MT 625 H EASY 49K ST3A S1 REPAIR MANUAL

647519EN (23/04/2018)
MT 625 H EASY 49K ST3A S1
REPAIR MANUAL
647519EN
2
DATE OF ISSUE OBSERVATION
20 / 01 / 2015 - 1st ISSUE
25 / 10 / 2017 - Partial UPDATE : GR80-04
23 / 04 / 2018 - Partial UPDATE : GR80-04
MANITOU BF S.A Limited liability company with a Board of Directors.

Head office: 430, Rue de l’Aubinière - 44150 Ancenis - FRANCE
Share capital: 39,548,949 euros
857 802 508 RCS Nantes
Tel: +33 (0)2 40 09 10 11
www.manitou.com
This manual is for information purposes only. Any reproduction, copy, representation, recording, transfer, distribution, or other,
in part or in whole, in any format is prohibited. The plans, designs, views, commentaries and instructions, even the document
organization that are found in this document, are the intellectual property of MANITOU BF. Any violation of the aforementioned
may lead to civil and criminal prosecution. The logos as well as the visual identity of the company are the property of MANITOU-BF
and may not be used without express and formal authorization. All rights are reserved.
647519
3 3
HOW TO USE THIS REPAIR MANUAL ?

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

4 notice
00
00
RULES FOR MAINTENANCE
Do not carry out any work on the machine unless you have followed
a suitable training course and have the knowledge required for it.
Make sure you have taken into consideration all the indicator plates
on the machine and in the instruction manual.
GENERAL INSTRUCTIONS AND SAFETY NOTICE
Be careful not to burn yourself when touching hot liquids or parts

when operations have to be done before the machine has had
time to cool down.
pages
PREAMBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
MAINTENANCE POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
RULES FOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Before carrying out any operation on an electrically powered

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

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

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

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

00
GENERAL CHARACTERISTICS AND SAFETY
10
ENGINE
20
TRANSMISSION
30
AXLE
40
BRAKE
50
BOOM
70
HYDRAULIC
80
ELECTRICITY
85
DRIVER'S CAB
90
FRAME - BODY
110
OPTIONS - ATTACHMENTS
00
GENERAL CHARACTERISTICS AND SAFETY
- GENERAL INSTRUCTIONS AND SAFETY

NOTICE
- GENERAL CHARACTERISTICS AND

SPECIFICATIONS
- GENERAL LOCATION
- GENERAL CONTROL AND ADJUSTMENT

00
GENERAL INSTRUCTIONS AND SAFETY NOTICE
pages
PREAMBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
MAINTENANCE POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
RULES FOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
(16/01/2015) 00-00-M245EN
2 GENERAL INSTRUCTIONS AND SAFETY NOTICE
00
PREAMBLE
This chapter deals with the general instructions and safety notice during inspection and maintenance
work.
Other instructions and warnings are indicated in each chapter concerned.
In order to reduce accident risks, make sure to:
– Follow the instructions in the truck operating and maintenance manual.

 This manual should be found in all trucks.
– Please follow all safety instructions.
– Use the appropriate tools for any work to be performed.
– Use original Manitou spare parts.
Any non-compliance increases the risk of accidents occurring which may lead to causing grievous bodily
harm and even death.
An efficient, dependable and profitable combination will be formed if the operator follows the safety
manual correctly and the machine is serviced properly.
When you see this symbol:
It means: Warning! Be careful! Your safety, somebody else’s or the safety of the lift truck itself
is at risk.
The manufacturer cannot predict all possible risky situations. Consequently, the safety instructions
given in the safety manual are not exhaustive.
At any time, as an operator, you must envisage, within reason, the possible risk to yourself, to others or
to the lift truck itself when you repair, service or drive it.
Manitou cannot be held responsible for the use of any lifting devices, tools or operating methods other
than those specified.
00-00-M245EN (16/01/2015)
GENERAL INSTRUCTIONS AND SAFETY NOTICE 3
00
MAINTENANCE POSITION
2 4
1 3
Before any intervention:
1 - Place the machine on a flat surface and chock the wheels.

2 - Turn off the engine and remove the ignition key.
3 - Let the machine cool down.
4 - Take all the pressure out of the circuits concerned.
(16/01/2015) 00-00-M245EN
00
RULES FOR MAINTENANCE
Do not carry out any work on the machine unless you have followed
a suitable training course and have the knowledge required for it.
Make sure you have taken into consideration all the indicator plates
on the machine and in the instruction manual.
Be careful not to burn yourself when touching hot liquids or parts

when operations have to be done before the machine has had
time to cool down.
Before carrying out any operation on an electrically powered

component, activate the battery cut-off.
1
2 b Press the battery switch at least 30 seconds after disconnecting

the electrical contact with the ignition key.
If the telehandler does not have a battery isolating switch, disconnect

the battery terminals then gather them.
b Before carrying out any welding operations, think of

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

specifically equipped. Moreover, local safety notices deal with
maintenance and repair work on such machines.
00-00-M245EN (16/01/2015)
GENERAL INSTRUCTIONS AND SAFETY NOTICE 5
00
Never step on a part of the machine that has not been designed for it.
Never wear clothes, jewelry or objects that could get caught during
work and cause accidents.
Always wear protection glasses, gloves, safety shoes as well as any

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

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

liquids, solids, gases that are harmful to the environment, make
sure the necessary precautions are taken to avoid contaminating
the environment.
(16/01/2015) 00-00-M245EN
00
When lifting or shoring a component of the machine, make sure

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

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

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

by the manufacturer.
MIN
00-00-M245EN (16/01/2015)
00
GENERAL CHARACTERISTICS AND SPECIFICATIONS
pages
CHARACTERISTICS AND FLUIDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

DIMENSIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
(16/01/2015) 00-01-M245EN
GENERAL CHARACTERISTICS AND
2 SPECIFICATIONS
Data obtained from the Instruction Manual:
i
00
647511 (16/01/2015)
CHARACTERISTICS AND FLUIDS
Designation Value Designation Type Quantity

MT 625 H EASY 49K ST3A S1 Fuel tank GNR HP diesel 63 ℓ
Truck weight with forks 4710 kg Engine oil MANITOU EVOLOGY oil - API CJ4 10W40 10,2 ℓ
Ground Front axle 2260 kg Cooling system Cooling liquid (protection -25° / -35°) 12 ℓ
distribution
with forks Rear axle 2450 kg Hydraulic tank MANITOU oil / ISO VG 46 Hydraulic 115 ℓ
Pulling force 3080 daN Brake system MANITOU oil / Mineral brake fluid 0,8 ℓ
Front transfer gear box MANITOU oil / SAE80W90 0,75 ℓ
Front / rear axle differential Special MANITOU oil for immersed brakes 4 ℓ / 3,8 ℓ
Front / rear wheel reduction

MANITOU oil / SAE80W90 0,8 ℓ / 0,9 ℓ
gear
DIMENSIONS
MT 625 H
Item EASY 49K
ST3A S1
A mm 1200
B mm 2300
C mm 991
C1 mm 928
D mm 3894
D1 mm 3831
D2 mm 3275
E mm 5094
F mm 1492
F1 mm 1492
G mm 240
G1 mm 330
G2 mm 253
G3 mm -
H ° -
H1 ° -
I mm 603
J mm 797
K mm 1015
L mm 45
N mm 1314
O mm 125
P2 ° 37
P3 ° 52
R mm 3150
S mm 6651,5
T mm 3935
U1 mm 1920
U2 mm 2054
V mm 4700
V1 mm 765
V2 mm 3310,5
W mm 1813
W1 mm -
W2 mm -
W3 mm -
Y ° 12
Z ° 117
00-01-M245EN (16/01/2015)
00
GENERAL LOCATION
pages
LOCATION OF NAME AND IDENTIFICATION PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
(16/01/2015) 00-03-M245EN
2 GENERAL LOCATION
00
LOCATION OF NAME AND IDENTIFICATION PLATE
Key:
1 - Manufacturer's plate 7 - Rear axle plate
2 - Engine plate 8 - Cab plate
3 - Hydraulic pump plate 9 - Attachment manufacturer's plate
4 - Hydrostatic pump plate 10 - Machine serial no.
5 - Hydrostatic motor plate 11 - Boom serial no.
6 - Front axle plate
MANITOU BF
44158 ANCENIS CEDEX
FRANCE
MODELE
8
N° dans la série
11 Année fabrication
Masse à vide
kg
C d G / Tablier
A vide / En charge : mm
Cap. Nominale
Pression de service
AVERTISSEMENT : RESPECTEZ
LA CAPACITE DE L'ENSEMBLE
"CHARIOT ET EQUIPEMENT"
N°207701
10
00-03-M245EN (16/01/2015)
00
GENERAL CONTROL AND ADJUSTMENT
pages
STANDARD TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
(13/02/2015) 00-04-M245EN
2 GENERAL CONTROL AND ADJUSTMENT
00
STANDARD TIGHTENING TORQUES

Standard tightening torque to be used when not otherwise indicated in the removal and refitting
operations:
- The following tightening torques are given for hexagon head screws without flanges and
cylinder head hexagon socket screws.
- The torques are given for a friction coefficient μ = 0,20 corresponding to dry-fitted zinc-plated
fasteners and for torque tools having a ± 20 % class C tightening torque accuracy (equivalent
to pneumatic screwdrivers).
1 - Tightening torque in N.m (±20%) for screw / nut connection (NF E 25-030-1):
Ø x “coarse” pitch Grade 8.8 Grade 10.9 Ø x “fine” pitch Grade 8.8 Grade 10.9
M6 x 1 8,2 12,1 - - -
M8 x 1,25 20 30 M8 x 1 22 32
M10 x 1,25 43 63
M10 x 1,5 40 59
M10 x 1 46 68
M12 x 1,5 74 108
M12 x 1,75 69 102
M12 x 1,25 78 115
M14 x 2 111 163 M14 x 1,5 123 181
M16 x 2 175 256 M16 x 1,5 190 279
M18 x 2,5 240 352 M18 x 1,5 279 410
M20 x 2,5 341 501 M20 x 1,5 391 574
M22 x 2,5 470 691 M22 x 1,5 531 780
M24 x 3 588 864 M24 x 2 659 967
M27 x 3 874 1284 M27 x 2 965 1418
M30 x 3,5 1181 1735 M30 x 2 1351 1984
M33 x 3,5 1614 2371 M33 x 2 1821 2674
b
M36 x 4 2068 3037 - - -
For hexagon screws with flanges (NF E 25-030-1) :
Apply an increased torque of +10%.
b Where washers are used, the following coefficient is to be applied (FD E 25-502) :
- Smooth tapered washer (CL): +5%
- Spring (or Grower) washer without jaws (W) : +10%
- Conical, internal teeth (CDJ-JZC) : +15%.
2 - Tightening torque in N.m (±20%) for screw / nut connection (with marking) :
4 5 6 7 8
4T 6T 8T
------------ ------------ ------------
5T 7T 11
Ø x Pitch (flange : 4.8T) (flange : 6.8T) (flange : 8.8T) (flange : 10.9T) (flange : 11.9T)
M6 x 1 5.4 (5.5) 6.5 7.8 (7.5) 11 12 (12) (15.5) (17.5)
M8 x 1,25 13 (13) 16 19 (19) 25 29 (29) (38) (42)
M10 x 1,25 25 (27) 32 39 (39) 52 61 (61) (80) (89)
M12 x 1,25 47 (50) 59 72 (71) 95 108 (110) (145) (160)
M14 x 1.5 75 (78) 91 108 (110) 147 172 (175) (230) (260)
b
M16 x 1.5 113 (120) 137 172 (170) 226 265 (270) (360) (400)
use the upper class where spring (or Grower) washers are used.
00-04-M245EN (13/02/2015)
ENGINE
10
- ENGINE CHARACTERISTICS AND
SPECIFICATIONS
- ENGINE COMPONENTS LOCATION
- ENGINE CONTROL AND ADJUSTMENT
- ENGINE REMOVAL
- ENGINE REFIT
- SPECIFIC ENGINE TOOLING
- ENGINE CHARACTERISTICS AND

SPECIFICATIONS
l647520EN
- ENGINE CONTROL AND ADJUSTMENT
(ENGINE V2607-DI-E3B)
- ENGINE TROUBLESHOOTING
- SPECIFIC ENGINE TOOLING

10
ENGINE CHARACTERISTICS AND SPECIFICATIONS
pages
CHARACTERISTICS: V2607-DI-E3B-MNT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
(14/01/2015) 10-01-M245EN
ENGINE CHARACTERISTICS AND
2 SPECIFICATIONS
CHARACTERISTICS: V2607-DI-E3B-MNT
 4 cylinders in line
 Firing order from the attachment belt: 1 - 3 - 4 - 2
10
 Anti-clockwise (viewed from flywheel)

 2,615 ℓ cubic capacity
 Direct injection
 Compression ratio: 20
 Power rating: 36 kW
 Maximum torque: 170 N.m (at 1600 rpm)
 Dry engine weight: 225 kg
 Speeds: - min rpm . . . . . . . . . . . . : 875 ± 25 rpm
- nominal laden . . . . . . : 2700 rpm
- max. unladen . . . . . . . : 2870 rpm
10-01-M245EN (14/01/2015)
10
ENGINE COMPONENTS LOCATION
pages
ENGINE ELEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
(14/01/2015) 10-03-M245EN
2 ENGINE COMPONENTS LOCATION
ENGINE ELEMENTS
Key:
1 - Cooling water inlet 10 - Fuel pre-filter
10
2 - Alternator/fan belt 11 - Fuel supply pump

3 - Water pump 12 - Fuel filter
4 - Alternator 13 - Injection pump
5 - Thermostat 14 - Starter
6 - Cooling water outlet 15 - Oil cooler
7 - Air inlet 16 - Oil filter
8 - Air intake manifold 17 - Injection hose
9 - Exhaust
10
8
17
6
12
17 17 5
17
13
11
1
4 2
14
Cooling (water)
16
Air
15
Diesel
Electricity
Lubrication
Exhaust
10-03-M245EN (14/01/2015)
10
ENGINE CONTROL AND ADJUSTMENT
pages
A - PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

B - FAN GRILL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
C - ALTERNATOR BELT REMOVAL / REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
D - ALTERNATOR REMOVAL / REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
E - STARTER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
F - FAN REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
G - RADIATOR REMOVAL/REFIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
H - WATER PUMP REMOVAL / REFIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
– REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
– REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
I - EXHAUST REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
J - AIR INTAKE REMOVAL/REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
– REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
K - ENGINE FUSE BOX REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
L - ENGINE ECU REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
(17/12/2014) 10-04-M245EN
2 ENGINE CONTROL AND ADJUSTMENT
A - PREPARATION AND SAFETY INSTRUCTIONS
Operate the battery cut-off.

Stabilize the machine on a horizontal floor.
10
Position the boom in the raised position and install the safety wedge.
Open the engine bonnet.
1 B - FAN GRILL REMOVAL

1
2
Undo the 4 screws (Item 1) and take off the fan protection grill
(Item 2).
1
C - ALTERNATOR BELT REMOVAL / REFIT

1
4  Carry out operation « B - FAN GRILL REMOVAL »
Undo the 2 screws (Item 1).

2 3 Pivot the alternator (Item 2) to release the belt (Item 3) and move
the belt behind the propellers (Item 4) to remove it.
1
Upon removal, set the belt tension on the belt run to more than
between 10 and 12 mm of bend with a pressure of 98 N.
D - ALTERNATOR REMOVAL / REFIT
2
1  Carry out operation « B - FAN GRILL REMOVAL »
 Carry out operation « C - ALTERNATOR BELT REMOVAL
/ REFIT »
1
Mark the position of the electrical wires and disconnect the

connectors (Item 1).
Undo the 2 screws (Item 2) and remove the alternator.
2
Upon removal, set the belt tension o C
10-04-M245EN (17/12/2014)
ENGINE CONTROL AND ADJUSTMENT 3
E - STARTER REMOVAL
4 Remove the 2 screws (Item 1) and take off the engine bonnet
locking lug (Item 2).
10
3
4 3 Disconnect the electrical connections (Item 3).
2 Undo the 2 nuts (Item 4) and remove the starter.

1
1
F - FAN REMOVAL
 Carry out operation « B - FAN GRILL REMOVAL »
2
6 Disconnect the hose (Item 1) from the expansion tank and
3
insert a plug (Item 2).
5
5 Unscrew the expansion tank support (Item 3) and move it to
4
the rear.
On the radiator, loosen the clamp of the upper engine water
hose and keep the hose towards the top (Item 4) and insert the
plugs (Item 5).
Remove the radiator support bracket fastening screw (Item 6).
Gently lift the radiator to free it from the silent blocks and move
it as far forward as possible.
Mark the direction of the fan.

7
Unscrew the fan's 4 fastening screws (Item 7).
Remove the fan (Item 8).
8
To refit it, put « Loctite 243 normal thread lock » on the 4 fastening
screws.
G - RADIATOR REMOVAL/REFIT

1
 Carry out operation « F - FAN REMOVAL »
Remove the 4 screws (Item 1) and remove the front draining

1
hatch from the engine housing (Item 2).
2
1
Drain the water and oil radiators.
1
(17/12/2014) 10-04-M245EN
Disconnect the lower oil radiator hose (Item 3).
Remove the radiator.

10
Disconnect the lower water radiator hose (Item 4).
Remove the clamp (Item 5) and unscrew the upper fuel hose
(Item 6).
Insert a plug into the radiator hole (Item 7)
5
Remove the radiator.
6
7
REFIT
Refit the different items in reverse order to removal.
Put in the correct amount of cooling liquid e See Instruction

Manual NI647511.
Start the engine to check operation and set the heating to

maximum to bleed the cooling circuit.
Top-up with coolant and hydraulic oil once more.
Refit the engine box lower cover.
10-04-M245EN (17/12/2014)
H - WATER PUMP REMOVAL / REFIT
2 1
 Carry out operation « C - ALTERNATOR BELT REMOVAL
10
/ REFIT »
 Carry out operation « F - FAN REMOVAL »
REMOVAL
Remove the fan support pulley cover (Item 1) (4 screws) and

remove the alternator drive pulley (Item 2).
Remove the water pump casing (Item 3).
Remove and discard the water pump seal.

4
REFIT
Proceed in the reverse order to removal.

To refit the fan support pulley cover (Item 1) put « Loctite 243
normal thread lock » on the retaining screws.
Top up with water, refit the fan e F, the belt e C, and the grill e B.
Start the engine, heat up to 85°C, stop the engine and top up
with water, check the machine is operating properly.
I - EXHAUST REMOVAL
1
3
Unscrew the two clips (Item 1) from the air intake hose (Item 2).
Insert a plug into the engine hole.
(17/12/2014) 10-04-M245EN
Remove the 2 nuts of the exhaust input (Item 4) and remove

the 2 screws.
4
10
Remove the 4 screws (Item 5) from the exhaust support clips.
5
5
5 5
Remove the exhaust (Item 6), remove the seal (Item 7) and
disregard it.
6
Insert a plug into the exhaust manifold of the engine (Item 8).
10-04-M245EN (17/12/2014)
J - AIR INTAKE REMOVAL/REFIT
REMOVAL
10
1 2
Loosen the clip (Item 1) and remove the air intake hose (Item 2).
Loosen the 2 screws (Item 3) and remove the air filter assembly.
3
REFIT
45°
Proceed in the reverse order to removal keeping a 45° angle
between the air filter inlet and the engine housing
K - ENGINE FUSE BOX REMOVAL
Unscrew the 3 screws (Item 1) and move the fuse box (if removing
the engine to access the hydrostatic pump, etc.)
3
3
L - ENGINE ECU REMOVAL
1 1
Undo the screws (Item 1).
3 Remove the screws (Item 2).
Remove the upper cover plate (Item 3).
2
2
(17/12/2014) 10-04-M245EN
Disconnect the connector (X400) from the engine ECU (Item 1).
Unscrew the 2 screws (Item 2) and remove the ECU.

X400
10
2
1
10-04-M245EN (17/12/2014)
10
ENGINE REMOVAL
pages
PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

ENGINE REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
– A – BONNET AND DRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– B – HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– C – ELECTRICITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
– D – DISMANTLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
(16/12/2014) 10-06-M245EN
2 ENGINE REMOVAL
PREPARATION AND SAFETY INSTRUCTIONS

10
Stabilize the machine on level ground.

Drive the machine in forward and reverse several times (wheels straight) in order to relieve any strain
on the steering and tires.
Position the boom in the raised position and install the safety wedge.
Deactivate battery power supply by means of the battery cut-off.
Specific tooling:
- 2 Floor cranes (minimum 400 Kg)

- Tray under the engine.
The following operations must be performed:
e 10 - ENGINE CONTROL AND ADJUSTMENT:

 Fan grill removal
 Fan removal
 Air intake Removal / Refit (remove only the air intake hose)
 Exhaust removal
 Engine fuse box removal
 ECU removal (Disconnect only)
10-06-M245EN (16/12/2014)
ENGINE REMOVAL 3
ENGINE REMOVAL
A – BONNET AND DRAINING
10
Slightly loosen the lower screw (Item 1) on the pneumatic
3 cylinder support for the engine cover (Item 2).
2 Remove the upper screw (Item 3).
1
Mark, trace the outlines of the 2 hinges (Item 4) and remove

the 3 fastening screws from each hinge.
Remove the engine cover assembly.
Drain the radiator with water.

4
B – HOSES
3
Disconnect the lower water hose for the engine (Item 1) and
insert the plugs.
Unscrew the clamp (Item 2) from the expansion tank hose (Item 3).
4
Disconnect the heating hose at the engine outlet (Item 4).
(16/12/2014) 10-06-M245EN
4 ENGINE REMOVAL
Remove the fuel supply hose (Item 5) and insert a plug.

Remove the fuel return hose (Item 6) and insert a plug.
Disconnect the accelerator cable (Item 7).

10
C – ELECTRICITY
Unclip the quick-release clip (Item 1) from the engine harness.

X04
Disconnect the starter terminals (Item 2) and the starter excitation
connector (X04).
2
1
X03 Disconnect the terminals (+) (X290) and the connector (X289)
from the alternator.
X403
Disconnect the air flow sensor (X403) and the preheating
terminal (X03).
X290
X289
Disconnect the oil pressure sensor (X404).

X404
10-06-M245EN (16/12/2014)
ENGINE REMOVAL 5
Disconnect the water temperature sensor (X402) and the speed

sensor (X401).
10
X402
X401
Disconnect the engine ground cable (X300).
X300
D – DISMANTLING
Unscrew the clamp (Item 1) from the hydraulic pump supply

hose (Item 2).
1
Disconnect the hydraulic pump supply tube (Item 2) and insert

the plugs.
Support the hydraulic pump using a strap, and loosen the 2

fastening screws (Item 3).
(16/12/2014) 10-06-M245EN
6 ENGINE REMOVAL
Place a lifting system at the rear of the lift truck.
Strap the hydrostatic pump (Item 4) taking care with the

connectors of the pump ECU.
10
Loosen the fastening screws of the hydrostatic pump by several

turns.
Remove the 2 fastening screws (Item 5) for each rear silent block
on the engine housing via the top of the engine with extensions
6 with catches (Item 6).
5 5
Remove the 2 fastening screws (Item 7) from the front silent block
7 7
Place a lifting system at the side of the lift truck.
Sling the thermal engine at the 2 fastening points (Item 8).
Support the engine.

8
8
Finish unscrewing the hydrostatic pump fastening screws.
Move the engine forward to disconnect the hydrostatic pump.
Lift the engine paying attention to the hoses and harnesses.
10-06-M245EN (16/12/2014)
10
ENGINE REFIT
pages

"I.C. ENGINE" REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
– ORDER OF INSTALLATION OF SILENT BLOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
LEVELS - VERIFICATION - TESTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
(05/01/2015) 10-07-M245EN
2 ENGINE REFIT
Specific tooling:
10
- 2 Floor cranes (minimum 400 Kg)

- Tray under the engine.
« I.C. ENGINE » REFIT

Lower the engine paying attention to the hoses and harnesses.
Put « Loctite 243 normal thread lock » on the retaining screws of

the fan and of the hydrostatic pump.
b When refitting the various components, please comply

with the tightening torques given in the following chapter:
e Group 20 - « Transmission control and adjustment »
ORDER OF INSTALLATION OF SILENT BLOCKS

70 N.m ±10%
3
110 N.m ±10%

70 N.m ±10%
y
110 N.m ±10% 27 mm
x 1
110 N.m ±10%

110 N.m ±10%
70 N.m ±10%
2
70 N.m ±10%
LEVELS - VERIFICATION - TESTING
- Top up the coolant level (cooler).

- Check and monitor the preceding assembly stages, particularly the electrical harness connections.
- Actuate the battery cut-off.
- Start and operate truck until it reaches a temperature of 85°C.
- Perform a few directional movements.
- Take off boom suspension safety system.
- Make full use of the hydraulic movements.
- Check the levels again and top up the oil if required.
10-07-M245EN (05/01/2015)
10
SPECIFIC ENGINE TOOLING
pages
ELECTRONIC TENSION METER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
(05/01/2015) 10-09-M245EN
2 SPECIFIC ENGINE TOOLING
ELECTRONIC TENSION METER
Electronic tension meter (Ref 895692) for controlling belt tension.

10
10-09-M245EN (05/01/2015)
TRANSMISSION
- TRANSMISSION SCHEMATIC DIAGRAMS
20
- TRANSMISSION COMPONENTS LOCATION
- TRANSMISSION CONTROL AND

ADJUSTMENT
- TRANSMISSION REMOVAL
- TRANSMISSION REFIT
- SPECIFIC TRANSMISSION TOOLING
- TRANSMISSION CHARACTERISTICS AND

SPECIFICATIONS l647039EN
- TRANSMISSION COMPONENTS CONTROL (HYDROSTATIC PUMP H1

AND ADJUSTMENT 045/053/060/068)
- COMPONENTS SECTIONS AND DIAGRAMS
- TROUBLESHOOTING l647069EN
- SPECIFIC TOOLING (HYDROSTATIC

MOTOR H1
060/080/110/160/250)
TRANSMISSION SCHEMATIC DIAGRAMS
20
pages
DRIVE TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
HYDROSTATIC TRANSMISSION IN FORWARD GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
– SCHEMATIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– FLUID FLOW DISPLAY IN FORWARD GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HYDROSTATIC TRANSMISSION IN REVERSE GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
– SCHEMATIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
– REVERSE GEAR FLUID FLOW DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
HYDROSTATIC TRANSMISSION COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
– FLUID FLOW DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
(05/01/2015) 20-02-M245EN
2 TRANSMISSION SCHEMATIC DIAGRAMS
DRIVE TRAIN
Front axle Rear axle

20
I.C. engine
Transfer
gear box Clockwise
Z6
Z2
Z1 Z1
Z2
Z7
Forward gear
Z3 Z5 Z4
Front and rear axles Transfer box

Gear Number of teeth Gear Number of teeth
Z1 11 Z6 36
Z2 31 Z7 58
Z3 70
Z4 14
Z5 27
20-02-M245EN (05/01/2015)
TRANSMISSION SCHEMATIC DIAGRAMS 3
HYDROSTATIC TRANSMISSION IN FORWARD GEAR (MAXIMUM SPEED/MINIMUM TORQUE) SCHEMATIC DIAGRAM

Key:
Suction system
Boost system
High Pressure
MH
L2 A Low Pressure
Cooling system
Y6
FRONT DRIVE AXLE
REAR DRIVE AXLE

Drainage system
110 cm3/tr Y7 70 See group « 70 - hydraulic »
20
BA Feed block + accumulator
CA Suction strainer
min max CAR One way valve
L1 FR Return filter
M Turbo engine
MH Hydrostatic motor
M5 M4 B
P Hydraulic pump
PH Hydrostatic pump
PP PP Pressure test port
R Main hydraulic tank
R1 Secondary hydraulic tank
RF Oil cooler
70
PPC
Forward gear Y10 Y8
T-
Pp 70
T+
BA Y12 Y9
Y11
A-
70
0.32 Litre A+
15 bar
AC
RVE Y13 Psahr
DR
Pin SAHR
70
EF
Y4 Y3 IN T
M3 L2 MA
28 cm3/tr
F00B F00A 12 cm3/tr 350 bar A
P 53 cm3/tr 70
M 70
M5 25 bar
PH 70
70
M4
350 bar B
S MB RF
VA
4 bar
FR R1
2 bar 4,5 bar Tank 2
CAR 3 bar
10μm
CA 90l/min
Tank 1
125μm
R
(05/01/2015) 20-02-M245EN
FLUID FLOW DISPLAY IN FORWARD GEAR

Key:
Suction system
Boost system
High Pressure
Low Pressure
Cooling system
Drainage system
90° MHRV Fan drive hydraulic motor
Y9
20
Y8 RF Oil cooler
Y3 Forward gear proportional electrovalve
Y12
Y4 Reverse proportional electrovalve
Y9
Y6 Hydrostatic motor 2P proportional electrovalve
Y8 Y13
Pe A
L1 Y7 BDP (Brake Pressure Defeat) electrovalve
Y8 Telescope plus or minus direction electrovalve
B Y9 Attachment plus or minus direction electrovalve
Y10 Proportional hydraulic pilot electrovalve
L1 (Telescope)
Pe
Y11 Y11 Proportional hydraulic pilot electrovalve

(Attachment)
Y6
Y10 A
L2 RF Y12 Hydraulic cut-off electrovalve (TUV)
Y7 Y13 Negative brake electrovalve
Y10
Y11
70
L2
Y3
M3
ea r
S
rd g
wa
B
For
Y4
20-02-M245EN (05/01/2015)
HYDROSTATIC TRANSMISSION IN REVERSE GEAR (MAXIMUM SPEED/MINIMUM TORQUE) SCHEMATIC DIAGRAM

Key:
Suction system
Boost system
High Pressure
MH Low Pressure
L2 A
Cooling system
Y6
Drainage system
110 cm3/tr Y7 70 See group « 70 - hydraulic »
20
ES.AR
ES.AV
CA Suction strainer
min max CAR One way valve
L1 FR Return filter
M Turbo engine
MH Hydrostatic motor
M5 M4 B
P Hydraulic pump
PH Hydrostatic pump
PP PP Pressure test port
R Main hydraulic tank
RF Oil cooler
70
PPC
Reverse gear Y10 Y8
T-
Pp 70
T+
BA Y12 Y9
Y11
A-
70
0.32 Litre A+
15 bar
AC
RVE Y13 Psahr
DR
Pin SAHR
70
EF
Y4 Y3 IN T
M3 L2 MA
28 cm3/tr
F00B F00A 12 cm3/tr 350 bar A
P 53 cm3/tr 70
M 70
M5 25 bar
PH 70
70
M4
350 bar B
S MB RF
VA
4 bar
FR R1
2 bar 4,5 bar Tank 2
CAR 3 bar
10μm
CA 90l/min
Tank 1
125μm
R
(05/01/2015) 20-02-M245EN
REVERSE GEAR FLUID FLOW DISPLAY

Key:
Suction system
Boost system
High Pressure
Low Pressure
Cooling system
Drainage system
90° MHRV Fan drive hydraulic motor
Y9
20
Y8 RF Oil cooler
Y3 Forward gear proportional electrovalve
Y12
Y4 Reverse proportional electrovalve
Y9
Y6 Hydrostatic motor 2P proportional electrovalve
Y8 Y13
Pe A
L1 Y7 BDP (Brake Pressure Defeat) electrovalve
Y8 Telescope plus or minus direction electrovalve
B Y9 Attachment plus or minus direction electrovalve
Y10 Proportional hydraulic pilot electrovalve
L1 (Telescope)
Pe
Y11 Y11 Proportional hydraulic pilot electrovalve

(Attachment)
Y6
Y10 A
L2 RF Y12 Hydraulic cut-off electrovalve (TUV)
Y7 Y13 Negative brake electrovalve
Y10
Y11
70
L2
Y3
M3
ea r
S
s e g
B
Y4 e ver
R
20-02-M245EN (05/01/2015)
HYDROSTATIC TRANSMISSION COOLING Key:

Hot hydraulic oil
FLUID FLOW DISPLAY
Hydraulic oil cools
RF Oil cooler
20
L2
RF
(05/01/2015) 20-02-M245EN
20
20-02-M245EN (05/01/2015)
TRANSMISSION COMPONENTS LOCATION
20
pages
HYDROSTATIC TRANSMISSION CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

– MT 625 H EASY 49K ST3A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
(05/01/2015) 20-03-M245EN
2 TRANSMISSION COMPONENTS LOCATION
HYDROSTATIC TRANSMISSION CIRCUIT
MT 625 H EASY 49K ST3A
Accumulator unit
Main hydraulic tank Hydrostatic motor
20
Secondary
hydraulic
tank
Front axle
Rear axle
Universal joint Hydrostatic pump
20-03-M245EN (05/01/2015)
TRANSMISSON CONTROL AND ADJUSTMENT
20
pages
HYDROSTATIC TRANSMISSION PRESSURE TEST PORT LOCATION . . . . . . . . . . . . . . . . . . . .2

PRESSURE TEST PORT VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
TOWING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
(06/01/2015) 20-04-M245EN
2 TRANSMISSON CONTROL AND ADJUSTMENT
HYDROSTATIC TRANSMISSION PRESSURE TEST PORT LOCATION
1
20
CC1
CAN
PPC
PSC
PPU
CC2
Key:
1 - Pressure test port PP (M5) (Hydrostatic motor)
PRESSURE TEST PORT VALUES
MT 625 H EASY 49K ST3A

No. Correspondence Min. (bar) Max .(bar) Comments
20 25 Static. Corresponds to boost pressure.

PP HP Pressure
Forward + reverse gear, maximum speed
350
with maximum load.
20-04-M245EN (06/01/2015)
TRANSMISSION CONTROL AND ADJUSTMENT 3
TOWING PROCEDURE
If the lift truck is not on level ground, chock it so that it does not descend the slope.
b The lift truck must be towed at very slow speed (less than 5 km/h) over the shortest possible
distance (less than 100 m).
- For towing a lift truck, the high pressure limiters must be unlocked to avoid damaging the hydrostatic
transmission, and the parking brake on the front axle must be released.
20
- Switch on lift truck ignition.
- Set the forward/reverse selector to neutral.
- Release the parking brake.
1 UNLOCKING THE HIGH PRESSURE LIMITERS:
- Open the engine bonnet.

- Loosen the nuts (Item 1) on the hydrostatic pump (Item 2) by
1 2
no more than three turns.
RELEASING THE PARKING BRAKE ON THE FRONT AXLE:
- Unscrew the screws (Item 3) on the front axle, remove the shims
(Item 4) and fully retighten the screws (Item 3).
4
3 TOWING:
- Switch on the hazard warning lights.

- Since there will be no steering or braking hydraulic assistance,
operate the steering and pedal slowly avoiding sudden or jerky
movements.
- After towing, retighten nuts (Item 1) (tightening torque 70 N.m).
- Unscrew the screws (Item 3), refit the shims (Item 4) and retighten
the screws (Item 3) (tightening torque 95 - 115 N.m).
(06/01/2015) 20-04-M245EN
4 TRANSMISSON CONTROL AND ADJUSTMENT
TIGHTENING TORQUES
590 N.m ± 10%
20
37 N.m ± 10%
37 N.m ± 10%
69 N.m ± 20%
69 N.m ± 20%
102 N.m ± 20 N.m

238 N.m ± 10%
480 N.m ± 10% 102 N.m ± 20 N.m
175 N.m ± 10%
60 N.m ± 12 N.m
50 N.m ± 10%
3,5 N.m max.
50 N.m ± 10%
60 N.m ± 12 N.m
3,5 N.m max.

20-04-M245EN (06/01/2015)
TRANSMISSION REMOVAL
20
pages
COMPONENTS LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
HYDROSTATIC MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
(06/01/2015) 20-06-M245EN
2 TRANSMISSION REMOVAL
COMPONENTS LOCATION
B
20
A
Key:
A - Hydrostatic pump
B - Hydrostatic motor
• Stabilize the machine on level ground.

• Position the boom in the raised position and install the safety wedge.
• Decompress all hydraulic components before dismantling.
• Deactivate battery power supply by means of the battery cut-off.
Specific tooling:
• Lifting crane or hoist + slings.
The following operations must be performed:
e 10 - ENGINE CONTROL AND ADJUSTMENT:

 Air intake hose removal
 Exhaust removal
 Engine fuse box removal
 Disconnect the ECU
20-06-M245EN (06/01/2015)
TRANSMISSION REMOVAL 3
HYDROSTATIC PUMP
Slightly loosen the lower screw (Item 1) on the pneumatic

cylinder support for the engine cover (Item 2).
Remove the upper screw (Item 3).
3 4 Mark, trace the outlines of the 2 hinges (Item 4) and remove

the 3 fastening screws from each hinge.
2
20
1
Remove the engine cover assembly.
Unscrew the 2 screws (Item 5) and remove the hydrostatic pump

draining hatch (Item 6).
3
3
Remove the brackets securing the 3 hoses (Item 1). Remove the
5 seals and plug the ports.
Disconnect the electrical connectors (Item 2) of the hydrostatic

pump.
3
2 Disconnect the hoses (Item 3). Remove the seals and plug the
2 ports.
1 2
2
1
1
Sling the hydrostatic pump (Item 4) taking care with the connectors
of the pump ECU.
4
Remove the 2 fastening screws (Item 5) of the hydrostatic pump
and disconnect it from the motor.
Lift and remove the hydrostatic pump.
(06/01/2015) 20-06-M245EN
HYDROSTATIC MOTOR
1 1
3
Remove the screws (Item 2).
Remove the upper cover plate (Item 3).
2
20
Remove the lower cover plate (Item 4).
6 Disconnect the front transmission universal joint (Item 5) by

7 removing the two brackets (Item 6) using the four screws (Item 7).
6 7
Remove the 4 hoses (Item 8).

8
X62 8
Disconnect the connector (X62).
8
8
20-06-M245EN (06/01/2015)
TRANSMISSION REMOVAL 5
Disconnect the two connectors (X260 and X261).
X261
X260
20
Sling the hydrostatic motor to a hoist.
9 9 Remove the 4 fastening screws (Item 9).
Remove the hydrostatic motor via the bottom of the machine.
(06/01/2015) 20-06-M245EN
20
20-06-M245EN (06/01/2015)
TRANSMISSION REFIT
20
pages
HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
HYDROSTATIC MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
LEVELS - VERIFICATION - TESTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
(07/01/2015) 20-07-M245EN
2 TRANSMISSION REFIT
COMPONENTS LOCATION
B
20
Key:
A - Hydrostatic pump
B - Hydrostatic motor
b When refitting the various components, please comply with the tightening torques given in the
following chapter: e Group 20 - « Transmission control and adjustment »
Specific tooling:
20-07-M245EN (07/01/2015)
TRANSMISSION REFIT 3
HYDROSTATIC PUMP
2
Lower the hydrostatic pump taking care with the hoses and
harnesses and connect the hydrostatic motor (Item 1) to the
1
I.C. engine.
20
Put « Loctite 243 normal thread lock » on the screws (Item 2)
of the hydrostatic pump.
HYDROSTATIC MOTOR
2
Place the hydrostatic motor (Item 1) under the truck.
2
1 Install a sling on the hydrostatic motor and install a hoist.
Position the hydrostatic motor with the hoist.
Connect the transfer gear box hydrostatic motor then tighten

the four fastening screws (Item 2).
Reconnect the two connectors (X260 and X261).
X261
X260
Reconnect the connector (X62).

3
X62 3
Reconnect the 4 hoses (Item 3).
3
3
(07/01/2015) 20-07-M245EN
4 TRANSMISSION REFIT
Position and attach the front transmission universal joint (Item

4 4) and refit the 2 brackets (Item 5) using the 4 screws (Item 5)
5 (tightening torque: 37 N.m ±10%).
6
5 6
20
Refit the lower cover plate (Item 7).
Refit cover plate (Item 8).

Tighten the screws (Item 9).
10 10 Retighten the screws (Item 10).
8
Start up the engine and check for leaks.
Top up with hydraulic oil.

9
9
LEVELS - VERIFICATION - TESTING
- Check and monitor the preceding assembly stages, particularly

the electrical harness connections.
- Operate the battery cut-off.
- Start and operate truck until it reaches a temperature of 85°C.
- Perform a few directional movements.
- Take off boom suspension safety system (OPTION).
- Make full use of the hydraulic movements.
- Check the levels again and top up the oil if required.
20-07-M245EN (07/01/2015)
SPECIFIC TRANSMISSION TOOLING
20
pages
BASIC MANOMETER SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

DIGITAL MANOMETER SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
(07/01/2015) 20-09-M245EN
2 SPECIFIC TRANSMISSION TOOLING
BASIC MANOMETER SET
This box contains all the components required for measuring

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

2 - 1 gauge 0/40 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549883
3 - 2 gauge 0/60 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549884
4 - 1 gauge 0/400 bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549885
5 - 2 gauge 0/600 bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549886
6 - 4 standard hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549887
7 - 2 hoses for telehandler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549888
8 - 7 gauge tap connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549889
20-09-M245EN (07/01/2015)
SPECIFIC TRANSMISSION TOOLING 3
DIGITAL MANOMETER SET
FUNCTIONS:
• Gauge function: the display allows the following combinations:
 The upstream pressure temperature at +/- 2°C

 The upstream temperature P1 with its mini and maxi (700 bar
20
in class 0.1)
 Downstream pressure P2 with its min. and max. (700 bar
in class 0.1)
 Differential pressure ΔP=P1-P
• Hold function: The user can freeze the screen display at any
time to take notes
• Unit function: The user can change the unit of measurement

at any time (bar, psi, kPa, mCe).
• Function Tare: Enables offset to zero
• Leak test function: Can measure a pressure variation over a

specified time
• Record function: A maximum of 16000 readings can be recorded.

The sampling period can be configured.
• Reset function: The 2 sensors are reset to zero
Digital Manometer kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .662187
Consisting of:
1 - 1 digital gauge ΔP HP 700 bar

2 - 1 measurement hose DN2 1215/1620, L = 1,5m, 630 bar
3 - 2 measurement hoses DN2 1620/1620, L = 1,5m, 630 bar
4 - 2 gauge adaptors 1620
(07/01/2015) 20-09-M245EN
4 SPECIFIC TRANSMISSION TOOLING
20
20-09-M245EN (07/01/2015)
AXLE
- AXLE CHARACTERISTICS AND

SPECIFICATIONS
l647041
- AXLE CONTROL AND ADJUSTMENT
(AXLE 211/221)
- SPECIFIC AXLE TOOLING
30
BRAKES
- BRAKE CHARACTERISTICS AND

SPECIFICATIONS
- BRAKE SCHEMATIC DIAGRAMS e 70 - HYDRAULIC
- BRAKE CONTROL AND ADJUSTMENT
40
- SPECIFIC BRAKE TOOLING
BRAKE CHARACTERISTICS AND SPECIFICATIONS
pages
40
SERVICE BRAKE / PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
(07/01/2015) 40-01-M245EN
BRAKE CHARACTERISTICS AND
2 SPECIFICATIONS
40
40-01-M245EN (07/01/2015)
SPECIFICATIONS 3
SERVICE BRAKE / PARKING BRAKE
SHELL L.H.M S8 214 B brake fluid Hydrostatic pump
Non-exhaustive illustrative diagram:
e chapter « hydraulic schematic diagram »
Master cylinder ø 28,57 mm
Displacement: 19,68 cm3 Feed block
MAX
Piston surface area: 641,30 mm2 PPC
T-
T+
M3 L2 MA
A
Parking brake control
A-
switch
255 A+
M5 Battery positive (+)
SAHR
M4
B
S L1 MB T
47
40
Negative parking brake operation:
P
- If P = 0b -> Braking axle
- If P = 15b -> Non-braking axle
Braking ratio:
255 / 47 = 5,4
P2
Oil bath disc brake: P1
Total number of discs for the axle 6

Braking area per disc face 109,92 cm ²
Recommended operating pressure 80 bars max.
Friction material WELLMAN N°266
Disk diameter 178 mm
Disk thickness 3,7 mm
Epicycloidal
step-down gear Acting radius 78,3 mm
R = 1/6 Number of slave cylinders 1
Wear compensation No
Track width 22,5 mm
SERVICE BRAKE (Front axle) PARKING BRAKE (Front axle)
(07/01/2015) 40-01-M245EN
4 SPECIFICATIONS
40
40-01-M245EN (07/01/2015)
BRAKE CONTROL AND ADJUSTMENT
pages
40
BRAKE AND INCHING PEDAL ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
BLEEDING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
(07/01/2015) 40-04-M245EN
2 BRAKE CONTROL AND ADJUSTMENT
BRAKE AND INCHING PEDAL ADJUSTMENT
E
40
– Screw the rubber pad (Item A) until in contact with the nut
(Item C).
Shim
B 1,5 mm thick
A
– Place a 1,5 mm shim between the rubber pad (Item A) and
C the pedal support (Item B).
d al
Pe
Contact with the piston

of the master cylinder – Loosen the nut (Item E)
– Adjust the rod (Item D) by loosening or tightening so that it

is in contact with the piston of the master cylinder.
– Retighten the nut (Item E) to lock the rod.

D
E – Remove the 1,5 mm shim between the rubber pad (Item A)

and the pedal support (Item B).
40-04-M245EN (07/01/2015)
BRAKE CONTROL AND ADJUSTMENT 3
BRAKE AND INCHING PHASES: REST, BRAKING AND ASSOCIATED SAUER MODULE VALUES
+35°
-35°
(4.5V) 0°
(0V)
40
– Start the truck, move forward approx. 2 meters braking until the pedal is in the bottom position.
– Leave the I.C. engine running during the control operations.
CORRELATION TABLE - FORCE ON PEDAL / VOLTAGES / BRAKING CIRCUIT PRESSURE / PEDAL ANGLE
Braking circuit pressure

Pedal position Force on pedal (N) Potentiometer voltage (V) Pedal angle (°)
(Bar)
Pedal released (rest position) 4,5 1,4 0 0
1 9 2 3 5
2 11 2,5 4,5 10
3 15 2,9 6 15
4 70 3,3 50 20
(07/01/2015) 40-04-M245EN
BLEEDING PROCEDURE
Location:
5
40
2
3
Key:
1 - Master cylinder
2 - Service Brake Pedal
3 - Accumulator
4 - Front axle
5 - Brake fluid tank
40-04-M245EN (07/01/2015)
12
2 4
3
13
8 X30
2
8 X30
6
X31
X31 1
5
40
X31
X31 4
X31 3
2
X30
8
11
(07/01/2015) 40-04-M245EN
Master cylinder purge:
– Unclip 2 heating outlets (Item 1)

– Take out 2 screws (Item 2) behind the 2 outlets (Item 1).
– Unclip the set of 3 switches (Item 3).
– Take out screw (Item 4) behind the set of 3 switches (Item 3).
– Remove steering column casing (Item 5) after taking out 2 screws (Item 6).
– Unclip temperature button (Item 7).
– Take out 2 heating tap screws (Item 8) behind temperature button (Item 7).
– Disconnect 4-position fan button switch (Item 9).

– Disconnect air-conditioning run/stop connector (Item 10).
10
– Take out air hose (Item 11) that goes to instrument panel
(Item 12).
– Disconnect set of switches (Items 3 + 13) so as to be able to
40
take out instrument panel.
– Remove brake fluid reservoir plug and fit bleeder (Item 15)
adapter (Item 14).
– Operate the bleeder.
15
14
– Bleed master cylinder by undoing screw (Item 16).

– Wait until oil is out then do up screw.
16
40-04-M245EN (07/01/2015)
17
18
Bleed front axle service brake:
– Fit transparent recovery piping to bleeder screw (Item 17).

– Loosen the bleed screw, then re-tighten it once the brake fluid is flowing without air bubbles.
40
Bleed front axle parking brake:
– Carry out same operation on bleeder screw (Item 18).
– Top up the brake fluid tank level.
(07/01/2015) 40-04-M245EN
40
40-04-M245EN (07/01/2015)
SPECIFIC BRAKE TOOLING
pages
40
HYDRAULIC BRAKE BLEEDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
(07/01/2015) 40-09-M245EN
2 SPECIFIC BRAKE TOOLING
HYDRAULIC BRAKE BLEEDER
Bleed valve supplied with all the components required for

bleeding the hydraulic brake circuits of all Manitou products.
40
MANITOU Reference
HYDRAULIC BRAKE BLEED KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .554019
SPARE PARTS:
– TOP MANOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 719980
– BOTTOM MANOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 719981
– Membrane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 661913
– HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 661914
40-09-M245EN (07/01/2015)
BOOM
- BOOM CHARACTERISTICS AND

SPECIFICATIONS
- BOOM COMPONENTS LOCATION
- BOOM CONTROL AND ADJUSTMENT
- BOOM REMOVAL
- BOOM REFIT
50
BOOM CHARACTERISTICS AND SPECIFICATIONS
pages
DUPLEX BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
50
(07/01/2015) 50-01-M245EN
2 BOOM CHARACTERISTICS AND SPECIFICATIONS
DUPLEX BOOM
Consists of 2 components:
- 1 FIXED
- 1 MOBILE (T1)
Machines equipped with a Duplex boom:
- MT 625 H EASY 49K ST3A
Boom ground:
- ≈ 900 Kg
T1
50
Fixed element
Retracted boom
hitch points
50-01-M245EN (07/01/2015)
BOOM COMPONENTS LOCATION
pages
INDEX OF COMPONENT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

LOCATION OF THE DUPLEX BOOM MAIN COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
50
(07/01/2015) 50-03-M245EN
2 BOOM COMPONENTS LOCATION
INDEX OF COMPONENT CODES
Item Designation Comments

T1 TELESCOPE 1
VE COUNTERBALANCE VALVE
VI TILTING CYLINDER e 70 - HYDRAULIC
VT TELESCOPE CYLINDER
X134 POSITION SENSOR e 80 - ELECTRICITY
50
50-03-M245EN (07/01/2015)
BOOM COMPONENTS LOCATION 3
LOCATION OF THE DUPLEX BOOM MAIN COMPONENTS
T1
VI
FIXED COMPONENT
X134
50
VE
VT
(07/01/2015) 50-03-M245EN
4 BOOM COMPONENTS LOCATION
50
50-03-M245EN (07/01/2015)
BOOM CONTROL AND ADJUSTMENT
pages
DUPLEX BOOM COMPONENT DISMANTLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

– GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– TELESCOPE CYLINDER REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
50
– TELESCOPE T1 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DUPLEX BOOM COMPONENT REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
– BOOM REASSEMBLY T1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
– SHIM INSTALLATION AND GREASING AREA RECOMMENDATIONS . . . . . . . . . . . . . . . . 11
– TIGHTENING TORQUE AND GREASING AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
– TELESCOPING CIRCUIT REFIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
(08/01/2015) 50-04-M245EN
2 BOOM CONTROL AND ADJUSTMENT
DUPLEX BOOM COMPONENT DISMANTLING

50
GENERAL INFORMATION
Order of dismantling must be followed in order to access components.

• Fully retract the telescope.
• If an attachment is mounted on the carriage, remove it.
• Decompress all hydraulic components.
• Place the boom in the horizontal position
Specific tooling:
– Lifting crane or hoist + slings.

– Support stand
– Mallet.
– Trestles.
– Flare nut wrench with extension and key e 50 "Specific tooling".
50-04-M245EN (08/01/2015)
BOOM CONTROL AND ADJUSTMENT 3
TELESCOPE CYLINDER REMOVAL
b
Place an oil collecting tray under the cylinder.
1
Decompress the boom’s hydraulic circuits.
2
Remove the casing (Item 1) located at the front of the boom
head (Item 2).
50
Disconnect the hoses (Item 3) (24 mm wrench) from the tilting
cylinder (Item 4) at the front of the boom head (Item 2) and plug
their ends.
2
3
5
Remove the clamp (Item 5) securing the 2 tilting cylinder (Item
4) supply hoses (Item 3).
3
3
(08/01/2015) 50-04-M245EN
Remove the screw (Item 7) from the tilting cylinder pivot pin
(Item 8).
7
Hold the tilting cylinder in place using a strap (Item 9) and a hoist.
9 Remove the tilting cylinder pivot pin (Item 8) using a mallet
8
50
Progressively lower the hoist to free the access to the telescope

cylinder retaining nut (Item 10).
Unscrew the nut (Item 10) (46 mm socket + tube).

10
Disconnect the electrical connector (Item 11) at the foot of the

boom.
11
50-04-M245EN (08/01/2015)
Disconnect the 6 hydraulic pipes:
- (x2) telescoping circuit (Item 12)

- (x2) tilting circuit (Item 13)
- (x2) attachment circuit (Item 14)
Place a container under the pipes to collect the oil.

12
12
14
14
13 13
Remove the retaining bracket (Item 15) securing the hydraulic

pipes by removing the 2 screws (Item 16).
16
16
15
50
Remove the 4 screws (Item 17) from the foot of the telescoping
cylinder.
17
17
17
17
19 Position a strap (Item 18) connected to a lifting device (Item 19)

on to the foot of the telescope cylinder.
18 Gently lift and extract the assembly and place it on a stable surface.
(08/01/2015) 50-04-M245EN
Disconnect the tilting cylinder hoses (Item 20).
20
20
T1
50
TELESCOPE T1 REMOVAL
22
22
Remove the 2 pad cover plates (Item 21) by unscrewing the 6
21
screws (Item 22).
Remove the pads.

22
Using a strap and a lifting system (hoist), remove the telescope

T1 by pulling it out.
50-04-M245EN (08/01/2015)
DUPLEX BOOM COMPONENT REFIT
50

b
b
Comply with greasing and torque tightening values described hereafter.
Apply « Loctite 243 normal thread lock » to all nut/screw interfaces situated only on the inside
of the boom.
Specific tooling:
– Lifting crane or hoist + slings.

– Support stand
– Mallet.
– Trestles.
– Flare nut wrench with extension and key e 50 "Specific tooling".
(08/01/2015) 50-04-M245EN
T1
BOOM REASSEMBLY T1
b
b
Follow the shim installation and greasing recommendations set out below .
b
When refitting the pads, check their condition and replace if necessary.
Mount the pads in the correct direction

50
Pad summary tables:
Pad with straight edges Pad with beveled edges
Color Part number Width Length Thickness Color Part number Width Length Thickness
270 059 30 180 9 288041 60 180 11

270 121 30 180 10 276 852 60 180 12
270 122 30 180 11 276 853 60 180 13
270 123 30 180 12 276 854 60 180 14
270 124 30 180 13 276 855 60 180 15
Place the bottom rear slide pads (Item 1) ensuring that they are
mounted in the correct direction.
Grease the sliding faces of the pads.
1
1
50-04-M245EN (08/01/2015)
Insert telescope T1 in the boom foot using a strap (Item 2) and

2 a jib crane.
Remove the support stand (Item 3)
T1
4
Place the 4 pad cages (Item 4)
4
Place the bottom front slide pads (Item 5) ensuring that they are
mounted in the correct direction.
Grease the sliding faces of the pads (o SHIM INSTALLATION AND
GREASING AREA RECOMMENDATIONS).
5 5
4 4
50
Insert telescope T1 into the boom foot (Item 6) to within 400
6
mm of the end.
T1
m m
400
Place the top front pads (Item 7) in the correct direction and to
7 the specified clearance (o SHIM INSTALLATION AND GREASING
7
AREA RECOMMENDATIONS).
Grease the sliding faces of the pads (o SHIM INSTALLATION AND
GREASING AREA RECOMMENDATIONS).
(08/01/2015) 50-04-M245EN
Push telescope T1 to the left.
8 Insert the RH side pads (Item 8).
b The pads must only be inserted by hand, do not use a

mallet.
Repeat the same operation to insert the LH side pads to the

8
specified clearance (o SHIM INSTALLATION AND GREASING AREA
RECOMMENDATIONS).
9 10
Refit the 2 pad cover plates (Item 9) with the 6 screws (Item 10)
(tighten to the correct torque, o TIGHTENING TORQUE AND
10 GREASING AREA).
10
11
Grease the sliding faces of the pads (Item 11) (oRECOMMENDATIONS

FOR FITTING BLOCKS AND GREASING AREAS).
10
50
12 12
Place the top rear pads (Item 12) in the correct direction and to
the specified clearance (o SHIM INSTALLATION AND GREASING
14 13 AREA RECOMMENDATIONS).
Shift telescope T1 to the left and insert the RH rear side pads
(Item 13), then shift telescope T1 to the right with the help of
a crow bar to insert the LH side pads (Item 14), providing the
correct clearance (o RECOMMENDATIONS FOR FITTING BLOCKS
14 13 AND GREASING AREAS).
T1
b The pads must only be inserted by hand, not with a mallet.
Refit the upper and lower pad cover plates (Item 14) with the 2
screws (Item 15) (tighten to the correct torque, o TIGHTENING
14
15 15 TORQUE AND GREASING AREA).
Fully insert telescope T1 into the boom foot.
15 15
14
50-04-M245EN (08/01/2015)
SHIM INSTALLATION AND GREASING AREA RECOMMENDATIONS
Rear slide pads 65 Nm
Front slide pads

Jh
80 80
50
50
Front slide pads J1 J2
50
50
50
80 80
65 Nm
Rear slide pads
80 80
50
50
Jh
: Greasing surface J1
J2
Grease the tube slip faces in the specified areas, the grease spread is 0,2 kg/m².
50
50
Jh: Height clearance => 0,5 mm < Jh < 1,5 mm
Jl: Side clearance => 1 mm < J1+J2 < 2 mm
The symmetrical tolerance of the shim is 1 mm: permissible thickness difference between the right and left slide pads.
80 80
(08/01/2015) 50-04-M245EN
TIGHTENING TORQUE AND GREASING AREA
600 N.m ± 15%
Position the clamp relative to the adhesive

tape on the hose
60-80 N.m
19 N.m ± 10%
50
V2
V1
V1
V2
19 N.m
145 N.m ± 20%
19 N.m ± 10%
Greasing 15 N.m ± 10%
Greasing recommendations before axle assembly:
- Fill the cells and hinge bushings.

- Apply a thin film of grease to the pin bearing surface of un-bushed
bearings.
50-04-M245EN (08/01/2015)
TELESCOPING CIRCUIT REFIT
Insert the « cylinder + channel » assembly into the telescope

3 3 (Item 1).
Attach the clamp (Item 2) with the nuts and washers (Item 3)
(tighten to the correct torque and if replacing the hose, follow
2
the instructions, o TIGHTENING TORQUE AND GREASING AREA).
50
1
Reconnect all hoses, hydraulic pipes and reattach the clamp.
Reconnect the electrical connector.
Finish inserting the « cylinder + channel » assembly into the

telescope.
Attach the cylinder with the screws and washers (Item 4).
NOTE: Clean the threads with a tap in order to remove dry
thread lock and clean the screws. Refit the screws with
normal thread lock (tighten to the correct torque,
o TIGHTENING TORQUE AND GREASING AREA).
4
4
4
4
(08/01/2015) 50-04-M245EN
Turn the cylinder rod so that the flat is in the vertical direction.
Attach the cylinder head with the washer (Item 6) and nut (Item
7) (tighten to the correct torque, o TIGHTENING TORQUE AND
GREASING AREA).
7
6
50
Tilting cylinder
8 Refit the tilting cylinder pin (Item 8).
Reconnect the hoses and the clamp to the tilting cylinder.

Reconnect the hoses to the attachment circuit pipes.
Refit the closing panel (Item 9) at the telescope head.
Refit the rear casing.

9
50-04-M245EN (08/01/2015)
b DRAIN THE TELESCOPE CYLINDER

– Start the engine.
– Extend the telescope by 0,5 m.
– Retract the telescope.
– Extend the telescope by 1 m.
– Extend the telescope by 1,5 m.
– Extend the telescope by 2 m.
b CARRY OUT THE CHECK AGAIN AND IF NECESSARY THE ADJUSTMENT:

– Angular potentiometer.
– The telescope retraction limit switch.
– If necessary, repeat angle + strain gage calibration.
b CLEAN AND GREASE THE BOOM

– Fully extend the boom.
– Apply grease with a brush (o SHIM INSTALLATION AND GREASING AREA RECOMMENDATION)
to the 4 sides of the telescope.
50
– Telescope the boom several times in order to spread the coat of grease evenly.
– Remove the surplus of grease.
(08/01/2015) 50-04-M245EN
50
50-04-M245EN (08/01/2015)
BOOM REMOVAL
pages
DUPLEX BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
50
(08/01/2015) 50-06-M245EN
2 BOOM REMOVAL
DUPLEX BOOM
50
GENERAL INFORMATION
Position boom at half height
Weight of complete boom ≈ approx. 900 Kg
Specific tooling:
- Lifting system (Hoist + sling)

- Mallet
50-06-M245EN (08/01/2015)
BOOM REMOVAL 3
Remove the screw (Item 1) (17 mm wrench).
Remove the pin (Item 2) from the compensating cylinder (Item 3).
1
3
Disconnect the electrical connector (Item 4) located at the base

of the boom.
50
Unscrew the boom angle sensor ball joint (Item 5)
Disconnect all hydraulic pipes and remove the clamp.
Place a container under the pipes to collect the oil.
(08/01/2015) 50-06-M245EN
4 BOOM REMOVAL
Remove the retaining bracket (Item 6) securing the 2 pipes (Item

7) by removing the screw.
10
11
11
14 Hold/Secure the boom in place (Item 12) using a strap (Item 13)
and a lifting system (pulley) (Item 14).

13
Position a block between the frame and the lifting cylinder to
12
hold it in place.
Remove the screw (Item 15) from the pin of the lifting cylinder
15
(Item 16).
50
16
Remove the pin from the lifting cylinder (Item 16).
Place a block between the frame and the compensating cylinder

(Item 17) to hold it in position when the boom is removed.
Remove the screw (Item 18) from the pin of the compensating
cylinder (Item 19).
19
Remove the pin from the compensating cylinder (Item 19).

18
17
Remove the screw (Item 20) from the boom foot pivot pin (Item
21).
21
Remove boom foot pivot pin (Item 21).

20
50-06-M245EN (08/01/2015)
BOOM REMOVAL 5
Lift the boom (Item 22) using the hoist + strap (Item 23), then
23
set it down on a flat surface.
22
50
(08/01/2015) 50-06-M245EN
6 BOOM REMOVAL
50
50-06-M245EN (08/01/2015)
BOOM REFIT
pages
DUPLEX BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
50
(08/01/2015) 50-07-M245EN
2 BOOM REFIT
DUPLEX BOOM
50
GENERAL INFORMATION
Specific tooling:
- Lifting system (hoist + slings or straps)

- Mallet
50-07-M245EN (08/01/2015)
BOOM REFIT 3
Using a hoist + strap (Item 1), position the boom (Item 2) on the
1
truck so that the connecting pins are aligned.
Greasing recommendations before pivot pin assembly:

- Apply a fine film of grease on the pin bearing surface.
3 Insert the pin (Item 3) in the boom foot.
Attach the pin to the boom foot by tightening the screw (Item 4).
4
50
7
Insert the pin (Item 5) in the lifting cylinder head (Item 6), then
secure it by tightening the screw (Item 7).
6
5 Remove the block.
Refit the retaining bracket (Item 8) on the 2 pipes (Item 9) and

fasten the assembly with the screw.
8
9
(08/01/2015) 50-07-M245EN
4 BOOM REFIT
Reconnect all hydraulic pipes and reattach the clamp.
Screw the ball joint of the boom angle sensor (Item 10) observing
a center distance from the connecting rod of 145 mm.
10
145 mm
50
Connect the electrical connector (Item 11) located on the boom

foot.
11

Insert the pin (Item 12) in the head of the compensating cylinder
12
(Item 13), then secure it by tightening the screw (Item 14).
13
14 Remove the block.
Test the machine: retract/extend all cylinders to end of travel in

order to fill them with hydraulic oil.
50-07-M245EN (08/01/2015)
SPECIFIC BOOM TOOLING
pages
FLARE NUT WRENCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
50
(08/01/2015) 50-09-M245EN
2 SPECIFIC BOOM TOOLING
FLARE NUT WRENCH
30 mm Flare nut wrench . . . . . . . . . . . . . . . . . . . . . . .Part no.: 947228

50
50-09-M245EN (08/01/2015)
HYDRAULIC
- HYDRAULIC CHARACTERISTICS AND

SPECIFICATIONS
- HYDRAULIC SCHEMATIC DIAGRAMS
- HYDRAULIC CONTROL AND ADJUSTMENT
- HYDRAULIC COMPONENTS REMOVAL
- HYDRAULIC COMPONENTS REFIT
- HYDRAULIC SPECIFIC TOOLING
70
HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS
HYDRAULIC COMPONENT SHEETS
– DISTRIBUTOR 5000 (INLET ELEMENT)

– DISTRIBUTOR 5000 (LIFTING ELEMENT)
– DISTRIBUTOR 5000 (TILTING ELEMENT)
– DISTRIBUTOR 5000 (ATTACHMENT ELEMENT)
– DISTRIBUTOR 5000 (TELESCOPING ELEMENT)
– POWER SOURCE + ACCUMULATOR
70
– STEERING BLOCK
– COUNTERBALANCE VALVE VBSN
– COMPENSATION INSULATION VALVE VIC
– 3 POSITION STEERING SELECTOR
– MANIPULATOR BLOCK + AGGRAVATING MOVEMENT CUT-OFF
(09/01/2015) 70-01-M245EN
70
70-01-M245EN (09/01/2015)
SPECIFICATIONS 1
DISTRIBUTOR 5000 (INLET ELEMENTS)

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

2. Dynamic flow priority valve. -T : Tank Return.
3. Safety valve. - P1 : Main pressure.
- P2 : Steering pressure.
- Pp : Pressure test port.
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(10/02/2012) F70-3-0048EN
HYDRAULIC CHARACTERISTICS
2 AND SPECIFICATIONS
DISTRIBUTOR 5000 (INLET ELEMENTS)

The hydraulic flow arrives at P1.

LS P2
At start-up, the flow passes through the dynamic flow
priority valve (VPDD) and reaches the orbitrole.
T
235 bar
8 bar
P1
Pp
VPDD VS
As the orbitrole is closed, the pressure increases and
LS P2 the VPDD spool moves to direct the oil towards the
safety valve (VS) that is open to the tank.
T
235 bar
8 bar
P1
Pp
70
VPDD VS
When the operator turns the steering wheel, an LS
LS P2 signal is sent from the orbitrole to the VPDD, forcing
it to give priority of flow towards the steering system.
T
235 bar
8 bar
P1
Pp
VPDD VS
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
F70-3-0048EN (10/02/2012)
SPECIFICATIONS 1
DISTRIBUTOR 5000 (LIFTING ELEMENT) d1

Role:
- Enables several actuators to be supplied according to pilot-operated
deviation spool position.
A B
3 4
2 5 1 2
1. Distribution spool
2. Pilot head
3. Non-return valve
4. Anti-shock valve
5. Non-return valve
70
5 3 4
LS P 1b 1A 1B 2b 2A 2B 3b 3A 3B 4b 4A 4B
245 bar 245 bar 245 bar 180 bar D
T
235 bar
8 bar
Pp
1a 2a 3a 4a
1 2 EL 2 EI EA ET
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(10/02/2012) F70-3-0049EN
DISTRIBUTOR 5000 (LIFTING ELEMENT)

1b 1A 1B The spool is in neutral.

245 bar
The flow passes through the spool and returns to the tank.
1a
EL
70
The spool moves downwards under the effect of a pilot pressure at 1b. 1b 1A 1B
245 bar
The flow is directed to 1B and the pressure on the lifting movement
increases.
T
1a
EL
F70-3-0049EN (10/02/2012)
SPECIFICATIONS 1
DISTRIBUTOR 5000 (TILTING ELEMENT)

Role:
distribution spool position.
A B
3 4
2 5 1 2
2. Pilot head
3. Secondary valve
4. Secondary valve
5. Non-return valve
70
5 3 4
2b 2A 2B
LS P 1b 1A 1B 3b 3A 3B 4b 4A 4B
245 bar 245 bar 245 bar 180 bar D
T
235 bar
8 bar
Pp
1a 2a 3a 4a
EL 1 2 EI 2 EA ET
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(13/02/2012) F70-3-0050EN
DISTRIBUTOR 5000 (TILTING ELEMENT)


245 bar 245 bar
2a
EI
70
245 bar 245 bar
The flow is directed to 2B and the pressure on the lifting movement
increases.
T
2a
EI
F70-3-0050EN (13/02/2012)
SPECIFICATIONS 1
DISTRIBUTOR 5000 (ATTACHMENT ELEMENT) d1

Role:
A B
2 3 1 2
2. Pilot head
3. Non-return valve
70
3
2b 2A 2B
LS P 1b 1A 1B 3b 3A 3B 4b 4A 4B
245 bar 245 bar 245 bar 180 bar D
T
235 bar
8 bar
Pp
1a 2a 3a 4a
EL EI 1 2 EA 2 ET
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(13/02/2012) F70-3-0051EN
DISTRIBUTOR 5000 (ATTACHMENT ELEMENT)

3a
EA
70
The flow is directed to 3B and the pressure on the tilting movement
increases.
T
3a
EA
F70-3-0051EN (13/02/2012)
SPECIFICATIONS 1
DISTRIBUTOR 5000 (TELESCOPING ELEMENT)

Role:
A B
3 4
2 5 1 2
2. Pilot head
3. Relief valve
4. Non-return valve
5. Non-return valve
70
5 3 4
4b 4A 4B
LS P 1b 1A 1B 2b 2A 2B 3b 3A 3B
245 bar 245 bar 245 bar 180 bar D
T
235 bar
8 bar
Pp
1a 2a 3a 4a
EL EI EA 1 2 ET 2
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(13/02/2012) F70-3-0052EN
DISTRIBUTOR 5000 (TELESCOPING ELEMENT)

The spool is in neutral.

4b 4A 4B
180 bar
4a
ET
The spool moves downwards under the effect of a pilot pressure at 4b.
4b 4A 4B
180 bar
70
The flow is directed to 4B and the pressure on the tilting movement

increases.
4a
ET
F70-3-0052EN (13/02/2012)
SPECIFICATIONS 1
FEED BLOCK + ACCUMULATOR

Role:
Provide a reserve of pressurised oil for:
- Braking assistance.
- Distributor control (according to machine).
- Manipulator feed.
- AC : Membrane accumulator.
- Pp : Aggravating movement cut-off block (BCMA)
supply pressure test port. BA PPC
- Pin : Pressure test port (boost). Pp
- SAHR : Parking brake supply. Y10 Y8
- Psahr : Parking brake pressure switch. T-

Y12
- IN : Feed. T+
-T : Tank Return.
Y11 Y9
- PPC : BCMA and VS control. A-
70
- BA : Feed block.
0.32 Litre A+
- RVE : Non-return valve. 15 bar
- DR : Accumulator discharge nozzle. Y13
Psahr
RVE
- Y8 : Telescoping direction selection EV. AC DR
SAHR
- Y9 : Attachment direction selection EV. Pin EF
- Y10 : Telescope proportional pilot EV.
IN T
- Y11 : Attachment proportional pilot EV.
- Y12 : Hydraulic cut-off EV.
- Y13 : Parking brake EV.
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(13/02/2012) F70-3-0053EN
70
F70-3-0053EN (13/02/2012)
SPECIFICATIONS 1
STEERING PUMP / STEERING UNIT OSPC 160 LS d1

Role:
- To direct and dose the flow in order to supply a steering circuit.
- It is a rotating distributor.
1. Anti-shock valve.
L R 1 2. Distributor pump.
3. LS relief valve.
70
-P : Supply Pressure.
-T : Tank return.
2 -R
-L
: Output to right.
: Output to left.
- LS : Pilot line.
3
Détail 2
P T LS
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(13/02/2012) F70-3-0055EN

STEERING PUMP / STEERING UNIT OSPC 160 LS d1
L R
When the driver turns the steering wheel to the left, the flow is passed
from P to L, and a pilot pressure is sent to the distributor to obtain
priority.
– Orbitrole pressure
– LS pressure
– Tank return
P T LS
L R
When there is an impact on a wheel, the pressure increases in the

line. This pressure opens the valve which enables the resulting
pressure to be evacuated and therefore protects the hydraulic and
mechanical steering components.
P T LS
L R
70
When the wheels are on full lock, the pressure in the steering
circuit rises. The LS line operates the relief valve and directs the flow
to the tank.
P T LS
F70-3-0055EN (13/02/2012)
SPECIFICATIONS 1
COUNTERBALANCE VALVE VBSN

On lifting cylinder On telescoping cylinder
V1
VE 3 1
210 bar
1 V1 V2
210 bar
VT 2
VL V2 2
VE
70
2
Operation:
Pilot-assisted counterbalance valves are a combination of two valves; a non-return valve and a pressure
relief valve. The non-return valve allows free flow from the distributor (chamber 2) to the load (chamber 1),
while a pilot-assisted direct acting pressure relief valve controls the flow from chamber 1 to chamber 2.
The effective pressure relief valve setting is lowered by the pilot pressure at port 3 to a value determined
by the pilot ratio.
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(14/02/2012) F70-3-0056EN
70
F70-3-0056EN (14/02/2012)
SPECIFICATIONS 1
COMPENSATION INSULATION VALVE VIC

On compensating cylinder
VE
VC V1 2
1
V2 3
1 2
70
3
3 2
Operation:
Pilot-assisted counterbalance valves are a combination of two valves; a non-return valve and a pressure
relief valve. The non-return valve allows free flow from the distributor (chamber 2) to the load (chamber 1),
while a pilot-assisted direct acting pressure relief valve controls the flow from chamber 1 to chamber 2.
The effective pressure relief valve setting is lowered by the pilot pressure at port 3 to a value determined
by the pilot ratio.
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(14/02/2012) F70-3-0057EN
70
F70-3-0057EN (14/02/2012)
AND SPECIFICATIONS 1
3 POSITION STEERING SELECTOR

Role:
A T
P B - Allows the selection of 3 steering modes, depending on
the steering alignment switch position (See instructions).
A B T 2
3 1
3 2 1
AV AR
SD 3 2 1
P
70
Position of steering selector switch:
1 - Front and rear wheels face opposite directions (circle).

2 - Front wheels steer (road mode).
3 - Front and rear drive wheels in the same direction (crab steering).
Nominal pressure (bar) 315

Nominal flowrate (liters/minute) 45
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(21/06/2012) F70-3-0062EN
70
F70-3-0062EN (21/06/2012)
SPECIFICATIONS 1
MANIPULATOR BLOCK + AGGRAVATING MOVEMENT CUT-OFF BLOCK

Role:
- This block cuts-off tilting movement and controls rising
and lowering movement flow rates.
BMHP : Hydraulic proportional manipulator block

CMA : Aggravating movement cut-off block
EV2 EV1 : Tilting cut-off EV

EV2 : Lowering proportional cut-off EV
EV3 : Lifting proportional cut-off EV
EV3
EV1
BMHP + CMA
4 3
3 4
70
1 2
1
2
Y15
Y14 Y18
EV1 EV2 EV3
I- I+ L- T L+ P
Notes : ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(09/01/2015) F70-3-0104EN
2 SPECIFICATIONS
70
F70-3-0104EN (09/01/2015)
HYDRAULIC SCHEMATIC DIAGRAMS
pages
KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
HYDRAULIC DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
70
(09/01/2015) 70-02-M245EN
2 HYDRAULIC SCHEMATIC DIAGRAMS
KEY
Position on
Item Designation Characteristics (Options)
diagram
BA Feed Block + Accumulator (AC) M15
BMHP + CMA Proportional hydraulic manipulator block + aggravating movement cut-off O27
BLR(O) Isolation valve A34 OPTION
CA Suction strainer S11
CAR One way valve S11
D Distributor K36
D3 3 position steering distributor C13
EVTF (O) Telescope head electrovalve C40 OPTION
FDAR Rear disc brake C18
FDAV Front brake disc C4
FR Return filter Q15
M Engine O3
MC Master cylinder G6
MH Hydrostatic motor A10
P Hydraulic pump O5
PAAV Front attachment plug C37
PAAV (O) Front attachment plug A34 OPTION
PDD Dynamic steering pump G16
PH Hydrostatic pump O12
PP Pressure test port E9/K24/M15
PRF (O) Leak return plug G40 OPTION
R Main hydraulic tank S15
R1 Secondary hydraulic tank Q19
RF Cooler Q13
RLF Brake fluid reservoir G6
VC Compensating cylinder A30 DE 115x60 C310
VE Counterbalance valve A27/E27/E37
VDAR Rear steering cylinder C16
VDAV Front steering cylinder C6
VI Tilting cylinder A25 DE 125x65 C 396
VIC Compensation Isolation Cylinder A32
VL Lifting cylinder E24 DE 120x70 C 1100
VT Telescope cylinder E35 DE 70x45 C 2200
70
VVT (O) Carriage Locking Cylinder A37 DE 60x45 C 183 - OPTION

Y3 Forward gear proportional electrovalve O7
Y4 Reverse proportional electrovalve O6
Y6 2P SAUER hydrostatic motor (PCOR) proportional electrovalve C9
Y7 BDP (Brake Pressure Defeat) electrovalve C10
Y8 Telescoping electrovalve + or - direction M19
Y9 Attachments electrovalve + or - direction M19
Y10 Proportional hydraulic pilot electrovalve (telescoping) M18
Y11 Proportional hydraulic pilot electrovalve (Attachment) M18
Y12 Hydraulic cut-off electrovalve (TUV) M16
Y13 Negative brake electrovalve M19
Y14 Lowering cut-off electrovalve (aggravating movements cut-off ) O25
Y15 Tilting cut-off electrovalve (aggravating movement cut-off ) O25
Y17 Telescope head electrovalve C38 OPTION
Y18 Proportional lifting electrovalve O27
1 Telescope retraction-4b M21 12 Attachment K34

2 Telescope extension-4a M21 13 Telescoping K35
3 Unlocking attachment-3b M21 14 (80 L/min) lowering G29
4 Unlocking attachment-3a M21 15 (80 L/min) lift G30
5 Lifting-1b O28 16 (80 L/min) tilt up G31
6 Lowering-1a O30 17 (80 L/min) tilt down G32
7 Tilt up-2a O31 18 (80 L/min) attachment unlocking G33
8 Dump-2b O29 19 (80 L/min) attachment locking G34
9 Dynamic flow priority valve K26 20 (80 L/min) telescope extension G35
10 Lifting K29 21 (80 L/min) telescope retraction G36
11 Tilting K32 22 Safety valve K28
70-02-M245EN (09/01/2015)
HYDRAULIC SCHEMATIC DIAGRAMS 3
HYDRAULIC DIAGRAM MT 625 H EASY 49K ST3A S1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
3 2 1 VVT(O)
VC VIC
A
AV AR
V1
PAAV(O) V2 V1 A
3 2 1
VI VE V2
V2
A B T 270 bar
MH L2 A V1
3 2 1 PAAV
Y6
VDAV P B1 B2
P1 110 cm3/tr Y7 D3 FDAR BLR (O)
C1 C2
C P2 A1 A2 C
ES.AR
ES.AV
min max
L1
VDAR
FDAV
V1
M5 M4 B
210 bar
VL V2 210 bar
PP V1 VT V2
E E
VE
L R VE
200b 200b
RLF
14 16 18 20
PDD 15 17 19 21
B2 B1
G 160cm3/tr PRF(O) G
MC 140 b
P T LS
I I
LS P 1b 1A 1B 2b 2A 2B 3b 3A 3B 4b 4A 4B
245 b 245 b 245 b 180 b
T
235 b 8b
P
70
PP
K 5 K
PP D
1a 2a 3a 4a
PPC 8 9 10 11
22 12 13
Y10 Y8 1
T-
Pp
T+ 2
BA Y12 Y9
Y11 3
M A- M
0.32 Litre 4 3
A+ 4
15 bar 3 4
AC
RVE Y13 Psahr
DR 1 2
Pin SAHR
EF 2
1
Y4 Y3 6 7
IN T
M3 L2 MA Y15
O 28 cm3/tr Y14 Y18 BMHP O
r=1.16
F00B F00A 12 cm3/tr 350 bar A +
P 53 cm3/tr EV1 EV2 EV3
M CMA
M5 25 bar I- I+ L- T L+ P
PH
M4
350 bar B
Q RF Q
S MB VA
4 bar
FR
2 bar 4,5
CAR 3 bar
bar
R1
10μm
S 90l/min S
CA
125μm
R
(09/01/2015) 70-02-M245EN
4 HYDRAULIC SCHEMATIC DIAGRAMS
70
70-02-M245EN (09/01/2015)
HYDRAULIC COMPONENTS LOCATION
pages
KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
LOCALIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
70
(12/01/2015) 70-03-M245FR
2 HYDRAULIC COMPONENTS LOCATION
KEY
Item Designation Characteristics (Options)
BMHP + CMA Proportional hydraulic manipulator block + aggravating movement cut-off
CA Suction strainer
D Distributor
D3 3 position steering distributor
FR Return filter
JSM Hydraulic control lever
P / PV Hydraulic pump
PDD Dynamic steering pump
R1 Main hydraulic tank
RLF Brake fluid reservoir
VC Compensating cylinder
Vdar Rear steering cylinder
Vdav Front steering cylinder
VI Tilting cylinder
VIC Compensation insulation valve
VE Counterbalance valve
VL Lifting cylinder
VT Telescope cylinder
LOCATION
PDD D3 VT VI
JSM
70
BMHP
+ CMA
BA
D
VE
Vdav
VE
R2
VC
VIC
VE
VL
P
CA
R1
Vdar
FR
70-03-M245FR (12/01/2015)
HYDRAULIC CONTROL AND ADJUSTMENT
pages
PRESSURE TEST PORTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

– VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– LOCALIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DISTRIBUTOR TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
70
(12/01/2015) 70-04-M245EN
2 HYDRAULIC CONTROL AND ADJUSTMENT
PRESSURE TEST PORTS
VALUES
Values (bar)
Element No. of pressure test ports Correspondence
Min. Max.
Joystick supply pressure

Pp 25 25
(if Y12 supplied)
Accu. Unit
Pin Booster pressure 25 25
PP Main pressure 10 235
Dynamic steering pump

Distributor P line 10 140
(PDD) supply
Signal (LS) line Priority valve control 4 130
V1 line Isolation rod side 2 245

VIC
Compensating isolation
valve
70
V2 line Isolation drum side 2 245
Hydrostatic pump
Hydrostatic motor
e 20 « TRANSMISSION CONTROL AND ADJUSTMENT »
70-04-M245EN (12/01/2015)
HYDRAULIC CONTROL AND ADJUSTMENT 3
LOCATION
BA
Pin
Pp
70
VIC PP
D
Pp-V2 Pp-V1
(12/01/2015) 70-04-M245EN
4 HYDRAULIC CONTROL AND ADJUSTMENT
DISTRIBUTOR TIGHTENING TORQUES
Item Distributor (N.m)

1A
100 ± 15 N.m
2A
3A 60 ± 9 N.m
RV 4A
1B 100 ± 15 N.m
Pg 2B
S2
3B 60 ± 9 N.m
S4
4B 100 ± 15 N.m
S1 B1
65 ± 7 N.m
B2
LS 60 ± 9 N.m
P 100 ± 15 N.m
4B
Pg 25 N.m
3B
2B S1 45 ± 5 N.m
S2 1B S2
B1 24 ± 3 N.m
LS S3
S3 4A S4 9,5 ± 1,5 N.m
S1 P 3A
2A SS
SS 60 ± 9 N.m
1A T
B2
S4 V1a
RV T V2a
RV
V3a
V4a
V1b 25 N.m
70
V2b
V3b
V5b V4b
RV V4b
V5b
V3b
V2b RV 45± 5 N.m
RV V1b
S3
S4
S2
S3 S1
a
V4
a
V3 S2
a
V2
a
V1
S4
70-04-M245EN (12/01/2015)
HYDRAULIC COMPONENTS REMOVAL
pages
HYDRAULIC PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
ACCUMULATOR BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
SUCTION STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
70
(12/01/2015) 70-06-M245EN
2 HYDRAULIC COMPONENTS REMOVAL
COMPONENTS LOCATION
A
70
Key:
A - Hydraulic pump
B - Distributor
C - Accumulator unit

• Raise the boom and secure in position.
• Decompress all hydraulic components before dismantling.
Specific tooling:
70-06-M245EN (12/01/2015)
HYDRAULIC COMPONENTS REMOVAL 3
A
HYDRAULIC PUMP
 Carry out operation « EXHAUST REMOVAL » e 10 - ENGINE

CONTROL AND ADJUSTMENT
1
Unscrew the clip (Item 2) from the lower suction hose (Item 2),
2 disconnect it and insert a plug.
Unscrew the clip (Item 3) from the hydraulic hose at the main
pump outlet (Item 4).
3
Unscrew the hydraulic tube from the main pump outlet (Item
4) and plug the holes.
70
A
Remove the 2 retaining screws from the pump (Item 5).
Remove the hydraulic pump (Item A).

4
(12/01/2015) 70-06-M245EN
DISTRIBUTOR
4
3
2
Remove protection cover (Item 1) by undoing the 6 screws (Item 2).
2
2 Remove protection cover (Item 3) by undoing the 2 screws (Item 4).

1
Mark the hoses with a marker pen.
Unload the accumulator using the discharge valve (DR).
e Accumulator hydraulic diagram
Disconnect the hydraulic hoses.

70
Remove the distributor bracket (Item 5) by unscrewing its 4

screws (Item 6).
70-06-M245EN (12/01/2015)
HYDRAULIC COMPONENTS REMOVAL 5
Mark the hoses located behind the distributor with a marker pen.
Disconnect 4 hydraulic hoses.
ACCUMULATOR BLOCK
1 1
3 Remove the screws (Item 2).
Remove the cover plate (Item 3).
2
2
Mark the hoses with a marker pen (Item 4).
70
5 6 Remove the 8 hoses (Item 5).
5
Disconnect the 8 connectors (Item 6).
5 7
5
Remove the 2 screws (Item 7).

6
7 Remove the accumulator unit.

6 6 4
(12/01/2015) 70-06-M245EN
SUCTION STRAINER
 Carry out operation e 10 - ENGINE REMOVAL

1
2
Using a screwdriver (Item 1), remove the clamp (Item 2) from
the hose (Item 3).
3
70
4
Unscrew the suction strainer (Item 4) using a pin wrench (Item 5).
70-06-M245EN (12/01/2015)
HYDRAULIC COMPONENTS REFIT
pages
HYDRAULIC PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
ACCUMULATOR BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
70
(13/01/2015) 70-07-M245EN
2 HYDRAULIC COMPONENTS REFIT
COMPONENTS LOCATION
A
70
Key:
A - Hydraulic pump
B - Distributor
C - Accumulator unit

• Raise the boom and secure in position.
b When refitting the various components, please comply with the tightening torques given in the
following chapter: e Group 20 - « Transmission control and adjustment »
Specific tooling:
70-07-M245EN (13/01/2015)
HYDRAULIC COMPONENTS REFIT 3
HYDRAULIC PUMP
A
Place the hydraulic pump (Item A) against the. engine (Item 1).
Attach the hydraulic pump by tightening the 2 screws (Item 1).
If the connector (Item 2) has been withdrawn, retighten it
3 (tightening torque 120 N.m).
2
1 Reconnect the hydraulic hose at the main pump outlet (Item 3).
Retighten the clip (Item 4) securing the main pump hydraulic

outlet pipe (Item 3).
A
If the connector (Item 5) has been withdrawn, retighten it
(tightening torque 60 N.m).
70
Reconnect the lower suction hose (Item 6) to the connector
5 (Item 5).
5
Tighten the clip (Item 7) (tightening torque max. 8 N.m).
 Carry out operation « EXHAUST REFIT » e 10 - ENGINE

CONTROL AND ADJUSTMENT
(13/01/2015) 70-07-M245EN
DISTRIBUTOR
1 Reconnect the 4 hydraulic hoses (Item 2) behind the distributor

1 according to the marks made when dismantling.
1
1
Refit the distributor bracket (Item 2) by screwing the 4 screws

(Item 3).
Reconnect the hydraulic hoses according to the marks made

when dismantling.
70
5
4 Refit the cover plate (Item 4) using 2 screws (Item 5).
Refit the cover plate (Item 6) using 6 screws (Item 7).

7
7
27
6
70-07-M245EN (13/01/2015)
HYDRAULIC COMPONENTS REFIT 5
ACCUMULATOR BLOCK
Refit the accumulator block (Item 1) using 2 screws (Item 2).

4 3
1 Reconnect the 8 connectors (Item 3).
4
Reconnect the 8 hoses (Item 4) according to the marks made
4 2 when dismantling.
4
3 3
7 7
Refit cover plate (Item 5).
Tighten the screws (Item 6).
5 Retighten the screws (Item 7).
6 Top up with hydraulic oil.

6
70
(13/01/2015) 70-07-M245EN
70
70-07-M245EN (13/01/2015)
HYDRAULIC SPECIFIC TOOLING
pages
BASIC MANOMETER SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

DIGITAL MANOMETER SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
70
(13/01/2015) 70-09-M245EN
2 HYDRAULIC SPECIFIC TOOLING
BASIC MANOMETER SET
This box contains all the components required for measuring

pressure on all Manitou products.
2 3 5
1 3 4 5
70
Basis gauge kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .549671
Consisting of:
1 - 1 gauge 1/9 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549882

2 - 1 gauge 0/40 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549883
3 - 2 gauge 0/60 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549884
4 - 1 gauge 0/400 bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549885
5 - 2 gauge 0/600 bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549886
6 - 4 standard hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549887
7 - 2 hoses for telehandler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549888
8 - 7 gauge tap connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549889
70-09-M245EN (13/01/2015)
HYDRAULIC SPECIFIC TOOLING 3
DIGITAL MANOMETER SET
FUNCTIONS:
• Gauge function: the display allows the following combinations:
 The upstream pressure temperature at +/- 2°C

 The upstream temperature P1 with its mini and maxi (700 bar
in class 0.1)
 Downstream pressure P2 with its min. and max. (700 bar
in class 0.1)
 Differential pressure ΔP=P1-P
• Hold function: The user can freeze the screen display at any
time to take notes
• Unit function: The user can change the unit of measurement

at any time (bar, psi, kPa, mCe).
• Function Tare: Enables offset to zero
• Leak test function: Can measure a pressure variation over a

specified time
• Record function: A maximum of 16000 readings can be recorded.

The sampling period can be configured.
70
• Reset function: The 2 sensors are reset to zero
Digital Manometer kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .662187
Consisting of:
1 - 1 digital gauge ΔP HP 700 bar

2 - 1 measurement hose DN2 1215/1620, L = 1,5m, 630 bar
3 - 2 measurement hoses DN2 1620/1620, L = 1,5m, 630 bar
4 - 2 gauge adaptors 1620
(13/01/2015) 70-09-M245EN
4 HYDRAULIC SPECIFIC TOOLING
70
70-09-M245EN (13/01/2015)
ELECTRICITY
- ELECTRICAL CHARACTERISTICS AND

SPECIFICATIONS
- ELECTRICAL SCHEMATIC DIAGRAMS
- ELECTRICAL COMPONENTS LOCATION
- ELECTRICAL CONTROL AND ADJUSTMENT
- ELECTRICAL COMPONENTS REFIT
- ELECTRICAL TROUBLESHOOTING
- ELECTRICAL SPECIFIC TOOLING
80
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
pages
WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
– FUSES AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– ELECTRICAL CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
– SPLICES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
– CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
– DIODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
BLOCK DIAGRAM OF ELECTRICAL AND ELECTRONIC SYSTEM. . . . . . . . . . . . . . . . . . . . . . . .17
INPUTS/OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
– DASHBOARD MODULE (BAUSER) - A1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
– TRANSMISSION COMPUTER - A2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
– MAIN ECU - SPU 25-15 - A3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
– ENGINE ECU - EVG - A13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
80
DATA SHEETS FOR ELECTRICAL COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
(05/02/2015) 80-01-M245EN
2 SPECIFICATIONS
WIRING
FUSES AND RELAYS
ENGINE HOUSING (BF1)

Module Item Designation Pos Wire No. Color To
F41 Engine ECM 44 Yellow BF1/M2-F51
51 Red X310B-C1
F42 Key switch
52 Red X310B-C8
F43 Alternator 46 Red X290-B+
Module 1 53 Yellow X310B-A1
F44 BF2 cab fuse box supply
54 Yellow X310B-A8
F45 Starter relay power supply 726 Red BF1/M3-K22-30
F46 Preheat + diesel decongealant option 43 Red BF1/M2-K20-30
X201 711 Black X159
A 44 Yellow BF1/M1-F41
F51 Engine computer
B 799 Yellow EP31
Engine indicator lamps on dashboard A 667 Green BF1/M2-F54-A
F52
(Electric plate indicator lamp A12) B 668 White X310B-B3
A 45 Green X310B-B1
Starter relay control +
F53 660 White BF1/M3-K22-86
Engine ECU info (A13) B
803 Grey X400-21
18 Yellow BF1/M2-F55-A
F54 Free A
667 Green BF1/M2-F52-A
18 Yellow BF1/M2-F54-A
A
19 Yellow X310B-B8
Module 2 F55 Alternator excitation / engine ECU alert (A13)
9 White X289-IG
B
802 Orange X400-44
F56 Free
F57 Free
F58 Free
F59 Free
F60 Free
80
2 (85) 41 Black X300

5 (87) 2 Red X03
K20 Preheater relay (70A)
3 (30) 43 Red BF1/M1-F46
1 (86) 801 Grey X400-39
30
85
K21 Free
86
87
Module 3
30 726 Red BF1/M1-F45
85 804 Grey X400-40
K22 Starter relay (35A)
86 660 White BF1/M2-F53-B
87 727 Red X4
80-01-M245EN (05/02/2015)
SPECIFICATIONS 3
2 4 1 86 F40 F30 F20 F10

5 87 87a 30
3
85
K3 K6
2 4 1
K8 K10
86
5
3 87 87a 30
K2 K5
2 4 1 2 4 1 85
5 5 K7 K9
2
4
4
1
1
3 3
-2A-
F64
F63
F62
F61
F74
F73
F72
K1 K4 8 F31 F21 F11 F1
8
7
5
6
6
MODULE 5 MODULE 4 MODULE 3 MODULE 2 MODULE 1
CAB (BF2)
Shunt bar A
A
279 White X2-6
F1 Bauzer module (A1) + Electric plate indicator lamp (A12)
169 White X60-13
B
171 White X13-26
A Shunt bar A
Alternator excitation / engine ECU alert (A13)
F2 99 Green X58-2
+ LLMI (A5) B
268 Yellow X118A-7
A Shunt bar A
F3 Digicode (A6) + Diagnostic plug 271 Green X118A-2
B
272 Green X115-1
A Shunt bar A
SAUER ECU (A2) + JSM (A4)
F4 76 White X67-8
+ parking brake B
81 Yellow EP13
A Shunt bar A
F5 12V plug + car radio (A7) 233 Green X93-4
B
234 Yellow X46-1
A Shunt bar A
Seat switch + boom angle sensor
F6 58 Green EP15
+ boom retraction switch B
83 Green X274-1
A Shunt bar A
F7 Hydraulic ECU (A3) 7 Yellow X138-6
B
355 Yellow EP5
A Shunt bar A
Attachment locking switch + tilt neutralization +
F8 91 White X375-5
hydraulic movement shunt B
359 Green X372-9
Module 1 A Shunt bar A
F9 Reverse gear light + reversing buzzer + stop lights
B 179 Yellow BF2/M5-K2-3(30)
Shunt bar A
A
277 White X2-5
F10 Front and rear wheel alignment sensors
164 White X66-B
B
335 White X65-B
Shunt bar B
80
A
F11 Hazard warning light switch 278 White X2-5
B 217 Green X308-8
A Shunt bar B
F12 Rear fog lights switch
B 219 Green X312-1
F13 Free A Shunt bar B
F14 Rotating beacon light switch B 221 Green X313-5
A Shunt bar B
Rear windscreen wiper control stalk + roof windscreen
F17 246 Yellow X11-1
wiper switch (option) + rear windscreen washer B
247 Orange X277A-3
A Shunt bar B
Front windscreen wiper + front windscreen washer
F18 249 Green X11-5
stalk switch B
250 Yellow X11-3
A Shunt bar B
F19 Shut bar C (F27/F28/F29/F30)
B 350 Yellow BF2/M2-F30-A
Shunt bar B
A
F20 Heating (A8) 280 White X2-6
B 292 Yellow BF2/M4-K7-3(30)
(05/02/2015) 80-01-M245EN
4 SPECIFICATIONS
CAB (BF2)
A 152 Green BF2/M2-F22-A
F21 Left side lights power supply 117 Green X40-7
B
118 Green X35-4
152 Green BF2/M2-F21-A
A
154 Green EP2
F22 Right side lights power supply
104 Green X40-5
B
106 Green EP20
A 145 Yellow X14-3
F23 Power supply codes 97 Green X36-2
B
98 Green X35-2
A 147 Yellow X14-4
F24 Headlights power supply 101 Green X36-3
B
102 Green X35-3
A 150 Green X14-8
F25 Right indicator lights supply 112 Green X40-4
B
114 Green X36-5
A 151 Green X14-9
F26 Left indicator lights supply 109 Green X40-1
B
111 Green X35-5
A Shunt bar C
F27 Telescope head electrovalve plug (option)
B 313 Yellow X106A-1
F28 Free A Shunt bar C
F29 Free A Shunt bar C
Shunt bar C
Module 2 A
F30 2 front working lights + 2 rear working lights 350 Yellow BF2/M1-F19-B
B 226 White X314-6
Shunt bar D
A
F31 Light commutator switch 54 Yellow X310A-A8
B 144 Yellow X14-1
A Shunt bar D
F32 Flashing unit
B 215 Yellow X308-2
A Shunt bar D
F33 Digicode option + Diagnostic plug 269 Green X118A-1
B
270 White X115-16
A Shunt bar D
F34 Horn + roof light 148 Green X14-6
B
149 White X277A-1
A Shunt bar D
F35 Car radio (A7)
B 237 Orange X93-7
A Shunt bar D
F36 Hydraulic ECU (A3)
B 71 White X56-7
A Shunt bar D
F37 Reset to zero rear windscreen wiper motor
B 319 Yellow X276A-6
A Shunt bar D
F38 Reset to zero front windscreen wiper motor
B 255 Yellow X25-3
F39 Air conditioning compressor option A Shunt bar D
Shunt bar D
F40 Air-conditioning fan motor option A
53 Yellow X310A-A1
181 White BF2/M4-F62-2
1
F61 Bauzer module (A1) 186 Green X373
5 172 Green X13-18
80
2 181 White BF2/M4-F61-1

F62 Easy Manager
6 433 White X10-3
1 (86) 276 White BF2/M4-K7-3(30)
300 Black BF2/M4-K8-(-)(87a)
2 (85)
299 Black BF2/M5-K6-2(85)
Module 4 K7 Heating cut-off
276 White BF/M4-K7-1(86)
3 (30)
292 Yellow BF2/M1-F20-B
5 (87) 275 Yellow X286-B
4(+) 218 Yellow X308-6
310 Black X304B
5(-)
K8 Flashing unit 300 Black BF2/M4-K7-2(85)
6(C) 158 Green X308-5
8(R) 177 White X60-7
80-01-M245EN (05/02/2015)
SPECIFICATIONS 5
CAB (BF2)
295 Black BF2/M5-K4-2(85)
K1 Free 2(85)
... Black BF2/M5-K2-2(85)
30 White X310A-C6
1(86)
69 White X67-12
296 Black BF2/M5-K1-2(85)
2(85)
K2 Reverse light and buzzer relay 297 Black BF2/M5-K5-2(85)
179 Yellow BF2/M1-F9-B
3(30)
180 Yellow BF2/M5-K3-3(30)
5(87) 182 Green X32-1
1(86) 36 White X19A-12
Module 5 ... 37 Black X19A-11
Module
K3 Stop light relay 180 Yellow BF2/M5-K2-3(30)
5
188 Green X40-6
5(87)
189 Green X31-1
294 Black X304B
K4 Free 2(85)
295 Black BF2/M5-K1-2(85)
297 Black BF2/M5-K2-2(85)
K5 Free 2(85)
298 Black BF2/M5-K6-2(85)
298 Black BF2/M5-K5-2(85)
K6 Free 2(85)
299 Black BF2/M4-K7-2(85)
ELECTRICAL CONNECTORS
Item Pos. Wire No. Color To Illustration

1 51 Red X310A-C1
X1
2 52 Red X310A-C8 4
2 1
3
277 White BF2/M1-F10A
5 5
278 White BF2/M1-F11A 6
X2 6
9
7 273 Green X118A-08 10
X3 1 2 Red BF1/M2-K20-5 (87)
X4 1 727 Red BF1/M3-K22-87
95 Black X36-1
80
X9 1
96 Black X303A
1 431 White EP25

2 432 White X115-01
3 433 White BF2/M4-F62-6 1 12
4 414 Black X304A 2
5 408 Red X115-06 11
X10 3 10
8 409 Green X115-14
11 411 White X305-01 4 9
5 8
12 412 White EP06 6 7
1 246 Yellow BF2/M1-F17B

2 248 Yellow X276A-5 1
3 250 Yellow BF2/M1-F18B 2
4 245 White X26A-2
X11 5 249 Green BF2/M1-F18B 3
6 244 White X26A-1 7
7 251 Yellow X25-2 4 8
8 252 Yellow X25-4 5 6 9
1 253 Green X276A-2
X12 1
2 254 Green X25-1
2
(05/02/2015) 80-01-M245EN
6 SPECIFICATIONS

2 178 Green X63-1
3 166 Green X21-1
4 176 White EP28
8 93 White EP25
9 14 White EP30 7
10 8 White EP27 1
14 90 White X302-01
15 107 White EP20
8
X13 18 172 Green BF2/M4-F61-5 14 13
21 68 Can red EP22
Can 20 19
22 67 EP21
green 26
23 13 White X60-10
24 32 White X60-6
25 170 Black X303B
26 171 White BF2/M1-F1B
2 153 Green EP01
3 145 Yellow BF2/M2-F23A
4
146 White X60-11 1
147 Yellow BF2/M2-F24A 2
5 119 Green X39 3
X14
6 148 Green BF2/M2-F34B
7 157 Yellow X308-5 7
150 Green BF2/M2-F25A 4 8
8
214 Green X308-01 5 6 9
151 Green BF2/M2-F26A
9
216 Green X308-03
1 671 Red X179-1
2 672 Green X179-2
3 673 Yellow X179-3
4 674 Yellow X179-4
5 675 Green X179-5
6 676 Red X179-6
7 678 Black EP26 1
X19A 2
8 59 Can red EP19
Can 3
9 60 EP18
green 4
Bare 5 12
10 61 EP16 11
drain 6
11 37 Black BF2/M5-K3-2(85) 7 8 9 10
12 36 White BF2/M5-K3-1(86)
8 59 Can red EP58
9 60 Can green EP59 1 12
10 65 Bare drain EP60 2 11
X19B 11 37 Black X296-2 3 10
4 9
12 36 Green X296-1 5 8
6 7
80
1 166 Green X13-03

X21 1
2 165 Black X304A
2
1 6 White EP28
X22
2 242 Black X26A-3
1 254 Green X12-2 2

2 251 Yellow X11-7 1
X25 4 252 Yellow X11-8
6
6 256 Black X303B 5
4
1 244 White X11-6
2 245 White X11-4
X26A 242 Black X22-2 1
3
243 Black X303B 3 2
1 293 Black X303B
2 385 Yellow X286-L 2
X29
3 387 White X286-H 4
1
4 386 Purple X286-M 3
80-01-M245EN (05/02/2015)
SPECIFICATIONS 7

1 189 Green BF2/M5-K3-5(87)
2 168 Green X37-1
6
3 116 Green X40-7
X31 5
4 191 Black X304A
4
5 199 Green X40-2 1
2
6 110 Green X40-1 3
1 182 Green BF2/M5-K2-5(87)
2 194 Green X38-1
6
3 105 Green X40-5
X32 5
4 193 Black X304A
4
5 190 Green X40-6 1
2
6 113 Green X40-4 3
1 100 Black X303A
6
X35 5
4
1
5 111 Green BF2/M2-F26B 2
3
1 95 Black X09
6
X36 5
4 108 Green EP20
4
1
3
1 168 Green X31-2
X37 1
2 4 Black X304B
2
1 194 Green X32-2
X38 1
2 192 Black X304A
2
X39 1 119 Green X14-5
109 Green BF2/M2-F26B

1
110 Green X31-6
198 Green X312-5
2
199 Green X31-5
3 200 Black X304B
4
X40 113 Green X32-6
5
105 Green X32-3
188 Green BF2/M5-K3-5(87)
6
190 Green X32-5
116 Green X31-3
7
80
X46 1
2 235 Black X304B
2
1 352 White EP05
2 123 Green X265-1
5 128 Black X269-2
6 173 Black EP24
8 56 Green X100-6
9 467 White X306-07
11 196 White X305-01
12 259 White EP11 1
13 287 Green EP07
8
X56 14 124 Green X267-1
15 94 White X375-01 14 7
16 205 White X311-02 20 13
17 316 White EP06
19
26
18 263 White X67-06
20 434 Black X303B
21 84 White EP17
23 466 White X306-01
24 426 White X68-1
25 49 Green X100-3
26 435 Black X303B
(05/02/2015) 80-01-M245EN
8 SPECIFICATIONS

1 345 Can red EP19
Can
2 346 EP18
green
3 285 Green EP07
4 286 Green EP07
5 126 Green X264-1
6 202 Green X270-1
7 127 Green X269-1
8 353 Green EP05
9 354 Green EP05
12 267 White X67-09
13 85 White X60-15 1
15 328 White X134-4 10
X57 18
16 264 White X67-07 9
19 351 White X372-07 26 17
20 427 White X68-2 25
22 281 Green X274-2 34
23 139 White X134-2
24 262 White EP08
25 174 Green X377-1
Bare
28 344 EP16
drain
29 120 Green X266-1
31 284 Black EP12
32 201 Green X275-1
34 436 Black X303B
1 140 Black X303A
3 141 Can red EP22 4
X58 3
1
Can
4 142 EP21 2
green
1 317 Black X303B
2 15 White EP30
3 5 White EP28
4 70 White X310A-A3
5 3 White EP27
6 32 White X13-24
7 177 White BF2/M4-K8-R(87)
X60 8 162 White X66-A
9 334 White X65-A
10 13 White X13-23
11 146 White X14-4
14 668 White X310A-B3
15 85 White X57-13
16 86 White EP17
2 562 Grey X292-4
3 563 Grey X295-5
1
4 564 Grey X295-3
X62 2 6
80
3 5
5 565 Grey X295-4 4
1 178 Green X13-02

X63 1
2 187 Black X304B
2
A 334 White X60-09
B 335 White BF2/M1-F10B
A
X65
C 336 Black X303B
C
B
A 162 White X60-08

B 164 White BF2/M1-F10B
A
X66
C 167 Black X304A C
B
1 183 Black EP12

2 257 White EP11
3 258 White EP11
4 260 White EP08 1 12
5 261 White EP08 2 11
X67 6 263 White X56-18 3 10
7 264 White X57-16 4 9
8 76 White BF2/M1-F4B 5 8
9 267 White X57-12 6 7
11 31 White X310A-C5
12 69 White BF2/M5-K2-1(86)
80-01-M245EN (05/02/2015)
SPECIFICATIONS 9

1 426 White X56-24
X68 3
2 427 White X57-20
2
1
1 27 Green X310A-C3
X92 1
2 28 Black X310A-C2
2
7 237 Orange BF2/M2-F35B
1 2
23
4
3
X93
8 236 Black X304B 5 6
8
7
1 238 White X204-1

2 239 Black X204-2
7 240 White X205-1
1 24 2
4
X94 3
5 6
8 241 Black X205-2
8
7
Bare
1 401 X115-05
drain 4
2 402 Red EP17 3
5
3 403 Black EP12 2
1
4 404 White X115-06
X99
5 405 Blue X115-14
1 47 Black X304A
2 48 Green EP15
6
3 49 Green X56-25
5
80
X100 4 50 Black X304A
4
5 55 Green EP15 1
2
6 56 Green X56-8 3
2
X106A
2 312 Black X304B 1
1
432 White X10-02
87 Can red EP22
3
406 Red X115-06
129 Black X304A
4
130 Black X115-05
Bare
89 EP23
drain
5 130 Black X115-04
Bare
401 X99-1
X115 drain
404 White X99-4 16
8
6 406 Red X115-03 9
1
408 Red X10-05
Can
88 EP21
11 green
407 Green X115-14
405 Blue X99-5
14 407 Green X115-11
409 Green X10-08
(05/02/2015) 80-01-M245EN
10 SPECIFICATIONS

5 266 Green X138-3 5
6 265 Yellow X138-2 4 7
X118A 3 8
8 273 Green X02-7 2
10
1
11
12 274 Black X304B 12
1 134 White EP30

X133
2 133 Black X303A
1 327 White EP15

2 139 White X57-23
3 138 White EP15
X134
1
4 328 White X57-15 2 4
3
1 82 Yellow EP07
2 265 Yellow X118A-06
6
3 266 Green X118A-05
X138 5
4 45 Green X310A-B1
4
5 19 Yellow X310A-B8 1
2
1 72 Black EP09
2 74 White EP10
6
3 21 White X310A-B6
X139 5
4 73 Black EP09
4
5 75 White EP10 1
2
6 20 White X310A-B7 3
X159 1 711 Black BF1/M1: X201
1 671 Red X19A-01

2 672 Green X19A-02 X179
3 673 Yellow X19A-03
X179 4 674 Yellow X19A-04
5 675 Green X19A-05
6 676 Red X19A-06
1 238 White X94-1

X204
2 239 Black X94-2
80
1 240 White X94-7

X205
2 241 Black X94-8
1 22 Green X292-03
X260 1
2 23 Black X300
2
1 26 Green X292-08
X261 1
2 24 Black X300
2
1 126 Green X57-05
X264 1
2 131 Black X303A
2
1 123 Green X56-02
X265 1
2 132 Black X303A
2
1 120 Green X57-29
X266 1
2 121 Black X303A
2
1 124 Green X56-14
X267 1
2 122 Black X303A
2
80-01-M245EN (05/02/2015)
SPECIFICATIONS 11

1 127 Green X57-07
X269 1
2 128 Black X56-05
2
1 202 Green X57-06
X270 1
2 185 Black EP24
2
2 281 Green X57-22
6
X274 5
3 282 Green EP06 4
1
2
3
1 201 Green X57-32
X275 1
2 184 Black X303B
2
1 223 Green X313-01
2 253 Green X12-1
3 229 Yellow X314-01 4
4 320 Black X303B 3 8
X276A 5 248 Yellow X11-2
2 7
7 225 Yellow X314-02 1 6
8 321 Black X303B 5
3 247 Orange BF2/M1-F17B
2
X277A 4
4 322 Black X304B 1
3
B 275 Yellow BF2/M4-K7-(87)
H 387 White X29-3
L 385 Yellow X29-2
X286
M 386 Purple X29-4
IG 9 White BF1/M2-F55-B
X289
L 12 White X310B-A2
X290 B+ 46 Red BF1/M1-F43
1 20 White X310B-B7
3 22 Green X260-1
4 562 Grey X62-2 1 12
5 17 White X310B-B5 2 11
X292 6 16 Black X310B-B4 3 10
7 21 White X310B-B6 4 9
80
8 26 Green X261-1 5 8
9 28 Black X310B-C2 6 7
10 27 White X310B-C3
1 40 Black X300
2 38 Green X310B-C4
3 564 Grey X62-4 1 12
4 565 Grey X62-5 2 11
X295 5 563 Grey X62-3 3 10
4 9
6 31 White X310B-C5
5 8
7 30 White X310B-C6 6 7
12 39 White X310B-C7
1 36 Green X19B-12
X296
2 37 Black X19B-11
2 1
1 62 Can red EP58
Can
X299 2 63 EP59
green 3
Bare 2
3 64 EP60 1
drain
23 Black X260-2
24 Black X261-2
40 Black X295-01
X300 1
41 Black BF1/M1-K20-2 (85)
697 Black EP60
700 Black EP32
(05/02/2015) 80-01-M245EN
12 SPECIFICATIONS

1 90 White X13-14 8
79 White X302-9 10 2
5
80 Green EP13
9
X302 78 White X306-09
9 7
79 White X302-5
159 Black X306-10 1
10
160 Black X303B
96 Black X09
100 Black X35-1
121 Black X266-2
122 Black X267-2
X303A 1 131 Black X264-2
132 Black X265-2
133 Black X133-2
140 Black X58-1
323 Black X304A
160 Black X302-10
170 Black X13-25
184 Black X275-2
207 Black X308-10
243 Black X26A-3
256 Black X25-6
293 Black X29-1
X303B 1 317 Black X60-01
320 Black X276A-4
321 Black X276A-8
336 Black X65-C
400 Black EP23
434 Black X56-20
435 Black X56-26
436 Black X57-34
47 Black X100-1
50 Black X100-4
129 Black X115-04
165 Black X21-2
167 Black X66-C
X304A 1 191 Black X31-4
192 Black X38-2
193 Black X32-4
323 Black X303A
371 Black X305-10
414 Black X10-04
4 Black X37-2
187 Black X63-2
235 Black X46-2
236 Black X93-8
X304B 1 274 Black X118A-12
294 Black BF2/M5-K4-2(85)
310 BLACK BF2/M4-K8-(-)(87a)
312 Black X106A-2
322 Black X277A-4
196 White X56-11 8
80
1
411 White X10-11 10 2
135 White X372-09
5 9
X305 136 White X305-09
9 136 White X305-05 7
370 Black X372-10 1

10
371 Black X304A
1 466 White X56-23
8
206 Black X311-06
3 10 2
465 Black X306-10
7 467 White X56-09 9
X306
78 White X302-09 7
9
204 White X311-09 1
159 Black X302-10
10
465 Black X306-03
1 214 Green X14-8
3 216 Green X14-9 8
157 Yellow X14-7 10 2
5
158 Green BF2/M4-K8-C(85)
9
X308 6 218 Yellow BF2/M4-K8-(+)(86)
7 213 White X308-08 7
213 White X308-07 1
8
207 Black X303B
10
208 Black X312-10
80-01-M245EN (05/02/2015)
SPECIFICATIONS 13

A1 53 Yellow BF2/M2-F40A
A2 12 White EP25
A3 70 White X60-04
A7 11 White EP27 1 2 3 4 5 6 7 8
A8 54 Yellow BF2/M2-F31A A1 A
B
A
B
A8
B1 45 Green X138-4 B1 C
1 2 3 4 5 6 7 8
C B8
B3 668 White X60-14 C1 C8
B4 16 Black EP09
B5 17 White EP10
B6 21 White X139-3
X310A
B7 20 White X139-6
B8 19 Yellow X138-5
C1 51 Red X01-1
C2 28 Black X92-2
C3 27 Green X92-1
C4 38 Green EP13
C5 31 White X67-11
C6 30 White BF2/M5-K2-1(86)
C7 39 White EP06
C8 52 Red X01-2
A1 53 Yellow BF1/M1-F44
A2 12 White X289-L
A3 70 Grey X400-13
A8 54 Yellow BF1/M1-F44 A1 A
1 2 3 4 5 6 7 8
A
A8
B1 45 Green BF1/M2-F53-A B1
B
C
B
C B8
B3 668 White BF1/M2-F52-B C1
1 2 3 4 5 6 7 8
C8
B4 16 Black X292-06
B5 17 White X292-05
B6 21 White X292-07
X310B B7 20 White X292-01
B8 19 Yellow BF1/M2-F55-A
C1 51 Red BF1/M1-F42
C2 28 Black X292-09
C3 27 White X292-10
C4 38 Green X295-02
C5 31 White X295-6
C6 30 White X295-7
C7 39 White X295-12
C8 52 Red BF1/M1-F42
2 205 White X56-16 8
197 Black X311-10 10 2
6
206 Black X306-03
9
X311 9 204 White X306-09
7
197 Black X311-06
10 1
211 Black X314-10
219 Green BF2/M1-F12B 8
1 2
220 White X312-09 10
5 198 Green X40-2
9
X312 9 220 White X312-01
7
208 Black X308-10
10 1
209 Black X313-10
80
1 223 Green X276A-1 8
221 Green BF2/M1-F14B 10 2
5
222 White X313-09
9
X313 9 222 White X313-05
7
209 Black X312-10
10 1
210 Black X314-10
1 229 Yellow X276A-3
224 Green EP03
2 8
225 Yellow X276A-7
10 2
227 Green X314-06
3
228 Green X314-09 9
X314
226 White BF2/M2-F30B 7
6
227 Green X314-03 1
9 228 Green X314-03
210 Black X313-10
10
211 Black X311-10
368 Black X375-10 8
5
369 Black X372-10 10 2
7 351 White X57-19
9
X372 135 WHITE X305-05
9 7
359 GREEN BF2/M1-F8B
369 Black X372-05 1
10
370 Black X305-10
X373 1 186 Green BF2/M4-F61-1
(05/02/2015) 80-01-M245EN
14 SPECIFICATIONS

1 94 White X56-15 8
91 White BF2/M1-F8B 10 2
5
92 White X375-09
X375 9 92 White X375-05 9
7
10 368 Black X372-05 1
1 174 Green X57-25

X377 1
2 175 Black EP24
2
1 809 GREY X402-1
2 807 GREY X401-2
6 810 GREY X402-2
13 70 GREY X310B-A3
15 813 GREY X404-1
16 706 BLACK EP32
17 707 BLACK EP32 1
18 708 BLACK EP32
19 709 BLACK EP32
20 806 GREY X401-1
X400 21 803 GREY BF1/M2-F53-B 23
22 800 ORANGE EP31
22
25 694 RED CAN EP58
GREEN
26 695 EP59 44
CAN
36 811 GREY X403-1
39 801 GREY BF1/M2-K20-86
40 804 GREY BF1/M3-K22-85
41 812 GREY X403-2
43 808 GREY X401-3
44 802 ORANGE BF1/M2-F55-B
1 806 GREY X400-20
X401 2 807 GREY X400-02
3 808 GREY X400-43 3 1
1 809 GREY X400-01

X402
2 810 GREY X400-06 2
1
1 811 GREY X400-36 1 2
X403
2 812 GREY X400-41
X404 1 813 GREY X400-15

80
80-01-M245EN (05/02/2015)
SPECIFICATIONS 15
SPLICES
Item Wire no. Color To Item Wire no. Color To

EP01 153 Green X14-2 68 Can red X13-21
154 Green POWER SUPPLY BF2/M2-F22A 87 Can red X115-03
EP02 EP22
155 Green EP04 141 Can red X58-3
EP03 224 Green X314-02 347 Can red EP19
EP04 155 Green EP02 66 Bare drain NOT WIRED
352 White X56-01 89 Bare drain X115-05
353 Green X57-08 EP23 143 Bare drain NOT WIRED
EP05
354 Green X57-09 349 Bare drain EP16
355 Yellow BF2/M1-F7B 400 Black X303B
39 White X310A-C7 173 Black X56-06
282 Green X274-3 EP24 175 Black X377-2
EP06
316 White X56-17 185 Black X270-2
412 White X10-12 12 White X310A-A2
82 Yellow X138-1 EP25 93 White X13-08
285 Green X57-03 431 White X10-01
EP07
286 Green X57-04 669 Bare drain CABLE 14
287 Green X56-13 EP26 670 Bare drain CABLE 13
260 White X67-4 678 Black X19A-07
EP08 261 White X67-5 3 White X60-05
262 White X57-24 EP27 8 White X13-10
16 Black X310A-B4 11 White X310A-A7
EP09 72 Black X139-1 5 White X60-03
73 Black X139-4 EP28 6 White X22-1
17 White X310A-B5 176 White X13-04
EP10 74 White X139-2 29 White BF2/M5-K1-1(86)
75 White X139-5 EP29 32 White X60-06
257 White X67-02 33 White X13-24
EP11 258 White X67-03 14 White X13-09
259 White X56-12 EP30 15 White X60-02
183 Black X67-1 134 White X133-1
EP12 284 Black X57-31 799 Yellow BF1/M2-F51-B
EP31
403 Black X99-3 800 Orange X400-22
38 Green X310A-C4 700 Black X300
EP13 80 Green X302-5 706 BLACK X400-16
81 Yellow BF2/M1-F4B EP32 707 BLACK X400-17
48 Green X100-2 708 BLACK X400-18
80
55 Green X100-5 709 BLACK X400-19
EP15 58 Green BF2/M1-F6B 59 RED CAN X19B-08
138 White X134-3 EP58 62 RED CAN X299-1
327 White X134-1 694 RED CAN X400-25
61 Bare drain X19A-10 60 GREEN CAN X19B-09
EP16 344 Bare drain X57-28 EP59 63 GREEN CAN X299-2
349 Bare drain EP23 695 GREEN CAN X400-26
84 White X56-21 64 BARE DRAIN X299-3
EP17 86 White X60-16 EP60 65 BARE DRAIN X19B-10
402 Red X99-2 697 BLACK X300
60 Can green X19A-09
EP18 346 Can green X57-02
348 Can green EP21
59 Can red X19A-08
EP19 345 Can red X57-01
347 Can red EP22
EP20 107 White X13-15
108 Green X36-4
67 Can green X13-22
88 Can green X115-11
EP21
142 Can green X58-4
348 Can green EP18
(05/02/2015) 80-01-M245EN
16 SPECIFICATIONS
CAN
Item Wire no. Start point To end Color Type

CABLE 1 67 X13-22 EP21 Green CAN L J1939
68 X13-21 EP22 Red CAN H J1939
66 NOT WIRED EP23 Bare drain CAN 01 Shielding
87 X115-06 EP22 Red CAN H J1939
89 X115-05 EP23 Bare drain CAN 02 Shielding
CABLE 3 348 EP18 EP21 Green CAN L J1939
347 EP19 EP22 Red CAN H J1939
349 EP16 EP23 Bare drain CAN 03 Shielding
CABLE 4 401 X99-1 X115-05 Bare drain CAN 04 Shielding
402 X99-2 EP17 Red Gage power supply
403 X99-3 EP12 Black Gage ground
404 X99-4 X115-06 White CAN H J1939
405 X99-5 X115-14 Blue CAN L J1939
141 X58-3 EP22 Red CAN H J1939
143 NOT WIRED EP23 Bare drain CAN 05 Shielding
CABLE 6 346 EP18 X57-02 Green CAN L J1939
345 EP19 X57-01 Red CAN H J1939
344 EP16 X57-28 Bare drain CAN 06 Shielding
CABLE 7 60 X19A-09 EP18 Green CAN L J1939
59 X19A-08 EP19 Red CAN H J1939
61 X19A-10 EP16 Bare drain CAN 07 Shielding
CABLE 8 60 X19B-09 EP59 Green CAN L J1939
59 X19B-08 EP58 Red CAN H J1939
65 X19B-10 EP60 Bare CAN 08 shielding drain
62 X299-1 EP58 Red CAN H J1939
64 X299-3 EP60 Bare CAN 09 shielding drain
695 X175-17 EP59 Green CAN L J1939
Twisted wire
694 X175-37 EP58 Red CAN H J1939
CABLE 13 671 X179-1 X9A-01 Red Accelerator 1 potentiometer power supply
672 X179-2 X9A-02 Green Accelerator 1 potentiometer ground
674 X179-4 X9A-04 Yellow Accelerator 1 potentiometer signal
670 DRAIN CABLE 13 EP26 Bare drain Cable 13 shielding
676 X179-6 X9A-06 Red Accelerator 2 potentiometer power supply
80
CABLE 14
675 X179-5 X9A-05 Green Accelerator 2 potentiometer ground
673 X179-3 X9A-03 Yellow Accelerator 2 potentiometer signal
669 DRAIN CABLE 14 EP26 Bare drain Cable 14 shielding
DIODES
Start point Item End point

EP1 V1 EP2
EP3 V2 EP4
80-01-M245EN (05/02/2015)
SPECIFICATIONS 17
BLOCK DIAGRAM OF ELECTRICAL AND ELECTRONIC SYSTEM
IHM
Stability display
Seat sensor
Strain gage
ECU
Hydraulic
y
ECU
Transmission
+
-
Boom angle sensor
Control pressure block 80

Pilot control line
Inching potentiometer STOP
Hydrostatic motor
Hydrostatic pump
Transmission CAN Bus Brake lights

Hydraulic function Stability control Operator presence
(05/02/2015) 80-01-M245EN
18 SPECIFICATIONS
INPUTS/OUTPUTS
DASHBOARD MODULE (BAUSER) - A1
Key:
NC: Not Wired
A1
X13
PIN Designation Function on truck Comments

No.
Engine coolant temperature indicator lamp ON (If r
01 Temperature resistance analog input Engine coolant temperature analog gage
> 0,118 KΩ)
02 Fuel resistance analog input Analog fuel gage Reserve indicator lamp ON and buzzer (If r > 170 Ω)
Clogging indicator lamp ON and buzzer (If pressure
03 Hydraulic filter pressure switch logic input Clogged hydraulic filter (Indicator lamp)
> 2 bar)
Level indicator lamp ON and buzzer (If NO switch
04 Brake fluid level logic input Brake fluid level (Fault indicator lamp)
closed)
05 Engine oil pressure switch logic input Engine oil pressure (Fault indicator lamp) Indicator lamp ON and buzzer (If oil pressure < 10 bar)
06 Rxd Not used Plug
07 Txd Not used Plug
Battery charge indicator lamp and hour Indicator lamp ON and buzzer (If voltage < 4v and
08 Logic input D+ alternator
meter power supply hour meter running if u>4v)
09 Brake hydraulic pressure switch logic input (Parking brake on indicator lamp) Indicator lamp ON if brake applied (No circuit pressure)
10 Headlight logic input Main beam indicator lamp Indicator lamp ON if main beam headlights enabled
80
11 Indicator lamp logic input Right or left indicator lamp Lit with lighting stalk switch and warning switch
Engine coolant temperature indicator lamp Lit if NO temperature switch and buzzer closed (If
12 Engine coolant temperature logic input
/ switch temperature > 110°)
13 NC Air filter clogging Indicator not fitted on MT (plug)
Start of preheat info (time delay / temperature
14 Preheat logic input Preheat control information
probe)
15 Dashboard LCD lighting logic input Dimmed dashboard backlight Only LCD / no buttons or indicator lamps
16 Nc Not used Plug

17 Nc Not used Plug
18 Clock power supply + battery Clock power supply + battery Consumption in standby mode (1mA)
19 Nc Not used Plug
20 Nc Not used Plug
21 CAN high CAN H J1939 Twisted shielded cable 1 (red cable 0,6 mm²)
22 CAN low CAN L J1939 Twisted shielded cable 1 (green cable 0,6 mm²)
23 NC Not used Plug
24 NC Not used Plug
25 Bauser ground Bauser ground
26 Power supply + after ignition key Power supply + after ignition switch Bauser alert
80-01-M245EN (05/02/2015)
SPECIFICATIONS 19
TRANSMISSION COMPUTER - A2
Key:
NC: Not Wired
ECU: Electronic Control Unit
A2
X295/C1
X299/C2
C3
C4 C5
X292/C6
PIN No. Designation Function on truck Comments

01 Ground Transmission ECU ground
Transmission ECU 12V or 24V power supply
02 Power supply
(fuse F4)
03 Hydr. motor speed sensor power supply Hydrostatic motor speed sensor power supply Cable on MLT version
X295 04 Hydr. motor speed sensor ground Hydrostatic motor speed sensor ground Cable on MLT version
/ Hydrostatic motor speed sensor frequency input
05 Hydr. motor speed sensor frequency input Cable on MLT version
C1 (rpm)
06 Forward gear logic input Data input
07 Reverse gear logic input Data input
08 to 11 NC Not used Plug
12 Neutral logic input Neutral input (seat NO sensor) - driver presence
X299 01 CAN H CAN bus high

/ 02 CAN L CAN bus low
C2 03 Ground CAN CAN bus shielding
01
C3 NC Not used Plug
to 06
80
01 Forward gear power supply Forward gear power supply
02 Reverse gear power supply Reverse gear power supply
C4 03 to 04 NC Not used Plug
05 Reverse gear ground Reverse gear ground
06 Forward gear ground Forward gear ground
01 Hydr. pump speed sensor power supply Hydrostatic pump speed sensor power supply Wired by ECU supplier
C5 Hydrostatic pump speed sensor frequency input
02 Hydr. pump speed sensor frequency input Wired by ECU supplier
(rpm)
03 Hydr. pump speed sensor ground Hydrostatic pump speed sensor ground Wired by ECU supplier
01 Pedal analog input 2 Inching pedal analog input 2 (0,5V to 4,5V)
NO sensor closed when pedal
02 NC Accelerator pedal sensor info (driver presence)
released
03 Analog output Proportional motor control valve
04 Hydr. motor speed sensor analog input Hydrostatic motor speed sensor analog input Only used on agricultural version
X292 05 Sensor power supply Inching sensor 5V power supply

/ 06 Sensor ground Inching sensor ground
C6 07 Analog input Inching pedal analog input 1 (4,5V to 0,5V)
08 ON/OFF output 3A Direction selection valve on motor
09 PWM - / ON/OFF output 3A Stop light relay ground
10 NC Not used Plug
11 Digital in mode 1 Slow/fast speed switch input
12 NC Accelerator pedal sensor info (driver presence) NC sensor open when pedal released
(05/02/2015) 80-01-M245EN
20 SPECIFICATIONS
MAIN ECU - SPU 25-15 - A3
Key :
APC : Post contact power NO : Normally Open
+BAT : Permanent supply NC : Normally Close
GND : Ground S.P.U. : Safety Power Unit
A3
1
8
14 7
20 13
19
X56 26
Pin Active
Type Function on carriage Remarks
N° state
1 Supply APC ECU supply
2 Proportional output 0V to 12V Attachment sense proportional electrovalve
3 Head boom electrovalve
Logic output GND
4 Not used
5 Security electrovalve (VS)
Logic output GND
6 Proportional electrovalve (Lowering)
7 Supply +BAT ECU supply
0.5V to Boom angle sensor lane 2
8 Analog input
4.5V
9 Logic input GND Not used
10 Logic input GND Easy Connect System switch (NF)
Disabling «agravating» hydraulic movement cut-off Support valid only for 1 min
11 Logic input APC
switch (NO)
12 Logic input APC Neutral roller 1 contact (NO) Telescoping
13 ECU wake-up input APC ECU wake-up (NO) Cut-off by emergency stop
14 Proportional output 0V to 12V Attachment sense proportional electrovalve
15 Logic input APC Tilting neutralization switch (NO)
80
Hydraulic movement neutralisation switch

16 Logic input GND
(NO) (TÜV)
17 Logic input APC Conductor presence seat contact (NO)
18 Analog input 0V to 12V JSM roller 1 potentiometer Telescoping
19 Stabilized output 5V Not used
20 Ground GND ECU ground
21 Stabilized output 10V Strain gauge supply - Attachment control selector control
22 Logic input GND Forced operation switch (NO)
23 Logic input GND Not used
24 Logic input APC Not used
0.5V to Boom angle sensor lane 1
25 Analog input
4.5V
26 Ground GND ECU ground
80-01-M245EN (05/02/2015)
SPECIFICATIONS 21
Key :
APC : Post contact power NO : Normally Open
+BAT : Permanent supply NC : Normally Close
GND : Ground S.P.U. : Safety Power Unit
A3
1
10
18 9
26 17
X57 25
34
Pin Active
Type Function on carriage Remarks
N° state
1 CAN 1 High CAN H J1939
2 CAN 1 Low CAN L J1939
3 Supply APC ECU supply Cut-off by emergency stop
4 Supply APC ECU supply Cut-off by emergency stop
5 Proportional output 0V to 12V Telescope direction electrovalve power supply
6 Proportional output 0V to 12V Lowering proportional electrovalve power supply
7 Logic output APC Security electrovalve (VS)
10 CAN 2 High CAN H - not used
11 CAN 1 120 Ω Not used
12 Logic input APC JSM Switch 1 (NO) EV TDF
13 Analog input 0V to 12V Attachment flow selector
14 Logic input APC Ventilation control switch (NO)
15 Logic input APC Retracted telescope sensor (NO)
16 Analog input 0V to 12V JSM roller 2 potentiometer Attachment
17 Logic output APC Control fan speed electrovalve
18 CAN 2 Low CAN L - not used
19 Logic input GND Lock attachment switch (NO)
80
20 Logic input APC Not used
21 Logic input GND Overload detection (NO)
22 Logic input APC Conductor presence seat contact (NF)
23 Logic input APC Retracted telescope sensor (NC)
24 Logic input APC neutral roller 2 contact (NO) Attachment
25 Proportional output 0V to 12V Lifting proportional electrovalve
26 LIN Interface Not used
27 CAN 2 120 Ω Not used
28 Ground Ground CAN Shield
29 Proportional output 0V to 12V Telescoping proportional electrovalve control output
30 Logic output APC Fan drive directional electovalve
31 Ground GND Ground Analog sensor
32 Logic output APC Tilting neutralization electrovalve (VCI)
33 Logic output APC Forced operation activation lamp
34 Ground ECU ECU ground
(05/02/2015) 80-01-M245EN
22 SPECIFICATIONS
ENGINE ECU - EVG - A13
Key:
APC: Power supply after contact GND: Ground
+BAT: Fixed power supply NC: Not Wired
A13
23
22
44
PIN Type Active state Function on truck Comments

No.
1 Analog output GND Coolant liquid temperature sensor ground
2 Analog input 0V to 12V Engine speed sensor signal
6 Analog input Coolant liquid temperature sensor signal
13 Logic output GND Preheating indicator lamp
15 Logic input GND Oil pressure switch
16
17
Ground GND ECU ground
18
19
20 Analog input GND Engine speed sensor ground
21 Logic input 12V Starter control
22 Power supply +BAT Computer supply
25 CAN High CAN H J1939
26 CAN Low CAN L J1939
80
36 Logic output GND Injection pump solenoid

39 Logic output 12V Preheat relay coil
40 Logic output GND Starter relay coil
41 Logic output 12V Injection pump solenoid
43 Logic output 12V Engine speed sensor power supply
44 Logic input APC Key contact
80-01-M245EN (05/02/2015)
SPECIFICATIONS 23
DATA SHEETS FOR ELECTRICAL COMPONENTS
Electrical ref. Designation Pages
A4+A5 JSM 24
A6 ANTI-THEFT OUTPUT 25
B1 REVERSING BUZZER 25
B2 HORN 26
B3 ENGINE OIL PRESSURE SWITCH 26
B4 ENGINE WATER TEMPERATURE SENSOR 27
B5 ENGINE WATER THERMO SWITCH 28
B7 HYDRAULIC CLOGGING FILTER CONTACT 28
B8 MASTER CYLINDER PRESSURE SWITCH 29
B9 INCHING PEDAL ANGLE SENSOR 29
B11 BOOM ANGLE SENSOR 30
B12+B21 WHEEL ALIGNMENT SENSOR 31
B13 TRANSMISSION SPEED SENSOR 31
B34 FUEL GAGE 32
B35 AIR FILTER SWITCH 33
B+/IG-L ALTERNATOR 33
E15 ROTATING BEACON LIGHT 34
S2 STARTER IGNITION SWITCH 34
S11 BRAKE FLUID SWITCH 35
S34 BOOM RETRACTED SWITCH 35
Y3+Y4 FORWARD AND REVERSE ELECTROVALVE 36
Y8+Y9 TELESCOPING EV + ATTACHMENT 36
Y10+Y11 TELESCOPING PROPORTIONAL HYD. EV + ATTACHMENT 37
80
Y12 HYDRAULIC CUT-OFF EV (VS) 37
Y13 NEGATIVE BRAKE EV 38
Y14+Y18 LOWERING + LIFTING PROPORTIONAL CUT-OFF EV 39
Y15 TILTING CUT-OFF EV (VCI) 39
(05/02/2015) 80-01-M245EN
24 SPECIFICATIONS
A4+A5 JSM X67

(Joystick Switch and Move)
R
PIN Function
N
1 Controlleur ground
F
R1 2 Roller 1 direction A (+)
12
11
3 Roller 1 direction B (-)
R2
4 Roller 2 direction A (+)
UP DOWN
6
5 5 Roller 2 direction B (-)
8
4 7
1
3 8 6 Signal Roller 1
9
7
FNR 2
DOWN 10 7 Signal Roller 2
1
5
11
D+ D-
BP2 12 8 Power supply (+12 V)
4
R2
UP
Telescope head electrovalve
6
BP1 9
button
3
D+ D-
R1
2
10 Option
BP2
10
11 Forward gear
9
12 Reverse gear
BP1
PIN Function
2
1 1 Speed Up
1
2
2 Speed Down Diagram
Correspondent connectors
12 pins connectors PIN Minimum Typical Maximum

Current in potentiometer under 12 V ± 10% 2 mA 4 mA
Supply voltage 1 12 V
6-7 1V 6V 11 V
Outlet voltage
2-3-4-5 0V 12 V
Note :
Rollers 1 or 2 direction (+) or (-) 0 V = neutral rollers
12 V = direction validations (+) or (-)
2 pins connecteurs PIN BP (+ / -) appuyés BP (+ / -) relâchés

80
1 (+) 0V 12 V
Outlet voltage
2 (-) 0V 12 V
Note : ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80-01-M245EN (05/02/2015)
SPECIFICATIONS 25
A6 ANTI-THEFT OUTPUT X118
PIN Function
1 Power supply + Battery
2 Power Supply + Post contact
3 Plug 4 8 12
4
6
5 5 Starter solenoid inlet
4 7
8 6 Emergency stop outlet
3 12 11 10 9 8 7 6 5 4 3 2 1
9 Engine electrovalve relay

2 7
10 inlet
1
11
12 8 Power supply 12V Diagram
9
10
11
12 Rear cab Ground
Corresponding connector
PIN Minimum Typical Maximum

Supply voltage 12 V
Manimux current 4 mA 6 mA
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
B1 REVERSING BUZZER X38
PIN Function 1 2
1 1 Buzzer power supply
80
2 Rear cab ground
Diagram
PIN Minimum Typical Maximum

Resistance (10%) 19,5 Ω 21,7 Ω
Average current 0,60 A 0,75 A
Voltage 12 V
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
(05/02/2015) 80-01-M245EN
26 SPECIFICATIONS
B2 HORN X39
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: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
B3 ENGINE OIL PRESSURE SWITCH X17
PIN Function 1
1 Pressure information NO
80
Diagram
Typical
Supply voltage 12 V
Current 10 mA
Threshold of pressure (closure) 0.45 bar

Note :
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80-01-M245EN (05/02/2015)
SPECIFICATIONS 27
B4 ENGINE WATER TEMPERATURE SENSOR X291
PIN Function 1 2
1 Water temperature info
2
2 Engine ground
1
Diagram
PIN Minimum Typical Max

Supply voltage 12 V
Resistance range 92Ω 1130Ω
Temperature range 40°C 120°C
Number of de
Temperature (°C) Min resistance (Ω) Max resistance (Ω)
segments powered
< 40 1130 1
40 < X < 60 540 1130 2
60 < X < 80 280 540 3
80 < X < 85 243 280 4
85 < X < 90 207 243 5
90 < X < 95 181 207 6
95 < X < 100 155 181 7
80
100 < X < 105 135 155 8
105 < X < 110 118 135 9
110 < X < 120 92 118 10
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(05/02/2015) 80-01-M245EN
28 SPECIFICATIONS
B5 ENGINE WATER THERMO SWITCH X18
PIN Function 1
1 Dashboard info NO
t°
Diagram
Typical
Supply voltage 12 V
Supply current 10 mA
Seuil d’activation 110°C ±0.3
Seuil de désactivation 104°C

Note :
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
B7 HYDRAULIC CLOGGING FILTER CONTACT X21
PIN Function 1 2
1 Oil pressure info

1
2
80
2 Cab rear ground
Corresponding connector P
Diagram
PIN Min Typical Max

Supply voltage 1 10 V 12 V 14 V
Current 1 8 mA 10 mA 12 mA
Seuil d’activation 1.7 bar 2 bar 2.3 bar
Seuil de désactivation 1.5 bar 1.8 bar 2.1 bar
Input type Digital output

Note :
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80-01-M245EN (05/02/2015)
SPECIFICATIONS 29
B8 MASTER CYLINDER PRESSURE SWITCH X64
PIN Function 1
1 Pressure information
2 Cab front Ground

P
Diagram
PIN Typical
Supply voltage 1 12 V
Current 1 200 mA
Activation threshold 6 bar ±0.2
Deactivation threshold 3 bar

Note :
Ignition of stop lights = Connection 3 to 8 bars
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
B9 INCHING PEDAL ANGLE SENSOR X139
PIN Function
2 3 1 5 6 4
1 Common earth
6 2 Common 5 V power supply
5
80
4 3 Track 1 angle signal
1
2 4 Common earth
3
5 Common 5 V power supply
6 Track 2 angle signal Pedal Inching 5V

output 0.5 to 4.5V
Diagram

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

Note :
Each machine should be calibrated (min. angle, max. angle) at km 0 (0 mileage), see part 40
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(05/02/2015) 80-01-M245EN
30 SPECIFICATIONS
B11 BOOM ANGLE SENSOR X100
PIN Function
1 Ground
2 12 V Power supply
Track 1 angle signal (0,5 to

3
6 4,5 V)
5
4 2 3 1 5 6 4
1
4 Ground
2 + S 0 + S 0
3 5 12 V Power supply
Track 2 angle signal (0,5 to

6
4,5 V)
Diagram
Typical
Supply voltage 12 V
Direct current 10 mA
Outlet voltage See notes and diagrams
Load resistance 20 kΩ
Angular range 0° - 90°

Note :
Adjustment of the angle sensor and calibration (mini angle, max angle) are provided on each machine to 0 km.
Both procedures are detailed in the following chapter:
e Group 80 - Electrical control and adjustment

Voltage (V)
S1 S2 Centring of adjustment range
5V
4,5 V
80
S1
S2
0,5 V
-45° 0° 45°
Potentiometer angle (°)
Representation of a potentiometer track (the other track is of the same

value but reversed).
 Black, the operating range of the potentiometer.
 Red, range and setting values.
 represents the angle of the truck.
Adjusting the angle sensor is detailed in the following chapter:
e Group 80 - Electrical control and adjustment
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80-01-M245EN (05/02/2015)
SPECIFICATIONS 31
B12+B21 WHEEL ALIGNMENT SENSOR X65+X66
PIN Function A B C
A Signal
C B Power supply
B
A
C Ground +
Diagram
PIN Typical
Supply voltage A 12 V
Direct current A 10 mA
Outlet logic Switch closed = wheels aligned
Type of outlet PNP at Vbat

Note :
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
B13 TRANSMISSION SPEED SENSOR X62
PIN Function
1 PLUG 1 2 3 4 5 6
6 2 Speed sensor direction

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

Supply voltage 4 4.9 V 5V 6.1 V
Low level voltage 0.3 V 0.45 V 0.6 V
High level voltage 4.4 V 4.55 V 4.7 V
Teeth frequency 3 0 Hz
Remarques :
MLT version only.
The speed sensor is excited by a ring of 78 teeth.
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(05/02/2015) 80-01-M245EN
32 SPECIFICATIONS
B34 FUEL GAGE X63
PIN Function 1
1 Level info
2 1
2 Cab rear ground
Diagram

Supply voltage 12 V
Resistance range 240 Ω 30 Ω
Level range 42. mm >264. mm
Height (mm) Resistance (Ω) Height (mm) Resistance (Ω)

>264 30 138 114
264 42 117 132
243 54 96 150
222 66 75 168
201 78 h 54 204
180 90 42 240
159 102
Note :
Reserve indicator lamp lit and buzzer if R > 170 Ω
80
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80-01-M245EN (05/02/2015)
SPECIFICATIONS 33
B35 AIR FILTER SWITCH X20
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 :
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
B+/IG-L ALTERNATOR X290+X289
PIN Function
IG L B+
B+
B+ Battery power supply
G
3~
80
Engine EV info U
IG IG
12V +APC
IG-L
L
L Pre-heating signal
Corresponding connector Diagram

Engine running: B+ = 12 V
Outlet logic B+
Engine not running: B+ = 0 V
Supply voltage IG 10 V 12 V 14 V
Voltage (Engine not running) L 0V 0V 0V
Voltage (Engine running) L 13 V 13.8 V 16 V

Note :
(Black cable: ground / Grey cable: info)
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(05/02/2015) 80-01-M245EN
34 SPECIFICATIONS
E15 ROTATING BEACON LIGHT X6
PIN Function
1 Power supply
2
2 Ground
1
M
Diagram
Typical
Voltage 12 V
Resistance (10%) 2,82 Ω
Current 4,62 A
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
S2 STARTER IGNITION SWITCH X1 - X2
PIN Function
1 + Battery
2 + Battery
4 3 Un used
80
2 1
3 4 Shunt preload
OP
5 + After contact (+APC) 30 30 17 17 50a 19 19 54 15 58
1 2 3 4 7 8 9 5 6 10
6 + After contact (+APC)

5 7 Starter
6
7 8 Shunt preheating
8 Diagram
9 9 Preheating control relay
10
10 Un used
POS
Note : PIN
ITIO
N O P Maxi - 12 V
Voltage drop : 300 mV 7 (50a) x 18 A / 1min
8 (19) x x 70 A / 3.5min
9 (19) x x 70 A / 3.5min
5 (54) x x x 65 A / ∞
6 (15) x x x 65 A / ∞
10 (58) x 8A/∞
x -> PIN = 12 V
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80-01-M245EN (05/02/2015)
SPECIFICATIONS 35
S11 BRAKE FLUID SWITCH X22
PIN Function A
1 Module A1 info (dashboard)
2 Cab Front Ground

N
Diagram
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
S34 BOOM RETRACTED SWITCH X134
PIN Function
Power supply 1 4 3 2
1
BF2/M1-F6
2 NC Switch
80
1
2 4
3 Power supply
3
BF2/M1-F6
4 NO Switch
Diagram

Supply current 4 mA 6 mA
Note :
When the boom is retracted, the NO switch is closed and the NC switch is open.
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(05/02/2015) 80-01-M245EN
36 SPECIFICATIONS
Y3+Y4 FORWARD AND REVERSE ELECTROVALVE X134
PIN Function 1 2
1 ECU A2 power supply

1
2 2 Ground
Diagram
Typical
Voltage 12 V
Current 2,3 A
Resistance 6,3 Ω
Note :
Measurements taken at 20°C
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
Y8+Y9 TELESCOPING EV + ATTACHMENT X264+X265
PIN Function 1 2

1
2
80
2 Cab front Ground
Diagram
PIN Min Typical Max

Supply voltage 12 V
Supply current 1,5 A
Power 18 W
Resistance 8Ω
Note :
- X264: Telescope electrovalve + or - direction
- X265: Attachments EV + or - direction
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80-01-M245EN (05/02/2015)
SPECIFICATIONS 37
Y10+Y11 TELESCOPING PROPORTIONAL HYD. EV + ATTACHMENT X266+X267
PIN Function 1 2

1
2 2 Cab front Ground
Diagram
Typical
Supply voltage 12 V
Resistance 5,2 Ω
Note :
- X266 : Telescope proportional hydraulic pilot EV
- X267 : Attachment proportional hydraulic pilot EV
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
Y12 HYDRAULIC CUT-OFF EV (VS) X269
PIN Function 1 2

1
2
80
2 ECU A3 ground
Diagram
PIN Min Typical Max

Supply voltage 12 V
Power 18 W
Resistance 8Ω
Note :
X269 : Hydraulic cut-off EV (Safety valve)
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(05/02/2015) 80-01-M245EN
38 SPECIFICATIONS
Y13 NEGATIVE BRAKE EV X93
PIN Function 1 2
1 Power supply
1
2 2 Cab front Ground
Diagram
PIN Min Typical Max

Supply voltage 12 V
Power 18 W
Resistance 8Ω
Note :
X92: Negative brake EV
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80
80-01-M245EN (05/02/2015)
SPECIFICATIONS 39
Y14+Y18 LOWERING + LIFTING PROPORTIONAL CUT-OFF EV X377+X270
PIN Function 1 2

1
2 2 ECU A3 ground
Diagram

Supply voltage 12 V
Resistance 4,72 Ω
Note :
- X270 : lowering proportional cut-off EV
- X377: lifting proportional cut-off EV
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
Y15 TILTING CUT-OFF EV (VCI) X275
PIN Function 1 2
1
2
80
2 Cab front Ground
Diagram

Supply voltage 12 V
Supply current 1.6 A
Resistance 7,5 Ω
Note :
X275: Tilting cut-off EV (VCI)
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(05/02/2015) 80-01-M245EN
40 SPECIFICATIONS
80
80-01-M245EN (05/02/2015)
ELECTRICAL SCHEMATIC DIAGRAMS
pages
ELECTRICAL DIAGRAM CODIFICATION EXAMPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

CABLE IDENTIFICATION ON A WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
POSITION OF CONNECTORS BY DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
ELECTRICAL DIAGRAMS BY FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
– 1 – START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
– 2 – CAN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
– 3 – TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
– 4 – HYDRAULIC MOVEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
– 5 – SENSORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
– 6 – LIGHTING AND SIGNALING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
– 7 - OPTIONS / FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
80
(05/02/2015) 80-02-M245EN
2 ELECTRICAL SCHEMATIC DIAGRAMS
ELECTRICAL DIAGRAM CODIFICATION EXAMPLE

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
V
M -M
Ca - M2
Ch
S2
Ba
ot 3
b
as
1
t
-M
1
2
III II I O P
A 4
30 30 17 17 50a 19 19 54 15 58
2 3 4
7
3 X1 1 7 8 9 5 6 10 X2
769
669
444
719
713
705
+ APC 6 X151 5
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
12 11 4 235 25
72 169 X162 Y40
85
86
421
234 55 420
4
5 369
16 A2 Version Standard
F5 6 1 233 10
9 421 2
X201 X116 MP 22
555 69
420 1
CN1-P2
BF2 / M3
CAN A H
CAN A L Y16
E F3 469
X161
EP7
719
71 72 10
15
14
666
412
369
2
G 12 11 41 42
13 412
420 1
69
58
569 EP12
69
CN1-P1
Masse CAN A
CAN A H
CAN A L
Sch.3
59
X161 Y15
77
91
90 76
89 47 X38-7 X168
EP5 M1
Sch. 8 Sch. 5 9 X76B
88 46
I
17
87 17 9
X166A X166B
R 16
86
S25 N
12 183 30 P
F
11 182 59
A1 B06
8 82
179
JSM 1 34 MP 12
172
K 7 178 49
X149
5 176 88 58
440 440
80
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
10 232 89
M S16 X160
A12 S15 9 180 56
X67 X148
Example of marking on cables and components on an electrical diagram
Key:
1 - Marking grid
2 - + Permanent 10 - Electrical component name
3 - + After ignition 11 - Splice
4 - Grounds 12 - Version choice
5 - Wire N° 13 - Other diagram reference
6 - Electrical connector 14 - CAN
7 - Electrical connector name 15 - CAN Shielding
8 - Electrical connector PIN N° 16 - Option
9 - Electrical component
80-02-M245EN (05/02/2015)
ELECTRICAL SCHEMATIC DIAGRAMS 3
CABLE IDENTIFICATION ON A WIRING HARNESS

The electrical harnesses installed on the truck are composed of connectors.
In order to identify the connectors and their wires, each wire carried a marking.
X32/88/X64
Joins
Wire N° End points X64
X32 / 88 / X64 X32 / 88 / X64
X32
80
(05/02/2015) 80-02-M245EN
POSITION OF CONNECTORS BY DIAGRAM

Connectors Diag. 1 Diag. 2 Diag. 3 Diag. 4 Diag. 5 Diag. 6 Diag. 7
C1 I17 / K16
C2 K18
C4 K19
C5 K22
X1 A9
X2 A13
X3 K25
X4 M11
X6 Q26 / Q25
X9 I12
X10 K35
X11 K36
X12 O36
X13 I14 A22
X14 C13
X19A Q11 M29 K11
X19B Q11 M30 K12
X21 M22
X22-1 I7
X22-2 K7
X25 Q34
X26A Q30
X26B Q30
X27 Q31
X28 Q32
X29 E36
X31 Q9
X32 Q12
X35 I9
X36 I15
X37 Q8
X38 Q15
80
X39 G12
X40 Q19
X46 O6
X50 M28
X56 M27 O12 I30 C26
X57 M25 O12 K30
X58 C35
X59 Q28
X60 E29 / I32
X62 G18
X63 C22
X65 G5
X66 G3
X67 C22 C22
X67 C22 C22
X68 C19
X92 M27
X93 G17
X94 G20
X99 O20
X100 A27
80-02-M245EN (05/02/2015)
X101 A40
X102 A40
X106A O19
X107 M30
X115 O39
X118A E13
X118C E13
X133-1 M6
X133-2 M7
X134 I27
X138 C16
X139 M24
X159 C1
X160 M12
X179 K26
X200A C1
X200B C1
X201 E1 G7
X202 C40
X203 C40
X204-1 E20
X204-2 E18
X205-1 E20
X205-2 E21
X260 O30
X261 O32
X264 Q34
X265 Q35
X266 Q37
X267 Q38
X269 Q32
X270 Q24
80
X274 C13 K23
X275 Q25
X276A O24 M12 / S12
X276B Q24 M12 / Q12
X277A K28
X286 C36
X289 K12
X290 K14
X292 K32
X295 K11 I16
X296 K13
X297 M20
X299 M11
X300 I41 / S41 / S41 S41 M41 / O41
X301 A40
X302 E30
Q40 / Q40 / Q40
X303A C40 C40 S41 K41
/ Q40
X303B I40 E40 / G40 S40 C41 / E41 / S41 S41 / E41
X304A C40 Q40 E40 S40
X304B E40 C40 / C40 A41 / Q41 C41 / K41 / S41 O41 / K41 / G41
(05/02/2015) 80-02-M245EN
X305 Q18
X306 E30
X308 A20
X310A E9 E6 K28 / G27 C1 E4
X311 O18
X312 M15
X313 M24
X314 I10
X328 O13 / O13
X329 O15 / O15
X330A M14 / Q14
X330B O14 / O14
X331 M11 / Q11
X332 M12 / Q12
X370 I29
X372 I11
X373 A1
X375 C7
X377 Q22
X400 M20 G32
X400 M20 G32
X401 G36
X401 G36
X402 G36
X403 Q24
X404 I36
80
80-02-M245EN (05/02/2015)
80
(05/02/2015) 80-02-M245EN
ELECTRICAL DIAGRAMS BY FUNCTION
1 – START-UP
Connectors Components
Wiring harness Component Position on Hydraulic Hydraulic
Item Designation Item Designation Position on diagram
type name diagram correspondence correspondence
Main X1 S2 Ignition switch A9 A6 Digicode module E16
Main X2 S2 Ignition switch A13 A13 Engine computer O21
Engine X3 R1 Preheat K25 G1 Battery 12V / 110 Ah A1
Engine X4 M1 Starter excitation M11 G2 Alternator K13
Cable X101 M1 Cable - cab / fame A40 M1 Starter M12
Cable X102 M3 Cable - cab / fame A40 R1 Preheating plugs K25
S1 Battery cut-off C1
Main X118A 0 Digicode predisposition E13
S2 Ignition switch A10
Option X118C A6 Transponder or Digicode E13
S50 Emergency stop switch A16
Main X138 S50 Emergency stop button C16
Y5 Injection solenoid Q25
Engine X159 S1 Starter (+ bat) / fuse box C1
Engine X160 M1 Starter (+ bat) / battery cut-off M12
Engine X200A S1 Battery cut-off (+BAT) C1
Engine X200B S1 Battery cut-off (+BAT) C1
Fuses and relays
Engine X201 BF1 STUD BF1/M1 E1
Cable X202 M6 Frame / engine ground cable C40 Item Designation Position on diagram
Cable X203 M5 Frame / engine ground cable C40
BF1
Engine X289 G2 Alternator IG / L K12
F41 Engine computer E3
Engine X290 G2 Alternator B+ K14
F42 Key switch E3
Engine X300 M6 Engine ground I41 / S41 / S41
F43 Alternator E3
Engine X301 M5 Cable + battery 70 mm2 / frame A40
F44 BF2 cab fuse box supply E3
Main X303A M1 Front cab ground C40
F45 Starter relay power supply G3
Main X304A M2 Cab rear ground C40
F46 Preheat G3
Main X304B M2 Cab rear ground E40
F51 Engine computer I8
Main X310A 0 Main harness / main harness interconnection E9
F52 Power supply and engine indicator lamps on electric plate I8
Engine X310B 0 Main harness / engine harness interconnection E7
F53 Starter relay control / Engine ECU info M8
Main X373 G1 Terminal + BAUSER module permanent A1
F54 Free I8
Engine X400 0 Engine computer M20
F55 Alternator excitation / engine ECU alert I8
Engine X403 0 Injection pump solenoid Q24
80
K20 Preheater relay I24

K22 Starter relay M10
BF2
F2 Alternator excitation / LLMI + ECM alarm C12
F3 Digicode + Diagnostic plug C12
F33 Digicode + OBD II diagnostic plug E9
Splices
Item Position on diagram
EP25 G10
EP31 O19
EP32 Q19
EP47 Q19
80-02-M245EN (05/02/2015)
Diagram 1 - Starter
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
186 BF2/M4
M 1 M ot
Sch.2
3
S2
M 6M
M 2C r
X373 G1
4 ab
B-
M
714 70 mm2
5
Ch
o
as
B+
s
A A
70 mm2
OP
X1 30 30 17 17 50a 19 19 54 15 58 X2 S50 714 X301 M3
DEM
EVM
SPU
1 2 3 4 7 8 9 5 6 10
277
279
280 25 mm² X101 M1
51
52
273
BF2/M1-F20
713
278 Sch.7 X102 M3

X200A BF2/M1-F11
277
279
S1 Sch.6
A BF2/M1 X138
323 X303A M1
3 4 2 5 1 6 7 F7
266
45
265
19
82
EP7 Sch. 2
X304A M2
F3
F2
Sch. 2
C X200B
C
712 70 mm2 99 X58-2 70 mm² X202 M6
268 Sch. 2
271
272
X159 X203 M5
711
X115-1
Sch. 2
269 274 274 X304B M2
268
265
271
266
273
X118A 1 2 10 9 8 7 6 5 4 3 11 12
25 mm2
BF1/M1
F41 44 X310B X310A X118C 12 11 10 9 8 7 6 4 5 3 2 1
E F42
51 5 mm2 51 C1 51 E
52 5 mm2 52 C8 52
F43 46 16 mm2 A6
711 X201
BF2/M2
53 4 mm2 53 A1 53 D F33
F44 269
54 4 mm2 54 A8 54
270 X115-16
F45 726 45 B1 45 Sch.2
F46 19 B8 19
43 X60-4
70 A3 70 X10-1
Sch.6 431 Sch. 2
12 A2 12 93 X13-8
G EP25 Sch. 6 G
BF1/M2
44 A
F51 799
A F52 B
5 mm2
18 667
A F54 B BF1/M2
K20
9
I 19 A F55 B 43 30
87 2 I
802
801 86 85 41 41 X300 M5
2
X3
K R1 K
9
12
46
X289 X290
IG L B+
70 mm2 G2
3~
BF1/M3 U
K22
712
726 X4
80
30
87 727 + X160
BF1/M2
M 45 A F53 B
660 86 85 804
M1 X400 M
802 44
803
33
12V 40A -
801 39
804 40
803 21
70 13
67
799 800 22
EP31 47
21
O 18
46
O
66
38
45
58
A13 65
78
43
23 X403
36 811 811 1 Y5
3
41a 812 812 1
709 19
61
708 18
42
Q 7 mm² 700
EP32
707 17
62 Q
706 16 ECM
EVG
652
EP47
651 40 KUBOTA
652 X300 M6
S 700 X300 M5 S
(05/02/2015) 80-02-M245EN
2 – CAN
Connectors Fuses and relays

Wiring harness Component Position on Hydraulic Item Designation Position on diagram
Item Designation
type name diagram correspondence
BF1
Main X10 0 Easy manager K35
F44 BF2 cab fuse box supply G7
Main X13 A1 Dashboard module I14
BF2
Main X19A A2/C2 Main harness / engine harness interconnection Q11
F1 Dashboard module + Electric plate indicator lights C13
Engine X19B A2/C2 Main harness / engine harness interconnection Q11
F2 Alternator excitation / LLMI + ECM alarm C14
Main X56 A3 SPU CN1-A hydraulic ECU M27
F3 Digicode + Diagnostic plug C14
Main X57 A3 SPU CN1-B hydraulic ECU M25
Hydrostatic pump ECU, seat contact, JSM, parking brake, hydraulic movement
F4 C14
Main X58 A5 LLMI safety module C35 cut-off
Main X99 A11 Redundant strain gage O20 F7 Hydraulic ECU C15
Main X115 0 Diagnostic plug O39 F33 Digicode + OBD II diagnostic plug C28
Engine X201 BF1 STUD BF1/M1 G7 F36 Hydraulic ECU micro-controller power supply C28
Engine X295 A2 CC1 C1 transmission ECU K11 F61 Dashboard power supply K3
Engine X299 A2/C2 CAN C2 transmission ECU M11 F62 Easy Manager power supply K3
Engine X300 M6 Engine ground S41 / S41
Main X303A M1 Front cab ground C40
S40 / O40 / M40 /
Main X303B M1 Front cab ground
M40 / I40
Main X304A M2 Cab rear ground M40 / Q40 Splices
EP5 O25
EP7 O26
EP12 O27
EP13 E12
EP16 Q31
EP17 I28
Components EP18 Q30
Hydraulic
Item Designation Position on diagram EP19 Q29
correspondence
EP21 Q34
A1 Dashboard module E14
EP22 Q34
80
A2 Transmission ECU M11

EP23 Q35
A3 Hydraulic ECU M28
EP58 O11
A5 Longitudinal security module (LLMI) A37
EP59 O12
A11 CAN gauge M21
EP60 O13
A13 Engine computer O18
B6 Dashboard fault buzzer G26
BP1 Dashboard button 1 G28
BP2 Dashboard button 2 G29
D Distributor C28
E1 Cluster light E29
P1 Hour meter module G30
P2 Fuel gage module G27
80-02-M245EN (05/02/2015)
Diagram 2 - CAN
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
M 1 M ot
3
M 6M
VB
AP
M 2C r
4 ab
M
at
C
M
5
Ch
o
as
s
A A
277
279 A5
279
277
LLMI
BF2/M2
54
53
BF2/M1
GND
ALIM 12 V
CAN H
CAN L
D
A
F33
F36
F1
F2
F3
F4
F7
X58 1 2 3 4
C C
271
171
268
81
76
7
355
169
99
272
140
89
141
142
269
270
71
140 X303A M1
X302-5
Sch.3 X118A-1
X60-13 X118A-7 X67-8
Sch.1
Sch.6 Sch.1 Sch.3
81
80
EP13 X138-6
X118A-2 Sch.1
38
Sch.1
E E
X310A
53
54
38
A1 A8 C4 A1
E1
RPM
53
54
38
X310B
BF1/M1
F44
HORAMETRE
G MICRO CONTROLEUR B6
P1
G
P2
711
X201
X159
Sch.1 711 BP1 BP2
CAN H
CAN L
X13 26 18 25 22 21
171
67
69
170 X303B M1
170
172
I I
X60-16
Sch.6
86
402
EP17
BF2/M4
84
X373
Sch.1 186 1
F61 5 172 Option Easy manager
181
X10
2
F62 6 433 433 3
EP6 412 12
Sch.4
K X305-1
411 11 K
Sch.4 409 8
408 5
40
38
X295 432 2
352
287
434
435
84
71
1 2 C1 X56 1 13 21 07 20 26 431 1
A2 EP25
BAT -
BAT +
A Sch. 1 414
CAN / CABLE 1
4
REF OUT 10V

CAN GND
12 VP IN
GND PW
GND PW
CAN H
CAN L
80
C2 414 X304A M2
X299 1 2 3
434 X303B M1
M A3 M
CAN 1 LOW
62
63
DRAIN 64
GND ANA
GND CAN
435 X303B M1
CAN 1 HI
A11
GND PW
R120
CABLE 9
ROUGE
NOIR
CAN L
CAN H
8 9 3 4
64
X57 31 34 28 02 01
436
344
346
345
284
353
354
285
286
352 436 X303B M1
EP5 EP7
355
287
82
CABLE 5
EP58
X99
1 2 3 4 5
X138-1 X115
Sch.1 270
402
404
405
401
403
694 272 16
O O
284
25 CAN H
EP59 A13 X67-1 183 432
CABLE 10695 26 CAN L EP12
CABLE 6
696 Sch.4 1
60CABLE 8
EP60 120 Ohm
403
65
696
409
697
BLUE 405
407 14
88
59
65
X19B EP61 143

408 11
X19A 1 2 3 Sch.5 400 404
66 EP23
59
60
61
61 406 6
349
87 3
344
EP16 401
141
142
89
89
Q 5 Q
349
130
346
345
CAN / CABLE 4
69
WHITE
67
CABLE 7
129 4
60 348 348 88 129 X304A M2
EP18 EP21
CABLE 7 59 347 CABLE 3 87 CABLE 2
EP19 347
EP22
400 X303B M1
S 697 X300 M5 S
40 X300 M5
(05/02/2015) 80-02-M245EN
3 – TRANSMISSION
Pump H C1 Y3 Forward electrovalve I17 / K16 Y13 Negative Brake electrovalve O27
Pump H C2 Y4 Reverse electrovalve K18
Pump H C4 Y3/Y4 Forward and reverse gear electrovalve K19
Pump H C5 B14 Hydrostatic pump speed sensor K22
Main X56 A3 SPU CN1-A hydraulic ECU O12
Main X57 A3 SPU CN1-B hydraulic ECU O12
Engine X62 B13 Hydrostatic motor speed sensor G18
Fuses and relays
Main X65 B21 Front wheel alignment sensor G5
Main X66 B12 Rear wheel alignment sensor G3 Item Designation Position on diagram
Main X67 A4/B15/B16/S7 JSM C22 BF2

Main X68 A4/S9/S8 High low speed JSM C19 Hydrostatic pump ECU, seat contact, JSM, parking brake, hydraulic movement
F4 C3
Main X92 Y13 Negative Brake electrovalve M27 cut-off
Main X139 B9 Redundant brake pedal potentiometer (inching) M24 F10 Sensors + wheel slighment indicator lights C3
Engine X260 Y6 Y6 hydrostatic motor O30
Engine X261 Y7 Y7 hydrostatic motor O32
Engine X292 A2/C6 CC2 transmission ECU K32
Engine X295 A2 CC1 transmission ECU I16
Engine X297 B14 Hydrostatic pump speed sensor M20
Splices
Engine X300 M6 Engine ground M41 / O41
Main X302 S15 Parking brake switch S15 E30 Item Position on diagram
Main X303B M1 Front cab ground E40 / G40
EP9 K25
Main X304A M2 Cab rear ground E40
EP10 K24
Main X310A 0 Main harness / main harness interconnection K28 / G27
EP13 E25
Engine X310B 0 Main harness / engine harness interconnection K28 / I27
Components
Hydraulic
Item Designation Position on diagram
correspondence
80
A2 Transmission ECU I16

A3 Hydraulic ECU O12
A4 Joystick Switch and Move (JSM) A20
B9 Inching pedal redundant angle sensor M26 / M25
B12 Frame aligned rear wheels sensor G4
B13 Hydrostatic motor speed sensor I19
B14 Hydrostatic pump speed sensor M20
B15 Roller 1 on JSM (Telescope) A23
B16 Roller 2 on JSM (Attachment) A24
B21 Frame aligned front wheels sensor G6
H15 Parking brake control indicator lamp G31
S4 FNR (Forward/Neutral/Reverse) selector A25
S8 JSM BP- A20
S9 JSM BP+ A20
S15 Negative parking brake switch E31
Y3 Forward gear proportional electrovalve M16
Y4 Reverse proportional electrovalve M18
Y6 2P SAUER hydrostatic motor proportional electrovalve O31
Y7 BDP (Brake Pressure Defeat) electrovalve O32
80-02-M245EN (05/02/2015)
Diagram 3 - Transmission
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
M 1 M ot
3
M 6M
VB
AP
M 2C r
4 ab
M
at
C
M
5
Ch
A4
as
s
A B15 B16 A
277
279
S9 S8 S4
A BF2/M1 PB+ PB-
F10
F N R
F4
+ - + -
335
81
76
164
C X68 1 2 X67 9 2 3 6 4 5 7 1 8 11 12 C
267
31
426
427
76
69
167 X304A M2
336 X303B M1
E 1
E
81
80
69
30 BF2/M5 K2-1 0
EP13 Sch.6 X302 S15
X13-14 90 1
38
5 80
X60-8 X60-9 Sch.6
7
Sch.6 Sch.6
2
6
79
8
H15 X306-9
160 10 9 78 78 Sch.5
162
164
167
334
335
336
G X66 A B C X65 A B C 159 X306-3 G
159
EP6
Sch.5
Sch.4
562
563
564
565
X62 2 3 4 5
160 X303B M1
38
31
30
30
+ + X310A
B12 B21 B13 C4 C5 C6 C7
- -
CF X310B
565
563
564
38
31
30
30
X295 4 3 5 8 9 10 11 2 6 7 12
I A2 CC1 I
RPM SENSOR -
RPM MOT +
RPM IN MOT
HYDR
BAT +
D IN FORW
D IN REV
D IN NEUT
ANA IN RPM MOT
HYDR
ANA INCHING
PED1
RPM IN PUMP
PWM +/ D OUT +
ANA IN PED2
RPM PUMP +
ANA OUT 2P
RPM PUMP -
PWM -/ D OUT -
D OUT BDP
PWM OUT
FORW +
PWM OUT
FORW -
PWM OUT
REV +
PWM OUT
REV -
SENSOR +
SENSOR -
C4 CC2
C5
1 6 2 5 1 2 3 4 5 7 6 1 10 9 3 8
X292
562
17
21
16
20
27
28
22
26
X310B
B5 B6 B4 B7
C3 C2
K X310A K
17
21
16
20
1 2
27
28
C1 1 2 C2
EP10
EP9
F R
73
72
74
75
Y3 Y4
74
21
72
75
20
73
X297 4 3 5
X139 2 3 1 5 6 4
80
M M
27
28
B14 CF
X92 1 2
B9 B9
23 X300 M6
Pedal Inching 5V
output 0.5 to 4.5V 24 X300 M6
22
23
26
24
Y13 X260 1 2 X261 1 2
427
267
X57
O B 20 12 2P BDP O
A3
A 19 24 Y6 Y7
X56
426
Q Q
S S
(05/02/2015) 80-02-M245EN
4 – HYDRAULIC MOVEMENTS
Wiring harness Component Position on Hydraulic
Main X56 A3 SPU CN1-A hydraulic ECU I30 BF2
Main X57 A3 SPU CN1-B hydraulic ECU K30 F6 Seat switch + angle sensor + telescope retraction sensor A2
A4/B15/B16/
Main X67 JSM C22 F8 Override + X305 + X372 + X363 + X375 switch indicator lights A2
S7
Main X100 B11 Telescope angle redundant potentiometer A27 F16 Special business free I3
Main X134 S34 Telescope bottom switch I27 K1 Special business free A15
Main X264 Y8 Telescope extend EV Q34
Main X265 Y9 Attachment pos direction 1 Q35
Main X266 Y10 Telescope proportional electrovalve Q37
Main X267 Y11 Proportional attachment EV Q38
Main X269 Y12 Hydraulic cut-off EV (VS) Q32 Splices
Main X270 Y14 Lowering proportional cut-off EV (VRP) Q24
EP6 G13
Main X274 S5/S6 Seat switch C13 EP8 C24
Main X275 Y15 Tilting cut-off EV (VCI) Q25 EP11 C23
Q40 / Q40 / Q40 /
Main X303A M1 Front cab ground EP15 G28
Q40
Main X303B M1 Front cab ground S40 EP24 Q25
Main X304A M2 Cab rear ground S40
Main X304B M2 Cab rear ground C40 / C40
Main X305 S31 Hydraulic movement cut-off shunt switch Q18
Main X311 S14 Hydraulic movement neutralization switch O18
Main X372 S33 Attachment locking switch I11
Main X375 S52 Tilting neutralization switch C7
Main X377 Y18 Proportional lifting EV Q22
Engine X401 0 Engine speed sensor #N/A
Engine X402 0 Coolant temperature sensor #N/A
Components
Item Designation Position on diagram Hydraulic correspondence
A3 Hydraulic ECU I33

A4 Joystick Switch and Move (JSM) A22
B11 Telescope angle redundant potentiometer A28
B15 Roller 1 on JSM (Telescope) A23
80
B16 Roller 2 on JSM (Attachment) A24

H14 Hydraulic movement cut-off indicator lamp (TUV) O18
H31 Overload safety shunt indicator lamp (override switch) S18
H33 Attachment locking indicator lamp I11
H52 Tilting neutralization control indicator lamp E6
S4 FNR (Forward/Neutral/Reverse) selector A26
S5 NO seat switch C13
S6 NC seat switch C14
S14 Hydraulic cut-off switch (TUV) O18
S31 Hydraulic/overload movement cut-off shunt switch (override) Q18
S33 Attachment line locking switch I11
S34 Boom retract NO/NC sensor K27
S52 Tilting neutralization switch C7
Y8 Telescope electrovalve + or - direction S34
Y9 Attachments electrovalve + or - direction S36
Y10 Proportional hydraulic pilot electrovalve (Telescope) S37
Y11 Proportional hydraulic pilot electrovalve (Attachment) S39
Y12 Hydraulic cut-off electrovalve (VS) S32
Y14 Lowering proportional cut-off EV (VRP) S24
Y15 Tilting cut-off electrovalve (VCI) S26
Y18 Proportional lifting electrovalve S22
80-02-M245EN (05/02/2015)
Diagram 4 - Hydraulic movements
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
B11
M 1 M ot
3
M 6M
A4
VB
AP
M 2C r
4 ab
M
at
C
M
5
277 B15 B16
Ch
o
as
s
A 279
BF2/M5 A
419
BF2/M1 S4
A 1
K1 3
F N R
F6
F8
+ 2 3 1 5 6 4
- + - X100
48
49
47
55
56
50
2 5
58
83
359
91
83 BF2/M5
X67
295
9 2 3 6 4 5 7 1 8 11 12
296 K2-2
1 X274 Sch.6
267
257
258
263
260
261
264
183
76
C BF2/M5 C
K4-2 50 X304B M2
Sch.6
EP11 EP8 EP12 BF2-M1 47 X304B M2
S52 SEAT Sch.2 F4
262
259
X375 Sch.3
S5 S6
94 1
5 91
3 2
92
368 10 9
282
281
H52
E E
282
X10-12 412 316
EP6
Sch.2
39
58
48
G X310A-C7
327
EP15
55 G
Sch.3
138
280
278
S33 X60-15
X372
Sch.6
BF2/M1
128
205
196
49
56
173
316
259
263
94
124
123
267
267
262
264
B 1
5 368
351 7 X56 05 16 11 25 08 06 17 12 18 15 22 10 14 02 03 13 12 24 16
F16
369
I 359 9 10 370 A I
327
328
138
139
OUT LS 1
IN TOR 12
IN TOR 4
IN ANA V 1
IN ANA V 2
OUT LS 1
IN TOR 1
IN TOR 14
IN ANA V 3
IN TOR 10
IN TOR 3
IN TOR 13
OUT PWM 7
OUT PWM 8
OUT LS 2
IN ANA V 8
IN TOR 16
IN TOR 15
IN ANA V4
135
H33 X134 1 4 3 2
A3
419
OUT PWM 11
OUT PWM 10
OUT PWM 4
OUT PWM 2
OUT PWM 3
OUT PWM 1
OUT PWM 6
OUT PWM 5
OUT PWM 9
IN TOR 11
IN TOR 8
IN TOR 5
IN TOR 6
IN TOR 9
S34 B
X57 22 15 23 32 06 25 14 17 30 07 05 19 29 33
281
328
139
201
202
174
127
126
120
K K
80
M M
1
S14
0
X311
1
5
7
206 X306-3
O 205 2
6 197 Sch.5 O
8
H14
X314-10 212 10 9 204 X306-9
Sch.7 197 Sch.5
131 X303A M1
173
132 X303A M1
175
1 EP24 121 X303A M1
Q S31 122 X303A M1 Q
127
128
126
131
123
132
120
121
124
122
0 X269 X264 X265 X266 X267
1 2 1 2 1 2 1 2 1 2
X305
174
175
202
185
201
184
X10-11 411
X377 1 2 X270 1 2 X275 1 2
Sch.2
196 1
5 135
136
370 10 9
371
H31 Y12 Y8 Y9 Y10 Y11
Y18 Y14 Y15 VS T+ A+
184 X303B M1
S 371 X304A M2 S
(05/02/2015) 80-02-M245EN
5 – SENSORS
Connectors
Item Designation
Main X19A A2 Main harness / engine harness interconnection O29
Engine X19B A2 Main harness / engine harness interconnection O30
Main X21 B7 Hydraulic filter clogging M22
Main X22-1 S11 Brake fluid level I7
Main X22-2 S11 Brake fluid level K7
Main X56 A3 SPU CN1-A hydraulic ECU C26
Main X63 B34 Fuel gage C22
Main X133-1 B10 Negative brake pressure switch M6
Main X133-2 B10 Negative brake pressure switch M7
Main X179 Not used O26
Main X303A M1 Front cab ground S41
Main X304B M2 Cab rear ground A41 / Q41
Main X306 S3 Not used E30
Engine X400 A13 Engine computer G32
Engine X401 B8 Engine speed sensor G36
Engine X402 B4 Coolant temperature sensor G36
Engine X404 B3 Oil pressure switch I36
Components
Hydraulic
correspondence
A1 Dashboard module G6
A3 Hydraulic ECU C26
A13 Engine computer G30
B3 Engine oil pressure switch I39
B4 Engine temperature sensor I39
B7 Hydraulic filter clogging O22
B8 Engine speed sensor G38
B10 Negative Brake info pressure switch O6
B34 Fuel gage C22
S11 Brake fluid level sensor K7
80
Splices
EP26 M28
EP27 E6
EP28 I7
EP30 G6
80-02-M245EN (05/02/2015)
Diagram 5 - Sensors
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
M 1 M ot
3
M 6M
VB
AP
M 2C r
4 ab
M
at
C
M
5
Ch
o
as
s
A A
187 X304B M2
802 F35 Sch.1
799 F51 Sch.1
A3
187
C C
178
X63
1 2
A
X56
467
466
B34
X306
206 X311-6
466 Sch.4
467
465
X310B
E X310A A7 X302-9 78 159 E
11
Sch.3
3 X60-5
204
EP27 Sch.6
X302-10
8
178
Sch.3
X13
10 2
X311-9
171 F1 Sch.2 171 26 Sch.4
A1 M1
170 Sch.2
172 F16 Sch.2 172 18
9 4 3 25
X400
G X401 B8 G
14
176
802 Sch.1
166
44 20 806 806
170 Sch.2 1
X60-2 15 A13 2 807 807

CF
2
Sch.6
EP30
43 808 808 3
134
X402
5 X60-3
6 810 810 1 B4
EP28 Sch.6
799 Sch.1
EP.31 Sch.1
800 T
1 809 809 2
ECM
6
I X22.1 EVG I
KUBOTA
N
X404 P B3
15 813 813 1
S11
X22.2 709 19
242
708 18
700 Sch.1 707 17

K EP.32 Sch.1
706 16
K
X26-3
Sch.6 652 Sch.1 651 40
EP.47 Sch.1
80
652 Sch.1 M6
700 Sch.1 M5
M 165
M
166
133
134
X21 1 2
X133-1 X133-2
P
670
1
P B7 1 671
4 CABLE 13 674 4
B10
2 672 2
6 676 6
O 3 CABLE 14 673 3
O
5 675 5
669 678 7
X179 EP26
X19A X19B
Q 165 X304B M2 Q
133 X303A M1
S S
(05/02/2015) 80-02-M245EN
80
80-02-M245EN (05/02/2015)
6 – LIGHTING AND SIGNALING
Cab X6 E15/M3 Rotating beacon light Q26 / Q25 A1 Dashboard module A23
Main X9 B2 Horn ground terminal I12 A2 Transmission ECU M14
Main X11 S28 Wiper stalk switch K36 A12 Martin technologies Dashboard indicator lamps plate E29
Main X12 S28 Wiper stalk switch O36 B1 Reversing buzzer Q16
Main X13 A1 Dashboard module A22 B2 Main horn I12
Main X14 S27 Light commutator switch C13 B6 Dashboard fault buzzer A35
Main X19A A2/C2 Main harness / engine harness interconnection K11 D Distributor C4
Engine X19B A2/C2 Main harness / engine harness interconnection K12 E2 Reverse light Q14
Main X25 M6 Front windscreen wiper motor Q34 E3 Right and left stop lights Q11 / Q13
Main harness/front windscreen washer pump harness E4 Rear fog light Q11
Main X26A M5/M8 Q30
interconnection E7 License plate light (TUV 25km/h) Q7
Main harness/front windscreen washer pump harness E8 Left front and rear side lights I10 / Q11
Cab X26B M5/M8 Q30
interconnection
E9 Right front and rear side lights I16 / Q14
Main X27 M5 Front windscreen washer pump Q31
E10 Left front and rear indicator lights I10 / Q12
Main X28 M8 Rear windscreen washer pump Q32
E11 Right front and rear indicator lights I17 / Q13
Main X31 E8/E4/E3/E10 Rear left headlight Q9
E12 Right and left codes I16 / I10
Main X32 E2/E3/E9/E11 Rear right headlight Q12
E13 Right and left headlights I15 / I9
E8/E10/E12/
Main X35 Front left headlight I9
E13 E15 Rotating beacon light S27
E9/E11/E12/ E16 Roof light M29
Main X36 Front right headlight I15
E13
H1 Battery charge indicator lamp A24
Main X37 E7 Rear number plate light Q8
H2 Active negative brake indicator lamp (parking brake) G31 / G32
Main X38 B1 Reversing buzzer Q15
H3 Engine oil pressure indicator lamp A24
Main X39 B2 Horn G12
H4 Engine coolant temperature indicator lamp A25
Main X40 PER Rear electric socket Q19
H5 Hydraulic filter clogging indicator lamp A26
Main X46 S17 Cigarette lighter O6
H6 Brake fluid tank level indicator lamp G33 / G33
Cab X50 S25/E16 Roof light M28
H7 Headlight indicator lamp G40 / E40
Cab X59 M7 Rear windscreen wiper Q28
H8 Indicator light indicator lamp G37 / E38
Main X60 A12 Dashboard indicator lamps connector E29 / I32
H9 ECU fault or degraded mode indicator lamp A27
Cab X107 M4/S29 Roof windscreen wiper M30
H10 Fuel reserve indicator lamp A28
M3/M7/E17/
Main X276A Main harness/front cab harness interconnection O24 H11 Low / High speed indicator lamp G35 / G35
E18
M3/M7/E17/ H13 Low / High speed indicator lamp G36 / E36
Cab X276B Main harness/front cab harness interconnection Q24
E18 H16 Warning switch indicator lamp A20
Main X277A R6 Main harness/rear cab harness interconnection K28 H18 Rear fog light control indicator lamp M15
80
Engine X296 0 Stop switch control via SAUER K13 H19 Rotating beacon light control indicator lamp O24
Main X303A M1 Front cab ground K41 H24 Rear wheel alignment light G38 / E38
Main X303B M1 Front cab ground C41 / E41 / S41 H25 General fault indicator lamp A28
Main X304B M2 Cab rear ground C41 / K41 / S41 H26 Air filter clogging indicator lamp A29
Main X308 S16 Warning switch A20 H27 Preheating Indicator lamp G30 / G30
Engine X310B 0 Main harness / engine harness interconnection I5 H28 Forward gear indicator lamp A30
Main X310A 0 Main harness / main harness interconnection C1 H29 Neutral indicator lamp A31
Engine X310B 0 Main harness / engine harness interconnection C2 H30 Reverse gear indicator lamp A31
Main X312 S18 Rear fog light switch M15 H35 Front wheel alignment light G39 / E39
Main X313 S19 Rotating beacon light switch M24 H37 Dashboard manual parked regeneration indicator lamp A32
Option X370 A12 Selector for attachment line flow / MT plate I29 H38 Dashboard DPF soot level indicator lamp A33
H39 Dashboard active regeneration indicator lamp A34
H40 Inhibited regeneration indicator lamp A34
H41 Engine ECM warning indicator lamp A35
H43 Dashboard telescope suspension indicator lamp G37 / E37
H44 Water in diesel indicator lamp G34 / E34
H45 Reserve lamp G32 / G32
M3 Rotating beacon light motor Q27
M5 Front windscreen washer pump motor S31
M6 Front windscreen wiper motor S35
M7 Rear windscreen wiper motor S29
(05/02/2015) 80-02-M245EN
Components
Hydraulic Fuses and relays
correspondence
M8 Rear windscreen washer pump motor S32 Item Designation Position on diagram
PER Trailer electrical connector Q19
BF1
S16 Warning switch A20
F44 BF2 cab fuse box supply A2
S17 12V plug with back lighting O7
F52 Power supply and engine indicator lamps on electric plate I3
S18 Rear fog light switch M15
BF2
S19 Rotating beacon light switch M24
F1 Dashboard module + Electric plate indicator lights M5
S25 Roof light control switch M29
F5 12V plug + car radio M5
S26 Horn control A16
F9 K2 + K3 power supply M5
S27 Light commutator switch A14
F11 Flashing unit K5
S28 Wiper stalk switch S38
F12 Rear fog light switch K5
V1 P600J or P600K diode C6
F14 Rotating beacon light K5
V2 P600J or P600K diode A7
F17 Rear windscreen wiper + rear windscreen washer control K5
F18 Front windscreen wiper + front windscreen-washer control I5
F21 Left side lights power supply G5
F22 Right side lights power supply G5
F23 Power supply codes G5
F24 Headlights power supply G5
F25 Right indicator lights supply E5
F26 Left indicator lights supply E5
F31 Light commutator switch E5
F32 Warning switch + flashing unit E5
F34 Horn E5
F37 Power (+bat) reset to zero rear windscreen wiper motor E5
F38 Power (+bat) reset to zero front windscreen wiper motor C5
K2 Reverse light and buzzer relay M10
K3 Stop light relay M14
K4 Working lights on telescope option A4
K8 Flashing unit C18
Splices
80

EP1 C7
EP2 C6
EP3 A7
EP4 A7
EP20 G8
EP39 K32
80-02-M245EN (05/02/2015)
Diagram 2 - Lights signaling
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
1
M 1 M ot
S16 A1
3
M 6M
VB
AP
M 2C r
M2 0 H1 H3 H4 H5 H9 H10 H25 H26 H28
4 ab
H29 H30 H37 H38 H39 H40 H41
M
at
C
M
BF2/M4 X304B X308
5
214
216
155
215
Ch
BF2/M5 K7-2(85)
6
2
as
EP4 57/58 49
Sch.7 8 217
310
56a 54s
s
1 3 56b 54d
A K4
V2 S26 300
3
5 158
A
1 L 0 R
213
0 2 1 MICRO CONTROLEUR B6
EP3
224
157
218 10
S27 BF2/M4 213 7
BF1/M1 2 5 X314-2 30 L 31
5(-) 4(+) H16
207
X13 10 15 8 14 23 24
F44 Sch.7
3(R2)
295
294
107
93
90
13
32
CL
BF2/M5 K8 EP25 X302-1
208
K1-2 1 2 3 4 8 9 6 5 7 X14 Sch.1 Sch.3
X310A
155
Sch.4 8(R) 6(C)
X310B 154
V1 153 153
177
158
151
148
119
X303B M1
157
207
145
147
150
A8
55 216
214
146
144
C A1 54
EP2 EP1
294 X304B M2 C
BF2/M2 X310A-A3 EP30 EP28 EP27 X66-A X65-A

D F38 255 Sch.1 Sch.5 Sch.5 Sch.5 Sch.3 Sch.3
F37 319
X303B M1
668
169
177
162
334
146
317
148
70
15
05
03
13
32
F34 149 X60
14 04 13 02 12 03 05 10 06 07 08 09 11 01
F32 215 A12JP1
E F31 144
H44
E
111
151 F26 109
114
150
F25 H27 H2 H45 H6 H11 H13 H43 H8 H24 H35 H7
112
101
147
F24 102
99
145
F23 98
107
154 F22
G 106 106
EP20 108 H27 H2 H45 H6 H44 H11 H13 H43 H8 H24 H35 H7 G
104
F21 15 85 X57-13
152 118 3K Sch.4
119
117 X39 1K 16 86 EP17
BF1/M2 1.5K Sch.2
BF1/M2
100
98
102
118
111
98
101
108
114
F54-A
95
X310B B2 JP1 X60
Sch.1 667
F52 B3
X35 1 2 3 4 5 6 X36 1 2 3 4 5 6
A B 668 668 0.5K
JP2
4 3 1 2
X9 X370
E13E12 E8 E10 E13E12 E9 E11
I I
95
96
BF2/M1
280
B F18 249
250
F17 247
246
F14 221 96 X303A M4
149
247
322
K F12 219 X277A 1 4 3 K
322 322 X304B M2
149
278 F11 217
407
322
X11
149
407
EP39 246
247
174
X19A X19B X296
277 36 12 36 1 3
A2 X50 A C B
X107 1 2 408 X316-2 1
Sch.7 248
X67-12 X310A-C6 1 2
37 11 37 2 4
F9 179 Sch.3 Sch.3 S18 250
C4 0 S25 3
80
F5 X312 245
234 4
233 X93-4 198 249
5
F1
M 279 169 Sch.7
M
69
219 1
S19 1
E16
5
179
180
244
30
36
180
A BF2/M5 0 6
1 251
BF2/M5 1 3
K3
3 H18 X313
K2 220 9 10 208
1 223 252
7
221 5
235
234
8
209
X46 1 2
222
H19 9
2 5 2 5
9 10 210 X314-10
188
296
297
181
189
12V 37 Sch.7 X22-2 0

Sch.5
198
209
190
109
188
S17 110 1
O BF2/M5 BF2/M5
199
1 X12 O
K5-2(85) 2 6 253
K1-2(85)
117
Sch.4 Sch.7 116 7 1

320 X331-2 254
3 5 104 Sch.7 243 2
406
321
223
253
319
248
4
242
244
245
X276A
PER 1 8 6 2 5 4 X26A
200
105
1 2 3
112 X40
113 X276B X26B
168
253
4
192
cable n°5
cable yellow/green
116
199
189
110
194
168
113
190
105
181
194
193
191
2 1 X37
X31 4 2 3 5 1 6 X32 6 5 3 1 2 4 X38 1 2
Q STOP STOP
X330-2&4 Q
569
570
244
253
248
406
254
255
252
251
256
319
242
Sch.7 X25 0
X59 1 3 2 4 2 X28 2 1 3 5 4 2 6
X6 X6 X27 1 1
E8 E4 E3 E10 E11 E3 E9 E2 1 2
B1
E7 M3 M M vit2
+perm
vit1
S28
+perm vit
M raz M F
E15 raz M5 M8 -
-
M7 M6
200
193
4
191
192
243
100
256
321
320
235 X304B M2
S X303B M1 S
(05/02/2015) 80-02-M245EN
22 ELECTRICAL SCHEMATIC DIAGRAMS 7 - OPTIONS / FAN

Main X29 M9 Heating ventilator E36 BF1
Main X93 A7 Car radio power supply G17 F44 BF2 cab fuse box supply E3
Main X94 A7 Car radio HP G20 BF2
Main harness / special case predisposition harness
Main X106A S32 O19 F5 12V plug + car radio C3
interconnection
F19 Shunt bar C power supply (F27/F28/F29/F30) A3
Main X204-1 HPD + right HP E20
F20 Heating A3
Main X204-2 HPD - right HP E18
F27 Electrical boom prewiring E7
Main X205-1 HPG + left HP E20
F29 Pneumatic seat C7
Main X205-2 HPG - left HP E21
F30 2 front working light + 2 rear working lights C7
Main X274 S5/S6 Seat switch K23
F35 Car radio (power) E7
M3/M7/E17/
Main X276A Main harness/front cab harness interconnection M12 / S12 K5 Special business free A39
E18
M3/M7/E17/ K6 Special business free A37
Cab X276B Main harness/front cab harness interconnection M12 / Q12
E18 K7 Special business free A35
Main X286 S24 Heating fan control C36
Main X303B M1 Front cab ground S41 / E41
Main X304B M2 Cab rear ground O41 / K41 / G41
Front and rear cab working light switch + telescope light
Main X314 S20 I10
option
Option X328 E18 Front right working light O13 / O13
Option X329 E18 Left front working light O15 / O15
Main X330A E18 Front working lights M14 / Q14
Cab X330B E18 Front working lights O14 / O14
Cab X331 E17 Rear working lights M11 / Q11
Cab X332 E17 Rear left working light M12 / Q12
Components
Hydraulic
correspondence
80
A7 Car radio G19

A8 Heating unit C36
E17 Left and right rear working lights O12 / O11
E18 Left and right front working lights O13 / O15
H20 Front/rear working light control indicator lamp K10
M9 Heating motor fan E36
M11 Pneumatic seat motor M23
M Engine M24
S20 Front/front+rear working light switch + telescope light option I10
S24 Heating control switch C35
S44 Pneumatic seat control K23
80-02-M245EN (05/02/2015)
DIAGRAM 7 - Options / Fan
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
M 1 M ot
3
M 6M
VB
AP
M 2C r
4 ab
M
at
C
M
5
Ch
o
as
BF2/M1
s
A A
280
B F20 292
292
F19 350 276
BF2/M4
1 86 3 30
278 K7 K6 K5
277
279
F5 233 2 85 5 87 4 87a 2
234 K8-5(-) 300 299 298 297 K2-2(85)

A X46-1
Sch.6 Sch.6
Sch.6
C C
275
BF2/M2
- A8
HPD
C F30
275
350 226 S24
+
F29 Off L X286
558 M 293 X303B M1
B
BF1/M1 F27 X204-2 X204-1 + H
313 C
HPG
X310B X310A
293
387
386
385
-
388
F44 54 A1
54 D
3 4 2 1 X29
239
238
55 A8 55 F35 237
E E
X205-1 X205-2
241
240
M9
237
238
240
X93 X94
1 3 5 7 1 3 5 7
ALIM-AUTO HP-AUTO
2 4 6 8 2 4 6 8
233
236
239
241
G 236 X304B M2 G
A7
I I
1
S20
0 224 V2
X314
Sch.6
226 6 2 225
1 229
3 399 X304B M2
227
H20
9 10 212 X311-10
K 228 K
398
399
Sch.4
4 5
210
X274
X313-10 S44
Sch.6
229
225
X276A 3 7
80
M
X276B
229
M M11 M
cable n°1
cable n°3
229
X330A
X331 1 X332 1 1 3
X330B
X329
X328 1 1
313
312 312 X304B M2

E17 E17 E18 E18 X106A
1 2
O O
X329
X328 2 2
X330B
2 4
X331 2 X332 2
X330A
X6-2
Sch.6
Q Q
cable yellow/
green
cable n°2
cable n°4
320
X59-4 406
Sch.6
X276B 4 8
X276A
321
320
S X303B M1 S
(05/02/2015) 80-02-M245EN
80
80-02-M245EN (05/02/2015)
ELECTRICAL COMPONENTS LOCATION
pages
KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
– CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– DIODES AND SPLICES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2D LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
– CAB HARNESSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
– HARNESS ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
– MAIN HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
– ENGINE HARNESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3D LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
– MAIN HARNESS IN CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
– MAIN HARNESS ON FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
– HARNESS IN ENGINE HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
80
(05/02/2015) 80-03-M245EN
2 ELECTRICAL COMPONENTS LOCATION
KEY
CONNECTORS
Position on 2D harness Position on 3D harness

Item Designation
Cab Assembly Main Engine In cab On frame In engine
X1 Ignition switch I24 K24 I17

X2 Ignition switch I24 K23 I18
X3 Preheat O28 Q35 G30
X4 Starter excitation Q24 M27 Q9
X6 Rotating beacon light I8 E25
X9 Horn ground terminal M35 G34 M34
X10 Easy manager I19 O29 / K5
X11 Wiper stalk switch G26 E28 I12
X12 Wiper stalk switch G26 E30 I12
X13 Dashboard module I30 E23 / I11 C17
X14 Light commutator switch E26 E32 K14
X19A Main harness / engine harness interconnection M29 I40 / M13 Q22
X19B Main harness / engine harness interconnection S16
X21 Hydraulic filter clogging M13 Q14 I20
X22-1 Brake fluid level E31 E8 C3
X22-2 Brake fluid level G31 G8 E6
X25 Front windscreen wiper motor G26 E31 I11
X26A Main harness/front windscreen washer pump O4 G31 G8 M12
harness interconnection
X27 Front windscreen washer pump O17
X28 Rear windscreen washer pump O17
X29 Heating / air-conditioning fan E30 G13 M7
X31 Rear left headlight G3 Q9 A20
X32 Rear right headlight O3 Q3 E5
X35 Front left headlight G36 I34 G35
80
X36 Front right headlight Q36 I36 K18

X37 Rear number plate light K2 S6 C14
X38 Reversing buzzer M2 Q3 G9
X39 Horn M34 G33 M34
X40 Rear electric socket I4 S10 C18
X46 Cigarette lighter light K18 Q18 E33
X50 Roof light K18
X56 SPU CN1-A hydraulic ECU O31 E39 Q28
X57 SPU CN1-B hydraulic ECU O32 E38 / K13 Q27
X58 LLMI safety module K27 G32 / I10 A19
X59 Rear windscreen wiper E3 E15
X60 Dashboard indicator lamps connector I30 E24
X62 Hydrostatic motor speed sensor K34 C16 O5
X63 Fuel gage K7 Q2 G8
X65 Front wheel alignment sensor M34 G35 M31
X66 Rear wheel alignment sensor K9 Q11 G18
X67 JSM K20 M28 M18
X68 High low speed JSM K20 M27 M18
X92 Negative brake electrovalve M29 K32 K30
X93 Car Radio power supply I14 O11
80-03-M245EN (05/02/2015)
ELECTRICAL COMPONENTS LOCATION 3

Item Designation
X94 Car radio HP I14 O13

X99 Redundant strain gage I16 O15 / M7 A31
X100 Telescope angle redundant potentiometer K2 Q8 A14
X101 Cable - cab / fame A38
X102 Cable - cab / fame A40
X106A Main harness / special case predisposition harness G16 K16 I39
interconnection
X107 Roof windscreen wiper K18
X115 Diagnostic plug K20 Q28 / K1 G35
X118A Digicode predisposition I20 O28 G34
X118B Anti-theft shunt G35
X118C Transponder or Digicode
X133-1 Negative brake pressure switch K32 K40 I27
X133-2 Negative brake pressure switch M32 K40 I25
X134 Telescope bottom switch K2 Q4 E10
X138 Emergency stop button I25 M23 M15
X139 Redundant brake pedal potentiometer (inching) E27 E9 M12
X159 Starter (+ bat) / fuse box M34 K15 C41
X160 Starter (+ bat) / battery cut-off
X179 Accelerator pedal I27 E13 M15
X200A Battery cut-off (+BAT) C41
X200B Battery cut-off (+BAT) C41
X201 STUD BF1/M1
X202 Frame / engine ground cable
X203 Frame / engine ground cable
X204-1 + right HP K12 O8
X204-2 - right HP K13 O7
X205-1 + left HP E12 O3
X205-2 - left HP E13 O3
X260 Y6 hydrostatic motor K35 A17 S7
X261 Y7 hydrostatic motor M35 A19 S9
80
X262 Y21 Telescope suspension EV1
X263 Y22 Telescope suspension EV2
X264 Telescope extend EV M29 K32 I29
X265 Attachment pos direction 1 M29 K32 I31
X266 Telescope proportional electrovalve M32 M39 K26
X267 Proportional attachment EV M32 M39 K26
X269 Hydraulic cut-off EV (VS) K29 I32 K30
X270 Lowering proportional cut-off EV (VRP) K25 K33 C24
X274 Seat switch I18 Q16 I35
X275 Tilting cut-off EV (VCI) K24 M33 E24
X276A Main harness/front cab harness interconnection C16 E30 G10 M6
X277A Main harness/rear cab harness interconnection K15 M18 G39

X286 Heating / air conditioning fan control E30 G14 M6
X289 Alternator IG / L Q26 I36 O4
X290 Alternator B+ S25 K33 O21
X292 CC2 C6 transmission ECU S15 S10 K4
X295 CC1 C1 transmission ECU S15 S12 E4
X296 Stop switch control via SAUER S14 Q5 K17
X299 CAN C2 transmission ECU S15 S28 E2
(05/02/2015) 80-03-M245EN

Item Designation
X300 Engine ground O21 S20 G28

X301 Battery ground cable 70 mm2 / frame K32 A40
X302 Parking brake switch S15 I29 E26 E21
X303A Front cab ground K29 G33 I13 A38
X303B Front cab ground K29 I33 I13 A38
X304A Cab rear ground G17 K18 / M3 I36
X304B Cab rear ground I17 K19 I37
X305 Hydraulic movement cut-off shunt switch I19 M34 G29
X306 Not used G29 E25 E20
X308 Warning switch I31 A4 G17
X310A Main harness / main harness interconnection M29 G40 Q22
X310B Main harness / engine harness interconnection C26
X311 Hydraulic movement neutralization switch G29 E24 E19
X312 Rear fog light switch I31 A4 G17
X313 Rotating beacon light switch I31 C4 E18
X314 Front and rear cab working light switch + I31 C4 E18
telescope light option
X316-1 Rear windscreen defrost K13
X316-2 Rear windscreen defrost K14
X330 Front working lights G6 E26
X331 Rear working lights C4 E15
X372 Attachment locking switch I20 O34
X373 Terminal + BAUSER module permanent M34 G35 I2
X375 Tilting neutralization switch I22 Q35
X377 Proportional lifting EV K24 M33 E26
X400 Engine computer Q33 C12 K39
X401 Engine speed sensor S22 K24 G13
X402 Engine cooling sensor S22 I20 E11
X403 Injection pump solenoid O26 O38 M9
X404 Oil pressure switch Q27 O35 S10
80
80-03-M245EN (05/02/2015)
DIODES AND SPLICES

Item Designation
V1 Diode E26 E31

V2 Diode I29 C12
EP1 Splice E25 E31
EP2 Splice E25 G31
EP3 Splice I29 C11
EP4 Splice I29 C13
EP5 Splice O31 G38
EP6 Splice M31 G38
EP7 Splice M31 G38
EP8 Splice K19
EP9 Splice G27 E10
EP10 Splice G27 E11
EP11 Splice K19 O27
EP12 Splice I20
EP13 Splice I25 K29
EP14 Splice
EP15 Splice I3 Q8
EP16 Splice M32
EP17 Splice I20 O29
EP18 Splice M33 I37
EP19 Splice M32 K29
EP20 Splice I25 K29
EP21 Splice I26 K29
EP22 Splice I26 K29
EP23 Splice I26 I29
EP24 Splice I25 K31
EP25 Splice I27 I29
EP27 Splice I29 G25
80
EP28 Splice I28 G26
EP30 Splice I28 G26 C16
EP31 Splice C17
EP32 Splice Q6
EP58 Splice Q19 K18
EP59 Splice Q19 K18
EP60 Splice Q19 M18
(05/02/2015) 80-03-M245EN
2D LOCATION
CAB HARNESSES
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Key:
A Flexible sheath type GREMFLEX PET
CAB HARNESS 1
Option X331-1
C AR
X331-2
Frame
X276B
harness
AR X59
E M
Option X330
AV
I X6-1 X6-2
K
80
CAB HARNESS 2 AV
X27
Main X26B
O harness
X28
AR
80-03-M245EN (05/02/2015)
HARNESS ASSEMBLY
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
Key:
A A
Main harness
Engine harness
Cab Harness 1
Cab Harness 2
C C
Cab Harness 3
Connection between harnesses

X276A
X29 Splice
X205-1 X205-2 X286
E X332 E
X331 X6 X330
EP1 X33 X34
EP2
X59 X14 X139 X22-1
V1 X35
EP9 X22-2
EP10 X26A
X11
X31
G X12 G
X106A X25
X311
X304A X306
X179
X304B X10 X302
7
X274
X305 X372 X1 X2 X138 EP2 X13 X308
X40 X375 X60 X312

EP21
I EP15 EP12 EP13 EP28 I
X99 0 V2 X313
EP3
BF2
EP17 EP23 X314
X93 EP20 EP4 EP3
X118A EP19 EP22 EP25
X94 EP24
X46 X115 X303A
X100 X204-1 X204-2 EP8 X58
X277A EP11 X67 X303B
X377 X275 X270 X301
X50 X68
EP39
X37 Bat-
K X316-1 X316-2 K
X66 X107
X134
X269 X133-1 X62
X63
X260
X92 X133-2
X159 X261
X264 X266
80
X265 X267 X39
X21
X38 X9
M M
X310A EP16 EP18 X65
X373
EP6
X19A EP19
EP7
EP5
X403
X56 X57
O X300 O
EP31
EP30
X3
X32
X400
X4
X36
Q Q
BF1 EP59
EP60
EP58 X289 X404
X402
X290
X299 X401
X296 X292
X295
S S
Forward gear
(05/02/2015) 80-03-M245EN
MAIN HARNESS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
DÉTAIL A DÉTAIL B
X308 Key:
A Diode V1 Diode V2 A
FIL 154 FIL 224 Top section slotted ringed sheath
X312 WIRE 154 WIRE 224
FIL 450 FIL 155 Flexible sheath
WIRE 450 FIL 155 FIL 156 WIRE 155
WIRE 155 WIRE 156
Splice
X313
C C
Opt. ARD Ep.3
X314 V2
Opt. ARG Détail B
100 Ep.4 Opt.
A.S.
X302 X12 M
X306
100 X311 X11 X25

X139 X57 X56
Stop 100
X179
E Ep.9 E
X60 X14
X22-1 Ep.10
50 Ep.1
50
50
X13 V1
25 Détail A
X22-2
.27
Ep.5
50
Ep
Ep.2
.28
X39 X9 X65 X310A
50
Ep
.30
Ep.7
Ep
AV
G AR X26A X58 G
X29 X373
X303A
X276A X286
Ep.6
X303B
25 25 50
50
Ep.18 Ep.16
X58 X19A
CAN Ep.19
50
I 4
Ep.25 I
ARCHITECTURE X13
25
3
22 Ep.23
5
N° X269 X35 X36
LE
25
8
B 21 Ep.22
7 X10 CA X92
X57 Opt. AVG AVD
25
6 Ep.21
A.S. X133-1
°1 1
X264
LE N
AIN
X115
DR
CAB
5 2
25
EP21
11
E N°6 Ep.20 X265
CABL
DRA 28
14 EP22
IN
X106A X304A X133-2
EP18
K
IN
K
25
DRA X304B
BL
AIN X1 Ep.19
UE
3
CABLE N°2 IN
EP23
DRAIN CABLE N°3 EP19 DR
X270 EV
25
DRA DR
6 AIN EP16 Ep.13
DRA
IN X2
DRAIN
CA
5 DR W
HIT BL Ep.24 X266
AIN E EN X275 EV
4
1
°7 1
IN
DRA
WHITE 2 50 X267
CABLE N°4 BLU
E
4
X99 DR
X138
80
AIN
X304A 5 3 + X377
CAN H
M CAN L
DRAIN
X19A - M
X68
X277A X67
Bus Bus Bus Bus 50 X305

- + Bar Bar Bar Bar 25
D C B A Ep.17
HP AUTO ALIM AUTO 87 25A 20A 5A 20 Ep.12 X372

K3 Ep.11 Opt.
X204-2 X204-1 X94 X93 15 87a 31
30A 15A
K8
- 50 Ep.8
5A
K6 15A 15A
30
10A 15A 15A
X205-2
O K2
K10 3A 7,5A 10A
X10 O
7,5A 10A
87
+ K5 K7 7,5A 15A 7,5A 10A
1 2 3
85 87a 86 5A 15A 5A
X205-1
4 5 6
50 X99
15A 5A 5A 5A
X118A 7 8 9
30 0 #
*
Ep.15
F64
F63
F62
F61
20A 5A 15A 7,5A

K1 K4 K9 F31 F21 F11 F1
X63 X375
MODULE 5 MODULE 4 MODULE 3 MODULE 2 MODULE 1 Opt.
X274
X115
Diag
Q Q
X46
X32 X38 X134 X100 X31 X66
X21
X37 12 V
ARD ARG
X40
134 CDG 92
S S
80-03-M245EN (05/02/2015)
ENGINE HARNESS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
X260 X261
A A
X19B
X62 X310B
X400
C C
EP30
50
EP31
50
E E
G G
X300
I I
X289
X402
X290
K
BF1 K
EP58
X159 X401
EP59
EP60
80
M M
X4
X404
O O
X403
EP55 X3
Q Q
X175
X296
CABLE 10
X19B X171 EP61
X295 EP58
EP59
CABLE 11
X292 CABLE 8
X299 EP60 X299
S X300 S
CABLE 9
(05/02/2015) 80-03-M245EN
3D LOCATION MAIN HARNESS IN CAB
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
A A
X58
X13
C C
X22-1 X46
X30
2
X30
E 6 E
X22-2 X31
X3 1
X31 15
X3 4
X31 13
2
X30
8
X363
X383 X307 X277A
o MAIN HARNESS ON FRAME X322
G G
X115
X118A X118B
X106A
X1
X303A X305 X304A

I X2 X274 I
X303B X304B
X25 X12 X11
X14
X276A
K K
X26A X138
X276B
80
X67
X68
M M
X286
X139
X29 X179
O O
Q Q
S S
80-03-M245EN (05/02/2015)
MAIN HARNESS ON FRAME
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
X101
o Main Harness in cab X303B X301
X303A
A X100 X31 X102 A
X99
X91 X40 X159
C X200B C
X377
X37 Ground cable X200A
Frame/Cab
X134 X275
X32
X270
E E
To Battery (+)
To starter
X71A
To battery (-) To fuse box
X38
X66
G X63 G
X35
X21 X368
X133-1 X264
I I
X265
X373 X133-2
To battery cut-off X20-1 X269
X20-2 X266
To dashboard
module
X267
K To Frame Ground K
X36 X92
X9
80
X39
M M
X65
X19A
O O
X62
Engine Harness
X56
X310A
Q Q
X57
X260 X261
S S
(05/02/2015) 80-03-M245EN
HARNESS IN ENGINE HOUSING
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
Engine / main interconnection
A A
To starter
To fuse box
C C
X402
E X295 E
X299
X401
X300
G X3 G
I I
K X292 K
X296 X400
80
M M
X403
X290
O O
X289
X4
Q Q
X404
S S
80-03-M245EN (05/02/2015)
ELECTRICAL CONTROL AND ADJUSTMENT
pages
« BOOM ANGLE » ANGULAR SENSOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

–– OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– ON-TRUCK ADJUSTMENT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
LONGITUDINAL STABILITY INDICATOR (LLMI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
–– ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
–– TESTING THE LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE . . . . . . . . . 5
–– STRAIN GAGE AND ANGLE SENSOR CALIBRATION (DEALER PROCEDURE) . . . . . . . . . 6
–– STRAIN GAGE RECALIBRATION (CLIENT PROCEDURE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
–– “AGGRAVATING” HYDRAULIC MOVEMENTS CUT-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
–– LED ILLUMINATION ACCORDING TO CHANGES IN GAGE SIGNAL . . . . . . . . . . . . . . . . . . 8
DASHBOARD CALIBRATION MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
–– LIFT TRUCK SERIAL NUMBER DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
80
–– RESETTING THE PARTIAL HOUR METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
–– INCHING BRAKE PEDAL CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
–– TELESCOPING SPEED CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
–– ATTACHMENT FLOW RATE CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
–– MAINTENANCE HOUR METER RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
–– END OF CALIBRATION MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
(23/04/2018) 80-04-M245EN
2 ELECTRICAL CONTROL AND ADJUSTMENT
« BOOM ANGLE » ANGULAR SENSOR ADJUSTMENT
OPERATION
The «boom angle» sensor transmits information to the computer about the actual position of the boom
in relation to the frame . The potentiometer and all the links fitted between the boom and the frame have
the same operating angle as the boom in relation to the frame actually in operation . The boom angle
potentiometer is fitted with two tracks (two sensors whose range of adjustment is between 0,5 volts
and 4,5 volts reversed one in relation to the other) . If the potentiometer is faulty, incorrectly connected
or badly adjusted, this leads to a fault on the overload indicator and hydraulic movement malfunction .
If there is a fault on the potentiometer, calibration is not possible .
The operating range must be centred in the acceptance range of the potentiometer (0,5 volts to 4,5 volts) .
To consult the electrical characteristics of the angular sensor:
e Group 80 - Electrical characteristics and specifications – data sheets for electrical components.
ON-TRUCK ADJUSTMENT PROCEDURE
Key:
A
A - Brake nut and bolt
B B - Potentiometer pin
C - Link
80
b
C
The adjustment must be made without altering the length

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

2 - Select «Diagnostic» and then confirm .
3 - Select your machine, and then confirm .
Maxi
4 - Select the type of machine range and then confirm .
5 - Select the type of machine and then confirm .
6 - Switch on the ignition, start the machine and then confirm .
7 - If the truck is fitted with stabilisers, they must be placed on
the ground in order to increase the lifting angle .
8 - Place the boom in the top position .
80-04-M245EN (23/04/2018)
ELECTRICAL CONTROL AND ADJUSTMENT 3
9 - Select «Diagnostic global (tous les calculateurs)» and then confirm .

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

potentiometer sensor .
15 - Loosen the brake nut and bolt (Item A) on the lever .
16 - Using a screwdriver, turn the potentiometer pin (Item B) to obtain the adjustment values defined
below .
Note: The adjustment is done by slightly turning the pin in the lever housing .
Adjustment values to be obtained:
Mini Maxi
Voltage 0 .7 V 4 .3 V
80
17 - Then tighten the brake nut and bolt (Item A) .
18 - Place the boom in the down position (stabilizers retracted) .

Mini
19 - Check that the values are similar to those found in the top boom position and are within the
recommended adjustment range .
20 - Calibrate the boom angle sensor .
e Group 80 - Electrical control and adjustment - Strain gauge and angle sensor calibration.
(23/04/2018) 80-04-M245EN
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)
80-04-M245EN (23/04/2018)
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 .
(23/04/2018) 80-04-M245EN
STRAIN GAGE 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.

80-04-M245EN (23/04/2018)
STRAIN GAGE 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
2 - Two audible
80
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).
(23/04/2018) 80-04-M245EN
“AGGRAVATING” HYDRAULIC MOVEMENTS CUT-OFF

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

80
Increasing value
of the gauge signal:
100% (L8)
92% (L7)
84% (L6)
76% (L5)
68% (L4)
60% (L3)
52% (L2)
0% (L1)
80-04-M245EN (23/04/2018)
DASHBOARD CALIBRATION MENU
CALIBRATION MODE: ACTIVATION
Switch on lift truck ignition.

Simultaneously press the button and for 10 seconds.
CALIBRATION SELECTION
Press on the key to select the calibration menu 1,2…, End.

Press on the key to validate the calibration choice.
LIFT TRUCK SERIAL NUMBER DISPLAY
Select the menu . Press the key .
When ordering spare parts or requesting technical information, always specify the lift truck serial number:
Example of 7-figure number appearing o the digital screen scrolling from right to left:
Press the key , return to calibration selection menu .
80
RESETTING THE PARTIAL HOUR METER
The digital screen indicates whether or not the operator can reset the partial hour meter:
The operator cannot reset the partial hour meter.
The operator can reset the partial hour meter.
NOTE: By default the parameter is .

Press the key to change the value or .
(23/04/2018) 80-04-M245EN
INCHING BRAKE PEDAL CALIBRATION
Press the menu . Press the Inactive Transmission key .
: « Brake pedal end of travel » position calibration.
Start the truck, move forward approx. 2 meters braking until the pedal is in the bottom position.
Leave the engine running.
Press down the brake pedal for 2 seconds at end of travel position.
I f the value recorded at connector X139 is between 1150 and 1500 mV and the sand timer is displayed
.
Go to stage .
If the value recorded does not correspond to the authorized range tolerances, the sand timer is not
displayed and the stage remains active.
: « Brake pedal rest » position calibration.
Check that the brake pedal is in the rest position and the engine is running.
Hold the idle position for 2 seconds.
If the value recorded at connector X139 is between 2250 et 3800 mV and the sand timer is displayed
.
If the value recorded does not correspond to the authorized range tolerances, the sand timer is not
displayed and the stage remains active.
TELESCOPING SPEED CALIBRATION
Select the menu . Press the key (the telescope line remains active at 100% in both directions
80
of movement, telescope retraction and extension).
Telescope extension speed limitation:
Push the telescope extension button A towards the front to define the maximum telescope extension
speed (resolution 5%), e.g. .
If the operator pushes the button A backwards the screen will
show .
NOTE: Below 10%, the adjustments are not recorded, the old values
A remain memorized.
Press on the key to proceed to the next stage.
80-04-M245EN (23/04/2018)
Telescope retraction speed limitation:
Push the telescope retraction button A towards the rear to define

the maximum telescope retraction speed (resolution 5%), e.g.
.
If the operator pushes button A towards the front, the screen will
display .
A
remain memorized.
ATTACHMENT FLOW RATE CALIBRATION
bb Take into account the attachment characteristics.
Select the menu . Press the button (the attachment line remains active at 100% in both
directions of movement).
Attachment « + » direction flow rate limitation.
Push the attachment button B towards the rear to define the

maximum attachment flow rate in the « + » direction (resolution
5%), e.g .
If the operator pushes button B button towards the rear, the screen
will display .
80
B
remain memorized.
- Press on the key to proceed to the next stage.
Attachment « - » direction flow rate limitation.

Push the B attachment button backwards to define the maximum attachment flow in the « - » direction
(resolution 5%), example .
If the operator pushes button B button towards the front, the screen will display .
NOTE: B
elow 10%, the adjustments are not recorded, the old values remain memorized.
(23/04/2018) 80-04-M245EN
MAINTENANCE HOUR METER RESET
The digital screen indicates whether or not the operator can reset the maintenance hour meter:
The operator cannot reset the maintenance hour meter.
The operator can reset the maintenance hour meter.
NOTE: By default the parameter is .

Press the key to change the value or .
END OF CALIBRATION MENU
NOTE: If the lift truck ignition is switched off during one of the calibration phases, previous or default
calibration values will remain active.
80
80-04-M245EN (23/04/2018)
ELECTRICAL COMPONENTS REFIT
pages
STRAIN GAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
80
(28/01/2015) 80-07-M245EN
2 ELECTRICAL COMPONENTS REFIT
STRAIN GAGE
LOCATION
C
80
KEY:
A - Strain gage
B - Front axle
C - Rear axle
b PREPARATION AND SAFETY INSTRUCTIONS

 The wheels must be aligned and the rear axle free from any load (tipped truck).
 The contact surface must be perfectly clean.
 Do not apply any Loctite to the screws.
 Replace the gage if faulty.
 Store the gage and axle at the same temperature.
 Wear a mask and gloves when applying adhesive.
80-07-M245EN (28/01/2015)
ELECTRICAL COMPONENTS REFIT 3
CHARACTERISTICS OF THE SURFACE OF THE AXLE IN CONTACT WITH THE STRAIN GAGE
The area in contact with the strain gage (Item 1) has protective
painted film coating. Scrape this coating with a filling knife,
aiming to remove as much film as possible. Any remaining
1
adhesive traces can be removed with Soft Surface Cleaner
(aerosol degreaser).
Sand the area to be glued (Item 2) to roughen the surface and

achieve a good bond.
80
CHARACTERISTICS OF PRODUCTS USED
ACROBOND PU 284/30 (two-part polyurethane structural adhesive): Part no. 273504.
b
Handling time before start of polymerization and hardening phase is approx. 30 min.
If the product stays inside the mixer for more than 30 minutes, replace the mixer.
(28/01/2015) 80-07-M245EN
CHARACTERISTICS OF FASTENING SCREWS
The screws used are supplied with the strain gage.
 Hex. screw M10x30, thread pitch 1.5, Grade 10.9.
ASSEMBLY PRECAUTIONS AND TIGHTENING TORQUE
1 The two components (strain gage and axle) must be kept

at the same temperature for a minimum of four hours
before commencing assembly.
The strain gage must be fitted to an axle that is totally

free of stress.
For this:
1 - Lift the rear axle off the ground with a hydraulic jack
(Item 1) (Manitou Part no. 505507).
1
2 - Secure the machine by placing a two stands (Item 2)
2
(Manitou Part no. 554772), one on either side of the
frame.
3 - Remove the jack to completely unload the axle.
2
80
80-07-M245EN (28/01/2015)
ELECTRICAL COMPONENTS REFIT 5
STEP 1:
Using a gun, apply the two-part mixture to the axle by placing

4 daubs of adhesive as shown opposite (Item 1).
b Wear a mask and gloves when using this product.
STEP 2:
Place two M10x30 screws on the strain gage and then place
the assembly on the axle.
Take care not to place adhesive on the central part of the
gage.
Area free of glue
STEP 3:
80
The two M10 screws should be tightened progressively, as follows:
– Tighten screw No. 1 to a torque of 34 N.m
– Tighten screw No. 2 to a torque of 34 N.m
– Tighten screw No. 1 to the rated torque C = 67 N.m ± 5%
– Tighten screw No. 2 to the rated torque C = 67 N.m ± 5%
(28/01/2015) 80-07-M245EN
STEP 4:
Next, install the plastic casing (Item 1) and secure it with

the two M4x10 pan-head screws.
1
b Do not apply grease to the heads of the M10x30
screws, as it is incompatible with the adhesive.
80
80-07-M245EN (28/01/2015)
ELECTRICAL TROUBLESHOOTING
pages
READING OF ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

– DASHBOARD ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– PAD ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ERROR CODES / CONTROL UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
– DASHBOARD ECU (A1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– TRANSMISSION ECU (A2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
– HYDRAULIC ECU (A3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
80
(22/01/2015) 80-08-M245EN
2 ELECTRICAL TROUBLESHOOTING
READING OF ERROR CODES
DASHBOARD ERROR CODES
The appearance of the maintenance key on the hour meter screen together with the
sounding of an audible beep, indicate that an fault has been detected by one of the lift truck's Electronic
Control Units (ECU).
– Press the button to display the information on the upper screen, as well as the error
code .
– If there are several error codes, press the button to scroll through all the error codes.
– Press the button again to return to the hour meter screen, the maintenance key will remain
displayed as long the as the required repairs have not been carried out.
NOTE: A faulty fuse can generate several error codes. When « error codes » and « maintenance interval »
are displayed together, the maintenance reminder time will appear at the end of the list.
PAD ERROR CODES

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

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

2 Incoherent signal value
3 Signal voltage too high: + battery short circuit
4 Signal voltage too low: ground short circuit
5 Circuit impedance too high: open circuit
6 Circuit impudence too low: Short circuit or short circuit
7 Faulty actuator (mechanical problem)
8 Signal frequency out of normal value range
9 Information not available on the CAN bus
10 Abnormal signal value variation for correct operation
11 Nature of problem not known
12 Faulty sensor or actuator
13 Out of range signal value defined by the calibration
14 Not used
19 Transmitted signal value on CAN bus invalid
80-08-M245EN (22/01/2015)
ELECTRICAL TROUBLESHOOTING 3
ERROR CODES / CONTROL UNITS
A1
Dashboard ECU (A1)

Error Code Problem description Machine response Repair actions Comments
RPM value - > « - - - » and
520400 Network link fault Check CAN network wiring
LED 16 lit
520401 Fuel gage fault Incorrect fuel gage display Check gage wiring
Incorrect temperature
520402 Engine temperature sensor fault Check sensor wiring
display
Incorrect Hour meter value
520404 Man-Frame interface fault Replace dashboard module
and LED 16 lit
Incorrect fuel gage and
520405 Man-Frame interface fault temperature display LED Replace dashboard module
16 lit
Incorrect Hour meter value
520406 Man-Frame interface fault Replace dashboard module
and LED 16 lit
520407 Man-Frame interface fault LED 16 lit Replace dashboard module
520410 Man-Frame interface fault LED 16 lit Replace dashboard
520411 Man-Frame interface fault LED 16 lit Replace dashboard
Hydrostatic transmission network RPM value - > « - - - » and
520412 Check CAN network wiring
link fault LED 16 lit
Electronic controller network
80
520413 LED 16 lit Check CAN network wiring
connection fault
(22/01/2015) 80-08-M245EN
A2
Transmission ECU (A2)

Hydraulic transmission electronic

520201 ECU internal fault Change battery, check ECU supply voltage
control unit voltage fault
Hydraulic transmission electronic Change ECU. See Manitou specification for

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

low or high speed (servo No requirement. The replacement of
Hydrostatic motor regulator control
520215 piston), it is dangerous for the component does not require special
fault
the operator to leave the calibration
ECU in normal mode.
Hydrostatic motor plate Transmission in degraded

520216 Check wiring and electrovalve.
electrovalve control fault mode (reduced speed)
The stop lights are no longer
lit by the ECU. The braking Change ECU. See Manitou specification for
520217 Stop light control fault
system pressure switch lights inching pedal configuration and calibration
the stop lights
Can be driven, limited For MLT 625-75
520218 Hydraulic motor speed sensor fault Change sensor
performance H only
As the ‘BPD’ also manages
the low or high speed
No requirement. The replacement of
Hydrostatic motor operating control pressure (servo
520224 the component does not require special
electrovalve control fault piston), it is dangerous for
calibration
the operator to leave the
ECU in normal mode.

80

Hydraulic transmission electronic Change ECU. See Manitou specification for 520227 ECU
control unit fault inching pedal configuration and calibration internal fault

520273 Forward/reverse selector error Cannot be driven the component does not require special
calibration
Can be driven, limited Change inching sensor. Inching pedal
520274 Inching sensor error
performance calibration by MMI
Hydrostatic pump reverse operation
520275 Reverse gear unavailable the component does not require special
control fault
calibration
Hydrostatic pump forward
520276 Forward gear unavailable the component does not require special
operation control fault
calibration
Automotive driving mode no
520277 Hydraulic pump speed sensor fault the component does not require special
longer possible
calibration
Temperature outside operating
520281 Machine shutdown
range
Transmission in degraded
520282 Pedal high switch Check switch and harness (MLT only)
mode (reduced speed)
80-08-M245EN (22/01/2015)
A3
Hydraulic ECU (A3)

2662 Telescope control setting fault Loss of telescope movement Check JSM roller wiring
2663 Attachment control setpoint fault Loss of attachment movement Check JSM roller wiring
520300 Seat sensor fault Truck cannot move Check seat wiring and switches
Proportional telescope control
520307 Loss of telescoping movement Check telescope wiring and PWM valve
fault
Telescope extension movements
520310 Telescope control ON/OFF fault Check telescope wiring and ON/OFF valve
only
Proportional attachment
520315 Loss of attachment movement Check attachment wiring and PWM valve
control fault
Attachment control ON/OFF Attachment movement possible in
520318 Check attachment wiring and ON/OFF valve
fault one direction only
Handling electronic controller
520336 Total loss of hydraulic movement Change ECU
fault
Handling electronic controller
520337 Total loss of hydraulic movement Restart machine
fault
Electronic handling controller
520338 Total loss of hydraulic movement
temperature fault
Only one set of outputs can be
For MLT 625-75
520341 Attachment selector fault configured, access to -100%, 100% Check wiring and selector switch
H only
outputs lost
Proportional ventilation For MLT 625-75
520350 Maximum or no cooling Check valve wiring
adjustment fault H only
Maximum cooling or permanent For MLT 625-75

520351 Fan ON/OFF control fault Check valve wiring
fan reversal H only
80
Manual override button
520352 Manual override unobtainable Check manual override wiring and switch
indicator lamp
520362 Loss of movements Check ECU wiring
10 V output fault
Manual override indicator lamp off
Attachment forced operation Check indicator lamp and indicator lamp
520363 when in manual override operation
indicator fault wiring
mode
Switch off the after ignition key supply
Attachment hydraulic control Loss of telescope head electrovalve (APC) and restore it to check whether fault
520364
button fault control reoccurs
Check wiring of JSM switch BP1
Attachment easy hydraulic Attachment line decompression (APC) and restore it to check whether fault
520365
connection button fault not possible reoccurs
Check Easy Connect System button wiring
Head telescope electrovalve Loss of telescope head electrovalve
520366 Check valve wiring
fault control
Check fault 520384

Repeat stability system test Fault detected
520370 Telescope retracted sensor fault Machine performance unchanged
Instruction Manual during the test
Check sensor wiring and operation
(22/01/2015) 80-08-M245EN
Hydraulic ECU (A3)

520371 Certain valves not controlled Check ECU power supply connections
supply fault
A - Fault indicator lamp lit + LEDs
(APC) and restore it to check whether fault
A1, A7, A4 and A8 flashing.
520376 Stability indicator fault reoccurs
B - Fault indicator lamp + LEDs A7
If fault A: check the CAN network
and A8 lit
If fault B: replace the stability indicator
Movements no longer disabled
Aggravating hydraulic (APC) and switch back on to check whether
520382 when the OVERRIDE button is
movement cut-off disable fault fault reoccurs
pressed
Check button wiring and operation
No movements or machine Check wiring between ECU and safety,
520383 Computer ground output fault
response unchanged lowering control and lifting control valves
No disabling of movement control
520384 Telescope retracted sensor fault and cut-of when telescope Check sensor wiring and operation
retracted
520386 Boom angle sensor fault Reduced movement speed Check angle senor attachment and wiring
No more movements. All stability Check fault 520362

520387 Strain gage fault
LEDs lit Check strain gage wiring
No movements. Faulty stability
520388 Network communication fault Check CAN network
indicators
Tilting movement permanently
520391 Tilting cut-off valve fault Check valve wiring
cut-off or permanently on
Check fault 520386
Repeat stability system test
Fault detected
520392 Angle calibration fault Machine performance unchanged Instruction Manual
during the test
Redo overall system calibration
80 - Control and adjustment
Check fault 520387
(APC) and restore it to check whether fault
Fault detected
520393 Gage calibration fault Machine performance unchanged reoccurs
during the test
Repeat stability system test
Instruction Manual
Perform stability system reset
Movements permanently cut-off or
520394 Safety valve fault Check valve wiring
permanently on
80
Check fault 520394

520395 Safety valve cut-off fault Machine performance unchanged
Check safety valve operation
Loss of lowering movement or no

520396 Lowering control valve fault Check valve wiring
lowering control
Check fault 520396

520397 Control fault Machine performance unchanged
Check lowering control valve operation
520398 Raising control valve fault Loss of boom raising movement Check valve wiring
80-08-M245EN (22/01/2015)
A13
Engine ECU
Hexadecimal Decimal
COMPONENT PROBLEMS
SPN FMI SPN FMI
00064 01 100 1 Oil pressure switch Oil pressure error
0006E 00 110 0 Coolant temperature sensor Engine overheating, temperature higher than ≥ 120°C (248°F)
0006E 03 110 3 Coolant temperature sensor Voltage higher than normal, or short circuited to power supply source
0006E 04 110 4 Coolant temperature sensor Voltage lower than normal, or short circuited to power supply source
0009E 03 158 3 Battery Voltage higher than 18V, or short circuited to power supply source
000BE 00 190 0 Engine speed Engine speed higher than normal
00DB5 04 3509 4 Power supply connector (44 pin) Power supply voltage of connector pin 22 lower than normal
7FDFB 02 523771 2 Starter electrovalve Circuit open or short circuited to power supply source
7FDFC 02 523772 2 Engine speed sensor Circuit open or short circuited to power supply source
80
(22/01/2015) 80-08-M245EN
80
80-08-M245EN (22/01/2015)
ELECTRICAL SPECIFIC TOOLING
pages
DIAGNOSTIC TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
– VERSION 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– VERSION 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
BREAKOUT BOXES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
ELECTROVALVE ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
80
(06/02/2015) 80-09-M245EN
2 ELECTRICAL SPECIFIC TOOLING
DIAGNOSTIC TOOLS
VERSION 1
DIAGNOSTIC CASE
80
1 - PAD (hardened PC + case set) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .No longer supplied

2 - Styli (set of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745368
3 - VCI (Vehicle Communication Interface/PAD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745439
4 - Manitou OBD Diag. Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745245
5 - VCI portable cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745244
6 - Manitou RC2/RC4 Diag. Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745246
7 - LI-ION Battery 7,4 V/9,6 AH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745367
8 - CE standard mains lead L: 3 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745247
9 - Diag Supply Unit 3G 60 W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745251
10 - Cigarette lighter power supply cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745240
11 - Black battery clip cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745242
12 - Red battery clip cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745241
13 - Power supply cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745243
80-09-M245EN (06/02/2015)
ELECTRICAL SPECIFIC TOOLING 3
ADAPTATION KIT FOR ENGINES
1
3
Box fitness for engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .894942
Consisting of:
1 - Communication box EDL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 894937
2 - Electric Cable OBD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 894940
3 - Electric Cable USB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 894938
CONNECTION TO TRUCK
CASE No. 1: MACHINE DIAGNOSTIC
PAD
VCI
CÂBLE DIAG OBD
REF. 745245
Note: The cable Ref. 745245 can diagnose the entire machine except the engine. 80
CASE No. 2: ENGINE DIAGNOSTIC
PAD
REF. 894937
CÂBLE USB CÂBLE DIAG OBD
EDL
REF. 894938 REF. 894940
USB
Note: The case Ref. 894 942 is used to diagnose the engine.
(06/02/2015) 80-09-M245EN
ATTACHMENTS
Docking station (battery charging)........................................................................ 745236

80
Workshop area (trolley + station set) .................................................................... 745235
80-09-M245EN (06/02/2015)
VERSION 2
DIAGNOSTIC CASE
80
Diagnostic case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .947349
Diagnostic case (Specific for Russia) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .947350
Consisting of:
1 - Tablet (with accessories and cables). . . . . . . . . . . . .895845 / 947351 (Specific for Russia)
2 - Digitizer Touch Pen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947208
3 - Tether . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947355
4 - VCI (Vehicle Communication Interface / PAD) (with cable USB et OBD) . . . . . . . 895986
5 - OBD diag cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947201
6 - USB/Ethernet cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947202
7 - Battery (6 cellules : 8h) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947206
8 - AC Adaptor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947353
9 - Case (not shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947345
Sold separately :
10 - Docking station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947354
11 - Legacy diag cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947204
12 - Battery (9 cellules : 17h) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947207
(06/02/2015) 80-09-M245EN
CONNECTION TO TRUCK
CASE 1
PAD
VCI
CÂBLE DIAG OBD
RÉF. 947201
Note: The cable Ref. 947201 can diagnose the entire machine.
80
80-09-M245EN (06/02/2015)
BREAKOUT BOXES
Breakout box kit ...................................................................................................... 785503
Consisting of:
1 - 1 breakout box (DT connectors) ..........................................................................................785504

2 - 1 breakout box (DTM connectors) ......................................................................................785505
ELECTROVALVE ADAPTER
80
1 - Solenoid adapter.......................................................................................................................662196
(06/02/2015) 80-09-M245EN
80
80-09-M245EN (06/02/2015)

MT 625 H EASY 49K ST3A S1 REPAIR MANUAL

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MT 625 H EASY 49K ST3A S1 REPAIR MANUAL

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647519EN (23/04/2018)

MT 625 H EASY 49K ST3A S1

DATE OF ISSUE OBSERVATION

20 / 01 / 2015 - 1st ISSUE

25 / 10 / 2017 - Partial UPDATE : GR80-04

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

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

HOW TO USE THIS REPAIR MANUAL ?

3 4 General instructions and safety

RULES FOR MAINTENANCE

GENERAL INSTRUCTIONS AND SAFETY NOTICE

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

Before carrying out any operation on an electrically powered

Before carrying out any welding operations, think about

A machine operating in a contaminated environment should be

547982 : See the repair manual N° 547982.

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

- GENERAL INSTRUCTIONS AND SAFETY

- GENERAL CHARACTERISTICS AND

- GENERAL CONTROL AND ADJUSTMENT

In order to reduce accident risks, make sure to:

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

When you see this symbol:

Before any intervention:

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

RULES FOR MAINTENANCE

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

Before carrying out any operation on an electrically powered

2 b Press the battery switch at least 30 seconds after disconnecting

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

b Before carrying out any welding operations, think of

A machine operating in a contaminated environment should be

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

When carrying out maintenance operations near a mobile object,

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

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

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

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

Never control any leaks using a hand.

MAX Never adjust a component to over the maximum capacity indicated

CHARACTERISTICS AND FLUIDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Designation Value Designation Type Quantity

Front / rear wheel reduction

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

LOCATION OF NAME AND IDENTIFICATION PLATE

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

STANDARD TIGHTENING TORQUES

- ENGINE COMPONENTS LOCATION

- ENGINE CONTROL AND ADJUSTMENT

- SPECIFIC ENGINE TOOLING

- ENGINE CHARACTERISTICS AND

- SPECIFIC ENGINE TOOLING

 Anti-clockwise (viewed from flywheel)

2 - Alternator/fan belt 11 - Fuel supply pump

A - PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

A - PREPARATION AND SAFETY INSTRUCTIONS

Operate the battery cut-off.

1 B - FAN GRILL REMOVAL

C - ALTERNATOR BELT REMOVAL / REFIT

4  Carry out operation « B - FAN GRILL REMOVAL »

Undo the 2 screws (Item 1).

D - ALTERNATOR REMOVAL / REFIT

Mark the position of the electrical wires and disconnect the