MR 647792en 2020 01

647792EN (20/01/2020)
MT-X 733 95P ST3A S1

MT-X 1033 ST 100P ST3A S1
REPAIR MANUAL
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DATE OF ISSUE OBSERVATION
30 / 07 / 2019 - 1st ISSUE

20/01/2020 - Partial update : GR00 - GR10 - GR80
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.
GENERAL CHARACTERISTICS AND SAFETY
00
ENGINE
10
TRANSMISSION
20
AXLE
30
BRAKE
40
BOOM
50
HYDRAULIC
70
ELECTRICITY
80
DRIVER’S CAB
85
FRAME - BODY
90
110
OPTIONS - ATTACHMENTS
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INTERACTIVE REPAIR MANUAL

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

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

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

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

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

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

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

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

air-conditioning block.
HMI Human-Machine Interface: dashboard screens.
i.V. Interactive View: 2nd generation MANITOU machine diagnostics software.
JSM Joystick Switch & Move: Control handle serving to perform all telescope
movements, as well as to control machine forward and reverse movements
with one hand.
lat. Latin: signifies a word of Latin origin.
LIN Local Interconnect Network.

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LLMI Longitudinal Load Moment Indicator: displaying machine stability.
LS Low Side: ground side power supply.
LSU Load Sensing Ultra: hydraulic load detection.
m Metre: unit of measurement for length. It is one of the basic International

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

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

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

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

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

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GENERAL, CHARACTERISTICS AND SAFETY
00
CONTENTS
00.1 WORK DURING THE WARRANTY PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
00.2 GENERAL INSTRUCTIONS AND SAFETY NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
00.2.1 FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
00.2.2 SERVICING POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
00.2.3 EXPLANATION OF SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
00.2.4 SERVICING RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
00.3 GENERAL CHARACTERISTICS AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
00.3.1 CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
00.3.2 LUBRICANTS AND FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
00.3.3 DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
00.4 GENERAL LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
00.4.1 LOCATION OF THE NAME AND IDENTIFICATION PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
00.5 GENERAL CONTROL AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
00.5.1 STANDARD TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
00.5.2 METRIC - IMPERIAL UNIT CONVERSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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GENERAL, CHARACTERISTICS AND SAFETY
00.1 WORK DURING THE WARRANTY PERIOD

Please check the warranty period of your equipment before any operations.
The guarantee would no longer be covered if the intervention performed during this period did not
comply with recommendations.
00.2 GENERAL INSTRUCTIONS AND SAFETY NOTICE
00.2.1 FOREWORD
This chapter deals with the general instructions and safety notice during inspection and maintenance
work.
Other instructions and warnings are indicated in each chapter concerned.
In order to reduce accident risks, make sure to:
– Follow the instructions in the truck operating and maintenance manual.

⇒ This manual should be found in all trucks.
– Please follow all safety instructions.
– Use the appropriate tools for any work to be performed.
– Use original Manitou spare parts.
Any non-compliance increases the risk of accidents occurring which may lead to causing grievous bodily
harm and even death.
An efficient, dependable and profitable combination will be formed if the operator follows the safety
manual correctly and the machine is serviced properly.
00.2.2 SERVICING POSITION
Before any intervention:
1 - Place the machine on a flat surface and chock the wheels.

2 - Turn off the engine and remove the ignition key.
3 - Let the machine cool down.
4 - Take all the pressure out of the circuits concerned.
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00
00.2.3 EXPLANATION OF SYMBOLS
The symbols shown below are used to warn of potential hazards as well as to provide useful information
concerning a procedure.
SYMBOLE OBSERVATION
Indicates an imminent hazardous situation which, if not avoided

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

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

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

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

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

to be applied.
1 "OPTION": Indicates the presence of an option.
The manufacturer cannot predict all possible risky situations. Consequently, the safety instructions
given in the manual are not exhaustive.
At any time, as an operator, you must consider, within reason, the possible risk to yourself, to others
or to the lift truck itself when you repair, service or drive it.
Manitou cannot be held responsible for the use of any lifting devices, tools or operating methods other
than those specified.
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00.2.4 SERVICING RULES
Do not carry out any work on the machine unless you have
followed a suitable training course and have the knowledge
required for it.
4 Make sure you have taken into consideration all the indicator
plates on the machine and in the instruction manual.
CAUTION
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.
PRÉCAUTION
Protect electrical components from electrostatic discharge.
Touch a metallic mass with your hands.
1 WARNING
Before carrying out any operation on an electrically powered component,
2
activate the battery cut-off.
CAUTION
Press the battery switch at least 30 seconds after disconnecting the electrical
contact with the ignition key.
WARNING
If the telehandler does not have a battery isolating switch, disconnect the
battery terminals then gather them.
ECU
CAUTION
Before carrying out any welding operations, think of disconnecting computers.
CAUTION
A machine operating in a contaminated environment should be specifically

equipped. Moreover, local safety notices deal with maintenance and repair
work on such machines.
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WARNING
Never step on a part of the machine that has not been designed for it.
WARNING
Never wear clothes, jewelry or objects that could get caught during work and
cause accidents.
Always wear protection glasses, gloves, safety shoes as well as any other
protection required for the work to be carried out.
DANGER
When carrying out maintenance
operations near a mobile object,
make sure it is securitized.
PROTECT THE ENVIRONMENT
When changing, or draining oils or fuel, or any other operation with liquids,
solids, gases that are harmful to the environment, make sure the necessary
precautions are taken to avoid contaminating the environment.
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DANGER
When lifting or shoring a component of the machine, make sure the equipment
used is suitable for at least the load for which it is subjected by the component
and that it meets the national standards for lifting devices.
When using a jack, make sure it is used on a flat, uniform surface, is sturdy
enough to support the load, that its lifting capacity is sufficient and that it is
correctly placed and positioned under the machine.
CAUTION
Make sure no object or tool which could cause an accident is left in the machine.
WARNING
Never control any leaks using a hand.
max.
min.
CAUTION
MAX Never adjust a component to over the maximum capacity indicated by the
manufacturer.
MIN
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00.3 GENERAL CHARACTERISTICS AND SPECIFICATIONS
00.3.1 CHARACTERISTICS
Designation MT-X 733 MT-X 1033
Lift truck weight with standard
6620 kg 7810 kg
attachment
Weight distribution FRONT 3200 kg 4170 kg
per axle with standard
attachments REAR 3420 kg 3640 kg
Traction force (unladen) 5295 daN 6340 daN
00.3.2 LUBRICANTS AND FUEL

Designation Type Quantity
Fuel tank GNR HP (High-Performance Non-Road Diesel): EN590 / ASTM D975 120 ℓ
Engine oil MANITOU Premium oil 15W40 API CJ4 11 ℓ
Cooling system Cooling liquid (protection -35°) 18.5 ℓ
Gearbox MANITOU Automatic transmission oil 16.6 ℓ
Angle gear box MANITOU SAE80W90 Mechanical transmission oil 2.2 ℓ
Hydraulic tank MANITOU ISO VG 46 Hydraulic oil 110 ℓ
Brake system MANITOU Mineral brake fluid 1ℓ
Front axle differential Special MANITOU oil for immersed brakes 8.1 ℓ
Rear axle differential Special MANITOU oil for immersed brakes 8.1 ℓ
Front wheel reduction gear MANITOU SAE 80W90 Mechanical transmission oil 2 x 0.8 ℓ
Rear wheel reduction gear MANITOU SAE 80W90 Mechanical transmission oil 2 x 0.8 ℓ
Lubrication of pins and pivots MANITOU blue multi-purpose lubricant
Boom pad lubrication MANITOU black multi-purpose lubricant
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00.3.3 DIMENSIONS
MT-X 733 95P ST3A S1 ℓ11
d2
h19
h17
h15
a1
a2
a4
m7
m3
m2
ℓ10
a5
d3 y ℓ5
ℓ ℓ3
ℓ1
b4
b9 b10
b1
a2
W
b5
4
Wa a1
W
e
t 2
As
a6
W
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MT-X 1033 100P ST3A S1
ℓ11
d2
d1
h19
h17
h15
a1
a2
a4
m7
m3
m2
ℓ10
a5
d3 y ℓ5
ℓ ℓ3
ℓ1
b4
m5
b10
b9
b7
b1
a2
W
b5
4
Wa a1
W
e
t 2
As
a6
W
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Item Unit Value

MT-X 733 MT-X 1033
ℓ1 mm 5929 6128
ℓ3 mm 4729 4928
ℓ5 mm 725 725
ℓ10 mm 4160 4040
ℓ11 mm 4673 5017
b1 mm 2250 2250
b4 mm 890 890
b7 mm 2210
b9 mm 1846 1846
b10 mm 1846 1846
h15 mm 1650 1717
h17 mm 2300 2300
h19 mm 2500 2500
d1 mm 1130
d2 mm 1138 1602
d3 mm 1194 1513
Ast2 mm 3490 3720
ℓ mm 1200 1200
e mm 1040 1040
s mm 45 45
e1 mm 125 125
Wa1 mm 3763 3662
Wa2 mm 4800 4950
Wa4 mm 3561 3460
Wa6 mm 1310 1230
m2 mm 435 435
m3 mm 435 435
m5 mm 135
m7 mm 435 435
a1 ° 38 40
a2 ° 64 64
a4 ° 12 12
a5 ° 114 115
y mm 2810 2690
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00.4 GENERAL LOCATION
00.4.1 LOCATION OF THE NAME AND IDENTIFICATION PLATE

Key:
1- Manufacturer's plate 6- Front axle plate
2- Rear axle plate 7- Gearbox
3- Air-conditioning compressor 8- Hydraulic pump
4- Engine plate 9- Distributor
5- Angle transmission 10 - Cab plate
MANITOU
10A..........
..........
P0............ 8
38/09
10
3 4
4
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00.5 GENERAL CONTROL AND ADJUSTMENT
00.5.1 STANDARD TIGHTENING TORQUES
b Standard tightening torques

To be used. unless otherwise indicated in the removal or refit operations.
SCREW / NUT ASSEMBLY
- with hexagon head screws without flanges ou cylinder head hexagon socket screws.
- for dry-fitted zinc-plated fasteners and for torque tools having a ± 20 % class C tightening torque
accuracy (equivalent to pneumatic screwdrivers).
1 - NF E 25-030-1 :
Ø x “coarse” pitch Grade 8.8 Grade 10.9 Ø x “fine” pitch Grade 8.8 Grade 10.9
N.m lb-in N.m lb-in N.m lb-in N.m lb-in
M6 x 1 8.2 72.57 12.1 107 - - -
M8 x 1.25 20 177 30 265 M8 x 1 22 195 32 283
M10 x 1.5 40 354 59 522 M10 x 1.25 (x 1) 43 (46) 380 (407) 63 (68) 558 (602)
M12 x 1.75 69 611 102 903 M12 x 1.5 (x 1.25) 74 (78) 655 (690) 108 (115) 956
M14 x 2 111 982 163 1443 M14 x 1.5 123 1088 181 1602
M16 x 2 175 1549 256 2266 M16 x 1.5 190 168 279 2470
M18 x 2.5 240 2124 352 3115 M18 x 1.5 279 2469 410 3629
M20 x 2.5 341 3018 501 4434 M20 x 1.5 391 3460 574 5080
M22 x 2.5 470 4160 691 6116 M22 x 1.5 531 4700 780 6903
M24 x 3 588 5204 864 7647 M24 x 2 659 5833 967 8559
M27 x 3 874 7735 1284 11364 M27 x 2 965 8541 1418 12550
M30 x 3.5 1181 10453 1735 15356 M30 x 2 1351 11957 1984 17560
M33 x 3.5 1614 14285 2371 20985 M33 x 2 1821 16117 2674 23667
b
M36 x 4 2068 18303 3037 26880 - - - - -
For hexagon screws with flanges (NF E 25-030-1) :

Apply an increased torque of +10%.
b Where washers are used. the following coefficient is to be applied (FD E 25-502) :
- Plate : +0% - Spring (or Grower) washer without jaws (W) : +10%
- Smooth tapered washer (CL): +5% - Conical. internal teeth (CDJ-JZC) : +15%.
2 - With marking :
4 5 6 7 8
4T 6T 8T
------------ ------------ ------------
5T
(N.m)
7T
(N.m)
11
(flange : 4.8T) (flange : 6.8T) (flange : 8.8T) (flange : 10.9T) (flange : 11.9T)
Ø x Pitch N.m lb-in N.m lb-in N.m lb-in N.m lb-in N.m lb-in N.m lb-in N.m lb-in
5.4 48 7.8 69 12 106
M6 x 1 6.5 57.5 11 97 (15.5) (137.2) (17.5) (155)
(5.5) (49) (7.5) (66) (12) (106)
13 115 19 168 29 257
M8 x 1.25 16 142 25 221 (38) (336) (42) (372)
(13) (115) (19) (168) (29) (257)
25 221 39 345 61 540
M10 x 1.25 32 283 52 460 (80) (708) (89) (788)
(27) (239) (39) (345) (61) (540)
47 416 72 637 108 956
M12 x 1.25 59 522 95 841 (145) (1283) (160) (1416)
(50) (443) (71) (628) (110) (974)
75 664 108 956 172 1522
M14 x 1.5 91 805 147 1301 (230) (2036) (260) (2301)
(78) (690) (110) (974) (175) (1549)
b
113 1000 172 1522 265 2345
M16 x 1.5 137 1213 226 2000 (360) (3186) (400) (3540)
(120) (1062) (170) (1504) (270) (2390)
use the upper class where spring (or Grower) washers are used.
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00.5.2 METRIC - IMPERIAL UNIT CONVERSION
CONVERSION COEFFICIENTS:
Metric Unit (S.I) Coefficient Imperial Unit US
°C (Celsius degree) x 1.8 + 32 = °F (Fahrenheit degree)
cm3 (centimeter cube) x 0.06102 = cu.in. (cubic inches)
cv (cheval vapeur) x 0.9859 = hp (horsepower)
bar (bar) x 14.5038 = psi (pound-force/square inch)
N/mm² (Newton/millimeter²) x 145.038 = psi (pound-force/square inch)
g (gram) x 0.0353 = oz av (ounce avoirdupois) (oz : lat. onza)
kg (kilogram) x 2.2046 = lb (pound) (lat . libra)
km/h (kilometer per hour) x 0.6214 = mph (miles per hour)
kW (kilowatt) x 1.34048 = hp (horsepower)
ℓ (liter) x 0.2642 = gal US (US gallon)
ℓ (liter) x 1.0567 = qt US (quart US gallon)
m (meter) x 3.2808 = ft (foot)
m (meter) x 39.3701 = in (inch)
mℓ (milliliter) x 0.0338 = fl oz (fluid ounce) (fl : fluid, oz : lat. onza)
mm (millimeter) x 0.03937 = in (inch)
µm (micrometer) x 0.03937 = mil (thousands of an inch)
N (Newton) x 0.2248 = lbf (pound-force) (lb : lat. libra, f : force)
N.m (Newton meter) x 0.7376 = ft-lb (pound-force-foot) (ft : foot, lb : lat. libra)
rad/s (radian/second) x 9.5493 = rpm (revolution per minute)
t (metric ton) x 2204.62 = lb (pound) (lat. libra)
tr/min (tour per minute) x 1 = rpm (revolution per minute)
OTHER UNIT CONVERSIONS:
Unit Coefficient Unit
ft (foot) x 12 = in (inch) (pouce)
lb (pound) (lat. libra) x 16 = oz av (once avoirdupois)
m (meter) x 1000 = mm (millimeter)
mm (millimeter ) x 1000 = µm (micrometer)
t (metric ton) x 1000 = kg (kilogram)
rad (radian) x 57.2958 = ° (angle degree)
bar (bar) x 10 = N/mm² (Newton/millimeter²)
Example :
1 ℓ (liter) corresponds to 0.2642 US gal (US gallon)
1 x 0.2642 = 0.2642
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ENGINE
10
CONTENTS
10.1 ENGINE CHARACTERISTICS AND SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
10.1.1 ELECTRONIC CONTROL MODULE ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
DEFINITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
REAR PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
ELECTRICAL POWER SUPPLY AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
SENSOR AND PROBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
10.1.2 ENGINE EARTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
10.1.3 LOW PRESSURE FUEL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

10.1.4 HIGH PRESSURE FUEL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
10.2 ENGINE CONTROL AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
10.2.1 ENGINE TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
ENGINE SILENTBLOCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
EURO 3 DIESEL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
10.2.2 FUEL GAUGE ADJUSTMENT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
10.2.3 ALTERNATOR/CRANKSHAFT BELT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
ALTERNATOR/CRANKSHAFT DRIVE BELT TENSION ADJUSTMENT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
10.2.4 COOLING CIRCUIT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
FAN PULLEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
FAN BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
647792EN
24 ENGINE 10 - 20/01/2020
10
LINKS TO REPAIR MANUALS:
MANUAL REFERENCE
DESIGNATION
NUMBER
647016 ENGINE 1104D EURO3 (80 TO 100 CV)
647017 ENGINE 1104D EURO3 (120 CV)

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ENGINE
10.1 ENGINE CHARACTERISTICS AND SPECIFICATION
10
10.1.1 ELECTRONIC CONTROL MODULE ECM
DEFINITION
The electronic control module, ECM (1) is the regulator and computer for the fuel circuit. The ECM
receives signals from the sensors to control the engine’s timing and speed.
The electronic circuit is made up of the ECM, sensors on the engine and inputs from the whole of
the machine. The ECM is the computer. The personalization module is the computer software. The
personalization module contains the performance curves.
The performance curves define the following characteristics of the engine:

• Engine power
• Torque curves
• Engine speed (rpm)
• Engine noise
• Smoke and emissions
Module de commande électronique
(ECM)
J1
J2
REAR PLUG
25 26 27 28 29 30 31 32 57 58 59 60 61 62 63 64
7mm
17 18 19 20 21 22 23 24 49 50 51 52 53 54 55 56
9 10 11 12 13 14 15 16 41 42 43 44 45 46 47 48
1 2 3 4 5 6 7 8 33 34 35 36 37 38 39 40
647792EN
10 - 20/01/2020
R4
B24
canale analogique 305 306

1
+ 8
1K 4
ep:45
19 11
- 2
9
canale IVS 6 ep:44
- N
B15
B16
B17
Y32
Y30
Y35
Y33
Y31
5
631
ep:42 + 3
652 653 651 654 655 613
A19
F41
656 657 658 659 660 663

7 8 15 16 43 45 33 54 41 62 22 20 21 46 38 55 48 40 51 47 39 56 35 57 34 58 33 59 8 64 44 17
51 Bat+ Bat+ Bat+ Bat+ +8V val 0V sig +5V phm CAN GNDCAN H CAN L 5V m p air 5V m p comb 5V m p hui m inj 1 m inj 2 m inj 3 m inj 4 m dech
ELECTRICAL POWER SUPPLY AND INSTALLATION
J1
J2
n Bat- Bat- Bat- Bat- Bat-
+ ap cont prech ent sort ent stop war prech t∞ eau alim t∞ air v mot 8V vit pompe inj sol m J1939+ J1939- cdl- cdl+ batt- batt+
M1
1 2 3 9 10 40 57 44 35 38 60 59 63 43 37 42 52 10 53 25 26 24 23 20 21 45 18
19
637 638 639 640 641 646 628 650 643 647 615 614 642
G1 T T WA
N N N C C
WB
P D ECM
ep:43
636 P 573 6 572
WC
B29
Y34
B18
Z Z Z
B30
WD
B19
4 5 17 16 645 649
WE
B6
ep:1
K16
N N N N 612
WF
644 WG
225 10 22 11 N 648
ep:46
B4
H20
H22
H21
J
ENGINE
26
10
647792EN
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Key:
- Negative power supply

+ Positive power supply
10
A19 Engine ECM
B4 Water in diesel fuel sensor
B6 Engine air filter clogging pressure switch
B15 Air intake pressure sensor
B16 Fuel pressure sensor
B17 Engine oil pressure sensor
B18 Coolant liquid temperature sensor
B19 Air intake temperature sensor
B24 Accelerator TPS potentiometer
B29 Primary speed sensor
B30 Secondary speed sensor
F41 Engine ECM fuse
H20 Preheat
H21 Engine pollution
H22 Fault stop engine immediately
K16 Preheat relay
P D ECM ECM diagnostic plug
R4 Resistance 120 ohm 1/2 W
Y30 Electronic injector 1
Y34 Injection pump solenoid
Y35 Discharge electronic valve
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28 ENGINE 10 - 20/01/2020
SENSOR AND PROBE

10
2 3
1
8 7
1 - Air pressure sensor
ECM Moteur
J2
1 46 Alimentation 5V
2 38 Masse
3 55 Signal
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2 - Preheat plug
ECM Moteur
J1
10
1 57 Commande relais
3 - Air temperature sensor
ECM Moteur
J2
1 42 Signal
2 37 Alimentation
4 - Fuel pressure sensor
ECM Moteur
J2
2 40 Masse
3 51 Signal
5 - Speed sensor
ECM Moteur
J2
2 52 Signal
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30 ENGINE 10 - 20/01/2020
6 - Speed sensor
ECM Moteur
J2
10
2 53 Signal
7 - Oil pressure sensor
ECM Moteur
J2
2 39 Masse
3 56 Signal
8 - Water temperature sensor
ECM Moteur
J2
1 43 Signal
2 37 Alimentation
9 - Longitudinal safety module
A5
canal analogique
1
+ 1K 4
- 2
canal IVS 6
-
5
+ 3
22 23 21 24 20
43 45 33 54 41
+8V val 0V sig +5V
J1
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10 - Air filter clogging
ECM Moteur
J1
10
38 Signal
Signal
35 EARTH
Retour
11 - Water in diesel fuel sensor
ECM Moteur
J1
1 44 Signal
2 33 Masse
10.1.2 ENGINE EARTH
Ground Point Ground Point

Option 1 Option 2
Ground Point Option 3

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10.1.3 LOW PRESSURE FUEL CIRCUIT

10
Fuel supply
Low Pressure
Tank return
High Pressure
Key:
(1) Primary fuel filter

(2) Water separator
(3) Fuel supply pump
(4) Fuel-cooled ECM.
(5) Fuel cooler (option)
(6) Secondary fuel filter
(7) Injection pump
(A) High pressure fuel feed to high pressure fuel collector
(B) Relief valve (PRV) return to high pressure fuel collector
(C) Return to fuel tank
(D) Electronic unit injector return
(E) Fuel feed from fuel tank
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10.1.4 HIGH PRESSURE FUEL CIRCUIT
10
Key:
(1) Electronic Unit Injector

(2) High pressure fuel collector
(3) Fuel level sensor
(4) Fuel relief valve
(5) Fuel supply pump
(6) Injection pump electrovalve
(7) Injection pump
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10.2 ENGINE CONTROL AND ADJUSTMENT
10.2.1 ENGINE TIGHTENING TORQUES

10
ENGINE ASSEMBLY
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ENGINE SILENTBLOCS
10
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36 ENGINE SPECIFICATION 10 - 20/01/2020
EURO 3 DIESEL CIRCUIT

10
Bouchon
Réservoir carburant
Jauge
Retour injecteur
Filtre séparateur d’eau

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10.2.2 FUEL GAUGE ADJUSTMENT PROCEDURE
Fig.A Fig.B
10
A
Fig.C Fig.D
1
1
3 2
1 1
4
– Position the gauge 1 (Fig. A) in the tank so that the spring 2 (Fig. C) is placed in the housing 3 (Fig.
A) provided for this purpose at the bottom of the tank.
NOTE: To guide you, empty the tank and insert a light through the drain hole 4 (Fig. A).
– A 12 to 14 mm gap A (Fig. B) between the top of the gauge and the tank indicates that the gauge
is correctly positioned. If not, restart the operation.
– Position the top of the gauge to align the fixing holes with the tappings on the tank. Just one position
is possible as the holes are not equidistantly spaced (Fig. D).
– If necessary remove the remnants of the sealant from the fastening screws.
– Place a copper washer (Ref. 48 499) under the head of each of the five screws 1 (Fig. D), then fix the
assembly to the tank.
– Connect the harness.
– If removed earlier, re-fit the drain plug, and then re-fill the tank.
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10.2.3 ALTERNATOR/CRANKSHAFT BELT ADJUSTMENT

10
Upper belt run

Alternator
X
F
Pump
T
Y
Engine
Lower belt run
UPPER BELT RUN LOWER BELT RUN

Deflection Static tension
Frequency Deflection X Frequency Deflection Y
force F T
First tensioning 50 N ± 2.1 N 550 N ± 50 N 157 Hz ± 5 Hz 5 mm ± 0.5 125Hz ± 5 Hz 6.3mm ± 0,5
Re-tensioning 50 N ± 2.1 N 400N ± 50N 134Hz ± 4Hz 6.2mm ± 0,5 107Hz ± 4Hz 7.8mm ± 0,5
b
ALTERNATOR/CRANKSHAFT DRIVE BELT TENSION ADJUSTMENT PROCEDURE
Refer to the instructions.

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10.2.4 COOLING CIRCUIT ADJUSTMENT

FAN PULLEY
10
Key:
1. Clamping ring
2. Fan pulley
3. Bracket
4. Bearing
5. Snap ring
6. Hub
7. Fan
647792EN
40 ENGINE 10 - 20/01/2020
REMOVAL AND FITTING PROCEDURE FOR THE PULLEY CLAMPING RING (Item 1)
10 - 1
7
Removal:
1 - Remove the fan pulley holder assembly (Item 3).
3
2 - Remove the fan (Item 7).
10
10 - 2
3 - Loosen the 6 screws (Item 8) a few turns and then tap the
8 heads lightly to release the ring.
4 - Remove the ring (Item 1).
Assembly:
5 - Carefully clean the shaft and the pulley drill hole.
6 - Lightly oil all the surfaces with mineral oil. (Do not use
molybdenum disulphide oils).
10 - 3 7 - - Position the clamping ring (Item 1) in the pulley drill hole

1
(Item 2).
b ever put the ring up to the end stop on the pulley shoulder
N
as this will make future removal very difficult.
8- Fit the assembly on the shaft.

9- To prevent the clamping ring from twisting, tighten the
screws both uniformly and diagonally by a quarter turn, preferably
using a torque wrench, up to 50% of the specified tightening
torque, i.e. 0.85 daNm.
10 - 4
6
10 - Repeat this operation to reach the final tightening torque
for the screws: 1.7 daNm.
11 - Remove the hub (Item 6) from the pulley using either a press,
a long-nosed hub extractor or a brass jet and a hammer.
12 - Use the same tools to fit the new hub.
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FAN BELT
FAN BELT TENSION
10
11
10
11
9
10
12
1- Check the condition of the fan belt and replace it if necessary.

2- Loosen the screw (Item 9) on the tensioning pulley.
3- Loosen the lock-nut (Item 10) and the screw (Item 11).
4- Bring the belt just into contact with pulley (Item 12) (on the lift truck, check this operation by
touch).
5 - Make a mark on the head of screw (Item 11) and tighten, turning it 5 times.
6 - Tighten the lock-nut (Item 10).
7 - Re-tighten the tensioning pulley screw (Item 11).
b When changing the fan belt, retighten the screw (Item 11) by one and a half turns, having
allowed the engine to idle for 30 minutes.
Permissible inter-pulley alignment offset:

1.5
1.1
1.1
1.5
Fan shaft Idler pulley shaft Engine shaft

647792EN
42 ENGINE 10 - 20/01/2020
10
TRANSMISSION
CONTENTS
20.1 TRANSMISSION COMPONENTS LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
20
20.1.1 PG 115 GEAR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
GEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
OPERATING LOGIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
DRIVE TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
PRESSURE TAP LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
20.2 TRANSMISSION CONTROL AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
20.2.1 TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
MT-X 733 95P ST3A S1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
MT-X 1033 100P ST3A S1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
20.3 TRANSMISSION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
20.3.1 PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
20.3.2 REMOVE THE GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
20.4 SPECIFIC TRANSMISSION TOOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
20.4.1 BASIC MANOMETER BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
20.4.2 DIGITAL MANOMETER BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
20.4.3 HYDROMATIK KIT (2ND FITTING - PUMP A 4 VG - DA/ENGINE A 6 VM - DA)/HOSE AND
VALVE CONNECTOR TH7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
20.4.4 GEARBOX REMOVAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

647792EN
44 TRANSMISSION 20 (30/07/2019)
20
MANUAL REFERENCE
DESIGNATION
NUMBER
647058FR ANGLE TRANSMISSION 15930-15932
647027FR GEARBOX PG115
647030DE/EN A4VG PUMP
647031FR/EN A6VM ENGINE
647379 TRANSFER BOX TYPE 357

647792EN
20 (30/07/2019) TRANSMISSION 45
TRANSMISSION
20.1 TRANSMISSION COMPONENTS LOCATION
20.1.1 PG 115 GEAR BOX

COMPONENTS
20
5
1 2
LP FL
R 6
LP FH
3 4
12
7
11
9
8
10
Key:
1- Dipstick
2- Main LP = 15 bars
3- Converter LP = 6 bars
4- Filling hole
5- Control electrovalve unit
6- Speed sensor
7- Hand brake mechanism
8- Transmission filter
9- Cold start valve = 26 bars
10- Pump suction strainer
11- Converter
12- Transmission pump
647792EN
46 TRANSMISSION 20 (30/07/2019)
Shaft and clutch
FL forward low speed

FH forward high speed
clutch
clutch
20
Clutch No. 1
Lay-shaft
Front axle output shaft
Clutch No. 3
Clutch No. 2
Rear axle output shaft
GEARING
FL forward low speed clutch
T7
FH forward high speed

clutch
T9
T8
Clutch No. 1
T6
Clutch, reversing
Clutch No. 2
T10
T4
Clutch No. 3
647792EN
20 (30/07/2019) TRANSMISSION 47
OPERATING LOGIC
Speeds FORWARD gear REVERSE gear
Clutch Maximum speed Clutch Maximum speed
1st FL+1 5.8 R+1 5.8
2ème FH+1 9,4 R+2 12,4
3ème FL+2 12,4 R+3 24
4ème FH+2 19.7
5ème FL+3
6th FH+3 38,1
DRIVE TRAIN
20
Forward movement: 1st gear/2nd gear
R R
24 24
42 42
42 42
FH FL FH FL
24 24
32 32
46 46
44 38 1 44 38 1
19 19
32 48 32 48
37 37
3 2 3 2
28 28
26 26
25 25
Forward movement: 3rd gear/4th gear

R R
24 24
42 42
42 42
FH FL FH FL
24 24
32 32
46 46
44 38 1 44 38 1
19 19
32 48 32 48
37 37
3 2 3 2
28 28
26 26
25 25
647792EN
48 TRANSMISSION 20 (30/07/2019)
Forward movement: 5th gear/6th gear
R R
24 24
42 42
42 42
FH FL FH FL
20
24 24
32 32
46 46
44 38 1 44 38 1
19 19
32 48 32 48
37 37
3 2 3 2
28 28
26 26
25 25
647792EN
20 (30/07/2019) TRANSMISSION 49
PRESSURE TAP LOCATIONS
20
T5 T7 T9 T11 T10 T4 T2 T1 T3 T8 T6
T1: Converter pressure T7: Slow forward movement FL pressure

T2: Not used T8: Reversing clutch pressure
T3: Pump pressure T9: Fast forward movement FH pressure
T4: 3rd gear clutch pressure T10: 2nd gear clutch pressure
T5: Lubrication pressure T11: Not used
T6: 1st gear clutch pressure
647792EN
50 TRANSMISSION 20 (30/07/2019)
ECU
The ECU (Electronic Control Unit) is a transmission control box. It provides the control for several gearbox
functions.
- Gear changes
- Electrovalve wiring harness diagnostics
- Input diagnostics
The ECU drive train is as follows:

20
- Information from:
the shuttle lever
the hand brake/transmission cut-out
the crawler gear switch/5th gear lock
the speed sensor
Electrovalve power
supply
41 52
27 28
Output to
ECU
dashboard display
1 2 3 14
ECU
647792EN
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20.2 TRANSMISSION CONTROL AND ADJUSTMENT
20.2.1 TIGHTENING TORQUE

20
Couple de serrage 630 N.m ±15%
647792EN
52 ENGINE SPECIFICATION 20 (30/07/2019)
MT-X 1033 100P ST3A S1

20
Couple de serrage 630 N.m ±15%

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20 (30/07/2019) TRANSMISSION 53
20.3 TRANSMISSION REMOVAL
20.3.1 PREPARATION AND SAFETY INSTRUCTIONS

DANGER
Stabilise the machine on level ground.
Manoeuvre the tyres several times to free the constraints.
Raise the boom.
Install the safety chock.
20
CAUTION
Switch off the ignition.
Wait for at least 30 seconds.
Activate the battery cut-off.
Specific tools:
– Lifting jib (min. 250 kg).
– Hoists.
– Wheeled container or pallet truck.
– 2 x M12 lifting rings
20.3.2 REMOVE THE GEARBOX

20 - 1
1- Remove the casing (1).
20 - 2
2- Place a 12 ℓ container under the gearbox.

3- Drain the gearbox (1).
1
647792EN
54 TRANSMISSION 20 (30/07/2019)
20 - 3
4- Disconnect the front universal joint from the front axle
(Item 1), 4 self-locking screws to be replaced for reassembly.
1
20
20 - 4
5- Disconnect the rear universal joint for the gearbox (1).

6- Discard the 4 screws.
7- Strap on the right-hand side.
20 - 5
8- Remove the converter closing plate

9- Remove the 6 coupling screws (Item 1) by turning the engine
universal joint with a spanner.
1
(620.4.4 GEARBOX REMOVAL TOOLS, 5 62)
20 - 6
10 - Take off the screw (1), remover the gear lever.
1
647792EN
20 (30/07/2019) TRANSMISSION 55
20 - 7
Loosen the adjusting nut (1).
11 -
Remove the cotter pin (2) and the spring (3).
12 -
Change the spring if the loop is too twisted.
13 - Remove the parking brake cable.

3
2 14 - Move the cable away to the top left.
20
20 - 8
15 - Unscrew the cooling hose.

16 - Put in a plug (M30x2.00).
20 - 9
17 - Unscrew the cooling hose.

18 - Put in a plug (M30x2.00).
20 - 10
1
19 - Unscrew the 6 lower screws on the housing coupling the
gearbox to the angle transmission (Item 1).
647792EN
56 TRANSMISSION 20 (30/07/2019)
20 - 11
20 - Unscrew the 2 screws of the housing support (1).
1
20
20 - 12
21 - Unscrew the 2 screws from the accumulator support (1).
20 - 13
Unscrew the bolt for the priority valve support (1), hold it
22 -
on the left.
20 - 14
23 - Unscrew the collar support at the right of the angle
transmission (1).
1
647792EN
20 (30/07/2019) TRANSMISSION 57
20 - 15
24 - Undo the collar screw above the gearbox (1).
20
20 - 16 Unscrew the 5 upper screws on the housing coupling the
25 -
gearbox to the angle transmission (Item 1).
26 - Leave the last coupling screw in place (2).
27 - Disconnect the electrovalves and the sensors X80 and X86.

1
20 - 17
1 28 - Remove the two plugs on the M12 tapped holes (1).
29 - Place the two M12 rings.
30 - Install a suitable lifting device (min. 250 kg), tension it.
Unscrew the bolt of the left-hand Silentbloc (1), change the

31 -
locknut, then the four support screws (2).
20 - 18
1
2
647792EN
58 TRANSMISSION 20 (30/07/2019)
20 - 19
32 - Unscrew the bolt of the right-hand Silentbloc (1), change
the locknut, then the four support screws (2).
1
2
20
20 - 20
33 - Unscrew the last screw from the gear box to angle transmission
coupling housing (1).
34 - Place a wheeled container or a pallet truck under the gearbox.

1 Lower it, being careful of the harnesses, hoses or cables. Move the
gearbox forwards, being careful to ensure that the converter comes
out with the gearbox, and being careful with the electrovalve and
sensor connections.
35 - Lay the gearbox in the container and pass it under the front
axle.
3
20 - 21 Place the gearbox on a suitable support and fit the new
36 -
4 gearbox.
3
37 - Apply the brake with the stop screw, unscrew the 8 universal
joint screws (1).
38 - Unscrew the 2 screws of the parking brake cable support (2).

2 1
39 - Unscrew the 2 connectors (3).
40 - Unscrew the return spring support screw for the gear lever (4).
2
41 - Remove the converter, tilting it to avoid loosing too much

20 - 22
oil (1).
42 - Wipe the housing well to avoid diagnosing a false oil leak.
43 - Refill the new converter when changing it before installation.

44 - When refitting, fill the gearbox with oil.
1
647792EN
20 (30/07/2019) TRANSMISSION 59
20.4 SPECIFIC TRANSMISSION TOOLING
20.4.1 BASIC MANOMETER BOX
This box contains all the components required for measuring

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

2 - 1 gauge 0/40 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549883
3 - 2 gauge 0/60 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549884
4 - 1 gauge 0/400 bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549885
5 - 2 gauge 0/600 bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549886
6 - 4 standard hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549887
7 - 2 hoses for telehandler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549888
8 - 7 gauge tap connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549889
647792EN
60 TRANSMISSION 20 (30/07/2019)
20.4.2 DIGITAL MANOMETER BOX
Digital Manometer Set 0 to 600 bar (0 - 8,700 psi) allows:

20
- MIN and MAX values to be stored.

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

2 - 1 Pressure connector adapter (M16x200)
3 - 1 Pressure connector hose 1,500 mm long
647792EN
20 (30/07/2019) TRANSMISSION 61
20.4.3 HYDROMATIK KIT (2ND FITTING - PUMP A 4 VG - DA/ENGINE A 6 VM - DA)/

HOSE AND VALVE CONNECTOR TH7
1 1 1 3 3 3 3 3 4
8x100
12x150 14x150
7
6
20
8 9
5 5 30x200
8 9
14x150 14x150
2 2 2 2 2 2
16x150 18x150
ø20 (S) ø8 (L) ø6 (L)
Hydromatik kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .209572
Consisting of:
1 - 3 Gauge connector 8x100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58181

2 - 6 «O» ring ø 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58197
3 - 5 Gauge connector 12x150. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 477484
4 - 1 Gauge connector 14x150. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58189
7 - 1 Connection ø 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173568
8 - 2 Adaptator connection M/F - ø8L + M8x100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165711
9 - 2 Adaptator connection M/F - ø6L + M8x100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 706653
Flexible (TH7 by-pass valve) Connection (connection flexible valve TH7)

M14x150
M14x150
1 8L :
24°
ø8
2
M16x150
M16x150
8S :
24°
ø8
M16x150
M16x150
10L :
ø10
24°
By-pass valve TH7 consisting of:
1 - either 1 Flexible (8L) (M14x150) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191000

either 1 Flexible (8S) (M16 x 150) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199854
either 1 Flexible (10L) (M16 x 150) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203788
2 - either 1 Connection (8L) (M14x150) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 491632
either 1 Connection (8S) (M16 x 150) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201746
either 1 Connection (10L) (M16 x 150) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206493
647792EN
62 TRANSMISSION 20 (30/07/2019)
20.4.4 GEARBOX REMOVAL TOOLS
PART NO. DESIGNATION

479307 Hand press
479309 Input shaft and reverse lay shaft bearing puller
563390 4WD shaft bearing puller
563391 Output shaft front bearing puller
563392 Lay shaft and output shaft rear bearing puller
20
563394 Lay shaft front bearing puller

563393 Press for compressing the input shaft spring
563395 Feeler gauge set adapter
479307 Bearing puller
600743 Piston seal calibration ring
563390 Bearing puller for the font and rear bearings of the 4WD shaft and reverse lay shaft and input shaft front bearings
563392 Bearing puller for the front and rear bearings of the counter-shaft, the output shaft and the Crawler shaft
600744 Input shaft rear bearing puller
563394 Output and crawler shaft front bearing puller
600745 Press for compressing the clutch kit spring. (Adaptable to all shafts except the output shaft)
600746 Press for compressing the clutch kit spring. (Adaptable to all shafts)
600747 Feeler gauge set adapter kit
600748 Feeler gauge set adapter
AXLE
CONTENTS
30.1 AXLE CONTROLS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
30.1.1 TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
30
MANUAL REFERENCE
DESIGNATION
NUMBER
547983 AXLE 212

647792EN
64 AXLE 30- <18/03/2019>
AXLE
30.1 AXLE CONTROLS AND ADJUSTMENTS
30.1.1 TIGHTENING TORQUES

(620.2.1 TIGHTENING TORQUE, 5 51)
30
BRAKE
CONTENTS
40.1 CHARACTERISTICS AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
40.1.1 PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
40.1.2 SERVICE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
40.2 LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
40.2.1 HYDRAULIC BRAKING CIRCUITS MT-X 733 95P ST3A S1 ET MT-X 1033 100P ST3A S1 . . . . . . . 70
MT-X 733 95P ST3A S1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
MT-X 1033 100P ST3A S1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
40.3 CONTROL AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
40
40.3.1 ADJUSTING THE PEDAL HEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
TRANSMISSION CUT-OFF SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
40.3.2 BLEEDING THE BRAKE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
40.3.3 ADJUSTING THE PARKING BRAKE CALLIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
ADJUSTING THE CONNECTING ROD TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
ADJUST THE STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
ADJUST THE CABLE TENSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
40.3.4 CHECKING AND ADJUSTING THE PARKING BRAKE WITH THE LEVER . . . . . . . . . . . . . . . . . . . . . . . . 76
LIFT TRUCK WITHOUT TRACTOR ROAD HOMOLOGATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
40.4 REMOVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
40.4.1 REMOVE THE BRAKING ASSISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
40.4.2 REMOVE THE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
40.4.3 REMOVE THE PARKING BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
REFITTING THE PARKING BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
40.5 SPECIFIC TOOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
40.5.1 BRAKE FLUID BLEEDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

647792EN
66 BRAKE 40 - <30/07/2019>
40
647792EN
40 - <30/07/2019> BRAKE 67
BRAKE
40.1 CHARACTERISTICS AND SPECIFICATIONS

Braking circuit characteristics MT-X 733 95P ST3A S1 et MT-X 1033 100P ST3A S1
Disc brake (Parking):

Number of discs per wheel 1
Braking area per disc face 30.8 cm2
Total braking area 61.6 cm2
Friction material asbestos-free (CARLISLE
CORP.)
Dynamic friction coefficient 0.2
Static friction coefficient 0.4
Static application:
* Maximum permissible force at brake linkage (Fmax) 1890 N
* Average friction radius (Ravg) 81 mm
* Max torque (Cmax= 0.014 x Fmax x Ravg) 2143 Nm
Brand TURNER POWERTRAIN
40
Disc diameter 203.8 mm
Disc thickness 9.5 mm
Wear adjustment mechanical
Oil bath disc brake (Service):

Number of discs per wheel 4
Braking area per disc face 146.85 cm2
Total braking surface (front axle only) 2350 cm2
Total truck braking surface 4699 cm2
Recommended operating pressure 70 to 80 bar
Friction material WELLMAN N°266
Dynamic friction coefficient 0.115
Static friction coefficient 0.095
Brand DANA
Disc diameter 201.5 mm
Disc thickness 4.75 - 4.85 mm
Action radius 88 mm
Number of slave cylinders 1
Slave cylinder surface area 41.88 cm2
Wear compensation Auto
Track width 26.75 mm
647792EN
68 BRAKE 40 - <30/07/2019>
40.1.1 PARKING BRAKE

40
647792EN
40 - <30/07/2019> BRAKE 69
40.1.2 SERVICE BRAKE
40
647792EN
70 BRAKE 40 - <30/07/2019>
40.2 LOCATIONS
40.2.1 HYDRAULIC BRAKING CIRCUITS MT-X 733 95P ST3A S1 ET MT-X 1033
100P ST3A S1
Key:
Item Designation
1 Master cylinder
2 Flip-Flop valve
3 Front axle
4 Rear axle
1
4
2
40
MT-X 1033 100P ST3A S1

1
4
3
647792EN
40 - <30/07/2019> BRAKE 71
40.3 CONTROL AND ADJUSTMENT
40.3.1 ADJUSTING THE PEDAL HEIGHT

BRAKE PEDAL
– Set the height of the brake pedal (Item A) 155 mm above the cab floor (without floor mats) by means
of the stop (Item B).
– Tighten the locknut (Item E).
– Adjust the pedal free play (Item A) (3 to 4 mm), by turning the push rod (Item C).
– Tighten the locknut (Item D).
TRANSMISSION CUT-OFF SWITCH
– Pedal in its rest position (against stop Item B).
– Adjust the position of the switch, Item F, so that transmission cut-off activates when the pedal is at
a height of 130 mm above the cab floor (see diagram).
40
647792EN
72 BRAKE 40 - <30/07/2019>
40.3.2 BLEEDING THE BRAKE CIRCUIT

Tooling required: Brake fluid bleeder (640.3.4 CHECKING AND ADJUSTING THE PARKING BRAKE WITH
THE LEVER, 5 76)
40 - 1
DANGER
- Stabilise the machine on level ground.
- Manoeuvre the machine a number of times in forward and reverse in order to
release any stresses acting on the steering and tyres.
- Raise the boom and install the safety wedge.
1 - Remove the cover plate at the front of the machine.
2 - Remove the screw (1), and remove the casing.
1
40 - 2
40
3 - Remove the brake fluid tank plug and fit the adapter (1) of
1
the bleeder.
4- Operate the bleeder.
40 - 3
5- lace a transparent recovery hose on the rear left-hand
P
1 bleed screw (1).
6- Operate the bleeder.
2 7- Loosen the bleed screw, then once the brake fluid is flowing
without air bubbles,
8- retighten the bleed screw.
9- Repeat the operation for the other bleed screws on the front
and rear axle (2).
10 - Top up the brake fluid
4 Fluid to be used: see Instructions 647777
647792EN
40 - <30/07/2019> BRAKE 73
40.3.3 ADJUSTING THE PARKING BRAKE CALLIPER

Position truck on level, horizontal ground.
40 - 4
Key:
– Cable stop (1)
– Cable (2)
2
1 – Connecting rod (3)
– Spring (4)
4
– Stop (5)
3
40 - 5
ADJUSTING THE CONNECTING ROD TRAVEL
2 1 - Release handbrake
2 - Remove the handbrake cable (1) from the cable stop (2).
40
1 3 - Remove the pin and shaft (3) from the connecting rod (4).
3
40 - 6
4- Remove the spring (1) from the support.

5- Loosen the lock nut (2).
1 4 6- Screw the stop (3) so that it is no longer in contact with the
connecting rod (4).
3
2
40 - 7
7- Measure the distance between the connecting rod (1) and
the support (2).
1
647792EN
74 BRAKE 40 - <30/07/2019>
40 - 8
8 - Put the brake pads in contact with the disc by pushing the
connecting rod by hand (1).
9 - Once again measure the distance between the connecting
1 3
rod (2) and the support (3).
10 - The difference between the two measurements should be
2 12 ± 2 mm
40 - 9
1
11 - To reduce the difference between the two measurements:
12 - Loosen the lock nut (1).
13 - Tighten the nut (2) until 12 mm is obtained.
40
14 - Tighten the lock nut (1) (60 N.m).
40 - 10
ADJUST THE STOP

1
1 - Push the connecting rod (1) and bring the screw head (2)
to 5 mm.
2 - Tighten the lock nut (3) (40 N.m).
3 2
40 - 11
ADJUST THE CABLE TENSION.

2 1 - Refit the shaft and pin (1).
2 - Reposition the spring (2).
647792EN
40 - <30/07/2019> BRAKE 75
40 - 12
1
3 - Tighten the nut (1) on the cable stop (2) to tension the
cable (3).
3 4 - Loosen the connecting rod (4) slightly from the stop (5).
6 2
5 - Tighten the lock nut (6).
6 - Tighten the nut (1) on the cable stop (2) to tension the
cable (3).
4 7 - Loosen the connecting rod (4) slightly from the stop (5).
8 - Tighten the lock nut (6).
5
40 - 13
1
9- Manoeuvre the handbrake several times.
Check that the tension of the cable (1) is correct.
10 -
Check that the connecting rod (2) is always slightly away
11 -
40
from the stop (3).
2
40 - 14
A
12 - Unscrew the end of the lever until the lever is locked in
position A.
B 13 - Carry out the procedure "CHECKING AND ADJUSTING THE
PARKING BRAKE WITH THE LEVER".
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76 BRAKE 40 - <30/07/2019>
40.3.4 CHECKING AND ADJUSTING THE PARKING BRAKE WITH THE LEVER
LIFT TRUCK WITHOUT TRACTOR ROAD HOMOLOGATION
1 - Place the lift truck on a slope of at least 15% with the rated
40 - 15
load in the transport position.
1 2 - Check braking by locking the parking brake (Item 1) in
position A.
⇒ The adjustment is correct when the lift truck remains stationary
A on the slope.
B 3 - Carry out adjustments if necessary:
- Depress the service brake pedal, unblock and release the
parking brake (Item 1) in position B.
- Progressively tighten the end of the lever (Item 1) and
recheck braking.
- Repeat the operation until the correct braking adjustment
is obtained.
40
647792EN
40 - <30/07/2019> BRAKE 77
40.4 REMOVALS
40.4.1 REMOVE THE BRAKING ASSISTANCE
40 - 16
1- Remove the screw (1), and remove the casing.
40 - 17
40
2
2- Disconnect the stop switch X73.
3- Loosen the 2 connectors (2).
4- Remove the screws (3).
40.4.2 REMOVE THE MASTER CYLINDER
40 - 18 2
3 1 - Remove the screw (1), and remove the casing (see

Fig. 40- 5).
2 2 - Remove the pin from the pedal shaft (1).
3 - Loosen the 3 connectors (2).
4 - Block the fluid inlet pipework.
2 3
5 - Remove the 2 fastening screws (3).
1
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78 BRAKE 40 - <30/07/2019>
40.4.3 REMOVE THE PARKING BRAKE PADS

1- Place the lift truck on horizontal ground, with the parking brake off and in neutral.
2- Chock the lift truck.
3- Remove the parking brake cable (Item 1).

4- Remove the upper calliper screw (Item 2).
1 5- Swivel the calliper around the lower screw (Item 3).
6- Compress the spring (Item 4) with two screwdrivers.

40
5 7- Remove the pads (Item 5).
REFITTING THE PARKING BRAKE PADS

1 - Position the pads at the bottom of the housing.
4
2 - Check that the return spring is in position.
5
3 - Refit the pads by reversing the operations described in
"REMOVING THE PADS".
4 - Check and adjust the parking brake.
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40.5 SPECIFIC TOOLING
40.5.1 BRAKE FLUID BLEEDER
Bleed valve supplied with all the components required for

bleeding the brake circuits of Manitou products.
Operating instructions included.
40
MANITOU Reference
BRAKE BLEED KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .554019
SPARE PARTS:
– TOP MANOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 719980
– BOTTOM MANOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 719981
– Membrane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 661913
– HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 661914
– FLEXIBLE BRAKE (ORANGE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 720693
– VALVE RETRACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 744747
– SET OF 6 CAPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 787147
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BOOM
CONTENTS
50.1 BOOM CHARACTERISTICS AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
50.1.1 DUPLEX BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
50.1.2 TRIPLEX BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
50.2 LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
50.2.1 MAIN COMPONENTS OF THE DUPLEX BOOM (6 AND 7 M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
50.2.2 MAIN COMPOENTS OF THE TRIPLEX BOOM (9 AND 10 M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
50.3 CONTROL AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
50.3.1 TIGHTENING TORQUES/LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
SCREW/INSERT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
NUT / SCREW ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
BOOM HEAD LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
LUBRICATION OF JOINTS WITH BUSHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
50
LUBRICATION OF JOINTS WITHOUT BUSHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
INTERIOR TELESCOPE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
50.4 REMOVAL - REFITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
50.4.1 REMOVAL OF ELEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
REMOVE THE BOOM HEAD BEARING PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
REMOVE BOOM FOOT BEARING PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
REMOVE THE TELESCOPIC BOOM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
50.4.2 REMOVE THE TRIPLEX BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
REMOVE TELESCOPES T1 AND T2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
REMOVE TELESCOPE T2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
50.4.3 REFITTING THE TRIPLEX BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
50.4.4 BOOM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
BOOM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
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BOOM
50.1 BOOM CHARACTERISTICS AND SPECIFICATIONS
50.1.1 DUPLEX BOOM

Consisting of 2 elements:
– 1 fixed
– 1 mobile
Boom weight:
50
– Weight of complete boom ≈ 1250 kg (6 metres), 1390 kg (7 metres)
50.1.2 TRIPLEX BOOM

Consisting of 3 elements:
– 1 fixed
– 2 mobile
Boom weight:
– Weight of complete boom ≈ 1680 kg (9 metres), 1760 kg (10 metres).
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50.2 LOCATION
50.2.1 MAIN COMPONENTS OF THE DUPLEX BOOM (6 AND 7 M)

Item Designation
CSP Counterbalance valve
T Telescope (Boom head)
VI Tilting cylinder
VT Telescopic boom cylinder
VT
T1
CSP
Boom foot
50
V1
V2
D C
B
VI
A
CSP
A
C
D
A
B
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50.2.2 MAIN COMPONENTS OF THE TRIPLEX BOOM (9 AND 10 M)

Item Designation
CSP Counterbalance valve
CSPD Double counterbalance valve
T1 Telescope 1
T2 Telescope 2 (Boom head)
VI Tilting cylinder
VT1 Telescopic boom cylinder 1
VT2 Telescopic boom cylinder 2
Key to hoses
1 - Tilting V1
2 - Telescope V2 4
1
6
V1
CSP
3 - Tilting V2 3
2 5
V2
4 - Attachment 1
5 - Telescope V1
6 - Attachment 2 V2
CSP V1
50
CSPD
V1
2
V2
2 6
5 5
4
1
6 3 6
1
1
4 2 4
5 5
3 6
4
1
2
3 3
VI
CSP
VT1
T2
CSPD T1
VT2
CSP
Boom foot
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50.3.1 TIGHTENING TORQUES/LUBRICATION

Item Designation
CSP Pilot safety valve
T1 Telescope T1
VI Tilting cylinder
- A.A -
C1=15 N.m ±15%

9 mini
Calage / Wedging
C2=88 N.m ±10%

- B.B -
0 +0,5
50
T1
A B
VI
CSP
A
VT
B
CSP
X
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SCREW/INSERT ASSEMBLY
– Apply the Loctite to all the screw/insert connections.
– Screw the headless screw and apply a tightening torque of 15 Nm ± 15%.
NUT / SCREW ASSEMBLY
– If necessary chock depending on the play between the tubes.
– Apply Loctite to the nut/screw connections that are not accessible from the exterior after fitting the
boom (nuts fitted inside the tubes at the rear).
– Put the H. M12 nut in place and provide the tightening of the C2 tightening torque
– Make sure the 9 mm is observed.
BOOM HEAD LUBRICATION
– Before assembling the boom tubes, lubricate the lower area on the exterior side of the boom head
tube over a length of 550 mm.
– Retinax HDX2 Shell grease.
LUBRICATION OF JOINTS WITH BUSHES
– When fitting, fill the cells or holes of the bushes.
– Apply a thin film of grease to the pin seatings.
– Relubricate after function tests (before delivery).
– Then lubricate every 50 hours.
LUBRICATION OF JOINTS WITHOUT BUSHES
– Apply a thin film of grease to the pin bearing surface of un-bushed bearings.
INTERIOR TELESCOPE LUBRICATION
50
– Grease the lower interior of the inner boom over length X (the area in which the inner cylinder slide
pad moves) using RETINAX HDM grease.
b Apply the correct slide pad tightening torques (see diagram). Apply "Loctite 243 Normal Thread
Lock" only to all fixings, studs/inserts and nuts/studs on the inside of the boom.
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50.4 REMOVAL - REFITTING
50.4.1 REMOVAL OF ELEMENTS

50 - 1
1 REMOVE THE BOOM HEAD BEARING PADS

1 - Locate the 4 plates and unscrew the 8 screws (10 mm wrench)
(Item 1).
2 - Locate the shims.
2
3 - Unscrew the 16 nuts: lock nut (17 mm wrench) and screw
(6 mm Allen key) (Item 2).
4 - For the lower pads, raise the telescope,head in order to remove
them.
5 - When reassembling, balance the shims.
50 - 2
2
1
REMOVE BOOM FOOT BEARING PADS
1 - Remove the two side hose deflectors (Item 1).
2 - Locate the shims.
3 - Unscrew the 16 nuts: lock nut (17 mm wrench) and screw (6
50
mm Allen key) (Item 2).

4 - For the upper shims, extend the telescope approx. 300 mm,
and remove the telescope suspension option low boom
position sensor.
5 - For the lower pads, lift the telescope head with a crowbar and
wedges.
50 - 3
REMOVE THE TELESCOPIC BOOM CYLINDER
1 - D ecompress all the hydraulic components (switch on the
ignition and operate the manipulator).
1
2 - Extend the boom to expose the telescopic boom cylinder
head pin (Item1).
3 - Unclip the telescope cylinder head pin (Item 2), remove the
pin with a mallet.
4 - Retract the cylinder.
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50 - 4
5 - Disconnect the hoses

6 - Remove the boom rear casing, undo the 4 screws (Item 1), and
disconnect the light cable harness.
1 1
1
1
50 - 5
2
7 - Remove the rear left headlight support bracket (Item 1).
8 - Unscrew the 6 boom base hoses (Item 2), and plug them.
50
50 - 6
9 - Position the boom in such a way as to align the telescope

cylinder base pin with the opening (Item 1), remove the circlips
from both ends of the pin.
10 - Remove the pin with a mallet.
1
11 - Remove the cylinder.
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50.4.2 REMOVE THE TRIPLEX BOOM

50
Key:
A- Telescope T1
B- Telescope T2
PREPARATION AND SAFETY INSTRUCTIONS
– Stabilise the machine on level ground.
– Fully retract the telescope.
– If an attachment is mounted on the carriage, remove it.
– Decompress all hydraulic elements.
– Place the boom in the horizontal position with the carriage tilted fully upwards.
– Deactivate battery power supply by means of the battery cut-off.
Specific tooling:
– Jib crane or hoist + slings (min. 1,000 kg).
– Mallet.
– Trestles.
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REMOVE TELESCOPES T1 AND T2
50 - 7
1 - Remove the telescope cylinder circlip (Item 1)
2 - Place a block between the telescope cylinder and the boom.
1
50
50 - 8
3 - Remove the telescope cylinder pivot pin (Item 2).
50 - 9
4 - Strap the boom and extend it halfway (Item 3).

3
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50 - 10
5
5 - Hold/Secure the boom (Item 4) at its centre of gravity using a

strap (Item 5) and a lifting system (hoist).
50 - 11
6 6 - Remove the cradle (Item 6) using a 13 mm wrench.
7 - Dismantle then remove the six slide pads (Item 7).
7 7
7
50
50 - 12
8
8 - Fully remove the boom (Item 8).

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50 - 13
9 - Identify and unscrew the six hoses
- (x2) telescoping circuit (Item 9)
- (x2) tilting circuit (Item 10)
- (x2) attachments circuit (Item 11)
10
11
11
9
9
10
50 - 14
10
10
11
9
50
9 11
13
50 - 15
10 - Set down the boom (Item 12) on trestles with the hoist + strap
(Item 13).
12
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REMOVE TELESCOPE T2
50 - 16
1 - Remove the telescopic boom cylinder circlip (Item 1)

1
2 - Remove the telescope cylinder pivot pin (Item 2).
2
50
50 - 17
3
3 - Place a strap around the boom and pull the boom head out
halfway (Item 3).
4 - Hold/Secure the boom (Item 3) at its centre of gravity using a
strap and a lifting system (hoist).
50 - 18
4
5 - Dismantle then remove the six slide pads (Item 4).
4 4 6 - Fully remove the boom head.
4
4 7 - Set the boom head don on trestles.
4 4
4
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50.4.3 REFITTING THE TRIPLEX BOOM
b
Carry out the reverse procedure to that described above.
Follow the block assembly and greasing recommendations given below.
b Apply "Loctite 243 normal thread lock" to all nut/screw interfaces situated only on the inside
of the boom.
RECOMMENDATION FOR FITTING SHIMS AND LUBRICATION AREAS

– Grease the tube slip faces in the specified areas, the grease spread is 0,2 kg/m².
– Grease the slip face of each slide pad before installation.
– Install the slide pads in the following order: side pads, upper pads, lower pads.
– Finish adjusting the shimming system, at the upper part of the tubes by inserting slide pads while
complying with the operating clearances shown.
50
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50.4.4 BOOM REMOVAL

50
PREPARATION AND SAFETY INSTRUCTIONS

– Stabilise the machine on level ground.
– Fully retract the telescope.
– If an attachment is mounted on the carriage, remove it.
– Decompress all hydraulic elements.
– Deactivate battery power supply by means of the battery cut-off (wait for 30 seconds after switching
off the ignition).
Weight of complete boom ≈ 1250 kg (6 meters), 1390 kg (7 meters), 1680 kg (9 meters), 1760 kg (10 meters).
Specific tools:
– Floor crane (minimum 2000 kg).
– Hoists
– Axle stand
– Mallet
– Slide hammer puller
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BOOM REMOVAL
50 - 19
1
1 - Place a container under the vehicle beneath the boom foot
2 - Raise the boom until the head pin of the lifting cylinder can
just be seen above the engine bonnet.
3 - Slingthe boom by the front ring (Item 1) using a suitable
lifting method.
50 - 20
4 - Chock the lifting cylinder.

5 - Unscrew the locking screw from the lifting cylinder head pin
(17 mm spanner) (Item 1).
1 6 - Release the pin with a slide hammer puller (M12).
50
50 - 21
7 - Unscrew the 6 boom foot hoses and plug them.

8 - Chock the compensating cylinder.
9 - Unscrew the locking screw from the cylinder head pin (17 mm
spanner) (Item 1).
10 - Release the pin with an inertia hub extractor (M12).
1
50 - 22
11 - Remove rear casing of the boom.

12 - Undo the 4 screws (Item 1).
1 1
13 - Disconnect the headlight harness.
1
1
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98 BOOM 50 (30/07/2019)
50 - 23
14 - Remove the angle sensor link rod (Circlips) (Item 1).

15 - Disconnect the telescope retraction sensor (X134) (Item 2).
1
50 - 24
1
1
16 - Remove the boom position sensor for the boom suspension
option.
17 - Undo the 2 screws (Item 1).
50
50 - 25
18 - U nscrew the locking screw of the boom foot pin (27 mm

wrench) (Item 1)
19 - Release the pin.
1
20 - Retrieve the spacer on the boom foot.
21 - Lift the boom and set it down on a suitable support.
When at rest, put the 6 hoses in order on the boom. They must not cross each other. Check that they
are not under torsional stress and then tighten them.
Recalibrate the boom angle sensor and the strain gauge.
(680.4.1 “BOOM ANGLE” ANGULAR SENSOR ADJUSTMENT, 5 198)
HYDRAULICS
CONTENTS
70.1 HYDRAULIC CHARACTERISTICS AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
70.1.1 HYDRAULIC COMPONENT SHEETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
SDM 140 DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
70.2 HYDRAULIC SCHEMATIC DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
70.2.1 MT-X 733 95P ST3A S1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
70.2.2 MT-X 1033 ST 100P ST3A S1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
70.3 HYDRAULIC COMPONENTS LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
70.3.1 MT-X 733 95P ST3A S1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
70.3.2 MT-X 1033 ST 100P ST3A S1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
70.4 HYDRAULIC CONTROLS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
70.4.1 DISTRIBUTOR CONTROL LOGIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
70.4.2 AGGRAVATING MOVEMENTS CUT-OFF OPERATING PRINCIPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
70
70.4.3 CASAPPA KP30 - 22 PUMP TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
70.5 SPECIFIC TOOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
70.5.1 BASIC AND DIGITAL MANOMETER BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
70.5.2 INFLATION KIT BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

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70
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HYDRAULICS
70.1 HYDRAULIC CHARACTERISTICS AND SPECIFICATIONS
70.1.1 HYDRAULIC COMPONENT SHEETS

SDM 140 DISTRIBUTOR
Values for information purposes only.
Role:
70
- Limit maximum pressure.
- Direct the hydraulic flow to the receivers.
- Cut off hydraulic movements (VS).
- Limit shock pressure (Valve anti shock).
- Set the return flow in the neutral manipulator.
Notes : ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
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V4
V3
V2
T1
V1
PP
EA
ET
EI
EL
1. Tilt cut-off valve (VCI). 5. Anti-cavitation valve.

70
2. Boom descent valve (VRD). 6. Anti-cavitation valve.

3. Movement cut-off valve (VS). 7. Valve slide
4. Pressure limiter. PP : Taking Pressure
P T
MA
6 5 6 5 1 2 3 4
PP
P A1 B1 V1 V3 A2 B2 V A3 B3 A4 B4 A5 B5 T
280 bar
200 bar
200 bar
D
3
280 bar
VS
4
260 bar
VCI
EE EL EI ET EA EA (O) EF
V2 T1 V4
7 2 7 1 7 7 7
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1. Tilt cut-off valve (VCI) (12 V - 6.8 Ω + freewheel diode on Pin 1)
V3 A2 B2 Permit or not the tilt function depending on

machine overload and machine software.
200 bar
- When it is powered a 35 bar pressure is
280 bar applied to both sides of the spool, thereby
stopping any tilt movement.
- When unpowered, pressure can be applied
to one side or the other, thus allowing
movement.
VCI
EI
V4
2. Boom flow control on descent valve (VRD) (12 V - 4.7 Ω - 1.5 A)
A1 B1 V1 - Makes it possible to limit the descent speed

280 bar of the boom no matter what the load.
70
EL
V2 T1
3. Safety valve (VS) (12 V - 6.3 Ω + diode de roue libre sur Pin 1 et 2)
P - The VS makes it possible to cut off all

hydraulic movements by directing the flow
divider pilot pressure to the tank.
VS
260 bar
EE
Notes : ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
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4. Pressure limiter.
P - The pressure relief valve makes it possible

to limit the internal pressure in the hydraulic
circuit, by diverting excess flow to the low
return.
VS
260 bar
EE
5. Anti-cavitation valve.
- The function of the anti-

V3 A2 B2 V A3 B3
cavitation valve is to protect
200 bar
200 bar
the cylinder and hoses from

any excessive pressures.
280 bar
70
VCI
EI ET
V4
6. Anti-cavitation valve.
A1 B1 V1 V3 A2 B2
280 bar
200 bar
280 bar
VCI
EL EI
V2 T1 V4
Notes : ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
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7. Valve slide.
A1 B1 V1 V3 A2 B2 V A3 B3 A4 B4 A5 B5
280 bar
200 bar
200 bar
280 bar
VCI
EL EI ET EA EA (O)
V2 T1 V4
A B
1 0 2
A B
T P LC P T P T
P A B T
1 0 2
A B
A B
70
T P LC P T P T
A B
1 0 2
A B
T P LC P T P T
P B A T
Notes : ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
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ACCUMULATOR BLOCK
1 - Role:
Provides a reserve of pressurized oil fir:
- Power assisted braking.

- Control valve control (depending on machine).
2 - Description:
70
P1/P2 : Pressure port

WV : Circuit selector
DM : Pressure reducer
T : Tank return
DB : Pressure relief valve (45 bar)
RV : Non-return valve
SBO : Membrane accumulator
U : Service port
Notes : ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
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STEERING UNIT OSPC 200 LS
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:
647792EN
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DISCHARGE VALVE
c Role:
- Discharge or accumulative flow from two different hydraulic
lines.
T
P
1. Non-return valve
70
2. Tank slide.
3. Pilot electrovalve.
3
C VD
Ø0,7
P T
2
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
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PILOT SAFETY VALVE (ON CYLINDER)
Values for information purposes only
V2
Role:
– Isolates the cylinder in the event of hose breakage.

V1
– Limits max. pressure from impacts.
Key:
1 - One way valve

2 - Load hold check valve
3 - Variable flow restrictors
70
4 - Valve
C1 C2 2
1
3
3 2
335b
4
V1 V2
Note:
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70.2 HYDRAULIC SCHEMATIC DIAGRAMS

NOTE:
1- The calibration pressures of the main relief valves on the inlet elements are given for maximum
engine speed.
2 - The calibration pressures of the secondary relief valves are at an engine speed of 1,000 rpm.
3 - The pressure relief valves should be adjusted at an oil temperature of 50°C
4 - ADDITIONAL DISTRIBUTION IN ACCORDANCE WITH DOC-BE-BDM-002.
70.2.1 MT-X 733 95P ST3A S1

KEY
Item Designation Position on diagram Hydraulic correspondence
BA Power supply unit + Accumulator F14
CA Suction strainer J3 125 microns absolute
CSP Pilot safety valve D10, E11, E13
D Distributor H9
EA Attachment element J12
EE Inlet element J9
EF Closing element J12
EI Tilting element J10
EL Lifting element J10
ET Telescope element J11
EVTDF (O) Boom head electrovalve (option) B12, B14
FDAR Rear disc brake E9
FDAV Front disc brake E1
10 microns absolute 1st fit
FR Return Filter I4
15 microns absolute PR
Idling speed: 930 rpm +20/0
M Engine D6 Nominal speed laden: 2200 rpm
Max speed unladen; 2400 rpm
MA Manipulator G14
MC Master cylinder B1
70
N Level J2
P Hydraulic pump D5
PAAV(O) Front attachment connector (option) A11, A13, A14, B12, B13, B14
PD Steering pump B3
PP Pressure connector I9
PRF(O) Leakage return plug (option) G2
Average level: 104 ℓ
R Hydraulic tank J2 Capacity 128 litres
Steering reserve
RLF Brake fluid tank C1
SC Circuit selector B3
Position 1: short turning
SD 3-position steering selector A3 Position 2: front wheel turning
Position 3: crab turning
VAI (O) Isolation valve (option) A12, A13
VC Compensating cylinder of 100*50 C 310 D10
VCI Tilting cut-off valve I11
VD Discharge valve G5
VDAR Rear steering cylinder E8
VDAV Front steering cylinder E2
VI Tilting cylinder of 130*65 C 380 C10
VL Lifting cylinder of 140*70 C 720 C13
VRP Pressure control valve I10
VS Safety valve I9
VT Telescopic boom cylinder of 70*50 C 2750 D11
VVT (O) Carriage locking cylinder (option) of 60*45 C 183 A12, A14
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DIAGRAM
1 2 3 4 5 6 7 8 9 10 11 12 13 14
MANIPULATOR CONTROLS BOOM HEAD ELECTROVALVE
OPTION AND HYDRAULIC
LOCKING
A B T 2
A 3 1 VVT (O)
VAI (O)
2 1 HYDRAULIC LOCKING OPTION BOOM HEAD
3
ELECTROVALVE OPTION
SD FRONT
2 1
REAR PAAV (O)
VVT (O)
PAAV (O) PAAV (O)
3
P VAI (O)
R L
200b 200b PAAV (O) PAAV (O)
PD
PAAV (O)
FT C3
C4
C2
C1
C3
C4
C2
C1
B 200 cm3/rev
B L N EVTDF (O) EVTDF (O)
P2 P1 P2 P1
MC
SC
V1 V2 LS
B1
RLF S
140b
T P
C
VI
VL
C1 C2
OUT 300b
EF CF
FT VT
D CSP
C1 C2
LS V1 V2
FRONT AXLE
335b
REAR AXLE
M
P
IN VC C1 C2
21.99 cm3/rev
21.99 cm3/rev 335b
30b CSP
FDAV VDAV VDAR FDAR V1 V2
E
30b CSP
V1 V2
0.7 L
13 bars
P2 35b BA
70
U
F 45±5b
P1
T
10 μm
FCD
P T
MA
PRF(O)
G
C
VD 1 2 3 4
P1
H P A1 B1 V1 V3 A2 B2 V A3 B3 A4 B4 T
200 bar
D
200 bar
280 bars 280 bars
P T
VS
FR
I 6b
5b
FT VRP
10 microns absolute 1st fit PP 260 bars VCI
15 microns absolute PR.
EE EL EI ET EA EF FT
V2 T1 V4
N
CA
J Average level: 104 L
125
microns
absolute
In the case of modifications in pressure, flow rate, In the case of modification also see steering
FT FT speed, etc. see technical data sheet update ! hydraulic diagram
R Capacity 128 litres Steering reserve
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70.2.2 MT-X 1033 ST 100P ST3A S1

DIAGRAM
1 2 3 4 5 6 7 8 9 10 11 12 13 14
MANIPULATOR CONTROLS BOOM HEAD ELECTROVALVE

OPTION AND HYDRAULIC BOOM HEAD ELECTROVALVE TSDL + HYDRAULIC LOCKING OPTION
LOCKING OPTION AND TSDL
A A B T 2
VVT (O)
3 1 VTSDL (O)
VAI (O) VAI (O)
HYDRAULIC LOCKING OPTION BOOM HEAD TSDL OPTION AND COUPLERS
3 2 1 ELECTROVALVE OPTION VTSDL (O) VVT (O)
VAI (O)
SD
FRONT REAR PAAV (O) PAAV (O) PAAV (O)
VVT (O) VTSDL (O)
3 2 1 VAI (O) VAI (O)
P
R L
200b 200b PAAV (O) PAAV (O) PAAV (O) PAAV (O)
PD PAAV (O) PAAV (O)
FT C3
C4
C2
C1
C3
C4
C2
C1
C3
C4
C2
C1
C3
C4
C2
C1
B
B L N 200 cm3/rev EVTDF (O) EVTDF (O) EVTDF (O) EVTDF (O)
P2 P1 P2 P1 P2 P1 P2 P1
MC
SC
B1
V1 V2 LS
RLF 140b
P S
T P
C VT2
VL
VI
C1 C2
EF CF OUT 315b +15
0 VSD VSG
FT C1 C2 CSP
300b 110b C1 C2 C1 C2
V1 V2 280b 100b 100b 280b
C1 C2
LS
FRONT AXLE
D CSPD 335b
M CSP
REAR AXLE
P VT1
IN
V1 V2 V1 V2 V1 V2
21.99 cm3/rev
21.99 cm3/rev
VC 30b CSP
FDAV VDAV VDAR FDAR C1 C2 B V1 V2
300b
CSPD 300b VSS
E B A
V1 V2
VSS 0.7 L
13 bars
A
70
P2 35b BA
U
45±5b
F P1
T
10 μm
FCD
P T
PRF(O) MA
G 2 3 4
C 1
VD
P1
P A1 B1 V1 V3 A2 B2 V A3 B3 A4 B4 T
H D
200 bar 200 bar
0
P A2 B2 A3 B3 T
280 bars 280 bars
P T
VS
FR P1 T1
6b
I 5b
VRP
FT
PP 260 bars VCI
15 microns absolute PR.
EE EL EI ET EA EF FT ESD ESG
V2 T1 V4
N
CA
125
J Average level: 104 L microns
absolute
FT In the case of modifications in pressure, flow rate, In the case of modification also see steering
R Steering reserve
FT speed, etc. see technical data sheet update ! hydraulic diagram
Capacity 128 litres
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KEY
Item Designation Position on diagram Hydraulic correspondence
BA Power supply unit + Accumulator E14
CA Suction strainer J3 125 microns absolute
CSP Pilot safety valve D10, D11, E14
CSPD Double pilot safety valve D12, E11
D Distributor H8
EA Attachment element I11
EE Inlet element I8
EF Closing element I11
EI Tilting element I9
EL Lifting element I9
ESD Right stabiliser element I11
ESG Left stabiliser element I12
ET Telescope element I10
EVTDF (O) Boom head electrovalve (option) B10, B11, B13, B14
FCD Distributor control filter F14
FDAR Rear disc brake E9
FDAV Front disc brake E1
FR Return Filter I4
15 microns absolute PR
Idling speed: 930 rpm +20/0
M Engine D7 Nominal speed laden: 2200 rpm
Max speed unladen; 2400 rpm
MA Manipulator G14
MC Master cylinder B2
N Level J2
P Hydraulic pump D6
A8, A10, A11, B9, B10, B11, B12,
PAAV(O) Front attachment connector (option)
B13, B14
PD Steering pump B4
PP Pressure connector I8
PRF(O) Leakage return plug (option) G2
70
Average level: 104 ℓ
R Hydraulic tank J2 Capacity 128 litres
Steering reserve
RLF Brake fluid tank C1
SC CIRCUIT SELECTOR B3
Position 1: short turning
SD 3-position steering selector A3 Position 2: front wheel turning
Position 3: crab turning
VAI (O) Isolation valve (option) A10, A12, A14, B9, B11
VC Compensating cylinder of 100*50 C 310 E10
VCI Tilting cut-off valve I10
VD Discharge valve G5
VDAR Rear steering cylinder E8
VDAV Front steering cylinder E2
VI Tilting cylinder of 120*60 C 416 C10
VL Lifting cylinder of 140*70 C 720 C14
VRP Pressure control valve I9
VS Safety valve I8
VSD Right stabiliser cylinder of 125*60 C 200 D12
VSG Left stabiliser cylinder of 125*60 C 200 D13
VSS Stabiliser safety valve E12
VT1 Telescopic boom cylinder 1 of 100*60 C 2850 D11
VT2 Telescopic boom cylinder 2 of 80*50 C 2850 C11
VTSDL (O) Single side-shift carriage cylinder (option) A12, A13
VVT (O) Carriage locking cylinder (option) of 60*45 C 183 A9, A11, A14
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70
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70.3 HYDRAULIC COMPONENTS LOCATION
70.3.1 MT-X 733 95P ST3A S1

VI
Item Designation
BA Power supply unit + Accumulator
CA Suction strainer VT
D Distributor
FR Return Filter
P Hydraulic pump
PD Steering pump
R Hydraulic tank
SD Steering selector
VC Compensating cylinder CSP
VD Discharge valve
VI Tilting cylinder
VD
VL Lifting cylinder
VC
CSP
D
R
BA
PD
70
VL
FR
P
CA
SD
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70.3.2 MT-X 1033 ST 100P ST3A S1
Item Designation
VI
BA Power supply unit + Accumulator
CA Suction strainer
CSPD Double pilot safety valve
D Distributor
FR Return Filter
VT
P Hydraulic pump
PD Steering pump
R Hydraulic tank
SD Steering selector CSP
VC Compensating cylinder
VD Discharge valve
VD
VI Tilting cylinder
VL Lifting cylinder
CSPD VC
VSD Right-hand stabiliser cylinder
VSG Left-hand stabiliser cylinder
VSS Stabiliser safety valve D
R
CSP
VL PD
70
SD
VSG
FR
BA
CA
P
VSD VSS
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70.4 HYDRAULIC CONTROLS AND ADJUSTMENTS
70.4.1 DISTRIBUTOR CONTROL LOGIC

The JSM sends directional and proportional value information for roller 1 and 2 to the SPU computer.
The computer converts this information into PWM control for the coils corresponding to the attachment
and telescope movements.
1 12
2 11
3 10
4 9
5 8
6 7
1
8
14 7
20 13
19
26
1
10
18 9
26 17
25
34
70
1 12
2 11
3 10
4 9
5 8
6 7
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70.4.2 AGGRAVATING MOVEMENTS CUT-OFF OPERATING PRINCIPLE

Movement cut-off is cut by VRP/SPU or VCI at 105% of the signal from the gauges. If the signal from the
gauges is exceeded at 112%, the VS is then also cut. These values change depending on the boom angle.
The VS cut-off occurs 7% after proportional cut-off to warn if the SPU takes longer time to cut-off by the
proportionals. The VS therefore cuts off all movements at 112%.
P T
MA
1 2 3 4
P A1 B1 V1 V3 A2 B2 V A3 B3 A4 B4 T
200 bar
D
200 bar
280 bar 280 bar
VS
2
VRP
260 bar VCI
EE EL EI ET EA EF FT
70
V2 T1 V4
3 1
1- Tilting cut-off valve (VCI).
2- Movement cut-off valve (VS)
3- Control Regulation Valve (VRP).
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70.4.3 CASAPPA KP30 - 22 PUMP TIGHTENING TORQUES
100 Nm
15 Nm 15 Nm
70
100 Nm
90 Nm
280 Nm
30 Nm
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70.5.1 BASIC AND DIGITAL MANOMETER BOX
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
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Digital Manometer Set 0 to 600 bar (0 - 8,700 psi) allows:

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

2 - 1 Pressure connector adapter (M16x200)
3 - 1 Pressure connector hose 1,500 mm long
70.5.2 INFLATION KIT BOX
In cases where it is normal to apply a load less than the
70
truck’s maximum capacity, it is possible that the load loss
rate is not optimal. In this situation, continue with checking
and adjusting accumulator load pressure.
INFLATION KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .781673

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70
ELECTRICITY
CONTENTS
80.1 ELECTRICITY CHARACTERISTICS AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
80.1.1 RELAY AND FUSE HOLDER ELECTRIC PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
RELAY AND FUSE HOLDER PLATE: DETAILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
80.1.2 ECU INPUTS/OUTPUTS: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
ACTI WAYS ECU SPU 25-15 (288734 - A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
80.1.3 ELECTRICAL COMPONENT SHEETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
X8 - GEARBOX OIL TEMPERATURE SENSOR (B70) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
X12 - MECHANICAL TRANSMISSION HANDBRAKE SWITCH (S19) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
X14 - HORN (B2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
X15 - X21 - WHEEL ALIGNMENT SENSOR (B9 - B10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
X20 - REVERSING SOUND ALARM (B1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
X22 - HYDRAULIC FILTER PRESSURE SWITCH (B7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
X23 - HYDRAULIC CUT-OFF EV/VS (Y20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
X28 - X29 - X34 - X35 - PROPORTIONAL TELESCOPE EV (Y15-Y16-Y17-Y18) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
X36 - JSM JOYSTICK (A12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
X54 & X55 - IGNITION SWITCH (S2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
X68 - HOUR METER REV. COUNTER (P1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
X72 - BRAKE FLUID LEVEL SWITCH (S11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
X73 - STOP PRESSURE SWITCH (B11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
X79 - WIPER STALK (S4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
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X89 - WATER TEMPERATURE INDICATOR (P3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
X90 - FUEL LEVEL INDICATOR (P2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
X92 - BOOM LOWERING PROPORTIONAL EV/VRD (Y19) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
X93 - TILTING CUT-OFF EV/VCI (Y7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
X98 - GEARBOX OIL PRESSURE SENSOR (B69) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
X99 - STRAIN GAUGE (B20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
X100 - ANGLE BOOM POTENTIOMETER (B23) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
X114 - EMERGENCY STOP (S50) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
X134 - TELESCOPE RETRACTED POSITION SENSOR(S34) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
X145 A & X145 B - MAGNETIC ROTATING BEACON LIGHT (E15) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
X165 - FUEL LEVEL SENSOR (R2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
X166 - ENGINE AIR FILTER CLOGGING PRESSURE SWITCH (B6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
X188 - LIGHTING STALK (S5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
80.2 WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
80.2.1 EXAMPLES OF CODING ON THE WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

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80.2.2 CABLE MARKING ON AN ELECTRICAL WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
80.2.3 MT-X 733 95P ST3A S1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
POSITION OF CONNECTORS BY DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
KEY DIAGRAM 1 - STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
DIAGRAM 1 - STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
DIAGRAM 2: CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
DIAGRAM 3: TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
KEY DIAGRAM 4: HYDRAULIC MOVEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
DIAGRAM 4: HYDRAULIC MOVEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
KEY DIAGRAM 5: SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
DIAGRAM 5 - SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
KEY DIAGRAM 6: VENTILATION, WIPERS AND AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
DIAGRAM 6: VENTILATION, WIPERS AND AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
KEY DIAGRAM 7: OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
DIAGRAM 7: OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
KEY DIAGRAM 8: LIGHTS AND SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
DIAGRAM 8: LIGHTS AND SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
80.2.4 MT-X 1033 ST 100P ST3A S1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
POSITION OF CONNECTORS BY DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
POSITION OF CONNECTORS BY DIAGRAM (CONT.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
KEY DIAGRAM 1 - STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
DIAGRAM 1 - STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
KEY DIAGRAM 2: CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
DIAGRAM 2: CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
KEY DIAGRAM 3: TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
DIAGRAM 3: TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

80
DIAGRAM 4: HYDRAULIC MOVEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
DIAGRAM 4: HYDRAULIC MOVEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
DIAGRAM 5 - SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
DIAGRAM 5 - SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
DIAGRAM 7: OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
DIAGRAM 7: OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
80.3 ELECTRICITY LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
80.3.1 KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
80.3.2 MAIN HARNESS MT-X 733 2D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
80.3.3 MAIN HARNESS MT-X 733 3D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
80.3.4 MAIN HARNESS MT-X 1033 2D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
80.3.5 MAIN HARNESS MT-X 1033 3D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

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80.3.6 ENGINE 2D HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
80.3.7 ENGINE 3D HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
80.3.8 DISTRIBUTOR 2D HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
80.3.9 DISTRIBUTOR 3D HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
80.4 CONTROL AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
80.4.1 “BOOM ANGLE" ANGULAR SENSOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
80.4.2 LONGITUDINAL STABILITY INDICATOR (LLMI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
TESTING THE LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
STRAIN GAUGE AND ANGLE SENSOR CALIBRATION (DEALER PROCEDURE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
STRAIN GAUGE RECALIBRATION (CLIENT PROCEDURE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
"AGGRAVATING" HYDRAULIC MOVEMENTS CUT-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
LED ILLUMINATION ACCORDING TO CHANGES IN GAUGE SIGNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
80.5 ELECTRICITY REMOVAL -REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
80.5.1 REPLACE THE STRAIN GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
AXLE PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
CHARACTERISTICS OF PRODUCTS USED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
CHARACTERISTICS OF FASTENING SCREWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
ASSEMBLY PRECAUTIONS AND TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
STRAIN GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
80.6 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
80.6.1 ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
MAIN ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
80.7.1 BREAKOUT BOXES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
80
80.7.2 ELECTROVALVE ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
80.7.3 DIAGNOSTIC TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
DIAGNOSTICS CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
CONNECTIONS TO LIFT TRUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
ENGINE ADAPTATION KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

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ELECTRICITY
80.1 ELECTRICITY CHARACTERISTICS AND SPECIFICATIONS
80.1.1 RELAY AND FUSE HOLDER ELECTRIC PLATE
K17 + K18 - F31 + F32

80
647792EN
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RELAY AND FUSE HOLDER PLATE: DETAILS
Element Item Current Designation

F1 Option
F2 15 A Rear working light (option)
F3 10 A Rear windscreen wiper + roof windscreen wiper + side windscreen wiper (option)
F4 7.5 A Engine stop or cab ECM EV
F5 7.5 A Rotating beacon light
F6 5A Wheel alignments + option
F7 7.5 A Llmi safety module + Deactivation of aggravating hydraulic movement cut-off
F8 15 A JSM joystick + transmission cut-off - Relays K2 K3 K4
F9 5A Control instruments panel
F10 10 A Horn + stop switch
F11 15 A Working light on telescope (option)
F12 10 A Flashing light unit
F13 20 A Ventilation/Heating
F14 10 A 12V connector
F15 20 A Hydraulic movement control unit (SPU)
F16 5A Diagnostics plug + heating relay control
FUSES F17 10 A Cleanfix self-cleaning fan (option) + Engine immobiliser system (option)
F18 15 A Front working lights (option)
F19 15 A Rear windscreen defrost (option)
F20 10 A Pneumatic seat (option)
F21 10 A Front windscreen wiper + front windscreen washer
F22 10 A Boom electrical predisposition (option) or TDF EV (option).
F23 7.5 A Right front and rear sidelights + control instrument panel lighting
F24 7.5 A Left front and rear sidelights + number plate lighting (option)
F25 7.5 A Front and rear right hand indicator lights
F26 7.5 A Front and rear left hand indicator lights
F27 15 A Dipped beam headlights + rear fog lights.
F28 15 A Main beam headlights
F29 15 A Hazard warning lights + roof light + engine immobiliser predisposition + clock + rev counter
F30 25 A Lighting, horn and indicator switch
F31 5A Starter relay
F32 5A Diagnostics plug + SPU + driver presence plug
F40 40 A Ignition switch

FUSES F41 40 A Ignition switch
ENGINE
100 CV F42 80 A Engine preheat
F43 80 A Alternator
80
F40 80 A Ignition switch
FUSES F41 30 A Engine ECM
ENGINE
120 CV F42 80 A Preheat
F43 100 A Alternator
OPTION F50 15 A Fuel thinner (option)
OPTION F60 30A Air conditioning (option)
K0 Air conditioning relay ST 3A (option)
K1 Transmission cut-off reverser
K2 Transmission power supply
K3 Reverse gear or reversing light
K4 Forward gear (mechanical transmission)
K5 Buzzer
RELAYS
K6 JSM activation relay
K7 Hydraulic movement cut-off safety device (option)
K8 Anti-start
K9 Flashing light unit
K17 Fault indicator lamp test relay
K18 Starting in neutral safety relay
647792EN
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80.1.2 ECU INPUTS/OUTPUTS:

ACTI WAYS ECU SPU 25-15 (288734 - A)
Key:
APC: Power supply after contact NO: Normally Open
+BAT: Fixed power supply NC: Normally Closed
GND: Ground S.P.U.: Safety Power Unit
1
8
14 7
20 13
19
26
Pin
Type Active state Function on truck Comments
N°
APC ECU power supply
1 Power supply
or +BAT *
2 Proportional output 0V to 12V Attachment way “-” proportional electrovalve
3 Telescope head electrovalve
Logic output GND
5 Safety solenoid valve (VS)
Logic output GND
6 Flow control solenoid valve (VRD)
7 Power supply +BAT ECU power supply
8 Analog input 0.5V to 4.5V Angle sensor boom track 2 *
9 Logic input GND Parked regeneration switch (NO)
10 Logic input GND Easy Connect System Switch (NO)
Switch disabling the “aggravating” hydraulic movement Maintained contact 60° max.
11 Logic input APC
cut-off (NO) * delay 1 minute max.
12 Logic input APC Neutral contact roller 1 (NO) Telescoping
13 ECU wake-up input APC ECU wake-up (NO) Cut-off by emergency stop
14 Proportional output 0V to 12V Attachment way “+” proportional electrovalve
80
Brake pedal transmission cut-off switch (NF) (on PS machine) *

15 Logic input APC
Gear lever transmission cut-off switch (NF) (on non PS machine) *
Hydraulic movements neutralization switch (NO) (TÜV)
16 Logic input GND
APC Driver seat presence sensor (NO)

17 Logic input
or +BAT *
18 Analog input 1V to 11V JSM potentiometer roller 1 Telescoping
19 Stabilised output 5V Not used
20 Ground GND ECU ground
21 Stabilised output 10V Strain gauge / stability warning *
22 Logic input GND Forced operation switch (NO)
Handbrake switch Contact idle = brake applied
23 Logic input ø MLT & MT: Contact NO
or GND MLT PS: Contact NF
24 Logic input APC Ventilation reversal switch (NO) *
25 Analog input 0.5V to 4.5V Angle sensor boom track 1*
* According to version, see on the wiring diagram

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Key:
APC: Power supply after contact NO: Normally Open
+BAT: Fixed power supply NC: Normally Closed
GND: Ground S.P.U.: Safety Power Unit
1
8
14 7
20 13
19
26
Pin
Type Active state Function on truck Comments
N°
APC ECU power supply
1 Power supply
or +BAT *
2 Proportional output 0V to 12V Attachment way “-” proportional electrovalve
Logic output GND
5 Safety solenoid valve (VS)
Logic output GND
6 Flow control solenoid valve (VRD)
7 Power supply +BAT ECU power supply
8 Analog input 0.5V to 4.5V Angle sensor boom track 2 *
9 Logic input GND Parked regeneration switch (NO)
10 Logic input GND Easy Connect System Switch (NO)
Switch disabling the “aggravating” hydraulic movement Maintained contact 60° max.
11 Logic input APC
cut-off (NO) * delay 1 minute max.
12 Logic input APC Neutral contact roller 1 (NO) Telescoping
13 ECU wake-up input APC ECU wake-up (NO) Cut-off by emergency stop
14 Proportional output 0V to 12V Attachment way “+” proportional electrovalve
Brake pedal transmission cut-off switch (NF) (on PS machine) *
15 Logic input APC
Gear lever transmission cut-off switch (NF) (on non PS machine) *
Hydraulic movements neutralization switch (NO) (TÜV)
16 Logic input GND
80
APC Driver seat presence sensor (NO)
17 Logic input
or +BAT *
18 Analog input 1V to 11V JSM potentiometer roller 1 Telescoping
19 Stabilised output 5V Not used
21 Stabilised output 10V Strain gauge / stability warning *
22 Logic input GND Forced operation switch (NO)
Handbrake switch Contact idle = brake applied
23 Logic input ø MLT & MT: Contact NO
or GND MLT PS: Contact NF
24 Logic input APC Ventilation reversal switch (NO) *
25 Analog input 0.5V to 4.5V Angle sensor boom track 1*
* According to version, see on the wiring diagram

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80.1.3 ELECTRICAL COMPONENT SHEETS

X8 - GEARBOX OIL TEMPERATURE SENSOR (B70)
PIN Function
1 Signal info
Corresponding connector
Diagram
Temperature Typical
25 °C 2000 Ω
70 °C 2800 Ω
100 °C 3400 Ω
120 °C 4000 Ω
Comments:
Normal operating temperature is between 70 and 120 °C
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
X12 - MECHANICAL TRANSMISSION HANDBRAKE SWITCH (S19)

PIN Function 1 2 3 4
1 ECU info output
1
2 4
3 2 Ground
80
3 Lamp output
4 Ground
Diagram
PIN Typical
LED power consumption 3 25 mA
SPU power consumption 1 6 mA

Comments:
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
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X14 - HORN (B2)
PIN Function
1 Buzzer power supply
Diagram
Typique
Supply voltage 12 V
Resistance 2,17 Ω
Consumption 6,00 A
Nominal frequency 500 ± 20 Hz
Sound level 107 dB(A) / 13V
Note :
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
X15 - X21 - WHEEL ALIGNMENT SENSOR (B9 - B10)
___________________________________________________________________________________________
PIN Function
1 Ground
3 2 Signal _ +
2
1 3 Power supply
80
B A C
Diagram
PIN Typical
Supply voltage B 12 V
Direct current A 10 mA
Outlet logic Switch closed = wheels aligned
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
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B1 REVERSING
X20 - REVERSING SOUND
SOUND ALARM
ALARM (B1) X20
PIN Function 1 2
1 Power supply
2 Cab rear ground
Diagram
Typical
Voltage 12 V
Sound frequency 2800 Hz

Comments:
Sound cycle: 50% off 50% on, with 1,2 pulses per second
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
X22 - HYDRAULIC FILTER PRESSURE SWITCH (B7)
PIN Function 1 2
1 Oil pressure info

1
2
80
2 Rear cab ground
Corresponding connector P
Diagram
Comments:
Type 1 negative logic input (ELN1)
Trigger value : 5 bars.
Filter bypass opening pressure of 6 bar.
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
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X23 - HYDRAULIC CUT-OFF EV/VS (Y20)
PIN Function
1 Power supply
1 2
1
V
2 2 Ground
V3
V2
V4
T1 V1 Corresponding connector
Diagram
Typical
Supply voltage 12 V
Resistance (at 20 °C) 9,6 Ω
Tolerance 10 %
Consumption 1,4 A
Comments:
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
X28 - X29 - X34 - X35 - PROPORTIONAL TELESCOPE EV (Y15-Y16-Y17-Y18)
PIN Function 1 2
1 1 Power supply
2 2 Ground
80
V
V3
V2
V4
Diagram
Min. Max.
Supply voltage 0 6V
Consumption 0 1,5 A
Coil resistance (at 20 °C) 4,2 Ω
Tolerance 10%
Comments:
Electrovalve control is by current variation. Voltage is indicative only.
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
647792EN
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X36 - JSM JOYSTICK (A12)

(Joystick Switch and Move)
R
PIN Function
N
1* Power supply or Ground
F
R1 2 Roller 1 direction A (+)
12
3 Roller 1 direction B (-)
11
R2
4 Roller 2 direction A (+)
6
−
5 5 Roller 2 direction B (-)
+
7
8
4
3 8 6 Signal Roller 1
1
HM 9
FNR 2
– 10 7 Signal Roller 2
7
1
11
8* Power supply or Ground
5
BP2 12
D+ D-
+
4
9 BP1
R2
BP1
6
10 BP2 Option
3
D+ D-
11 Forward gear
R1
2
12 Reverse gear
BP2
10
PIN Function
9
1 1 Speed +
2
BP1
2 Speed –
2
1
4
1 4 Dead man button
2
BP HM
4
3
Corresponding connectors Diagram
12-way connector PIN Min. Typical Max.

Current ± 10% 1 mA 2 mA
Potentiometers Supply voltage ** 1 or 8 5V
under 5 V (10% to
90%) 6-7 0.5 V 2.5 V 4.5 V
Output voltage
2-3-4-5 0V 5V
Current ± 10% 1 mA 2 mA
Potentiometer under Supply voltage ** 1 or 8 12 V

12 V (25% to 75%)
80
6-7 3V 6V 9V
Output voltage
2-3-4-5 0V 12 V
2-way connector PIN Min. Max.

1 0V 5 or 12 V
Output voltage
2 0V 5 or 12 V
4-way connector PIN Min. Max.

Output voltage 4 0V 5 or 12 V
Remarks:
* Depending on the machine range, pins 1 and 8 may be a ground or a power supply connection.
Determine which option applies e Group 80 - Electrical schematic diagrams - Electrical diagrams by
function.
** Depending on the machine range the supply voltage may be either 5 V or 12V.
Check on the power supply pin.
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X54 & X55 - IGNITION SWITCH (S2)
PIN Function
1 + Battery
2 + Battery
4 3 Un used
2 1
3 4 Shunt preload
OP
5 + After contact (+APC) 30 30 17 17 50a 19 19 54 15 58
1 2 3 4 7 8 9 5 6 10
6 + After contact (+APC)

5 7 Starter
6
7 8 Shunt preheating
8 Diagram
9 9 Preheating control relay
10 POS
10 Un used PIN
ITIO
N O P Maxi - 12 V
7 (50a) x 18 A / 1min
8 (19) x x 70 A / 3.5min
9 (19) x x 70 A / 3.5min
Note : 5 (54) x x x 65 A / ∞
Voltage drop : 300 mV 6 (15) x x x 65 A / ∞
10 (58) x 8A/∞
x -> PIN = 12 V
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
X68 - HOUR METER REV. COUNTER (P1)
PIN Function
26
1 + Battery (permanent)
13 1 2 3 4 8 9 11 15 16 17 25 2 3 4
2 Ground
14
80
Satellite BUS
Alimentation
Battery
Ground
CAN High
CAN Low
K-Line
Analog input 3
0-5V DC input
llumination
Ignition
Analog
GND ANA
Input 1
10 RPM
15
x
1 3 CAN H 15
100 10 RPMx100 20
9 20
4 CAN L
5 25
30
0 25
2651
29
30 8 K-Line
9 Analog input 1
11 Analog input 3
Diagram
PIN Function 15 0-5 V Power Supply
2 Satellite Bus 16 Rear lighting

1 2 3 Analog ground 17 After ignition
3
4 4 Satellite power supply 25 Analog ground
PIN Min. Typical Max.
Voltage 8,5 V 12 V 32 V
Consumption 150 mA
Comments:
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
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X72 - BRAKE FLUID LEVEL SWITCH (S11)
PIN Function A
1 Module A1 info (dashboard)
2 Cab Front Ground

N
Diagram
Note : contact closed = Level OK
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
X73 - STOP PRESSURE SWITCH (B11)
PIN Function A B
A 12 V power supply
80
B Stop Light Control
P
Diagram
Note :
- The Pressure switch contact closes at a pressure of 3 ± 0,4 bar in the braking circuit.
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
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X79 - WIPER STALK (S4)
PIN Function
F
0
0
Rear windscreen wiper and
1
2
1
windscreen washer power supply 0
2
2 Rear screen wiper control
1
1 3 Front windscreen wiper power supply

2
3 4 Rear screen washer
7 5 Front screen washer supply
4 8
1
5 6 9 6 Front screen washer control 0
9
7 Front screen wiper speed 1 8
7
8 Front screen wiper speed 2 6
5
9 Intermittent 4
1
1 Rear screen wiper parking 2
2 2 Front windscreen wiper parking 1
Corresponding connector Diagram
Typical
Voltage 12 V
Consumption As per outputs
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
X89 - WATER TEMPERATURE INDICATOR (P3)
PIN Function 1 2 3
1 Satellite Bus
Satellite BUS
Ground
Battery
1
4 3
6 2 Ground
80
3 Power supply
Diagram
Min. Typical Max.

Voltage 10 V 12 V 16 V
100 mA without rear lighting
Consumption
150 mA with rear lighting
Note :
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
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X90 - FUEL LEVEL INDICATOR (P2)

PIN Function 1 2 3 4 5 6
1 Satellite Bus
Satellite BUS
Ground
Battery
Satellite BUS
Ground
Battery
1 2 Ground
4 3
6 3 Power supply
4 Satellite Bus
5 Ground
6 Power supply
Diagram
Min. Typical Max.

Voltage 10 V 12 V 16 V
100 mA without back-lighting
Consumption
150 mA with back-lighting
Comments:
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
X92 - BOOM LOWERING PROPORTIONAL EV/VRD (Y19)
PIN Function 1 2
1 1 Power supply
V
2 2 Ground
80
V3
V2
V4
Diagram
Min. Max.
Supply voltage 0 6,9 V
Consumption 0 1,5 A
Tolerance 10 %
Comments:
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
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X93 - TILTING CUT-OFF EV/VCI (Y7)
PIN Function 1 2
1 Power supply
1
V 2 2 Ground
V3
V2
V4
Diagram
Typical
Supply voltage 12 V
Tolerance 10%
Consumption 1,5 A
Comments:
When cut-out is in effect, the VCI is not powered.
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
X98 - GEARBOX OIL PRESSURE SENSOR (B69)
PIN Function
1 Signal
80
P
Diagram
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
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X99 - STRAIN GAUGE (B20)
PIN Function
4
3
5 1 Shielding
2 R120
1
2 Power supply
CAN H
CAN L
Black
Red
3 Ground
4 CAN_H
5 CAN_L
Corresponding connector 1 5 4 2 3
Diagram
Typical
Supply voltage 12 V
Consumption 150 mA
Comments:
- CAN integrated terminal resistance 120 Ω.
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80
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X100 - ANGLE BOOM POTENTIOMETER (B23)
PIN Function
1 Ground
2 12 V Power Supply
6 Track 1 angle signal

5 3
(0.5 to 4.5V)
4
1 2 3 1 5 6 4
2 4 Ground
3 + S 0 + S 0
5 12 V Power Supply
Diagram
Track 2 angle signal
6
(4.5 to 0.5 V)
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
S1
80
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: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
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X114 - EMERGENCY STOP (S50)
PIN Function
1 Power supply Battery +

6
DEM
EVM
SPU
5 2 Engine EV power supply
4
1 3
Power supply + after
2 ignition starting 1 2 1 2 1 2
3
4 Starter relay output
5 Engine EV output 3 4 2 5 1 6
6 SPU Power Supply

Diagram
Comments:
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
X134 - TELESCOPE RETRACTED POSITION SENSOR(S34)
PIN Function
12 V power supply ignition

1
on
1
2 4 12 V power supply ignition
3 2
80
on
3 NC switch info output
4 NO switch info output

1 4 3 2
Diagram
Note :
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
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X145 A & X145 B - MAGNETIC ROTATING BEACON LIGHT (E15)
PIN Function
1 Power supply
2
2 Ground
1
M
Diagram
Typical
Voltage 12 V
Resistance (10%) 2,82 Ω
Current 5A
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
X165 - FUEL LEVEL SENSOR (R2)
PIN Function 2 1
1 Analog input
1
2 2 Ground
80
N
Diagram
PIN Min. Typical Max.

Supply voltage 1 / 12 V /
Comments:
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
647792EN
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X166 - ENGINE AIR FILTER CLOGGING PRESSURE SWITCH (B6)
PIN Function A B
A Clogging info
B Ground
P
Diagram
PIN Typical
Nominal depression 62 mbar ± 5%
Voltage B Ground
Consumption 25 mA
Note : contact closed = clogged filter
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
X188 - LIGHTING STALK (S5)
PIN Function 2
4
1 Light power supply
3
Dipped beam
0
80
2 9
headlights
1 8
2 3
Headlight 57/58 56a 56b 54s 54d 49
6
L 0 R
3 signal 0 1 2
5
7 4 Main beam headlights
4 8
7
5 6 9 5 Horn 30 L 31 1
6 Horn power supply

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

Voltage 12 V 24 V
Consumption 3A 5A 7A
Note :
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
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80
647792EN
146 ELECTRICITY 80 (20/01/2020)
80.2 WIRING DIAGRAMS
80.2.1 EXAMPLES OF CODING ON THE WIRING 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
Y16
CAN A L
E F3 469
X161
EP7
719
71 72 10
15
14
666
412
369
G 13 412 2
12 11 41 42
1
69
58
569 EP12 420
69
CN1-P1
Masse CAN A
CAN A H
CAN A L
Sch.3
59
X161 Y15
77
91
90 76
89 47 X38-7 X168
EP5 M1
Sch. 8 Sch. 5 9 X76B
88 46
I
17
87 17
X166A X166B
R 16
86
S25 N
12 183 30 P
F
11 182 59
A1 B06
80
8 82
179
JSM 1 34 MP 12
172
K 7 178 49
X149
5 176 88 58
440 440
B16
-
4 175 87
CN2-P1
Option ETDF Version EP/RC

+
6 177 19
B15 3 174 86 58
449 2 Y28
-
EP68
16
+
2 173 85 1
S16 10 232 89
X160
M
A12 S15 9 180 56
X67 X148
Example of marking on cables and components on an electrical diagram
Key:
1 - Marking grid
2 - + Permanent 10 - Electrical component name
3 - + After ignition 11 - Splice
4 - Grounds 12 - Version choice
5 - Wire N° 13 - Other diagram reference
6 - Electrical connector 14 - CAN
7 - Electrical connector name 15 - CAN Shielding
8 - Electrical connector PIN N° 16 - Option
9 - Electrical component
647792EN
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80.2.2 CABLE MARKING ON AN ELECTRICAL 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
80
647792EN
148 ELECTRICITY 80 (20/01/2020)
80.2.3 MT-X 733 95P ST3A S1

POSITION OF CONNECTORS BY DIAGRAM
Item Diag. 1 Diag. 2 Diag. 3 Diag. 4 Diag. 5 Diag. 6 Diag. 7 Diag. 8
X1 H8
X2 I6
X3 I6
X4 E2 H3 H2
X8 E13
X9 D10
X10 D10
X11 I5
X12 I11
X13 G6
X14 E12
X15 H12
X16 G9
X17 G7
X18 G11
X19 G10
X20A G10
X20B G11
X21 H13
X22 I13
X23 H12
X24 D3
X25 H14
X26 F8 I11
X27 A11
X28 I8
X29 H8
X30 D1
X31 G3
X32 G10
X33 E11
X34 H7
X35 H6
X36 D7
X37(D) B2 B2 D4
X38(I) C12
80
X39(C) D5
X40(B) C6,C7 B2 B2 B4 D3
X41(A) B3 B3 B3 D2
X42(H) C6 B12
X44(G) B7 B3
X45(K) A5 C11 B14
X46 F4
X47 C5
X48 A2
X49 G12
X50 I12
X51 I13
X52 F10
X53 A11
X54 B2
X55 B4
X56 C6 F6 C5
X57 C7 E7 C9
X58 G8
X59 I2
X60 I2
X61 I3
X68 I4
647792EN
80 (20/01/2020) ELECTRICITY 149

X70 E6
X71 H8
X72A D11
X72B E11
X73A I12
X73B I12
X74 G5, D12
X75 D6 A8
B14, C14, C14 D14 B14, F14,
X76A J14 G14 C14
I14 E14 H14, J14
C14, H14,
X76B C14,H14 G14 G14 F14 G14 E14
J14
X77 E6
X79 C6
X80 C7
X84 H13
X85 H13
X86 B12
X87 E7
X89 I5
X90 I3
X91 G11
X92 H11
X93 H9
X94 H6
X95 F14
X96 G10
X97 G5
X98 E13
X99 H6
X100 A8
X101 C14
X103 E7
B14, H14,
X105 G14 I14
I14
F14, G14,
X106 B14
H14
X107 H14 B14
X108 B14
X114 B8 B5
80
X115 B12
X116 F12
X117 E12
X118 C7, D7
X119 E13
X133 H12
X134 A10
G14, E14,
X135 B14 G14
F14
X136 I6
X138A B11
X138B B11
X139A B12
X139B B12
X140 J6
X141 J6
X142 I10
X143 I7
X144 I9
X145A I7
X145B I8
X146 J8
X147 J10
X148A I9
647792EN
150 ELECTRICITY 80 (20/01/2020)

X148B I9
X148C I9
X149 H6
X150 J11
X151 I12
X152 J13
X153 H12
X154A G10
X154B H10
X160 D1
X161 E13
X162 H8
X163 H9
X164 H6
X165 E6
X166A E6
X166B E7
X167 H6
B14, D14,
X168 F14, J14
X169 H7
X170A H9
X170B H10
X171 F3
X172 D2
X173 D2
X174 A1
X175 D5
X176 C14 J14
X180(E) C8
X181(F) C11
X182 D7
X183 D8
X184 D12
X185 D7
X187 A10
X188 B5
X189 A5
X190 A6
80
X191 A7
X192 A11
X196 B14
X200A A1
X200B A2
X202 D13
X203 E4
X204 G3
X205 H3
X206 I3
X207 I3
X208 I4
X209 I4
X210 H13
X211 H14
X212 I9
X213 G8
X214 C2
X215 G3
X235 B7
X236 B6
X238 B13
X239 C7
647792EN
80 (20/01/2020) ELECTRICITY 151

X273 I14, J14
X284A G11
X284B G11
X285 H6, I6 H5, H6
X287 I6 I6
X292 E7
X292A D7
X292B E8
X292C E9
X293 G14
X326 D6
80
647792EN
152 ELECTRICITY 80 (20/01/2020)
KEY DIAGRAM 1 - STARTING

CONNECTOR
Pos. Harness Component Designation Position
X24 ENGINE/MAIN Main harness/engine interface D3
X40(B) MAIN A15 Starting safety/wheel alignment/brake fluid tank C6,C7
X42(H) MAIN A15 Fuse plate C6
X45(K) MAIN Plate power supply and earth fuses -relay A5
X47 MAIN Starter Atofuse fuse holder C5
X54 MAIN S2 4-way ignition switch A B2
X55 MAIN S2 6-way ignition switch A B4
X76A MAIN Cab left-hand earth B14,C14,I14
X76B MAIN Cab left-hand earth C14,H14
X86 MAIN A21 Discharge valve module B12
X101 CABLE Mid-frame/earth engine C14
X105 MAIN/DISTR Distributor harness earth connection B14,H14,I14
X107 MAIN Cab rear earth H14
X108 MAIN Front frame earth on cab support B14
X114 MAIN S50 Emergency stop B8
X133 MAIN Y8 Discharge EV H12
X135 OPT Cab options right-hand earth B14
X160 ENGINE WIRE BF1 Battery fuse box A BF1 D1
X161 ENGINE M1 Starter electrovalve E13
X162 ENGINE Y1 Engine stop electrovalve H8
X163 ENGINE M2 Diesel pump H9
X164 ENGINE B3 Engine oil pressure H6
X165 ENGINE R2 Fuel gauge E6
X166A ENGINE B6 Air filter clogging E6
X166B ENGINE B6 Air filter clogging E7
X167 ENGINE R1 Preheat H6
X168 ENGINE Engine Earth B14,D14,F14,J14
X169 ENGINE Y2 KSB cold start H7
X170A ENGINE B5 Engine water thermoswitch H9
X170B ENGINE R7 Engine water thermoswitch H10
X171 ENGINE K16 Preheat relay F3
X172 ENGINE BF1 Preheat/alternator power fuses D2
X173 ENGINE BF1 Equipment power fuses (MLT) - ECM fuse (MT) D2
X174 ENGINE S1 Clock earth A1
X175 ENGINE LSU Potentiometer D5
X176 CABLE Engine unit earth on frame C14
80
X200A OPT/STD S1 Battery cut-off A1

X200B OPT/STD S1 Battery cut-off A2
X214 OPT Diesel preheater regular fuse holder C2
X215 OPT K15 Diesel preheater relay G3
FUSES AND RELAYS

Pos. Current Designation Position
F31 25 A Starter solenoid/PERKINS C4
F40 40 A Ignition switch D2
F42 80 A Preheat D2
F43 80 A Alternator E2
F47 15 A Diesel decongealant C1
K8 Anti-start relay C6
K15 Diesel decongealant relay G3
K16 Preheat relay F3
SPLICES
Pos. Position
EP1 G8
EP5 H8
EP32 C12
647792EN
80 (20/01/2020) ELECTRICITY 153
DIAGRAM 1 - STARTING
1 2 3 4 5 6 7 8 9 10 11 12 13 14
X174 X200B
M 10
609
as 5/
(X
se X1
M 76
Ch 0 1
S1
as A/
(X sse /X1
as /X
se X7 teu )
A
si 1 0
X200A
M 16
s
Ca 6B r
S2
a 8
(X
bi /X
ne 13
8)
m 76
CDE A21
DEM
EVM
o
EV DECHARGE
5/
X1
X45(K)
07
OP
EV OUT
G1 S50 1
-
)
BAT+
GND
2 1 2
W2
30 30 17 17 50a 19 19 54 15 58 69 4 K6-85
X54 1 2 3 4 7 8 9 5 6 10 X55 7
Sch.3 X114 X168
66 X192-4 3 4 2 5 7 3 13 14
Sch.7
X86 X76A
92
82
92
315
316
69
184
314
65
6
8
227
395
499
20
+
B 68 5 X135
63
13
64
16
12
7
67 6
64 2
X118-8
X108
X95-4 X41(A)-11
63 1 X192-7 Sch. 3 Sch. 7 Sch.7
Sch.7
X48-1 151 315 X105
Sch. 2
X40(B)
A15 K8
X292-3
Sch. 7
184
9
X40(B)
82 15 15 3 30
87 5
3 14
EP32
141 X68--5 X176
X47 Sch.8
1 2 2 1 86 85
24
X214 X118-7 2 X101
C 1 2
X59-2
Sch.8
X38(I)-3
Sch.7
236 1
Sch.8
F31
X42(H) X38(I)-1 X89-5 11 X76B
EP94 Sch.8 Sch.8
Sch.8 10 X76A
F47
X90-5 X38(I)-7
267
20
14
Sch.8
21
11
26
10
19
18
24
16
12
13
25
17
Sch.8
X24
6
7
A1 A8 C8 C1 B3 A2 A6 A4 A3 C3 C4 C2 A7 B2 B4 B1 A5 B6 B5 B8
BF1 X168
604
605
602
617
624
616
607
623
605
608
611
606
603
612
609
601
613
610
632
634
633
608
X173
F40 A 606 604 X168
D
611
F41 B 603
632
634
633
X160 X175
X172 2 3 1 622
F42 A
629
621
607
X165 B+
F43 B
620
2 1
623
621
X166A X166B
617
F46
E Sch. 6 X161
M1
R2
P
B6
X171
627
K16 3
629
F 30
87 5
622 X168
628 628 X168
86 85 2
612
1
80
X215
602
G K15 630
2
EP1
85 86
625
626
1
87
30
3 40 X76B
V8
5
40 X107
H
627
613
630
EP5
616
624
X167 X164 X169 X170A X170B 317 X105
1
620
601
610
316
317
X133
619
618
625
X162 X163
626
1 2
D+
B+ W
2 1
2 1 129 X76A
3~
G P
Y2
U
R5 R1 X105
B3 129
I
M
G2 B5 R7
Y8
Y1 M2
635 X168
X168
J
X168
647792EN
154 ELECTRICITY 80 (20/01/2020)
Key Diagram 2: CAN

CONNECTOR
X37(D) MAIN A15 Plate power connector B2
X41(A) MAIN A15 Options and roof light power supply B3
X48 MAIN Atofuse fuse holder for DIAG plug + SPU A2
X56 MAIN A3 SPU CN1-A C6
X57 MAIN A3 SPU CN1-B C7
X58 MAIN A5/LLMI LLMI safety module G8
X76B MAIN Cab left-hand earth C14, H14, J14
X99 MAIN B20 Vishay gauge connector H6
X107 MAIN Cab rear earth B14
X115 MAIN OBD II Diagnostics B12
X284A MAIN Easy Manager (Module Trackunit) Option G11
X284B MODULE A25 Easy Manager (Module Trackunit) Option G11
Key Pad Option (Digicode/RFID Card Reader) for Easy
X293 MAIN G14
Manager
FUSES AND RELAYS

F15 20 A SPU B2
F16 5A Diagnostics plug + heating relay control (ST3B) B3
Diagnostics plug + SPU power supply +switch near
F32 5A A2
condenser + Easy Manager opt
SPLICES
Pos. Position
EP25 E7
EP35 D9
EP36 D9
EP37 D9
EP38 C6
EP43 A4
EP58 G11
80
647792EN
80 (20/01/2020) ELECTRICITY 155
DIAGRAM 2: CAN
1 2 3 4 5 6 7 8 9 10 11 12 13 14
AP
Vb
at
C
M
X45(K)-1
as
Sch.1 151 2
se
M 76
A EP43
sC
as A
(X
151
si / X
ha
2
ss
Ca 76B
X48
is
1 2
bi )
259
487
188
189
(X
ne
10
7)
F32
X285-1
Sch. 3
X45(K)
Sch. 1 A15 S50
SPU
X115
F15
F16
B 1 2
A3 16 14 6 10 7 6 5 4 9 8 1
X114 SPU
OUT SENSOR
489
120 ohms
488
385
GND CAN 1
CAN1-120
1 6
W UP IN
487
394
CAN1 H
486
CAN1 L
485
X37 X41
12VD
12VD
12VC
12VC
12VB
12VP
GND
GND
GND
497
498
(D) 2 3 7 (A) 489 X107
X56 7 1 20 26 13 CN1-A 21 X57 4 3 9 8 34 CN1-B 28 1 2 11
261
181
492
470
260
189
188
186
185
180
183
182
187
61
497
182
183
488
388
61
498 181
EP38 X76B
C 187
180 389
261
260
492
494 486
EP36
493 485
EP35
D EP37
491
490
470
79
EP25
495
E OPTION A25 Trackunit®
EASY MANAGER ME 501-4
réf. 52551094
Digital Input 1 (max 200mA)

(version CAN + M8)
Digital Input 2 (+APC)
Digital Input 3 (libre)

Digital Input 1 (D+)
Digital Input 4
Bus 1-wire
+ BAT 12V
- BAT 0V
CAN H
CAN L
+ 5V
Dérivation moulée
F
infos transmises
via réseau CAN
1 2 3 4 5 6 7 8 9 10 11 12 - + OUT
X284B X293
80
2 3 1
X119-10
Sch. 4 X284A 1 2 3 4 5 6 7 8 9 10 11 12
G 1 2 3
4 5 6
384
385
386
387
389
390
391
392
490
491
388
398
A26
31
79
X58 1 2 3 4 7 8 9
* 0 #
394
EP58
ALIM 12V
GND
CAN H
CAN L
393
Trackunit®
389
OPTION DualID
EP28
Sch. 4 (Key pad)
495
494
493
496
H X99 2 3
1 4 5
A5 / LLMI EP94 X292-1 X59-2 X292-4 X119-1 EP95
Sch. 8 Sch. 7 Sch. 8 Sch. 7 Sch. 4 Sch. 3
398 X76B
I R120
B20
185 X76B
J 186 X76B
647792EN
156 ELECTRICITY 80 (20/01/2020)
KEY DIAGRAM 3: TRANSMISSION

CONNECTOR
X01 MAIN S21 Transmission cut-off on gear lever H8
X02 MAIN S46 Seat switch power supply I6
X03 MAIN S46 Seat switch information I6
X09 MAIN V10, Y3 Forward EV D10
X10 MAIN V10, Y4 Reverse EV D10
X12 MAIN S19 Handbrake switch I11
X15 MAIN B9 Front wheel alignment H12
X21 MAIN B10 Rear wheel alignment H13
X36 MAIN A12 JSM D7
X42(H) MAIN A15 Fuse plate B12
X44(G) MAIN A15 Relay/hydraulic movement cut-off/Transmission cut-off/EV B7
X50 MAIN E8, H13 Front wheel alignment indicator lamp I12
X51 MAIN E8, H14 Rear wheel alignment indicator lamp I13
X52 MAIN S31 Front and rear wheel alignment switch F10
X56 MAIN A3 SPU CN1-A F6
X57 MAIN A3 SPU CN1-B E7
X61 MAIN S30 Transmission cut-off switch I3
X71 MAIN S20 Transmission cut-off on brake pedal H8
X75 MAIN A12 TUV sidelight control by working light on boom D6
X76A MAIN Cab left-hand earth J14
X76B MAIN Cab left-hand earth G14
X95 MAIN K18 Hella K12-K18 mini relay holder F14
X105 MAIN/DISTR Distributor harness earth connection G14
X116 MAIN S14 Easy Connect system switch F12
X196 PS GEAR BOX EVR B14
X285 MAIN Seat additive harness H6, I6
X287 MAIN S46 Pneumatic seat + Driver presence switch I6
X326 MAIN A12 Dead man switch on JSM D6
FUSES AND RELAYS

F8 15 A Relays K2/K3/K4 + transmission cut-off + JSM/FNR A6
K0 Hare speed relay (ST3A) A7
K1 NC transmission cut-off relay A8
K2 NO transmission cut-off relay A8
K3 20 A Reverse gear relay A9
80
K4 Forward gear relay A10

K6 5A Tortoise speed relay (ST3A) A11
K18 Neutral safety relay F13
SPLICES
Pos. Position
EP2 H11
EP4 E5
EP6 E13
EP7 E13
EP12 E13
EP23 E8
EP24 E8
EP26 E7
EP27 E7
EP95 G7
647792EN
80 (20/01/2020) ELECTRICITY 157
DIAGRAM 3: TRANSMISSION
1 2 3 4 5 6 7 8 9 10 11 12 13 14
AP
Vb
M
a
C
as
t
se
A15 X45-4
M
Ca
as
Sch.1
bi
se
X45(K)
ne
A
Ch
(X
Sch. 1
as
76
K0 K1
si
A/
K2 K3 K4 K6
s
1 5 4 1 5 4 1 5 2 5 4
X
1 5 1 5
(X
76
10
86 87 87a 86 87 87a 86 87 86 87 86 87 85 87
B/
5)
F8
X
A15-Timer
19
Sch.8
6)
85 30 85 30 85 30 85 30 85 30 86 30
2 3 2 3 2 3 2 3 2 3 1 3
B
(G) 19 6 20 7 8 9 21 10 18 16 4 5 15 1 11 2 X42 5 4 3
X44 (H)
EP13
197
205
205
148
197
226
166
232
167
212
213
Sch. 8
C A12
µC
R1 R2
212
269
230
213
268
230
BP1 BP2
38
D+ D- D+ D-
F N R V10 V10
X10 X09
1 2 1 2
1 2 3 4 9 10 2 3 6 4 5 7 1 8 11 12
X326
D X36
773
774
775
776
Y4 Y3
240
241
777
37
174
175
172
173
168
170
36
X76A X44-15 EP28
Sch. 4
242 777
242 EP 93
37
X118-4 39
Sch. 7
EP 4
166
EP26 EP27 EP24 232
36
167
EP23 EP6 EP7
E 46
27 V4 V5
X117-9
477
169
168
240
171
170
476
77E
Sch. 4
12 18 X57 12 24 16 22 14
1 9 X114-3
1 0
EP12
IN TOR 8
IN TOR 9
479
277
Sch. 1
X46-3
OUT PWM 2
A3 SPU
IN TOR 10
Sch. 8
IN TOR 2
0 1 9
IN TOR
223
231
227
226
1
5 S31
13
10
2 1 5 4 3 X95
X52
X56 15 17 CN1-A 23 10 12 17 CN1-B
F
134
S14
32
58
148
1 5 4
479
146
X40(B)-7
397
77E 5
206
10
Sch.7 ECS X116
86 87 87a
480
85 30
X103-10 75C 2 3
Sch. 4
K18 480 X76B
M1
397
80
60
EP95
392
G
X284A-12 28 X105
Sch. 2
38
203 47
113
EP 2
29
47
46
48
28
27
X15 C B A X21 C B A
262
258
_ + _ +
EP43
H Sch. 2 X285-04
X38(I)-5
Sch. 7 B9 B10
Sch. 8
206
139
133
259
60
49
77D
X71
146
X01
203
113
133
X285
45
49
1 2 1 2 2 1
71 32
1 2 3 4 X12
29
48
1 7 2 8 9
0
1
X285 1 2 X285 1 2 X50 2 1 2 1 X51
I S30 X02 X03 X287 1 3

5
X61
6 10
S21 S19
S20 E8 H13 H14
132
41
77D
S46 S46
258 X76A
X118-9 X76A
132
Sch. 7
J
647792EN
158 ELECTRICITY 80 (20/01/2020)
KEY DIAGRAM 4: HYDRAULIC MOVEMENTS
CONNECTOR
X04 MAIN POWER SUPPLY options E2
X23 DISTRIB Y20 Hydraulic cut-off EV/VS H12
X28 DISTRIB Y16 Telescope retraction EV I8
X29 DISTRIB Y15 Telescope extension EV H8
X32 MAIN S7 Cigarette lighter socket G10
X33 MAIN S33 Hydraulic movement neutralisation switch E11
X34 DISTRIB Y18 Attachment Direction- EV H7
X35 DISTRIB Y17 Attachment Direction+ EV H6
X40(B) MAIN A15 Starting safety/wheel alignment/brake fluid tank B2
X76A MAIN Cab left-hand earth G14
X87 MAIN Distributor harness interface (Mlt) E7
X91 MAIN S7 Cigarette lighter light G11
X92 DISTRIB Y19 Proportional electrovalve on boom lowering/VRD-VRP H11
X93 MAIN/DISTR Y7 Tilting cut-off EV/VCI H9
X94 OPT Y12 Boom head electrovalve H6
X97 MAIN S10 Boom head electrical predisposition or boom head EV G5
X100 MAIN B23 EN 15000 boom angle sensor A8
X103 MAIN S29 TDF OR TDF EV Electric plug switch E7
X106 MAIN Rear frame earth B14
X117 MAIN S28 Attachment locking switch E12
X119 MAIN S27 Override Switch E13
X134 MAIN S34 Telescope retraction sensor A10
Aggravating mvt cut-off power supply on non-
X203 OPT E4
EN15000 version
X273 DISTRIB Distributor harness earth connection I14, J14
FUSES AND RELAYS

F1 7.5 A LSU + AS option A3
LLMI + override switch + sensors + blue light opt
F7 7.5 A A3
(15 A)
80
F22 10 A Max. Boom suspension + boom electrical predisposition + boom head EV A2

K7 Free A3
SPLICES
Pos. Position
EP28 B6
EP29 A7
EP49 B10
647792EN
80 (20/01/2020) ELECTRICITY 159
DIAGRAM 4: HYDRAULIC MOVEMENTS

1 2 3 4 5 6 7 8 9 10 11 12 13 14
AP
Vb
B23 S34
at
C
M
as
se
X45(K)
A15 X45-4
Ch
Sch. 1
A
a
Sch.1
M 76
ss
as A/
K7
is
(X
1 5
X100
(X
se X7
X134
10
86 87
Ca 6B
2 3 1 5 6 4
F22
6/
1 4 3 2
bi )
F1
F7
X2
ne
468
469
466
465
467
464
375-481
483
482
484
73
468
85 30 469
)
2 3
X36-1 EP29 483
Sch. 3 EP49 377
455
484
(B) 2 17 14 12 13 3
X40 X44 (G)
X106
241
467
156
155
377
163
218
455
496
B X99-3
Sch. 2
EP28 466 X106
210
MT1033 ST
481-376
465
482
210
464
X56 CN1-A 25 8 X57 15 23 31 CN1-B
IN TOR 5
IN TOR 6
IN ANA 1
IN ANA 2
IN ANA 5
AGND
OUT PWM 10
A3
OUT PWM 4
OUT PWM 1
OUTPWM 8
OUTPWM 5
OUTPWM 6
OUTPWM 7
OUT TDR 1
OUT LS 12
OUT LS 11
OUT LS 22
SPU
IN TOR 12
IN TOR 11
C
IN TOR 4
IN TOR7
4 14 2 16 6 5 11 29 6 7 5 32 19
179
191
178
456
478
204
177
176
196
471
234
42
44
D X116-9 X284A-11
Sch. 3 Sch. 2
277
391
77C
77B
472
478
128
456
217
204
1 9 1 7 2 8 9 1 9 0 1 9
1 0 1 0 1 0 1
163
128
475
156
155
191
176
177
234
196
179
X04
178
42
44
X87
E 6 5 9
S29 3 4 1 2 9
X202-5 5 10
7 8 5 6
5
S33 6 10 5 S28 10 5 S27 10
OU
178
179
176
177
191
196
234
Sch. 5 X119
42
44
X103 X33 X117
77C
112
X203
475
134
131
190
75B 190 75A
218
77B
31
30
X52-10 X49-10 X58-1
Sch. 8 Sch. 2
Sch. 3
F
80
30 X76A
X37(D)-5 EP 3
Sch. 8 Sch. 8
101 X76B
G
471
472
X97 2 1
112
101
100
98
X32 1 2 X91
S10
S7
234
264
192
193
195
194
176
177
178
179
H 2 1 X94 X35 X34 X29 X28 1 2
191
1 2 1 2
X93
196
1 2 1 2
X92 X23
42
44
1 2 1 2
Y12 Y17 Y18 Y15 Y16

Y7
EVTDF ACCES + ACCES - SORTIE RENTREE VCI Y19 Y20
I TELES TELES VRD VS
264 X273
M11
193 X273 M11
192 X273
M11
194 X273 M11
195 X273 M11
J
647792EN
160 ELECTRICITY 80 (20/01/2020)
KEY DIAGRAM 5: SENSORS
CONNECTOR
X22 MAIN B7 Hydraulic filter clogging I13
X73A MAIN B11 Stop switch I12
X73B MAIN B11 Stop switch I12
X105 MAIN/DISTR Distributor harness earth connection I14
G14, E14,
X135 OPT Cab options right-hand earth
F14
X202 OPT S15 Poultry blue light switch D13
X212 OPT S35 Cleanfix switch I9
X213 OPT M11, Y5 Cleanfix G8
X238 OPT R6 Preheat rod B13
FUSES AND RELAYS

SPLICES
Pos. Position
80
647792EN
80 (20/01/2020) ELECTRICITY 161
DIAGRAM 5 - SENSORS
1 2 3 4 5 6 7 8 9 10 11 12 13 14
M
M
as
as
s e
s
M
e
Ch
M
ot
as
eu
as
s
r(X
e
is
Ca
A
19
(
X1
bi
6)
05
ne
)
(X
13
5)
B
X238 1 3 2
R6
1 9
1 0
D
5
S15 10
X202
X04-9 X135
Sch.4
E
E20 E21 E22 E23
X135
80
X135
X135
G X135
X213
1 4 3 2
H
1 9
1 0
EP15
A9 Y5 S35 Sch.8
X38(I)-7
M11 5 10 Sch.8
X212
X40(B)-5
Sch.8
9 X105
57
X22
4
X73A
9
8
X04-2 X73B 2 1
Sch. 7
B11 B7
J
647792EN
162 ELECTRICITY 80 (20/01/2020)
KEY DIAGRAM 6: VENTILATION, WIPERS AND AIR CONDITIONING
CONNECTOR
X26 MAIN Cab upper harness F8
X30 MAIN A8 Heating/Ventilation D1
X31 MAIN Air conditioning option G3
X70 MAIN M7 Front windscreen washer pump E6
X72A MAIN S11 Brake fluid tank D11
X72B MAIN S11 Brake fluid tank E11
C14 D14
X76A MAIN Cab left-hand earth
E14
X76B MAIN Cab left-hand earth F14
X77 MAIN M3 Front windscreen wiper E6
X79 MAIN S4 Wiper stalk C6
X80 MAIN S4 Wiper reset C7
X142 CAB M4 Rear windscreen wiper I10
X143 CAB M6 Side windscreen wiper I7
X144 CAB M5 Roof windscreen wiper I9
X149 CAB S115 Roof/side windscreen wiper switch H6
X153 CAB S16 Defrost switch H12
X154A CAB R3 Rear defrost G10
X154B CAB R3 Rear defrost H10
X176 CABLE Engine unit earth on frame J14
X204 OPT B46 Air-conditioning high pressure sensor G3
X205 OPT A6 Remote air-conditioning module H3
X206 OPT A6 Remote air-conditioning module I3
X207 OPT M10 Air-conditioning compressor I3
X208 OPT M12 Air-conditioning fan motor 1 I4
FUSES AND RELAYS

F3 10A Rear windscreen wiper + Roof/side windscreen wiper A2
F13 20A Fan A2
80
F19 15A Rear windscreen defrost A2

F21 10A Front windscreen wiper + front windscreen washer A2
F46 125A General fuse G4
SPLICES
Pos. Position
EP52 H10
EP57 I9
647792EN
80 (20/01/2020) ELECTRICITY 163
DIAGRAM 6: VENTILATION, WIPERS AND AIR CONDITIONING

1 2 3 4 5 6 7 8 9 10 11 12 13 14
AP
Vb
at
C
M
A15
as
se
X45(K)
M 76
as A/
A
M
(X
Sch. 1
se X7
ot
eu
Ca 6B
r(
bi )
X1
ne
F21
F13
F19
76
F3
)
(A) 0 1 0
(B) 1 (D) 6 9 10 X41
X40 X37
S4
80
84
85
135
B F
X79 1 2 3 4 5 6 7 8 9 X80 1 2
85
103
104
99
59
80
96
78
94
97
95
C
83 X76A
93 X76A
X40(B)-13
EP 3
Sch.8
Sch. 8
55
136
164
153
154
83
84
X72A
X30 A B C D E F
59
43
95
78
96
93
94
S11
A8 X70 X77 2 3 6 4 1
2 1
BP M7 3 2
+perm vit 1
M3 2
E 1 1
raz
M X72B
0
2 -
43
56
3 6
56 X76A
M16
199 X76B
X76B
F 200
201 X76B
X160
199
200
201
103
104
135
99
Sch. 1 X26
3 8 9 11 13 12 4
80
710
709
708
723
724
750
711
153
164
154
X31
G
A B C
F46
753
753
751
X154A
717
720
718
714
1 0 1 9
X204 1 2 R3
X205 1 2 3 4 5 6 S115
1 0 3 7 4 8 9
HP 2
S16
5 10
B46 A6 X153
X154B
710
709
708
H 751
750
754
752
1 5 2 6 10
725 754
EP 52
R1 RT7sec RT7sec
X149 752
721
715
722
719
726
722 727
717 711
714
X206 715
C B A
716 713
EP 57
727
719
716
718
720
721
712
723
713
724
725
726
X143 3 1 2 4 X144 3 1 2 4 X142 3 1 2 4
X207 X208 1 2 X209 1 2
1 2 1 2 1 2
C
+perm
M6 vit +perm
M5
vit +perm
M4
vit
3
raz
M 3
raz
M 3
raz
M
J - - -
M10 M12 M13
4 4 4
LAT TOIT AR
X176
647792EN
164 ELECTRICITY 80 (20/01/2020)
KEY DIAGRAM 7: OPTIONS
CONNECTOR
X04 MAIN POWER SUPPLY options H3
X11 MAIN M15 Pneumatic Seat I5
X27 MAIN Cab loudspeaker harness A11
X45(K) MAIN Plate power supply and earth fuses -relay C11
X53 MAIN A7 Car radio output to loudspeakers A11
X76A MAIN Cab left-hand earth C14
X118 MAIN A10 Engine immobiliser module predisposition C7, D7
X135 OPT Cab options right-hand earth G14
X138A CAB B28 Left loudspeaker B11
X138B CAB B28 Left loudspeaker B11
X139A CAB B27 Right loudspeaker B12
X139B CAB B27 Right loudspeaker B12
X192 PLATE A7 Car Radio power supply A11
A13, A14,
X235 OPT Engine immobiliser unit B7
A1
A11, A10,
X236 OPT Fintronic engine immobiliser unit B6
H36
X239 OPT A1 Engine immobiliser unit C7
X285 MAIN Seat additive harness H5, H6
X287 MAIN M15 Pneumatic seat + Driver presence switch I6
Additional engine immobiliser harness Easy Manager
X292 MAIN E7
option
Shunt if no Easy Manager immobiliser option (by
X292A MAIN D7
default)
Additional engine immobiliser harness NF Easy
X292B MAIN K26 E8
Manager
Additional harness starting authorisation relay NO
X292C MAIN K27 E9
Easy Manager
FUSES AND RELAYS

15 A
F4 Engine stop or Engine ECM + Cab ECM EV B3
Max.
80
F6 5A Wheel alignments + AS option B4

F17 5A Fan drive + rear hydraulics + engine immobiliser switch B3
F20 10A Pneumatic seat + AS option B4
K26 NF engine immobiliser relay via Easy Manager unit D8
K27 N0 engine immobiliser relay via Easy Manager unit D9
SPLICES
Pos. Position
647792EN
80 (20/01/2020) ELECTRICITY 165
DIAGRAM 7: OPTIONS
1 Vb 2 3 4 5 6 7 8 9 10 11 12 13 14
AP
at
C
A7
M
as
se
X45(K)
Ca
A Sch. 1
bi
ne
X192 4 7 8
X53 8 7 2 1
(X
X45(K)
7
252
251
254
253
6A
Sch. 1
/X
76
X27
B/
1 3 2 4
X13
5)
X45(K)
A15
744
745
746
747
Sch. 1
A11
OPTION X138B X138A X139B X139A
ANTIVOL A13 A14
B H36
F17
F20
F4
F6
X236 B28 B27
X235
4 8 12 1 2 3 4 5 6 7 8 9 10 11 12
X41(A) 2 8 11 12 4 X40(B) 7 8 X45 4
(K)
69 69 X76A
58
161
A1
160
159
157
314
214
158
(+) apres contact

A10
Detection 1
Detection 2
X52-5
Blockage
Com C3
Com C2
Com C1
(+) batt
(-) batt
NC C1
NC C2
NC C3
Sch. 3
C
X86-14 12 9 10 4 6 3 5 8 7 11 2 1
Sch.1
X239
X118 X118
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1
K26 K27
D
X118
X292A
12 11 10 9 8 7 6 5 4 3 2 1 1 2 3 4 1 2 3 4 1 2 3 4
X292B X292C
216
499
236
225
214
211
41
39
215
X292 1 2 3 4
Option Anti-démarrage
393
225
395
390
X61-5 X42-1
Sch. 3 Sch. 1
X114-2 EP4 X37(D)-1
EASY Manager
E Sch. 1 Sch. 3 Sch-8
EP58 X114-4 X284A-9
Sch. 2 Sch. 1 Sch. 2
80
X135
216 X76B
EP-02
Sch. 3
262
263
159
211
161
160
157
158
263
H X285 4 3
X04
1 2 7 8 3
X285 4 3 X285 4 3
X11 1 2 X287 5 4
S44 S44
M15 M15
I C C
X212-5
Sch. 5
J
647792EN
166 ELECTRICITY 80 (20/01/2020)
KEY DIAGRAM 8: LIGHTS AND SIGNALS
CONNECTOR CONNECTOR
Pos. Harness Component Designation Position Pos. Harness Component Designation Position
X04 MAIN POWER SUPPLY options H2 X210 OPT E18 Working light on left-hand boom H13
X08 MAIN B70 Transmission oil thermostat (PS: on PS gear box) E13 X211 OPT E19 Working light on right-hand boom H14
X13 MAIN E2 Front right LIGHT G6
X14 MAIN B2 Horn E12
X16 MAIN E4 Rear left LIGHT G9 FUSES AND RELAYS
X17 MAIN E3 REAR LEFT LIGHT G7 Pos. Current Designation Position
X18 MAIN E7 Plate light G11 F2 15A Rear working lights B2
X19 MAIN Rear trailer socket G10 F5 7,5A Rotating beacon light B2
X20A MAIN B1 (+) Reversing sound alarm G10 F9 5A Module + dashboard indicator lamps B3
X20B MAIN B1 (-) Reversing sound alarm G11 F10 10A Horn + stop switch B4
X25 MAIN Working lights on boom option H14 F11 15A Working lights on boom B3
X26 MAIN Cab upper harness I11 F12 10A Indicator lights B7
X37(D) MAIN A15 Plate power connector D4 10/25 A
X38(I) MAIN A15 Plate fault indicator lamp connector C12 F14 Cigarette lighter + Oil cooler opt on MLT741H B4
MAX.
X39(C) MAIN A15 Lighting harness D5 F18 15A Front working lights B2
X40(B) MAIN A15 Starting safety/wheel alignment/brake fluid tank D3 F23 7,5A Right sidelight + lighting module B6
X41(A) MAIN A15 Options and roof light power supply D2 F24 7,5A Left sidelight + rear plate lighting B5
X45(K) MAIN K9 Plate power supply and earth fuses -relay B14 F25 7,5A Right indicator lights B6
X46 MAIN K17 Hella k17 mini relay holder F4 F26 7,5A Left indicator lights B6
X49 MAIN S32 Rear fog light switch G12 F27 15A Dipped headlight + fog light B5
X59 MAIN P4 Clock I2 F28 15A Headlights B5
X60 MAIN P4 Clock light I2 Warning + ceiling light + anti-theft + clock + rev
F29 15A B3
X68 MAIN P1 Hour meter rev counter module I4 counter
X74 MAIN E1, A2 Front left HEADLIGHT G5, D12 F30 25A Lighting stalk B4
X75 MAIN TUV sidelight control by working light on boom A8 K5 Machine fault alarm B11
B14, F14, K9 Flashing light/Warning unit B10
H14, J14 K17 Indicator lamps module relay G4
X76B MAIN Cab left-hand earth E14
X89 MAIN P3 Engine water temperature module I5
X90 MAIN P2 Fuel level module I3
SPLICES
"OPT (MT)/
X96 E6 Rear 7-pin base electric plug G10 Pos. Position
STANDARD"
EP3 F10
X98 MAIN B69 Transmission oil pressure switch (PS: On PS gearbox) E13
EP8 G9
F14, G14,
X106 MAIN Rear frame earth EP9 F7
H14
X136 CAB Front working light interconnection I6 EP10 F8
X140 CAB E13 Front left working light J6 EP11 G8
80
X141 CAB E12 Front right working light J6 EP13 F8

X145A CAB E15 Rotating beacon light I7 EP14 G7
X145B CAB E15 Rotating beacon light I8 EP15 G7
X146 CAB E16 Rear left working light J8 EP16 I3
X147 CAB E17 Rear right working light J10 EP17 I3
X148A CAB E14 Roof light I9 EP19 E4
X148B CAB E14 Roof light I9 EP20 E4
X148C CAB E14 Roof light I9 EP50 I6
X150 CAB S12 Revolving beacon light switch J11 EP51 I6
X151 CAB S139 Working light switch I12 EP52 I8
X152 CAB S54 Boom working light switch J13 EP53 I8
X180(E) PLATE A15 Indicator lamp harness connector E C8 EP54 H9
X181(F) PLATE A15 Indicator lamp harness connector F C11 EP55 I8
X182 PLATE A2 Dashboard indicator lamps (4-way) D7 EP56 I7
X183 PLATE A2 Dashboard indicator lamps (16-way) D8 EP94 E2
X184 PLATE Battery charge indicator lamp D12
X185 PLATE Steering fault indicator lamp D7
X187 PLATE S13 Warning switch A10
X188 PLATE S5 Light stalk B5
X189 PLATE V2 Awaiting commutator switch-plate TUV diode A5
X190 PLATE V2 Awaiting plate-commutator switch TUV diode A6
X191 PLATE V2 Awaiting plate-working lights TUV diode A7
647792EN
80 (20/01/2020) ELECTRICITY 167
DIAGRAM 8: LIGHTS AND SIGNALS

1 2 3 4 5 6 7 8 9 10 11 12 13 14
X189 X190 X191 X75
AP
Vb
208
at
C
M
as
4
se
M 76
V2 V2
Ch
A
as A/
(X
3
as
se X 7
57/58 56a 56b 54s 54d 49
X187
sis
Ca 6B
0
9
1 L R
S13
(X
0 2 2 8 5 10
bi )
1 0
10
ne
6)
8
6
S5 30 L 31
5
6 3 1 7
7
1
X188
A15 X45(K)
B X45(K)
X45(K)
Sch. 1 4
Sch. 1 K5
85 BUZZEUR 87
87a 86
K9
CENTRALE 69 X76A
F18
F29
F11
F10
F14
F30
F27
F28
F24
F23
F26
F25
F12
F2
F5
F9
85 CLIGNOTANTE 87
3.5 sec ±0.5

Timer
K4-5
Sch. 3
C
Fuse Therm 2A
(A) (B) (D) (C) (E)

X41 X40 X37 X39 X180 X181 (F) X38 (I)
1 3 5 6 13 12 4 6 5 11 10 13 1 4 5 3 4 5 7 1 13 6 12 9 10 11 2 8 5 8 1 6 2 3 7 4 6 7 4 5 3 1 8 4 2 7 5 1 3 6
X185
28
33
26
25
23
72
71
22
30
34
32
31
99
88
86
87
143
149
73
224
55
266
150
110
107
114
109
108
115
52
53
50
51
21
89
142
202
45
19
90
33
17
98
81
57
105
215
72
8
38
27 X184 X24-A4
X72A Sch. 1
D Sch.6 X24-B2 X12-3
X73A X118-1 X32-1 X182 X183 X24-A5
71
31
Sch. 1 Sch. 3
22
28
33
27
26
25
23
72
30
32
24
34
29
Sch.5 Sch.7 Sch.4 Sch.1
X74
17 18 19 20 16 10 6 7 8 9 5 1 2 3 4 11 12 13 14 15
X22-2
Sch. 5
150
202
X14 X08 X98
Tempo 1.5s
33
EP19
V9
X24-A6 H20 H21 H22 H23 H24 H25 H26 H27 H28 H29 H30 H31 H32 H33 H34 H35
E Sch. 1 EP20 T P
B2
B70 B69
18
384 X284A-01
EP94 Sch. 2 X95-2
Sch. 3
A2
396
222 222 X76B

54 X76A
111 X76A
X106
396
124
224
223
X46
74
123 239
2 1 5 4 3
X44-4
EP10 125 X106
F 5
EP13 247
122
Sch. 3 V1 243 X106
1 5 4
86 87 87a 114 100 X91
EP 3
246
145 SCh. 4
136 X30-B
1 249
EP 9
245
244
85 30 SCh. 6
2 3 255 144
EP 8 X106
118
237
K17 115
80
248
EP11
3 250
238 X106
EP14
77A
144
235
X73B 4 117
249
250
256
247
245
248
235
243
Sch. 5 EP15
238
246
G X19 1 9
121
0
X18
244
145
117
122
1
239
237
125
X16 3 1 7 2 8 6 5 4
X20B
51
54
X20A
52
53
50
X74
111
109
110
107
108
X17
255
X13
118
123
120
116
124
2 1
1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 6
6 5 4 3 2 1
3 1 7 2 6 5 4 X96 A B
STOP
5 S32 10
X103-10
149
162 STOP
X49
STOP STOP
B1 E7
131
Sch. 4
130
X76A
143
X04 H1 H3 H6 H5 H2
130
H8 H9 H7 H11 H8 H9 H7 H10 77A
4 H2 H5 H4 H3 H1
E1 AV GA E2 AV DR E3 AR GA E4 AR DR E5 E6
102 X106
106
738
EP 54 737 X25
729 1 2
733
H
730
735
737
1 0 2
1 7 2 8 9
X210 X211
734
208
102
105
162
1 2 1 2
87
86
88
89
265
EP17
126
731 740 10 15 6 5 16 7 14 S139
219 EP 52 X26 3 4 10 X151
731
730
E18 E19
127
701
743
736
756
702
728
755
732
728
732
734
759 733
707
2 1
X284A-4 X24-A2 70
EP16
140 X136 704
EP 56
758
Sch.2 Sch.1
735
736
755
X24-A7 220 X24-B6
749
766
765
Sch-1
I Sch-1
91
EP32 706 748 704 703

Sch-1 EP 53 1 7 2 8 9
X148C
706
705
1 0
X145A X145B
738
742
0 1 9
1
743
749
X148A
766
387
267
266
265
220
219
140
126
EP 55
142
127
141
25
90
X59 X60 X90 X89 761

72
81
26
70
X68 EP 50
1 2 3 4 5 6
1 2 3 4 5 6 1 2 3 4 5 6
EP 51 X148B
2 1 5 S54 6 10
S12
740
739
X147
742
741
X150 X152
signal
signal
n.c
Battery
Ground
Ground
illumination
Sensor (+)
Sensor (-)
X146
Battery
Ground
Ground
n.c
signal
signal
ignition
Battery
Ground
illumination
illumination
5
761
762
763
764
10
+ -
M + - 1 2
756
759
X140 X141 1 2
701
1 2 1 2
702 703 757 758
H15 10
15
20
E15 E16 E17
E14
RPMx100
91 X76A
J 5 25 E13 E12
P4 P2 30
P3
P1
647792EN
168 ELECTRICITY 80 (20/01/2020)
80.2.4 MT-X 1033 ST 100P ST3A S1

POSITION OF CONNECTORS BY DIAGRAM
Item Diag. 1 Diag. 2 Diag. 3 Diag. 4 Diag. 5 Diag. 6 Diag. 7 Diag. 8 Item Diag. 1 Diag. 2 Diag. 3 Diag. 4 Diag. 5 Diag. 6 Diag. 7 Diag. 8 Item Diag. 1 Diag. 2 Diag. 3 Diag. 4 Diag. 5 Diag. 6 Diag. 7 Diag. 8
X1 H8 X68 I4 X144 I9
X2 I6 X70 E6 X145A I7
X3 I6 X71 H8 X145B I8
X4 E2 H3 H2 X72A D11 X146 J8
X8 E13 X72B E11 X147 J10
X9 D10 X73A I12 X148A I9
X10 D10 X73B I12 X148B I9
X11 I5 X74 G5, D12 X148C I9
X12 I11 X75 D6 A8 X149 H6
X13 G6 B14, C14, C14 D14 B14, F14, X150 J11
X76A J14 G14 C14
X14 E12 I14 E14 H14, J14 X151 I12
X15 H12 C14, H14, X152 J13
X76B C14,H14 G14 G14 F14 G14 E14
J14
X16 G9 X153 H12
X77 E6
X17 G7 X154A G10
X79 C6
X18 G11 X154B H10
X80 C7
X19 G10 X160 D1
X84 H13
X20A G10 X161 E13
X85 H13
X20B G11 X162 H8
X86 B12
X21 H13 X163 H9
X87 E7
X22 I13 X164 H6
X89 I5
X23 H12 X165 E6
X90 I3
X24 D3 X166A E6
X91 G11
X25 H14 X166B E7
X92 H11
X26 F8 I11 X167 H6
X93 H9
X27 A11 B14, D14,
X94 H6 X168
X28 I8 F14, J14
X95 F14 X169 H7
X29 H8
X96 G10 X170A H9
X30 D1
X97 G5 X170B H10
X31 G3
X98 E13 X171 F3
X32 G10
X99 H6 X172 D2
X33 E11
X100 A8 X173 D2
X34 H7
X101 C14 X174 A1
X35 H6
X103 E7 X175 D5
X36 D7
B14, H14, X176 C14 J14
X37(D) B2 B2 D4 X105 G14 I14
I14
X38(I) C12 X180(E) C8
80
F14, G14,
X39(C) D5 X106 B14 X181(F) C11
H14
X40(B) C6,C7 B2 B2 B4 D3 X182 D7
X107 H14 B14
X41(A) B3 B3 B3 D2 X183 D8
X108 B14
X42(H) C6 B12 X184 D12
X114 B8 B5
X44(G) B7 B3 X185 D7
X115 B12
X45(K) A5 C11 B14 X187 A10
X116 F12
X46 F4 X188 B5
X117 E12
X47 C5 X189 A5
X118 C7, D7
X48 A2 X190 A6
X119 E13
X49 G12 X191 A7
X133 H12
X50 I12 X192 A11
X134 A10
X51 I13 X196 B14
G14, E14,
X52 F10 X135 B14 G14 X200A A1
F14
X53 A11 X136 I6 X200B A2
X54 B2 X138A B11 X202 D13
X55 B4 X138B B11 X203 E4
X56 C6 F6 C5 X139A B12 X204 G3
X57 C7 E7 C9 X139B B12 X205 H3
X58 G8 X140 J6 X206 I3
X59 I2 X141 J6 X207 I3
X60 I2 X142 I10
X61 I3 X143 I7
647792EN
80 (20/01/2020) ELECTRICITY 169
POSITION OF CONNECTORS BY DIAGRAM (CONT.)

X208 I4
X209 I4
X210 H13
X211 H14
X212 I9
X213 G8
X214 C2
X215 G3
X235 B7
X236 B6
X238 B13
X239 C7
X273 I14, J14
X284A G11
X284B G11
X285 H6, I6 H5, H6
X287 I6 I6
X292 E7
X292A D7
X292B E8
X292C E9
X293 G14
X326 D6
80
647792EN
170 ELECTRICITY 80 (20/01/2020)
KEY DIAGRAM 1 - STARTING
CONNECTOR
ENGINE/
X24 Main harness/engine interface D3
MAIN
X40(B) MAIN A15 Starting safety/wheel alignment/brake fluid tank C6,C7
X42(H) MAIN A15 Fuse plate C6
X45(K) MAIN Plate power supply and earth fuses -relay A5
X47 MAIN Starter Atofuse fuse holder C5
X54 MAIN S2 4-way ignition switch B2
X55 MAIN S2 6-way ignition switch B4
X76A MAIN Cab left-hand earth B14,C14,I14
X76B MAIN Cab left-hand earth C14,H14
X86 MAIN A21 Discharge valve module B12
X101 CABLE Mid-frame/earth engine C14
X105 MAIN/DISTR Distributor harness earth connection B14,H14,I14
X107 MAIN Cab rear earth H14
X108 MAIN Front frame earth on cab support B14
X133 MAIN Y8 Discharge EV H12
X135 OPT Cab options right-hand earth B14
X160 ENGINE WIRE BF1 Battery fuse box A BF1 D1
X161 ENGINE M1 Starter electrovalve E13
X162 ENGINE Y1 Engine stop electrovalve H8
X163 ENGINE M2 Diesel pump H9
X164 ENGINE B3 Engine oil pressure H6
X165 ENGINE R2 Fuel gauge E6
X166A ENGINE B6 Air filter clogging E6
X166B ENGINE B6 Air filter clogging E7
X167 ENGINE R1 Preheat H6
X168 ENGINE Engine Earth B14,D14,F14,J14
X169 ENGINE Y2 KSB cold start H7
X170A ENGINE B5 Engine water thermal switch H9
X170B ENGINE R7 Engine water thermal switch H10
X171 ENGINE K16 Preheat relay F3
X172 ENGINE BF1 Preheat/alternator power fuses D2
X173 ENGINE BF1 Equipment power fuses (MLT) - ECM fuse (MT) D2
X174 ENGINE S1 Clock earth A1
X175 ENGINE LSU Potentiometer D5
80
X176 CABLE Engine unit earth on frame C14

X200A OPT/STD S1 Battery cut-off A1
X200B OPT/STD S1 Battery cut-off A2
X214 OPT Diesel preheater regular fuse holder C2
X215 OPT K15 Diesel preheater relay G3
FUSES AND RELAYS

F31 25 A Starter solenoid/PERKINS C4
F42 80 A Preheat D2
F43 80 A Alternator E2
F47 15 A Diesel decongealant C1
K8 Anti-start relay C6
K15 Diesel decongealant relay G3
K16 Preheat relay F3
SPLICES
Pos. Position
EP1 G8
EP5 H8
EP32 C12
647792EN
80 (20/01/2020) ELECTRICITY 171
DIAGRAM 1 - STARTING
1 2 3 4 5 6 7 8 9 10 11 12 13 14
X174 X200B
Fr 10
609
am 5/
(X
e 10
Ca 76 e e 76
gr 1
S1
ou /X
b A/X ar )
X
(X gin /X1
ea 7 th
nd 10
X200A
En 16
rt 6B
S2
h
(X
A
8)
ESD A21
8
DEM
EVM
/X
13
DISCHARGE EV
5/
X1
X45(K)
07
EV OUT
G1 S50 1
-
)
BAT+
GND
2 1 2
W2
30 30 17 17 50a 19 19 54 15 58 69 4 K6-85
OP Sch.3 X114 X168
X54 1 2 3 4 7 8 9 5 6 10 X55 66 7 X192-4 3 4 2 5 7 3 13 14
Diag.7
X86 X76A
92
82
92
315
316
69
184
314
65
6
8
227
395
499
20
+
63 68 5 X135
13
64
16
12
7
67 6
B 64 2 X108
X95-4 X118-8 X41(A)-11
63 1 X192-7 Diag. 3 Diag. 7 Diag.7
Diag.7
X48-1 151 315 X105
Diag. 2
X40(B)
A15 K8
X292-3
Diag. 7
184
9
X40(B)
82 15 15 3 30
87 5
3 14
EP32
141 X68--5 X176
X47 Diag.8
1 2 2 1 86 85
24
X214 X118-7 236 1 2 X101
X59-2 X38(I)-3
1 2 Diag.8 Diag.7
Diag.8
F31
X42(H) X38(I)-1 X89-5 11 X76B
C EP94 Diag.8 Diag.8
Diag.8 10 X76A
F47
X90-5 X38(I)-7
267
20
14
Diag.8
21
11
26
10
19
18
24
25
17
Diag.8
16
12
13
X24
6
7
A1 A8 C8 C1 B3 A2 A6 A4 A3 C3 C4 C2 A7 B2 B4 B1 A5 B6 B5 B8
BF1 X168
604
605
602
617
624
616
607
623
605
608
611
606
603
612
609
601
613
610
632
634
633
608
X173
F40 A 606 604 X168
611
D F41 B 603
632
634
633
X160 X175
X172 2 3 1 622
F42 A
629
621
607
X165 B+
F43 B
620
2 1
623
621
X166A X166B
617
F46
Diag. 6 X161
M1
E R2
B6 P
X171
627
K16 3
629
30
87 622 X168
5
F 628 628 X168

86 85 2
612
1
80
X215
602
K15 630
2
EP1
G 85 86
625
626
1
87
30
3 40 X76B
V8
5
40 X107
627
613
630
EP5
616
624
X167 X164 X169 X170A X170B 317 X105
H 1
620
601
610
316
317
X133
619
618
625
X162 X163
626
1 2
D+
B+ W
2 1
2 1 129 X76A
3~
G
Y2
U
R5 R1 P X105
B3 129
M
G2 B5 R7
Y8
I Y1 M2
635 X168
X168
X168
J
647792EN
172 ELECTRICITY 80 (20/01/2020)
KEY DIAGRAM 2: CAN

CONNECTOR
X48 MAIN Atofuse fuse holder for DIAG plug + SPU A2
X58 MAIN A5/LLMI LLMI safety module G8
X76B MAIN Cab left-hand earth C14, H14, J14
X99 MAIN B20 Vishay gauge connector H6
X107 MAIN Cab rear earth B14
X115 MAIN OBD II Diagnostics B12
X284A MAIN Easy Manager (Module Trackunit) Option G11
X284B MODULE A25 Easy Manager (Module Trackunit) Option G11
Key Pad Option (Digicode/RFID Card Reader) for Easy
X293 MAIN G14
Manager
FUSES AND RELAYS

F15 20 A SPU B2
F16 5A Diagnostics plug + heating relay control (ST3B) B3
Diagnostics plug + SPU power supply +switch near
F32 5A A2
condenser + Easy Manager opt
SPLICES
Pos. Position
EP25 E7
EP35 D9
EP36 D9
EP37 D9
EP38 C6
EP43 A4
EP58 G11
80
647792EN
80 (20/01/2020) ELECTRICITY 173
DIAGRAM 2: CAN
1 2 3 4 5 6 7 8 9 10 11 12 13 14
AP
Vb
a
C
Ch
X45(K)-1
as
Diag.1 151 2
Ca 76
si
EP43
se
b A/X
(X
151
ar
ea 7
2
th
rt 6B
A X48
s(
1 2
259
487
188
189
X1
07
)
)
F32
X285-1
Diag. 3
X45(K)
Diag. 1 A15 S50
SPU
F15 X115
F16
1 2
A3 16 14 6 10 7 6 5 4 9 8 1
B X114 SPU
OUT SENSOR
489
120 Ohms
488
GND CAN 1
CAN1-120
1 6
W UP IN
487
394
CAN1 H
486
CAN1 L
485
X37 X41
12VD
12VD
12VC
12VC
12VB
12VP
GND
GND
GND
497
498
(D)(A) 2 3 7 489 X107
X56 7 1 20 26 1 CN1-A 3 21 X57 4 3 9 8 34 CN1-B 28 1 2 11
261
181
492
470
260
189
188
186
185
180
183
182
187
61
497
182
183
488
388
61
498 181
EP38 187 X76B
180 389
C
261
260
492
494 486
EP36
493 485
EP35
EP37
491
490
D
470
79
EP25
495
EASY A25 Trackunit®
MANAGER OPTION ME 501-4
E
Part no. 52551094
Digital Input 1 (max 200 mA)

(version CAN + M8)
Digital Input 2 (+APC)
Digital Input 3 (free)

Digital Input 1 (D+)
Digital Input 4
+ BAT 12 V
Bus 1-wire
- BAT 0 V
CAN H
CAN L
+5V
Moulded shunt
F
Info sent
via CAN network
1 2 3 4 5 6 7 8 9 10 11 12 - + OUT
X284B 2 3 1
X293
80
X119-10
Diag. 4 X284A 1 2 3 4 5 6 7 8 9 10 11 12
1 2 3
4 5 6 A26
384
385
386
387
389
390
391
392
490
491
388
398
G
31
POWER SUPPLY 12V79

X58 1 2 3 4 7 8 9
* 0 #
394
EP58
GND
CAN H
CAN L
393
Trackunit®
DualID OPTION
EP28
Diag. 4 (Keypad)
495
494
493
496
X99 2 3
H
1 4 5
A5 / LLMI EP94 X292-1 X59-2 X292-4 X119-1 EP95
Diag. 8 Diag. 7 Diag. 8 Diag. 7 Diag. 4 Diag. 3
398 X76B
R120
I
B20
185 X76B
186 X76B
J
647792EN
174 ELECTRICITY 80 (20/01/2020)
KEY DIAGRAM 3: TRANSMISSION

CONNECTOR
X01 MAIN S21 Transmission cut-off on gear lever H8
X02 MAIN S46 Seat switch power supply I6
X03 MAIN S46 Seat switch information I6
X09 MAIN V10, Y3 Forward EV D10
X10 MAIN V10, Y4 Reversing EV D10
X12 MAIN S19 Handbrake switch I11
X15 MAIN B9 Front wheel alignment H12
X21 MAIN B10 Rear wheel alignment H13
X36 MAIN A12 JSM D7
X42(H) MAIN A15 Fuse plate B12
X50 MAIN E8, H13 Front wheel alignment indicator lamp I12
X51 MAIN E8, H14 Rear wheel alignment indicator lamp I13
X52 MAIN S31 Front and rear wheel alignment switch F10
X56 MAIN A3 SPU CN1-A F6
X57 MAIN A3 SPU CN1-B E7
X61 MAIN S30 Transmission cut-off switch I3
X71 MAIN S20 Transmission cut-off on brake pedal H8
X75 MAIN A12 TUV sidelight control by working light on boom D6
X76A MAIN Cab left-hand earth J14
X95 MAIN K18 Hella K12-K18 mini relay holder F14
X105 MAIN/DISTR Distributor harness earth connection G14
X116 MAIN S14 Easy Connect system switch F12
X196 PS GEAR BOX EVR B14
X285 MAIN Seat additive harness H6, I6
X287 MAIN S46 Pneumatic seat + Driver presence switch I6
X326 MAIN A12 Dead man switch D6
FUSES AND RELAYS

F8 15 A Relays K2/K3/K4 + transmission cut-off + JSM/FNR A6
K0 Hare speed relay (ST3A) A7
K1 NC transmission cut-off relay A8
K2 NO transmission cut-off relay A8
K3 Reverse gear relay A9
80
K4 Forward gear relay A10

K6 Tortoise speed relay (ST3A) A11
K18 Neutral safety relay F13
SPLICES
Pos. Position
EP2 H11
EP4 E5
EP6 E13
EP7 E13
EP12 E13
EP23 E8
EP24 E8
EP26 E7
EP27 E7
EP93 D6
EP95 G7
647792EN
80 (20/01/2020) ELECTRICITY 175
DIAGRAM 3: TRANSMISSION
1 2 3 4 5 6 7 8 9 10 11 12 13 14
AP
Vb
Ca
at
C
b
ea
A15 X45-4
Ch
rt
h
Diag.1
as
(X
X45(K)
si
76
s
Diag. 1
ea
A/
rt
X7
K0 K1
h
A K2 K3 K4 K6
(X
1 5 4 1 5 4 1 5 1 5 1 5 2 5 4
B/
10
86 87
X1
86 87 87a 86 87 87a 86 87 86 87 85 87
5)
9
F8
6)
A15-Timer
Diag.8
85 30 85 30 85 30 85 30 85 30 86 30
2 3 2 3 2 3 2 3 2 3 1 3
(G) X42
B 19 6 20 7 8 9 21 10 18 16 4 1 2
(H)
5 4 3
X44
EP13 5 15 11
197
205
205
148
197
226
166
232
167
212
213
Diag. 8
A12
C
R1 R2
212
269
230
213
268
230
BP1 BP2
38
µC
V10
D+ D- D+ D-
F N R V10
X10 X09
1 2 1 2
1 2 3 4 9 10 2 3 6 4 5 7 1 8 11 12
X326
X36
773
777
774
775
776
Y4 Y3
240
241
37
174
175
172
173
168
170
36
D
X76A X44-15 EP28
Diag. 4
242 777
242 EP 93
37
X118-4 39 166
EP 4
Diag. 7
166
EP26 EP27 EP24 232
36
167
EP23 EP6 EP7
46
27 V4 V5
E X117-9
477
169
168
240
171
170
476
77E
Diag. 4
12 18 X57 12 24 16 22 14
1 9 X114-3
1 0
EP12
IN TOR 8
IN TOR 9
479
277
Diag. 1
X46-3
OUT PWM 2
A3 SPU
IN TOR 10
Diag. 8
IN TOR 2
0 1 9
IN TOR
223
231
227
226
1
5 S31
13
10
2 1 5 4 3 X95
X52
X56 15 17 CN1-A 23 10 12 17 CN1-B
134
S14
32
58
148
1 5 4
479
146
X40(B)-7
397
77E 5
206
10
F Diag.7 ECS X116

86 87 87a
480
85 30
X103-10 75C 3
Diag. 4
K18
2
480 X76B
M1
397
80
60
EP95
392
G X284A-12
Diag. 2
28 X105
38
203 47
113
EP 2
29
47
46
48
28
27
X15 C B A X21 C B A
262
258
EP43
_ + _ +
Diag. 2 X285-04
X38(I)-5 B9 B10
H Diag. 8
Diag. 7
206
139
133
259
60
49
77D
X71
146
X01
203
113
133
X285
45
49
1 2 1 2 2 1
71 32
1 2 3 4 X12
29
48
1 7 2 8 9
0
1
X285 1 2 X285 1 2 X50 2 1 21 X51
S30 X02 X03 X287 1 3

5
X61
6 10
S21 S19
I S20 E8 H13 H14
132
41
77D
S46 S46
258 X76A
X118-9 X76A
132
Diag. 7
J
647792EN
176 ELECTRICITY 80 (20/01/2020)

CONNECTOR
X04 MAIN POWER SUPPLY options E2
X23 DISTRIB Y20 Hydraulic cut-off EV/VS H12
X28 DISTRIB Y16 Telescope retraction EV I8
X29 DISTRIB Y15 Telescope extension EV H8
X32 MAIN S7 Cigarette lighter socket G10
X33 MAIN S33 Hydraulic movement neutralisation switch E11
X34 DISTRIB Y18 Attachment Direction- EV H7
X35 DISTRIB Y17 Attachment Direction+ EV H6
X76A MAIN Cab left-hand earth G14
X87 MAIN Distributor harness interface (Mlt) E7
X91 MAIN S7 Cigarette lighter light G11
X92 DISTRIB Y19 Proportional EV on boom lowering/VRD-VRP H11
X93 MAIN/DISTR Y7 Tilting cut-off EV/VCI H9
X94 OPT Y12 Boom head electrovalve H6
X97 MAIN S10 Boom head electrical predisposition or boom head EV G5
X100 MAIN B23 EN 15000 boom angle sensor A8
X103 MAIN S29 TDF OR TDF EV Electric plug switch E7
X106 MAIN Rear frame earth B14
X117 MAIN S28 Attachment locking switch E12
X119 MAIN S27 Override Switch E13
X134 MAIN S34 Telescope retraction sensor A10
Aggravating mvt cut-off power supply on non-
X203 OPT E4
EN15000 version
X273 DISTRIB Distributor harness earth connection I14, J14
FUSES AND RELAYS

F1 7.5 A LSU + AS option A3
F7 7.5 A LLMI + override switch + sensors + blue light opt (15 A) A3
F22 10 A Max. Boom suspension + boom electrical predisposition + boom head EV A2
80
K7 Free A3
SPLICES
Pos. Position
EP28 B6
EP29 A7
EP49 B10
647792EN
80 (20/01/2020) ELECTRICITY 177

1 2 3 4 5 6 7 8 9 10 11 12 13 14
AP
Vb
B23 S34
at
C
Ch
a ss
X45(K)
is
A15 X45-4
e
Diag. 1
ar
Diag.1
Ca 76
A
th
K7
b A/X
(X
1 5
X100
(X
ea 7
X134
10
86 87
r t 6B
2 3 1 5 6 4
6/
h
F22
1 4 3 2
X2
F1
F7
468
469
466
465
467
464
375-481
73
483
482
484
468
469
)
85 30
)
2 3
X36-1 EP29 483
Diag. 3 EP49 377
455
484
(B) 2 17 14 12 13 3
X40 X44 (G)
X106
241
467
156
155
377
163
218
455
X99-3 496
B Diag. 2
EP28 466 X106
210
MT1033 ST
481-376
465
482
210
464
X56 CN1-A 25 8 X57 15 23 31 CN1-B
IN TOR 5
IN TOR 6
IN ANA 1
IN ANA 2
IN ANA 5
AGND
OUT PWM 10
A3
OUT PWM 4
OUT PWM 1
OUTPWM 8
OUTPWM 5
OUTPWM 6
OUTPWM 7
OUT TDR 1
OUT LS 12
OUT LS 11
OUT LS 22
SPU
IN TOR 12
IN TOR 11
IN TOR 4
IN TOR7
C
4 14 2 16 6 5 11 29 6 7 5 32 19
179
191
178
456
478
204
177
176
196
471
234
42
44
D X116-9 X284A-11
Diag. 3 Diag. 2
277
391
77C
77B
472
478
128
456
217
217
204
1 9 1 7 2 8 9 1 9 0 1 9
1 0 1 0 1 0 1
163
128
475
156
155
191
176
177
234
196
179
X04
178
42
44
X87
E 6 5 9
S29 3 4 1 2 9
X202-5 5 10
7 8 5 6
5
S33 6 10 5 S28 10 5 S27 10
OR
178
179
176
177
191
196
234
Diag. 5 X119
42
44
X103 X33 X117
77C
112
X203
475
134
131
190
75B 190 75A
218
77B
31
30
X52-10 X49-10 X58-1
Diag. 8 Diag. 2
Diag. 3
80
30 X76A
X37(D)-5 EP 3
Diag. 8 Diag. 8
101 X76B
471
472
G
X97 2 1
112
101
100
98
X32 1 2 X91
S10
S7
234
264
192
193
195
194
176
177
178
179
H 2 1 X94 X35 X34 X29 X28 1 2
191
1 2 1 2
X93
196
1 2 1 2
X92X23
42
44
1 2 1 2
Y12 Y17 Y18 Y15 Y16

Y7
EVTDF ACCESS + ACCESS - TELESCOPE TELESCOPE VCI Y19Y20
I EXTENSION RETRACTION VRD VS
264 X273
M11
193 X273 M11
192 X273
M11
194 X273 M11
195 X273 M11
J
647792EN
178 ELECTRICITY 80 (20/01/2020)
DIAGRAM 5 - SENSORS
CONNECTOR
X22 MAIN B7 Hydraulic filter clogging I13
X73A MAIN B11 Stop switch I12
X73B MAIN B11 Stop switch I12
X105 MAIN/DISTR Distributor harness earth connection I14
X135 OPT Cab options right-hand earth G14, E14, F14
X202 OPT S15 Poultry blue light switch D13
X212 OPT S35 Cleanfix switch I9
X213 OPT M11, Y5 Cleanfix G8
X238 OPT R6 Preheat rod B13
FUSES AND RELAYS

SPLICES
Pos. Position
80
647792EN
80 (20/01/2020) ELECTRICITY 179
DIAGRAM 5 - SENSORS
1 2 3 4 5 6 7 8 9 10 11 12 13 14
En
Ch
gi
as
ne
si
ea
se
Ca
rt
ar
b
h
th
ea
(X
rt
19
(X
A
10
6)
(X
5)
13
5)
B
X238 1 3 2
R6
1 9
1 0
D
5
S15 10
X202
X04-9 X135
Diag.4
E
E20 E21 E22 E23
X135
80
X135
X135
G X135
X213
1 4 3 2
H
1 9
1 0
EP15
A9 Y5 S35 Diag.8
X38(I)-7
M11 5 10 Diag.8
X212
X40(B)-5
Diag.8
9 X105
57
X22
4
X73A
9
8
X04-2 X73B 2 1
Diag. 7
B11 B7
J
647792EN
180 ELECTRICITY 80 (20/01/2020)
CONNECTOR
X26 MAIN Cab upper harness F8
X30 MAIN A8 Heating/Ventilation D1
X31 MAIN Air conditioning option G3
X70 MAIN M7 Front windscreen washer pump E6
X72A MAIN S11 Brake fluid tank D11
X72B MAIN S11 Brake fluid tank E11
X76A MAIN Cab left-hand earth C14 D14 E14
X76B MAIN Cab left-hand earth F14
X77 MAIN M3 Front windscreen wiper E6
X79 MAIN S4 Wiper stalk C6
X80 MAIN S4 Wiper reset C7
X142 CAB M4 Rear windscreen wiper I10
X143 CAB M6 Side windscreen wiper I7
X144 CAB M5 Roof windscreen wiper I9
X149 CAB S115 Roof/side windscreen wiper switch H6
X153 CAB S16 Defrost switch H12
X154A CAB R3 Rear defrost G10
X154B CAB R3 Rear defrost H10
X176 CABLE Engine unit earth on frame J14
X204 OPT B46 Air-conditioning high pressure sensor G3
X205 OPT A6 Remote air-conditioning module H3
X206 OPT A6 Remote air-conditioning module I3
X207 OPT M10 Air-conditioning compressor I3
FUSES AND RELAYS

F3 10A Rear windscreen wiper + Roof/side windscreen wiper A2
F13 20A Fan A2
F19 15A Rear windscreen defrost A2
F21 10A Front windscreen wiper + front windscreen washer A2
80
F46 125A General fuse G4
SPLICES
Pos. Position
EP52 H10
EP57 I9
647792EN
80 (20/01/2020) ELECTRICITY 181
1 2 3 4 5 6 7 8 9 10 11 12 13 14
AP
Vb
at
C
En
A15
gi
X45(K)
Ca 76
ne
b A/X
(X
Diag. 1
A
ea
ea 7
rt
rt 6B
h
h
(X
17
F21
F13
F19
6)
F3
)
(A) 0 1
(B)(D) 1 6 9 1 X41 0 0
X40 X37
S4
80
84
85
135
B F
X79 1 2 3 4 5 6 79 8 X80 1 2
85
103
104
99
59
80
96
78
94
97
95
C
83 X76A
93 X76A
X40(B)-13
EP 3
Diag.8
Diag. 8
55
136
164
153
154
83
84
X72A
X30 A B C D E F
59
43
95
78
96
93
94
S11
A8 X70 X77 2 3 6 4 1
2 1
BP M7 3 2
+perm vit 1
M3 2
E 1 1
reset
M X72B
0
2 -
43
56
3 6
56 X76A
M16
199 X76B
200 X76B
F
201 X76B
X160
199
200
201
103
104
135
99
Diag. 1 X26
80
3 8 9 11 13124
710
709
708
723
724
750
711
153
164
154
X31 A B C
G F46
753
753
751
X154A
717
720
718
714
1 0 1 9
X204 1 2 R3
X205 1 2 3 4 5 6 S115
1 0 3 7 4 8 9
HP 2
S16
5 10
B46 A6 X153
X154B
710
709
708
H 751
750
754
752
1 5 2 6 10
725 754
EP 52
R1 RT7sec RT7sec
X149 752
721
715
722
719
726
722 727
717 711
714
X206 715
C B A
716 713
EP 57
727
719
716
718
720
721
712
723
713
724
725
726
X143 3 1 42 X144 3 1 2 4 X142 3 1 2 4
X207 X208 1 2 X209 1 2
1 2 1 2 1 2
C
+perm
M6 vit +perm
M5
vit +perm
M4
vit
3
reset
M 3
reset
M 3
reset
M
J M10
- - -
M12 M13
4 4 4
SIDE ROOF REAR
X176
647792EN
182 ELECTRICITY 80 (20/01/2020)
DIAGRAM 7: OPTIONS
CONNECTOR
X04 MAIN POWER SUPPLY options H3
X11 MAIN M15 Pneumatic Seat I5
X27 MAIN Cab loudspeaker harness A11
X45(K) MAIN Plate power supply and earth fuses -relay C11
X53 MAIN A7 Car radio output to loudspeakers A11
X76A MAIN Cab left-hand earth C14
X118 MAIN A10 Engine immobiliser module predisposition C7, D7
X135 OPT Cab options right-hand earth G14
X138A CAB B28 Left loudspeaker B11
X138B CAB B28 Left loudspeaker B11
X139A CAB B27 Right loudspeaker B12
X139B CAB B27 Right loudspeaker B12
X192 PLATE A7 Car Radio power supply A11
A13, A14,
X235 OPT Engine immobiliser unit B7
A1
A11, A10,
X236 OPT Fintronic engine immobiliser unit B6
H36
X239 OPT A1 Engine immobiliser unit C7
X285 MAIN Seat additive harness H5, H6
X287 MAIN M15 Pneumatic seat + Driver presence switch I6
Additional engine immobiliser harness Easy Manager
X292 MAIN E7
option
Shunt if no Easy Manager immobiliser option (by
X292A MAIN D7
default)
Additional engine immobiliser harness NF Easy
X292B MAIN K26 E8
Manager
Additional harness starting authorisation relay NO
X292C MAIN K27 E9
Easy Manager
FUSES AND RELAYS

15 A
F4 Engine stop or Engine ECM + Cab ECM EV B3
Max.
80
F6 5A Wheel alignments + AS option B4

F17 5A Fan drive + rear hydraulics + engine immobiliser switch B3
F20 10A Pneumatic seat + AS option B4
K26 NF engine immobiliser relay via Easy Manager unit D8
K27 N0 engine immobiliser relay via Easy Manager unit D9
SPLICES
Pos. Position
647792EN
80 (20/01/2020) ELECTRICITY 183
DIAGRAM 7: OPTIONS
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Vb
AP
at
C
A7
Ca
A
b
ea
X45(K)
rt
h
Diag. 1
(X
76
X192 4 7 8
X53 8 7 2 1
A/
X45(K)
X7
252
251
254
253
Diag. 1
6B
/ X1
X27
35
1 3 2 4
)
X45(K)
A15
744
745
746
747
Diag. 1
A11
ANTI-THEFT X138B X138A X139B X139A
B
OPTION A13 A14
H36
F17
F20
F4
F6
X236 B28 B27
X235
4 8 1 2 1 2 3 4 5 6 7 8 9 10 11 12
X41(A) 2 8 11 12 4 X40(B) 7 8 X45 4
(K)
69 69 X76A
58
161
A1
160
159
157
314
214
158
(+) after ignition

C A10
Detection 1
Detection 2
(+) battery
(-) battery
X52-5
Blockage
Com C3
Com C2
Com C1
NC C1
NC C2
NC C3
Diag. 3
X86-14 12 9 1 40 6 3 5 8 7 11
1 2
Diag.1
X239
X118 X118
12 11 10 9 8 7 6 5 4 31 2 12 11 10 9 8 7 6 5 4 3 1 2
D
K26 K27
X118
X292A
12 11 10 9 8 7 6 5 4 31 2 1 2 3 4 1 2 3 4 1 2 3 4
X292B X292C
216
499
236
225
214
211
41
39
215
X292 1 2 3 4
Engine immobiliser option
393
225
395
390
X61-5 X42-1
E Diag. 3 Diag. 1
EASY Manager
X114-2 EP4 X37(D)-1
Diag. 1 Diag. 3 Diag-8
EP58 X114-4 X284A-9
Diag. 2 Diag. 1 Diag. 2
80
X135
216 X76B
G
EP-02
Diag. 3
H
262
263
159
211
161
160
157
158
263
X285 4 3
X04
1 2 7 8 3
X285 4 3 X285 4 3
X11 1 2 X287 5 4
S44 S44
I M15 M15
C C
X212-5
Diag. 5
J
647792EN
184 ELECTRICITY 80 (20/01/2020)

CONNECTOR
Pos. Harness Component Designation Position FUSES AND RELAYS
X04 MAIN POWER SUPPLY options H2 Pos. Current Designation Position
X08 MAIN B70 Transmission oil thermostat (PS: on PS gear box) E13 F2 15A Rear working lights B2
X13 MAIN E2 Front right LIGHT G6 F5 7,5A Rotating beacon light B2
X14 MAIN B2 Horn E12 F9 5A Module + dashboard indicator lamps B3
X16 MAIN E4 Rear left LIGHT G9 F10 10A Horn + stop switch B4
X17 MAIN E3 REAR LEFT LIGHT G7 F11 15A Working lights on boom B3
X18 MAIN E7 Plate light G11 F12 10A Indicator lights B7
X19 MAIN Rear trailer socket G10 10/25 A
F14 Cigarette lighter + Oil cooler opt on MLT741H B4
X20A MAIN B1 (+) Reversing sound alarm G10 MAX.
X20B MAIN B1 (-) Reversing sound alarm G11 F18 15A Front working lights B2
X25 MAIN Working lights on boom option H14 F23 7,5A Right sidelight + lighting module B6
X26 MAIN Cab upper harness I11 F24 7,5A Left sidelights + rear plate lighting B5
X37(D) MAIN A15 Plate power connector D4 F25 7,5A Right indicator lights B6
X38(I) MAIN A15 Plate fault indicator lamp connector C12 F26 7,5A Left indicator lights B6
X39(C) MAIN A15 Lighting harness D5 F27 15A Dipped headlight + fog light B5
X40(B) MAIN A15 Starting safety/wheel alignment/brake fluid tank D3 F28 15A Headlights B5
X41(A) MAIN A15 Options and roof light power supply D2 Warning + ceiling light + anti-theft + clock + rev
F29 15A B3
X45(K) MAIN K9 Plate power supply and earth fuses -relay B14 counter
X46 MAIN K17 Hella k17 mini relay holder F4 F30 25A Lighting stalk B4
X49 MAIN S32 Rear fog light switch G12 K5 Machine fault alarm B11
X59 MAIN P4 Clock I2 K9 Flashing light/Warning unit B10
X60 MAIN P4 Clock light I2 K17 Indicator lamps module relay G4
X68 MAIN P1 Hour meter rev counter module I4
X74 MAIN E1, A2 Front left HEADLIGHT G5, D12
X75 MAIN TUV sidelight control by working light on boom A8 SPLICES
B14, F14, H14, Pos. Position
J14 EP3 F10
X76B MAIN Cab left-hand earth E14 EP8 G9
X89 MAIN P3 Engine water temperature module I5 EP9 F7
X90 MAIN P2 Fuel level module I3 EP10 F8
"OPT (MT)/ EP11 G8
X96 E6 Rear 7-pin base electric plug G10
STANDARD"
EP13 F8
X98 MAIN B69 Transmission oil pressure switch (PS: On PS gearbox) E13
EP14 G7
X106 MAIN Rear frame earth F14, G14, H14
EP15 G7
X136 CAB Front working light interconnection I6
EP16 I3
X140 CAB E13 Front left working light J6
EP17 I3
X141 CAB E12 Front right working light J6
80
EP19 E4
X145A CAB E15 Rotating beacon light I7
EP20 E4
X145B CAB E15 Rotating beacon light I8
EP50 I6
X146 CAB E16 Rear left working light J8
EP51 I6
X147 CAB E17 Rear right working light J10
EP52 I8
X148A CAB E14 Roof light I9
EP53 I8
X148B CAB E14 Roof light I9
EP54 H9
X148C CAB E14 Roof light I9
EP55 I8
X150 CAB S12 Revolving beacon light switch J11
EP56 I7
X151 CAB S139 Working light switch I12
EP94 E2
X152 CAB S54 Boom working light switch J13
X180(E) PLATE A15 Indicator lamp harness connector E C8
X181(F) PLATE A15 Indicator lamp harness connector F C11
X182 PLATE A2 Dashboard indicator lamps (4-way) D7
X183 PLATE A2 Dashboard indicator lamps (16-way) D8
X184 PLATE Battery charge indicator lamp D12
X185 PLATE Steering fault indicator lamp D7
X187 PLATE S13 Warning switch A10
X188 PLATE S5 Light stalk B5
X189 PLATE V2 Awaiting commutator switch-plate TUV diode A5
X190 PLATE V2 Awaiting plate-commutator switch TUV diode A6
X191 PLATE V2 Awaiting plate-working lights TUV diode A7
X210 OPT E18 Left boom working light H13
X211 OPT E19 Right boom working light H14
647792EN
80 (20/01/2020) ELECTRICITY 185

1 2 3 4 5 6 7 8 9 10 11 12 13 14
2
X189 X190 X191 X75
AP
Vb
208
a
C
Ch
as
49
0
sis
C a 76
V2 V2 1
ea
b A/X
(X
3
ea 7
57/58 56a 56b 54s54d 49
rth
X187
rt 6B
(X
1 L R
S13
h
0 2 2 8 5 10
10
0
6)
8
)
6
S5 30 L 31
5
6 3 1 7
7
1
B X188
X45(K)
A15 X45(K)
X45(K) Diag. 1 4
Diag. 1 K5
85 BUZZER 87
87a 86
K9
FLASHING 69 X76A
F18
F29
F11
F10
F14
F30
F27
F28
F24
F23
F26
F25
F12
F2
F5
F9
85 LIGHT UNIT 87
3.5 sec ±0.5

Timer
K4-5
C Diag. 3
Fuse Therm 2 A
(A) (B) (D) (C) (E)

X41 X40 X37 X39 X180 X181 (F) X38 (I)
1 3 5 6 13 12 4 6 5 1113 10 1 4 5 3 4 5 7 1 1 6 31211 9 1 2 80 5 8 1 6 2 3 7 4 6 7 4 5 3 1 8 4 2 7 5 1 3 6
D X185
28
33
26
25
23
72
71
22
30
34
32
31
99
88
86
87
143
149
73
224
55
266
150
110
107
114
109
108
115
52
53
50
51
21
89
142
202
45
19
90
33
17
98
81
57
105
215
72
8
38
27 X184 X24-A4
X72A Diag. 1
Diag.6 X24-B2 X12-3
X73A X118-1 X32-1 X182 X183 X24-A5
71
31
Diag. 1 Diag. 3
22
28
33
27
26
25
23
72
30
32
24
34
29
Diag.5 Diag.7 Diag.4 Diag.1
X74
17 18 19 20 16 10 6 7 8 9 5 1 2 3 4 11 12 13 14 15
X22-2
Diag. 5
150
202
X14 X08
Time-out 1.5 s
X98
33
EP19
E V9
X24-A6 H20 H21 H22 H23 H24 H25 H26 H27 H28 H29 H30 H31 H32 H33 H34 H35
Diag. 1 EP20 T P
B2
B70 B69
18
384 X284A-01
EP94 Diag. 2 X95-2
Diag. 3
A2
396
222 222 X76B

54 X76A
111 X76A
F X106
396
124
224
223
X46
74
123 239
2 1 5 4 3
X44-4 5
EP10 125 X106
EP13 247
122
Diag. 3 V1 243 X106
1 5 4
86 87 87a 114 100 X91
EP 3
246
2
145 Diag. 4
80
136 X30-B
1 249
EP 9
245
244
85 30 Diag. 6
3 255144
EP 8 X106
118
237
K17 115
EP11 248
3 250
238 X106
EP14
G 77A
144
235
X73B 4 117
249
250
256
247
245
248
235
243
Diag. 5 EP15
238
246
X19 1 9
121
0
X18
244
145
117
122
1
239
237
125
X16 3 1 7 2 8 6 5 4
X20B
51
54
X20A
52
53
50
X74
111
109
110
107
108
X17
255
X13
118
123
120
116
124
2 1
1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 STOP 6
6 5
STOP 4 3 2 1
3 1 7 2 6 5 4 X96 A B
STOP STOP
5 S32 10
X103-10
149
162 X49
B1 E7
131
Diag. 4
130
X76A
143
X04 H1 H3 H6 H5 H2
130
H7
H8 H9H11 H8 H9 H7 H10 77A
4 H2 H5 H4 H3 H1
E1 FRONT LEFT E2 FRONT RIGHT E3 REAR LEFT E4 REAR RIGHT E5 E6
102 X106
H
106
738
EP 54 737 X25
0 729 7 1 2
733
730
735
737
1 2 8 9
1 2
X210 X211
734
102
105
162
1 2 2 1
87
86
88
89
265
EP17
126
731 740 10156516714 S139
219 EP 52 X26 3 4 10 X151
736208
731
730
E18 E19
127
701
743
756
702
728
755
732
728
732
734
759 733
707
I
2 1
X284A-4 X24-A2 70
EP16
140 X136 704
EP 56
758
Sch.2 Diag.1
735
736
755
X24-A7 220 X24-B6
749
766
765
Diag-1 Diag-1
91
EP32 706 748 704 703

Diag-1 EP 53 1 7 2 8 9
X148C
706
705
1 0
X145A X145B
738
742
0 1 9
1
743
749
X148A
766
387
267
266
265
220
219
140
126
EP 55
142
127
141
25
90
X59 X60 X90 X89 761

72
81
26
70
X68 EP 50
1 2 3 4 5 6
1 2 3 4 5 6 1 2 3 4 5 6
EP 51 X148B
2 1 5 S54 6 10
S12
740
739
X147
742
741
X150 X152
n.c
Ground
Ground
signal
signal
Battery
X146
Battery
Ground
Ground
n.c
signal
signal
Lighting
Ground
Lighting
Sensor (-)
Ignition
Sensor (+)
Battery
Lighting
5
761
762
763
764
10
+ -
M + - 1 2
756
759
X140 X141 1 2
701
1 2 1 2
702 703 757 758
J
H15 10
15
20
E15 E16 E17
E14
RPMx100
91 X76A
5 25 E13 E12
P4 P2 30
P3
P1
647792EN
186 ELECTRICITY 80 (20/01/2020)
80.3 ELECTRICITY LOCATIONS Pos. Designation

3D 2D
Main Engine Dist. Main Engine Dist.
X16 RIGHT REAR LIGHT D14
80.3.1 KEY X17 LEFT REAR LIGHT
X18 PLATE LIGHT
3D 2D X19 REAR TRAILER CONNECTOR
Pos. Designation
Main Engine Dist. Main Engine Dist. X20A (+) REVERSING ALARM
EP01 PUMP GO + EV POWER SUPPLY B10
X20B (-) REVERSING ALARM
EP02 EARTH C5
X21 REAR WHEEL ALIGNMENT D12
EP03 RIGHT SIDE LIGHT POWER SUPPLY C5
X22 HYDRAULIC FILTER CLOGGING D12
EP04 JSM/K1 POWER SUPPLY C5
X23 HYDRAULIC CUT-OFF EV/VS C6 B7
EP05 FREE WHEEL DIODE B9
X24 MAIN HARNESS/ENGINE INTERFACE D8 B9 B11
EP06 FORWARD NEUTRAL CONTROL D4
X25 WORKING LIGHTS ON BOOM OPTION
EP07 REVERSE GEAR NEUTRAL CONTROL D4
X26/
EP08 FOG LIGHT POWER SUPPLY C12 CAB UPPER HARNESS D8
X26A
EP09 REAR LEFT SIDE LIGHT POWER SUPPLY C12
X27/
EP10 REVERSING LIGHT DIODE V1 C8 CAB LOUDSPEAKER HARNESS D9
X27A
EP11 REAR RIGHT INDICATOR LIGHT POWER SUPPLY C13 X27B
EP12 NEUTRAL CONTROL D5 X28 TELESCOPE RETRACTION EV E4 C8
EP13 REVERSING LIGHT DIODE V1 C8 X29 TELESCOPE EXTENSION EV E3 F8
EP14 REAR LEFT INDICATOR LIGHT POWER SUPPLY C13 X30 HEATING/VENTILATION F8
EP15 BRAKE LIGHT POWER SUPPLY C13 X31 AIR CONDITIONING OPTION F7
EP16 DASHBOARD MODULE EARTH G3 X32 CIGARETTE LIGHTER SOCKET F8
EP17 DASHBOARD MODULE INDICATOR LAMP G3 X33 HYDRAULIC MOVEMENT NEUTRALISATION SWITCH F8
EP19 INDICATOR LAMP MODULE DIODE V9 D5 X34 ATTACHMENT DIRECTION- EV F3 E8
EP20 INDICATOR LAMP MODULE DIODE V9 D5 X35 ATTACHMENT DIRECTION+ EV E4 D8
EP23 FORWARD CONTROL C8 X36 JSM D7
EP24 REVERSE CONTROL C8 X37 PLATE POWER CONNECTOR E7
EP25 Amendment A3/LLMI-GAUGE POWER SUPPLY E10 X38 PLATE FAULT INDICATOR LAMP CONNECTOR D6
EP26 ROLLER 1 D7 X39 LIGHTING HARNESS G7
EP27 ROLLER 2 D7 X40 STARTING SAFETY/WHEEL ALIGNMENT/BRAKE FLUID TANK G7
EP28 SPU ANALOGUE EARTH + FORCED MARCH + JSM E10 X41 OPTIONS AND ROOF LIGHT POWER SUPPLY G6
ANA BOOM ANGLE SENSOR POWER SUPPLY + BOOM
EP29 C10 X42 FUSE PLATE F5
RETRACTION + FORCED MARCH
X44 RELAY/HYDRAULIC MOVEMENT CUT-OFF/TRANSMISSION CUT-OFF/EV D6
EP32 ALT W C5
X45 PLATE POWER SUPPLY AND EARTH FUSES -RELAY C5
EP35 CAN H D10
X46 HELLA K17 MINI RELAY HOLDER D5
EP36 CAN L D10
X47 STARTER ATOFUSE FUSE HOLDER D5
EP37 Amendment A3/CAN A EARTH D10
X48 ATOFUSE FUSE HOLDER FOR DIAG PLUG + SPU D5
EP38 SPU POWER SUPPLY C8
X49 REAR FOG LIGHT SWITCH G5
EP43 Amendment A3/SPU POWER SUPPLY-SEAT CONNECTOR-EASY MANAGER C4
X50 FRONT WHEEL ALIGNMENT INDICATOR LAMP G5
EP49 TELESCOPE RETRACT INFORMATION C9
80
X51 REAR WHEEL ALIGNMENT INDICATOR LAMP G5

EP50 FRONT WORKING LIGHT POWER SUPPLY
X52 FRONT AND REAR WHEEL ALIGNMENT SWITCH G5
EP51 FRONT WORKING LIGHT EARTH
X53 CAR RADIO OUTPUT TO LOUDSPEAKERS F4
EP52 CAB HARNESS EARTH
X54 4-WAY IGNITION SWITCH A G3
EP53 ROTATING BEACON LIGHT EARTH- REAR LEFT LIGHT- ROOF LIGHT
X55 6-WAY IGNITION SWITCH A G3
EP54 REAR RIGHT WORKING LIGHT POWER SUPPLY
X56 SPU CN1-A G11
EP55 REAR LEFT WORKING LIGHT POWER SUPPLY
X57 SPU CN1-B G11
EP56 ROTATING BEACON LIGHT POWER SUPPLY
X58 LLMI SAFETY MODULE A1
EP57 WINDSCREEN WIPER POWER SUPPLY
X59 CLOCK I2
POWER SUPPLY + EASY MANAGER PERM + EASY MANAGER
EP58 E8 X60 CLOCK LIGHT I2
ENGINE IMMOBILISER RELAY
EP94 INFO D+ C5 X61 TRANSMISSION CUT-OFF SWITCH G4
EP95 INFO SWITCH NO SEAT ON SPU + EASY MANAGER C6 X68 HOUR METER REV COUNTER MODULE I3
X01 TRANSMISSION CUT-OFF ON GEAR LEVER B2 X70 FRONT WINDSCREEN WASHER PUMP I2
X02 SEAT SWITCH POWER SUPPLY X71 TRANSMISSION CUT-OFF ON BRAKE PEDAL I1
X03 SEAT SWITCH INFORMATION X72A BRAKE FLUID TANK H1
X04 POWER SUPPLY OPTIONS C2 X72B BRAKE FLUID TANK H1
X08 TRANSMISSION OIL THERMOSTAT (PS: on PS gear box) A6 X73A STOP SWITCH H1
X09 FORWARD EV B8 X73B STOP SWITCH H1
X10 REVERSE EV B8 X74 FRONT LEFT HEADLIGHT G1
X12 HANDBRAKE SWITCH A6 X75 TUV SIDELIGHT CONTROL BY WORKING LIGHT ON BOOM G2
X13 FRONT RIGHT LIGHT A11 X76A CAB LEFT-HAND EARTH E1
X14 HORN C12 X76B CAB LEFT-HAND EARTH E1
X15 FRONT WHEEL ALIGNMENT B12 X77 FRONT WINDSCREEN WIPER D1
647792EN
80 (20/01/2020) ELECTRICITY 187
3D 2D
Pos. Designation
Main Engine Dist. Main Engine Dist.
X79 WIPER STALK C1
X80 WIPER RESET C1
X84 LEFT STABILISER EV B10
X85 RIGHT STABILISER EV B10
X86 DISCHARGE VALVE MODULE G10
X87 DISTRIBUTOR HARNESS INTERFACE (MT) G4 D9 E2
X89 ENGINE WATER TEMPERATURE MODULE I3
X90 FUEL LEVEL MODULE I3
X91 CIGARETTE LIGHTER LIGHT F9
X92 PROPORTIONAL EV ON BOOM LOWERING/VRD-VRP C4 H7
X93 TILTING CUT-OFF EV/VCI D4 H6
X94 BOOM HEAD ELECTROVALVE
X95 HELLA K12-K18 MINI RELAY HOLDER D5
X96 REAR 7-PIN SOCKET ELECTRIC CONNECTOR
X97 BOOM HEAD ELECTRICAL PREDISPOSITION OR BOOM HEAD EV
X98 TRANSMISSION OIL PRESSURE SWITCH (PS: on PS gearbox)
X99/
VISHAY GAUGE CONNECTOR D11
X99A
X100 EN 15000 BOOM ANGLE SENSOR
X101 MID-FRAME/EARTH ENGINE
X103 TDF OR TDF EV ELECTRIC PLUG SWITCH G4
X105 DISTRIBUTOR HARNESS EARTH CONNECTION A2 D10 A6
X106 REAR FRAME EARTH D14
X107 CAB REAR EARTH G10
X108 FRONT FRAME EARTH ON CAB SUPPORT
X114 EMERGENCY STOP A3
X115 OBD II DIAGNOSTICS G10
X116 EASY CONNECT SYSTEM SWITCH A4
X117 ATTACHMENT LOCKING SWITCH F8
X118A ENGINE IMMOBILISER MODULE PREDISPOSITION D1
X119 OVERRIDE SWITCH A2
X133 DISCHARGE EV D9
X134 TELESCOPE RETRACTION SENSOR
X135 CAB OPTIONS RIGHT-HAND EARTH
X136 FRONT WORKING LIGHTS INTERCONNECTION
X138A LEFT LOUDSPEAKER
X138B LEFT LOUDSPEAKER
X139A RIGHT LOUDSPEAKER
80
X139B RIGHT LOUDSPEAKER
X140 FRONT LEFT WORKING LIGHT
X141 FRONT RIGHT WORKING LIGHT
X142 REAR WINDSCREEN WIPER
X143 SIDE WINDSCREEN WIPER
X144 ROOF WINDSCREEN WIPER
X145A ROTATING BEACON LIGHT
X145B ROTATING BEACON LIGHT
X146 REAR LEFT WORKING LIGHT
X147 REAR RIGHT WORKING LIGHT
X148A ROOF LIGHT
X148B ROOF LIGHT
X148C ROOF LIGHT
X149 ROOF/SIDE WINDSCREEN WIPER SWITCH
X150 REVOLVING BEACON LIGHT SWITCH
X151 WORKING LIGHT SWITCH
X152 WORKING LIGHT SWITCH ON BOOM
X153 DEFROST SWITCH
X154A REAR DEFROST
X154B REAR DEFROST
X160 BATTERY FUSE BOX A BF1
X161 STARTER ELECTROVALVE E5 6B
X162 ENGINE STOP ELECTROVALVE E4 A5
X163 DIESEL PUMP F5 B6
647792EN
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3D 2D
Pos. Designation
Main Engine Dist. Ens. Engine Dist.
X164 ENGINE OIL PRESSURE E4 C6
X165 FUEL GAUGE A2 D2
X166A AIR FILTER CLOGGING B3 D3
X166B AIR FILTER CLOGGING B3 D3
X167 PREHEAT D4 E4
X168 ENGINE EARTH G4
X169 KSB COLD START D4 E6
X170A ENGINE WATER THERMOSWITCH E5
X170B ENGINE WATER THERMOSWITCH E4 E6
X171 PREHEAT RELAY H4 E11
X172 PREHEAT/ALTERNATOR POWER FUSES G4 E11
X173 EQUIPMENT POWER FUSES (MLT) - ECM FUSE (MT) H4 D11
X174 CLOCK EARTH G4 D11
X175 LSU POTENTIOMETER E4 E7
X176 ENGINE UNIT EARTH ON FRAME
X180 INDICATOR LAMP HARNESS CONNECTOR E
X181 INDICATOR LAMP HARNESS CONNECTOR F
X182 DASHBOARD INDICATOR LAMPS (4-way)
X183 DASHBOARD INDICATOR LAMPS (16-way)
X184/
BATTERY LOAD LAMP
X184A
X185 STEERING FAULT INDICATOR
X187 WARNING SWITCH
X188 LIGHTING STALK
X189 AWAITING COMMUTATOR SWITCH-PLATE TUV DIODE
X190 AWAITING PLATE-COMMUTATOR SWITCH TUV DIODE
X191 AWAITING PLATE-WORKING LIGHTS TUV DIODE
X192 CAR RADIO POWER SUPPLY
X200A BATTERY CUT-OFF
X200B BATTERY CUT-OFF
X201 REAR RIGHT FRAME EARTH M5
X202 POULTRY BLUE LIGHT SWITCH
X203 AGGRAVATING MVT CUT-OFF POWER SUPPLY ON NON EN15000 VERSION
X204 AIR-CONDITIONING HIGH PRESSURE SENSOR
X205 REMOTE AIR-CONDITIONING MODULE
X206 REMOTE AIR-CONDITIONING MODULE
X207 AIR-CONDITIONING COMPRESSOR
X208 AIR-CONDITIONING FAN MOTOR 1
80
X209 AIR-CONDITIONING FAN MOTOR 2

X210 WORKING LIGHT ON LEFT-HAND BOOM
X211 WORKING LIGHT ON RIGHT-HAND BOOM
X212 CLEANFIX SWITCH
X213 CLEANFIX
X214 DIESEL PREHEATER REGULAR FUSE HOLDER
X215 DIESEL PREHEATER RELAY
X235A ENGINE IMMOBILISER UNIT
X236 FINTRONIC ENGINE IMMOBILISER UNIT
X238 PREHEAT ROD
X239/
ENGINE IMMOBILISER UNIT
X239A
X284A EASY MANAGER (MODULE TRACKUNIT) OPTION F9
X284B EASY MANAGER (MODULE TRACKUNIT) OPTION
X285 SEAT ADDITIVE HARNESS A5
X287 PNEUMATIC SEAT + DRIVER PRESENCE SWITCH
ADDITIONAL ENGINE IMMOBILISER HARNESS EASY MANAGER
X292 F9
OPTION
SHUNT IF NO EASY MANAGER ENGINE IMMOBILISER OPTION (BY
X292A
DEFAULT)
ADDITIONAL ENGINE IMMOBILISER HARNESS NF EASY
X292B
MANAGER
ADDITIONAL HARNESS STARTING AUTHORISATION RELAY NO
X292C
EASY MANAGER
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KEY PAD OPTION (DIGICODE/RFID CARD READER) FOR EASY

X293
MANAGER
X326 DEAD MAN SWITCH ON JSM D7
ALT (W) ALTERNATOR W F3
ALT EXIT
ALTERNATOR D+ /ALTERNATOR L E3
( D+ )/ (L)
ALT POWER
ALTERNATOR B+ E3
SUPPLY (B+)
80
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80.3.2 1 MAIN HARNESS

2 MT-X 733
3 2D 4 5 6 7 8 9 10 11 12 13 14
F
80
J
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80.3.3 MAIN HARNESS MT-X 733 3D

1 2 3 4 5 6 7 8 9 10 11 12 13 14
X165
X166A
D
X166B
X23
E X167
W X162
D X161
B X24
F
X169
80
X170B
X174
X175
G
X164
X163
X168
H
X172
X173
X171
J
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1 2 3 4 5 6 7 8 9 10 11 12 13 14
F
80
J
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1 2 3 4 5 6 7 8 9 10 11 12 13 14
X165
X166A
D
X166B
X23
X167
E
W X162
D X161
B X24
F
X169
X170B
80
X174
X175
G
X164
X163
X168
H X172
X173
X171
J
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80.3.6 ENGINE 2D HARNESS

1 2 3 4 5 6 7 8 9 10 11 12 13 14
F
80
J
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80.3.7 ENGINE 3D HARNESS

1 2 3 4 5 6 7 8 9 10 11 12 13 14
X165
X166A
X166B
D
X167
W
E
D
X162
B
X161 X24
X169
F
X170B
80
X175
X164
X163
X174
X168
X172
J
X173
X171
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80.3.8 DISTRIBUTOR 2D HARNESS
1 2 3 4 5 6 7 8 9 10 11 12 13 14
F
80
J
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80.3.9 DISTRIBUTOR 3D HARNESS

1 2 3 4 5 6
X105
X23
C X92
X93
X28
X29
X35
F X34
G
80
X87
J
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80.4.1 “BOOM ANGLE" ANGULAR SENSOR ADJUSTMENT
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. 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 80 - Electrical characteristics and specifications - data sheets for electrical components.
Key:
A
A - Brake nut and bolt
B B - Potentiometer pin
C - Connecting rod
b
80
The adjustment must be made without altering the length

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

2- Select "Diagnostic" or ‘Monitoring”.
3- Select your machine then follow the steps.
Maxi
4- If the truck is fitted with stabilisers, they must be placed on
the ground in order to increase the lifting angle.
5- Operate the boom.
6- Select the computer if necessary.
7- Read the parameters.
8- Select “Hydraulique” (Hydraulic).
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9 - View the boom angle sensor status.
The diagnostic software shows the voltages of each boom angle potentiometer sensor.
10 - Loosen the brake nut and bolt (Item A) on the lever.
11 - 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:
Min. Max.
Voltage 0.7 V 4.3 V
12 - Then tighten the brake nut and bolt (Item A).

Mini
13 - Place the boom in the down position (stabilisers retracted).
14 - Check that the values are similar to those found in the top boom
position and are within the recommended adjustment range.
15 - Calibrate the boom angle sensor.
e Group 80 - Electrical control and adjustment - Strain gauge and angle sensor calibration.
80
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80.4.2 LONGITUDINAL STABILITY INDICATOR (LLMI)

ERROR CODES
The error codes are indicated by LEDs A3 to A7 on the warning device and
longitudinal stability limiter. A7
A6
A5
A4
A3
ERROR CODES
LEDS
DESCRIPTIONS
A7 A6 A5 A4 A3
Regulating fault (fault detected during the test).
Lowering regulating valve fault.
Safety valve cut-off fault (fault detected during the test).
Safety valve fault.
Gauge calibration fault (fault detected during the test).
Resetting the longitudinal stability limiter and warning device may resolve the problem.
(o : 3 - MAINTENANCE: G - OCCASIONAL MAINTENANCE)
Angle calibration fault (fault detected during the test).
Inclination cut-off valve fault.
Strain gauge fault.
Jib angle sensor fault.
Telescope or attachment control fault.
Telescope retracted senor fault.
Computer earth output fault.
Aggravating hydraulic movement cut-off disable fault.
Fan drive valve fault.
80
Stability indicator fault.

Electronic handling controller fault.
Hydraulic control lever control setting fault.
Transmission cut-off output fault.
Electronic handling controller supply fault.
Telescope retracted sensor fault (fault detected during the test).
Tilt cut-off valve fault (according to model)
Boom head solenoid valve fault. (OPTION)
Button fault, accessory hydraulic easy attachment (OPTION)
Electrovalve attachment hydraulic control and electrical jib provision fault button. (OPTION)
Forced operation indicator fault (OPTION)
Electric handling controller 10 V output fault.
Forced operation button fault (OPTION)
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TESTING THE LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE

– These tests are essential for checking the correct operation and adjustment of the different components of the device.
b
– Place the lift truck on fl at, level ground with the wheels straight.
Use the test button only when instructed, following the guidance for a short press (less than 1 second)
or a long press (5 seconds).
In case of doubt during the test procedure, a clean exit can be made by a short press on the “BUCKET” MODE
or “SUSPENDED LOAD” buttons .
Long press on the test button
TEST OK
Short - One audible beep and progresses to
press stage 2.
the test
STAGE 1 1 button. TEST NOT OK
- Two audible beeps and lighting of
- Place the lift truck without any
attachment, with the jib fully the fault warning light .
- An audible beep. retracted and raised. - Exit test mode.
- First green LED flashing. - On stabilizers if fitted. - Go to stage 4.
- Test button lit.
TEST OK
Short - One audible beep and progresses to
press stage 3.
2 the test
STAGE 2 button. TEST NOT OK
1 -- Lower the jib with the engine - Two audible beeps and lighting of
running at full revs and the
the fault warning light .
- First green LED continuously lit. hydraulic control at the maximum
- Exit test mode.
- Second green LED flashing. setting. Calibrated speed until
- Go to stage 4.
- Test button lit. movement is cut-off.
TEST OK
- Conformity of aggravating
Short movement cut-off.
press - Exit test mode. All the LEDs will light
3
the test for 2 seconds and an audible beep
STAGE 3 2 - Lower the jib until the movement is will be sounded.
button.
1 cut-off.
80
- Try in the following order a reverse TEST NOT OK
- The first and second green LED’S tilt, a forward tilt (dumping) and a
continuously lit. telescope extension. None of these 3 - Fault warning light comes on .
- The third green LED flashing. movements should be possible. - Exit test mode.
- Test button lit. - Go to stage 4.
- The fault indicator and a beep indicate a fault.
- Press the button briefly to view the error code.
- If there are several error codes, press the button briefly several times to loop through
the error codes.
NOTE: A defective fuse can generate several error codes. If this is the case, check the fuses (see: 2 -
DESCRIPTION: 11 - FUSES AND RELAYS IN THE CAB)
STAGE 4 Should there be the error code shown
opposite, adjusting the longitudinal A7
stability limiter and warning device A6
- The fault warning light remains may solve the problem (see: 3 -
permanently on until the error is MAINTENANCE: G - OCCASIONAL A4
repaired. MAINTENANCE). A3
- Consult your dealer, specifying the error codes(s).

NOTE: For the stage 3 test, specify the non-conforming aggravating hydraulic movements, if
necessary.
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STRAIN GAUGE AND ANGLE SENSOR CALIBRATION (DEALER PROCEDURE)
Stability limit Error light

light
BUCKET mode
switch
Overload
indicator SUSPENDED
LOAD mode
indicator
Test button
Machine position: flat ground, wheels pointing forward, parking brake on, safe area.
RECORDING MINIMUM ANGLE:
- Press the “PARACHUTE” switch (activated for the next 10 seconds).
STAGE - Before the end of the 10 seconds press at the same time the “SUSPENDED LOAD” and “TEST” buttons. +
1
- Completely retract and lower the boom.
- Press the «TEST» button (short press) to record stage 1.
RECORDING THE MAXIMUM ANGLE + MAXIMUM GAUGE STRAIN:
STAGE
2 - Completely raise and retract the boom, without accessories. (If applicable use the ground stabilizers)
MEASURING THE TIME OF DESCENT FROM MAXIMUM TO MINIMUM ANGLE:
STAGE
3 - Lower the boom to its stop with the engine running at maximum revolutions (boom retracted).
80
- Ensure that the boom is below 4° (boom retracted).

STAGE
4
RECORDING MINIMUM GAUGE STRAIN:
t
- Activate the «PARACHUTE» switch to enable hydraulic movements.
STAGE The boom must be below 4°.

5
- Extend the boom until the rear wheels leave the ground.
Wait several seconds for the machine to stabilize.
t After this calibration, check that movement cut-offs work correctly.

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STRAIN GAUGE RECALIBRATION (CLIENT PROCEDURE)
According to the use the telehandler is put to, the strain gauge may require to be periodically reset.
This operation can be carried out by the operator. The procedure is described below. Only the gauge is calibrated.
Main conditions:
– Have a load at equal to at least half the machine’s maximum capacity.

– The rear axle temperature must be below 50°C. If this temperature is exceeded the operator must not carry out the procedure.
– The procedure must be carried out on flat ground with all wheels facing the front.
Simultaneously press and hold down
STAGE 1
START the «BUCKET» MODE and TEST . buttons
- Without attachments.
- Two audible beeps will be sounded and all the LEDs will flash twice to confirm the start of the procedure.
- Jib fully retracted and raised.
- On stabilizers if fitted.
Short press
the test
STAGE 2 1 - Without attachments. button.
- Stabilizers raised, if fitted.
- Carriage tilted fully backward.
- An audible beep. - Jib fully retracted and in the down position a few centimeters off the ground.
- First green LED flashing.
- Flashing test button.
Short press
/ the test
- With the fork carrier or the bucket and a load (keep jib retracted to allow all other button.
hydraulic movements).
- Jib fully retracted and in the down position a few centimeters off the ground.
b 80
2 - Two audible
STAGE 3 beeps will
1 / be sounded
- First green led continuously Keep the load as close to the ground as possible throughout this operation. and all the
LEDs will
lit.
- Hold down the disable the «aggravating» hydraulic movement cut-off flash twice to
- Second green led flashing.
button (indicator lamp lit), and extend the jib until the rear wheels are off the confirm the
- Flashing test button.
ground. end of the
NOTE: This stage consists of unloading the rear axle. It can be done using a jack procedure.
but without bearing on the rear axle..
STAGE 4
FINISH /
- After completing the resetting procedure, the telehandler is in an overloaded condition. Retract the
boom to restore the situation.
- All LEDs lit.
- A continuous audible beep
b When the reset is completed, check the operation of the longitudinal stability limiter and warning device (see:
TESTING THE LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE (LLMC).
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"AGGRAVATING" HYDRAULIC MOVEMENTS CUT-OFF
Lift truck behaviour Work zone

Movement not restricted. A - stability
Gauge signal and speed of boom angle sensor monitored.
Rapid movements that may cause the lift truck to overturn are stopped pre-emptively.
B - Dynamic movement cut-off
Stopping a rapid movement suddenly could cause the lift truck to overturn.
Slow movements may lead to the lift truck's stability limit being reached.
Cut-off of all aggravating movements: boom extension and lowering. C - stability limit
If the lift truck is not behaving normally:
=> Check the movement cut-off by referring to the load charts and inspecting the sensors.
A B C
80
LED ILLUMINATION ACCORDING TO CHANGES IN GAUGE SIGNAL

Increasing value
of the gauge signal:
100% (L8)
92% (L7)
84% (L6)
76% (L5)
68% (L4)
60% (L3)
52% (L2)
0% (L1)
Hysteresis: - 2% decreasing of the gauge signal:

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80.5 ELECTRICITY REMOVAL -REFIT
80.5.1 REPLACE THE STRAIN GAUGE

LOCATION
KEY:
A - Strain gage
b PREPARATION AND SAFETY INSTRUCTIONS 80

⇒ 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-M230FR (10/12/2015)
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AXLE PREPARATION
The area in contact with the strain gauge (Item 1) is covered

with a protective painted coating.
1
1 - Scrape this surface with a spatula.
2 - If there are any remaining traces of adhesive, use Soft

Surface Cleaner Degreaser (aerosol).
3 - Sand the area to be glued to roughen the surface and

2
achieve a good bond (Item 2).
80
CHARACTERISTICS OF PRODUCTS USED

Part nos.
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.
80-07-M230FR (10/12/2015)
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CHARACTERISTICS OF FASTENING SCREWS
The screws used are supplied with the strain gage.
e Refer to the spare parts catalogue.

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 gage must be assembled on an axle that

is completely free of stress.
1 - Lift the rear axle off the ground using an appropriate

hydraulic jack (Item 1). The axle must be lifted without
the wheels losing contact with the ground.
b
1
2 The wheels must not lift off the ground so as to not

put the axle under stress and distort adjustment of
the gauge.
2 - Secure the machine by placing two stands (Item 2), one

on either side of the frame.
80
3
3 - Remove the jack to completely unload the rear axle.
Representations for information purposes

only
80-07-M230FR (10/12/2015)
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STRAIN GAUGE
STEP 1:
1 - Note the month/year of the gauge and enter into the lift
truck data sheet.
STEP 2:
2 - Apply glue to the grooves of the strain gauge (a total of

8 daubs of glue).
STEP 3:
80
3 - Place two M10 screws on the strain gauge and then place
b
the assembly on the axle.
Take care not to place adhesive on the central part
of the gage.
Gradually tighten the two M10 screws according to this

procedure:
– Tighten screw No. 1 to a torque of 34 Nm
– Tighten screw No. 2 to a torque of 34 Nm
– Tighten screw No. 1 to rated torque C = 67 Nm ± 5%
– Tighten screw No. 2 to the rated torque C = 67 Nm ± 5%
80-07-M230FR (10/12/2015)
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⇒ Gently knock the 2 screws with 2 blows of a 1 kg

hammer, from a height of approximately 100 mm.
STEP 4:
1 2
4 - Mark the heads of the screws, the gauge and the axle
in red.
– Install the plastic casing (Item 1) and secure it with the

two M4x10 screws.
b Do not apply grease to the tops of the M10 screws,

as it is incompatible with the adhesive.
80
– Check the red marks, then apply a green mark to the

heads of the screws.
80-07-M230FR (10/12/2015)
647792EN
ELECTRICITY
210Appuyer 80 (20/01/2020)
sur le bouton (A) de défilement sous l’afficheur pour passer successivement d’un écran à l’autre.
Écran défaut SPU et nombre de défaut Affichage du code défaut
80.6 TROUBLESHOOTING Appui long sur A
80.6.1 ERROR CODES

Appui court sur A
Écran défaut moteur et nombre de défaut

MAIN ECU
NAVIGATION MENU DISPLAY
Appuyer sur le bouton (A) de défilement sous l’afficheur pour passer successivement d’un écran à l’autre.
Écran défaut SPU et nombre de défaut Affichage du code défaut
A3
Appui long sur A
Appui court sur A
Écran défaut moteur et nombre de défaut
SPU 25-15 - A3 ERROR CODES LIST

A3
SPU 25-15
Code on
PAD code machine
screen COMPONENT FAILURE
Hexa- Decimal
decimal SPN FMI
010203 520450 03 Sensors power supply output Signal voltage too high: + battery short circuit
010204 520450 04 Sensors power supply output Signal voltage too low: ground short circuit
010303 520451 03 Forced operation button indicator lamp Signal voltage too high: + battery short circuit
010304 520451 04 Forced operation button indicator lamp Signal voltage too low: ground short circuit
010603 520454 03 Telescope head electrovalve output Signal voltage too high: + battery short circuit
010604 520454 04 Telescope head electrovalve output Signal voltage too low: ground short circuit
010605 520454 05 Telescope head electrovalve output SPU 25-15 Circuit impedance too high: open circuit
010703 520455
Code on03 Levelling authorization output Signal voltage too high: + battery short circuit
010704
PAD code 520455
machine04 Levelling authorization output Signal voltage too low: ground short circuit
010705 screen05
520455 Levelling authorization output
COMPONENT Circuit impedance too high: open circuit
FAILURE
80
011203
Hexa- Decimal03
520466 Lifting cut-off electrovalve output Signal voltage too high: + battery short circuit
decimal
011204 SPN
520466 FMI
04 Lifting cut-off electrovalve output Signal voltage too low: ground short circuit
010203
011205 520450
520466 03
05 Sensorscut-off
Lifting powerelectrovalve
supply output
output Signal voltage
Circuit too high:
impedance + battery
too high: open short
circuitcircuit
010204
011303 520450
520467 04
03 Sensors powerauthorization
Transmission supply outputoutput low: ground
Signal voltage too high: short
+ battery circuit
short circuit
010303
011304 520451
520467 03
04 Forced operation
Transmission button indicator
authorization output lamp high:ground
Signal voltage too low: + battery short
short circuit
circuit
010304
011305 520451
520467 04
05 Forced operation
Transmission button indicator
authorization output lamp Signal voltage
Circuit too low:
impedance ground
too high: short
open circuit
circuit
010603
012103 520454
520481 03 Telescope
Safety head electrovalve
electrovalve output 2 output Signal voltage too high: + battery short circuit
010604
012104 520454
520481 04 Telescope
Safety head electrovalve
electrovalve output 2 output Signal voltage too low: ground short circuit
010605
012105 520454
520481 05 Telescope head electrovalve
Safety electrovalve output 2 output Circuit impedance too high: open circuit
010703
012303 520455
520483 03 Levelling
Cut-off authorization
electrovalve output
output Signal voltage too high: + battery short circuit
010704
012304 520455
520483 04 Levelling
electrovalve output
output Signal voltage too low: ground short circuit
010705
012305 520455
520483 05 Levelling
electrovalve output
output Circuit impedance too high: open circuit
011203
012503 520466
520485 03 Lifting cut-off
Telescope electrovalve
extension outputoutput
electrovalve Signal voltage too high: + battery short circuit
011204
012504 520466
electrovalve Signal voltage too low: ground short circuit
011205
012505 520466
electrovalve Circuit impedance too high: open circuit
011303
013103 520467
520497 03 Transmission
Tilting authorization
neutralization outputoutput
electrovalve Signal voltage too high: + battery short circuit
011304
013104 520467
electrovalve Signal voltage too low: ground short circuit
011305
013105 520467
electrovalve Circuit impedance too high: open circuit
012103 520481 03 Safety electrovalve output 2 Signal voltage too high: + battery short circuit
012104 520481 04 Safety electrovalve output 2 Signal voltage too low: ground short circuit
012105 520481 05 Safety electrovalve output 2 Circuit impedance too high: open circuit
012303 520483 03 Cut-off electrovalve output Signal voltage too high: + battery short circuit
012304 520483 04 Cut-off electrovalve output Signal voltage too low: ground short circuit
012305 520483 05 Cut-off electrovalve output Circuit impedance too high: open circuit
012503 520485 03 Telescope extension electrovalve output Signal voltage too high: + battery short circuit
012504 520485 04 Telescope extension electrovalve output Signal voltage too low: ground short circuit
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SPU 25-15
Code on
PAD code machine
Hexa- Decimal
decimal SPN FMI
Out of range signal value defined by the calibration: Calibration
01330D 520499 13 Strain gauge calibration error
not carried out or carried out incorrectly
013403 520500 03 Safety electrovalve output Signal voltage too high: + battery short circuit
013404 520500 04 Safety electrovalve output Signal voltage too low: ground short circuit
013405 520500 05 Safety electrovalve output Circuit impedance too high: open circuit
013507 520501 07 Safety electrovalve operation error Faulty actuator (mechanical problem)
013603 520502 03 Control electrovalve output Signal voltage too high: + battery short circuit
013604 520502 04 Control electrovalve output Signal voltage too low: ground short circuit
013605 520502 05 Control electrovalve output Circuit impedance too high: open circuit
013707 520503 07 Control electrovalve operation error Faulty actuator (mechanical problem)
014503 520517 03 Telescope retraction electrovalve output Signal voltage too high: + battery short circuit
014504 520517 04 Telescope retraction electrovalve output Signal voltage too low: ground short circuit
014505 520517 05 Telescope retraction electrovalve output Circuit impedance too high: open circuit
014603 520518 03 Attachment line A control electrovalve output Signal voltage too high: + battery short circuit
014604 520518 04 Attachment line A control electrovalve output Signal voltage too low: ground short circuit
014605 520518 05 Attachment line A control electrovalve output Circuit impedance too high: open circuit
014703 520519 03 Attachment line B control electrovalve output Signal voltage too high: + battery short circuit
014704 520519 04 Attachment line B control electrovalve output Signal voltage too low: ground short circuit
014705 520519 05 Attachment line B control electrovalve output Circuit impedance too high: open circuit
014803 520520 03 Fan rotation direction reversal electrovalve output Signal voltage too high: + battery short circuit
014804 520520 04 Fan rotation direction reversal electrovalve output Signal voltage too low: ground short circuit
014805 520520 05 Fan rotation direction reversal electrovalve output Circuit impedance too high: open circuit
014903 520521 03 Fan speed control electrovalve output Signal voltage too high: + battery short circuit
014904 520521 04 Fan speed control electrovalve output Signal voltage too low: ground short circuit
014905 520521 05 Fan speed control electrovalve output Circuit impedance too high: open circuit
020102 520705 02 Forced operation button Erratic signal value
020402 520708 02 Telescope head electrovalve activation button Erratic signal value
020502 520709 02 Attachment line decompression button Erratic signal value
021007 520720 07 Retracted telescope not detected Faulty actuator (mechanical problem)
021402 520724 02 JSM FNR selector Erratic signal value
021602 520726 02 Longitudinal stability display Erratic signal value
02160C 520726 12 Longitudinal stability display Faulty sensor or actuator
021702 520727 02 Aggravating movements contact 1 Erratic signal value
022202 520738 02 Override button Erratic signal value
80
022402 520740 02 Retracted telescope sensor Erratic signal value
022602 520742 02 Boom lifting angle sensor Erratic signal value
022609 520742 09 Boom lifting angle sensor Information not available on the CAN bus
022610 520742 16 Boom lifting angle sensor Upper sensor signal value at normal value
022612 520742 18 Boom lifting angle sensor Lower sensor signal value at normal value
022700 520743 00 Strain gauges Upper sensor signal value at normal value
022701 520743 01 Strain gauges Lower sensor signal value at normal value
022702 520743 02 Strain gauges Erratic signal value
022709 520743 09 Strain gauges Information not available on the CAN bus
02270A 520743 10 Strain gauges Abnormal signal value variation for correct operation
022713 520743 19 Strain gauges Transmitted signal value on CAN bus invalid
Out of range signal value defined by the calibration: Calibration
02320D 520754 13 Boom angle sensor calibration error
not carried out or carried out incorrectly
024102 520769 02 Telescope roller sensor Erratic signal value
024110 520769 16 Telescope roller sensor Upper sensor signal value at normal value
024113 520769 19 Telescope roller sensor Lower sensor signal value at normal value
024202 520770 02 Attachment roller sensor Erratic signal value
024210 520770 16 Attachment roller sensor Upper sensor signal value at normal value
024213 520770 19 Attachment roller sensor Lower sensor signal value at normal value
024302 520771 02 Tilting movement slide contact Erratic signal value
024402 520772 02 Attachment movement slide contact Erratic signal value
024A05 520778 05 Air intake temperature sensor Circuit impedance too high: open circuit
031101 520977 01 ECU power supply voltage Lower sensor signal value at normal value
041609 521238 09 Longitudinal stability display Information not available on the CAN bus
647792EN
212 ELECTRICITY 80 (20/01/2020)
SPU 25-15
Code on
PAD code machine
Hexa- Decimal
decimal SPN FMI
044009 521280 09 CAN bus fault Information not available on the CAN bus
044B09 521291 09 VDO dashboard fault Information not available on the CAN bus
044D09 521293 09 Casappa computer fault Information not available on the CAN bus
051500 521493 00 Computer Upper sensor signal value at normal value
05150C 521493 12 Computer Faulty sensor or actuator
022810 520744 16 Throttle manual senseur fault Upper sensor signal value at normal value
022812 520744 18 Throttle manual senseur fault Lower sensor signal value at normal value
80
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80 (20/01/2020) ELECTRICITY 213
80.7.1 BREAKOUT BOXES
Breakout box kit ...................................................................................................... 785503
Consisting of:
1 - 1 breakout box (DT connectors) ..........................................................................................785504

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

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214 ELECTRICITY 80 (20/01/2020)
80.7.3 DIAGNOSTIC TOOLS

DIAGNOSTICS CASE
80
Diagnostic case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .947349

Diagnostic case (Russia specific) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .947350
Consisting of:
1 - Tablet (with accessories and cables). . . . . . . . . . . . . . . . 895845 / 947351 (Russia specific)
2 - Styli . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947208
3 - Stylus strap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947355
4 - VCI (Vehicle Communication Interface / PAD) (with USB cable and OBD) . . . . . 895986
5 - OBD Diag. cable Manitou . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947201
6 - USB cable/Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947202
7 - Battery (6 cells: 8h) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947206
8 - Mains power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947353
9 - Transport case (not shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947345
Sold separately:
10 - Docking station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947354
11 - Legacy Diag. cable Manitou. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947204
12 - Battery (9 cells: 17h) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947207
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80 (20/01/2020) ELECTRICITY 215
CONNECTIONS TO LIFT TRUCK

CASE No. 1: MACHINE DIAGNOSTIC
VCI
Note: Cable P/N 947201 enables diagnostics to be carried out on the entire machine.
CASE No. 2: ENGINE DIAGNOSTIC
EDL
USB
Note: Case P/N 894942 can be used to diagnose the engine, e ENGINE ADAPTATION BOX.
80
ENGINE ADAPTATION KIT
1
3
Adaptation kit for engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .894942
Consisting of:
1 - EDL communication box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 894937
2 - OBD electrical cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 894940
3 - USB electrical cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 894938
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216 ELECTRICITY 80 (20/01/2020)
80
DRIVER'S CAB
CONTENTS
85.1 DRIVER'S CAB CONTROL AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
85.1.1 TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
85
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218 DRIVER'S CAB 85 (30/07/2019)
DRIVER'S CAB
85.1 DRIVER'S CAB CONTROL AND ADJUSTMENT
85.1.1 TIGHTENING TORQUES

85
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85 (30/07/2019) DRIVER'S CAB 219
85
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220 DRIVER'S CAB 85 (30/07/2019)
85
CONTENTS
110 AIR CONDITIONING OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

110.1 CHARACTERISTICS AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
110.1.1 DESCRIPTION OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
110.1.2 OPERATING PRINCIPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
110.2 LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
110.2.1 LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
110.3 AIR CONDITIONING CONTROLS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
110.3.1 GENERAL CHECK POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

110.3.2 ASSEMBLY INSTRUCTIONS FOR AIR CONDITIONING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
110.3.3 SAFETY MEASURES FOR HANDLING THE R134A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
110.3.4 REFRIGERANT FLUID LOAD FOR THE AIR CONDITIONING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . 228
110.3.5 AIR-CONDITIONING INSPECTION FORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
110.4 REMOVAL - REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
110.4.1 AIR CONDITIONING BELT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
110.4.2 AIR CONDITIONING BELT REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
110.5 AIR CONDITIONING TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
110.5.1 TEMPERATURE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
110.5.2 ABNORMAL NOISE ON A/C SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
110.5.3 UNPLEASANT SMELL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
110.6.1 FITTING WEDGE FOR ELASTIC DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
110 CLEANFIX OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

110.1 CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
PRESENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
110.2 SCHEMATIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
110.3.1 REPAIR KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
110.3.2 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

110
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222 OPTIONS - ATTACHMENTS 110 (30/07/2019)
110
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110 (30/07/2019) OPTIONS - ATTACHMENTS 223
110 AIR CONDITIONING OPTION
110.1 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
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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
647792EN
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.

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110.2 LOCATION
110.2.1 LOCATION
Connector
u
cea
ais
n F al
HP Co
nnexio rincip
P
Pressure X31
switch
ceau
fais
avecoteur
tion m
Fixa
Receiver-drier
Condenser
X255
X172
ec
n av r
tio oteu
nnec m
Co ceau
fais
LP connector
Evaporator
HP connector
Compressor
110
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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
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
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external
Location Hose module internal diameter coupling thread
diameter
Between compressor and condenser Module 8 10 mm 20.5 mm 3/4˝-16 UNF
Between drier filter and reducing valve Module 6 8 mm 18 mm 5/8˝-18 UNF
Between evaporator and compressor Module 10 13 mm 23.5 mm 7/8˝-14 UNF
To evaporator:
– Tightening torque on Module 10: 25 Nm, 22 mm wrench and + 25/26 mm counter-wrench on
expansion valve
– Tightening torque on Module 6: 16 Nm, 16/17 mm wrench and + 25/26 mm counter-wrench on
expansion valve
110.3.3 SAFETY MEASURES FOR HANDLING THE R134A
WARNING
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: 950 g ± 50 g and 135 ml of PAG SP20 oil.
110
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110.3.5 AIR-CONDITIONING INSPECTION FORM

– W
ith the engine at min. revs, ventilation speed set to "I", air-conditioning in operation and set to
minimum heating position.
– Check the output air temperature and note:
Temperature Pressures Compressor

Date Machine No.
External Air output BP HP cut-off
110
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110.4 REMOVAL - REFIT
110.4.1 AIR CONDITIONING BELT REMOVAL
1-1
1 - Take off the belt casing (1).
1-2
2
2 - Fix the special wedge (1).
(6 110 - SPECIFIC AIR CONDITIONING TOOLING) on ribbed
4 pulley (2).
1 3 - Lock the wedge with the nut (3).
4 - Make a rotation movement on the pulley shaft (4). This will

2
drive the tool and lift the belt.
1-3
5 - Pull the belt by hand to release it, continue turning and remove
the belt and the tool.
110
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110.4.2 AIR CONDITIONING BELT REFIT

1-4
1 - Fix the wedge (1).

(6 110 - SPECIFIC AIR CONDITIONING TOOLING) on ribbed
pulley (2).
3
2
1 2 - Lock the wedge with the nut (3).
4 5 3 - Position the belt on the pulley (4) outside the machine and
have it pass just behind the nut (3), and position it in the
middle of the pulley (2).
4 - Turn the pulley (5).

5 - Install the belt and remove the wedge.
TIP
Once the wedge is removed, turn the pulleys manually for a number of revolutions to check that the new belt is properly positioned
in the grooves.
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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).
110
647792EN
110.6.1 FITTING WEDGE FOR ELASTIC DRIVE BELT
Tool for facilitating elastic belt installation (Ref. 894113).
110
647792EN
110 CLEANFIX OPTION
110.1 CHARACTERISTICS
PRESENTATION
NB: If there is a boom K17 + K18 - F31 + F32
head elec trovalve 3

5
3
5
21
option, fit a 15 A fuse.
4
2
4
2
1
1
K0
K1
3 3 3
7
5 5 5 I
G
5
4
2
4
2
4
2
1
1
K2
K3 K4
H
1
87
87 8 1
87a
8
85
87a
86
85
86
K5 E F
30
K6
30
85
S35
87
3
1
87a 30 1
85
6
86
87a
87
5
K8 K9 86
30
K7
4
2
1
F13 F14 F15
F17
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12
20A
30A
D
7.5A
10A
10A
15A
10A
15A
5A
5A
F30
F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 F28 F29
25A
7.5A
7.5A
7.5A
7.5A
10A
15A
15A
15A
5A
X212
10A
A B C 1
X4-2
X135
Tightening torque
19 Nm ± 10%
X213
Y5
M11
A9
A9: Module
110
M11: Compressor
S35: Switch
Y5 : Electrovalve
647792EN
OPERATION
110 - 1 "Clean Fix" is a reversible flow fan:

- which draws air in and blows it out
- on an automatic cycle
Adjustable blades (running-in) (Item 1).

1
1
110 - 2
Cooling
It allows the direction of the fan blades to change, to create a

powerful airflow which cleans the radiator honeycomb and grille
(15 s/3 min).
110 - 3
Cleaning
110
647792EN
110.2 SCHEMATIC DIAGRAM

F17
X04 1 2 3 4 5 6 7 8 9
X212
S35
1 0 1 9
5 10
SWF 525 005

+
SWF 586 373 S10
X213
1 4 3 2
A9 Y5
X135
Cab earth
M11
Frame earth
A9: Module
M11: Compressor
S35: Switch
Y5 : Electrovalve
110
647792EN
110.3.1 REPAIR KIT
b If one of the CleanFix fan blades breaks, blades must be changed in sets of three, to stop the
fan going out of balance.
110 - 4
1- Remove the fan from your machine.
110 - 5
2- Remove the nine (M8-80) screws (A) at the front.

3- Remove casing B at the rear.
4- Replace the damaged blade as well as the two blades which
B
are at 120° to it.
5 - Refit the fan and perform a function test.
110 - 6
6- Blade repair kit Part No. 787966.

7- Blades must be replaced in sets of three (120°).
110
647792EN
110 - 7
8- Repair kit for air intake pipework and 1 spring Part No. 786994
110.3.2 MAINTENANCE
110 - 8 Filter change every 500 hours.

Part no.: 781443
110 - 9
1
110

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647792EN (20/01/2020)

MT-X 733 95P ST3A S1

DATE OF ISSUE OBSERVATION

30 / 07 / 2019 - 1st ISSUE

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

INTERACTIVE REPAIR MANUAL

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

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

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

BMEP Bloc Manipulateur ÉlectroProportionnel - Electro-proportional joystick unit:

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

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

CRC Comfort Ride Control: Boom suspension.

CVT Continuous Variable Transmission.

DPF Diesel Particulate Filter : o FAP.

DTC Diagnostic Trouble Code: fault codes

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

FMI Failure Mode Identifier: identifies the type of fault:

gr. Greek: signifies a word of Greek origin.

HS High Side: power side power supply.

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

HMI Human-Machine Interface: dashboard screens.

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

lat. Latin: signifies a word of Latin origin.

LIN Local Interconnect Network.

LLMI Longitudinal Load Moment Indicator: displaying machine stability.

LS Low Side: ground side power supply.

LSU Load Sensing Ultra: hydraulic load detection.

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

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

NO Normally Open: normally open contact.

NOx Nitrogen Oxide: regulated air pollutants.

PAD Plug And Diag: MANITOU machine diagnostics software.

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

PWM Pulse Width Modulation: modulation of the pulse

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

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

SPU Safety Power Unit: machine controller.

USB Universal Serial Bus.

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

00.1 WORK DURING THE WARRANTY PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

00.2 GENERAL INSTRUCTIONS AND SAFETY NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

00.2.2 SERVICING POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

00.2.3 EXPLANATION OF SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

00.2.4 SERVICING RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

00.3 GENERAL CHARACTERISTICS AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

00.3.2 LUBRICANTS AND FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

00.4 GENERAL LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

00.4.1 LOCATION OF THE NAME AND IDENTIFICATION PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

00.5 GENERAL CONTROL AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

00.5.1 STANDARD TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

00.5.2 METRIC - IMPERIAL UNIT CONVERSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

GENERAL, CHARACTERISTICS AND SAFETY

00.1 WORK DURING THE WARRANTY PERIOD

00.2 GENERAL INSTRUCTIONS AND SAFETY NOTICE

In order to reduce accident risks, make sure to:

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

00.2.2 SERVICING POSITION

Before any intervention:

11 - Water in diesel fuel sensor