 X148-30 1/2
1 Request
0 Filter not clogged
Hydraulic clogging filter contact 3 8 X148-60 1/2
1 Clogged filter
0 Normal load
Load limiter entry (Australia) 4 1 X148-04 1/2
1 Too high load
0 Pedal not pressed
Throttle NC switch 4 2 X148-05 1/2
1 Pedal pressed

(05/25/2016) 80-08-M257EN
 8 ELECTRICAL TROUBLESHOOTING

(continued)
Component description Line Column PIN Page State Consequence
0 Opened door
Door NO contact 4 3 X148-06 1/2
1 Closed door
0 Movement request
L+ Lifting B contact 4 4 X148-07 1/2
1 Inactive
0 Movement request
L- Descent A contact 4 5 X148-09 1/2
1 Inactive
0 Movement request
Incline B contact 4 6 X148-10 1/2
1 Inactive
0 Inactive
Incline A contact 4 7 X149-88 1/2
1 Movement request
0 Inactive
Tilting B contact 4 8 X149-03 1/2
1 Movement request
0 Movement request
Tilting A contact 1 1 X149-33 2/2
1 Inactive
0 Inactive
+Right stabiliser downward A contact 1 2 X149-04 2/2
1 Movement request
0 Inactive
-Left stabiliser lift B contact 1 3 X149-34 2/2
1 Movement request
0 Inactive
-Right stabiliser lift B contact 1 4 X149-64 2/2
1 Movement request
0 Inactive
+Left stabiliser downward A contact 1 5 X149-05 2/2
1 Movement request
0 Pressure OK
Gear box oil pressure switch 1 6 X149-27 2/2
1 Pressure not OK
0 Low level
Coolant level 1 7 X149-57 2/2
1 Normal level
Pressure (movement
0
under way)
WALVOlL safety valve pressure switch 1 8 X149-28 2/2
No pressure
1
(no movement)
0 Normale pressure
Brake assistance pressure switch (TUV option) 2 1 X149-29 2/2
1 Low pressure
0 Not implemented
P1 basket overload (category 3) 2 2 X149-30 2/2
1
80

80-08-M257EN (05/25/2016)
 ELECTRICAL TROUBLESHOOTING 9

< IDENT OUTOR INTOR OUTANA INANA ERROR >

MC

MP1

Component description Line Column PIN Page State Consequence

MP2
/ 1 1 X150-23 1/1
/ 1 2 X150-53 1/1
/ 1 3 X150-24 1/1
/ 1 4 X150-54 1/1
0 Boom extended
Intermediary inductive 1 (Access option) 1 5 X150-25 1/1
1 Return boom
0 Boom extended
Intermediary inductive 2 (Access option) 1 6 X150-55 1/1
1 Return boom
0 State OK
Lifting proportional electrovalve State 1 7 X150-26 1/1
1 State not OK
0 State OK
Incline proportional electrovalve State 1 8 X150-56 1/1
1 State not OK
0 State OK
Auxiliary proportional electrovalve State 2 1 X150-27 1/1
1 State not OK
0 State OK
Telescope proportional electrovalve State 2 2 X150-57 1/1
1 State not OK
/ 2 3 X150-83 1/1
/ 2 4 X150-84 1/1
0 Inactive
Boom suspension pressure switch 1 2 5 X150-85 1/1
1 Active
0 Inactive
Boom suspension pressure switch 2 2 6 X150-86 1/1
1 Active
/ 2 7 X150-87 1/1
/ 2 8 X150-88 1/1
/ 3 1 X150-89 1/1
/ 3 2 X150-58 1/1

80
0
Hydrostatic speed sensor engaged 3 3 X150-29 1/1
1
/ 3 4 X150-59 1/1
0 No contact
Emergency key contact (Access option) 3 5 X150-30 1/1
1 Contact
/ 3 6 X150-60 1/1
0 Cab
Basket hydraulic request source selection (Access option) 3 7 X150-04 1/1
1 Basket
Remote control hydraulic request source selection (Remote 0 Cab
3 8 X150-05 1/1
control option) 1 remote control
0 Not pressed
Emergency button (Access option) 4 1 X150-06 1/1
1 Pressed

(05/25/2016) 80-08-M257EN
 10 ELECTRICAL TROUBLESHOOTING

"OUTANA" CODES DESCRIPTION

< INFO CLOCK LCD OPT DIAG XPERT >

Press OK to
Enter Diag Mode

OK

< IDENT OUTOR INTOR OUTANA INANA ERROR >

MC Component description Line Column PIN Page

/ / / / 1/1

MP1

MP2
80

80-08-M257EN (05/25/2016)
 ELECTRICAL TROUBLESHOOTING 11

< IDENT OUTOR INTOR OUTANA INANA ERROR >

MC

MP1 Component description Line Column PIN Page

Forward electrovalve current 1 1 X148-62 1/9
Reverse electrovalve current 2 1 X148-63 1/9
Right trailer direction indicator lights current 3 1 X149-65 1/9
MP2 Reverse trailer lights current 4 1 X149-66 1/9
Fog trailer lights current 1 1 X149-67 2/9
Left trailer direction indicator lights current 2 1 X149-68 2/9
/ 3 1 X149-69 2/9
Parking brake electrovalve current 4 1 X149-40/70 2/9
Safety valve current (VS) 1 1 X148-61 3/9
Trailer stop light current 2 1 X148-64 3/9
Stop light current 3 1 X149-42/72 3/9
Left sidelight current 4 1 X149-14/15/45/75 3/9
Reverse light current 1 1 X149-44/75 4/9
Left direction indicator lights current 2 1 X149-43/73 4/9
Boom head electrovalve current 3 1 X149-77 4/9
Right indicator light current 4 1 X149-48/78 4/9
Fog light current 1 1 X149-79 5/9
Right sidelight current 2 1 X149-16/17/46/76 5/9
Left working light current 3 1 X149-87 5/9
Right working light current 4 1 X149-59/89 5/9
Horn current 1 1 X149-90 6/9
Right dipped headlight current 2 1 X149-60 6/9
Left headlight current 3 1 X149-31 6/9
Right headlight current 4 1 X149-61 6/9
Rotating beacon light current 1 1 X149-62 7/9
Left dipped headlight current 2 1 X149-63 7/9
Flow reduction WALVOIL electrovalve current 3 1 X148-66/36 7/9
WALVOIL direction A auxiliary current 4 1 X148-67/37 7/9
WALVOIL direction B auxiliary current 1 1 X148-68/38 8/9
WALVOIL telescoping output current 2 1 X148-69/39 8/9

80
WALVOIL telescoping retract current 3 1 X148-70/40 8/9
Roller power supply voltage 4 1 X148-34 8/9
Gear box pressure sensor power supply voltage 1 1 X148-02/03/32 9/9
Throttle pedal power supply voltage 2 1 X149-01/02 9/9

(05/25/2016) 80-08-M257EN
 12 ELECTRICAL TROUBLESHOOTING

< IDENT OUTOR INTOR OUTANA INANA ERROR >

MC

MP1

MP2 Component description Line Column PIN Page

Boom descent movement discharge electrovalve current 1 1 X150-62 1/7
Anti-clockwise electrovalve current 2 1 X150-63 1/7
Boom suspension electrovalve current 1 3 1 X151-65 1/7
Hydrostatic rapid speed electrovalve current 4 1 X151-66 1/7
Boom suspension electrovalve current 2 1 1 X151-67 2/7
Hydrostatic slow speed electrovalve current 2 1 X151-68 2/7
Hydrostatic motion direction electrovalve current 3 1 X151-69 2/7
/ 4 1 X151-40/70 2/7
/ 1 1 X150-61 3/7
/ 2 1 X150-64 3/7
DANFOSS right stabilizer electrovalve current 3 1 X151-42/72 3/7
2A Wheel alignment electrovalve current 4 1 X151-14/15/45/75 3/7
DANFOSS left stabiliser electrovalve current 1 1 X151-44/75 4/7
DANFOSS levelling electrovalve current 2 1 X151-43/73 4/7
2B Wheel alignment electrovalve current 3 1 X151-77 4/7
3A Wheel alignment electrovalve current 4 1 X151-48/78 4/7
3B Wheel alignment electrovalve current 1 1 X151-79 5/7
/ 2 1 X151-16/17/46/76 5/7
/ 3 1 X151-87 5/7
/ 4 1 X151-59/89 5/7
Hydrostatic slow gear electrovalve current 1 1 X151-90 6/7
DANFOSS telescope electrovalve 2 1 X151-85 6/7
DANFOSS auxiliary electrovalve 3 1 X151-26 6/7
DANFOSS lifting electrovalve 4 1 X151-86 6/7
DANFOSS tilting electrovalve 1 1 X151-56 7/7
80

XT electroproportionnal manipulator bloc power supply voltage 2 1 X150-2/3/32 7/7

XL electroproportionnal manipulator bloc power supply voltage 3 1 X151-1/2 7/7
4 1 7/7

80-08-M257EN (05/25/2016)
 ELECTRICAL TROUBLESHOOTING 13

"INANA" CODES DESCRIPTION

< INFO CLOCK LCD OPT DIAG XPERT >

Press OK to
Enter Diag Mode

OK

< IDENT OUTOR INTOR OUTANA INANA ERROR >

MC Component description Line Column PIN Page

Fuel gauge 1 1 X13-27 1/1
/ 2 1 X13-37 1/1

MP1

MP2

< IDENT OUTOR INTOR OUTANA INANA ERROR >

MC

MP1 Component description Line Column PIN Page

Joystick R1 1 1 X148-19 1/5
Joystick R2 2 1 X148-49 1/5

80
Forward pressure sensor 3 1 X148-79 1/5
MP2 Reverse pressure sensor 4 1 X148-20 1/5
Boom 1 angle tension 1 1 X148-50 2/5
Boom 2 angle tension 2 1 X148-80 2/5
Analog throttle pedal (PSR09I for ST3A)
3 1 X148-21 2/5
Right stabilisator analog pressure sensor voltage
Left stabilisator analog pressure sensor voltage 4 1 X148-51 2/5
1 1 X149-06 3/5
2 1 X149-37 3/5
3 1 X149-07 3/5
Parking brake pressure switch 4 1 X149-09 3/5
Gear box oil temperature (PSR09) 1 1 X149-10 4/5
Front wheel alignment sensor 2 1 X149-11 4/5
Rear wheel alignment sensor 3 1 X149-41 4/5
/ 4 1 X149-71 4/5
Inductive chain boom sensor 1 1 1 X149-39 5/5
Inductive chain boom sensor 2 2 1 X149-08 5/5
Outputs security line (LSS) signal 3 1 X149-24 5/5
4 1 X148-81 5/5

(05/25/2016) 80-08-M257EN
 14 ELECTRICAL TROUBLESHOOTING

< IDENT OUTOR INTOR OUTANA INANA ERROR >

MC

MP1

MP2 Component description Line Column PIN Page

Joystick XL1 1 1 X150-19 1/3
Joystick XT1 2 1 X150-49 1/3
3 1 X150-79 1/3
Inclinometer X signal 4 1 X150-20 1/3
Joystick XL2 1 1 X150-50 2/3
Joystick XT2 2 1 X150-80 2/3
Inclinometer Y signal 3 1 X150-21 2/3
4 1 X150-51 2/3
Outputs security line (LSS) signal 1 1 X151-24 3/3
2 1 X150-81 3/3
80

80-08-M257EN (05/25/2016)
 ELECTRICAL TROUBLESHOOTING 15

ERROR CODES (DTC)

MC

< INFO CLOCK LCD OPT DIAG XPERT >

Press OK to enter Diag Mode

OK

< IDENT OUTOR INTOR OUTANA INANA ERROR >

MC

MP1

MP2

ENG

DTC Error code

Problems Component Repair
(Hexa)
0400CA Fuel electrovalve output open circuit Fuel electrovalve Wiring check
0400CD Screen wiper output open circuit Windscreen wiper Wiring check
DPF regeneration switch lighting output ground short
040157 DPF LED switch Wiring and component check
circuit
0500CA Fuel electrovalve output open circuit Fuel electrovalve Wiring check
0500CD Screen wiper output open circuit Windscreen wiper Wiring check
220028 Out of range fuel level fault Fuel gage Calibration

80
240146 Fault Inhibited DPF regeneration switch Wiring and component check
240147 Fault Forced DPF regeneration switch Wiring and component check
260069 Fault Override switch Wiring and component check
730000 Manimux cluster CAN dialog error Cluster (HMI) Wiring and cluster check
800000 Cluster ECU overheating Cluster (HMI) Cluster change
820001 Out of range LSS (cluster) LSS cluster (HMI) Cluster change
820002 Strain gage 1 DHD fault Strain gage 1 Wiring check
820003 Strain gage 2 DHD fault Strain gage 2 Wiring check
A00003 Engine high temp (engine overheat DTC) Thermal engine Wiring check
A00006 High temperature transmission oil fault Gear box Wiring check
A00007 Clogged air filter fault Air filter Wiring check
A00008 Clogged hydraulic filter fault Hydraulic filter Wiring check
A00009 Engine speed fault Thermal engine Wiring check
A10002 Low engine oil pressure Thermal engine Wiring check
A10004 Low brake liquid level Brake system Wiring check
A10005 Low transmission oil pressure fault Gear box Wiring check
A10051 Alternator charge fault Alternator Wiring check
A20000 Strain gage integrity fault DHD Strain gauges Wiring check
A2040A DPF inconsistency switch Particle filter switch Wiring and component check

(05/25/2016) 80-08-M257EN
 16 ELECTRICAL TROUBLESHOOTING

MP1

< INFO CLOCK LCD OPT DIAG XPERT >

Press OK to enter Diag Mode

OK

< IDENT OUTOR INTOR OUTANA INANA ERROR >

MC

MP1

MP2

ENG

DTC Error code

Problems Component Repair
(Hexa)
030001 Reverse buzzer Vbat short circuit Reversing sound alarm Wiring check
030002 Horn Vbat short circuit Horn Wiring check
03000A Forward motion electrovalve Vbat short circuit Gear box Wiring check
03000B Reverse motion electrovalve Vbat short circuit Gear box Wiring check
Walvoil descent regulation proportional electrovalve Vbat
03000C Flow regulator Wiring check
short circuit
Check attachment wiring
030026 Auxiliary proportional electrovalve Vbat short circuit 1 Hydraulic distributor
and proportional valve
Check attachment wiring
030027 Auxiliary proportional electrovalve Vbat short circuit 2 Hydraulic distributor
and proportional valve
80

Check telescope wiring

030028 Telescope proportional electrovalve Vbat short circuit 1 Hydraulic distributor
and proportional valve
Check telescope wiring
030029 Telescope proportional electrovalve Vbat short circuit 2 Hydraulic distributor
and proportional valve
030039 Boom head Vbat short circuit Telescope head electrovalve Wiring check
03003A VS2 electrovalve Vbat short circuit Safety valve (VS) Wiring check
030064 Stop light Vbat short circuit Stop lights Wiring check
030065 Working light Vbat short circuit Front working lights Wiring check
030066 Reverse light Vbat short circuit Reverse light Wiring check
030067 Rear fog light Vbat short circuit Rear fog light Wiring check
030069 Left sidelight Vbat short circuit Left-hand sidelight Wiring check
03006A Right sidelight Vbat short circuit Right sidelight Wiring check
03006B Left dipped beam Vbat short circuit Left dipped beam headlight Wiring check
03006C Left dipped beam Vbat short circuit Left-hand main beam headlight Wiring check
03006D Left indicator light Vbat short circuit Left-hand indicator lights Wiring check
03006E Right indicator light Vbat short circuit Right indicator lights Wiring check
030078 Rotating beacon light Vbat short circuit Rotating beacon light Wiring check
03007B Trailer stoplight Vbat short circuit Trailer stoplight Wiring check
03007C Working light Vbat short circuit Front working light Wiring check
03007D Trailer reverse light Vbat short circuit Trailer reversing light Wiring check
03007E Rear fog light Vbat short circuit Trailer rear fog light Wiring check
03007F Right dipped beam Vbat short circuit Right dipped beam headlight Wiring check
030080 Right front headlight Vbat short circuit Right-hand main beam headlight Wiring check

80-08-M257EN (05/25/2016)
 ELECTRICAL TROUBLESHOOTING 17

DTC Error code

Problems Component Repair
(Hexa)
030081 Trailer left indicator light Vbat short circuit Trailer left indicator light Wiring check
030082 Trailer right indicator light Vbat short circuit Trailer right indicator light Wiring check
03008F Vbat short circuit output fleet brake 2 Parking brake Wiring check
040001 Buzzer Vbat short circuit Reversing sound alarm Wiring check
040002 Horn ground short circuit Horn Wiring check
04000A Forward motion electrovalve ground short circuit Gear box Wiring check
04000B Reverse motion electrovalve ground short circuit Gear box Wiring check
Walvoil descent regulation proportional electrovalve
04000C Flow controller Wiring check
ground short circuit
040026 Auxiliary proportional electrovalve ground short circuit 1 Hydraulic distributor Wiring check
040027 Auxiliary proportional electrovalve ground short circuit 2 Hydraulic distributor Wiring check
040028 Telescope proportional electrovalve ground short circuit 1 Hydraulic distributor Wiring check
040029 Telescope proportional electrovalve ground short circuit 2 Hydraulic distributor Wiring check
040039 Boom head ground short circuit Telescope head electrovalve Wiring check
04003A VS2 electrovalve ground short circuit Safety valve (VS) Wiring check
04003B AC120 logic Vbat ground short circuit Transmission computer power supply Wiring check
040064 Stoplight ground short circuit Stop lights Wiring check
040065 Left working light ground short circuit Front working lights Wiring check
040066 Reverse light ground short circuit Reverse light Wiring check
040067 Rear fog light ground short circuit Rear fog light Wiring check
040068 Roof light ground short circuit Roof light Wiring check
040069 Left sidelight ground short circuit Left-hand sidelight Wiring check
04006A Right sidelight ground short circuit Right sidelight Wiring check
04006B Left dipped beam ground short circuit Left dipped beam headlight Wiring check
04006C Left dipped beam ground short circuit Left-hand main beam headlight Wiring check
04006D Left indicator light ground short circuit Left-hand indicator lights Wiring check
04006E Right sidelight ground short circuit Right indicator lights Wiring check
040078 Rotating beacon light ground short circuit Rotating beacon light Wiring check
04007B Trailer stoplight ground short circuit Trailer stoplight Wiring check
04007C Right working light ground short circuit Right working light Wiring check
04007D Trailer reverse light ground short circuit Trailer reverse lights Wiring check
04007E Trailer rear fog light ground short circuit Trailer rear fog light Wiring check
04007F Right dipped beam ground short circuit Right dipped beam headlight Wiring check
040080 Right headlight ground short circuit Right-hand main beam headlight Wiring check
040081 Trailer left indicator light short circuit Trailer left indicator light Wiring check
040082 Trailer right indicator light ground short circuit Trailer right indicator light Wiring check
04008E Ground short circuit output fleet brake 1 Parking brake Wiring check
04008F Ground short circuit output fleet brake 2 Parking brake Wiring check
04014C CAN gages power supply ground short circuit Strain gage Wiring check

80
050001 Reverse buzzer open circuit Reversing sound alarm Wiring check
050002 Horn open circuit Horn Wiring check
05000A Forward motion electrovalve open circuit Gear box Wiring check
05000B Reverse motion electrovalve open circuit Gear box Wiring check
Walvoil descent regulation proportional electrovalve
05000C Flow controller Wiring check
open circuit
050026 Auxiliary proportional electrovalve open circuit 1 Hydraulic distributor Wiring check
050027 Auxiliary proportional electrovalve open circuit 2 Hydraulic distributor Wiring check
050028 Telescope proportional electrovalve open circuit 1 Hydraulic distributor Wiring check
050029 Telescope proportional electrovalve open circuit 2 Hydraulic distributor Wiring check
050039 Telescope head electrovalve open circuit Telescope head electrovalve Wiring check
05003A VS2 electrovalve open circuit Safety valve (VS) Wiring check
05003B APC120 logic Vbat electrovalve open circuit Transmission computer power supply Wiring check
050064 Stop light open circuit Stop lights Wiring check
050066 Reversing light diode open circuit Reverse light Wiring check
050067 Rear fog light open circuit Rear fog light Wiring check
050069 Sidelight open circuit Left-hand sidelight Wiring check
05006A Right sidelight open circuit Right sidelight Wiring check
05006B Left dipped head light short circuit Left dipped beam headlight Wiring check
05006C Left dipped head light short circuit Left-hand main beam headlight Wiring check
05006D Left direction indicator lights open circuit Left-hand indicator lights Wiring check
05006E Right direction indicator lights open circuit Right indicator lights Wiring check
050078 Rotating beacon light open circuit Rotating beacon light Wiring check
(05/25/2016) 80-08-M257EN
 18 ELECTRICAL TROUBLESHOOTING

DTC Error code

Problems Component Repair
(Hexa)
05007F Right dipped beam open circuit Right dipped beam headlight Wiring check
050080 Right headlight open circuit Right-hand main beam headlight Wiring check
05008E Open circuit output fleet brake 1 Parking brake Wiring check
05008F Open circuit output fleet brake 2 Parking brake Wiring check
05014C CAN gages power supply open circuit Strain gage Wiring check
22001E BVT box pressure voltage out of range Gear box pressure Wiring check
220020 Gearbox pressure voltage out of range Gear box pressure Wiring check
230130 Above range chain boom tire limit sensor 1 Boom chain sensors Wiring and sensor check
230131 Above range chain boom tire limit sensor 2 Boom mid-travel sensors Wiring and sensor check
240130 Below range chain boom tire limit sensor 1 Boom chain sensors Wiring and sensor check
240131 Below range chain boom tire limit sensor 2 Boom mid-travel sensors Wiring and sensor check
28000B Speed sensor error Speed sensor Wiring and sensor check
2D0011 Boom angle 1 calibration error Jib angle Calibration
2D0012 Boom angle 2 calibration error Jib angle Calibration
2D0024 Accelerator right pedal calibration error Accelerator Calibration
2D003E R1 calibration error (E62) JSM roller Calibration
2D003F Calibration error (E63) JSM roller Calibration
420006 Frequency sensor Vbat outside range voltage Frequency sensor Wiring and sensor check
420007 Boom angle sensor Vbat out of range voltage Jib angle Wiring and sensor check
42000A Box pressure sensor Vbat out of range voltage Gear box pressure Power supply fault
42000D JSM roller out of range voltage JSM roller Power supply fault
420015 Out of range chain fault detection sensors Vbat Jib chain sensors Wiring and sensor check
420016 Chain boom tire limitation sensors Vbat out of range Boom mid-travel sensors Wiring and sensor check
440001 Wheel alignment sensor Vbat ground short circuit Wheel alignment sensor Wiring and sensor check
440011 Gearbox temperature probe Vbat ground short circuit Gearbox temperature probe Probe and sensor check
440014 SAHR pressure sensor Vbat short circuit SAHR pressure sensor Wiring and sensor check
450001 Wheel alignment sensor Vbat open circuit Wheel alignment sensor Wiring and sensor check
450011 Gearbox temperature probe Vbat open circuit Gearbox temperature probe Probe and sensor check
450014 SAHR pressure sensor Vbat open circuit SAHR pressure sensor Wiring and sensor check
7303E8 Manimux cluster CAN dialog error Communication cluster (HIM) Wiring check
7303E9 J1939 CAN dialog error J1939 communication (HIM) Wiring check
7307D8 Engine computer communication fault Engine ECU communication Wiring and component check
7307D9 Option computer communication fault Communication ECU Option Wiring and component check
8003E8 Power 1 ECU overheat MP 1 computer unit Wiring check
8203E9 Out of range LSS (Power 1) MP 1 computer unit Wiring check
8203EC Out of range vaop (Power 1) MP 1 computer unit Wiring check
8303ED Smart PWM (Power 1) VBat short circuit MP 1 computer unit Wiring check
8403ED Smart PWM (Power 1) ground short circuit MP 1 computer unit Wiring check
80

8703EA 1 hs relay (Power 1) MP 1 computer unit Wiring check

A003F1 Overspeed Gear box Wiring check
A1046A Steering power assistance fault Power-assisted steering Wiring check
A1048A Braking power assistance fault Power-assisted braking Wiring check
A203E8 JSM inconsistency JSM Wiring check
A203EC Accelerator inconsistency Accelerator Wiring check
A203EF Boom angle inconsistency Jib angle Wiring check
A203F0 Door contact inconsistency Door switch Wiring check
A203F4 Boom retract contact inconsistency Boom retract switch Wiring check
A203FE R1/R1 contact inconsistency JSM roller Wiring check
A203FF R2/R2 contact inconsistency JSM roller Wiring check
A20400 DHD fault inconsistency incline contacts Tilt contact switch Wiring check
A20401 DHD fault inconsistency correction contacts Roll contact switch Wiring check
A20402 DHD lifting fault Lifting contact switch Wiring check
A20408 Walvoil vs pressure fault Safety valve (VS) Wiring check
A204B0 CAN strain gage 1 DHD fault CAN strain gauge 1 Wiring and component check
A204B1 CAN strain gage 2 DHD fault CAN strain gage 2 Wiring and component check
A204B4 CAN strain gage consistency DHD fault CAN strain gage Wiring and component check
A7013C Chain boom voltage fault Jib chain sensors

80-08-M257EN (05/25/2016)
 ELECTRICAL TROUBLESHOOTING 19

80

(05/25/2016) 80-08-M257EN
 20 ELECTRICAL TROUBLESHOOTING

MP2

< INFO CLOCK LCD OPT DIAG XPERT >

Press OK to enter Diag Mode

OK

< IDENT OUTOR INTOR OUTANA INANA ERROR >

MC

MP1

MP2

ENG

DTC Error code

Problems Component Repair
(Hexa)
020010 Danfoss lift electrovalve servo control error Hydraulic distributor Secured condition
020012 Danfoss tilt electrovalve servo control error Hydraulic distributor Secured condition
020014 Danfoss telescope electrovalve servo control error Hydraulic distributor Secured condition
020017 Danfoss auxiliary electrovalve servo control error Hydraulic distributor PVG error
03001B Danfoss leveling electrovalve Vbat short circuit Hydraulic distributor Wiring check
03001D Right outrigger electrovalve Vbat short circuit Right outrigger electrovalve Wiring check
03001F Left outrigger electrovalve Vbat short circuit Left outrigger electrovalve Wiring check
030022 VAP1 deflector Vbat short circuit QX 18M boom
030023 VAP2 deflector Vbat short circuit QX 18M boom
030024 VAP3 deflector Vbat short circuit QX 18M boom
80

030025 VAP12 deflector Vbat short circuit QX 18M boom

03002A Danfoss load-shedding electrovalve Vbat short circuit Load-shedding electrovalve Wiring check
03002B VBE no . 1 electrovalve Vbat short circuit Rear axle lock electrovalve 1 Wiring check
03002D Telescope suspension electrovalve Vbat short circuit 1 Telescope suspension electrovalve 1 Wiring check
03002E Telescope suspension electrovalve Vbat short circuit 2 Telescope suspension electrovalve 2 Wiring check
03002F High gear electrovalve Vbat short circuit Rapid speed 2 electrovalve Wiring check
030030 Slow gear Vbat short circuit Low gear electrovalve Wiring check
030031 Motion direction Vbat short circuit Forward/reverse selector electrovalve Wiring check
030032 Slow speed Vbat short circuit Rapid speed 1 electrovalve Wiring check
03007A VBE no . 2 electrovalve Vbat short circuit Rear axle lock electrovalve 2 Wiring check
030083 Discharge valve Vbat short circuit Discharge valve Wiring check
040011 Lifting ground short circuit Hydraulic distributor Wiring check
040013 Tilt ground short circuit Hydraulic distributor Wiring check
040016 Telescope ground short circuit Hydraulic distributor Wiring check
040019 Auxiliary ground short circuit Hydraulic distributor Wiring check
04001A Danfoss auxiliary deflector ground short circuit Hydraulic distributor Wiring check
04001B Danfoss cant electrovalve ground short circuit Hydraulic distributor Wiring check
04001D Right outrigger electrovalve ground short circuit Right outrigger electrovalve Wiring check
04001F Left outrigger electrovalve ground short circuit Left outrigger electrovalve Wiring check
040022 VAP1 deflector ground short circuit QX 18M boom
040023 VAP2 deflector ground short circuit QX 18M boom
040024 VAP3 deflector ground short circuit QX 18M boom
040025 VAP12 deflector ground short circuit QX 18M boom
04002A VBE no . 1 electrovalve ground short circuit Load-shedding electrovalve Wiring check
04002B VBE no . 1 electrovalve ground short circuit Rear axle lock electrovalve 1 Wiring check
04002D Telescope suspension electrovalve ground short circuit 1 Telescope suspension electrovalve 1 Wiring check

80-08-M257EN (05/25/2016)
 ELECTRICAL TROUBLESHOOTING 21

DTC Error code

Problems Component Repair
(Hexa)
04002E Telescope suspension electrovalve ground short circuit 2 Telescope suspension electrovalve 2 Wiring check
04002F High gear electrovalve ground short circuit Rapid speed 2 electrovalve Wiring check
040030 Low gear ground short circuit Low gear electrovalve Wiring check
040031 Motion direction short circuit Forward/reverse selector electrovalve Wiring check
040032 Slow speed ground short circuit Fast gear 1 electrovalve Wiring check
04007A VBE no . 1 electrovalve ground short circuit Rear axle lock electrovalve 2 Wiring check
040083 Discharge valve ground short circuit Discharge valve Wiring check
04008C Engine speed relay ground short circuit Engine speed relay Wiring check
04008D Engine start relay ground short circuit Engine starting relay Wiring check
05001A Danfoss auxiliary deflector open circuit Hydraulic distributor Wiring check
05001B Danfoss cant electrovalve open circuit Hydraulic distributor Wiring check
05001D Right outrigger electrovalve open circuit Right outrigger electrovalve Wiring check
05001F Left outrigger electrovalve open circuit Left outrigger electrovalve Wiring check
050022 VAP1 deflector open circuit QX 18M boom
050023 VAP2 deflector open circuit QX 18M boom
050024 VAP3 deflector open circuit QX 18M boom
050025 VAP12 deflector open circuit QX 18M boom
05002A Danfoss load-shedding electrovalve open circuit Load-shedding electrovalve Wiring check
05002B VBE no . 1 electrovalve open circuit Rear axle lock electrovalve 1 Wiring check
05002D Telescope suspension electrovalve 1 open circuit Telescope suspension electrovalve 1 Wiring check
05002E Telescope suspension electrovalve 2 open circuit Telescope suspension electrovalve 2 Wiring check
05002F High gear electrovalve open circuit Fast gear 2 electrovalve Wiring check
050030 Low gear electrovalve open circuit Low speed electrovalve Wiring check
050031 Motion direction electrovalve open circuit Forward/reverse selector electrovalve Wiring check
050032 Low gear electrovalve open circuit Fast gear 1 electrovalve Wiring check
05007A VBE no . 2 electrovalve open circuit Rear axle lock electrovalve 2 Wiring check
05008C Engine speed relay open circuit Engine speed relay Wiring check
05008D Engine start relay open circuit Engine starting relay Wiring check
220026 Out of range Y inclinometer Inclinometer Calibration
220032 Out of range X inclinometer Inclinometer Wiring and component check
230015 C1 sensor Vbat short circuit Intermediate boom extend sensor Wiring and component check
230027 Platform presence sensor Vbat short circuit 1 Platform presence sensor 1 Wiring check
230028 Platform presence sensor Vbat short circuit 2 Platform presence sensor 2 Wiring check
23002E C2 sensor Vbat short circuit Intermediate boom extend sensor 2 Wiring check
240015 C1 sensor ground short circuit or open circuit Intermediate boom extend sensor Wiring and component check
Platform presence sensor 1 ground short circuit or open
240027 Platform presence sensor 1 Wiring check
circuit
Platform presence sensor 2 ground short circuit or open
240028 Platform presence sensor 2 Wiring check
circuit
24002E C2 sensor groun open circuit or short circuit Intermediate boom extend sensor 2 Wiring check
2D003C XL1 calibration error Joystick base Calibration
2D003D XT1 calibration error Joystick base Calibration
2D0045 XL2 calibration error Joystick base Calibration
2D0046 XT2 calibration error Joystick base Calibration
42000B XL BMEP Vbat out of range voltage Joystick base Power supply fault

80
42000E XT BMEP Vbat out of range voltage Joystick base Power supply fault
Telescope sequence sensor power supply ground short
440008 QX 18M boom
circuit
Boom intermediary sensor power supply ground short
440012 Intermediate boom extend sensor Wiring check
circuit
450008 Telescope sequence sensor power supply open circuit QX 18M boom
450012 Boom intermediary sensor power supply open circuit Intermediate boom extend sensor Wiring check
7307D0 Manimux cluster CAN dialog error Cluster (HMI) Wiring check
7307D1 RC open can dialog error Radio control Wiring check
7307D2 ORH open can dialog error Platform control console Wiring check
8007D0 Power 2 ECU overheat MP 2 computer unit Wiring check
8207D1 Out of range LSS (Power 2) MP 2 computer unit Wiring check
8207D4 Out of range vaop (Power 2) MP 2 computer unit Wiring check
8307D3 2 hs relay (Power 2) MP 2 computer unit Wiring check
8307D5 Smart PWM (Power 2) VBat short circuit MP 2 computer unit Wiring check
8407D5 Smart PWM (Power 2) ground short circuit MP 2 computer unit Wiring check
8707D2 1 hs relay (Power 2) MP 2 computer unit Wiring check
A207D0 Telescope sequence error QX 18M boom
A207D1 Inconsistency sensor C1 C2 Intermediate boom extend sensor Wiring and component check

(05/25/2016) 80-08-M257EN
 22 ELECTRICAL TROUBLESHOOTING

ENG

< INFO CLOCK LCD OPT DIAG XPERT >

Press OK to enter Diag Mode

OK

< IDENT OUTOR INTOR OUTANA INANA ERROR >

MC

MP1

MP2

ENG

Engine Control Unit

Hexadecimal Decimal
PROBLEMS ACTION
SPN FMI SPN FMI
Consistency error between the sensor and the
idling operating switch (unladen), accelerator The error detection limit is a limit within the ECU . The accelerator
0001D 02 29 2 pedal detection . In the case of a manual gas pedal must have plausibly detected the full load and the unladen
knob with an idling operating switch (unladen), value at least once .
fault on the idling contact .
If the signal is below the acceptable limit APP_
uRawSRCHiHTLIS_C, the signal for breach of the range of correct
Switch of the unladen operation mode manual values is reset after the repair (debouncing) . If the CCP is active
0001D 03 29 3
80

validation lever; battery short circuit (CCP_stActive = 1) and the value read in the 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 .
If the signal value exceeds the acceptable limit APP_
uRawSRCHiHTLIS_C, the signal for breach of the authorized range
Switch of the unladen operation mode manual is reset after debouncing . If the CCP is active (CCP_stActive = 1)
0001D 04 29 4
validation lever; ground short circuit 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 .
00033 03 51 3 Battery short circuit of the throttle valve (A02)
00033 03 51 3 Battery short circuit of the throttle valve (A67)
Battery short circuit or open circuit of the
00033 03 51 3
throttle valve
00033 04 51 4 Ground short circuit of the throttle valve (A02)
00033 04 51 4 Ground short circuit of the throttle valve (A67)
00033 04 51 4 Ground short circuit of the throttle valve
Open circuit on the electrical harness of the
00033 05 51 5
throttle valve
Threshold exceeded on the throttle valve
00033 06 51 6
control current
Position of the throttle valve outside plausible
00033 07 51 7 range (deviation greater than 7 % compared to
the setpoint value)

80-08-M257EN (05/25/2016)
 ELECTRICAL TROUBLESHOOTING 23

Engine Control Unit

Hexadecimal Decimal
PROBLEMS ACTION
SPN FMI SPN FMI
Check the wiring, check the accelerator pedal sensor and replace
it if necessary, check the wire connection and repair it or replace
0005B 03 91 3 Acceleration pedal sensor error . high signal . it if necessary . 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 .
Check the wiring, check the accelerator pedal sensor and replace
it if necessary, check the wire connection and repair it or replace
Acceleration pedal sensor error . The signal is
0005B 04 91 4 it if necessary . If the signal is above the acceptable limit APP_
below the authorized range .
uRaw1SRCLow_C, the signal for breach of the range of authorized
values is reset after repair .
The error detection limit is a limit within the ECU . Check the
wiring, check the accelerator pedal sensor and replace it if
Consistency error between APP1 and APP2 or
0005B 0B 91 11 necessary, check the wiring connection and repair it or replace
APP1 and operating switch idling (unladen)
it if necessary, If the duration of PWM APP_tiPWMPer is between
APP_tiSRCLoPWMPer_C and APP_tiSRCHiPWMPer_C .
Check the low diesel pressure measuring device (diesel feed
0005E 01 94 1 low diesel pressure; alarm limit exceeded pump, relay, fuses, wiring and sensor) and repair or replace if
necessary .
Check the wiring and check that the sensor is working properly,
0005E 03 94 3 Diesel pressure sensor error; high signal 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,
0005E 04 94 4 Diesel pressure sensor error; low range signal 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 the presence of water on the diesel sensor .
Check the wiring, if the water level on the diesel sensor is not
00061 03 97 3 Water in diesel sensor error; high signal range
working, check the sensor and replace if necessary, Check the
connecting wire and repair or replace it if necessary .
00061 04 97 4 Water in diesel sensor error; low signal Check the wiring, the sensor and the ECU .
Water in the diesel level prefilter; maximum Measure the voltage on the water in diesel level sensor and
00061 0C 97 12
value exceeded change the wiring harness if necessary .
The error detection limit is a limit within the ECU . Check the oil
00064 01 100 1 Low oil pressure; alarm limit exceeded 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 . Check the oil
00064 01 100 1 Low oil pressure; engine stop limit exceeded level, oil leaks from the engine, measure the external oil pressure
to check the validity of the sensor measurement .
Check the batteries and wiring, Check the wiring . If the sensor is
not working properly, check it and replace it if necessary, check
00064 03 100 3 Oil pressure error; low range test signal
that the wire is connected correctly and repair or replace it if
necessary .
The gross measurement of the Oil_uRawPSwmp value exceeds

80
Oil_SRCPSwmp .uMin_C Check the wiring . If the sensor is not
00064 04 100 4 Oil pressure error; high range test signal 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!
Check for major leaks throughout the engine air inlet system,
Downstream pressure of the boost air coolant,
00066 01 102 1 particularly from the compressor to the air intake manifold . Check
pressure below the low physical limit
the air filter . Replace the boost air pressure sensor .
Check the waste gate system and replace TC is necessary, check
00066 02 102 2 Boost air pressure above the alarm threshold . 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
00066 02 102 2 Boost air pressure above the shutdown limit .
CAC channels are clean, check the air supply circuits if necessary .
Downstream pressure of the boost air coolant,
00066 02 102 2 Replace the boost pressure sensor Replace the ECU
consistency error
Check the wiring, if the boost air pressure/temperature sensor is
Downstream pressure of the boost air coolant,
00066 03 102 3 not working, check the sensor and replace if necessary, check that
battery short circuit or open circuit
the wire is connected and repair or replace it if necessary .
Check the wiring, if the boost air pressure/temperature sensor is
Downstream pressure of the boost air coolant,
00066 04 102 4 not working, check the sensor and replace if necessary, check that
grounding short circuit
the wire is connected and repair or replace it if necessary .
Boost air coolant temperature . Reaction of Check and clean the CAC system . Check if the fan is working,
00069 00 105 0 the system launched . High boost air coolant Check that the ventilation is working by measuring the
temperature . Alarm level exceeded . temperature .
Check and clean the CAC system . Check if the fan is working,
Low boost air coolant temperature . Engine stop
00069 00 105 0 Check that the ventilation is working by measuring the
level exceeded .
temperature .

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 24 ELECTRICAL TROUBLESHOOTING

Engine Control Unit

Hexadecimal Decimal
PROBLEMS ACTION
SPN FMI SPN FMI
Temperature of the boost air coolant
00069 01 105 1 downstream . Temperature below the Is the temperature below -40 °C? If so, change the sensor .
authorized physical limit .
The raw signal of the sensor Air_uRawTCACDs (voltage) >
Electrical fault on the boost air temperature .
Air_SRCTCACDs .uMin_C . Check the CAC sensor and replace if
00069 03 105 3 Physical value of the signal above the normal
necessary, check that the wire is connected correctly and repair or
range (SRC) .
replace it if necessary .
The signal of the sensor Air_uRawTCACDs (voltage) is below
Electrical fault on the boost air temperature .
Air_SRCTCACDs .uMin_C . Check the CAC sensor and replace if
00069 04 105 4 Physical value of the signal below the normal
necessary, check that the wire is connected correctly and repair or
range .
replace it if necessary .
If the signal PAirFltD_uRaw is below the authorized limit PAirFltD_
Error on the air filter’s differential pressure
0006B 00 107 0 uSRCMax_C, a measurement amplitude breach signal is reset after
sensor; grounding short circuit
debouncing repair . No detailed info .
Check the air filter and clean it or replace it if necessary, check the
Air filter differential pressure: ground short
0006B 00 107 0 wiring, check the sensor and replace if necessary, check that the
circuit
wire is connected correctly and repair or replace it if necessary
If the signal PAirFltD_uRaw is below the authorized limit PAirFltD_
Error on the air filter’s differential pressure
0006B 03 107 3 uSRCMax_C, a measurement amplitude breach signal is reset after
sensor; battery short circuit
debouncing repair . No detailed info
Clean the radiator, check the fan drive, check the coolant liquid
High cooling temperature; alarm signal limit
0006E 00 110 0 level, check the whole cooling system, check that the thermostat
exceeded
is working correctly, check the water pump .
Clean the radiator, check the fan drive, check the coolant level,
0006E 00 110 0 Cooling temperature; system reaction launched check the whole cooling system, check that the thermostat is
working correctly, check the water pump .
Check the low physical range on the cooling Check the wiring harnesses and the coolant temperature sensor
0006E 01 110 1
temperature . connected to it .
Error on the cooling temperature sensor; Signal Check the sensor and replace if necessary, check the cable
0006E 03 110 3
value above the normal range . connection and, if necessary, repair or replace it .
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 . Measure the
0006E 04 110 4
value below the normal range . voltage on the coolant liquid temperature sensor and replace the
wiring harness if necessary .
Check the coolant level, inspect the condition of the cooling
0006F 01 111 1 Shutdown request Coolant liquid level too low system in case of leaks and, if necessary, repair it, check the
sensors and the wiring .
Error on the pressure sensor on the rail . Voltage Check the wiring, check the pressure sensor on the rail and
0009D 03 157 3 sensor voltage exceeds the upper authorized replace if necessary, check that the wire is connected and repair or
limit . replace it if necessary .
Error on the pressure sensor on the rail . Voltage Check the wiring, check the rail pressure sensor and replace if
0009D 04 157 4 sensor voltage below the lower authorized necessary, check that the wire is connected and repair or replace
80

limit . it if necessary .
Operation in rail pressure security mode is not The error detection limit is a limit within the ECU . Reset the fault
000A4 02 164 2
executed correctly () and, if it reappears, check the ECU and the injection device
Check the alternator, the alternator regulator, and replace it if
000A8 00 168 0 Battery voltage too high
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
000A8 01 168 1 Battery voltage too low
system, check the battery and replace it if necessary, check the
battery terminals and replace it if necessary
High voltage on the battery: fault signal limit
000A8 02 168 2 Check the wiring harness and the alternator connected to it .
exceeded
Error signal on the battery voltage: high
000A8 03 168 3 signal range . Alarm: the error light indicator is Check the wiring harness and the alternator connected to it .
permanently on
Error signal on the battery voltage: low signal
000A8 04 168 4 Check the wiring harness and the alternator connected to it .
range .
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
000AB 03 171 3 sensor; air inlet temperature on the DPF
that the wires are connected correctly and repair or replace them
system; 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
000AB 04 171 4 sensor; air inlet temperature on the DPF
that the wires are connected correctly and repair or replace them
system; low signal range
if necessary .

80-08-M257EN (05/25/2016)
 ELECTRICAL TROUBLESHOOTING 25

Engine Control Unit

Hexadecimal Decimal
PROBLEMS ACTION
SPN FMI SPN FMI
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
Max . limit temperature value reached in the air sensor placed on a dirty air filter shroud situated over the engine
000AC 00 172 0
filter casing 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
Cold start temperature and ambient temperature < the limit
000AC 01 172 1 Air intake filter sensor: out of range Check the wiring harness to the sensor AFST Change the sensor
AFST
Engine speed above the authorized limit (FOC- Check the parameters of the running gear with regard to
000BE 00 190 0
Level 1) overspeed .
The error detection limit is a limit within the ECU . This is caused
by an offset between the crankshaft and the camshaft . Check
Offset angle between crankshaft and camshaft
000BE 02 190 2 the position of the incremental gear, clean it or reposition it if
sensor too great .
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 from the camshaft . Check the position of the
000BE 08 190 8 Camshaft speed sensor fault 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
Crankshaft sensor detection: out of limit, signal
000BE 08 190 8 of the incremental gear, clean it or reposition it if necessary,
lost, signal disrupted
check the correct location of the sensors . Check the sensor on the
camshaft and its wiring .
Engine speed above the authorized limit (FOC- Check the parameters of the running gear with regard to
000BE 0B 190 11
Level 2) overspeed .
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
Camshaft sensor detection: out of range,
000BE 0C 190 12 of the incremental gear, clean it or reposition it if necessary,
disrupted signal, no signal
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 or no signal from the crankshaft . Check the position
Speed detection; out of limit, signal lost,
000BE 0C 190 12 of the incremental gear, clean it or reposition it if necessary,
Crankshaft speed sensor; no more signal
check the correct location of the sensors on the crankshaft and its
wiring .
Engine speed above the authorized limit Check the parameters of the running gear with regard to
000BE 0E 190 14
(Overrun mode) overspeed .
The error detection limit is a limit within the ECU . Check the

80
Crankshaft and camshaft speed sensor signal
000BE 0E 190 14 wiring, check the wires and repair them or replace them if
unavailable on the CAN
necessary .
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) Problem with
Venturi module differential pressure on the EGR
0019B 00 411 0 EGR valve throttle valve blocked in closed position => check gas
circuit above the high physical limit
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
The error detection limit is a limit within the ECU . Check that the
Venturi module differential pressure on the EGR
0019B 01 411 1 differential pressure sensor is assembled correctly on the venturi
circuit below the low physical limit
tube Change the differential pressure sensor if it is broken .
Check the wiring, if the boost differential pressure sensor of the
Error on the differential pressure sensor of the EGR is not working, check the sensor and replace if necessary,
0019B 03 411 3
venturi module (EGR), low control signal check that the wire is connected and repair or replace it if
necessary .
Physical scale (measured) low for the EGR
0019B 04 411 4 Check the wiring harness and the EGR connected to it .
differential pressure
Check the wiring, if the boost differential pressure sensor of the
Error on the differential pressure sensor of the EGR is not working, check the sensor and replace if necessary,
0019B 04 411 4
venturi module (EGR), high control signal . check that the wire is connected and repair or replace it if
necessary .

(05/25/2016) 80-08-M257EN
 26 ELECTRICAL TROUBLESHOOTING

Engine Control Unit

Hexadecimal Decimal
PROBLEMS ACTION
SPN FMI SPN FMI
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
Check if consistency fault on deviation of the
EGR valve . Problem on the actuator of the EGR valve Problem with
desired and actual mass flow on the EGR, the
0019B 0B 411 11 the EGR coolant (check cooling water intake) Problem with EGR
second mentioned is calculated from the EGR
valve Gas inlet blocked in closed position => check the gas inlet
differential pressure sensor .
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
Electrical fault on the EGR coolant temperature Check the wiring harness to the TEGr sensor . Replace the TEGR
0019C 03 412 3
downstream High signal range . sensor .
Electrical fault on the EGR coolant temperature Check the wiring harness to the TEGr sensor . Replace the TEGR
0019C 04 412 4
downstream Low signal range . sensor .
Check the connection of the CAN Bus (programming of the Bus,
No engine braking Time exceeded error on
00208 09 520 9 polarity, short circuits, power supply circuit interruptions), test the
CAN-message; control signal
reception protocol, check the whole range of CAN functions .
The error detection limit is a limit within the ECU . There are no
solutions for resolving this error/failure . In each new reset phase,
00276 0C 630 12 EEPROM memory access error (delete) 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 .
The error detection limit is a limit within the ECU . There are no
solutions for resolving this error/failure . In each new reset phase,
00276 0C 630 12 EEPROM memory access error (read) 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 .
The error detection limit is a limit within the ECU . If it is not
00276 0C 630 12 EEPROM memory access error (write) programmed, the EEPROM is faulty --> If the ECU is faulty,
reprogram the ECU or replace if necessary .
Check the wiring of CAN bus A and replace or repair if necessary .
0027F 0E 639 14 Fault on BusOff-Status Can bus Check if CAN bus B has a resistance of 120 ohm . The error margin
is a fault limit within the ECU
The error detection limit is a limit within the ECU . Check the wiring
Injector 1 (following the firing order); short-
0028B 03 651 3 harness and the injectors and repair them or replace them if
circuited
necessary . Use the SERDIA injector test for the diagnosis .
The error detection limit is a limit within the ECU . Check the wiring
Injector 1 (following the firing order);
0028B 05 651 5 harness and the injectors and repair them or replace them if
interruption of the electrical connection
necessary .
The error detection limit is a limit within the ECU . Check the wiring
Injector 2 (following the firing order); short-
0028C 03 652 3 harness and the injectors and repair them or replace them if
circuited
necessary . Use the SERDIA injector test for the diagnosis .
The error detection limit is a limit within the ECU . Check the wiring
Injector 2 (following the firing order);
0028C 05 652 5 harness and the injectors and repair them or replace them if
80

interruption of the electrical connection

necessary .
The error detection limit is a limit within the ECU . Check the wiring
Injector 3 (following the firing order); short-
0028D 03 653 3 harness and the injectors and repair them or replace them if
circuited
necessary . Use the SERDIA injector test for the diagnosis .
The error detection limit is a limit within the ECU . Check the wiring
Injector 3 (following the firing order);
0028D 05 653 5 harness and the injectors and repair them or replace them if
interruption of the electrical connection
necessary .
The error detection limit is a limit within the ECU . Check the wiring
Injector 4 (following the firing order); short-
0028E 03 654 3 harness and the injectors and repair them or replace them if
circuited
necessary . Use the SERDIA injector test for the diagnosis .
The error detection limit is a limit within the ECU . Check the wiring
Injector 4 (following the firing order);
0028E 05 654 5 harness and the injectors and repair them or replace them if
interruption of the electrical connection
necessary .
The error detection limit is a limit within the ECU . Check the wiring
Injector 5 (following the firing order); short-
0028F 03 655 3 harness and the injectors and repair them or replace them if
circuited
necessary . Use the SERDIA injector test for the diagnosis .
The error detection limit is a limit within the ECU . Check the wiring
Injector 5 (following the firing order);
0028F 05 655 5 harness and the injectors and repair them or replace them if
interruption of the electrical connection
necessary .
The error detection limit is a limit within the ECU . Check the wiring
Injector 6 (following the firing order); short-
00290 03 656 3 harness and the injectors and repair them or replace them if
circuited
necessary . Use the SERDIA injector test for the diagnosis .
The error detection limit is a limit within the ECU . Check the wiring
Injector 6 (following the firing order);
00290 05 656 5 harness and the injectors and repair them or replace them if
interruption of the electrical connection
necessary .

80-08-M257EN (05/25/2016)
 ELECTRICAL TROUBLESHOOTING 27

Engine Control Unit

Hexadecimal Decimal
PROBLEMS ACTION
SPN FMI SPN FMI
The error detection limit is a limit within the ECU . Check the wiring
002A4 0B 676 11 Error on the cold start assist relay .
harness, replace the relay .
The error detection limit is a limit within the ECU . Check the wiring
002A4 0B 676 11 Error on the open cold start assist relay .
harness, replace the relay .
The error detection limit is a limit within the ECU . Check the
002A5 03 677 3 Power side start relay . battery short circuit . wiring, operate the relay and replace it if necessary, check the
wiring connection and repair it or replace it if necessary .
The error detection limit is a limit within the ECU . Check the
002A5 03 677 3 Control side start relay, battery short circuit . wiring, operate the relay and replace it if necessary, check the
wiring connection and repair it or replace it if necessary .
The error detection limit is a limit within the ECU . Check the
002A5 04 677 4 Power side start relay, ground short circuit . wiring, operate the relay and replace it if necessary, check the
wiring connection and repair it or replace it if necessary .
The error detection limit is a limit within the ECU . Check the
wiring, operate the relay and replace it if necessary, check the
002A5 04 677 4 Control side start relay, ground short circuit .
wiring connection on the terminal and repair it or replace it if
necessary .
The error detection limit is a limit within the ECU . Check the
Control side start relay, error due to absence of
002A5 05 677 5 wiring, operate the relay and replace it if necessary, check the
charge .
wiring connection and repair it or replace it if necessary .
The error detection limit is a limit within the ECU . Check the
Increase in temperature on the power stage of
002A5 0C 677 12 wiring, operate the relay and replace it if necessary, check the
the start relay .
wiring connection and repair it or replace it if necessary .
Incoming air heating device; short circuit on The error detection limit is a limit within the ECU . Electrical error,
002D9 03 729 3
the battery check the wiring of the air inlet preheater .
Incoming air heating device; short circuit on The error detection limit is a limit within the ECU . Electrical error,
002D9 04 729 4
power circuit ground check the wiring of the air inlet preheater .
The error detection limit is a limit within the ECU . Electrical error,
002D9 05 729 5 Error on the open cold start assist relay
check the wiring .
Check that the relay is working properly and replace it if necessary .
002D9 0C 729 12 Temperature error on the cold start assist relay . Check the temperature value around the cold start relay under the
worst-case operating conditions .
Check the connection of the CAN Bus (programming of the Bus,
00382 09 898 9 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 wiring of external components, check that the voltages
are compliant and correct them if necessary, check the connection
00437 0D 1079 13 Fault on power supply voltage sensor 1 .
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
00438 0D 1080 13 Fault on power supply voltage sensor 2 .
of the cables and repair them or replace them if necessary, If the

80
error cannot be corrected, replace the ECU .
00455 02 1109 2 Engine stop request ignored Depending on the error, the engine will need shutting down .
00470 00 1136 0 Out of range on ECU temperature Close the heating air circuits, replace the ECU
Check the wiring of CAN bus B and replace or repair if necessary .
004CF 0E 1231 14 Fault on BusOff-Status Can bus 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 .
004D3 0E 1235 14 CAN-Bus 2 = engine bus BusOff-Status Check if CAN bus C has a resistance of 120 ohm . The error margin
is a fault limit within the ECU .
If you have pressed the Block button for less than the maximum
reasonable time . Check the wiring . If the sensor is not working
004D5 02 1237 2 Forcing (override) switch; consistency error .
properly, check the switch and replace it if necessary, check that
the wire is connected correctly and repair or replace it if necessary .
Excessive firing failures identified on more than
0052A 0C 1322 12 Not used
one cylinder
Excessive firing failures identified on cylinder 1
0052B 0C 1323 12 Not used
(following the firing order)
Excessive firing failures identified on cylinder 2
0052C 0C 1324 12 Not used
(following the firing order)
Excessive firing failures identified on cylinder 3
0052D 0C 1325 12 Not used
(following the firing order)
Excessive firing failures identified on cylinder 4
0052E 0C 1326 12 Not used
(following the firing order)
Excessive firing failures identified on cylinder 5
0052F 0C 1327 12 Not used
(following the firing order)

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 28 ELECTRICAL TROUBLESHOOTING

Engine Control Unit

Hexadecimal Decimal
PROBLEMS ACTION
SPN FMI SPN FMI
Excessive firing failures identified on cylinder 6
00530 0C 1328 12 Not used
(following the firing order)
006E1 00 1761 0 DEF tank, DEF level above the normal high limit Check the level sensor and the gauge float
006E1 01 1761 1 DEF tank, DEF level below the normal low limit Check the level sensor and the gauge float
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
006E1 0E 1761 14 DEF tank, DEF level below the first alarm limit 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
DEF tank, DEF level below the second alarm
006E1 0E 1761 14 float; this must move freely . When the body of the sensor is lifted
limit
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 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
DEF tank, DEF level below the third alarm limit
006E1 0E 1761 14 is lifted up . The value of SCRUTnk_rVol_mp must change
value
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 .
EGR actuator, temperature high and becoming Leave the EGR actuator to cool and check how much heat builds
00AE7 00 2791 0
critical up during the worst-case scenarios .
The error detection limit is a limit within the ECU . Check the other
00AE7 02 2791 2 EGR actuator, CAN error components of the CAN bus . If no message is sent, repair the
wiring . If it is OK, change the EGR actuator .
Power voltage of the EGR actuator beyond the
00AE7 03 2791 3 Check the voltage of the battery .
maximum limit value
Power voltage of the EGR actuator below its
00AE7 04 2791 4 Check the voltage of the battery .
minimum limit value
Check the battery voltage . Check if the EGR is blocked or if it
Current on the EGR actuator beyond the
00AE7 06 2791 6 would not turn silently . If everything is OK, change the EGR
maximum limit
actuator .
The error detection limit is a limit within the ECU . Check the EGR
actuator and check that the EGR is not mechanically blocked
00AE7 07 2791 7 EGR actuator, actuator 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 . Replace the EGR
00AE7 07 2791 7 EGR actuator, broken spring detected
actuator .
Leave the EGR actuator to cool and check how much heat builds
00AE7 10 2791 16 EGR actuator, temperature too high .
up during the worst-case scenarios .
The error detection limit is a limit within the ECU . Replace the EGR
00AE7 0C 2791 12 EGR actuator, internal electrical fault
80

actuator .
The error detection limit is a limit within the ECU . Start Serdia
00AE7 0D 2791 13 EGR actuator, EOL calibration error 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 . Start Serdia Use
00AE7 0D 2791 13 EGR actuator fault
case to reset the EGR actuator .
EGR actuator, learning process outside The error detection limit is a limit within the ECU . Start Serdia
00AE7 0D 2791 13
authorized range Usecase to reset the EGR actuator .
Time exceeded on the ground short The error detection limit is a limit within the ECU . Check the
00AED 04 2797 4 circuit diagnosis on Cyl . Bank 0;_ wiring, the components and the ECU Note: the injector in
IVDiaShCirGndToutBnk_0 question must be determined following the firing order
Injector diagnosis; short circuit on the ground Check the wiring, the components and the ECU Note: the injector
00AED 04 2797 4
of cylinder row 0 in question must be determined following the firing order
Time exceeded on the ground short The error detection limit is a limit within the ECU . Check the
00AEE 04 2798 4 circuit diagnosis on Cyl . Bank 1;_ wiring, the components and the ECU Note: the injector in
IVDiaShCirGndToutBnk_1 question must be determined following the firing order
Injector diagnosis; short circuit on the ground Check the wiring, the components and the ECU Note: the injector
00AEE 04 2798 4
of cylinder row 1 in question must be determined following the firing order

80-08-M257EN (05/25/2016)
 ELECTRICAL TROUBLESHOOTING 29

Engine Control Unit

Hexadecimal Decimal
PROBLEMS ACTION
SPN FMI SPN FMI
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
DEF tank, DEF temperature above the physical work continuously? Check the wiring of the DEF quality sensor
00BD7 00 3031 0
limit 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
DEF tank, DEF temperature below the physical sensor?) Check the wiring of the DEF quality sensor Check the
00BD7 01 3031 1
limit 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 . Check the Nox
00C98 02 3224 2 DLC error on the CAN’s NOX sensor .
sensor and the CAN-BUS wiring .
Time exceeded error on the NOX sensor of the
00C98 09 3224 9 Check the NOX sensor and check that it is connected properly .
CAN-Receive-Frame AT1IG1Vol
Check the downstream NOX sensor and check that it is connected
00CA2 02 3234 2 DLC error on the CAN’s Nox
properly .
Check the downstream NOX sensor and check that it is connected
00CA2 09 3234 9 Time exceeded error on CAN
properly .
The error detection limit is a limit within the ECU . See if a
00D21 03 3361 3 DEF dosing valve; battery short circuit
substitution function needs anticipating Check the wiring
00D21 03 3361 3 DEF dosing valve; battery short circuit The error detection limit is a limit within the ECU . Check the wiring
Urea dosing valve; short circuit on ground or
00D21 04 3361 4 Check the wiring
control circuit
00D21 04 3361 4 DEF dosing valve; power side short circuit The error detection limit is a limit within the ECU . Check the wiring
DEF dosing valve; power too high at the end of
00D21 06 3361 6 Check the wiring Check the DEF injection valve
injection
Check the ECU wiring harnesses up to the DEF tank suction
DEF quality sensor, internal temperature sensor
00DBF 03 3519 3 unit Check the communications on the CAN bus . If the signal is
short circuit on battery or circuit open
degraded, replace the suction unit .

80
Check the ECU wiring harnesses up to the DEF tank suction
DEF quality sensor, internal temperature sensor
00DBF 04 3519 4 unit Check the communications on the CAN bus . If the signal is
short circuit on ground
degraded, replace the DEF tank suction unit .
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
00DBF 0C 3519 12 DEF tank temperature too high 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 .
Check the temperature of the system and/or the DEF quality
00DBF 0D 3519 13 Temperature value not valid on UQS
sensor
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
DE quality sensor, poor DEF quality detected or
00DC0 02 3520 2 connections Check the CAN bus A new quality control will be
DEF measurement impossible .
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
(05/25/2016) 80-08-M257EN
 30 ELECTRICAL TROUBLESHOOTING

Engine Control Unit

Hexadecimal Decimal
PROBLEMS ACTION
SPN FMI SPN FMI
The error detection limit is a limit within the ECU . Check the
DEF quality sensor; battery short circuit or ECU wiring harnesses up to the DEF tank suction unit Check the
00DC0 03 3520 3
circuit open 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
00DC0 04 3520 4 DEF quality sensor; ground short circuit
communications on the CAN bus . If the signal is degraded, replace
the suction unit .
00DC0 0D 3520 13 Urea quality not valid on UQS Check the quality of the DEF and/or that of the DEF quality sensor
Check the DEF tank sensor, check the wiring The gross voltage
00DCC 03 3532 3 DEF tank level sensor error; high signal range .
value SCR_uRawUTnkLvl is below SCR_SRCUTnkLvl .uMax_C .
00DCC 03 3532 3 DEF level on UQS outside the maximum range Check the quality of the DEF and/or that of the DEF quality sensor .
The gross voltage value SCR_uRawUTnkLvl is above SCR_
00DCC 04 3532 4 DEF tank level sensor error; low signal range
SRCUTnkLvl .uMin_C Check the DEF tank sensor, check the wiring .
00DCC 04 3532 4 Quality on UQS outside the minimum range Check the quality of the DEF and/or that of the DEF quality sensor .
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
Temperature too low or too high during an of the turbo (search for oil leaks) check the injectors: is an
00E7F 0C 3711 12
established regime main cycle 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
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
00F60 0E 3936 14 Stop request ignored for too long .
DPF soot load level is too high, remove the DPF => replace the
DPF .
Power reduction following too long without
00F60 0E 3936 14
having launched the required regeneration
DEF supply module pressure, DEF pressure Check the urea pump Check the supply module pressure sensor
010EE 00 4334 0
above the normal range Clean the urea pump (filter)
DEF supply module pressure sensor; weak Check the urea pump Check the supply module pressure sensor
010EE 01 4334 1
signal Clean the urea pump (filter)
Check the environment pressure sensor (EnvP_p) => is the value
80

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?
010EE 02 4334 2 DEF supply module pressure error 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
SCR-DEF heating main circuit; battery short The error detection limit is a limit within the ECU . Check the wiring
010F5 03 4341 3
circuit harness, Check the power supply circuit
SCR-DEF heating main circuit; ground short The error detection limit is a limit within the ECU . Check the wiring
010F5 04 4341 4
circuit harness, Check the power supply circuit
The error detection limit is a limit within the ECU . Check the wiring
010F5 05 4341 5 SCR-DEF heating relay main circuit open
harness, Check the power supply circuit
Pressurized DEF circuit on the SCR heater The error detection limit is a limit within the ECU . Check the wiring
010F7 03 4343 3
-Pressure circuit DEF; battery short circuit Check the heating element
Pressurized DEF circuit on the SCR heater The error detection limit is a limit within the ECU . Check the wiring
010F7 04 4343 4
-Pressure circuit DEF; ground short circuit Check the heating element
Primary side pressure circuit DEF heating relay The error detection limit is a limit within the ECU . Check the wiring
010F7 05 4343 5
SCR; circuit open Check the heating element
DEF return circuit on the SCR heater; battery The error detection limit is a limit within the ECU . Check the wiring
010F9 03 4345 3
short circuit Check the heating element
DEF return circuit on the SCR heater; ground The error detection limit is a limit within the ECU . Check the wiring
010F9 04 4345 4
short circuit Check the heating element
DEF return circuit on the SCR heater; circuit The error detection limit is a limit within the ECU . Check the wiring
010F9 05 4345 5
open Check the heating element
80-08-M257EN (05/25/2016)
 ELECTRICAL TROUBLESHOOTING 31

Engine Control Unit

Hexadecimal Decimal
PROBLEMS ACTION
SPN FMI SPN FMI
Check the temperature deviations along the DOC (Exh_tOxiCatDs-
Exh_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
Exhaust gas temperature upstream of the SCR-
01108 00 4360 0 intake circuits: EGR valve, gas inlet, leaks and correct operation
Cat exceeds the high physical limit
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 .
Cold start and ambient temperature < the limit? Poor detection
Exhaust gas temperature measured before the
01108 01 4360 1 Check the wiring harness to the sensor UCatUsT Change the
SCR-Cat < low physical limit
sensor UCatUsT
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
Exhaust temperature sensor error upstream of Exh_TOxiCatUs, Exh_tOxiCatDs and SCR_tSensUCatUsT after
01108 02 4360 2
the SCR, 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
Error on the temperature sensor upstream of
01109 03 4361 3 the SCR catalytic converter; Physical signal Check the sensor Check the wiring Replace the UCatUsT sensor
value above the normal range
Error on the temperature sensor upstream of
01109 04 4361 4 the SCR catalytic converter; Physical signal Check the sensor Check the wiring Replace the UCatUsT sensor
value below the normal range
The error detection limit is a limit within the ECU . The raw voltage
Urea tank temperature sensor error: battery
0110D 03 4365 3 value measured SCR_uRawUTnkT remains below SCR_SRCUTnkT .
short circuit
uMax_C . Check the wiring .
DEF quality sensor, tank temperature; battery
0110D 03 4365 3 Check the wiring harness and the DEF quality sensor
short circuit or circuit open
The error detection limit is a limit within the ECU . The raw voltage
Urea tank temperature sensor error: ground
0110D 04 4365 4 value measured SCR_uRawUTnkT is above SCR_SRCUTnkT .uMin_C .
short circuit .
Check the wiring .
DEF quality sensor; tank temperature; ground
0110D 04 4365 4 Check the wiring harness and the DEF quality sensor

80
short circuit
The error detection limit is a limit within the ECU . Check the wiring
SCR tank heating valve; short circuit on the
0110E 03 4366 3 Check the connections, replace the urea tank heating valve if
battery
necessary
The error detection limit is a limit within the ECU . Check the wiring
SCR tank heating valve; short circuit on the
0110E 04 4366 4 Check the connections, replace the urea tank heating valve if
ground
necessary
The error detection limit is a limit within the ECU . Check the wiring
0110E 05 4366 5 SCR tank heating valve main circuit open Check the connections, replace the urea tank heating valve if
necessary
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
01117 03 4375 3 Urea pump engine; battery short circuit
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 a short circuit with ground fault on the outlet power stage
01117 04 4375 4 Urea pump engine; ground short circuit of the PWM for the urea pump actuator module . This error is reset
by moving to bit 1 the measuring point UPmp-Mot_stPrevTstRslt_
mp Check the wiring Check the urea supply module pump
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
01117 05 4375 5 Urea pump engine; circuit open
pump actuator module . Check the wiring Check the urea supply
module pump
The error detection limit is a limit within the ECU . Check the wiring
01118 03 4376 3 Reversible SCR valve; battery short circuit
Check the urea supply module

(05/25/2016) 80-08-M257EN
 32 ELECTRICAL TROUBLESHOOTING

Engine Control Unit

Hexadecimal Decimal
PROBLEMS ACTION
SPN FMI SPN FMI
The error detection limit is a limit within the ECU . Check the wiring
01118 04 4376 4 Reversible SCR valve; ground short circuit
Check the urea supply module
The error detection limit is a limit within the ECU . Check the wiring
01118 05 4376 5 Reversible SCR valve; open load
Check the urea supply module
Check the engine's air circuit: EGR valve, gas inlet, Check the turbo
Temperature upstream of the DOC exceeds the and each of the pipes for leaks and correct operation Check the
0129D 00 4765 0
engine stop limit 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 Check the
0129D 00 4765 0
high alarm limit injectors: is an injector blocked? Change the temperature sensor
upstream of the DOC
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
Consistency error with the temperature position upstream of the DOC (and not upstream of the SCR
012A0 02 4768 2
upstream of the DOC . 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 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 for at least
Exhaust gas temperature sensor error upstream
012A0 02 4768 2 8 hours), compare the values EnvT_t, EngDa_tEng, Exh_TOxiCatUs,
and downstream of the DOC
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?
Electrical fault on the exhaust gas temperature
Check the wiring harness of the temperature sensor upstream of
012A0 03 4768 3 upstream (DOC); Physical value of the signal
the DOC Change the temperature sensor upstream of the DOC
above the normal range .
Electrical fault on the exhaust gas temperature
Check the wiring harness of the temperature sensor upstream of
012A0 04 4768 4 upstream (DOC); Physical value of the signal
the DOC Change the temperature sensor upstream of the DOC
below the normal range .
Alarm limit reached on an EGR air intake The mass air flow rate AFS_dm is greater than or equal to AFS_
01683 00 5763 0
internal actuator error PhysRng .Max_C
Engine stop limit reached on an EGR air intake
01683 01 5763 1 not used
internal actuator error
Position error on the EGR valve sensor actuator Check the wiring, check if fault on the actuator, check the actuator
01683 03 5763 3 or the throttle valve . Physical value of the signal and replace if necessary, check the connecting wire and repair or
80

above the normal range . replace it if necessary .

The error detection limit is a limit within the ECU . Check the
Operate the EGR valve or the throttle valve;
01683 03 5763 3 wiring, the components and the ECU Check the repairs using
battery short circuit
SerDia 2010 Use Case
The error detection limit is a limit within the ECU . Check the
Operate the EGR valve or the throttle valve;
01683 03 5763 3 wiring, the components and the ECU Check the repairs using
battery short circuit
SerDia 2010 Use Case
Position error on the EGR valve actuator sensor Check the wiring, check if fault on the actuator, check the actuator
01683 04 5763 4 or the throttle valve . Physical value of the signal and replace if necessary, check the connecting wire and repair or
below the normal range . replace it if necessary .
The error detection limit is a limit within the ECU . Check the
Operate the EGR valve or the throttle valve;
01683 04 5763 4 wiring, the components and the ECU Check the repairs using
ground short circuit
SerDia 2010 Use Case
The error detection limit is a limit within the ECU . Check the
Operate the EGR valve or the throttle valve;
01683 04 5763 4 wiring, the components and the ECU Check the repairs using
battery short circuit
SerDia 2010 Use Case
The error detection limit is a limit within the ECU . Check the wiring
01683 04 5763 4 Voltage below the low limit .
and the components
Error on the EGR valve actuator or the throttle Check the wiring, check the connecting wire and repair it or
01683 05 5763 5 valve; Physical value of the signal below the replace it if necessary, check the actuator with the SERDIA 2010
normal range test of the EGR and replace it if necessary .
The error detection limit is a limit within the ECU . Check the
Operate the EGR valve or the throttle valve;
01683 05 5763 5 wiring, the components and the ECU Check the repairs using
circuit open
SerDia 2010 Use Case
Error on the EGR valve actuator or the throttle Check the wiring and repair it or replace it if necessary, check the
01683 06 5763 6
valve . High signal range . actuator using a SERDIA test of the EGR and replace it if necessary .
80-08-M257EN (05/25/2016)
 ELECTRICAL TROUBLESHOOTING 33

Engine Control Unit

Hexadecimal Decimal
PROBLEMS ACTION
SPN FMI SPN FMI
Error on the EGR valve actuator or the throttle Check the wiring, check if fault on the actuator, check the actuator
01683 06 5763 6 valve; Physical value of the signal above the and replace if necessary, check the connecting wire and repair or
normal range replace it if necessary .
The error detection limit is a limit within the ECU . Check the
Operate the EGR valve or the throttle valve;
01683 06 5763 6 wiring, the components and the ECU Check the repairs using
current too strong
SerDia 2010 Use Case
Operate the EGR valve or the throttle valve; The error detection limit is a limit within the ECU . Check the wiring
01683 06 5763 6
overload due to short circuit and the components
The error detection limit is a limit within the ECU . Error detection
Position of the EGR valve actuator or the
01683 07 5763 7 limit, a deviation is only visible from a value > 7% . Troubleshoot
throttle valve not consistent
with SERDIA 2010, use Diagnostic EGR .
Increase in power stage temperature due to The error detection limit is a limit within the ECU . Check the wiring
01683 0B 5763 11
current being too strong . and the components
Error on the EGR valve actuator or the throttle
Check the wiring and repair it or replace it if necessary, check the
7F149 05 520521 5 valve; Physical value of the signal below the
actuator using a SERDIA test of the EGR and replace it if necessary .
normal range .
The pressure retaining valve (PRV) has reached Replace the pressure relief valve (PRV) and reset the fault using
7FB01 09 523009 9
the authorized cycle limit . Serdia .
The pressure retaining valve (PRV) opening
Replace the pressure relief valve (PRV) and reset the fault using
7FB01 0A 523009 10 time has passed, to ensure monitoring of its
Serdia .
condition
The error detection limit is a limit within the ECU . Check the wiring
7FB52 02 523090 2 brake pre-selection switch
and the switches . If the error persists, change the ECU .
Check the connection of the CAN Bus (programming of the Bus,
7FBCC 09 523212 9 Time exceeded error on CAN messages polarity, short circuits, power supply circuit interruptions), test the
reception protocol, check the whole range of CAN functions .
Time exceeded error on CAN; preheat control,
7FBD0 09 523216 9 Check the wiring harness and the client’s devices/equipment .
engine control
Check the connection of the CAN Bus (programming of the Bus,
Time exceeded error on CAN-message
7FBE8 09 523240 9 polarity, short circuits, power supply circuit interruptions), test the
FunModCtl; Control function mode
reception protocol, check the whole range of CAN functions .
The error detection limit is a limit within the ECU . Check the wiring
7FC56 04 523350 4 Injector in cylinder row 1; short-circuited 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
7FC58 04 523352 4 Injector in cylinder row 2; short-circuited harness and the injectors and repair them or replace them if
necessary .
Fault on the output of the injector’s power The error detection limit is a limit within the ECU . If the error
7FC5A 0C 523354 12
stage cannot be corrected, replace the ECU .
The pressure retaining valve (PRV) is forced to The error detection limit is a limit within the ECU . Reset the fault
7FCCE 02 523470 2
open, apply an increase in pressure . and, if it reappears, check the injection system .
The pressure retaining valve (PRV) is forced to

80
7FCCE 02 523470 2 Reset the fault and, if it reappears, check the injection system .
open, apply an increase in pressure .
(A) check the overpressure valve on the rail and replace it if
necessary, (B) check the high-pressure pumps, the overpressure
7FCCE 07 523470 7 maximum pressure on the rail exceeded (PRV) .
valves and the measuring device, (C) Replace the components if
necessary
The error detection limit is a limit within the ECU . Check the rail
Pressure retaining valve (PRV) error; pressure
7FCCE 0B 523470 11 pressure, check the relevance of the pressure sensor value on the
on the rail outside tolerance limits .
rail, check the FCU .
Pressure on the rail outside tolerance limits . At
The error detection limit is a limit within the ECU . Check the PRV
7FCCE 0B 523470 11 this stage, the PRV can no longer be opened by
and replace it if necessary .
a pressure shock .
The error detection limit is a limit within the ECU . Check the
The pressure retaining valve (PRV) is forced to
PRV opening counter and replace the PRV if necessary, check
7FCCE 0C 523470 12 open . Conditions achieved for stopping the
the relevance of the rail’s pressure sensor value and replace it if
engine .
necessary, check the FCU and replace it if necessary .
The error detection limit is a limit within the ECU . Check the PRV
The pressure retaining valve (PRV) is forced to opening counter and replace the PRV if necessary, check the
7FCCE 0C 523470 12
open . Alarm conditions achieved . relevance of the pressure sensor value on the rail and replace it if
necessary, check the FCU and replace it if necessary .
The error detection limit is a limit within the ECU . Only after
resetting the ECU . Check the PRV opening counter and replace
7FCCE 0E 523470 14 Open the pressure retaining valve (PRV) it 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 .

(05/25/2016) 80-08-M257EN
 34 ELECTRICAL TROUBLESHOOTING

Engine Control Unit

Hexadecimal Decimal
PROBLEMS ACTION
SPN FMI SPN FMI
The error detection limit is a limit within the ECU . Check the
Terminal 50 (excitation time of the starter has wiring, check whether the sensor is working, check the starter
7FD1E 0C 523550 12
been used for too long) switcher and replace it if necessary, check the wiring connection
and repair it or replace it if necessary .
Check the wiring of external components, check that the voltages
are compliant and correct them if necessary, check the connection
7FD51 0D 523601 13 Fault on power supply voltage sensor 3 .
of the cables and repair them or replace them if necessary, If the
error cannot be corrected, replace the ECU .
7FD55 09 523605 9 Time exceeded error on CAN-message No detailed info
Time exceeded error on CAN-message;
7FD56 09 523606 9 No detailed info
Postpone
7FD5C 03 523612 3 Overvoltage observed on power supply The error detection limit is a limit within the ECU .
7FD5C 04 523612 4 Undervoltage observed on power supply The error detection limit is a limit within the ECU .
The error detection limit is a limit within the ECU . Important:
7FD5C 0C 523612 12 ECU software error; injection interruption sequence error, check what the error is in the memory, in case
there are other errors .
Detection of surveillance within the ECU has The error detection limit is a limit within the ECU . If the error does
7FD5C 0C 523612 12
reported the error not disappear, replace the ECU .
The error detection limit is a limit within the ECU . Check the wiring
7FD5C 0C 523612 12 ECU has reported an internal software error and check the actuators connected to the sensors . If the error
does not disappear, replace the ECU .
The error detection limit is a limit within the ECU . Check the wiring
7FD5C 0C 523612 12 ECU has reported an internal software error and check the actuators connected to the sensors . If the error
does not disappear, replace the ECU .
The error detection limit is a limit within the ECU . If the error does
7FD5C 0C 523612 12 ECU has reported an internal software error
not disappear, replace the ECU .
The error detection limit is a limit within the ECU . If the error does
7FD5C 0C 523612 12 ECU has reported an internal software error
not disappear, replace the ECU .
The error detection limit is a limit within the ECU . If the error does
7FD5C 0C 523612 12 ECU has reported an internal software error
not disappear, replace the ECU .
The error detection limit is a limit within the ECU . If the error does
7FD5C 0C 523612 12 ECU has reported an internal software error
not disappear, replace the ECU .
Injection system; electrical failures on the The error detection limit is a limit within the ECU . If the error does
7FD5C 0C 523612 12
injectors not disappear, replace the ECU .
The error detection limit is a limit within the ECU . If the error does
7FD5C 0C 523612 12 ECU has reported an internal software error
not disappear, replace the ECU .
The error detection limit is a limit within the ECU . If the error does
7FD5C 0C 523612 12 ECU has reported an internal software error
not disappear, replace the ECU .
The error detection limit is a limit within the ECU . If the error does
7FD5C 0C 523612 12 ECU has reported an internal software error
not disappear, replace the ECU .
The error detection limit is a limit within the ECU . If the error does
7FD5C 0C 523612 12 ECU has reported an internal software error
80

not disappear, replace the ECU .

The error detection limit is a limit within the ECU . If the error does
7FD5C 0C 523612 12 ECU has reported an internal software error
not disappear, replace the ECU .
The error detection limit is a limit within the ECU . If the error does
7FD5C 0C 523612 12 ECU has reported an internal software error
not disappear, replace the ECU .
The error detection limit is a limit within the ECU . If the error does
7FD5C 0C 523612 12 ECU has reported an internal software error
not disappear, replace the ECU .
The error detection limit is a limit within the ECU . Check the
Diagnosis fault, check to report the accelerator
7FD5C 0C 523612 12 pedal, repair or replace it . Check the wiring . If the error does not
pedal position error
disappear, replace the ECU .
Diagnosis fault, check to report the engine The error detection limit is a limit within the ECU . If the error does
7FD5C 0C 523612 12
speed error not disappear, replace the ECU .
The error detection limit is a limit within the ECU . If the error does
7FD5C 0C 523612 12 Injection firing time consistency error
not disappear, replace the ECU .
The error detection limit is a limit within the ECU . If the error does
7FD5C 0C 523612 12 Firing angle start consistency error
not disappear, replace the ECU .
Control diagnosis of the fault, report the error The error detection limit is a limit within the ECU . If the error does
7FD5C 0C 523612 12
caused by ZFC non-plausibility not disappear, replace the ECU .
Fault diagnosis check report normal mode The error detection limit is a limit within the ECU . If the error does
7FD5C 0C 523612 12
request because of an error in the Pol2 quantity not disappear, replace the ECU .
Fault diagnosis to report the ICO request error The error detection limit is a limit within the ECU . If the error does
7FD5C 0C 523612 12
because of an error in the shutdown Pol2 not disappear, replace the ECU .
Fault diagnosis, check to report the
The error detection limit is a limit within the ECU . If the error does
7FD5C 0C 523612 12 international organization request error
not disappear, replace the ECU .
because of an error in the Pol3 efficiency factor

80-08-M257EN (05/25/2016)
 ELECTRICAL TROUBLESHOOTING 35

Engine Control Unit

Hexadecimal Decimal
PROBLEMS ACTION
SPN FMI SPN FMI
Internal ECU monitoring detection reported The error detection limit is a limit within the ECU . If the error does
7FD5C 0C 523612 12
error not disappear, replace the ECU .
The error detection limit is a limit within the ECU . If the error does
7FD5C 0C 523612 12 Monitoring of fuel quantity check
not disappear, replace the ECU .
The error detection limit is a limit within the ECU . Check the
Fault control diagnosis to report the plausibility
7FD5C 0C 523612 12 measuring device or the cable . Check the pressure on the rail .
error In the pressure control on the rail
Check the rail system and check for leaks .
Control diagnosis of the fault to report the The error detection limit is a limit within the ECU . If the error does
7FD5C 0C 523612 12
plausibility error when comparing the torques not disappear, replace the ECU .
Travel limitation diagnosis restricted by level 2 The error detection limit is a limit within the ECU . If the error does
7FD5C 0C 523612 12
ECU surveillance not disappear, replace the ECU .
Travel limitation diagnosis restricted by level 2 The error detection limit is a limit within the ECU . If the error does
7FD5C 0C 523612 12
ECU surveillance not disappear, replace the ECU .
Path limitation diagnosis restricted by level 2 The error detection limit is a limit within the ECU . If the error does
7FD5C 0C 523612 12
ECU surveillance . not disappear, replace the ECU .
Fault control diagnosis to report active WDA
The error detection limit is a limit within the ECU . Reset the
7FD5C 0C 523612 12 because of query/response communication
software .
errors
Error in active ABE report as a result of The error detection limit is a limit within the ECU . Reset the
7FD5C 0C 523612 12
undervoltage detection software .
Error in active ABE report as a result of The error detection limit is a limit within the ECU . Reset the
7FD5C 0C 523612 12
overvoltage detection software .
Fault control diagnosis to report active WDA/ The error detection limit is a limit within the ECU . Reset the
7FD5C 0C 523612 12
ABE for unknown reason software .
The error detection limit is a limit within the ECU . Reflash the ECU .
7FD5C 0C 523612 12 ECU software internal error
If the error persists, replace the ECU .
The error detection limit is a limit within the ECU . Check if there
are other errors that are still active, and repair them Check all
Engine starter, consistency error for the starting of the starting conditions required on the engine, for example
7FD5C 0C 523612 12
conditions 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 .
7FD5C 0E 523612 14 Softwarereset CPU SWReset_0 The error detection limit is a limit within the ECU .
7FD5C 0E 523612 14 Softwarereset CPU SWReset_1 The error detection limit is a limit within the ECU .
The error detection limit is a limit within the ECU . If possible,
7FD5C 0E 523612 14 Softwarereset CPU SWReset_2
perform a software reset . Replace the ECU .
The error detection limit is a limit within the ECU . (A) check for
Device for measuring pressure on the rail, leaks (B) check the pressure on the main diesel circuit (C) Replace
7FD5D 00 523613 0
positive deviation on the speed limiter 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 . (A) check for
Device for measuring pressure on the rail,

80
leaks (B) check the pressure on the main diesel circuit (C) Replace
7FD5D 00 523613 0 pressure drop on the rail . Maximum positive
the components, check the sensor and replace it if necessary,
pressure deviation on the rail exceeded .
check the diesel circuit and repair it if necessary
Device for measuring pressure on the rail The error detection limit is a limit within the ECU . (A) check the
Maximum positive pressure deviation on back-pressure (B) check that the injector is working correctly
7FD5D 00 523613 0
the rail exceeded on the measuring device using SerDia (C) Replace the components if necessary (measuring
(RailMeUn1) . device, injector)
The error detection limit is a limit within the ECU . (A) check the
Device for measuring pressure on the rail,
back-pressure (B) check that the injector is working correctly
7FD5D 00 523613 0 pressure deviation on the rail (RailMeUn2) . Leak
using SerDia (C) Replace the components if necessary (measuring
detected on the rail system (RailMeUn10) .
device, injector)
Device for measuring pressure on the rail, (A) check the back-pressure (B) check the overpressure valve and
7FD5D 00 523613 0
maximum pressure on the rail exceeded . the measuring device . (C) Replace the components if necessary
Device for measuring pressure on the The error detection limit is a limit within the ECU . (A) check the
rail, minimum pressure value on the rail back-pressure (B) check that the injector is working correctly
7FD5D 01 523613 1
exceeded Negative deviation on rail pressure using SerDia (C) Replace the components if necessary (measuring
(RailMeUn22) . device, injector)
Device for measuring pressure on the rail, The error detection limit is a limit within the ECU . (A) check
7FD5D 02 523613 2 setting point for the measuring device in forced the back-pressure (B) check the overpressure valve and the
mode inconsistent . measuring device (C) Replace the components if necessary
The error detection limit is a limit within the ECU . Check the wiring
Measuring device (on diesel circuits), battery
7FD5F 03 523615 3 harness and the measuring device, and repair them or replace
short circuit
them if necessary .
The error detection limit is a limit within the ECU . Check the wiring
Measuring device (on diesel circuits), battery
7FD5F 03 523615 3 harness and the measuring device, and repair them or replace
short circuit
them if necessary .

(05/25/2016) 80-08-M257EN
 36 ELECTRICAL TROUBLESHOOTING

Engine Control Unit

Hexadecimal Decimal
PROBLEMS ACTION
SPN FMI SPN FMI
The error detection limit is a limit within the ECU . Check the wiring
Measuring device (on diesel circuits),
7FD5F 04 523615 4 harness and the measuring device, and repair them or replace
grounding short circuit
them if necessary .
The error detection limit is a limit within the ECU . Check the wiring
Measuring device (on diesel circuits),
7FD5F 04 523615 4 harness and the measuring device, and repair them or replace
grounding short circuit
them if necessary .
The error detection limit is a limit within the ECU . Check the wiring
Measuring device (on diesel circuits), circuit
7FD5F 05 523615 5 harness and the measuring device, and repair them or replace
open
them if necessary .
The error detection limit is a limit within the ECU . Check the wiring
harness and the measuring device, and repair them or replace
Measuring device (on diesel circuits); excessive
them if necessary . Check that the measuring device is working
7FD5F 0C 523615 12 temperature on the power circuit; battery short
correctly and replace it if necessary . Check the temperature on
circuit
the measuring deice and modify its installation in the event of
overheating .
Error on the urea pump pressure sensor above
7FD70 03 523632 3 Check the wiring Check the urea supply module pressure sensor
the normal range
Urea pump pressure sensor error; Physical
7FD70 04 523632 4 Check the wiring Check the urea supply module pressure sensor
signal value below the normal range
7FD70 0B 523632 11 Pump engine unavailable The error detection limit is a limit within the ECU .
The error detection limit is a limit within the ECU . Check the
Engine stop request originating from the memory errors for additional error codes in order to determine the
7FDB2 0B 523698 11
supervision and control function initial cause . Depending on the additional errors, look for other
information in the section entitled "Actions for repairing the error" .
7FDB8 0C 523704 12 Time exceeded error on CAN-messages Check the wiring harness and the client’s CAN nodes .
The error detection limit is a limit within the ECU . Check the wiring
7FDC6 03 523718 3 SCR main relay; battery short circuit
Check the main SCR relay
The error detection limit is a limit within the ECU . Check the wiring
7FDC6 04 523718 4 SCR main relay; ground short circuit
Check the main SCR relay
The error detection limit is a limit within the ECU . Test the
Main relay of the primary side pressure circuit
7FDC6 05 523718 5 main relay of the SCR Check the wiring and replace the relay if
SCR; circuit open
necessary
The error detection limit is a limit within the ECU . Check the
SCR-DEF heating relay main module; battery
7FDC7 03 523719 3 wiring Check the connections, replace the power supply module
short circuit
if necessary
The error detection limit is a limit within the ECU . Check the
SCR-DEF heating main module; ground short
7FDC7 04 523719 4 wiring Check the connections, replace the power supply module
circuit
if necessary
The error detection limit is a limit within the ECU . Check the
7FDC7 05 523719 5 SCR-DEF heating relay main module open wiring Check the connections, replace the power supply module
if necessary
If the duty cycle of the SCR supply module heating is outside the
80

DEF supply module heating temperature; duty

7FDC8 08 523720 8 default value zone check the supply module and replace it if
cycle in invalid mode .
necessary . Check the wiring .
If the duty cycle of the SCR supply module heating is inside the
DEF supply module heating temperature; duty
7FDC8 08 523720 8 validity range, check the supply module and replace it if necessary .
cycle in non-valid mode .
Check the wiring .
DEF supply module temperature; duty cycle Check the supply module and replace it if necessary . Check the
7FDC9 08 523721 8
non-valid mode . 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
7FDC9 08 523721 8 <= SCR_rSMTVldMax_C), OR in a default value zone (SCR_
non-valid mode .
rSMFailMin_C <=SCR_rSMT <= SCR_rSMFailMax_C), check the
supply module and replace it if necessary . Check the wiring .
The error detection limit is a limit within the ECU . No load
Temperature measurement on the urea supply
7FDC9 0B 523721 11 shedding possible during the current duty cycle check the supply
module unavailable .
module and replace it if necessary . Check the wiring .
The duration of reception of the signal PWM SCR is within the range of values
PWM signal of the DEF supply module; time
7FDCA 08 523722 8 specified, from 150 ms to 250 ms Check the supply module and replace it if
outside validity limits .
necessary Check the wiring .
The error detection limit is a limit within the ECU . If a signal followed by
Fault detected on the PWM signal of the DEF temperature signal information is received and if a temperature signal
7FDCA 08 523722 8
supply module . for both pieces of information is received one after the other . Check the
supply module and replace it if necessary . Check the wiring .
7FDF6 09 523766 9 Time exceeded error on CAN-message No detailed info
7FDF7 09 523767 9 Time exceeded error on CAN-message No detailed info
7FDF8 09 523768 9 Time exceeded error on CAN-message Active No detailed info
7FDF9 09 523769 9 Time exceeded error on CAN-message Passive No detailed info
80-08-M257EN (05/25/2016)
 ELECTRICAL TROUBLESHOOTING 37

Engine Control Unit

Hexadecimal Decimal
PROBLEMS ACTION
SPN FMI SPN FMI
The error detection limit is a limit within the ECU . Check the
connection of the CAN Bus (programming of the Bus, polarity,
7FE00 09 523776 9 Time exceeded error on CAN-message active
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
7FE01 09 523777 9 Time exceeded error on CAN-message setpoint
the reception protocol, check the whole range of CAN functions,
check the actuators .
Check the connection of the CAN Bus (programming of the Bus,
No engine braking Time exceeded error on polarity, short circuits, power supply circuit interruptions), test
7FE02 09 523778 9
CAN- the 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
7FE03 09 523779 9 Passive time exceeded error on CAN-message
the reception protocol, check the whole range of CAN functions,
check the actuators .
The error detection limit is a limit within the ECU . Check the
Check if there is an IMA code missing from
7FE77 0D 523895 13 adjustment value of the injector (IMA) . This can be checked using
injector 1 (following the firing order) .
SERDIA .
The error detection limit is a limit within the ECU . Check the set of
Check if there is an IMA code missing from
7FE78 0D 523896 13 parameters and flash the correct adjustment value for the injector
injector 2 (following the firing order) .
(IMA) . This can be checked using SERDIA .
The error detection limit is a limit within the ECU . Check the
Check if there is an IMA code missing from
7FE79 0D 523897 13 adjustment value of the injector (IMA) . This can be checked using
injector 3 (following the firing order) .
SERDIA .
The error detection limit is a limit within the ECU . Check the
Check if there is an IMA code missing from
7FE7A 0D 523898 13 adjustment value of the injector (IMA) . This can be checked using
injector 4 (following the firing order) .
SERDIA .
The error detection limit is a limit within the ECU . Check the
Check if there is an IMA code missing from
7FE7B 0D 523899 13 adjustment value of the injector (IMA) . This can be checked using
injector 5 (following the firing order) .
SERDIA .
The error detection limit is a limit within the ECU . Check the
Check if there is an IMA code missing from
7FE7C 0D 523900 13 adjustment value of the injector (IMA) . This can be checked using
injector 6 (following the firing order) .
SERDIA .
Error on the gas valve, High voltage, or short The gross voltage value is above the minimum limit . Check the
7FE88 04 523912 4
circuit to power supply source throttle valve .
The error detection limit is a limit within the ECU . Check the wiring
7FE94 04 523924 4 Short circuit on relay of grounding actuator 2 harness and the charge value on the pins A01, K74, K91 and/or
reflash the ECU . If the error persists, replace the ECU .
7FE95 03 523925 3 Short circuit on battery Check the wiring harness and the charge value
The error detection limit is a limit within the ECU . Check the wiring
7FE95 04 523925 4 Short circuit on relay of grounding actuator 3 harness and the charge value on the pins A88, K57 . If the error

80
persists, replace the ECU .
The error detection limit is a limit within the ECU . Check the
The error light indicator is permanently on .
7FE96 04 523926 4 wiring harness and the charge value on the pins A90 . If the error
Short circuit on relay of grounding actuator 4
persists, replace the ECU .
Short circuit on battery: error on the SCR Check the wiring harness and the charge value on the pins: A04,
7FE97 03 523927 3
Heating relay/Valve message . A05
7FE9F 0C 523935 12 Time exceeded error on CAN-messages Check the wiring harness and the client’s CAN nodes .
7FEA0 0C 523936 12 Time exceeded error on CAN-messages Check the wiring harness and the client’s CAN nodes .
7FEA2 09 523938 9 Time exceeded error (BAM to packet) for CAN . Check the NOX sensor and check that it is connected properly .
Broadcast of calibration message for upstream
7FEA3 09 523939 9 Check the NOX sensor and check that it is connected properly .
NOx sensor has failed .
7FEA4 09 523940 9 Time exceeded error on CAN Check the NOX sensor and check that it is connected properly .
Check the downstream NOX sensor and check that it is connected
7FEA5 09 523941 9 Time exceeded error (BAM to packet) on CAN
properly .
Calibration message 1: message 1 of NOx Check the downstream NOX sensor and check that it is connected
7FEA6 09 523942 9
sensor after the catalytic converter has failed . properly .
Time exceeded error (PCK2PCK) on CAN- Check the downstream NOX sensor and check that it is connected
7FEA7 09 523943 9
Receive-Frame AT1OGCVol2 . properly .
EGR valve blocked open . Fault on the actuator of the EGR valve
Fault with the EGR coolant (check cooling water) . Fault on EGR
High value for EGR coolant temperature
7FEB8 00 523960 0 valve Gas inlet blocked in closed position Exhaust pressure
downstream .
too high Check the Nox sensor upstream of the SCR catalytic
converter Fault on venturi DP (differential pressure) sensor .

(05/25/2016) 80-08-M257EN
 38 ELECTRICAL TROUBLESHOOTING

Engine Control Unit

Hexadecimal Decimal
PROBLEMS ACTION
SPN FMI SPN FMI
EGR valve blocked open . Fault on the actuator of the EGR valve
Fault with the EGR coolant (check cooling water) . Fault on EGR
Low value for EGR coolant temperature
7FEB8 01 523960 1 valve Gas inlet blocked in closed position Exhaust pressure
downstream .
too high Check the Nox sensor upstream of the SCR catalytic
converter Fault on venturi DP (differential pressure) sensor .
Check wiring, alternator and wires and repair, or replace if
7FECE 00 523982 0 High battery voltage
necessary .
Check wiring, alternator and wires and repair, or replace if
7FECE 01 523982 1 Low battery voltage
necessary .
The error detection limit is a limit within the ECU . Check the
UB6; battery short circuit, error on actuator
7FED0 03 523984 3 wiring, the components and the ECU . Check the wiring, the
relay
components and the ECU .
The error detection limit is a limit within the ECU . Check the
7FED2 04 523986 4 SCR heating relay; ground short circuit
wiring, the components and the ECU .
UB6; ground short circuit, error on actuator The error detection limit is a limit within the ECU . Check the
7FED3 04 523987 4
relay wiring, the components and the ECU .
7FF12 0B 524050 11 CAN; not used not used
7FF13 0B 524051 11 CAN; not used not used
The error detection limit is a limit within the ECU . Check if the
Diesel supply pump, inadequate supply
7FF19 02 524057 2 pressure is too low on the diesel circuit (diesel supply pump, relay,
pressure
fuse, wiring, sensor), and repair them or replace them if necessary .
7FF1F 03 524063 3 Main SCR relay; battery 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
The main SCR relay on the reheating valve,
7FF1F 04 524063 4 to the control unit pin . If the error has disappeared, you must
ground short circuit .
check the wiring via the relay, and of course the reheating cables
and relays too .
7FF1F 05 524063 5 SCR reheating return circuit; circuit open Check the wiring and the components
7FF1F 05 524063 5 Main SCR relay could be not connected Check the wiring and the components
7FF1F 05 524063 5 Pressurized SCR reheating circuit; circuit open Check the wiring and the components
The main relay of the suction line is not
7FF1F 05 524063 5 Check the wiring and the components
connected
7FF1F 05 524063 5 SCR reheating supply module; circuit open Check the wiring and the components
7FF1F 05 524063 5 SCR reheating tank; circuit open Check the wiring and the components
Check: the environment temperature sensor the
7FF1F 0C 524063 12 DEF supply module, defrost time too long temperature sensor of the SCR supply module electrical heating of
the SCR supply module
7FF1F 0C 524063 12 DEF tank, defrost time too long Check the wiring and the components .
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
80

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
Pressure sensor upstream of the SCR-CAT,
7FF21 00 524065 0 connected to the vehicle frame => check that the sensor is free
pressure above the physical limit
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

80-08-M257EN (05/25/2016)
 ELECTRICAL TROUBLESHOOTING 39

Engine Control Unit

Hexadecimal Decimal
PROBLEMS ACTION
SPN FMI SPN FMI
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
Pressure sensor upstream of the SCR-CAT, of the pressure sensor upstream of the SCR catalytic converter
7FF21 01 524065 1
pressure below the normal low limit 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
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
Error on pressure sensor upstream of the SCR- outside environment . Is there water in the sensor? Is the sensor
7FF21 02 524065 2
CAT 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)
Check the pressure sensor wiring upstream of the SCR catalytic
Pressure sensor upstream of the SCR-CAT; converter . Check the pressure sensor upstream of the SCR catalytic
7FF21 03 524065 3
battery short circuit or circuit open converter . Replace the pressure sensor upstream of the SCR
catalytic converter
Check the pressure sensor wiring upstream of the SCR catalytic
Pressure sensor upstream of the SCR-CAT; converter . Check the pressure sensor upstream of the SCR catalytic
7FF21 04 524065 4
ground short circuit converter . Replace the pressure sensor upstream of the SCR
catalytic converter
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
DEF supply module, reheating temperature running? Check the wiring of the supply module Compare SCR_
7FF23 00 524067 0
above the normal upper limit 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
Compare SCR_tSMT with SCR_tSMHtrT . Are the two values
the same? Check the temperature of the urea tank (SCR_

80
tAdapUTnkT) . If it is very hot (> 70 °C), does reheating of the
urea tank operate continuously? Does the pump no longer stop
DEF supply module, reheating temperature running? Check the wiring of the supply module Compare SCR_
7FF23 00 524067 0
above the normal upper limit 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
DEF supply module, reheating temperature
7FF23 01 524067 1 module reheating module Replace the urea pump unit Fault on
below the normal lower limit
the supply module reheating temperature sensor Fault on the
supply module
Check if the ambient temperature EnvT_t is < the limit . Compare
SCR_tSMT with SCR_tSMHtrT Check the wiring of the supply
DEF supply module, reheating temperature
7FF23 01 524067 1 module reheating module Replace the urea pump unit Fault on
above the normal upper limit
the supply module reheating temperature sensor Fault on the
supply module
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
7FF23 02 524067 2 DEF supply module temperature error
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

(05/25/2016) 80-08-M257EN
 40 ELECTRICAL TROUBLESHOOTING

Engine Control Unit

Hexadecimal Decimal
PROBLEMS ACTION
SPN FMI SPN FMI
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
7FF23 02 524067 2 DEF supply module temperature error
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
The error detection limit is a limit within the ECU . Check the NOx
sensor downstream of the SCR catalytic converter: does it contain
NOx sensor downstream of the SCR-CAT, water? Shake the sensor after disassembling it => if there is water
7FF2A 09 524074 9
internal sensor open inside, replace the sensor . 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
NOx sensor downstream of the SCR-CAT,
7FF2B 0B 524075 11 inside, replace the sensor . Check the sensor assembly position,
internal sensor short circuit
and try to assess if water 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
NOx sensor downstream of the SCR-CAT, water? Shake the sensor after disassembling it => if there is water
7FF2C 09 524076 9
internal sensor open inside, replace the sensor . 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
NOx sensor upstream of the SCR-CAT, internal water? Shake the sensor after disassembling it => if there is water
7FF2D 0B 524077 11
sensor short circuit inside, replace the sensor . Check the sensor assembly position,
and try to assess if water 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
Nox sensor downstream of the SCR-CAT,
7FF2E 09 524078 9 values must be almost identical Check the CANBus of the NOx
lambda value above the normal high limit
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
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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? If the lambda
Nox sensor downstream of the SCR-CAT, value measured upstream of the SCR is greater (ComRxSCR_
7FF2F 09 524079 9
lambda value below the normal low limit 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
7FF30 09 524080 9
value above the normal high limit almost 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

80-08-M257EN (05/25/2016)
 ELECTRICAL TROUBLESHOOTING 41

Engine Control Unit

Hexadecimal Decimal
PROBLEMS ACTION
SPN FMI SPN FMI
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? Check the CANBus of the
Nox sensor upstream of the SCR-CAT, lambda
7FF31 09 524081 9 NOx sensor upstream of the SCR catalytic converter Check the
value below the normal low limit
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 Check the NOx sensor downstream of the SCR
Nox sensor downstream of the SCR-CAT,
7FF33 09 524083 9 catalytic converter wiring Check the NOx sensor downstream
lambda value below the minimum value
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 Check the NOx sensor upstream of the SCR
Nox sensor upstream of the SCR-CAT, lambda
7FF35 09 524085 9 catalytic converter wiring Check the NOx sensor upstream of the
value below the normal low limit
SCR catalytic converter itself Replace the NOx sensor upstream of
the SCR catalytic converter
7FF44 09 524100 9 Time exceeded error on CAN-message . Check the wiring and the components .
The error detection limit is a limit within the ECU . Check CANBUS
7FF48 09 524104 9 Time exceeded error on CAN-message . EAT Control Receive Message, PGN65348 . CM1 Module Customer
Receive Message .
Check the wiring of the CAN Bus (programming of the Bus,
7FF59 09 524121 9 Time exceeded error on CAN-message 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,
7FF5D 09 524125 9 Time exceeded error on CAN-message polarity, short circuits, power supply interruptions), test the
reception protocol, check the CAN functional range .
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
7FF6D 07 524141 7 DEF dosing valve, dosing valve blocked
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 .
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_
7FF73 07 524147 7 SCR system, reversible valve blocked 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

80
error is corrected each time, after the empty status (64) of the SCR
system has finished correctly => with a debounce time of 30 s . If
the error persists, change the supply module .
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? Has the DFC already
SCR system, generation of pressure towards the
7FF73 0D 524147 13 been checked and repaired? If none of this has given results at
top is not possible
this stage: 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)
Check the electrical connections on the urea quality sensor Check
7FF78 02 524152 2 Urea quality sensor; message on the CAN the engine CAN bus Check the urea quality sensor itself change
the urea quality sensor

(05/25/2016) 80-08-M257EN
 42 ELECTRICAL TROUBLESHOOTING

Engine Control Unit

Hexadecimal Decimal
PROBLEMS ACTION
SPN FMI SPN FMI
Check the electrical connections of the equipment suction sensor
Level and temperature of the urea tank on the (level and temperature sensor built into the tank) Check the
7FF79 02 524153 2
CAN bus, time exceeded message on the CAN engine CAN bus Check the level sensor itself Change the suction
unit
Check the wiring of the CAN Bus (programming of the Bus,
polarity, short circuits, power supply interruptions), test the
7FF7C 09 524156 9 Time exceeded error on CAN-message .
reception protocol, check the CAN functional range . Replace the
wheel speed sensor
- Check the DEF level in the tank; this should be higher than 12% .
SCR-CAT, Nox emissions higher than the - Check the quality of the DEF ComRxSCR_rAdBlu, which should
7FF8F 00 524175 0
maximum limit permitted 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 t
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 .
SCR system, DEF suction circuit clogged or Does the urea pressure increase? Have all of the errors already
7FF91 07 524177 7
blocked 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
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
SCR system, DEF pressure outside of limit
7FF92 07 524178 7 been dealt with? If nothing has got to the bottom of the problem
values
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
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DEF pump sensor

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
7FF9E 0E 524190 14 Limitation level 1 active 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 .
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
7FF9F 0E 524191 14 Limitation level 2 active
security level limit . Check the quality of the DEF in the tank . Check
if there are any other falsification or fault hardware errors

80-08-M257EN (05/25/2016)
 ELECTRICAL TROUBLESHOOTING 43

Engine Control Unit

Hexadecimal Decimal
PROBLEMS ACTION
SPN FMI SPN FMI
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
The stop time in regeneration mode exceeds
level allows: Put the engine in established speed and check the
the long limit threshold . Vehicle was in stop
7FFA1 08 524193 8 temperature reached upstream and downstream of the DOC: T
mode for too long or too often . Change the oil
upstream of the DOC in the region of 480-550 °C? Downstream of
and reset the counter .
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
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
The stop time in regeneration mode exceeds
level allows: Put the engine in established speed and check the
the short limit . Vehicle was in a short time lapse
7FFA2 08 524194 8 temperature reached upstream and downstream of the DOC: T
in stop mode for too long or too often . Change
upstream of the DOC in the region of 480-550 °C? Downstream of
the oil and reset the counter .
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

80
its air circuits

(05/25/2016) 80-08-M257EN
 44 ELECTRICAL TROUBLESHOOTING

Engine Control Unit

Hexadecimal Decimal
PROBLEMS ACTION
SPN FMI SPN FMI
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:
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 <
Stoppage request caused by crystallization
7FFA3 0E 524195 14 225 °C: ComRxSCR_rNOxUs = ComRxSCR_rNOxDs Clean the urea
being ignored for too long
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
Reduction in power caused by post-treatment
7FFA6 0B 524198 11
system component failure (master ECU)
Reduction in power caused by attempted
7FFA7 0B 524199 11
falsification on the SCR system (master ECU)
Reduction in power caused by too small a
7FFA8 0B 524200 11
quantity of DEF (master ECU)
7FFA9 0B 524201 11 DEF level error (master ECU)
7FFAA 0B 524202 11 DEF temperature error (master ECU)
7FFAB 0B 524203 11 DEF level error (master ECU)
7FFAC 0B 524204 11 DEF system bleed error (master ECU)
7FFAD 0B 524205 11 SCR system shutdown (master ECU)
7FFAE 0B 524206 11 DEF injection deactivation (master ECU)
7FFAF 0B 524207 11 Regeneration inhibition (master ECU)
7FFB0 0B 524208 11 Power reduction level 1 (master ECU)
80

7FFB1 0B 524209 11 Power reduction level 2 (master ECU)

7FFB2 0B 524210 11 DEF concentration fault (master ECU)
7FFB3 0B 524211 11 DEF quality error (master ECU)
7FFB4 0B 524212 11 DEF quality sensor error (master ECU)
7FFB5 0B 524213 11 DEF temperature sensor error (master ECU)
Reduction in power caused by post-treatment
7FFC6 0B 524230 11
system component failure (slave ECU)
Reduction in power caused by attempted
7FFC7 0B 524231 11
falsification on the SCR system (slave ECU)
Power reduction following poor DEF quality
7FFC8 0B 524232 11
(slave ECU)
7FFC9 0B 524233 11 DEF level error (slave ECU)
7FFCA 0B 524234 11 DEF temperature error (slave ECU)
7FFCB 0B 524235 11 DEF level error (slave ECU)
7FFCC 0B 524236 11 SCR system bleed error (slave ECU)
7FFCD 0B 524237 11 SCR system stop error (slave ECU)
7FFCE 0B 524238 11 DEF injection deactivation (slave ECU)
7FFCF 0B 524239 11 Regeneration inhibition (slave ECU)
7FFD0 0B 524240 11 Power reduction level 1 (slave ECU)
7FFD1 0B 524241 11 Power reduction level 2 (slave ECU)
7FFD2 0B 524242 11 DEF concentration error (slave ECU)
7FFD3 0B 524243 11 DEF quality error (slave ECU)
7FFD4 0B 524244 11 DEF quality sensor error (slave ECU)
80-08-M257EN (05/25/2016)
 ELECTRICAL TROUBLESHOOTING 45

Engine Control Unit

Hexadecimal Decimal
PROBLEMS ACTION
SPN FMI SPN FMI
7FFD5 0B 524245 11 DEF temperature sensor error (slave ECU)

80

(05/25/2016) 80-08-M257EN
 46 ELECTRICAL TROUBLESHOOTING
80

80-08-M257EN (05/25/2016)
 ELECTRICAL SPECIFIC TOOLING

pages

DIAGNOSTIC TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– VERSION 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– VERSION 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
BREAKOUT BOXES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ELECTROVALVE ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

80

(03/08/2016) 80-09-M257EN
 2 ELECTRICAL SPECIFIC TOOLING

DIAGNOSTIC TOOLS

VERSION 1

DIAGNOSTIC CASE
80

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

2 - Styli (set of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745368
3 - VCI (Vehicle Communication Interface / PAD) . . . . . . . . . . . . . . . . . . . . . . . . More supplied
4 - OBD Diag . cable Manitou . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745245
5 - VCI portable cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745244
6 - Manitou RC2/RC4 Diag . Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745246
7 - Battery LI-ION 7 .4V / 9 .6AH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745367
8 - CE standard mains lead L: 3 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745247
9 - Diag Supply Unit 3G 60W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745251
10 - Cigarette lighter power supply cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745240
11 - Black battery clip cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745242
12 - Red battery clip cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745241
13 - Power supply cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745243
14 - Reception station (battery charging) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745236
15 - Workshop area (trolley + station set) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . More supplied

80-09-M257EN (03/08/2016)
 ELECTRICAL SPECIFIC TOOLING 3

ADAPTATION KIT FOR ST3B ENGINES

CONNECTION TO TRUCK

CASE No. 1: MACHINE DIAGNOSTIC

PAD

VCI

Note: Cable P/N 745245 enables diagnostics to be carried out on the entire machine except for the engine.

CASE No. 2: ST3B ENGINE DIAGNOSTIC

PAD

EDL
USB

Note: Case P/N 894942 can be used to diagnose the engine, e ENGINE ADAPTATION BOX.

80

(03/08/2016) 80-09-M257EN
 4 ELECTRICAL SPECIFIC TOOLING

VERSION 2

DIAGNOSTIC CASE
80

Diagnostic case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .947349

Diagnostic case (Russia specific) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .947350

Consisting of:
1 - Tablet (with accessories and cables) . . . . . . . . . . . . . . . . 895845 / 947351 (Russia specific)
2 - Styli . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947208
3 - Stylus strap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947355
4 - VCI (Vehicle Communication Interface / PAD) (with USB cable and OBD) . . . . . 895986
5 - OBD Diag . cable Manitou . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947201
6 - USB cable/Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947202
7 - Battery (6 cells: 8h) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947206
8 - Mains power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947353
9 - Transport case (not shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947345

Sold separately:
10 - Docking station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947354
11 - Legacy Diag . cable Manitou . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947204
12 - Battery (9 cells: 17h) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947207
80-09-M257EN (03/08/2016)
 ELECTRICAL SPECIFIC TOOLING 5

CONNECTION TO TRUCK

CASE 1

PAD
VCI

Note: Cable P/N 947201 enables diagnostics to be carried out on the entire machine.

PAD

EDL
USB

Note: Case P/N 894942 can be used to diagnose the engine, e ENGINE ADAPTATION BOX.

80
2

1
3

Adaptation kit for engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .894942

Consisting of:
1 - EDL communication box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 894937
2 - OBD electrical cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 894940
3 - USB electrical cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 894938
(03/08/2016) 80-09-M257EN
 6 ELECTRICAL SPECIFIC TOOLING

BREAKOUT BOXES

Breakout box kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 785503

Consisting of:

1 - 1 breakout box (DT connectors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .785504

2 - 1 breakout box (DTM connectors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .785505

ELECTROVALVE ADAPTER
80

Solenoid adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .662196

80-09-M257EN (03/08/2016)
 DRIVER’S CAB

- DRIVER’S CAB REMOVAL

- DRIVER’S CAB REFIT

85
 DRIVER’S CAB REMOVAL

pages

ELECTRIC WINDOW AND ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

–– COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– ELECTRIC WINDOW AND ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REMOVE THE LOWER DASHBOARD LINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

85

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 2 DRIVER’S CAB REMOVAL

ELECTRIC WINDOW AND ENGINE REMOVAL

COMPONENT LOCATION

A
85

A - Electric window and engine

PREPARATION AND SAFETY INSTRUCTIONS

• Stabilize the machine on level ground.

85-06-M257EN (28/09/2018)
 DRIVER’S CAB REMOVAL 3

ELECTRIC WINDOW AND ENGINE REMOVAL

1

2 2 Remove the switch (Item 1).

Remove the two door handle screw covers (Item 2), then remove
4 the two exposed screws and the two screws at the bottom of
the door (Item 3).

3 Unclip and remove the door trim (Item 4).

3

Remove the plastic film (Item 5).

Remove the four screws (Item 6) from the bracket (window +

6 6 winder) (Item 7).

6
7

If the window is down, remove the roller from its rail. Then
rotate the assembly so that the bottom is facing left, in order
to access the connector.
8

If the window is up, shift the roll towards the back of the rack and
pinion engine assembly area, in order to access the connector.

Disconnect the connector (Item 8).

85

Remove the whole rack and pinion engine from the door by
lifting it upwards.

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 4 DRIVER’S CAB REMOVAL

REMOVE THE LOWER DASHBOARD LINING

1 - Remove the floor mat (1) inside the cabin .

2
2 - Remove the screws (1) .

3 - Remove the lower dashboard lining (2) .

1

1
85

85-06-M257EN (28/09/2018)
 DRIVER'S CAB REFIT

pages

CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– LOCATION OF COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– MOUNTING THE CAB ON SILENT BLOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– ELECTRICAL CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
–– HYDRAULIC CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

85

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 2 DRIVER'S CAB REFIT

CAB

LOCATION OF COMPONENTS

B
E

C
B

Key:

A - Cab
B - Front silent blocks
C - Rear silent blocks
D - Steering selector
85

E - Steering pump
F - Master cylinder

Specific tooling:

• Cab lifting system

• Cab weight = about 500 kg

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 DRIVER'S CAB REFIT 3

MOUNTING THE CAB ON SILENT BLOCKS

A

Position the lifting system (Item 1) on the cab " ".

Important. The space to position the cab is limited.

Lift the cab up and place it on the frame.

Watch out for the gear lever hole (Item 2) when installing the cab.

2
85
Fit and center the front silent blocks "B".

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 4 DRIVER'S CAB REFIT

Fit and center the rear silent blocks "C" on the frame (Item 3).

C
C

Insert the screws (Item 4) and washers (Item 5).

Using a bar (Item 6) positioned in the hole that is common to the

6
cab and the frame, form a lever to facilitate insertion of 2 screws.
85

Tighten the silent block screws ("B" & "C") as per the specified
torque.

Tightening torque:

- B: 140 N.m +/- 10%

- C: 140 N.m +/- 10%
B

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 DRIVER'S CAB REFIT 5

ELECTRICAL CONNECTION

Ground point between the cab and the frame (Item 1).

The ground point of the cab harness (Item 2).

4 3

Connect the electrical connections (Item 3) located around the

wiring unit then screw the housing (Item 4) on the cab.

4
85

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 6 DRIVER'S CAB REFIT

HYDRAULIC CONNECTION

Connect the hydraulic hoses to the steering selector "D".

D
T
"T": Towards the front axle assembly, right side
B A "A": Towards the rear axle assembly, left side
P "B": Towards the rear axle assembly, right side
"P": Towards the steering pump "E" (Via ‘R’)

Connect the hydraulic hoses to the steering pump "E".

T
E
L P "Ls": Towards the master cylinder (Via ‘L1’)
R "T": Towards the oil tank
"P": Towards the hydraulic pump (Via ‘CF’)
LS
Towards the feed block and accumulator (Via ‘P1’)
"L": Towards the left side front axle assembly
"R": Towards the wheel selection distributor (Via ‘P’)
85

85-07-M257EN (03/08/2016)
 DRIVER'S CAB REFIT 7

Connect the hydraulic hoses to "F".

R
"P" : Towards the feed block and accumulator (Via ‘U2’)
B
"B" : Towards the front and rear disc brakes
F N L.1
"L1": Towards the steering pump "E" (Via ‘Ls’)
L
"L" : Towards the hydraulic pump (Via ‘Ls’)
P
"N" : Towards the hydraulic tank
Towards the feed block and accumulator (Via ‘T’)
"R" : Towards the brake fluid tank

85

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 8 DRIVER'S CAB REFIT
85

85-07-M257EN (03/08/2016)
OPTIONS - ATTACHMENTS

CONTENTS

110 AIR-CONDITIONING OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

110.1 AIR CONDITIONING CHARACTERISTICS AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

110.1.1 DESCRIPTION OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

110.1.2 OPERATING PRINCIPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

110.1.3 EVAPORATOR TEMPERATURE PROBE CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

110.2 AIR-CONDITIONING LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

110.2.1 LOCATION AND TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

110.2.2 HVAC INTERIOR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

110.2.3 HVAC EXTERIOR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

110.2.4 CONDENSER COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

110.3 AIR CONDITIONING CONTROLS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

110.3.1 GENERAL CHECK POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

110.3.2 ASSEMBLY INSTRUCTIONS FOR AIR-CONDITIONING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

110.3.3 SAFETY MEASURES FOR HANDLING R134A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

110.3.4 REFRIGERANT FLUID LOAD FOR THE AIR CONDITIONING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . 11

110.3.5 CONTRÔLER LE CAPTEUR TEMPÉRATURE ÉVAPORATEUR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

110.4 AIR CONDITIONING REMOVAL - REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

110.4.1 AIR-CONDITIONING BELT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

110.4.2 AIR CONDITIONING BELT REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

110.5 AIR CONDITIONING TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

110.5.1 TEMPERATURE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

110.5.2 ABNORMAL NOISE ON A/C SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

110.5.3 UNPLEASANT SMELL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

110
 647583EN
2 OPTIONS - ATTACHMENTS 110 (28/09/2018)
110
647583EN
110 (28/09/2018) OPTIONS - ATTACHMENTS 3

OPTIONS - ATTACHMENTS
110 AIR-CONDITIONING OPTION

110.1 AIR CONDITIONING CHARACTERISTICS AND SPECIFICATIONS

WARNING
Only operators who are certified to handle refrigerant fluids may work on the air conditioning system, otherwise please contact
a specialist air-conditioning company.

110.1.1 DESCRIPTION OF OPERATION

The air-conditioning system reduces the atmospheric pressure in the cab interior by extracting
and dispersing the heat to the exterior.
This heat exchange is possible thanks to the use of a refrigerant fluid, R134a whose properties are to
obtain very low temperature at low pressures by dilating it and inversely high temperatures at average
pressure by compressing it.

The use of the properties of this fluid is done following the closed circuit cycle whose principle is:

Phase 1: compression
The fluid in the gaseous state at low pressure and at low temperature is drawn in and compressed
by the compressor which sends it at high pressure and high temperature to the condenser.

Phase 2: condensation
The fluid passes through the condenser to transmit its heat to the outside of the vehicle, by means
of the fan.
As it passes through the condenser the fluid liquefies while maintaining a high temperature and pressure.
It is then filtered in a drier (or desiccator).

Phase 3: expansion
The fluid enters a pressure reducing valve (or expansion valve) so as to lower its pressure and temperature
considerably while remaining in liquid state.

Phase 4: evaporation
The fluid passes through the evaporator to absorb the cab interior heat and vaporises while maintaining
a low temperature and pressure.
In this way, the cab interior air propelled by the fan motor cools and releases its moisture when in contact
with the evaporator. The condensation of the air is then drained and evacuated to the outside of the
vehicle.

The high and low pressures in the system are monitored by a HP and LP pressure switch attached
directly on the drier filter.
It has the following safety functions:
Complete shutdown of the air-conditioning system if the pressure is lower than 2 bars or greater than
27 bars.
110
 647583EN
4 OPTIONS - ATTACHMENTS 110 (28/09/2018)

110.1.2 OPERATING PRINCIPLE

Electromagnetic
clutch
Alternator
Compressor

Engine

Low pressure High pressure

steam circuit steam circuit

External
air

Axial fan

Condenser

Hot air
discharge
Drier Filter

Binary pressure
Warm air switch
Indicator lamp
Filters
High pressure
Centrifugal fan liquid circuit
(Turbine)
Pressure
reducing valve

Low pressure
liquid circuit
Evaporator

Thermostat
Condensate out
110

Diffusion of
cold air

CAB INTERIOR
647583EN
110 (28/09/2018) OPTIONS - ATTACHMENTS 5

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 on 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 vaporized at the evaporator outlet.

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
110

thermostat and this controls the compressor clutch relay.

 647583EN
6 OPTIONS - ATTACHMENTS 110 (28/09/2018)

110.1.3 EVAPORATOR TEMPERATURE PROBE CHARACTERISTICS

Temperature Resistor Temperature Resistor Temperature Resistor
(°C) (kΩ) ± 10% (°C) (kΩ) ± 10% (°C) (kΩ) ± 10%
-20 47.47 16 7.313 52 1,647
-19 44.80 17 7.041 53 1,587
-18 42.29 18 6.727 54 1,529
-17 39.94 19 6.428 55 1,473
-16 37.14 20 6,144 56 1,420
-15 35.67 21 5,875 57 1,369
-14 33.13 22 5,618 58 1,320
-13 31.90 23 5,374 59 1,273
-12 30.19 24 5,142 60 1.228
-11 28.58 25 4,922 61 1.184
-10 21.06 26 4.712 62 1.143
-9 25.64 27 4,512 63 1.103
-8 24.30 28 4,322 64 1.065
-1 23.03 29 4,140 65 1.028
-6 21.84 30 3.968 66 0.993
-5 20.72 31 3,803 67 0.959
-4 19.66 32 3,646 68 0.926
-3 18.61 33 3,491 69 0.895
-2 17.13 34 3,354 70 0.865
-1 16.84 35 3,218 71 0.836
0 16.00 36 3,088 72 0.808
1 15.21 37 2,964 73 0.781
2 14.46 38 2,846 74 0.756
3 13.15 39 2,733 75 0.731
4 13.09 40 2,625 76 0.707
5 12.46 41 2,522 77 0.684
6 11.86 42 2,424 78 0.662
1 11. 29 43 2,330 79 0.641
8 10.16 44 2,240 80 0,621
9 10.25 45 2,154 81 0,601
10 9.771 46 2.012 82 0,582
11 9.316 47 1,993 83 0,564
12 8.885 48 1,918 84 0,546
13 8.471 49 1,846 85 0,529
14 8.089 50 1,777
15 7.722 51 1,711
110
647583EN
110 (28/09/2018) OPTIONS - ATTACHMENTS 7

110.2 AIR-CONDITIONING LOCATIONS

110.2.1 LOCATION AND TIGHTENING TORQUES

HP connector
15 .4 N .m ± 1 .5
Cooled HP
connector Receiver-drier
15 .4 N .m ± 1 .5

LP connector
24 .4 N .m ± 2 .4
Cooled HP connector
15 .4 N .m ± 1 .5
Condenser

Electronic
condenser fan Evaporator
management
module

LP connector
24 .4 N .m ± 2 .4

Compressor

HP connector
15 .4 N .m ± 1 .5
110
 647583EN
8 OPTIONS - ATTACHMENTS 110 (28/09/2018)

110.2.2 HVAC INTERIOR COMPONENTS

110.2.3 HVAC EXTERIOR COMPONENTS

110
647583EN
110 (28/09/2018) OPTIONS - ATTACHMENTS 9

110.2.4 CONDENSER COMPONENTS

Electronic
condenser fan
management
module

110
 647583EN
10 OPTIONS - ATTACHMENTS 110 (28/09/2018)

110.3 AIR CONDITIONING CONTROLS AND ADJUSTMENTS

110.3.1 GENERAL CHECK POINTS

Before you repair or diagnose the A / C system, perform the following checkpoints:

• Check the positions of all control buttons referring to the user manual.
• Make a visual inspection of the state of the flexible A / C and heating.
• Check that the fins of the cooling condenser are not blocked by obstacles such as insects, leaves or
grass.
• Check that the condenser fans are running and rotating in the correct direction.
• Check the condition and tension of the compressor drive belt and repair if necessary.
• Check that the compressor is running in stop and start cycles.
• Check that the hoses of the evaporator are not bent (closed).
• Check that the heater is turned off in the cold mode position, so that the water valve is completely
closed.
• Check that the HVAC block fan has all operating speeds.
• Check that the air vents open and close completely.
• Check that there is no air leakage between the evaporator and the vents.

Control points of the electrical circuit of the air conditioning in operation:

• Check that the A / C button is pressed (cold demand).

• Check that the A / C button indicator lights up (producing cold).
• Check the signal from the electronic thermostat to the compressor relay.
• Check the voltage at the car harness connector.
• Check the voltage at the electronic module managing condenser fans.
• Check that both condenser fans are working.
• Check the compressor clutch voltage at the condenser connector.
• Check the engagement cycle of the compressor clutch (very audible “click” sound).
• Check the continuity of the clutch protection diode of the compressor.
• Check the clutch and compressor body grounding.

110.3.2 ASSEMBLY INSTRUCTIONS FOR AIR-CONDITIONING CIRCUIT

WARNING
Only operators who are certified to handle refrigerant fluids may work on the air conditioning system, otherwise please contact
a specialist air-conditioning company.

Perform the assembly operations in a dry dust-free location. Lubricate all seals and sealing surfaces with
PAG ISO SP20 oil before assembly.

Add new oil for each replaced or cleaned component, as shown below:
110

Evaporator: 30 cm3 Regulator: 30 cm3 Flexible: 10 cm3 Condenser: 30 cm3

Dehydrating filter: 30 cm3
After complete rinsing of the system, the compressor oil quantity is 160 cm3.

Tighten to the correct torques see: AIR-CONDITIONING COMPONENT LOCATION AND TIGHTENING
TORQUES
647583EN
110 (28/09/2018) OPTIONS - ATTACHMENTS 11

110.3.3 SAFETY MEASURES FOR HANDLING R134A

WARNING
Only operators who are certified to handle refrigerant fluids may work on the air conditioning system, otherwise please contact
a specialist air-conditioning company.

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.

110.3.4 REFRIGERANT FLUID LOAD FOR THE AIR CONDITIONING CIRCUIT

Refrigerant fluid: R134a

Charging equipment: Charging station
Quantity of fluid: 1500 gr ± 50 gr and 245 mL of PAG ISO SP20 oil .

110
 647583EN
12 OPTIONS - ATTACHMENTS 110 (28/09/2018)

Context :
110.3.5
This CONTRÔLER
control LE CAPTEUR
must be performed at a steady TEMPÉRATURE ÉVAPORATEUR
temperature and the engine cold.

Steps :
1-4
1 - Remove the ventilation grille.

2 - Remove the lower lining of the dashboard (6Group 85 - Remove

cabin bottom lining).
1

3 - Disconnect the probe from the block:

– Automatic air conditioning:
• Unclip the connector (1).

1-3
A
– Manual air conditioning:
2 • Disconnect the connector (1).
1
• Open the housing: Torx key (A) to remove it and open the
B
casing with a flat screwdriver in the slot (B).

4 - Remove the filter.

– Automatic air conditioning:
• Remove the module behind the filter to facilitate access to
the radiator.

1-2
5 - Insert a temperature probe into the evaporator (1) as close as
1
possible to the position of the block sensor (2).
6 - Record the measured temperature in ° C.

1-1

2
110
647583EN
110 (28/09/2018) OPTIONS - ATTACHMENTS 13

1-7
7 - Measure the ohmic value of the block temperature sensor

1
– Automatic air conditioning:
• On the pins (1).

1-6

– Manual air conditioning.

• Between the 2 wires on the electronic board (2).

8 - Refer to the table ( 6 EVAPORATOR TEMPERATURE PROBE

CHARACTERISTICS) for correspondence in ° C.
2

9 - Compare the 2 values from step 6 and step 8.

– If the difference between the value read and that of the board
is> 10% then the HVAC block must be changed.
– Otherwise continue the procedure

1-5
10 - Leave the measuring probe in the evaporator.
2 3 11 - Replace the cabin filter and grille.
1
12 - Reconnect the temperature probe of the block.
13 - Start the engine.
14 - Turn on the air conditioning (1) at the coldest (2) and the fan
speed 1 (3).
15 - Close the doors and windows.
16 - Wait 10 minutes for the air conditioning to stabilize at the
coldest (regulation).
4

17 - Check for a few clutch cycles of the compressor that the

measuring probe indicates a temperature in the evaporator
always> 0 ° C (4).
– If the temperature is> 0 ° C and close to 0 ° C, then the air
conditioning is working properly.
– If the temperature is not low enough, then you have to look
for the fault in the air conditioning circuit (hoses, compressor,
expansion valve ...).
– If the temperature is <0 ° C, then the fault must be found in
the electrical circuit outside the HVAC block (relay, harness,
110

clutch ...).
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110.4 AIR CONDITIONING REMOVAL - REFIT

110.4.1 AIR-CONDITIONING BELT REMOVAL

Remove the belt casing (Item 1) and the casing (Item 2)

Loosen the nut (Item 3) and the screw (Item 4) by two or three
1
thread turns to be able to swivel the alternator and release
the alternator belt (Item 5).

Remove the belt (Item 5).

4 5

2
7

110.4.2 AIR CONDITIONING BELT REFIT

Place the belt between the motor (Item 6) and compressor pulleys.
Ensure that it is properly seated in the grooves of each pulley, and that there is no dirt or residue from
the old belt on the pulleys.
Swivel the compressor to tighten the compressor belt (Item 5)
Re-tighten the nut (Item 3) and the screw (Item 4).

Check the belt tension (e 10 - SPECIFIC ENGINE TOOLING).

Cold engine With engine between 40°C and 60°C

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Static tension Strand frequency Static tension Strand frequency

1st tensioning 362.5 N ± 12.5 97.6 Hz ± 1.7 382.5 N ± 13.5 100.2 Hz ± 1.8
Re-tensioning 312.5 N ± 12.5 90.6 Hz ± 1.8 330 N ± 13.5 93.1 Hz ± 1.9
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110.5 AIR CONDITIONING TROUBLESHOOTING

110.5.1 TEMPERATURE TROUBLESHOOTING

Low pressure High pressure
Problem Probable cause
manometer manometer
Hot air infiltration into the appliance or evaporator block.
Normal Normal
Hot water infiltration at the heating water valve position or faulty water valve.
Normal situation if ambient temperature is very low. Obstruction in the HP hose
connected between the compressor and the condenser-filter-evaporator, before
the HP reading point.
Normal or low Low
Check for leaks.
Very low quantity of coolant.
Faulty compressor
Normal situation if the ambient temperature is very high.
Excess coolant load.
Little or no cooling 5 - 35% of condenser obstructed
Air present in the A/C system
Normal or high High Obstruction in the HP hose connected between the compressor and the condenser-
filter-evaporator, after the HP reading point.
Check for leaks.
Compressor belt non-driving.
Compressor clutch not engaged, compressor damaged
Clutch not engaging.
High Normal or low Pressure reducing valve blocked in open position.
Compressor damaged.
Low Normal or high Drier filter saturated with moisture

110.5.2 ABNORMAL NOISE ON A/C SYSTEM

Sometimes, for a variety of reasons, the A/C system may produce an abnormal noise. The following are
possible examples

Causes Problem Solution

1 The belt is worn or slipping. Check belt wear and tension

2 Noise of belt on the pulley. Replace
Check that the clearance between the compressor pulley
3 Electric clutch plate slippage.
and the clutch is 0.3-0.5 mm
Ensure that the bolts are properly tightened and the plate
4 Compressor support plate vibration and resonance.
is correctly positioned.
5 Whistling expansion valve. If the noise persists, replace the valve.

110.5.3 UNPLEASANT SMELL

Under certain conditions, mold and bacteria (normally present in the air) may form on the surface
of the evaporator core, producing an unpleasant smell inside the cab.
• Treat the evaporator with an anti-bacterial product.
• Keep the evaporator clean.
• Switch off the A/C system a few minutes before switching off the lift truck, while leaving the fan
running (this will dry the moisture from the evaporator core which encourages bacteria growth).
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