General

00
- General instructions and safety
notice

- General control and adjustment

 00
GENERAL INSTRUCTIONS AND SAFETY NOTICE

pages

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

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 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 (12/03/2013)
 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.

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 4 GENERAL INSTRUCTIONS AND SAFETY NOTICE
00

RULES FOR MAINTENANCE

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

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

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

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

1
Before carrying out any operation on an electrically powered
2 component, activate the battery cut-off.
If the telehandler does not have a battery isolating switch, disconnect
the battery terminals then gather them.

ECU bb  efore carrying out any welding operations, think of

B
disconnecting computers.

A machine operating in a contaminated environment should be

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

00 (12/03/2013)
 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.

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 6 GENERAL INSTRUCTIONS AND SAFETY NOTICE
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 (12/03/2013)
 00
GENERAL CONTROL AND ADJUSTMENT

pages

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

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 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).

NF E 25-030-1 Screw / Nut connection :

Tightening torque in N•m (±20%)
Ø x “coarse” pitch Grade 8.8 Grade 10.9 Ø x “fine” pitch Grade 8.8 Grade 10.9
M3 x 0,5 1 1,5 - - -
M4 x 0,7 2,4 3,5 - - -
M5 x 0,8 4,8 7,1 - - -
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
M36 x 4 2068 3037 - - -

bb For hexagon screws with flanges:   

Apply an increased torque of +10%.
(Standard NF E 25-030-1)

bb 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%

00 (12/03/2013) (XX/XX/XXXX)
 Engine

10
- Engine components location

- Engine control and adjustment

- Engine removal

- Engine refit

- Engine characteristics and 647370en

M
R
specifications
(ENGINE OM 904 LA
- Engine control and adjustment 120-150-175-CV EURO 3 )
 10
POSITION OF THE ENGINE COMPONENTS

page

MERCEDES ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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 2 POSITION OF THE ENGINE COMPONENTS

MERCEDES ENGINE
10

Engine cooling
water pump

Oil filter

Alternator

Fuel pump
and filter
Belt

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 POSITION OF THE ENGINE COMPONENTS 3

10
Oil filter
Turbocompressor

Alternator

Starter
motor

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 4 POSITION OF THE ENGINE COMPONENTS
10

10-03-M205EN (05/06/2012)
 10
REMOVING THE ENGINE

page

ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
REMOVING THE ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– A - REMOVING THE ALTERNATOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– B - REMOVING THE ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
–– C - REMOVING THE STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
–– D - REMOVING THE OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
–– E - REMOVING THE FUEL OIL FILTER AND PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
–– F - REMOVING THE ENGINE COOLING WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
–– G - REMOVING THE TURBOCOMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
–– DISASSEMBLY ORDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
–– REMOVING THE RADIATOR MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
–– REMOVING THE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
–– REMOVING THE I.C. ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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 2 REMOVING THE ENGINE

ENGINE COMPONENTS
10

5
8

6 4
1

3
7

Legend:

1 - Alternator
2 - Starter motor
3 - Alternator belt
4 - Fuel filter
5 - Oil filter
6 - Engine cooling water pump
7 - Fuel pump
8 - Turbocompressor

GENERAL INFORMATION

Mark all the hydraulic pipes and electrical connections with a marker pen, before disassembling, to
ensure correct positioning in the reassembly phase.

bb Plug all the hydraulic pipes and orifices to prevent impurities from contaminating the hydraulic circuit.

PREPARATION AND SAFETY INSTRUCTIONS

Deactivate the ignition key and disconnect the negative pole from the battery; wait for the engine
components to cool down.

Specific tools:
–– Crane for lifting (5000 kg. minimum).
–– Hydraulic jack.
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 REMOVING THE ENGINE 3

REMOVING THE ENGINE COMPONENTS

10
A - REMOVING THE ALTERNATOR BELT

Remove the guard (Ref. 1) after slackening the two screws (Ref. 2).
1

Insert an unlocking lever on the screw (Ref. 3), tilt the belt
tensioner roller upwards (Ref. 4) and remove the belt (Ref. 5).

5
4

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 4 REMOVING THE ENGINE
10

B - REMOVING THE ALTERNATOR

Carry out operation A.

1 2
1
1
Slacken the six screws (Ref. 1) and remove the lower guard (Ref. 2).

1
1 1

Slacken the two nuts (Ref. 3) which block the brackets (Ref.
4) which secure the air suction duct (Ref. 5), thereby allowing
4
easier access to the alternator support.

Slacken the four screws (Ref. 6) which block the alternator

support (Ref. 7).

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 REMOVING THE ENGINE 5

Unscrew the two screws (Ref. 8), slacken the screw (Ref. 9) and
turn the air manifold support (Ref. 10) upwards to make it easier
9 to remove the alternator.
8

10
8
10

Slacken the two screws (Ref. 11).

11

Disconnect the electric wires (Ref. 12 and 13) for connection

of the alternator.

12
13

The alternator (Ref. 14) can now be removed.

14

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 6 REMOVING THE ENGINE
10

C - REMOVING THE STARTER MOTOR

Slacken the six screws (Ref. 1) and remove the lower guard (Ref. 2).
1 2
1
1

1
1 1

Disconnect the electric wires (Ref. 3 and 4) for connection of

the starter motor.
3

Slacken the two nuts (Ref. 5) which block the brackets (Ref. 6)
6
which secure the air suction duct (Ref. 7), thereby allowing easier
access to the starter motor.

10-06-M205EN (25/06/2012)
 REMOVING THE ENGINE 7

Unscrew the screws and washers (Ref. 8 and 9) and remove the
remote control switch (Ref. 10)
9 8 from the starter motor (Ref. 11).

10
10

11

Slacken the three screws (Ref. 12) and remove the starter motor
12 (Ref. 11) from the engine base.

11

Remove the starter motor (Ref. 11), removing the slot present
11
on the lower side of the engine base.

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 8 REMOVING THE ENGINE
10

D - REMOVING THE OIL FILTER

4 3 Carry out operation B.

3 Slacken the screw (Ref. 1) and remove the belt tensioner (Ref. 2).
Slacken the screws (Ref. 3) and remove the bracket (Ref. 4).
1

Disconnect the oil inlet pipe (Ref. 5) .

Fix the pipe to the engine using a clamp so that it does not slip in
the bottom part of the engine housing and oil does not leak out.

Slacken the screw (Ref. 6) to free the alternator (Ref. 7) and rotate
it downwards.
8 Slacken the screws (Ref. 8) which block the oil filter (Ref. 9) on
9
the engine supports and remove the filter from the engine.

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 REMOVING THE ENGINE 9

10
E - REMOVING THE FUEL OIL FILTER AND PUMP

Carry out operation A.

Disconnect the incoming and outgoing fuel pipes (Ref. 1) from

the filter, taking care to keep these facing upwards to avoid
draining the tank.

3 Disconnect the connector (Ref. 2) from the fuel filter (Ref. 3).

3 Slacken the screws (Ref. 4) and remove the fuel filter (Ref. 3)
from the engine.

Slacken the screws (Ref. 5) and remove the fuel pump

(Ref. 6) from the engine.
4

5 6

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 10 REMOVING THE ENGINE
10

F - REMOVING THE ENGINE COOLING WATER PUMP

1
1 2
1
bb Carry out the operations on the cooling system only if
the coolant temperature is below 30℃.

Carry out operation A.

1
1 1 Slacken the six screws (Ref. 1) and remove the lower guard (Ref. 2).

Slacken the two clamps (Ref. 3) on the lower hose (Ref. 4).

Place containers large enough to hold the quantity of liquid to

be collected under the engine compartment.
Disconnect the lower hose (Ref. 4) from the pump, slowly
discharge overpressure from the system, let the liquid drain
out of the cooling system, and empty it completely.

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 REMOVING THE ENGINE 11

Slacken the two clamps (Ref. 5) on the upper hose (Ref. 6) and
disconnect it from the pump.
5

10
6
5

Slacken the four screws (Ref. 7) and remove the pulley (Ref. 8).

Slacken the screw (Ref. 9) and remove the belt tensioner (Ref. 10).

10

Slacken the screws (Ref. 11 and 12) and remove the bracket
(Ref. 13).
11
12

13

11

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 12 REMOVING THE ENGINE

Slacken the clamp (Ref. 14) and disconnect the drainage tube
(Ref. 15) from the thermostatic valve.
10

15
14

Disconnect the temperature sensor (Ref. 17) from the thermostatic

valve (Ref. 16).

16

17

Slacken the screws (Ref. 18 and 19) which block the thermostatic
valve (Ref. 16).

18
19

16

16 Slacken the seven screws (Ref. 20), remove the pump (Ref. 21)
and the thermostatic valve (Ref. 16) from the engine.

21

20
20

20 20

20

20 20

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 REMOVING THE ENGINE 13

10
G - REMOVING THE TURBOCOMPRESSOR

Slacken the six screws (Ref. 1) and remove the lower guard (Ref. 2).
1 2
1
1

1
1 1

Slacken the two nuts (Ref. 3) and remove the brackets (Ref. 4)
which secure the air suction duct (Ref. 5).
4

Slacken the screws (Ref. 6 and 7) and remove the bracket (Ref. 8).

6
7

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 14 REMOVING THE ENGINE

Slacken the clamp (Ref. 9) and remove the hose (Ref. 10).

10
10

Slacken the two clamps (Ref. 11) and remove the suction hose
(Ref. 12) from the air radiator.
12
11

11

Slacken the clamp (Ref. 13) and remove the suction hose (Ref.
14) from the turbocompressor (Ref. 15).
15

13

14

Unscrew the fitting (Ref. 16) and remove the lubrication delivery
tube (Ref. 17) from the turbocompressor.
17

16

10-06-M205EN (25/06/2012)
 REMOVING THE ENGINE 15

Unscrew the fitting (Ref. 18) and remove the lubrication delivery
tube (Ref. 19).

19

10
18

Slacken the four screws (Ref. 20) and remove the cover plate
(Ref. 21) from the exhaust manifold.

21

20

Slacken the screws (Ref. 22) which block the turbocompressor.

22

Slacken the two clamps (Ref. 23) and remove the suction hose
(Ref. 24) from the engine.

23

23

24

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 16 REMOVING THE ENGINE

Slacken the eight screws (Ref. 25) and remove the exhaust
manifold (Ref. 26).

25
10

25

25

26

Slacken the nuts (Ref. 27) and remove the turbocompressor

15
(Ref. 15) from the exhaust manifold (Ref. 26).

27
27

26

27
26
27

15

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 REMOVING THE ENGINE 17

REMOVING THE ENGINE

DISASSEMBLY ORDER

10
Step 1 REMOVING THE RADIATOR MOTOR

Step 2 REMOVING THE RADIATOR

Step 3 REMOVING THE I .C . ENGINE

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 18 REMOVING THE ENGINE

REMOVING THE RADIATOR MOTOR

Slacken the screw (Ref. 1) to release the gas spring (Ref. 2) from
1
the engine hood (Ref. 3).
10

2
3

Slacken the screws (Ref. 4) and remove the hood (Ref. 3) from
the vehicle.

4 4

Slacken the clamp (Ref. 5) and remove the hose (Ref. 6) from
the radiator.

5
6

8
Slacken the clamps (Ref. 7) and remove the bent rubber pipe
7 (Ref. 8) from the radiator.

10-06-M205EN (25/06/2012)
 REMOVING THE ENGINE 19

Slacken the clamps (Ref. 9) and remove the bent rubber pipe
(Ref. 10) from the radiator.

10
9

10

Slacken the screws (Ref. 11) and remove the guard (Ref. 12)
from the engine chassis.
11

12

Disconnect the pipes (Ref. 13) from the radiator hydraulic motor.

13

13

13

Place a hydraulic jack (Ref. 14) under the engine chassis.

14

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 20 REMOVING THE ENGINE

Slacken the screws (Ref. 15) which fix the engine chassis.

15
10

With the help of a hydraulic jack, remove the engine chassis

(Ref. 16)
from the vehicle.

16

Slacken the clamp (Ref. 17) and remove the bottom hose (Ref. 18)
from the radiator.
17
Slacken the bottom screws (Ref. 19) of the radiator.

19

18

Slacken the clamp (Ref. 20) and remove the upper hose (Ref. 21)
from the radiator.
20

21

10-06-M205EN (25/06/2012)
 REMOVING THE ENGINE 21

Slacken the screws (Ref. 22) and release the radiator frame (Ref.
23) from the engine chassis (Ref. 24).
22

10
23

24

Slacken the screws (Ref. 25) and remove the grille (Ref. 26).

25

26

Slacken the nuts (Ref. 27) used for fitting the fan (Ref. 28).

28

27

Remove the fan hub (Ref. 29).

29

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 22 REMOVING THE ENGINE

Slacken the fixing screws (Ref. 16) and remove the hydraulic
motor
(Ref. 30) from the grille (Ref. 31).
10

26

30

31

REMOVING THE RADIATOR

Carry out the "Disassembling the radiator motor" operation.

Unscrew the screws, nuts and washers (Ref. 1, 2, 3, 4, 5, 6 and 7) and remove the water radiator (Ref. 8).
Unscrew the screws and washers (Ref. 9, 10 and 11) and remove the air radiator (Ref. 12).

12

11
1
10

9
2
3

6
4 5

10-06-M205EN (25/06/2012)
 REMOVING THE ENGINE 23

REMOVING THE I.C. ENGINE

Slacken the screw (Ref. 1) to release the gas spring (Ref. 2) from
1
the engine hood (Ref. 3).

10
2
3

Slacken the screws (Ref. 4) and remove the hood (Ref. 3) from
the vehicle.

4 4

Slacken the screws (Ref. 5) and remove the front guard (Ref. 6).

5
5

Slacken the six screws (Ref. 7) and remove the lower guard (Ref. 8).

7 8
7
7

7
7 7

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 24 REMOVING THE ENGINE

Place containers large enough to hold the quantity of liquid to

be collected under the engine compartment.
Slacken the clamps (Ref. 9), remove the pipes (Ref. 10) and drain
the coolant from the tank.
10

10

Remove cap (Ref. 1) to make it easier to drain the fluid from

the tank.
11

Slacken the clamp (Ref. 12) and remove the hose (Ref. 13) from
the radiator.

12

13

Slacken the clamps (Ref. 14) and remove the bent rubber pipe
15
(Ref. 15) from the radiator.

14

10-06-M205EN (25/06/2012)
 REMOVING THE ENGINE 25

Slacken the clamps (Ref. 16) and remove the bent rubber pipe
(Ref. 17) from the radiator.

10
16

17

Slacken the clamp (Ref. 18) to free the pipe from the engine
(Ref. 19).

18

19

Remove the upper pipe (Ref. 20) from the water pump.

20

21
Slacken the clamps (Ref. 21) and disconnect the lower pipe
(Ref. 22) from the water pump.

22

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 26 REMOVING THE ENGINE

Disconnect the pipes (Ref. 23) for the fuel filter.

10

23

23

Slacken the screws (Ref. 24) and remove the guard (Ref. 25)
from the engine.

24

25

Disconnect the plug (Ref. 26) from the engine control unit (Ref.
27 27).

26

Disconnect all the electrical connections (Ref. 28) from the

alternator (Ref. 29).
28

28 29

10-06-M205EN (25/06/2012)
 REMOVING THE ENGINE 27

Disconnect all the electrical connections (Ref. 30) from the

starter motor (Ref. 31).

10
31
30

32
Disconnect the connectors (Ref. 32) for the fuel prefilter.
32

Slacken the screws (Ref. 33) and remove the fuel prefilter (Ref.
34) from the vehicle.

33

34

35 Disconnect the connector (Ref. 35) connecting the engine line

to the vehicle line.

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 28 REMOVING THE ENGINE

Slacken the clamp (Ref. 36) and remove the pipe (Ref. 37) from
the turbocompressor.

36
10

37

Slacken the screws (Ref. 38) and remove the side guard (Ref.
39) from the radiator.
38

39

Disconnect the pipes (Ref. 40) from the radiator hydraulic motor.

40

40

40

Place a hydraulic jack (Ref. 41) under the engine chassis.

41

10-06-M205EN (25/06/2012)
 REMOVING THE ENGINE 29

Slacken the screws (Ref. 42) which block the engine chassis.

42

10
With the help of a hydraulic jack, remove the engine chassis
(Ref. 43) from the vehicle.

43

Slacken the screws (Ref. 44) and remove the guard (Ref. 45)
from the turbocompressor.
44

45

Disconnect the upper pipes (Ref. 46) of the hydraulic pump on

the engine.

46

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 30 REMOVING THE ENGINE

Disconnect the lower pipes (Ref. 47) of the hydraulic pump on

the engine.
10

47

Secure the engine to an overhead crane.

Slacken the screws (Ref. 48) of the silent blocks of the engine
supports.
48

Slacken the screws (Ref. 49) which fix the engine on the hydraulic
pump supports.

49

Remove the engine from the vehicle with the help of the
overhead crane and place it on a pallet.

50

10-06-M205EN (25/06/2012)
 10
REINSERTING THE ENGINE

page

ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
REINSERTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– REINSERTION ORDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– REINSERTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
–– REINSERTING THE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
–– REINSERTING THE RADIATOR MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REINSERTING THE ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
–– A - REINSERTING THE TURBOCOMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
–– B - REINSERTING THE ENGINE COOLING WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
–– C - REINSERTING THE FUEL OIL FILTER AND PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
–– D - REINSERTING THE OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
–– E - REINSERTING THE STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
–– F - REINSERTING THE ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
–– G - REINSERTING THE ALTERNATOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

(25/06/2012) 10-07-M205EN
 2 REINSERTING THE ENGINE

ENGINE COMPONENTS
10

6 4
1

3
7

Legend:

1 - Alternator
2 - Starter motor
3 - Alternator belt
4 - Fuel filter
5 - Oil filter
6 - Engine cooling water pump
7 - Fuel pump
8 - Turbocompressor

GENERAL INFORMATION

Reposition all the pipes and connections correctly according to the markings made with a marker pen
during the disassembly.

PREPARATION AND SAFETY INSTRUCTIONS

Deactivate the ignition key and disconnect the negative pole from the battery.

Specific tools:
–– Crane for lifting (5000 kg. minimum).
–– Hydraulic jack.

10-07-M205EN (25/06/2012)
 REINSERTING THE ENGINE 3

REINSERTING THE ENGINE

REINSERTION ORDER

10
Step 1 REINSERTING THE I .C . ENGINE

Step 2 REINSERTING THE RADIATOR

Step 3 REINSERTING THE RADIATOR MOTOR

(25/06/2012) 10-07-M205EN
 4 REINSERTING THE ENGINE

REINSERTING THE ENGINE

Secure the engine (Ref. 1) to an overhead crane and reposition

it on the vehicle.
10

Tighten the screws (Ref. 2) to fix the engine on the hydraulic

pump supports.

Fit the silent blocks by means of the screws (Ref. 3) on the

engine supports.

Reconnect the lower pipe (Ref. 4) on the hydraulic pump

positioned on the engine.

10-07-M205EN (25/06/2012)
 REINSERTING THE ENGINE 5

Reconnect the upper pipes (Ref. 5) on the hydraulic pump.

10
5

Refit the guard (Ref. 6) on the turbocompressor by means of

the screws (Ref. 7).

With the help of a hydraulic jack, reposition the engine chassis

(Ref. 8) on the vehicle.

Fix the engine chassis to the vehicle by means of the screws

(Ref. 9).
9

(25/06/2012) 10-07-M205EN
 6 REINSERTING THE ENGINE

Remove the hydraulic jack from under the engine chassis.

Reconnect the pipes (Ref. 10) of the radiator hydraulic motor.

10
10

10

10

Refit the side guard (Ref. 11) on the radiator by tightening the
screws (Ref. 12).
12

11

Insert the hose (Ref. 13) on the turbocompressor and tighten

the clamp (Ref. 14).

14

13

15 Reconnect the connector (Ref. 15) connecting the engine line

to the vehicle line.

10-07-M205EN (25/06/2012)
 REINSERTING THE ENGINE 7

Refit the fuel prefilter (Ref. 16) on the vehicle by means of the
screws (Ref. 17).

17

10
16

18 Reconnect the connectors (Ref. 18) on the fuel prefilter.

18

Reconnect all the electrical connections (Ref. 19) on the starter

motor (Ref. 20).

20
19

Reconnect all the electrical connections (Ref. 21) on the alternator

(Ref. 22).

21

21 22

(25/06/2012) 10-07-M205EN
 8 REINSERTING THE ENGINE

Connect the plug (Ref. 23) on the engine control unit (Ref. 24).

24
10

23

Refit the guard (Ref. 25) on the engine by means of the screws
(Ref. 26).

26

25

Reconnect the pipes (Ref. 27) on the fuel filter.

27

27

29
Reconnect the lower hose (Ref. 28) on the water pump and
block by tightening the clamps (Ref. 29).

28

10-07-M205EN (25/06/2012)
 REINSERTING THE ENGINE 9

Refit the upper hose (Ref. 30) on the water pump and tighten
the clamp.

10
30

Block the hose (Ref. 31) on the engine and tighten the clamp
(Ref. 32).

32

31

Refit the bent rubber hose pipe (Ref. 33) on the radiator and
tighten the clamps (Ref. 34).

34

33

35
Refit the bent rubber hose pipe (Ref. 35) on the radiator and
tighten the clamps (Ref. 36).
36

(25/06/2012) 10-07-M205EN
 10 REINSERTING THE ENGINE

Refit the pipe (Ref. 37) on the radiator and tighten the clamp
(Ref. 38).
10

38

37

Fit the pipes (Ref. 39) and tighten the clamps (Ref. 40).

Reconnect the wires of the battery, remove the containers from

41 under the vehicle, start up the engine and run it for about one
minute.

Fill the cooling system tank (Ref. 41) with the liquid concerned;
the liquid level must be between the two notches indicating
the minimum and maximum levels (approx. 18 litres).
40

39

Refit the lower guard (Ref. 43) by means of the six screws (Ref. 42).

42 43
42
42

42
42 42

Refit the front guard (Ref. 44) by means of the screws (ref. 45).

44

45
45

10-07-M205EN (25/06/2012)
 REINSERTING THE ENGINE 11

Refit the hood (Ref. 46) on the vehicle fixing it by means of the
screws (Ref. 47).

47 47

10
46

Block the gas spring (Ref. 48) on the engine hood (Ref. 49) by
means of the screw (Ref. 50).

50

48
49

(25/06/2012) 10-07-M205EN
 12 REINSERTING THE ENGINE

REINSERTING THE RADIATOR

Refit the water radiator (Ref. 1) on the frame using the screws, nuts and washers (Ref. 2, 3, 4, 5, 6, 7 and 8).
Refit the air radiator (Ref. 9) on the frame by means of the screws and washers (Ref. 10, 11 and 12).
10

12
2
11

10
3
4

7
5 6

REINSERTING THE RADIATOR MOTOR

Insert the hydraulic motor (Ref. 1) on the grille (Ref. 2) and fix
by means of screws Ref. 3).
2

10-07-M205EN (25/06/2012)
 REINSERTING THE ENGINE 13

Insert the fan hub (Ref. 4).

10
4

Tighten the nuts (Ref. 5) used for fitting the fan (Ref. 6) on the
radiator.

Refit the grille (Ref. 2) by means of the screws (Ref. 8)

on the radiator (Ref. 7).
7
8

Tighten the screws (Ref. 8) to block the radiator frame (Ref. 9)

on the engine chassis (Ref. 10).
8

10

(25/06/2012) 10-07-M205EN
 14 REINSERTING THE ENGINE

Refit the upper hose (Ref. 11) on the radiator and tighten the
clamp (Ref. 12).
10

12

11

Fit the lower screws (Ref. 13) to fix the radiator frame to the
engine chassis.
Refit the lower hose (Ref. 14) on the radiator and tighten the
clamp (Ref. 15).
15

13

14

With the help of a hydraulic jack, reposition the engine chassis

(Ref. 16)
on the vehicle.

16

Fix the engine chassis to the vehicle by means of the screws

(Ref. 17).
17

10-07-M205EN (25/06/2012)
 REINSERTING THE ENGINE 15

Remove the hydraulic jack from under the engine chassis.

Reconnect the pipes (Ref. 18) on the radiator hydraulic motor.

18

10
18

18

Refit the side guard (Ref. 19) on the radiator by tightening the
screws (Ref. 20).
20

19

Refit the bent rubber hose pipe (Ref. 21) on the radiator and
tighten the clamps (Ref. 22).

22

21

Refit the bent rubber hose pipe (Ref. 23) on the radiator and
23
tighten the clamps (Ref. 24).

24

(25/06/2012) 10-07-M205EN
 16 REINSERTING THE ENGINE

Refit the pipe (Ref. 25) on the radiator and tighten the clamp
(Ref. 26).
10

26

25

Refit the hood (Ref. 27) on the vehicle fixing it by means of the
screws (Ref. 28).

28 28

27

Block the gas spring (Ref. 29) on the engine hood (Ref. 30) by
means of the screw (Ref. 31).

31

29
30

10-07-M205EN (25/06/2012)
 REINSERTING THE ENGINE 17

REINSERTING THE ENGINE COMPONENTS

10
A - REINSERTING THE TURBOCOMPRESSOR

Refit the turbocompressor (Ref. 1) on the exhaust manifold (Ref.

2) by screwing the nuts (Ref. 3); use a 30 Nm tightening torque.
3
2
3

3
3

Refit the exhaust manifold (Ref. 2) on the engine base using the
eight screws (Ref. 4); use a 30 Nm tightening torque.

(25/06/2012) 10-07-M205EN
 18 REINSERTING THE ENGINE

Reconnect the suction hose (Ref. 5) to the engine and tighten

the two clamps (Ref. 6).
10

Screw the turbocompressor (Ref. 1) on the engine by means of

the screws (Ref. 7).

Refit the cover plate (Ref. 8) on the exhaust mnifold by means

of the four screws (Ref. 9).
8

Refit the lubrication suction pipe (Ref. 10) by screwing in the

fitting (Ref. 11) on the water filter.
10

11

10-07-M205EN (25/06/2012)
 REINSERTING THE ENGINE 19

Refit the lubrication delivery pipe (Ref. 12) on the turbocompressor

by screwing in the fitting (Ref. 13).

12

10
13

Refit the suction hose (Ref. 14) on the turbocompressor (Ref. 1)

and tighten the clamp (Ref. 15).
1

15

14

Refit the suction hose (Ref. 16) on the air radiator and tighten
the two clamps (Ref. 17).
16
17

17

Refit the hose (Ref. 18) and tighten the clamp (Ref. 19).

18

19

(25/06/2012) 10-07-M205EN
 20 REINSERTING THE ENGINE

Refit the bracket (Ref. 20) on the air unit by means of the screws
(Ref. 21 and 22).

21
22
10

20

21

Refit the air suction pipe (Ref. 23) locking it by means of the
brackets (Ref. 24) and the two nuts (Ref. 25).
24

23

25

Refit the lower guard (Ref. 26) by means of the six screws (Ref. 27).

27 26
27
27

27
27 27

10-07-M205EN (25/06/2012)
 REINSERTING THE ENGINE 21

10
B - REINSERTING THE ENGINE COOLING WATER PUMP
2

Replace the gaskets of the water pump with new ones, refit
the pump (Ref. 1) and the thermostatic valve (Rif. 2) on the
1 engine by means of the seven screws (Ref. 3), on which Loctite
3 threadlock must be applied; use a 25 Nm tightening torque.

3
3

3
3

3 3

Block the thermostatic valve (Ref. 29) on the engine by means

of the screws
(Ref. 4 and 5), on which Loctite threadlock must be applied; use
a 25Nm tightening torque.

4
5

Reconnect the temperature sensor (Ref. 6) on the thermostatic

valve (Ref. 2).

(25/06/2012) 10-07-M205EN
 22 REINSERTING THE ENGINE

Refit the exhaust pipe (Ref. 7) on the thermostatic valve and

tighten the clamp (Ref. 8).
10

7
8

Refit the bracket (Ref. 9) on the air unit by means of the screws
(Ref. 10 and 11).
10
11

10

Refit the pulley (Ref. 12) by means of the screws (Ref. 13) on
which Loctite threadlock must be applied.

12

13

Refit the belt tightener (Ref. 14) by means of screws (Ref. 15)
on which Loctite threadlock must be applied; use a 50 Nm
tightening torque.

15

14

10-07-M205EN (25/06/2012)
 REINSERTING THE ENGINE 23

Refit the belt (Ref. 16) on all the pulleys with the exception of
the belt tightener roller.
Raise the belt-tightener roller (Ref. 14) by means of a lever, apply
the belt, then restore the belt-tightener roller to its position.
Remove the release lever and check to ensure the belt is housed

10
correctly on the pulleys.
16

14

Tighten the screws (Ref. 13) using a tightening torque of 25 Nm.

13
13

13 13

Refit the guard (Ref. 17) by means of the two screws (Ref. 18).

17

18

18

Refit the lower guard (Ref. 19) by means of the six screws (Ref. 20).

20 19
20
20

20
20 20

(25/06/2012) 10-07-M205EN
 24 REINSERTING THE ENGINE

Reconnect the upper hose (Ref. 21) on the pump and screw the
two clamps (Ref. 22) back on.
22
10

21
22

Reconnect the lower hose (Ref. 23) on the pump and screw the
two clamps (Ref. 24) back on.
23

24

24

Fill the cooling system tank (Ref. 25) with the liquid concerned;
the liquid level must be between the two notches indicating
the minimum and maximum levels (approx. 18 litres).
25

Remove the containers from under the engine compatment.

10-07-M205EN (25/06/2012)
 REINSERTING THE ENGINE 25

10
3 C - REINSERTING THE FUEL OIL FILTER AND PUMP

Reposition the fuel pump (Ref. 1) on the engine by means of

the screws (Ref. 2).

Reposition the fuel filter (Ref. 3) on the engine by means of the

4
screws (Ref. 4).
2

2
1

3 Reconnect the connector (Ref. 5) on the filter (Ref. 3).

3 Reconnect the fuel inlet and outlet pipes (Ref. 6) to the filter
(Ref. 3).

(25/06/2012) 10-07-M205EN
 26 REINSERTING THE ENGINE
10

D - REINSERTING THE OIL FILTER

2
Reposition the oil filter (Ref. 1) on the engine supports by means
1 of the screws (Ref. 2).
Restore the alternator (Ref. 3) to the correct position and tighten
the screws (Ref. 4) to lock it on the filter.
3

Release the oil inlet pipe (Ref. 5) from the clamp by means of
which it was fixed to the engine in the disassembly phase and
refit it on the filter (Ref. 1).
1

Reposition the tensioner (Ref. 6) using the screw (Ref. 7).

Reposition the bracket (Ref. 8) using the screws (Ref. 9).
8 9

10-07-M205EN (25/06/2012)
 REINSERTING THE ENGINE 27

10
E - REINSERTING THE STARTER MOTOR

4 3 Remove the remote control switch (Ref. 2) from the new starter
motor (Ref. 1) unscrewing the screws and washer (Ref. 3 and
4), to make it easier for the starter motor to pass through the
2 slot in the base.

Insert the starter motor (Ref. 1) through the slot present on the
lower side of the engine base
1

Fit the starter motor (Ref. 1) by means of the three screws (Ref.
5
5) on the engine base.

(25/06/2012) 10-07-M205EN
 28 REINSERTING THE ENGINE

Refit the remote control switch (Ref. 2) on the starter motor

(Ref. 1)
4 3 by means of the screws and washers (Ref. 3 and 4).
10

Refit the air suction pipe (Ref. 6) locking the two brackets (Ref.
7
7) by means of the nuts (Ref. 8).

Reconnect the electric wires (Ref. 9 and 10) to the starter motor
9
(Ref. 1).

10
1

Refit the lower guard (Ref. 11) by means of the six screws (Ref. 12).

12 11
12
12

12
12 12

10-07-M205EN (25/06/2012)
 REINSERTING THE ENGINE 29

10
F - REINSERTING THE ALTERNATOR

Reposition the alternator (Ref. 1) on the engine.

Reconnect the electric wires (Ref. 2 and 3) to the alternator (Ref. 1).

2
3

Fix the support (Ref. 4) to the engine by means of the four

screws (Ref. 5).

(25/06/2012) 10-07-M205EN
 30 REINSERTING THE ENGINE

Tighten the two screws (Ref. 11) to fix the alternator.

10

Reposition the air hose support (Ref. 7), fit the two screws (Ref.
8), tighten the screw (Ref. 9).
9
8

8
7

Refit the air suction pipe (Ref. 10) locking the two brackets (Ref.
11) by means of the nuts (Ref. 12).
11

10

12

Refit the lower guard (Ref. 13) by means of the six screws (Ref. 14).

14 13
14
14

14
14 14

10-07-M205EN (25/06/2012)
 REINSERTING THE ENGINE 31

10
G - REINSERTING THE ALTERNATOR BELT

Refit the belt (Ref. 1) on all the pulleys with the exception of
the belt tightener roller.
Lift the belt tensioner roller (Ref. 2) by means of a lever positioned
on the screw (Ref. 3), apply the belt, then bring the belt tensioner
1 roller backwards.
2
Remove the release lever and check to ensure the belt is housed
correctly on the pulleys.
3

Refit the guard (Ref. 4) by means of the two screws (Ref. 5).

(25/06/2012) 10-07-M205EN
 32 REINSERTING THE ENGINE
10

10-07-M205EN (25/06/2012)
 Transmission

- Transmission characteristics and

specifications

20
- Transmission schematic diagrams

- Transmission components location

- Transmission control and

adjustment

- Transmission removal

- Transmission refit

- Transmission troubleshooting

- Specific transmission tooling

647379
M
R

(DANA GEArbox 357a10)

647424EN
M
R

- Transmission characteristics and

specifications (Hydrostatic pump
sauer h1p078)
- Transmission control and
adjustment
647424EN
M
R

- Transmission sections and diagrams

(Hydrostatic motor
sauer h1b110)
 FEATURES AND TECHNICAL SPECIFICATIONS OF

20
THE TRANSMISSION

page

FEED PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
PUMP/ENGINE CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
PRESSURE LIMITER VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
FLUSHING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
NFPE AUTOMOTIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
NFPE ELECTRICAL PROPORTIONAL CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
PUMP REGULATOR VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FILTER (TOTAL FILTRATION IN PRESSURE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SWITCHING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
HYDRAULIC PILOT CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
AUTOMOTIVE CURVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SELECTOR (FORWARD/NEUTRAL/REVERSE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INCH SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
MODE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ENGINE CONTROL CURVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
UNIVERSAL SHAFT RPM LIMITER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
CONNECTIONS DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

(11/02/2013) 20-01-M205EN
 FEATURES AND TECHNICAL SPECIFICATIONS
2 OF THE TRANSMISSION

SAUER HYDROSTATIC TRANSMISSION

FEED PUMP

Generally integrated in the body of the main pump, these prevent the cavitation of the system by
recirculating the fluid lost by leakage to the circuit, also providing the pressure necessary for the system
for variation of the displacement of the main pump.
20

PUMP/ENGINE CONTROLS

These are organs which guide the displacement variation of both components.

PRESSURE LIMITER VALVES

Limit the maximum pressure on both branches of the transmission.

FLUSHING VALVE

The purpose of this valve is to optimise the operating conditions, making it easier to remove the
contamination from the closed circuit, helping thermal stability, expelling the air from the circuit rapidly.

20-01-M205EN (11/02/2013)
 FEATURES AND TECHNICAL SPECIFICATIONS
OF THE TRANSMISSION 3

HYDRAULIC CIRCUIT

20

(11/02/2013) 20-01-M205EN
 FEATURES AND TECHNICAL SPECIFICATIONS
4 OF THE TRANSMISSION

NFPE AUTOMOTIVE SYSTEM

FNR switch

Inch pedal
20

Drive/Creep/
Rocker pedal

Mode switch A
+ −

Batt.
12/24 VDC
Mode switch B

NFPE Valve

Pressure reducing Pressure reducing

valve forward valve reverse

PPU motor

Engine

PPU pump/engine

Motor displacement Vgmax

Brake pressure defeat

Brake light

Parking brake

Reverse buzzer

20-01-M205EN (11/02/2013)
 FEATURES AND TECHNICAL SPECIFICATIONS
OF THE TRANSMISSION 5

H1 SERIES PUMP

Electric displacement control Servo piston Auxiliary mounting pad “B”

Valve plate

Swashplate feedback pin

20
Piston

Slipper

Shaf t seal

Shaf t

Swashplate Cylinder block Charge pump

(11/02/2013) 20-01-M205EN
 FEATURES AND TECHNICAL SPECIFICATIONS
6 OF THE TRANSMISSION

NFPE ELECTRICAL PROPORTIONAL CONTROL

NFPE Proportional Actuation

100 %
NFPE control

r
0 ba
bar
20

= 30
=0
∆p

∆p
Signal Current (mA(DC avg ))

0
r

Displacement
0 ba

bar
= 30

=0
∆p

∆p

100 %

NFPE / C1 and C2 Location

NFPE Schematic
M14

C2 C1

F00B F00A T P
C2
C1

20-01-M205EN (11/02/2013)
 FEATURES AND TECHNICAL SPECIFICATIONS
OF THE TRANSMISSION 7

PUMP REGULATOR VALVES

High Pressure Relief Valves (HPRV) Pressure Reducing Solenoid Valves & MOR

20
Pressure limiter valves (PL)
Charge Pressure Relief Valve (CPRV)

(11/02/2013) 20-01-M205EN
 FEATURES AND TECHNICAL SPECIFICATIONS
8 OF THE TRANSMISSION

FILTER (TOTAL FILTRATION IN PRESSURE)

Technical Data, Pressures

Maximum Charge Pressure 30 bar [435 psi]
Filter Bypass Sensor ∆p 3.7 - 5.1 bar Connector
Switch Closure [54 - 74 psi] Deutsch DTM04-2P

∆p 5.6 ± 0.9 bar

Bypass Valve
[80 ± 13 psi]
M6
Before Filter (upstream)
20

0.5625-18UNF-2B
Technical Data, Electric [9/16 -18UNF-2B]
Max. Voltage 48 V
Max. Power 0.6 W
Switch open 510 Ω
Schematic
Switch closed 122 Ω M6 1 2
Resistor Tolerance 1% R1
-20 °C ÷ +100 °C

R2
Temperature Range
[-4 °F ÷ +212 °C]
IP Rating (IEC 60 529) +
DIN 40 050, part 9 IP 69K
with mating connector

Integral Filter Head with Filter Bypass Sensors

Filter
element
in out

Filter
bypass sensor

Bypass spool

20-01-M205EN (11/02/2013)
 FEATURES AND TECHNICAL SPECIFICATIONS
OF THE TRANSMISSION 9

H1 SERIES ENGINE

erential
servo piston
Loop flushing
relief valve
Valve segment

20
Bearing plate
Tapered
roller bearing

Ramp spring

Loop flushing
shuttle spool

Speed ring (optional )

Minimum displacement limiter

Electric proportional co ntrol

(11/02/2013) 20-01-M205EN
 FEATURES AND TECHNICAL SPECIFICATIONS
10 OF THE TRANSMISSION

HYDRAULIC CIRCUIT

L2 MA N

Ports:
A,B = Main pressure lines
20

L1 , L2 = Drain lines
MA , MB = Gage port system pressure for A and B
M4 , M5 = Gage porto servo pressure
N = Speed sensor
max min C1

L1

B
M4 M5 MB

SWITCHING VALVE

L2

System System A
loop A loop B

LOOP FLUSHING
SHUTTLE SPOOL

B
relief valve

L2

LOOP FLUSHING RELIEF

VALVE

Loop flushing relief valve

Loop Flushing Relief Valve Size

05 10 15
Low System Pressure minus Case Pressure

40 [580]

30 [435]
bar [psi]

20 [290]

10 [145]

0 10 20 30 40 50 60 70
[1.3] [5.3] [8.0] [10.6] [13.3] [15.9] [18.6]
Loop Flushing Flow l/min [US gal/min]
20-01-M205EN (11/02/2013)
 FEATURES AND TECHNICAL SPECIFICATIONS
OF THE TRANSMISSION 11

HYDRAULIC PILOT CONNECTION

7.5 microns

M14

M6
ΔP
3,7 - 5,1 bar

C1 C2
MA L1

EV EV ΔP
(S22) (S21) 5,6 - 0,9 bar A
M3

1,3 mm 1,3 mm

20
M5
350 bar
MA

M4 6,5 bar

A 110 cc

10 L/min
450 bar
480 bar
min.
disp.

RW
FW
0,6mm
C1
L4
16 bar
6,5 bar C5

M
34 bar
cw 0,6mm
L2
17 cc

78 cc B
n 480 bar H1B Motor

MB M4 M5
MH
450 bar
L3 B

MB
L2 L1 S
PH

3 bar

FA RAD

250 microns

The diagram above shows the working of the hydrostatic transmission control system consisting of the
hydrostatic pump (HP) with the electronic control device (ECD) and hydrostatic motor (HM).

The direction of rotation of the hydrostatic motor (HM) is controlled by two solenoid valves (S21 and S22).
Solenoid valve S22 controls the clockwise direction of rotation (CW) of the hydrostatic motor (HM),
thereby the forward movement of the vehicle.
Solenoid valve S21 controls the anticlockwise direction of rotation (CCW) of the hydrostatic motor (HM),
thereby the reversing movement of the vehicle.

The electronic device (ECD) is fitted on the hydrostatic pump (HP).

M14

C1 C2

EV EV
(S22) (S21)

EDC

FW RW
(11/02/2013) 20-01-M205EN
 FEATURES AND TECHNICAL SPECIFICATIONS
12 OF THE TRANSMISSION

PLUS+1 TM MC024-021 AUTOMOTIVE SYSTEM

The microprocessor controls the pump as well as the motor by means of the electric pressure reducers
positioned on the controls.

AUTOMOTIVE CURVE

The two different curves are studied in consultation with the customer, taking into account the features
20

of the diesel engine torque and the power necessary for the auxiliary services.

SELECTOR (FORWARD/NEUTRAL/REVERSE)

The direction of movement can be selected by means of a three-position electric selector.

The deceleration and acceleration times are set taking its position into account.

INCH SENSOR

The inch-brake pedal connected to the potentiometric sensor reduces the current to the proportional
valves of the pump until it is completely reset, if necessary.
The function makes it possible for the operator to reduce the vehicle speed during special movements
where a high number of diesel engine rpm must be used and make it possible for the services to work
efficiently.

20-01-M205EN (11/02/2013)
 FEATURES AND TECHNICAL SPECIFICATIONS
OF THE TRANSMISSION 13

MODE SWITCH

Two independent control curves (transfer/operation).

ENGINE CONTROL CURVE

The control curve of the engine reducer is generated by a calibration which depends on the diesel
engine rpm.

20
UNIVERSAL SHAFT RPM LIMITER

To prevent overspeed of the universal shaft the function reduces the current to the solenoid valve of
the proportional pressure control (NFPE).

(11/02/2013) 20-01-M205EN
 FEATURES AND TECHNICAL SPECIFICATIONS
14 OF THE TRANSMISSION

CONNECTIONS DIAGRAM

DEUTSCH connector
CC1 DTM/12 pin

Battery (-) 1 CC1p01

Battery (+) 2 CC1p02
Sensor (+) 3 CC1p03 CC1p03
Motor RPM/Direction
Sensor (-) 4 CC1p04 CC1p04
Motor RPM Input (Frequency) 5 CC1p05
Forward Input (Digital) 6
Reverse Input (Digital) 7
Sensor (+) 8 CC1p08
Sensor (-) 9 CC1p09
Drive Pedal Input (Analog-Nom) 10
Drive Pedal Input (Analog-Red) 11
Neutral Input (Digital) 12
20

Terminals
Sensor (+)
DEUTSCH connector
CAN DTM/3 pin
Terminals
Sensor (-)
CAN High 1 CANp01
CAN Low 2 CANp02 CAN Bus
CAN Shield 3 CANp03
Terminals
Batt. (+)
DEUTSCH connector
PPC DTM/6 pin 3
CC3p01

Sensor A (+) 1 Reverse

Analog Input A 2 Motion
Sensor A (-) 3
Sensor B (-) 4 CC3p02
Analog Input B 5
Sensor B (+) 6

PSC
DEUTSCH connector CC3
DTM/6 pin
DEUTSCH connector
DT/2 pin
PWM C1 (+) 1 PSCp01
PWM C2 (+) 2 PSCp06 C1
Digital Output A1 (+) 3 PSCp03 1
PSCp02 Electronic Displacement
Digital Output A2 (-) 4 PSCp04 2
Control Pump
PWM C2 (-) 5 PSCp05 C2
PWM C1 (-) 6
PPUp03
Terminals
PPUp02 Pump RPM
DEUTSCH connector Batt. (-)
PPU DTM/3 pin
PPUp01

Sensor (+) 1 PPUp01

Pump RPM Input (Frequency) 2
Sensor (-) 3 PPUp03
CC2p03 Electronic Displacement
PROP
Control Motor
CC2p08
DEUTSCH connector
CC2 DTM/12 pin
BPD

Inch Input (Analog-Red) 1 CC2p01

Mode Switch B Input (Digital-Nom) 2 1
Motor PROP/PCOR Driver 3 S1 2
Motor Direction Input (Analog) 4
F1
Sensor (+) 5 CC2p05 Rv
CC2p05
Sensor (-) 6 CC2p06
CC2p07 Inch Pedal + Batt. -
Inch Input (Analog-Nom) 7
Motor BPD Driver 8
CC2p06
Rv 12/24V DC
Digital Output B2 (-) 9
Digital Output B1 (+) 10
Mode Switch A Input (Digital) 11
CC2p10
Mode Switch B Input (Digital-Red) 12

CC2p09

Parking
Brake

20-01-M205EN (11/02/2013)
 TRANSMISSION LAYOUTS

20
page

HYDROSTATIC TRANSMISSION LAYOUT - FORWARD MOVEMENT . . . . . . . . . . . . . . . . . . .3

HYDROSTATIC TRANSMISSION LAYOUT - REVERSING MOVEMENT . . . . . . . . . . . . . . . . . .4

(07/01/2013) 20-02-M205EN
 2 TRANSMISSION LAYOUTS
20

20-02-M2053EN (07/01/2013)
 TRANSMISSION LAYOUTS 3
HYDROSTATIC TRANSMISSION LAYOUT - FORWARD MOVEMENT

Legend:
High pressure
Low pressure
Loading pressure
Drainage pressure
Boost pressure
Suction pressure

20
Return to discharge
Cooling
§ 70 See «70 - hydraulics» Chapter
EV(S21) Forward movement solenoid valve
EV(S22) Reversing solenoid valve
MH Variable displacement motor
PH Hydrostatic pump
R. Oil tank
RAD Radiator
FORWARD MOVEMENT

7.5 microns

M14
M6
ΔP
3,7 - 5,1 bar

C1 C2
MA L1
EV EV ΔP
5,6 - 0,9 bar A
(S22) (S21) M3
M5 1,3 mm 1,3 mm
MA 350 bar
M4 6,5 bar 110 cc
A
10 L/min

480 bar min.

disp.
flow out A

FW
450 bar
0,6mm C1

RW
L4
16 bar 6,5 bar C5

§ 70 34 bar
cw 0,6mm
L2
17 cc
78 cc B
n 480 bar
450 bar MB M4 M5
L3 B MH
H1B Motor
MB
L2 L1 S
PH
FRONT REAR
AXLE AXLE

FA
250 microns
3 bar
RAD
R.

(07/01/2013) 20-02-M205EN
 4 TRANSMISSION LAYOUTS
HYDROSTATIC TRANSMISSION LAYOUT - REVERSING MOVEMENT

Legend:
High pressure
Low pressure
Loading pressure
Drainage pressure
Boost pressure
Suction pressure
20

Return to discharge
Cooling
§ 70 See «70 - hydraulics» Chapter
EV(S21) Forward movement solenoid valve
EV(S22) Reversing solenoid valve
MH Variable displacement motor
PH Hydrostatic pump
R. Oil tank
RAD Radiator

REVERSING MOVEMENT
7.5 microns

M14
M6
ΔP
3,7 - 5,1 bar

C1 C2
MA L1
EV EV ΔP
A
(S22) (S21) 5,6 - 0,9 bar
M3
M5 1,3 mm 1,3 mm
MA 350 bar
M4 6,5 bar 110 cc
A
10 L/min

480 bar min.

disp.
flow out A
FW
450 bar
0,6mm C1

RW
L4
16 bar 6,5 bar C5

§ 70 34 bar
cw 0,6mm
L2
17 cc
78 cc B
n 480 bar
450 bar MB M4 M5
L3 B MH
H1B Motor
MB
L2 L1 S
PH
FRONT REAR
AXLE AXLE

FA
250 microns
3 bar
RAD
R.

20-02-M205EN (07/01/2013)
 POSITION OF THE TRANSMISSION COMPONENTS

20
page

HYDROSTATIC TRANSMISSION CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

HYDROSTATIC TRANSMISSION COOLING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

(25/06/2012) 20-03-M205EN
 POSITION OF THE TRANSMISSION
2 COMPONENTS
20

20-03-M205EN (25/06/2012)
 POSITION OF THE TRANSMISSION
COMPONENTS 3
HYDROSTATIC TRANSMISSION CIRCUIT

Hydrostatic
pump

20
Hydrostatic
motor

Gearbox

Rear axle

Shaft

Services
pump

Front axle

(25/06/2012) 20-03-M205EN
 POSITION OF THE TRANSMISSION
4 COMPONENTS
HYDROSTATIC TRANSMISSION COOLING CIRCUIT
20

Air radiator

Water radiator

Oil radiator

20-03-M205EN (25/06/2012)
 CHECKING AND ADJUSTING THE TRANSMISSION

20
page

CHECKING THE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

–– PRESSURE CONTROL POINTS ON PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– MOTOR PRESSURE CONTROL POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

(07/12/2012) 20-04-M205EN
 CHECKING AND ADJUSTING THE
2 TRANSMISSION

SAUER TRANSMISSION

CHECKING THE PRESSURE

PRESSURE CONTROL POINTS ON PUMP

20

Connections System A gage port “MA”

Port ISO 11926-1- 9/16-18
Ø28 max clearance dia
for fitting
Pressure control
points
Electrical
connections

Mounting flange surface

Flange 127 - 4 per ISO 3019-1
Paint free

Servo gage port “M4” Case pressure port

Port ISO 11926-1- 7/16-20 Port ISO 11926-1- 7/8-14
Ø21 max clearance dia Ø42 max clearance dia for fitting
for fitting

Spline data
Number of teeth : 23
System port “B” Pitch fractio : 16/32
Ø25,4 - 450bar Pressure angle : 30°
split flange boss Pitch-Ø : Ø36,513
per ISO 6162 Typ of fit : fillet root, side fit
M12 x 1,75 Per : ANSI B92.1-1996 Class 5
20 min. full thread depth
recommenden screw-in depth
1.5 x thread dia

Charge inlet port “S”

Port ISO 11926-1-1 5/16-12
Ø63 max clearance dia
for fitting

Paint free

Other side screw head space Nameplate

paint free

System port “A”

Ø25,4 - 450bar
split flange boss Coupling must not
per ISO 6162 protrude beyond
M12 x 1,75 this surface
20 min. full thread depth
recommenden screw-in depth
1.5 x thread dia

Case drain port “L4”

Port ISO 11926-1-1 1/16-12
Ø48 max clearance dia for fitting

Control connector “CAN” Control connector “CC2”

Deutsch DTM04-3P Deutsch DTM04-12P- B-
Paint free
Port Description For using the connector
Paint free

Port Description Sizes

the plug may be removed
View Z
Control connector “CC1”
A System Port “A ” Ø 25.4 Deutsch DTM04-12P- A-
Paint free
B System Port “B ” Ø 25.4
L2 Case Drain Port 1 1/16 -12
L4 Case Drain Port 1 1/16 -12
MA System “A” Gage Port 9/16 -18

MB System “B” Gage Port 9/16 -18

M3 Charge Gage Port, after Filtering 9/16 -18

M4 Servo Gage Port 7/16 -20

M5 Servo Gage Port 7/16 -20

M6 Charge Gage Port, before Filtering 7/16 -20

S Charge Inlet Port 1 5/16 -12

20-04-M205EN (07/12/2012)
 CHECKING AND ADJUSTING THE
TRANSMISSION 3

Connections
Pressure control
Control connector “CC3”
points
Deutsch DT06-2S
Paint free Electrical
Plug removing can cause
connections
contamination issues

Case pressure port

Port ISO 11926-1- 7/8-14
Ø42 max clearance dia
for fitting Servo gage port “M5”
Port ISO 11926-1- 7/16-20
Ø21 max clearance dia for fitting

Charge pressure construction port

20
Port ISO 11926-1- 5/16-24

Charge gage port “M3”

Port ISO 11926-1- 9/16-18
after filtering

Approximate center
Thread : M12x1,75-6H THD of gravity
Depth : 19.75 min. Case drain port “L2”
Recommended screw-in depth Port ISO 11926-1-1 1/16-12
1.5 x thread dia 4x Ø48 max clearance dia
for fitting
Note : Bolt length greater than
19,75 mm could result in
a leak or damage to thr unit
Approximate center
of gravity

Control connector “CC2”

Deutsch DTM04-12P-B
Paint free Control manual override“C2”
Depressing the plunger mechanically
moves the control spool. Actuation
allows full stroke pump response as
per coil and rotation dependent
control logic.

System B gage port “MB”

Port ISO 11926-1- 9/16-18
Ø28 max clearance dia for fitting

Port Description
Port Description Sizes
A System Port “A ” Ø 25.4
Control connector “CC3”
B System Port “B ” Ø 25.4 Deutsch DT06-2S
Paint free
L2 Case Drain Port 1 1/16 -12 For using the connector
the plug may be removed
L4 Case Drain Port 1 1/16 -12
MA System “A” Gage Port 9/16 -18
Control connector “CAN”
MB System “B” Gage Port 9/16 -18 Deutsch DTM04-3P
Paint free
Charge pressure construction port
M3 Charge Gage Port, after Filtering 9/16 -18 For using the connector
the plug may be removed Control manual override“C1”
Port ISO 11926-1- 5/16-24
Depressing the plunger mechanically
M4 Servo Gage Port 7/16 -20
Control connector “CC1” moves the control spool. Actuation
Deutsch DTM04-12P-A allows full stroke pump response as
M5 Servo Gage Port 7/16 -20
Paint free per coil and rotation dependent
control logic.
M6 Charge Gage Port, before Filtering 7/16 -20

S Charge Inlet Port 1 5/16 -12

(07/12/2012) 20-04-M205EN
 CHECKING AND ADJUSTING THE
4 TRANSMISSION
20

Filter bypass sensor connector

Deutsch DTM04-2P
Paint free

Charge gage port “M6”

Port ISO 11926-1- 9/16-18
Ø28 max clearance dia for
fitting before filter

Connections Port Description

Pressure Port Description Sizes

control points A System Port “A ” Ø 25.4

B System Port “B ” Ø 25.4
Electrical L2 Case Drain Port 1 1/16 -12
connections L4 Case Drain Port 1 1/16 -12
MA System “A” Gage Port 9/16 -18

MB System “B” Gage Port 9/16 -18

M3 Charge Gage Port, after Filtering 9/16 -18

M4 Servo Gage Port 7/16 -20

M5 Servo Gage Port 7/16 -20

M6 Charge Gage Port, before Filtering 7/16 -20

S Charge Inlet Port 1 5/16 -12

20-04-M205EN (07/12/2012)
 CHECKING AND ADJUSTING THE
TRANSMISSION 5

MOTOR PRESSURE CONTROL POINTS

View X Loop Flushing Valve Servo Pressure

Gauge Port “M4” + “M5”
200 System Pressure“A”+“B”
Pressure “A”+“B” 0.5625-18UNF-2B
[7.87 Gauge Port ”MA”+ “MB” 9/16 -18UNF-2B

0.5625-18UNF-2B (M5 on reverse side)

9/16 -18UNF-2B

8x 80.8 12.45
[3.18] [0.49]

[7.76]
Y

197

20
Ø152.375
X
[7.87]

[6.00]
200

[6.89]
175
Speed Sensor Connector:
4x 20.6 Min. Angle Deutsch DTM04-6P
Loop Flushing
Solenoid Connector: [0.81] Stop Adjustment
Shuttle Spool
Deutsch DT04-2P 316±2
[12.44±0.09]

89 89
[3.50] [3.50]
50 50
[1.97] [1.97]

Port Description
Connections Port Description Sizes
Pressure control A System Port “A M12x1.75
points B System Port “B M12x1.75
L1 Case Drain Port 1 1/16 -12
Electrical L2 Case Drain Port 1 1/16 -12
connections MA System “A” Gage Port 1 1/16 -12 Split Flange Boss “A”+”B”
MB System “B” Gage Port 1 1/16 -12 DN 25 Typ
T p I 40MPa Series
Ty
M4 Servo Gage Port 9/16 -18
per ISO 6162
M5 Servo Gage Port 9/16 -18 Thread: M12x1.75
21.5 [0.85] full Thread Depth
View Y

(07/12/2012) 20-04-M205EN
 CHECKING AND ADJUSTING THE
6 TRANSMISSION
20

20-04-M205EN (07/12/2012)
 REMOVING THE TRANSMISSION

20
page

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
REMOVING THE HYDROSTATIC TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

(25/06/2012) 20-06-M205EN
 2 REMOVING THE TRANSMISSION
20

GENERAL INFORMATION

The sequence for disassembly operations must be followed to access the various components.

PREPARATION AND SAFETY INSTRUCTIONS

Position the vehicle on a horizontal surface, rest the stabilisers on the ground to ensure utmost stability
and safety; switch off the I.C. engine.

Specific tools:
- Crane for lifting (5000 kg. minimum).
- Pallet jack.

20-06-M205EN (25/06/2012)
 REMOVING THE TRANSMISSION 3

REMOVING THE HYDROSTATIC TRANSMISSION

Place containers of suitable size to hold the quantity of liquid

to be collected under the drainage cap (Ref. 1) of the hydraulic
1
fluid tank.
Remove the cap (Ref. 1) and let the oil flow out.

20
To speed up draining of the tank, remove the filler cap (Ref. 2).

Slacken the screws (Ref. 3) and remove the brackets (Ref. 4)

which block the universal shaft (Ref. 5) on the front axle.

Slacken the screws (Ref. 3) and remove the brackets (Ref. 4)

which block the universal shaft (Ref. 5) on the rear axle.
Remove the universal shaft (Ref. 5) from the vehicle.

3
5

(25/06/2012) 20-06-M205EN
 4 REMOVING THE TRANSMISSION

Disconnect all the pipes of the hydraulic oil system and suction, from the hydrostatic pump (Ref. 6),
from the services pump (Ref. 7) and from the hydraulic motor (Ref. 8), taking care to mark the pipes and
connections with a marker pen before disassembly, to ensure correct repositioning during reassembly.

bb Plug all the hydraulic openings of the hydrostatic motor and pumps to prevent impurities from
contaminating the hydraulic circuit.
20

20-06-M205EN (25/06/2012)
 REMOVING THE TRANSMISSION 5

If necessary, remove the transmission oil filter (Ref. 9) from the

hydrostatic pump (Ref. 6) to be able to access the pump locking
6 screws for disassembly.

20
Disconnect all the electric connectors (Ref. 10) from the hydrostatic
pump.
10

10

10

Secure the pumps by means of belts or ropes to an overhead

crane, passing these through the central opening of the slewing
ring bearing.
11 Remove the screws (Ref. 11) which secure the pump (Ref. 6) to
the motor.

Place the pumps (Ref. 6 and 7) on a pallet jack and take these
out of the vehicle.
6

Slacken the screws (Ref. 12) and remove the washers (Ref. 13
and 14) to dismantle the hydrostatic pump (Ref. 6) from the
services pump (Ref. 7).
7

14 12

13

(25/06/2012) 20-06-M205EN
 6 REMOVING THE TRANSMISSION

Slacken the screws (Ref. 15) which block the hydrostatic motor
(Ref. 8)
on the gearbox.

Position a trolley under the motor (Ref. 8) and remove it from

the front axle reducer so that it comes to rest on the trolley.
15 Remove it from under the vehicle.
8
20

20-06-M205EN (25/06/2012)
 REINSERTING THE TRANSMISSION

20
page

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

(25/06/2012) 20-07-M205EN
 2 REINSERTING THE TRANSMISSION
20

GENERAL INFORMATION

The sequence for disassembly operations must be followed to access the various components.

PREPARATION AND SAFETY INSTRUCTIONS

Position the vehicle on a horizontal surface, rest the stabilisers on the ground to ensure utmost stability
and safety; switch off the I.C. engine.

Specific tools:
- Crane for lifting (5000 kg. minimum).
- Pallet jack.

20-07-M205EN (25/06/2012)
 REINSERTING THE TRANSMISSION 3

Position the motor (Ref. 1), with the help of a trolley, under the
vehicle.
Place the motor (Ref. 1) on the front axle reducer.

Tighten the screws (Ref. 2) which block the hydrostatic motor

(Ref. 1) on the gearbox.
2
Apply threadlock Loctite 241 on the screws (Ref. 2), tighten the
screws by applying a 210 Nm tightening torque.
1

20
Wipe the surface of the hydrostatic pump (Ref. 4) throughly
4 using a cloth, and apply a layer of "Motorseals" on it (stay time
15 minutes).
Refit the services pumps (Ref. 3) on the hydrostatic pump (Ref.
5 4), inserting the gasket (Ref. 5) and tightening the screws and
3 washers (Ref. 6 - 7 - 8).
Apply a 87 Nm tightening torque.

8 6

Secure the pumps by means of belts or ropes to an overhead

crane, passing these through the central opening of the slewing
ring bearing.
9
Lift the pump unit and position it on the engine, apply threadlock
Loctite 577 on the screws (Ref. 9) to fix the hydrostatic pump
(Ref. 4) to the I.C. engine.
Apply a 50 Nm tightening torque.
4

10 Reconnect all the electric connectors (Ref. 10) on the pump.

10

10

(25/06/2012) 20-07-M205EN
 4 REINSERTING THE TRANSMISSION

If the transmission oil filter (Ref. 11) had to be removed in the

disassembly step, refit it now on the hydrostatic pump (Ref. 4).

11
20

Wash and dry all the pipes of the hydraulic fluid system and suction thoroughly, fit the pipes on the
services pump (Ref. 3), on the hydrostatic pump (Ref. 4) and on the hydraulic motor (Ref. 1), taking care
to position these correctly back in place according to the markings made with the marker pen in the
dismantling phase.

20-07-M205EN (25/06/2012)
 REINSERTING THE TRANSMISSION 5

Refit the universal shaft (Ref. 12) on the rear axle after positioning
the brackets (Ref. 13) and tightening the screws (Ref. 14).
Apply a 40 Nm tightening torque.

14
12

13

20
Refit the universal shaft (Ref. 12) on the gearbox, positioning the
brackets (Ref. 13) and tightening the screws (Ref. 14).
Apply a 40 Nm tightening torque.
12

14

13

Refit the cap (Ref. 15) on the hydraulic fluid tank.

15

Fill the tank with fresh hydraulic fluid (see “LUBRICANTS” Manual
for type and quantity).
The oil level is correct when it is between the upper and lower
markings on the level indicator (Ref. 16) under the step ladder.

16

(25/06/2012) 20-07-M205EN
 6 REINSERTING THE TRANSMISSION

Bleed the transmission hydraulic system and refit the cap (Ref. 17).

17
15
20

20-07-M205EN (25/06/2012)
 TROUBLESHOOTING IN THE ELECTRICAL SYSTEM

20
page

SAUER TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– SAUER TRANSMISSION FAULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– SAUER TRANSMISSION ERRORS CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

(15/02/2013) 20-08-M205EN
 TROUBLESHOOTING IN THE ELECTRICAL
2 SYSTEM

SAUER TRANSMISSION

SAUER TRANSMISSION FAULTS

Problem Check Solution

Check the filling pressure in M3.
Replace the filter or add oil to the tank.
The pump is not pressurised.
Check the coupling between the pump
20

Replace pump shaft or hose if worn.

and diesel engine.
Check the current to the two reducers. Replace if necessary.
The pump gets pressurised but does not
rotate in two directions.
Check errors on dashboard. See errors Table.
Check the pressures in points M1 M2 M3.

Check to make sure the switching selector Try to invert or replace the relief valves.
valve on the motor is not blocked on
The pump has no thrust or does not move Replace the valve and check to make sure
one side.
in only one direction. there is no interference in the seat.
Check to make sure the change in
pressure across the filter at points M5 Change the filter.
and M6 is not more than 2.2 bar.
Check the filling pressure of the pump. Adjust the feed valve on the pump.
The vehicle movement in the two directions
is delayed. Check the filter for clogging, by checking Change the filter.
at points M5 and M6 on the pump.
Change the pump because it is damaged.
Check the deltaP of the filling pressure
in pump M3, between the zero position
and operating position.
Add oil.
Check the oil level in the tank.
Excessive heating of oil on transmission.
Change the oil or change the filters if
Check the type of oil used and make
clogged.
sure the filters are clean.

Check the efficiency of the radiator.

Clean the radiator.
Check Error.
See errors Table.
Check to make sure the operating and
filling pressure values on the pump are Change the pump because it is damaged.
correct.
The vehicle does not reach maximum speed.
C h e c k t o m a k e s u r e t h e m o t o r Check the position of the motor displacement
displacement is minimum, checking stop, start-point, regulator valve and flow
to make sure there is pressure at point reducers in control.
M3 of the motor and no longer any
pressure in point M4.

SAUER TRANSMISSION ERRORS CODE

The error codes of the Sauer transmission are displayed on control panel 3B6:
( 80-04 - CHECKING AND ADJUSTING THE ELECTRICAL SYSTEM)

20-08-M205EN (15/02/2013)
 SPECIAL TOOLS FOR THE TRANSMISSION

20
page

STANDARD BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

(25/06/2012) 20-09-M205EN
 2 SPECIAL TOOLS FOR THE TRANSMISSION

STANDARD BOX

Standard
7 7 7
7

3 4 6

2 4 5 6
20

Maniscopic
8 8

Hydromatik Kit –Assembly 2 - A4VG Pump - DA/A6VM Motor - DA

49 49 49 51 51 51 51 51 52

8x100
12x150 14x150
54
53-1

55 58
53 53 30x200 48
55 58
14x150 14x150
50 50 50 50 50 50

16x150 18x150
ø20 (S) ø8 (L) ø6 (L)

Flexible (By-pass valve TH7) Nipple (Valve with flexible connector TH7)
50
x1
14

56

14x150

57

14x150
14
x1
50

20-09-M205EN (25/06/2012)
 SPECIAL TOOLS FOR THE TRANSMISSION 3

Ref. Number Description Qty.

1 549 671 Standard box 1

2 549 882 1/9 bar Pressure gauge 1

3 549 883 0/40 bar Pressure gauge 1

20
4 549 884 0/60 bar Pressure gauge 2

5 549 885 0/400 bar Pressure gauge 1

6 549 886 0/600 bar Pressure gauge 2

7 549 887 Hose 4

8 549 888 Hose for MANISCOPIC 2

9 549 889 Fitting for pressure gauge 7

48 209 572 HYDROMATIK Kit 1

49 58 181 8x100 fitting for pressure gauge 3

50 58 197 O-ring ø 8 6

51 477 484 12x150 fitting for pressure gauge 5

52 58 189 14x150 fitting for pressure gauge 1

53 477 485 16x150 fitting for pressure gauge 2

53-1 199 175 18x150 fitting for pressure gauge 1

54 173 568 Connector ø 20 1

55 165 711 M/F adapter connector - ø8L + M8x100 2

58 706 653 M/F adapter connector - ø6L + M8x100 2

By-pass valve TH7

56 191 000 Hose 1

57 491 632 Connector (M14x150) 1

(25/06/2012) 20-09-M205EN
 4 SPECIAL TOOLS FOR THE TRANSMISSION
20

20-09-M205EN (25/06/2012)
 Axle

- Axle removal

- Axle refit

- Axle troubleshooting

30
- Axle characteristics and 647142

M
R
specifications
(AXLES DANA TYPE
- Axle control and adjustment front 212-302
REAR 212-640)
 REMOVING THE AXLE

30
page

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
REMOVING THE FRONT AXLE AND HYDROSTATIC MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REMOVING THE REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

(25/06/2012) 30-06-M205EN
 2 REMOVING THE AXLE

REMOVING THE FRONT AND REAR AXLES

30

GENERAL INFORMATION

The sequence for disassembly operations must be followed to access the various components.

Mark all the hydraulic pipes and electrical connections with a marker pen, before disassembling, to
ensure correct positioning in the reassembly phase.

b Plug all the hydraulic pipes and orifices to prevent impurities from contaminating the hydraulic
circuit.

PREPARATION AND SAFETY INSTRUCTIONS

Park the vehicle on horizontal ground and level it (chassis parallel to front axle).
Rest the stabilizers on the ground to ensure utmost stability and safety, bringing them to a height
necessary to remove the wheels and switch off the I.C. engine.

Specific tools:
– Crane for lifting (5000 kg. minimum).

30-06-M205EN (25/06/2012)
 REMOVING THE AXLE 3

REMOVING THE FRONT AXLE AND HYDROSTATIC

30
MOTOR

Unscrew all the nuts (Ref. 1) and remove the two front tyres
(Ref. 2).
1

Unscrew the fixing screws of the universal shaft flange (Ref. 3)

and disconnect the shaft.
Disconnect the tube (Ref. 4) (LH of the axle) concerned with the
working of the steering.

Disconnect the tube (Ref. 5) (RH of the axle) concerned with the
working of the steering.
Disconnect the two tubes (Ref. 6).
Disconnect the electrical connection (Ref. 7).

5
7
6
6

(25/06/2012) 30-06-M205EN
 4 REMOVING THE AXLE

Disconnect the two tubes (Ref. 8 and 9) concerned with the

working of the service brake and parking brake.
Disconnect the electrical connection (Ref. 10) of the wheels
8 10 alignment sensor.

Unscrew the connecting screws (Ref. 11) of the flanges (Ref.

30

12), on the two sides of the hydrostatic motor and disconnect

11
the tubes (Ref. 13 and 14).
Disconnect the hydraulic tubes (Ref. 15 and 16).
13

12

15

17 Disconnect the tubes from the "T" connector (Ref. 17) and
disconnect the wiring from the connector.
11

14

12

16

Secure the front axle and the hydrostatic motor to an overhead

crane or elevator suitable for the weight to be supported.
Slacken the screws (Ref. 18) fixing the axle to the LH levelling
cylinder.

18

30-06-M205EN (25/06/2012)
 REMOVING THE AXLE 5

Slacken the screws (Ref. 19) fixing the axle to the RH levelling
cylinder.

19

Slacken the screws (Ref. 20) fixing the front axle to the chassis

30
in front.

20

Slacken the screws (Ref. 21) fixing the front axle to the chassis
at the back.

Remove the front axle and the hydrostatic motor from the vehicle.

21

(25/06/2012) 30-06-M205EN
 6 REMOVING THE AXLE

REMOVING THE REAR AXLE

30

Unscrew all the nuts (Ref. 1) and remove the two rear tyres (Ref. 2).

Unscrew the fixing screws (Ref. 3) of the universal shaft flange

(Ref. 4) and disconnect the shaft.
Disconnect the tube (Ref. 5) (LH of the axle) concerned with the
working of the steering.

Disconnect the tube (Ref. 6) (RH of the axle) concerned with

the working of the steering.

30-06-M205EN (25/06/2012)
 REMOVING THE AXLE 7

Disconnect the electrical connection (Ref. 7) of the brake bulb.

Disconnect the tube (Ref. 8) concerned with the working of the
service brake.
9
Disconnect the electrical connection (Ref. 9) of the wheels
alignment sensor.
8

Secure the rear axle to an overhead crane or elevator suitable

30
for the weight to be supported.
Slacken the screws fixing the rear axle to the front of the chassis
(Ref. 10), taking care to mark the bracket and the chassis for
correct reassembly.

10

Slacken the screws fixing the rear axle to the front of the chassis
(Ref. 11), taking care to mark the bracket and the chassis for
correct reassembly.

Remove the rear axle from the vehicle.

11

(25/06/2012) 30-06-M205EN
 8 REMOVING THE AXLE
30

30-06-M205EN (25/06/2012)
 REINSERTING THE AXLE

30
page

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
REINSERTING THE REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REINSERTING THE FRONT AXLE AND HYDROSTATIC MOTOR . . . . . . . . . . . . . . . . . . . . . . . . 5

(25/06/2012) 30-07-M205EN
 2 REINSERTING THE AXLE

REINSERTING THE FRONT AND REAR AXLES

30

GENERAL INFORMATION

The sequence for disassembly operations must be followed to access the various components.

Reposition all the pipes and connections correctly according to the markings made with a marker pen
during the disassembly.

PREPARATION AND SAFETY INSTRUCTIONS

Park the vehicle on horizontal ground and level it (chassis parallel to front axle).
Rest the stabilizers on the ground to ensure utmost stability and safety, bringing them to a height
necessary to remove the wheels and switch off the I.C. engine.

Specific tools:
– Crane for lifting (5000 kg. minimum).

30-07-M205EN (25/06/2012)
 REINSERTING THE AXLE 3

REINSERTING THE REAR AXLE

30
Bring the rear axle to its original position and hold it steady.
Connect the axle to the front of the chassis by means of the
screws (Ref. 1).

Connect the axle to the rear of the chassis by means of the

screws (Ref. 2).

3
bb Before making the connection, ensure that the reference
(Rif. 3) punched on the chassis during the disassembly is
aligned with the reference (Ref. 4) of the bracket.

(25/06/2012) 30-07-M205EN
 4 REINSERTING THE AXLE

Reconnect the electrical connection (Ref. 5) of the brake bulb.

Reconnect the tube (Ref. 6) concerned with the working of the
service brake.
7
Reconnect the electrical connection (Ref. 7) of the wheels
alignment sensor.
6

Reconnect the tube (Ref. 8) (RH of the axle) concerned with the
30

working of the steering.

Reconnect the tube (Ref. 9) (LH of the axle) concerned with the
working of the steering.

Refit the universal shaft (Ref. 10) in its predefined position, using
Loctite 270 for fixing the screws.
9

10

Refit the two rear tyres (Ref. 11) using a tightening torque of
740 Nm for the nuts (Ref. 12).

12

11

30-07-M205EN (25/06/2012)
 REINSERTING THE AXLE 5

REINSERTING THE FRONT AXLE AND

30
HYDROSTATIC MOTOR

Bring the front axle and the hydrostatic motor to their original
1 position and hold them steady.
Connect the axle to the front of the chassis by means of the
screws (Ref. 1).

Connect the axle to the rear of the chassis by means of the

screws (Ref. 2).

Connect the RH levelling cylinder to the axle by means of the

screws (Ref. 3).

(25/06/2012) 30-07-M205EN
 6 REINSERTING THE AXLE

Connect the LH levelling cylinder to the axle by means of the

screws (Ref. 4).

Refit the flanges (Ref. 5) on the two sides of the hydrostatic

30

motors, tightening the screws (Ref. 6) and reconnect the tubes

6
(Ref. 7 and 8).
Reconnect the hydraulic tubes (Ref. 9 and 10).
7

11

Reconnect the tubes on the "T" connector (Ref. 11) and reconnect
the electrical connection on the connector.
6

10

Reconnect the two tubes (Ref. 12 and 13) concerned with the
12 14 working of the service brake and parking brake.
Reconnect the electrical connection (Ref. 14) of the wheels
alignment sensor.
13

30-07-M205EN (25/06/2012)
 REINSERTING THE AXLE 7

Reconnect the tube (Ref. 15) (RH of the axle) concerned with
the working of the steering.
Reconnect the two tubes (Ref. 16).
Reconnect the electrical connection (Ref. 17).

15
17
16
16

Reconnect the tube (Ref. 18) (LH of the axle) concerned with

30
the working of the steering.
Refit the universal shaft in its predefined position, using Loctite
270 for fixing the screws of the flange (Ref. 19).

18

19

Refit the two front tyres (Ref. 20) using a tightening torque of
740 Nm for the nuts (Ref. 21).

21
bb Before starting work with the vehicle, remember to check
the working of the braking system and, if necessary,
bleed the circuit ( 40 - BRAKE).

20

(25/06/2012) 30-07-M205EN
 8 REINSERTING THE AXLE
30

30-07-M205EN (25/06/2012)
 Brake

- Brake components location

- Brake control and adjustment

- Specific brake tooling

40
 POSITION OF THE BRAKES COMPONENTS

page

THE BRAKES COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

40

(29/08/2012) 40-03-M205EN
 2 POSITION OF THE BRAKES COMPONENTS

THE BRAKES COMPONENTS

Brakes fluid
tank
Brakes pump

Brake pedal
40

Front axle disk

brake

Rear axle disk

brake

40-03-M205EN (29/08/2012)
 CHECKING AND ADJUSTING THE BRAKES

page

40
PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
BRAKES BLEEDING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
DEACTIVATE THE NEGATIVE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
SETTING THE GEAR IN NEUTRAL (FOR TOWING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
BRAKES SYSTEM LAYOUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
SETTING VEHICLE PARAMETERS AND INCHING MRT EURO 3 PRIVILEGE
SAUER DANFOSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
– MATERIAL NECESSARY FOR THE SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
– INSTRUCTIONS FOR CARRYING OUT THE SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
– INSTRUCTIONS FOR CARRYING OUT THE CALIBRATION OF THE INCHING PEDAL . 9

(25/06/2012) 40-04-M205EN
 2 CHECKING AND ADJUSTING THE BRAKES

BLEEDING THE BRAKES AND ADJUSTING THE INCHING

40

PREPARATION AND SAFETY INSTRUCTIONS

Park the vehicle on a horizontal surface and switch off the I.C. engine.

Specific tools:
– Bleeding device.

40-04-M205EN (25/06/2012)
 CHECKING AND ADJUSTING THE BRAKES 3

BRAKES BLEEDING PROCEDURE

Disconnect the drainage pipe (Ref. 1) of the brakes fluid tank

and fit a hydraulic sealing cap.
Fill the brakes fluid tank completely.

Connect the brakes bleeding device (Ref. 2) on the tank S (see

“Brakes system layout”), on the dashboard.

40
Slacken the two bleed screws (Ref. 3) on the rear axle and fit
the transparent tubes on them.
Pressurise the brake bleed device, and wait for the air to flow
out completely through the transparent tubes.
Retighten the two bleed screws (Ref. 3) of the rear axle.
Repeat this procedure for the front axle.
Make sure the brake pump stroke is normal.
If this is not the case, adjust the brakes for both the axles.
( 30-06 - REMOVING THE AXLE).
3
– When the brakes bleeding procedure is complete, reconnect
the hydraulic tube (Ref. 1) to the exhaust manifold.

(25/06/2012) 40-04-M205EN
 4 CHECKING AND ADJUSTING THE BRAKES

DEACTIVATE THE NEGATIVE BRAKE

Deactivate the action of the "negative" parking brake with the

1
help of a 19 mm hex wrench:
– Unscrew the nut (Ref. 1).
2 – Tighten the screw to fit flush (Ref. 2).
Repeat the operation on both sides of the front axle.

SETTING THE GEAR IN NEUTRAL (FOR TOWING)

1

1 If the vehicle is to be towed, the gear must be set in neutral.

Disconnect the tubes (Ref. 1) of the gear, remove or insert the
40

2
pin (Ref. 2) (depending on the gear engaged) bringing it to the
central position.

40-04-M205EN (25/06/2012)
 CHECKING AND ADJUSTING THE BRAKES 5
BRAKES SYSTEM LAYOUT
Legend of brakes components:

FDAR Front axle disk brakes

FDAV: Front axle disk brakes
PF : Brake pedal
MC : Brakes pump
S
BRAKE BLEEDING DEVICE S: Brakes fluid tank
L R

200 bar 200 bar

Pressure Boost pressure
80 bar 33 / 35 bar
CST

PF
D (LS)
LS CR
4 4 MC
175 bar ID 8 8
P T 11 11

10 10

1 1

2 2
D (CF)

40
12 12

VFP
A
FDAR PP B
FDAV

b
P T CFP
11.2cc MV (A)

b
51cc
PP CR (3) B A

T
VD
P

VD
480
480

bar
bar

M3
VSLR BLEED BRAKES ON THE
VBP b B A
1 2
AXLES
PP
7.5 microns

3,7 - 5,1 bar

5,6 - 0.9 bar

bar

T P
ΔP

450
ΔP

FDAR VCLR FDAV

450
bar
2
1

bar
34

17 cc

VBPA
C2

1,3 mm

CSC
2
1

78 cc

FA FR
VBP 250 microns 25 microns
VBPA R
1,3 mm

cw
flow out A

BLEED BRAKES ON THE AXLES

n

PH
C1

(25/06/2012) 40-04-M205EN
 6 CHECKING AND ADJUSTING THE BRAKES
40

40-04-M205EN (25/06/2012)
 CHECKING AND ADJUSTING THE BRAKES 7

SETTING VEHICLE PARAMETERS AND INCHING MRT EURO 3 PRIVILEGE SAUER

DANFOSS
MATERIAL NECESSARY FOR THE SETTING

Control unit diagnostics socket connection cable.

Control unit/computer diagnostics socket connection cable.
Computer with “PLUS+1 GUIDE Service Tool” program installed.

INSTRUCTIONS FOR CARRYING OUT THE SETTING

Open the fuse box (Ref. 1) of the control unit ADM present inside
2
the cab (behind the driver's seat), acting on the two push-to-
1
lock closures (Ref. 2).
2

40
Connect the connector (Ref. 3) to the diagnostics socket present
on the control unit.

Connect the other end of the cable connected to the diagnostics

socket on the control unit (Ref. 4) to the USB cable meant for
the port present on the laptop (Ref. 5).

(25/06/2012) 40-04-M205EN
 8 CHECKING AND ADJUSTING THE BRAKES

Switch on the laptop and start up the program clicking on the

"PLUS+1 GUIDE Service Tool" icon (Ref. 6).

Turn the ignition key (do not start moving) of the forklift truck
and bring it to position "1" (Ref. 7).

7
40

Check to see that the "Connect" command (Ref. 8) (highlighted in

green) is displayed on the program screen page (at the bottom).
When the "Confirm" window is displayed, press "Yes" to confirm
(Ref. 9).

If this does not happen (connection to the forklift truck), click

on the "Communication", "Settings", "CG150" commands and
then "Enable" (Ref. 10).

10

40-04-M205EN (25/06/2012)
 CHECKING AND ADJUSTING THE BRAKES 9

Then click on the “File”, “Open” commands in succession and

select file “101076602_S0168_D0001” (with extension *.P1D)
(Ref. 11).
Confirm the selection by clicking on "Open" and wait for the
11
data to be downloaded.

After the data have been downloaded, select the "All Parameters
V157) command (present on the window to the LH) (Ref. 12).
Then click on the “Parameter” and “File Import” commands in
13 succession. Select file “10107602_S0168_P0001 FINAL TESTING
CENACCHI 28 NOVEMBER.xml” for Standard MRT models, or the
file “10107602_S0168_P0001 FINAL TESTING MACHINE FOR

40
12 GERMANY.xml” for the MRT TUV models (Ref. 13).
Confirm the selection by clicking on "Open" and wait for the
data to be downloaded.

Then click on the “Parameter” and “Download” commands (Ref.

14) in succession to save the parameters on the control unit.

14

INSTRUCTIONS FOR CARRYING OUT THE CALIBRATION OF

THE INCHING PEDAL

On the menu select the“Parameter Function”, “Inputs”, “Inching”,

“Set Defaults” commands in succession (Ref. 15).

15

(25/06/2012) 40-04-M205EN
 10 CHECKING AND ADJUSTING THE BRAKES

Check the brake pedal (Ref. 16) to make sure it is raised completely.

16

Select the “1” command in item “Calibrate Inch Potentiometer”

(Ref. 17).
Confirm the selection by clicking on “Download Parameters”
(Ref. 18)
and wait for the data to be downloaded.
Select the “0” command in item “Calibrate Inch Potentiometer”
(Ref. 17).
40

18 17
Confirm the selection by clicking on “Download Parameters”
(Ref. 18)
and wait for the data to be downloaded.

On the menu select the “Log Function”, “Calibration”, “Pedal

Data” commands in succession (Ref. 19).

19

Select the "Start Logging" button (present in the upper part of

the program), lower the brake pedal completely (Ref. 16) and
wait for about 3 seconds to allow calibration to be completed
(displayed by the green icons present on the screen page).
20 Return to the "All Parameter V157" screen page (Ref. 12).
Confirm the selection by clicking on "Download parameters"
and wait for the parameters to be saved (Ref. 20).
16

40-04-M205EN (25/06/2012)
 CHECKING AND ADJUSTING THE BRAKES 11

On the menu select the “Log Function”, “System”, “Electrical”

commands in succession (Ref. 21).
21 With the brake pedal completely raised, check to make sure
the value displayed in the inching pedal window (Ref. 22) is
between 450 and 550 mV.

22

With the brake pedal completely lowered, check to make sure

the value displayed in the inching pedal window (Ref. 22)
21 is between 4400 and 4700 mV.

b If the values displayed are not within the above-mentioned

40
ranges, proceed with the mechanical adjustment of the
inching potentiometer on the brake pedal. If the values
22 displayed are not changed by acting on the brake pedal,
check the inching potentiometer wiring.

(25/06/2012) 40-04-M205EN
 12 CHECKING AND ADJUSTING THE BRAKES
40

40-04-M205EN (25/06/2012)
 SPECIAL TOOLS FOR THE BRAKES

page

HYDRAULIC BRAKE VENTING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

40

(25/06/2012) 40-09-M205EN
 2 SPECIAL TOOLS FOR THE BRAKES

HYDRAULIC BRAKE VENTING VALVE

Venting valve complete with components necessary

for venting the brakes hydraulic systems for all Manitou
products.
40

MANITOU reference

Hydraulic brake venting valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 554019

Spare parts:
Maximum pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 719980
Minimum pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 719981
Diaphragm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .661913
Brake tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .661914

40-09-M205EN (25/06/2012)
 Boom

- Boom characteristics and

specifications

- Boom components location

- Boom control and adjustment

- Boom removal

- Boom refit

50
 FEATURES AND TECHNICAL SPECIFICATIONS OF THE
BOOM

page

–– BOOM WITH THREE EXTENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

50

(30/08/2012) 50-01-M205EN
 FEATURES AND TECHNICAL SPECIFICATIONS
2 OF THE BOOM

BOOM WITH THREE EXTENSIONS

Consists of four elements:

- 1 FIXED
- 3 MOVABLE (T1 - T2 - T3)

Distribution:

Distribution of boom with three extensions controlled simultaneously .

⇒ T1, T2 and T3 are extended simultaneously .

Vehicles provided with boom with three extensions:

– MRT 1850 PLUS-E3 PRIVILEGE

– MRT 2150 PLUS-E3 PRIVILEGE
– MRT 2540 PLUS-E3 PRIVILEGE

Boom weight:

Vehicle Boom weight:

MRT 1850 3187 kg
MRT 2150 3514 kg
50

MRT 2540 3910 kg

T1 T2 T3

Fixed element

50-01-M205EN (30/08/2012)
 POSITION OF THE BOOM COMPONENTS

page

POSITION OF THE COMPONENTS OF THE PENTAGONAL BOOM WITH THREE EXTENSIONS . . . .3

50

(30/08/2012) 50-03-M205EN
 2 POSITION OF THE BOOM COMPONENTS
50

50-03-M205EN (30/08/2012)
 POSITION OF THE BOOM COMPONENTS 3
POSITION OF THE COMPONENTS OF THE PENTAGONAL BOOM WITH THREE EXTENSIONS

III extension telescopic boom

II extension telescopic boom

I extension telescopic boom

Main boom

50
Extension cylinder
Slewing cylinder

Lift cylinder

Compensation
cylinder

(30/08/2012) 50-03-M205EN
 4 POSITION OF THE BOOM COMPONENTS
50

50-03-M205EN (30/08/2012)
 CHECKING AND ADJUSTING THE BOOM

page

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

ADJUSTING THE SLIDING BLOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– ADJUSTING THE I EXTENSION BOOM SLIDING BLOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– ADJUSTING THE II EXTENSION BOOM SLIDING BLOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

50
–– ADJUSTING THE III EXTENSION BOOM SLIDING BLOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ADJUSTING THE CHAINS OF THE BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

(09/07/2012) 50-04-M205EN
 2 CHECKING AND ADJUSTING THE BOOM

PENTAGONAL TELESCOPIC BOOM ADJUSTMENT

50

PREPARATION AND SAFETY INSTRUCTIONS

Park the vehicle on a horizontal surface, rest the stabilizers on the ground to ensure utmost stability
and safety (do not switch off the I.C. engine).
If the boom is dismantled, use a hydraulic control unit, connecting two pipes to the extension cylinder.

Execute the boom retract command to the extension cylinder limit stop.

50-04-M205EN (09/07/2012)
 CHECKING AND ADJUSTING THE BOOM 3

ADJUSTING THE SLIDING BLOCKS

ADJUSTING THE I EXTENSION BOOM SLIDING BLOCKS

From the rear to the front of the I extension boom, tighten the adjuster grub screws (Ref. 1) all the way
and then unscrew these anticlockwise through half a turn before tightening the side nuts (Ref. 2).
To secure the sliding blocks to the brackets, fit the screws (Ref. 1) (without locking them).
Lock the nuts (Ref. 2) (keeping the screws steady) and the screws (Ref. 3) which fix the sliding blocks
holder brackets on the outer booms on the side; use a tightening torque of 100 Nm.
Check to ensure the correct working of the boom by performing the extension and retraction operations.
If the boom is found to be jerky, slacken the screws (Ref. 1) through another half turn.
Make sure there is no oil leakage at the back of the boom (extension cylinder valve).

bb ATTENTION: the grub screws are sensitive to the slightest movement, therefore they must be
tightened only until the play between the booms is eliminated.

2 2
1 1

50
2 2
1 2
1 3 1 1
2

3
3
2 2

1 2 2
1 1
1 1
3
1 2
2

2
2
2
2

1 1
1 1
3 3

1 3 2
2
2
1 1 1 1 1
1
2 1 3
1 2 2 2 2

(09/07/2012) 50-04-M205EN
 4 CHECKING AND ADJUSTING THE BOOM

ADJUSTING THE II EXTENSION BOOM SLIDING BLOCKS

From the rear of the II extension boom, to the front of the I extension boom, tighten the adjuster grub
screws (Ref. 1) all the way and then slacken these anticlockwise through half a turn before locking the
side nuts (Ref. 2).
To secure the sliding blocks to the brackets, fit the grub screws (Ref. 1) without locking them).
Lock the nuts (Ref. 2) (keeping the screws steady) and the screws (Ref. 3) which fix the sliding blocks
holder brackets on the outer booms on the side; use a tightening torque of 100 Nm.
Check to ensure the correct working of the boom by performing the extension and retraction operations.
If the boom is found to be jerky, slacken the screws (Ref. 1) through another half turn.
Make sure there is no oil leakage at the back of the boom (extension cylinder valve).

bb ATTENTION: the grub screws are sensitive to the slightest movement, therefore they must be
tightened only until the play between the booms is eliminated.

2
2
1 1

1
2 1
2

3
50

1 1 1 2
3 1 1

2
2 2
1
2 2 1
2 1 1
1 2
1

2 2 1 3
2 2

50-04-M205EN (09/07/2012)
 CHECKING AND ADJUSTING THE BOOM 5

ADJUSTING THE III EXTENSION BOOM SLIDING BLOCKS

From the rear of the III extension boom, to the front of the II extension boom, tighten the adjuster grub
screws (Ref. 1) all the way and then slacken these anticlockwise through half a turn before locking the
side nuts (Ref. 2).
To secure the sliding blocks to the brackets, fit the grub screws (Ref. 1) without locking them).
Lock the nuts (Ref. 2) (keeping the screws steady) and the screws (Ref. 3) which fix the sliding blocks
holder brackets on the outer booms on the side; use a tightening torque of 100 Nm.
Check to ensure the correct working of the boom by performing the extension and retraction operations.
If the boom is found to be jerky, slacken the screws (Ref. 1) through another half turn.
Make sure there is no oil leakage at the back of the boom (extension cylinder valve).

bb ATTENTION: the grub screws are sensitive to the slightest movement, therefore they must be
tightened only until the play between the booms is eliminated.

1
1

2
2 2 2
2
1 1 1 1

50
3 2
3 3
1
2 1
2

2 2
1
1 3

1 1
2
2
3

2
3 1 2
2 1
2 1 2
1
2 1
1 1
1 2
2 2 1 3
2

(09/07/2012) 50-04-M205EN
 6 CHECKING AND ADJUSTING THE BOOM

ADJUSTING THE CHAINS OF THE BOOM

Pull the inner chains by tightening the nuts on the tierods.

Follow the values in the Table below (the measurements may
differ by 20-30mm):

mm
2 inner chains, 90/95 mm.
90/95

70/75 mm
1 inner chain, 70/75 mm.
50

Pull the outer chains by tightening the nuts on the tierods.

Follow the values in the Table below (the measurements may
differ by 20-30mm):

4 outer chains, 90/95 mm.

90/95 mm

2 outer chains, 70/75 mm.

70/75 mm

50-04-M205EN (09/07/2012)
 CHECKING AND ADJUSTING THE BOOM 7

Then:
Extend the telescopic boom completely horizontally to check the tension of the outer chains and re-
tighten if required.
Make sure the chains remain taut (keep the boom extension lever pressed for a few seconds).
Measure the distance between the lower side of the chain and boom using a gauge or ruler.
If the values are found to be less than those in the Tables shown below, adjust the chains.
For correct adjustment of the inner chains, retract the boom extensions completely and check to make
sure each of these rests perfectly on the mechanical stops provided.

II extension boom I extension boom

Minimum Minimum
H2 ≥ 80 mm H1 ≥ 80 mm
dimension dimension
MRT 1850-2150 MRT 1850-2150
Maximum Maximum
H2 ≤ 100 mm H1 ≤ 100 mm
dimension dimension
Minimum Minimum
H2 ≥ 116 mm H1 ≥ 59 mm
dimension dimension
MRT 2540 MRT 2540
Maximum Maximum
H2 ≤ 136 mm H1 ≤ 79 mm
dimension dimension

50
H1

H2

(09/07/2012) 50-04-M205EN
 8 CHECKING AND ADJUSTING THE BOOM
50

50-04-M205EN (09/07/2012)
 REMOVING THE BOOM

page

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
REMOVING THE TELESCOPIC BOOM FROM THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REMOVING THE COMPONENTS OF THE TELESCOPIC BOOM . . . . . . . . . . . . . . . . . . . . . . . . . 7

50
–– REMOVING THE HYDRAULIC SYSTEM AND ELECTRICAL SYSTEM OF THE BOOM . . . 7
–– REMOVING THE CYLINDERS FROM THE BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
–– REMOVING THE I, II AND III BOOM EXTENSIONS FROM THE OUTER BOOM . . . . . . . . 16
–– REMOVING THE II AND III EXTENSIONS FROM THE I EXTENSION BOOM . . . . . . . . . . . 19
–– REMOVING THE I EXTENSION BOOM FROM THE II EXTENSION BOOM . . . . . . . . . . . . . 21

(09/07/2012) 50-06-M205EN
 2 REMOVING THE BOOM

REMOVING THE PENTAGONAL TELESCOPIC BOOM

50

GENERAL INFORMATION

The sequence for disassembly operations must be followed to access the various components.
Mark all the hydraulic pipes and electrical connections with a marker pen, before disassembling, to
ensure correct positioning in the reassembly phase.

bb Discharge pressure from the hydraulic circuit before disconnecting the tubes. Plug all the
hydraulic pipes and orifices to prevent impurities from contaminating the hydraulic circuit.

PREPARATION AND SAFETY INSTRUCTIONS

Park the vehicle on a horizontal surface, rest the stabilizers on the ground to ensure utmost stability
and safety (do not switch off the I.C. engine).

Specific tools:
–– Crane for lifting (5000 kg. minimum).
50-06-M205EN (09/07/2012)
 REMOVING THE BOOM 3

REMOVING THE TELESCOPIC BOOM FROM THE

VEHICLE

Activate the boom lift command to bring the boom above the
cab (Ref. 1) dimensions, to allow for easy access to the hinge
1 pin of the rod-boom side lift cylinder from both sides.

Secure the boom to an overhead crane or an elevator by means

of the eyelets provided for the purpose (Ref. 2) in the upper
part of the boom.

2 2 Secure the lift cylinder to a support.

50
Unscrew the stop screw (Ref. 3) and remove the hinge pin of
the lift cylinder on the rod-boom side (Ref. 4).

Place the lift cylinder on the turret, resting it on a wooden beam

(Ref. 5) and retract the rod using the control in the cab.

Lower the telescopic boom to an almost horizontal position by

acting on the overhead crane or elevator used.

Stop the I.C. engine.

(09/07/2012) 50-06-M205EN
 4 REMOVING THE BOOM

Reactivate the ignition key to

position "I" (ignition key-dashboard
contact) and carry out all possible
movements with the commands to
discharge residual pressure from
the hydraulic circuit.

OK OK

Deactivate the ignition key and disconnect the terminals from

the battery.
Remove all the clamps (Ref. 6 and 7) on the hydraulic pipes
6 and electrical connections in the upper part on the back of the
6 6
boom, making sure, at the end of the operation, that these are
6
8 completely free of one another.
6 Disconnect the connector for the chains safety micro switches
cable (Ref. 8).
50

Act on the ring nut concerned to disconnect the plug-wiring

(Ref. 9) on the back of the boom, if present.

7
9
7

7
7 7

Disconnect the hydraulic feed pipes of the boom (Ref. 10).

10 10
10 10
10
10
10

50-06-M205EN (09/07/2012)
 REMOVING THE BOOM 5

To prevent oil leaks from the hydraulic circuit, fit plugs to seal
11
(Ref. 11) all the bulkhead connectors present on the boom.
11
11
11 11
11 11

Disassemble the limit stop micro switch for boom ascent (Ref.
12) with its support (Ref. 13) at the upper end of the turret,
without, however, disconnecting the wiring.
12
13

50
Disconnect connector "X2" (Ref. 14) of the safety system.

14

Act on the overhead crane or elevator to gently raise or lower

the boom (by a few degrees), to find a point of balance between
the anchoring force of the boom to the overhead crane and
reaction of the compensation cylinder, in such a way that the
boom does not weigh entirely on the hinge pin fixing the boom
to the turret.
16
15
Unscrew the screw and retainer nut (Ref. 15 and 16) and remove
17 the pin (Ref. 17) that hinges the boom to the turret.

(09/07/2012) 50-06-M205EN
 6 REMOVING THE BOOM

With the help of an overhead crane or elevator, extract the boom

by a few centimetres very gently and carefully towards the
front of the vehicle so that the hinge pin of the compensation
cylinder projects beyond the turret dimensions.
During this operation, take care to keep the boom horizontal,
take utmost care to avoid making sudden movements and
make sure the boom (only partly unconstrained) does not knock
against other components of the vehicle.

Remove the screw and retainer nut (Ref. 18 and 19) and remove
the hinge pin (Ref. 20) of the compensation cylinder using an
extractor, if necessary.

18

20

19
50

Remove the boom from its seat on the turret using an overhead
crane or elevator.

bb Take care while lifting. The boom must be guided by an

operator to prevent it from losing balance and rolling
on itself.

50-06-M205EN (09/07/2012)
 REMOVING THE BOOM 7

REMOVING THE COMPONENTS OF THE

1 TELESCOPIC BOOM

1
REMOVING THE HYDRAULIC SYSTEM AND ELECTRICAL SYSTEM
OF THE BOOM

After resting the telescopic boom horizontally on two stands,

disconnect the hydraulic pipes (Ref. 1) from the valve block on
the slewing cylinder.

50
Disconnect the hydraulic pipes (Ref. 2) from the quick-release
couplings (Ref. 3) on the LH at the top of the boom.
Disconnect the tube from the quick-release coupling on the RH
3 at the top of the boom.

2 3

Disconnect the cable of the cable reel of the "M.S.S." from the
ring (Ref. 4) present on the I extension boom.

(09/07/2012) 50-06-M205EN
 8 REMOVING THE BOOM

Remove the cable reel (Ref. 5) of the "M.S.S." with its bracket
(Ref. 6) in the front part to the LH of the outer boom.

Disconnect the sealed wiring of the micro switches on the

9
fittings of the chains in the upper front part of the boom and
remove the clamps (Ref. 7).
Remove the brackets of the micro switches (Ref. 8) and their
7 9 locators (Ref. 9), in the front upper part of the boom.
9
8
8

7
50

Open the box for the platform socket and disconnect the wiring
(Ref. 10) from the socket.

10

10

12 Extract the wiring from the box (Ref. 11) and free these from
the clamps (Ref.12).
11
12

50-06-M205EN (09/07/2012)
 REMOVING THE BOOM 9

Free the electric wiring and hydraulic pipes from the protective
sheaths (Ref. 13) and extract the hydraulic pipes through the
upper hole at the top of the boom (Ref. 14).

14
13

Release the electric wiring from the clamps (Ref. 15) in the
passages between the chain-holder tubes and tube-holder chains.
15 15
15

15
15

50
Release the hydraulic pipes from the III extension chain-holder
tube (Ref. 16) after removing the retainer collar (Ref. 17 - 18).
17
16

18

Disconnect the third tube-holder chain (Ref. 19) at the back of

the tubular element (Ref. 20).
19

20

(09/07/2012) 50-06-M205EN
 10 REMOVING THE BOOM

Extract the electric cables (Ref. 21) for the platform and the
hydraulic pipes (Ref. 22) from the chain-holder tube (Ref. 23).

21
22 23

Remove the tube (Ref. 24) from the III extension boom.

24
50

Remove the collars (Ref. 25) locking the elbow unions (Ref. 26
25
and 27) from the fixing plate (Ref. 28) on the II extension chain-
holder tube.
28

26

27

29 30
Disconnect the iron tubes (Ref. 26 and 27) from the hydraulic pipes
30 30
(Ref. 29 and 30) inside the third tube-holder chain; disconnect
the iron tubes (Ref. 26 and 27) from the hydraulic pipes (Ref.
29
31) inside the II extension chain-holder tube.

32
Extract the electric cables (Ref. 32) from the third tube-holder
32
chain towards the quick-release coupling.
31

31 31

31 31

50-06-M205EN (09/07/2012)
 REMOVING THE BOOM 11

Dismantle the third tube-holder chain (Ref. 33) from the chain-
33
holder tube (Ref. 34) by removing the screws concerned (Ref. 35).
35

34

Dismantle the second tube-holder chain (Ref. 36) at the back

of the chain-holder tube (Ref. 37).
36

37

50
Extract the electric cables and hydraulic pipes from the chain-
holder tube (Ref. 38).

38

Remove the chain-holder tube (Ref. 39) from the II extension

boom.

39

(09/07/2012) 50-06-M205EN
 12 REMOVING THE BOOM

Extract the electric cables (Ref. 40) from the second tube-holder
40 chain towards the quick-release coupling.

40

Remove the collars (Ref. 41) locking the elbow unions (Ref. 42
and 43) from the fixing plate on the I extension chain-holder
tube (Ref. 44).
45
45 45 45
45 Disconnect the iron tubes (Ref. 42 and 43) from the hydraulic
pipes (Ref. 45) inside the second tube-holder chain; disconnect
the iron tubes (Ref. 42 and 43) from the hydraulic pipes (Ref.
46) inside the I extension chain-holder tube.
41
44

46
50

43 42

Dismantle the second tube-holder chain (Ref. 47) from the

chain-holder tube (Ref. 48) by removing the screws concerned
(Ref. 49).

47

49

48

Free the cable (Ref. 50) from the clamps for the micro switch on
the single equaliser of the chain fitting to the I extension boom.
50

50-06-M205EN (09/07/2012)
 REMOVING THE BOOM 13

Dismantle the first tube-holder chain (Ref. 51) at the back of

the chain-holder tube (Ref. 52).

51

52

Extract the electric cables, the cable for the micro switch of the
chain fitting on the single chain equaliser and the hydraulic
pipes from the chain-holder tube (Ref. 53).

53

50
Remove the chain-holder tube (Ref. 54) from the I extension
boom.
54

Extract the electric cables (Ref. 55) from the first tube-holder
chain towards the quick-release coupling. Undo the clamps on
56 the cables (Ref. 56 and 57) for the micro switches of the chain
57 fittings on the chain equalisers.

55 55

(09/07/2012) 50-06-M205EN
 14 REMOVING THE BOOM

Remove the locking collars (Ref. 58) of the elbow unions (Ref.
59 and 60) from the fixing plate (Ref. 61) on the outer boom
62
62 62 62
62 chain-holder tube.
58 Disconnect the iron tubes (Ref. 59 and 60) from the hydraulic
pipes (Ref. 62) inside the first tube-holder chain; disconnect the
iron tubes (Ref. 59 and 60) from the hydraulic pipes (Ref. 63)
inside the outer boom chain-holder tube.
61

60 59

63

Dismantle the first tube-holder chain (Ref. 64) from the chain-
holder tube (Ref. 65) by removing the screws concerned (Ref. 66).

64

66
65 66
50

Free the hydraulic pipes and electric cables from the outer boom
by removing the brackets (Ref. 67).

67
67

Remove the hydraulic pipes and electric cables from the chain-
holder tube.

50-06-M205EN (09/07/2012)
 REMOVING THE BOOM 15

Remove the multiple socket (Ref. 68) for the platform from the
plate (Ref. 69).
69

Remove the plate (Ref. 69) for the electric socket at the back on
the RH of the outer boom.
68

Remove the collar (Ref. 70) and remove the hydraulic pipes
70
connected to the extension cylinder (Ref. 71 and 72).

72 71

50
Remove the hydraulic pipes in sequence (Ref. A - B - C - D - E -
F - G) from the bulkhead connectors.

G
D E
F

B C
A

Remove the chain-cholder tube (Ref. 73) on the RH of the outer

73
boom.

(09/07/2012) 50-06-M205EN
 16 REMOVING THE BOOM

Remove the bulkhead connectors in the perforated fin at the

back of the outer boom.

REMOVING THE CYLINDERS FROM THE BOOM

Remove the slewing cylinder from the III extension boom:

( 70 - HYDRAULICS).
50

Remove the extension cylinder from the boom:

( 70 - HYDRAULICS).

1 1
REMOVING THE I, II AND III BOOM EXTENSIONS FROM THE
1
OUTER BOOM

bb Take care and mark all the sliding blocks with their
shims dismantled from the telescopic boom to ensure
they are reassembled correctly.

Remove the rear sliding blocks fixed to the I extension with the
shims concerned (Ref. 1).

50-06-M205EN (09/07/2012)
 REMOVING THE BOOM 17

In the front upper part of the boom, release the six chains for
extension of the booms, dismantling the chain equalisers (Ref.
2
2) from the tierods (Ref. 3).
2 3
3

2
3

Dismantle the pulley (Ref. 4) in the front upper part of the II

extension boom after removing the pin (Ref. 5).

50
Dismantle the pulleys (Ref. 6) in the front upper part of the I
extension boom after removing the pin (Ref. 7).
6

Dismantle the sliding block (Ref. 8) for the sliding of the extension
cylinder and release from the II extension boom the end
9 9 connectors (Ref. 9) for connection of the chains for retraction
of the II extension (Ref. 10).

9 9

10 10

(09/07/2012) 50-06-M205EN
 18 REMOVING THE BOOM

Dismantle the pulley (Ref. 11) in the rear part of the I extension
boom.

With the help of an overhead crane or an elevator, extend the I

extension boom from the outer boom by about 20-30cm.

11 11

Dismantle the front upper side sliding blocks fixed to the outer
boom (Ref. 12) using the shims.

12

12
50

Lift the I extension boom with the help of an overhead crane

or an elevator and remove the lower front sliding blocks (Ref.
13) of the outer boom with the shims concerned.

13

13

Use an overhead crane or elevator to extend the I, II and III

extension booms from the outer boom.

50-06-M205EN (09/07/2012)
 REMOVING THE BOOM 19

Remove the two split pins (Ref. 14) and unscrew the nuts and
locks (Ref. 15) completely, release the chains for retraction of
the II extension boom in the lower front part of the outer boom.

15

15
14
14

REMOVING THE II AND III EXTENSIONS FROM THE I EXTENSION

BOOM
1
Release the retraction chain (Ref. 1) of the III extension boom
in the rear part of the booms.

50
2
Remove the end connector (Ref. 2) from the chain.

Slacken the grub screws of the rear side sliding blocks (Ref. 3)
3 3
with their shims fixed to the II extension boom.
3 3

(09/07/2012) 50-06-M205EN
 20 REMOVING THE BOOM

Remove the upper rear sliding blocks (Ref. 4) fixed to the II

4 4 extension boom.

Remove the chain from the pulley seat (Ref. 5).

5
50

Remove the front fixing block of the III extension retraction

6 6 chain by means of the screws (Ref. 6) and remove the chain by
pulling it towards the quick-coupling.

6 6

Dismantle the front sliding blocks on the sides and top (Ref. 7)
7
7 together with the shims fixed to the I extension boom.

50-06-M205EN (09/07/2012)
 REMOVING THE BOOM 21

Dismantle the front sliding blocks on the sides and below (Ref.
8) together with the shims fixed to the I extension boom.

8
8

Pass the four chains (Ref. 9) for extending the II extension

boom through the openings in the upper front part of the I
extension boom (Ref. 10), and stretch them out completely on
9 9 the II extension boom.
10 10
9
9 Tie the chains to the II extension boom.

50
Using an overhead crane or elevator, extend the II and III extension
booms from the I extension boom, keeping the chains on the
upper part stretched taut.

REMOVING THE I EXTENSION BOOM FROM THE II EXTENSION

BOOM

1 Dismantle the pulley (Ref. 1) in the rear part of the II extension

boom.

(09/07/2012) 50-06-M205EN
 22 REMOVING THE BOOM

Extend the III extension boom from the II extension boom by

about 20-30cm and remove the sliding blocks on the sides (Ref.
2) together with the shims fixed to the III extension boom in
the rear part.
2

Dismantle the front sliding blocks on the sides and top (Ref. 3)
together with the shims fixed to the II extension boom.

3
50

Raise the III extension boom in the front using an overhead

crane or elevator to dismantle the lower front sliding blocks
(Ref. 4) together with the shims fixed to the II extension boom.
4

Tie the chains (Ref. 5) to the III extension boom.

50-06-M205EN (09/07/2012)
 REMOVING THE BOOM 23

Using an overhead crane or elevator, extend the III extension

boom from the II extension boom, keeping the chains resting
on the upper part stretched taut, as they can get entangled.

Remove the upper end connectors in the front part of the four
chains (Ref. 6) for extension of the II extension boom.
6 6

50
Remove the tierods (Ref. 7) fixing the chains for extension of
7
the II extension boom, through the holes provided at the tail
end of the II extension boom.

Remove the tierods (Ref. 8) fixing the chains for extension of

the III extension boom, through the holes provided at the tail
end of the III extension boom.

(09/07/2012) 50-06-M205EN
 24 REMOVING THE BOOM

Disconnect the two end connectors of the upper chains (Ref. 9)

after removing the pair of single chain equalisers (Ref. 10).

9
9

10
50

50-06-M205EN (09/07/2012)
 REINSERTING THE BOOM

page

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
PRELIMINARY OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
REINSERTING THE COMPONENTS OF THE TELESCOPIC BOOM . . . . . . . . . . . . . . . . . . . . . . 3

50
–– PREASSEMBLING THE OUTER BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– PREASSEMBLY OF THE I EXTENSION BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
–– INSERT THE I EXTENSION BOOM IN THE OUTER BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
–– PREASSEMBLY OF THE II EXTENSION BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
–– INSERT THE II EXTENSION BOOM IN THE I EXTENSION BOOM . . . . . . . . . . . . . . . . . . . . . 17
–– PREASSEMBLY OF THE III EXTENSION BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
–– INSERT THE III EXTENSION BOOM IN THE II EXTENSION BOOM . . . . . . . . . . . . . . . . . . . . 22
–– FIT THE QUICK-RELEASE COUPLING AT THE HEAD OF THE BOOM . . . . . . . . . . . . . . . . . 30
REINSERTING THE TELESCOPIC BOOM ON THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

(25/06/2012) 50-07-M205EN
 2 REINSERTING THE BOOM

REINSERTING THE PENTAGONAL TELESCOPIC BOOM

50

GENERAL INFORMATION

Reposition all the pipes and connections correctly according to the markings made with a marker pen
during the disassembly.

PRELIMINARY OPERATIONS

Prepare the structural work, checking to make sure the threaded holes have been drilled correctly;
remove the burrs from the bushes for the pins, grind and smooth weld drips in the area where the
sliding blocks are to be housed.

PREPARATION AND SAFETY INSTRUCTIONS

Park the vehicle on a horizontal surface, resting the stabilizers on the ground to ensure utmost stability and safety.

Specific tools:
–– Crane for lifting (5000 kg. minimum).
50-07-M205EN (25/06/2012)
 REINSERTING THE BOOM 3

REINSERTING THE COMPONENTS OF THE

TELESCOPIC BOOM

PREASSEMBLING THE OUTER BOOM

Grease (see "Lubricants" Table in the Operation and Maintenance

Manual) the inner walls of the outer boom.

Then stretch out the chains (Ref. 1) for retraction of the II

extension boom.

50
1

3 Fit the tierods (Ref. 2) with the relative end connectors at the
front end of the chains (Ref. 3).
2

6 4 5

Insert the fixing tierods (Ref. 4) in the holes provided, in the lower
front part of the outer boom; for each tierod fit two washers,
one cylindrical the other tapered, and screw the nut and lock
nut (Ref. 5), then insert the split pin (Ref. 6).
4

(25/06/2012) 50-07-M205EN
 4 REINSERTING THE BOOM

Fit the end connectors (Fig. 7) at the rear end of the chains (Ref. 8)
and stretch these towards the rear of the outer boom.

8
8

Fit two outer chains tierods holder chain equalisers (Ref. 9), on
the upper wall of the outer boom.
9
50

Facing the boom from the front, on the front walls of the outer boom, prefit:
- RH, sliding blocks adjuster grub screws (Ref. 10) plus split washers and lock nuts (Ref. 11 and 12) and
sliding blocks fixing screws (Ref. 13);
- LH, sliding blocks adjuster grub screws (Ref. 10) with lock nuts (Ref. 12) and sliding blocks fixing screws
with split washer (Ref. 11 and 13);
- above, sliding blocks adjuster grub screws with (Ref. 10) lock nuts (Ref. 12);
- below, sliding blocks adjuster grub screws (Ref. 10) plus split washers and lock nuts (Ref. 11 and 12).

10 10 12
12 12
12
12
13 13 12

10 11 10
11
10 11 11 10

11 11

13
12
11 11
10 12
13
13 11 12
12 10 11 10 10 11 11
10
11 10 13
10 12 12 12 12

50-07-M205EN (25/06/2012)
 REINSERTING THE BOOM 5

Fit the bulkhead connectors in the perforated fin at the back

of the outer boom.

Fit the chain-carrier tube (Ref. 14) on the RH of the outer boom.

14

50
15

15
15

bb In all the chain-holder tubes, fit edge trim seals at the

rear (Ref. 15) and front ends (Ref. 16) to prevent breakage
of the hydraulic pipes.

16
16

(25/06/2012) 50-07-M205EN
 6 REINSERTING THE BOOM

23 22 21
Fit the slewing command hydraulic pipes (Ref. G and F) to the
20 19 18 17
bulkhead connectors (Ref. 17 and 18).
Fit the extension command hydraulic pipes (Ref. E and D) to
the bulkhead connectors (Ref. 19 and 20).
D E
F G
Fit the optional command hydraulic pipes (Ref. C and B) to the
bulkhead connectors (Ref. 21 and 22).
B C
Fit the hydraulic pipe for drainage (Ref. A) to the bulkhead
A
connector (Ref. 23).
Mark all the pipes with the corresponding number.

Fit the plate for the electric socket (Ref. 24) at the back to the
RH on the outer boom.
Fix the multiple electric socket (Ref. 25) of the cable for the
24 platform to the plate (Ref. 24).

25
50

Insert in the chain-holder tube (Ref. 14):

26
–– the cable for the platform socket (Ref. 26), keeping it towards
the outside of the tube;
G 27 –– the wiring for the 3 micro switches for chain anomalies (Ref.
F
26 27) on the outer boom.
C
B
A

14

Insert the hydraulic pipes (Ref. G - F - C - B - A), already fixed to

the bulkhead connectors, into the chain-holder tube (Ref. 14)
in sequence.
14

G
A B F
C

50-07-M205EN (25/06/2012)
 REINSERTING THE BOOM 7

Fix the hydraulic pipes (Ref. G - F - C - B - A) and the electric

cables (Ref. 26 and 27) to the outer boom by means of the
brackets (Ref. 28) .
Secure the electric cables to the hydraulic pipe by means of
clamps.

28 28

Fix the first tube-holder chain (Ref. 29) on the chain-holder tube
30
(Ref. 14) by means of the screws concerned (Ref. 30).
30

29

14

50
Secure the electric cable for the pair of micro switches directly
31
to the wall of the boom by means of clamps (Ref. 31).
Insert the cable for the connection with the single micro switch
in the tube-holder chain of the outer boom.

32

Prepare the hydraulic pipes then insert these in the tube-holder

chain (Ref. 29)
numbering them at the back (E - G = slewing; C - B = optional;
29 A = drainage).

(25/06/2012) 50-07-M205EN
 8 REINSERTING THE BOOM

35 Connect the elbow unions (Ref. 33) to the tubes (Ref. 34) inside
the tube (Ref. 14) and then the tubes (Ref. 35) inside the chain
B C
G F (Ref. 29) by following the sequence from inside the boom
A
36 towards the outside, alternating the long and short connectors.
Fix the connectors with the collars (Ref. 36) to the chain-holder
tube (Ref. 14).
Secure the electric cables to the hydraulic pipes by means of
the clamps in the passages between the chain-holder tubes
14 and tube-holder chains.
33
34

PREASSEMBLY OF THE I EXTENSION BOOM

Grease (see "Lubricants" Table in the Operation and Maintenance

Manual) the inner walls of the I extension boom then stretch
the chain (Ref. 1) for retraction of the III extension boom.

1
50

2
Preassemble the inner chain tie rod for retraction of III extension:
fit the tierod with the built-in end connector (Ref. 2) in the fitting
for the tierod (Ref. 3); screw a nut and lock nut (Ref. 4 and 5) on
3 the tierod and then insert the split pin (Ref. 6).
4

Fit the preassembled tierod (Ref. 7) to the front end of the inner
1
chain (Ref. 1), stretch the latter towards the front of the outer
boom.

50-07-M205EN (25/06/2012)
 REINSERTING THE BOOM 9

Fit the pulleys (Ref. 8) in the rear part of the I extension boom,
locking the pin (Ref. 9) by means of the screw and nut provided
(Ref. 10 and 11).
11

Grease the pulley pin (see "Lubricants" Table in the Operation

9
and Maintenance Manual).

8 10

On the front of the I extension boom, prefit on the outer walls:

–– RH, sliding blocks adjuster grub screws (Ref. 12) plus split washers and lock nuts (Ref. 13 and 14) and
sliding blocks fixing screws with split washer (Ref. 15 and 13);
–– LH, sliding blocks adjuster grub screws (Ref. 12) with lock nuts (Ref. 14) and sliding blocks fixing
screws with split washer (Ref. 15 and 13);
–– top, sliding blocks adjuster grub screws (Ref. 12) plus split washers and lock nuts (Ref. 13 and 14) and
sliding blocks fixing screws with split washer (Ref. 15 and 13);

14 15 15

50
14 12 14

13 13 15
13
12
12 13
13 14 12
13 13
15 13

14
13
15 12
13
14
14 12

12 14 14
13 13
13 14
12 13 12 13
13 12
15
13 12 14 12
14 13

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 10 REINSERTING THE BOOM

On the back of the I extension boom, prefit on the inner walls:

–– RH and LH, sliding blocks adjuster grub screws (Ref. 12) plus split washers and lock nuts (Ref. 13 and
14) and sliding blocks fixing screws with split washer (Ref. 15 and 13);
–– top, sliding blocks adjuster grub screws (Ref. 12) plus split washers and lock nuts (Ref. 13 and 14) and
sliding blocks fixing screws with split washer (Ref. 15 and 13);

13 14 14 13
13 12
12
13 13

12 15
14 12 14 14 12
12
13
15 15

13 13
13 13
13
12 14
14 12 12 14
12
12
15

13 14 12
14 13
50

Fit the chain-holder tube (Ref. 16) on the I extension boom,

fixing it in front by means of the screws (Ref. 17).

17
16

Fit the second tube-holder chain (Ref. 18) on the chain-holder

tube (Ref. 16) fixing it using the screws concerned (Ref. 19).

19

18

16

50-07-M205EN (25/06/2012)
 REINSERTING THE BOOM 11

Prepare the hydraulic pipes then insert these in the tube-holder

chain (Ref. 18)
numbering these at the back (E - G = slewing; C - B = optional;
A = drainage).

18

22
Connect the elbow unions (Ref. 20) to the tubes (Ref. 21) inside
g
a b c
e the tube (Ref. 16) and then the tubes (Ref. 22) inside the chain
23 (Ref. 18) by following the sequence from inside the boom
towards the outside, alternating the long and short connectors.
Fix the connectors with the collars (Ref. 23) to the chain-holder
tube (Ref. 16).
Secure the electric cables to the hydraulic pipes by means of
16 the clamps in the passages between the chain-holder tubes
20
21
and tube-holder chains.

50
Preassemble the sliding blocks (Ref. 24) and assemble these on
the lower side at the back of the I extension boom.

24
24

Then secure with adhesive tape (Ref. 25) so that they do not
fall from the tube.

25

(25/06/2012) 50-07-M205EN
 12 REINSERTING THE BOOM

INSERT THE I EXTENSION BOOM IN THE OUTER BOOM

Using an elevator or overhead crane lift the I extension boom

1 2 (Ref. 1)
and insert it into the outer boom (Ref. 2), leaving it to project
by about 30-40 cm.

6 5

Prepare the sliding blocks (Ref. 3) on its supports (Ref. 4).

3
3
3
3 Note: the sliding blocks and supports are of two different sizes.
Assembled, the smaller ones are positioned on the upper side of
the boom, while the larger ones are positioned on the lower side.

4
4
50

Fit the preassembled lower and lateral sliding blocks in front between the outer boom and the I extension (Ref. 5).
Fit only the sliding blocks support fixing screw (Ref. 7), present on the outer boom.

50-07-M205EN (25/06/2012)
 REINSERTING THE BOOM 13

Fit the preassembled upper and lateral sliding blocks in front between the outer boom and the I extension (Ref. 6).
Fit only the sliding blocks support fixing screw (Ref. 7), present on the outer boom.

7 7

6
6

Insert the I extension boom completely in the outer boom.

Prepare the sliding blocks (Ref. 8) and the rear upper sliding blocks support plate (Ref. 9), then the lateral
rear sliding blocks plus the supports (Ref. 10 and 11).

8 12 13

8 11

50
10

Fit the plate with the preassembled sliding blocks (Ref. 12) on the I extension boom, on the upper rear side.
Tighten the two screws (Ref. 14) to fix the plate (Ref. 9).
Fit the preassembled sliding blocks and lateral supports at the back on the I extension boom (Ref. 13).
Tighten the screws (Ref. 15) to fix the supports (Ref. 11).

12 12 12

14 15 14
14

13 15
15 15

13

14

Adjust all the sliding blocks of the I extension boom.

. 50-04 Checking and adjusting the boom

(25/06/2012) 50-07-M205EN
 14 REINSERTING THE BOOM

After making the connection, insert the electric cables and

hydraulic pipes, of the outer boom tube-holder chain, in the I
extension tube.
Fix the tube-holder chain (Ref. 16) of the outer boom on the
tubular element of the I extension by means of the screws (Ref.
17).
17

16

PREASSEMBLY OF THE II EXTENSION BOOM

Grease (see "Lubricants" Table in the Operation and Maintenance

Manual) the inner walls of the II extension boom.
50

On the front of the II extension boom, prefit on the outer walls:

–– RH, sliding blocks adjuster grub screws (Ref. 1) plus split washers and lock nuts (Ref. 2 and 3) and
sliding blocks fixing screws with split washer (Ref. 4 and 2);
–– LH, sliding blocks adjuster grub screws (Ref. 1) with lock nuts (Ref. 3) and sliding blocks fixing screws
with split washer (Ref. 4 and 3);
–– top, sliding blocks adjuster grub screws (Ref. 1) plus split washers and lock nuts (Ref. 2 and 3) and
sliding blocks fixing screws with split washer (Ref. 4 and 2);

3 2
3 1 3
2
2 4

1 2
1 3 1
2
4 2

3
2 2 2
1
4 1
2
3 2
3 1
3 3 1
3
1 2
2 1 1
2 2 3
2
2 3 2 4
1
2 3 3

50-07-M205EN (25/06/2012)
 REINSERTING THE BOOM 15

2 1
2
On the back of the II extension boom, prefit on the inner walls:
2 –– RH and LH, sliding blocks adjuster grub screws (Ref. 1) plus
3 split washers and lock nuts (Ref. 2 and 3) and sliding blocks
3 1
fixing screws with split washer (Ref. 5 and 2);
2 1 2
2 1 –– top, sliding blocks adjuster grub screws (Ref. 1) plus split
2
1
3 washers and lock nuts (Ref. 2 and 3) and sliding blocks fixing
5
3
5
3
screws with split washer (Ref. 5 and 2);
5
2 2
1 1
3 3

Stretch the four chains of the I extension boom on boom II (Ref. 6).
Assemble the chains using the end connectors (Ref. 7) and then
fix to the walls by means of the screws (Ref. 8), tightening these
6
6
from the inside.
Then secure the chains to the II extension wall by means of
7 adhesive paper.
7

50
8

8 8 8

8 8 8 8

Assemble the end connectors (Ref. 9) in front to the four extension

9
9
9
9 chains (Ref. 6).

(25/06/2012) 50-07-M205EN
 16 REINSERTING THE BOOM

Fit the chain-holder tube (Ref. 10) on the I extension boom,

fixing it in front by means of the screws (Ref. 11).

11
10

Fit the second tube-holder chain (Ref. 12) on the chain-holder

tube (Ref. 10) fixing it using the screws concerned (Ref. 13).

13

12

10
50

Prepare the hydraulic pipes then insert these in the tube-holder

chain (Ref. 12)
numbering these at the back (E - G = slewing; C - B = optional;
A = drainage).
12

16

e g Connect the elbow unions (Ref. 14) to the tubes (Ref. 15) inside
c
a b the tubular element (Ref. 10) and then the tubes (Ref. 16) inside
17
the chain (Ref. 12) by following the sequence from inside the
boom towards the outside, alternating the long and short
connectors.
Fix the connectors with the collars (Ref. 17) to the chain-holder
tube.
14 Secure the electric cables to the hydraulic pipes by means of
15 the clamps in the passages between the chain-holder tubes
and tube-holder chains.

50-07-M205EN (25/06/2012)
 REINSERTING THE BOOM 17

Preassemble the sliding blocks and assemble these at the back

on the lower side of the II extension boom, then secure with
adhesive paper to prevent them from falling from the tube.

INSERT THE II EXTENSION BOOM IN THE I EXTENSION BOOM

Using an elevator or overhead crane lift the II extension boom (Ref.

1 1) and insert it into the I extension boom, leaving it projecting
by 30-40cm.

50
1

7 5

2
2 Prepare the sliding blocks (Ref. 2) on its supports (Ref. 3).
2 2 Note: the sliding blocks and supports are of two different sizes.
Assembled, the smaller ones are positioned on the upper side of
the boom, while the larger ones are positioned on the lower side.

3
3

(25/06/2012) 50-07-M205EN
 18 REINSERTING THE BOOM

4 4 4 Remove the four chains from the front (Ref. 4) from the II extension
4
boom on the I extension boom.
4

Fit the preassembled lower and lateral sliding blocks in front between the I extension boom and the II extension boom (Ref. 5).
Fit only the sliding blocks support fixing screw (Ref. 6), present on the outer boom.

5 5
50

Fit the preassembled upper and lateral sliding blocks in front between the I extension boom and the
II extension boom (Ref. 7).
Fit only the sliding blocks support fixing screw (Ref. 6), present on the outer boom.

6
6

7
7

50-07-M205EN (25/06/2012)
 REINSERTING THE BOOM 19

10 Prepare the sliding blocks (Ref. 8) and the rear upper sliding
blocks support plate (Ref. 9).
8 8

Fit the plate with the preassembled sliding blocks (Ref. 10) on
10 10 the II extension boom, on the upper side at the back.
10 Tighten the screw (Ref. 11) to fix the plate.
Tighten the screws (Ref. 12) to fix the lateral rear sliding blocks
supports (Ref. 11).
12
11
12

50
Adjust all the sliding blocks of the II extension boom.

. 50-04 Checking and adjusting the boom

(25/06/2012) 50-07-M205EN
 20 REINSERTING THE BOOM

After having connected the tubes as shown earlier, insert the electric cables and hydraulic pipes of the
I extension tube-holder chain, in the II extension tube.
Fix the tube-holder chain of the I extension (Ref.13) on the tubular element of the II extension by means
of the screws meant for the purpose.

13
50

50-07-M205EN (25/06/2012)
 REINSERTING THE BOOM 21

4 4 PREASSEMBLY OF THE III EXTENSION BOOM

1 1

Stretch the two chains of the II extension boom externally on

the II extension boom (Ref. 1).
Assemble the chains using their end connectors (Ref. 2) and
2
then fix to the walls by means of the screws, tightening these
from the inside (Ref. 3).
Then tape the chains to the extension wall by means of adhesive
paper (Ref. 4).

Assemble the end connectors (Ref. 5) in front to the two extension

chains (Ref. 1).
Lock the 2 end connectors (Ref. 5) to their equalisers (Ref. 6),
5 5
by means of the screws and nuts.
Secure the chain equalisers to the boom head.
5 5

50
6

7
7 8
8 8 8

9
9 On the back of the III extension boom, prefit on the inner walls:
9 9 9
7 8
–– RH and LH, sliding blocks adjuster grub screws (Ref. 7) plus
7 7
8 8 8
split washers and lock nuts (Ref. 8 and 9) and sliding blocks
8
10
fixing screws with split washer (Ref. 10 and 8);
10 7
9 7 8
–– top, sliding blocks adjuster grub screws (Ref. 7) plus split
9
8
washers and lock nuts (Ref. 8 and 9) and sliding blocks fixing
screws with split washer (Ref. 10 and 8);

11

Preassemble the sliding blocks (Ref. 11) and assemble these

below and on the sides at the back of the III extension boom.
Then secure with adhesive tape (Ref. 12) so that they do not
fall from the tube.
11

12

11 11

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 22 REINSERTING THE BOOM

INSERT THE III EXTENSION BOOM IN THE II EXTENSION BOOM

Using an elevator or overhead crane lift the III extension boom

(Ref. 13) and insert it into the II extension boom, leaving it
projecting by 30-40cm.
13

18 16

Prepare the sliding blocks (Ref. 14) on its supports (Ref. 15).
14
14
14
14 Note: the sliding blocks and supports are of two different sizes.
Assembled, the smaller ones are positioned on the upper side of
the boom, while the larger ones are positioned on the lower side.

15
15
50

Fit the lower and lateral sliding blocks in front between the II Iextension boom and the III extension
boom (Ref. 16).
Fit only the sliding blocks support fixing screw (Ref. 17), present on the outer boom.
Fit the upper and lateral sliding blocks in front between the II extension boom and the III extension
boom (Ref. 18).
Fit only the sliding blocks support fixing screw (Ref. 17), present on the outer boom.

17
17

18

17 17
18

17
16

17

50-07-M205EN (25/06/2012)
 REINSERTING THE BOOM 23

21 Prepare the sliding blocks (Ref. 19) and the rear upper sliding
blocks support plate (Ref. 20).
19 19

20

Fit the plate with the preassembled sliding blocks (Ref. 21) on
the II extension boom, on the upper side at the back.
21 21 21 Tighten the screw (Ref. 22) to fix the plate.
Tighten the screws (Ref. 23) to fix the lateral rear sliding blocks
supports (Ref. 11).

Adjust all the sliding blocks of the III extension boom.

22
23 23
. 50-04 Checking and adjusting the boom

Close the III extension completely.

50

(25/06/2012) 50-07-M205EN
 24 REINSERTING THE BOOM

Prepare the pulley (Ref. 24) for the sliding of the single inner chain (Ref. 25), with its pin (Ref. 26) and
the 2 half-moon shaped supports (Ref. 27) for locking the pin.

24
27 27

26 24

28
27

27

25

31 Fit the pulley (Ref. 24) with the pin (Ref. 26) in their seat, in the
rear part of the III extension, keeping the two chamfers (Ref. 28)
30
of the pin facing upwards.
29 29 Lock the pin (Ref. 26) by means of the two half-moon shaped
50

29 29 supports (Ref. 27) using the screws (Ref. 29).

27 Use Loctite blu 243 before tightening the screws.
27
Tighten the screws (Ref. 29) using a tightening torque of 70 Nm.
35 35
Slide the single inner chain (Ref. 25) in the pulley (Ref. 24)
34 34 and fix its end connector (Ref. 30) in the lower wall of the III
25 extension, in its seat, by means of the screws (Ref. 31).
32 32

Run the two inner chains (Ref. 32) in the pulleys (Ref. 33) of the
I extension, in the rear part of the II extension, position the end
connectors (Ref. 34) of the chains on the lower wall of the II
extension, in its seat, fixing it by means of the screws (Ref. 35).

33
33

32
32

50-07-M205EN (25/06/2012)
 REINSERTING THE BOOM 25

Prepare the square sliding block (Ref. 36).

36

Then rest the support (Ref. 37) for the square sliding block on the
end connectors (Ref. 34) and fix by means of the screws (Ref. 38).
Then fit the square sliding block (Ref. 36) on the support, fixing
39 36
it by means of the screws (Ref. 39).
39

38 38

34 34
38 38

50
37

Insert the electric cables and hydraulic pipes of the II extension

tube-holder chain in the III extension tubular element.
Fix the tube-holder chain of the II extension on the tubular
element of the III extension by means of the screws meant for
40 the purpose (Ref. 40).

(25/06/2012) 50-07-M205EN
 26 REINSERTING THE BOOM

Reinsert the slewing cylinder on the head of the boom:

( 70 - HYDRAULICS).

Fit the box (Ref. 41) for the platform socket on the LH side of
41 the head.
Connect the electric cables in the multipin socket of the platform
(Ref. 42).
42

42
50

43
Secure (Ref. 43) the electric cable on the LH side of the III
extension boom head by means of a clamp.

41
43

Protect the electric cables for the platform socket and the
hydraulic pipes with a sheath (Ref. 45), then position the hydraulic
pipes on the chain-holder tube by means of the collar (Ref. 44),
leaving these free for sliding and positioning.
44

45

50-07-M205EN (25/06/2012)
 REINSERTING THE BOOM 27

Insert the tubes into the head of the boom through the hole at
the top (Ref. 46).

46

Fit the 90° hydraulic unions with quick-release couplings (male) (Ref. 47 and 48) on the LH and (female)
(Rif. 49) on the RH of the head of the boom. Fit the caps-holder on these.
Connect the hydraulic pipes (Ref. E and G) to the valve block (Ref. 50) on the slewing cylinder.
Insert the tubes for the optional (Ref. B and C) in the upper hole at the head of the boom and connect
the quick-release couplings (Ref. 47 and 48) on the LH of the head of the boom.
Insert the tube for drainage (Ref. A) in the upper hole on the head of the boom and connect the quick-
release coupling on the RH side on the head of the boom (Ref. 49).

50
48

49 50 E C

49
48

47
47
A B

Secure the electric cable together with the protective sheaths of

the slewing, optional and drainage command tubes by means
of clamps.

(25/06/2012) 50-07-M205EN
 28 REINSERTING THE BOOM

Fit the pulley (Ref. 51) in the front upper part of the II extension
boom locking the pin (Ref. 52) by means of the screw (Ref. 53).
Grease the pin of the pulleys (see "Lubricants" Table in the
53 Operation and Maintenance Manual).
51

52

Fit the pulleys (Ref. 54) in the front upper part of the I extension
boom locking the pin (Ref. 55) by means of the screw (Ref. 56).
Grease the pin of the pulleys (see "Lubricants" Table in the
54 Operation and Maintenance Manual).

54

56
55
50

Run the six chains for extension of the booms on the pulleys.
Fix the the chain equalisers to the end connectors of the four
chains
(Ref. 57).
57

57

Insert the single tierod of the two chains in the hole provided
on the I extension (Ref. 58) and lock by means of its nut (Ref.
59) and lock nut (Ref. 60).
63
Fix the single tierod (Ref. 61) in the equaliser (Ref. 62) of the two
59 58 chains by means of the bolts and nut (Ref. 63 and 64).

60 62
61
64

50-07-M205EN (25/06/2012)
 REINSERTING THE BOOM 29

Insert the two tierods (Ref. 65) of the four chains in the double
equaliser (Ref. 66) on the outer arm and block by means of its
shims (Ref. 67), nuts and lock nuts (Ref. 68 and 69).
66

69 68 67 65

Fix the two tierods in the equalisers of the four chains using the
70 bolts and nuts (Ref. 70 and 71).
Tighten all the bolts of the equalisers and tierods of the six chains.

70

71

50
Fit the half-moon shaped supports (Ref. 72) for the micro switches.

72

72
72

73 Reinsert the extension cylinder inside the boom:

( 70 - HYDRAULICS).
73

Fit the extension command hydraulic pipes (Ref. E and D) through

the bulkhead connector of the outer boom on the extension
cylinder and secure by means of the collars (Ref. 73 and 74).

d e
74

(25/06/2012) 50-07-M205EN
 30 REINSERTING THE BOOM

FIT THE QUICK-RELEASE COUPLING AT THE HEAD OF THE BOOM

With the help of an overhead crane or an elevator, insert the

quick-release coupling (Ref. 1) at the head of the boom.
2
Insert the hinge pin (Ref. 2) for connection with the head of the
3
boom and fix by means of the screw (Ref. 3).
Insert the pin (Ref. 2) for hinging with the slewing cylinder rod
(Ref. 4) and hold it in place using the ring nut (Ref. 5).
4

5
50

Prefit the three micro switches for chains anomalies (Ref. 6) on

the supports (Ref. 7 and 8).
6

Fix the micro switches on the boom by means of the screws

(Ref. 9).
9

50-07-M205EN (25/06/2012)
 REINSERTING THE BOOM 31

Adjust the distance between the micro switches and the half-
moon shaped supports to about 1 mm.

Connect the II and III extension chains micro switches and clamp
the cables if necessary.

50
10 Fit the cable reel of the "M.S.S." (Ref. 10) in the LH front part of
the outer boom.
Fix the cable of the cable reel of the "M.S.S." to the ring (Ref. 11)
11 present on the I extension boom.

bb The calibration of the «M.S.S.» safety system must be

done by authorised Manitou personnel.

Extend the boom completely and lubricate the outer parts with
grease (See Operation and Maintenance Table).

(25/06/2012) 50-07-M205EN
 32 REINSERTING THE BOOM

2
REINSERTING THE TELESCOPIC BOOM ON THE
VEHICLE

Set up the turret of the vehicle with the lift cylinder (Ref. 1) and
compensation cylinder (Ref. 2) in the positions indicated.
1

With the help of an overhead crane or an elevator, hook up the

boom in the eyelets concerned and position it on the vehicle
in the seat provided in the turret.

bb Take care while lifting. The boom must be guided by an

operator to prevent it from losing balance and rolling
on itself.
50

Align the compensation cylinder rod eyelet with the corresponding

bushing on the boom (Ref. 3).

Insert the compensation cylinder hinge pin (Ref. 4) in the boom

and fit the stop screw (Ref. 5).

50-07-M205EN (25/06/2012)
 REINSERTING THE BOOM 33

Act on the overhead crane and elevator to align the bushes

of the turret with that of the boom for assembling the boom
hinge pin to the turret.
Insert the boom hinge pin (Ref. 6) on the turret after greasing
it, and fit the stop screw (Ref. 7).
7

Act on the overhead crane or elevator to lower the telescopic

boom to align the lift cylinder eyelet with the bushes meant for
the purpose in the lower part of the boom (Ref. 8).

50
Insert the boom lift cylinder hinge pin (Ref. 9) and fit the pin
stop screw (Ref. 10).

9
10

Reconnect connector "X2" (Ref. 11) of the safety system.

11

(25/06/2012) 50-07-M205EN
 34 REINSERTING THE BOOM

Refit the limit stop micro switch for boom ascent (Ref. 12) with
its support (Ref. 13) at the upper end of the turret.
13 12
Restore the clamps of the electric cables present in the inner
part of the turret.

Reconnect the hydraulic pipes (Ref. 14) for the boom supply,
taking care to make sure the connections are correct.

14
14
14
14
14
14
14
50

Adjust the ring nut concerned to connect the plug-wiring (Ref.

15) on the back of the boom, if present.

16
15

16
16
16 16 16

Connect the connector for the chains safety micro switches

cable (Ref. 17).
Restore the clamps on the hydraulic pipes and electric cables
present in the upper rear part of the boom (Ref. 16 and 18).
18
18 Reconnect the terminals to the battery.
18 18 18

17 Check to ensure the correct working of the limit stop micro

switch (Ref. 12) for the boom ascent.

50-07-M205EN (25/06/2012)
 REINSERTING THE BOOM 35

bb Before using the vehicle, grease the telescopic boom sliding blocks as described below:
- Extend the telescopic boom completely.
- use a brush to apply a layer of grease (See the “FILLING TABLE” in the Operation and
Maintenance Manual) on the four sides of the telescopic boom.
- Operate the telescopic boom a number of times to distribute the grease uniformly.
- Wipe excess grease.

GREAS E
GREA S E
GREAS E

50
GREAS E
GREAS E
GREAS E

(25/06/2012) 50-07-M205EN
 36 REINSERTING THE BOOM
50

50-07-M205EN (25/06/2012)
 Hydraulic

- Hydraulic schematic diagrams

- Hydraulic components location

- Hydraulic control and adjustment

- Hydraulic components removal

- Hydraulic components refit

- Hydraulic specific tooling

70
 HYDRAULIC SYSTEM DIAGRAMS

page

LEGEND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
DIAGRAM 1 - HYDROSTATIC TRANSMISSION HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . .5
DIAGRAM 2 - STABILIZERS-LEVELLING-REAR AXLE BLOCK HYDRAULIC SYSTEM . . . . .6
DIAGRAM 3 - MOVEMENTS HYDRAULIC SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
DIAGRAM 4 - MOVEMENTS HYDRAULIC SYSTEM - BOOM SUSPENSION OPTION . . . . . .8
DIAGRAM 5 - BRAKES HYDRAULIC SYSTEM - STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
DIAGRAM 6 - BRAKES HYDRAULIC SYSTEM - STEERING - AIR CONDITIONING OPTION . . . . . . . .10

70

(07/12/2012) 70-02-M205EN
 2 HYDRAULIC SYSTEM DIAGRAMS
70

70-02-M205EN (07/12/2012)
 HYDRAULIC SYSTEM DIAGRAMS 3

LEGEND

Position Position Position Position Position Position Features

Ref. Description
diagram 1 diagram 2 diagram 3 diagram 4 diagram 5 diagram 6 (Optional)
A Accumulator C21 C20 / C22

C1 RH front stabilizer ascent-descent cylinder E3

C2 LH front stabilizer extension cylinder G5

C3 RH front stabilizer extension cylinder O5

C4 LH front stabilizer ascent-descent cylinder Q3

C5 RH rear stabilizer lift-descent cylinder C41

C6 LH rear stabilizer extension cylinder G38

C7 RH rear stabilizer extension cylinder O38

C8 LH rear stabilizer ascent-descent cylinder Q41

CA Air conditioner option compressor C37 OPTIONAL

CFP Parking brake command cylinder I37 K36
CR Rotation hydraulic manifold C27 K26 G8 G8 C16 E16
CSC Exhausts connection manifold on chassis O16 Q13 Q13 O26 O26
A37/C6/
G8/G35/
A20/A25/
CSP Controlled relief valve I7/M7/M8/ C25 / C27
A26
M35/S7/
S37
CST Exhausts connection manifold on turret G12 G12 C20 C20
D Directional control valve K37 K37
E Steering type selection solenoid valve K33 K33

70
ECL Levelling command solenoid valve M11
EV(S1) Lift Danfoss solenoid valve I22 / K22 K22 / K23
EV(S2) Extension Danfoss solenoid valve I25 / K25 K26
EV(S3) Rotation Danfoss solenoid valve I29 / K29 K30
EV(S4) Slewing Danfoss solenoid valve I32 / K32 K32
EV(S5) Optional Danfoss solenoid valve I35 / K35 K35
Oil pressure reduction Danfoss solenoid
EV(S6) I19 / K19 K20
valve
EV(S8) Parking brake solenoid valve I29 I29
EV(S11) RH front beam solenoid valve G19
EV(S12) LH front beam solenoid valve G22
EV(S13) LH rear beam solenoid valve G25
EV(S14) RH rear beam solenoid valve G25
EV(S15) Stabilizers retraction/ascent solenoid valve G16
EV(S16) RH front stabilizer solenoid valve G21 / G22
EV(S17) LH front stabilizer solenoid valve G24 / G25
EV(S18) LH rear stabilizer solenoid valve G27 / G28
EV(S19) RH rear stabilizer solenoid valve G30 / G31
EV(S21) Forward movement solenoid valve E13
EV(S22) Reversing solenoid valve E6
EV(S23) Rear axle release solenoid valve I36

(07/12/2012) 70-02-M205EN
 4 HYDRAULIC SYSTEM DIAGRAMS

Position Position Position Position Position Position Features

Ref. Description
diagram 1 diagram 2 diagram 3 diagram 4 diagram 5 diagram 6 (Optional)
EV(S21) Crab steering solenoid valve K34 K33
EV(S25) Concentric steering solenoid valve K30 K30
EV(S26) Rear axle release solenoid valve K36
EV(S27) High speed solenoid valve M28 M28
EV(S28) Low speed solenoid valve M28 M28
EV(S35) RH levelling solenoid valve I11
EV(S36) LH levelling solenoid valve M11
FA Suction filter Q14 S12 S13 Q32 Q32
FDAR Disk brakes on front axle I6 / M6 I6 / M6
FDAV Disk brakes on rear axle I38 / M38 I37 / M37
FM Delivery filter I22
FR Exhaust filter Q19 S14 S14 Q34 Q33
GES Stabilizers solenoid valves unit I31
ID Power steering E8 E8
M I.C. engine K5 M9 M9 S18 / S19 S18
MA Air conditioner option motor A34 OPTIONAL
MC Brakes pump C31 E28
MH Variable displacement motor K37
MRT Turret rotation motor K33 M33
MV Fan motor M17 O17
P Double gear pump K7 K7 K20 K19
PA Air conditioner option pump S19 / S20 OPTIONAL
Quick-release couplings for accessories on
PAAV A33 A33
the boom
PE Platform emergency motor pump Q9 Q9
PF Brakes pump activation pedal C24 C22
PH Variable displacement pump M20 M10 M10 S22 S21
70

A31/I11/ A31/I12/ I21/K22/ I20/K21/

PP Pressure plug A20
K11 K12 M8 O8
Quick-release coupling for return to tank
PRF C12 C12
on boom
R Oil tank S19 Q22 S15 S16 Q36 Q34
RAD Hydraulic fluid radiator Q32
RF Rotation brake action time regulator O30 O30
S Brakes pump fluid tank A34 A30
VA Air conditioning option solenoid valve E39 OPTIONAL
VB Block and rotation movement control O36 O36
VBP Rear axle block valve G37 / K37
VBPA Rear axle block cylinder I40 / M40
VC Compensation cylinder A30 A30
VCLR Slow-fast control cylinder M35 M33
VD Steering cylinders K38 / M5 K37 / M5
VFP Parking brake command cylinder I29 I29
VI Slewing cylinder A27 A27
VL Lift cylinder A19 A17
VL1 LH levelling cylinder M4
VL2 RH levelling cylinder I4
VSLR Slow-fast selector valve M25 M25
VTI Extension cylinder A24 A24

70-02-M205EN (07/12/2012)
 HYDRAULIC SYSTEM DIAGRAMS 5
DIAGRAM 1 - HYDROSTATIC TRANSMISSION HYDRAULIC SYSTEM

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
VFP (P)
b PP DIAGRAMS 5 - 6

VBP (1)

7.5 microns DIAGRAM 2 12 12 MC (P)

C C
DIAGRAMS 5 - 6

M14
CR
M6
ΔP
3,7 - 5,1 bar

E E
C1 C2
MA L1

EV EV ΔP
(S22) (S21) 5,6 - 0,9 bar A
M3

1,3 mm 1,3 mm
M5
350 bar
MA
G G
M4 6,5 bar

A 110 cc

10 L/min
450 bar
480 bar
min.
disp.
flow out A
I I

FW
0,6mm
C1
L4
16 bar

RW
6,5 bar C5

M
34 bar
cw 0,6mm

70
L2
17 cc
K K
78 cc B
n 480 bar H1B Motor

450 bar MB M4 M5
L3 B MH

MB
M L2 L1 S
VB (T)
M
PH
DIAGRAM 3

O O

3 bar

Q Q

FA RAD

250 microns

S S

(07/12/2012) 70-02-M205EN
 6 HYDRAULIC SYSTEM DIAGRAMS
DIAGRAM 2 - STABILIZERS-LEVELLING-REAR AXLE BLOCK HYDRAULIC SYSTEM

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

CSP

CSP

V2

C2
C C

C5
C2

V2

V1

C1
T P X A B A B A B A B
C1

V1

E E
C1

C1
V1
220 bar
V1
C1

A B A B A B A B
C6

C2
V2
P T P T P T P T
EV EV EV EV EV EV EV EV EV
G (S15) (S11) (S16) (S12) (S17) (S13) (S18) (S14) (S19) G
C2 CSP
C2

V2

CSP
VBP
EV
GES (S23)

2
1
I I
VL2 CSP
DX EV
V1
C1

(S35) 6 bar
FM VBPA
B A 6 6 D (HPCO)

DIAGRAMS 3 - 4 EV
C2

V2

16 microns (S26)
70

A P VFP (T)
K CR K

2
1
B
0.8 mm DIAGRAMS 5 - 6
T
V1
C1

VBP
PH (M3) VBPA
C2

V2

VL1 EV DIAGRAM 1
SX CSP (S36)
M ECL M

CSP CSP

C2
V2
C2

V2

C7
C3
O CSC O

C1
V1
V1
C1

C4
C1

V1

V2

C2
FR
Q 25 microns Q
R C8
V2
C2

V1

C1
CSP CSP
S S

70-02-M205EN (07/12/2012)
 HYDRAULIC SYSTEM DIAGRAMS 7
DIAGRAM 3 - MOVEMENTS HYDRAULIC SYSTEM

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

VL VI VC
VTI
A PP A
PAAV
b N.°2 N.°1
C1 C2 CSP
S C1 C2 CSP CSP C1 C2

DIAGRAMS 5 - 6 PRF

C
MC (T) V1 V2 315 bar
V1 V2 315 bar C
35 bar V1 V2
DIAGRAMS 5 - 6 0.7L A 350 bar

ID (LS) PVED-CX-157B4960 PVED-CX-157B4960 PVED-CX-157B4960 PVED-CX-157B4960 PVED-CX-157B4960 PVED-CX-157B4960

DIAGRAMS 5 - 6
E ID (P) E
DIAGRAMS 5 - 6
CF LS HPCO A B A B A B A B A B
157B5904 11108674 11061372 157B6200 157B6130 157B6230 157B6130 157B6100 157B2000

FM (A)
CST
280

CR 280bar 230 280

DIAGRAM 2 bar bar
6 6
G 3 3
G

1 1
2 2

9 9

5 5

I PP 10 bar I
7 bar

157B7004

157B7103
157B7101
157B7004
157B7044
b

11.2cc
EV EV 25L-MRT2540 EV EV EV
b

275 bar EV 100 L (S1) 100 L (S2) 40L-MRT18-2150 (S3) 100 L (S4) 65 L (S5)
51cc LS (S6)
PP

70
T P P

K P D K

A MRT
PH 175bar MV
R
D.550-7-35°
M M M

12 CC
L B B A
500 CC M
A C2 C1

VB
90 bar 90 bar
O O
B
RF
4 bar
T MH (L2)

CSC DIAGRAM 1
V2 C3 V1
1,7cc

Q PE Q

FA FR
S 250 microns 25 microns
R S

(07/12/2012) 70-02-M205EN
 8 HYDRAULIC SYSTEM DIAGRAMS
DIAGRAM 4 - MOVEMENTS HYDRAULIC SYSTEM - BOOM SUSPENSION OPTION

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

OPTION CRC
VL
A PR A
VI VC
VTI
0.35 mm 30 bar
1.5L
PP PAAV
b N.°2 N.°1
A C1 C2 CSP
S CSP C1 C2
320-335bar
DIAGRAMS 5 - 6 PRF
C C
MC (T) V1 V2 315 bar
35 bar V1 V2
DIAGRAMS 5 - 6 0.7L A 350 bar

T V1 V2

ID (LS) PVED-CX-157B4960 PVED-CX-157B4960 PVED-CX-157B4960 PVED-CX-157B4960 PVED-CX-157B4960 PVED-CX-157B4960

E E
DIAGRAMS 5 - 6
ID (P)
DIAGRAMS 5 - 6 CF LS HPCO A B A B A B A B A B
157B5904 11108674 11061372 157B6200 157B6130 157B6230 157B6130 157B6100 157B2000

FM (A)
CR CST
280

230 280
G DIAGRAM 2
280bar
bar bar G
6 6

3 3

1 1
2 2

9 9

5 5
I I
M
10 bar
PP
7 bar

157B7004

157B7103
157B7101
157B7004
157B7044
b

11.2cc
EV EV 25L-MRT2540 EV EV EV
b

275 bar EV
70

100 L (S1) 100 L (S2) 40L-MRT18-2150 (S3) 100 L (S4) 65 L (S5)

51cc LS (S6)
K PP K
T P P

P D

A MRT
175bar

M PH M
R
D.550-7-35°
M
12 CC
L B
MV B A
500 CC M
A C2 C1
O O
VB
90 bar 90 bar

B
RF
4 bar
T MH (L2)

CSC DIAGRAM 1
Q V2 C3 V1
Q
PE 1,7cc

S FA FR S
250 microns 25 microns
R

70-02-M205EN (07/12/2012)
 HYDRAULIC SYSTEM DIAGRAMS 9
DIAGRAM 5 - BRAKES HYDRAULIC SYSTEM - STEERING

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
S
L R

200 bar 200 bar

CST

C PF C

CR
D (LS)
MC
4 4
LS
8 8 DIAGRAMS 3 - 4
11 11

E 175 bar ID 10 10 E
P T
1 1

2 2

12 12

D (CF)

DIAGRAMS 3 - 4
G G

VFP
I EV A I
FDAR PP B
FDAV
(S8)

b
P T CFP
11.2cc MV (A)

DIAGRAMS 3 - 4
E

b
PP CR

70
51cc (3) B A
EV EV
K DIAGRAMS 3 - 4 (S24) VD K
(S25) P T

VD
480
480

bar
bar

VBP (1) M3

DIAGRAM 2
VSLR
B A
M 1 2 M
7.5 microns

3,7 - 5,1 bar

5,6 - 0.9 bar

bar

EV(S27)
EV(S28)
T P
ΔP

450
ΔP

b
FDAR PP VCLR FDAV
450
bar

bar
34

17 cc

O O
C2

1,3 mm

CSC
78 cc

FA FR
Q 250 microns 25 microns Q
R
1,3 mm

cw
flow out A

PH
C1

S S
M

(07/12/2012) 70-02-M205EN
 10 HYDRAULIC SYSTEM DIAGRAMS
DIAGRAM 6 - BRAKES HYDRAULIC SYSTEM - STEERING - AIR CONDITIONING OPTION

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

A A
OPTION A/C
S
MA
L R
200 bar 200 bar
D
CST C CA
C C
11,2cc
PF T
200 bar

CR
D (LS)
4 4 MC
LS DIAGRAMS 3 - 4 8 8

11 11
E E
10 10
175 bar ID 1 1
P T P
2 2 VA
12 12
7 7

D (CF)

G DIAGRAMS 3 - 4 G

I VFP I
A
FDAR PP EV B
FDAV
GES (S8)

b
DIAGRAM 2 P T
11.2cc MV (A)
CFP
DIAGRAMS 3 - 4
E

b
70

PP CR (3) B A
51cc
K DIAGRAMS 3 - 4 EV EV K
(S25) (S24)
P T VD
P

VD
480
480

bar
bar

VBP (1) M3
VSLR
DIAGRAM 2 B A
M 1 2 M
7.5 microns

3,7 - 5,1 bar

5,6 - 0.9 bar

EV(S28)
EV(S27)
T P
ΔP

ΔP

b
450

VCLR
bar

FDAR FDAV
450
bar

PP
bar
34

17 cc

O O
C2

1,3 mm

CSC
78 cc

FA FR
Q 250 microns 25 microns Q
R
1,3 mm

cw
flow out A

PH
C1

S M S
16cc PA
OPTION A/C
70-02-M205EN (07/12/2012)
 POSITION OF THE HYDRAULIC COMPONENTS

page

DIAGRAM 1 - POSITION OF HYDRAULIC COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

DIAGRAM 2 - POSITION OF HYDRAULIC COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
DIAGRAM 3 - POSITION OF HYDRAULIC COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
DIAGRAM 4 - POSITION OF HYDRAULIC COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
DIAGRAM 5 - CONNECTIONS ON HYDRAULIC MANIFOLD - UPPER PART . . . . . . . . . . . . .9
DIAGRAM 6 - CONNECTIONS ON HYDRAULIC MANIFOLD - LOWER PART . . . . . . . . . . . . .10

70

(15/10/2012) 70-03-M205EN
 POSITION OF THE HYDRAULIC
2 COMPONENTS
70

70-03-M205EN (15/10/2012)
 POSITION OF THE HYDRAULIC
COMPONENTS 3

LEGEND - POSITION OF THE HYDRAULIC COMPONENTS

Present on
Ref. Description
diagram No.
A Accumulator 3
C1 RH front stabilizer ascent-descent cylinder 1
C2 LH front stabilizer extension cylinder 1
C3 RH front stabilizer extension cylinder 1
C4 LH front stabilizer ascent-descent cylinder 1
C5 RH rear stabilizer ascent-descent cylinder 1
C6 LH rear stabilizer extension cylinder 1
C7 RH rear stabilizer extension cylinder 1
C8 LH rear stabilizer ascent-descent cylinder 1
CR Hydraulic manifold 2
D Danfoss directional control valve 3
DF Flow divider 4
EV(S1) 100l slider lift Danfoss soelnoid valve 3
EV(S2) 100l slider extension Danfoss solenoid valve 3
EV(S3) 40 l slider rotation Danfoss solenoid valve 3
EV(S4) 100l slider slewing Danfoss solenoid valve 3
EV(S5) 65l slider optional Danfoss solenoid valve 3
EV(S8) Parking brake solenoid valve 4
EV(S9) Stabilizers general solenoid valve 4
EV(S10) Hydraulic system exclusion emergency solenoid valve 4
EV(S11) RH front beam solenoid valve 4
EV(S12) LH front beam solenoid valve 4
EV(S13) LH rear beam solenoid valve 4
EV(S14) RH rear beam solenoid valve 4
EV(S15) Stabilizers retraction/ascent solenoid valve 4
EV(S16) RH front stabilizer solenoid valve 4

70
EV(S17) LH front stabilizer solenoid valve 4
EV(S18) LH rear stabilizer solenoid valve 4
EV(S19) RH rear stabilizer solenoid valve 4
EV(S21) Forward movement solenoid valve 3
EV(S22) Reversing solenoid valve 3
EV(S23) Rear axle release solenoid valve 1
EV(S24) Crab steering solenoid valve 4
EV(S25) Concentric steering solenoid valve 4
EV(S26) Rear axle release solenoid valve 1
EV(S27) High speed solenoid valve 4
EV(S28) Low speed solenoid valve 4
EV(S35) Levelling 1 command solenoid valve 4
EV(S36) Levelling 2 command solenoid valve 4
FA Suction filter 2
FM Delivery filter 2
FR Exhaust filter 2
GES Stabilizers solenoid valves unit 4
ID Power steering 2
LP Pressure relief valve 4
MC Brake pump 2
MI Variable displacement motor 3
MRT Turret rotation motor 2
MV Fan motor 3
P Gear pump 3
(15/10/2012) 70-03-M205EN
 POSITION OF THE HYDRAULIC
4 COMPONENTS

LEGEND - POSITION OF THE HYDRAULIC COMPONENTS

Present on
Ref. Description
diagram No.
PE Electric pump 2
PI Hydrostatic pump 3
R Oil tank 2
S Oil tank 2
VB Block valve and movement control 2
VBP Rear axle block valve 1
VBPA Rear axle block cylinder 1
VC Compensation cylinder 1
VD Steering cylinders 3
VI Slewing cylinder 1
VL Lift cylinder 1
VL1 RH levelling cylinder 1
VL2 LH levelling cylinder 1
VSLR Slow-fast selector valve 4
VTI 1st extension cylinder 1
70

70-03-M205EN (15/10/2012)
 POSITION OF THE HYDRAULIC
COMPONENTS 5
DIAGRAM 1 - POSITION OF HYDRAULIC COMPONENTS

VI

C2 VL2

VL
C4

VTI C1

EV(S23)
VBP C3
VBPA

70
C8
C6

VL1

VC
EV(S26)
VBP
VBPA

C5

C7

(15/10/2012) 70-03-M205EN
 POSITION OF THE HYDRAULIC
6 COMPONENTS
DIAGRAM 2 - POSITION OF HYDRAULIC COMPONENTS

MC

S
ID

FR

MRT

PE
CR
70

VB

FM

FA

70-03-M205EN (15/10/2012)
 POSITION OF THE HYDRAULIC
COMPONENTS 7
DIAGRAM 3 - POSITION OF HYDRAULIC COMPONENTS

VD
MV A

PI

70
VD
P
MI

VD

VD

(15/10/2012) 70-03-M205EN
 POSITION OF THE HYDRAULIC
8 COMPONENTS
DIAGRAM 4 - POSITION OF HYDRAULIC COMPONENTS

GES
EV(S27)
EV(S35)
EV(S36)

EV(S8)

EV(S28)
EV(S11) EV(S15)
EV(S12) EV(S16)
EV(S13)
EV(S14) EV(S17)
EV(S25)
EV(S18)
EV(S24)
EV(S19)
70

GES

70-03-M205EN (15/10/2012)
 POSITION OF THE HYDRAULIC
COMPONENTS 9
DIAGRAM 5 - CONNECTIONS ON HYDRAULIC MANIFOLD - UPPER PART

12 1 - To turret manifold
2 - To turret manifold
3 - Directional control valve delivery (P)
3 Front part of the 4 4 - To power steering (L)
vehicle 5 - To lower rotation directional control valve
6 - To stabilizers directional control valve (HPCO)
7 - Cap (Optional A/C)
8 - To power steering (R)
9 - To upper rotation directional control valve
10 - Brake pump second hole (Below)
11 - Brake pump first hole (Above)
10 12 - To brakes 7pump (P)

2 1
LH sleeve RH sleeve

70
5 6

9 8

11

(15/10/2012) 70-03-M205EN
 POSITION OF THE HYDRAULIC
10 COMPONENTS
DIAGRAM 6 - CONNECTIONS ON HYDRAULIC MANIFOLD - LOWER PART

1 - To chassis exhaust manifold

2 - To chassis exhaust manifold
3 - Delivery from movements pump
4 - LH front cylinder steering
5 - To rotation valve (V2)
6 - To stabilizers directional control valve (P)
7 - Cap (Optional A/C)
8 - To steering solenoid valve (P)
9 - To rotation valve (V1)
10 - Front service brake
11 - To rear brake
12 - Hydrostatic pump supercharging (M3)

12

10
9 9
8
11
70

6
5 5
7

2
3

70-03-M205EN (15/10/2012)
 CHECKING AND ADJUSTING THE HYDRAULIC
SYSTEM

page

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
LOCATION OF THE PRESSURE PLUGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
CHECKING THE PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
– BOOM MOVEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
– STABILIZERS MOVEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
– COMPENSATION CYLINDER BOTTOM MOVEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
– FAN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

70
– BOOST PUMP ON HYDROSTATIC TRANSMISSION (SAUER) . . . . . . . . . . . . . . . . . . . . . . . 7
GENERAL RULES FOR DISMANTLING THE CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
– ENTIRE ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
– PISTON AND LOCKING NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
– GASKETS FOR THE PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
– GASKETS OF THE LOCKING RING NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
– APPLICATION OF THREADLOCKERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
– LIFT CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
– SLEWING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
– COMPENSATION CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
– STABILIZER INCLINATION CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
– REAR AXLE BLOCKING CYLINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
– LEVELLING CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
ADJUSTING THE TURRET ROTATION BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
– MRT 1850 / 2150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
– MRT 2540 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

(25/06/2012) 70-04-M205EN
 CHECKING AND ADJUSTING THE
2 HYDRAULIC SYSTEM

GENERAL INFORMATION

The pressures must be checked by means of a suitable pressure gauge, the oil temperature must be
about 60°, the I.C. engine must be running at maximum speed for all the checks, except for checking
the rotation, which must be done at minimum speed.

PREPARATION AND SAFETY INSTRUCTIONS

Park the vehicle on a horizontal surface and rotate the turret through 180°.

Specific tools:
– Pressure gauge (600 bar):
70

70-04-M205EN (25/06/2012)
 CHECKING AND ADJUSTING THE
HYDRAULIC SYSTEM 3
LOCATION OF THE PRESSURE PLUGS

70
(25/06/2012) 70-04-M205EN
 CHECKING AND ADJUSTING THE
4 HYDRAULIC SYSTEM
70

70-04-M205EN (25/06/2012)
 CHECKING AND ADJUSTING THE
HYDRAULIC SYSTEM 5

CHECKING THE PRESSURES

BOOM MOVEMENTS

1
Position a pressure gauge on the pressure plug (Ref. 1) of the
directional control valve and one on the services pump (Ref. 2).

Check pressures Value

Power steering 275 bar
Ascent 275 bar
2
Descent 275 bar
Extension 280 bar
Retraction 275 bar
RH rotation (at minimum engine rpm) 90 bar
LH rotation (at minimum engine rpm) 90 bar
Optional 275 bar
Compensation (rod side) 230 ÷ 280 bar
Slewing (rod side) 280 bar
Slewing (bottom) 280 bar

Danfoss directional control valve 6 elements

70
OPTIONAL
SLEWING
ROTATION
EXTENSION
LIFT
OIL PRESSURE REDUCTION

(25/06/2012) 70-04-M205EN
 CHECKING AND ADJUSTING THE
6 HYDRAULIC SYSTEM

STABILIZERS MOVEMENTS

2
Check through the pressure plug (Ref. 2) on the services pump.

Check pressures Value Adjustment

Stabilizers circuit 220 bar Valve situated on stabilizers solenoid valve block

To regulate the stabilizers circuit pressure, act on the valve (Ref.

3) present on the stabilizers solenoid valve block.

3
70

COMPENSATION CYLINDER BOTTOM MOVEMENT

To check the pressure of the compensation cylinder bottom:

- connect the pressure gauge (Ref. 4) in the position shown;
- lift the boom completely;
- extend the slewing cylinder completely;
- accelerate the I.C. engine to the maximum speed and lower
the boom
4

During the descent the pressure value must reach 300 bar

70-04-M205EN (25/06/2012)
 CHECKING AND ADJUSTING THE
HYDRAULIC SYSTEM 7

FAN MOTOR

Check through the pressure plug (Ref. 5) on the services pump.

Check pressures Value Adjustment

70 bar Cooling fan speed 2000 rpm. The speed is adjusted automatically according to the pressure and
Cooling fan
70 bar Cooling fan speed 2100 rpm. is regulated by a valve inside the engine - fan

Note: The rpm of the cooling fan must be measured using a stroboscope.

The fan is of the suction type.

BOOST PUMP ON HYDROSTATIC TRANSMISSION (SAUER)

Pump P4: Check on the pressure plug (Ref. 1).

1
647039EN - Pump SAUER H1 45/53

Check pressures Value Adjustment 70

Parking brake
Brake servo control
34 bar On Booster pressure relief
Speed change command (slow and fast)
Rear axle block

(25/06/2012) 70-04-M205EN
 CHECKING AND ADJUSTING THE
8 HYDRAULIC SYSTEM

GENERAL RULES FOR DISMANTLING THE

CYLINDERS

1 2
ENTIRE ROD

DISASSEMBLY

Fit the cylinder in a vice with jaw facings, tighten the cylinder
moderately to prevent deformation of the body.
Unlock the lock nut (Ref. 1) using a pin wrench; if it is found to
be difficult to unlock the ring nut, consult the "DISASSEMBLY"
paragraph in the "Application of threadlocker" chapter.
Unscrew the locking nut (Ref. 1) completely and remove the
entire rod from the cylinder body.
Note: FOR VERY LONG CYLINDERS: Remove the rod to a maximum
of 200 mm, unscrew the locking nut (Ref. 1) through half a turn
(to be done gradually, without jerks).
3 Remove the rod by about 2500mm, support the rod (Ref. 3) at
the end to prevent strain on the locking nut.
Continue to unscrew the locking ring nut; if much effort is

b
required, raise and then lower the rod to reduce the friction.

Never apply force while unscrewing: risk of siezure.

CHECK

5
1 Remove the grease and wipe the inside of the cylinder.
70

Visually inspect the cylinder body for scratches, burrs, rust...

REASSEMBLY

Apply hydraulic fluid on the piston gaskets using a brush, refit

the entire rod in the cylinder body (Ref. 2).
Take care to avoid damaging the gaskets (Ref. 4) when passing
4 4 over the tapping on the cylinder body, apply hydraulic fluid on
the outer gaskets of the locking ring nut.
Apply Loctite 222 threadlocker (see "Application of threadlocker"
chapter) on the locking ring nut (Ref. 5).
6
Screw the ring nut, lock using a pin wrench and torque wrench
Nm
applying the torque shown in the Table (Ref. 6), turn the rod
450
through one complete turn to allow positioning of the gaskets.
400

350
Note: Test the cylinder hydraulically before refitting it on the
300 vehicle.
250 Move the piston rods in and out a number of times.
200

150

100

50

0 M
M40 M50 M60 M70 M80 M90 M100

70-04-M205EN (25/06/2012)
 CHECKING AND ADJUSTING THE
HYDRAULIC SYSTEM 9

PISTON AND LOCKING NUT

DISASSEMBLY

5
3 4 2
Hold the rod in a vice fitted with jaw facings, tighten to prevent
6 1 the unit from rotating.
Unlock the nut (Ref. 1) and unscrew completely using a polygonal
wrench or, depending on the version, remove the screw pin
(Ref. 2) using a hex wrench.

Remove the piston (Ref. 3) by pulling it out manually or, depending

on the model, unscrewing the piston (Ref. 4) with the help of
a pin spanner.

5
4
6

Remove the ring nut (Ref. 5) by sliding it along the rod.

70
5

CHECK

7 Use a comparator (Ref. 7) to check the linearity of the rod along

its entire length.
Check to make sure the rod is not cracked, corroded or scratched.

(25/06/2012) 70-04-M205EN
 CHECKING AND ADJUSTING THE
10 HYDRAULIC SYSTEM

REASSEMBLY

Refit the ring nut (Ref. 5) on the rod (Ref. 6), refit the piston (Ref.
3) on the rod.
5

8 Screw and block the nut (Ref. 1) using a polygonal wrench and a
Nm
torque wrench applying the torque indicated in the Table (Ref.
1400 8) or, depending on the model, screw the piston back (Ref. 3)
1200 on using a pin wrench (see tightening torque (Ref. 8) and lock
1000 with a screw pin (Ref. 2).
800 Note: Fit the screw pin after applying Loctite 243; see the
600 "Application of threadlocker" chapter.
400
Tightening torque for screw = 20 Nm.
200
Tap with a chisel to push back the metal on the screw.
0 M
M20 M30 M40 M50 M60 M70

GASKETS FOR THE PISTON

1 1
Note: Do not use sharp tools (screwdrivers, blades, etc.) for
70

assembling and removing the gaskets, for any reason whatsoever.

Work on clean work benches, free of shavings.
4
DISASSEMBLY

Remove the gaskets (Ref. 1-2-3) from the piston (Ref. 4 or 5).
Attention: avoid damaging the edges and grooves.
2
CHECK

Remove the grease and clean the piston.

3
Check to make sure the grooves and the surfaces are smooth and
free of scratches. The grooves must not contain foreign bodies.

REASSEMBLY
5
Position the gaskets on the piston (Ref. 4 or 5) according to the
assembly sequence.
To fit the outer gaskets (Ref. 1 and 3), open these just enough
to fit them into the grooves without breaking.
2
The inner gasket (Ref, 2) must be fitted manually.

70-04-M205EN (25/06/2012)
 CHECKING AND ADJUSTING THE
HYDRAULIC SYSTEM 11

1 2
GASKETS OF THE LOCKING RING NUT
3

Note: Do not use sharp tools (screwdrivers, blades, etc.) for

assembling and removing the gaskets, for any reason whatsoever.
Work on clean work benches, free of shavings.

DISASSEMBLY
4

Remove the gaskets of the locking ring nut.

5
Attention: avoid damaging the edges and grooves.

CHECK

Remove the grease and clean the locking ring nut.

Check to make sure the grooves and the surfaces are smooth
5 and free of scratches.
The grooves must not contain foreign bodies.
Insert the ring nut on the rod, sliding it along the entire length.
Play must not be excessive, nor must it block the ring nut rigidly.

REASSEMBLY
6
Position the gaskets following the assembly sequence (Ref.
1-2-3-4-5).
The gasket lips must face the pressure side.
To fit the gasket on the rod (Ref. 5), insert it in the groove holding
it with the thumb or using a push rod (Ref. 6) which does not

70
7
have sharp edges.
Push the gasket in the groove with the other hand or a smooth
punch (Ref. 7). If the gasket offers a great deal of resistance,
5 place it in a hydraulic fluid bath at 50°C to reduce the resistance.
Position the oil scraper ring (Ref. 4) using a thrust pad or a mallet.
Fit the O-rings (Ref. 2 and 3) and the anti-extrusion gasket (Ref.
1) manually.

(25/06/2012) 70-04-M205EN
 CHECKING AND ADJUSTING THE
12 HYDRAULIC SYSTEM

APPLICATION OF THREADLOCKERS

FEATURES

Low strength Loctite 222 Threadlocker

Application on the threads of the locking nuts.

Without Activator
Work-with time 10 - 30 min.
Cure time 3 - 6 hours
(Cylinder pressurised)
With Activator N Loctite
Work-with time 10 - 20 min.
Cure time 2 - 4 hours
(Cylinder pressurised)
Shear strength 1.5 - 4 N/mm2

Medium strength Loctite 243 threadlocker

Application on M8 screw for locking the pistons.

Without Activator
Work-with time 10 - 20 min.
Cure time 3 - 6 hours
(Cylinder pressurised)
With Activator N Loctite
Work-with time 5 - 15 min.
Cure time 2 - 4 hours
(Cylinder pressurised)
70

Shear strength 5 - 7.5 N/mm2

DISASSEMBLY

If the components fitted using threadlocker cannot be locked using standard tools, heat the glued area
to a temperature T = 250°C preferably using a hot air gun instead of a blow torch.

NOTE:

If the temperature is close to 0°C it is advisable to use a Loctite activator during assembly, to reduce
the polimerisation time.

70-04-M205EN (25/06/2012)
 CHECKING AND ADJUSTING THE
HYDRAULIC SYSTEM 13

LIFT CYLINDER

Tools required:
- 1 hook spanner (for ring nuts)
- 1 4mm Allen key

10 11 4

6
9
7
9

8
3 5

14
15
14
16
12
13
1

DISASSEMBLY

70
Unscrew the head (Ref. 1) using a hook spanner by dislodging the tab on the rim of the jacket that is
staked into a corresponding location on the head.
Remove the rod cylinder jacket (Ref. 2) + head (Ref. 1 and 3) + piston (Ref. 4) assembly.
Remove the Allen screw (Ref. 5) (4mm Allen key) of the piston.
Attention: screw locked with loctite (see "Application of threadlock" chapter).
Unscrew the piston (Ref. 4) of the cylinder using a hook spanner.
Remove the piston (Ref. 4) of the cylinder, the spacer (Ref. 6) and the head piece (Ref. 1 and 3) from the
rod.
Remove the gaskets (Ref. 7 and 8) and the guide rings (Ref. 9) of the piston.
Remove the gaskets (Ref. 10-11-12-13), the guide rings (Ref. 14) and the gaskets (Ref. 15 and 16) of the
head piece.
Check the condition of the valve, the valve seat and spring; change the gaskets and the components
if necessary.
Attention to the direction of reassembly.

REASSEMBLY

Operation reverse to that for disassembly.

Note: The outer tab of the jacket must be staked into the corresponding location on the head to prevent
the head from working loose.
Loctite threadlock must be used for fitting the Allen screw.
Smear hydraulic fluid on the gaskets.
(25/06/2012) 70-04-M205EN
 CHECKING AND ADJUSTING THE
14 HYDRAULIC SYSTEM

SLEWING CYLINDER

Tools required:
- 1 hook spanner (for ring nuts)
- 1 4mm Allen key

10
8 6
9

1
11 4
12
11
13

DISASSEMBLY
70

Unscrew the head (Ref. 1) using a hook spanner by dislodging the tab on the rim of the jacket that is
staked into a corresponding location on the head.
Remove from the rod assembly cylinder jacket (Ref. 2) + piston (Ref. 3) assembly.
Remove the Allen screw (Ref. 4) (4mm Allen key) of the piston.
Attention: screw locked with loctite (see "Application of threadlock" chapter).
Unscrew the piston (Ref. 3) of the cylinder using a hook spanner.
Remove the piston (Ref. 3) of the cylinder and the head piece (Ref. 1) from the rod.
Remove the gaskets (Ref. 5 and 6) and the guide rings (Ref. 7) of the piston.
Remove the gaskets (Ref. 8-9-10), the guide rings (Ref. 11) and the gaskets (Ref. 12 -13) of the head piece.
Check the condition of the valve, the valve seat and spring; change the gaskets and the components
if necessary.
Attention to the direction of reassembly.

REASSEMBLY

Operation reverse to that for disassembly.

Note: The outer tab of the jacket must be staked into the corresponding location on the head to prevent
the head from working loose.
Loctite threadlock must be used for fitting the Allen screw.
Smear hydraulic fluid on the gaskets.

70-04-M205EN (25/06/2012)
 CHECKING AND ADJUSTING THE
HYDRAULIC SYSTEM 15

COMPENSATION CYLINDER

Tools required:
- 1 hook spanner (for ring nuts)
- 1 4mm Allen key

7
5
7

10 6
8
9
1 4

11
12
11
13

DISASSEMBLY

70
Unscrew the head (Ref. 1) using a hook spanner by dislodging the tab on the rim of the jacket that is
staked into a corresponding location on the head.
Remove from the rod assembly cylinder jacket (Ref. 2) + piston (Ref. 3) assembly.
Remove the Allen screw (Ref. 4) (4mm Allen key) of the piston.
Attention: screw locked with loctite (see "Application of threadlock" chapter).
Unscrew the piston (Ref. 3) of the cylinder using a hook spanner.
Remove the piston (Ref. 3) of the cylinder and the head piece (Ref. 1) from the rod.
Remove the gaskets (Ref. 5 and 6) and the guide rings (Ref. 7) of the piston.
Remove the gaskets (Ref. 8-9-10), the guide rings (Ref. 11) and the gaskets (Ref. 12 and 13) of the head
piece.
Change the gaskets and components, if necessary.
Attention to the direction of reassembly.

REASSEMBLY

Operation reverse to that for disassembly.

Note: The outer tab of the jacket must be staked into the corresponding location on the head to prevent
the head from working loose.
Loctite threadlock must be used for fitting the Allen screw.
Smear hydraulic fluid on the gaskets.

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 CHECKING AND ADJUSTING THE
16 HYDRAULIC SYSTEM

EXTENSION CYLINDER

Tools required:
- 1 hook spanner (for ring nuts)
- 1 4mm Allen key

12
1 9
8
13 10
14 11
13
15

4
5

7
6 5
7
3

DISASSEMBLY
70

Unscrew the head (Ref. 1) using a hook spanner by dislodging the tab on the rim of the jacket that is
staked into a corresponding location on the head.
Remove from the rod assembly cylinder jacket (Ref. 2) + piston (Ref. 3) assembly.
Remove the Allen screw (Ref. 4) (4mm Allen key) of the piston.
Attention: screw locked with loctite (see "Application of threadlock" chapter).
Unscrew the piston (Ref. 3) of the cylinder using a hook spanner.
Remove the piston (Ref. 3) of the cylinder and the head piece (Ref. 1) from the rod.
Remove the gaskets (Ref. 5 and 6) and the guide rings (Ref. 7) of the piston.
Remove sealing ring (Ref. 8) and remove the spacer (Ref. 9).
Remove the gaskets (Ref. 10-11-12), the guide rings (Ref. 13) and the gaskets (Ref. 14 and 15) of the
head piece.
Check the condition of the valve, the valve seat and spring; change the gaskets and the components
if necessary.
Attention to the direction of reassembly.

REASSEMBLY

Operation reverse to that for disassembly.

Note: The outer tab of the jacket must be staked into the corresponding location on the head to prevent
the head from working loose.
Loctite threadlock must be used for fitting the Allen screw.
Smear hydraulic fluid on the gaskets.
70-04-M205EN (25/06/2012)
 CHECKING AND ADJUSTING THE
HYDRAULIC SYSTEM 17

STABILIZER TELESCOPIC CYLINDER

Tools required:
- 1 hook spanner (for ring nuts)
- 1 4mm socket spanner

7
9 5
8 7

12 3
10
11

6
1
13
15
13
14 4

DISASSEMBLY

70
Unscrew the head (Ref. 1) using a hook spanner by dislodging the tab on the rim of the jacket that is
staked into a corresponding location on the head.
Remove from the rod assembly cylinder jacket (Ref. 2) + piston (Ref. 3) assembly.
Remove the Allen screw (Ref. 4) (4mm Allen key) of the piston.
Attention: screw locked with loctite (see "Application of threadlock" chapter).
Unscrew the piston (Ref. 3) of the cylinder using a hook spanner.
Remove the piston (Ref. 3) of the cylinder and the head piece (Ref. 1) from the rod.
Remove the gaskets (Ref. 5 and 6) and the guide rings (Ref. 7) of the piston.
Remove sealing ring (Ref. 8) and remove the spacer (Ref. 9).
Remove the gaskets (Ref. 10-11-12), the guide rings (Ref. 13) and the gaskets (Ref. 14 and 15) of the
head piece.
Change the gaskets and components, if necessary.
Attention to the direction of reassembly.

REASSEMBLY

Operation reverse to that for disassembly.

Note: The outer tab of the jacket must be staked into the corresponding location on the head to prevent
the head from working loose.
Loctite threadlock must be used for fitting the Allen screw.
Smear hydraulic fluid on the gaskets.

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 CHECKING AND ADJUSTING THE
18 HYDRAULIC SYSTEM

STABILIZER INCLINATION CYLINDER

Tools required:
- 1 hook spanner (for ring nuts)
- 1 4mm Allen key

10

3
8
4

5 11
2

13
7

11
6

12

DISASSEMBLY
70

Unscrew the head (Ref. 1) using a hook spanner by dislodging the tab on the rim of the jacket that is
staked into a corresponding location on the head.
Remove from the rod assembly cylinder jacket (Ref. 2) + piston (Ref. 3) assembly.
Remove the Allen screw (Ref. 4) (4mm Allen key) of the piston.
Attention: screw locked with loctite (see "Application of threadlock" chapter).
Unscrew the piston (Ref. 3) of the cylinder using a hook spanner.
Remove the piston (Ref. 3) of the cylinder and the head piece (Ref. 1) from the rod.
Remove the gaskets (Ref. 5 and 6) and the guide rings (Ref. 7) of the piston.
Remove the gaskets (Ref. 8-9-10), the guide rings (Ref. 11) and the gaskets (Ref. 12 and 13) of the head
piece.
Check the condition of the valve, the valve seat and spring; change the gaskets and the components
if necessary.
Attention to the direction of reassembly.

REASSEMBLY

Operation reverse to that for disassembly.

Note: The outer tab of the jacket must be staked into the corresponding location on the head to prevent
the head from working loose.
Loctite threadlock must be used for fitting the Allen screw.
Smear hydraulic fluid on the gaskets.

70-04-M205EN (25/06/2012)
 CHECKING AND ADJUSTING THE
HYDRAULIC SYSTEM 19

REAR AXLE BLOCKING CYLINER

4
1

7
5

DISASSEMBLY

70
Remove the rod (Ref. 1) from the cylinder jacket.
Remove the gasket (Ref. 2), the anti-extrusion rings (Ref. 3 and 4) and the guide rings (Ref. 5) of the
cylinder (Ref. 7).
Change the gaskets and components, if necessary.

REASSEMBLY

Operation reverse to that for disassembly.

Note: Smear hydraulic fluid on the gaskets.

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 CHECKING AND ADJUSTING THE
20 HYDRAULIC SYSTEM

LEVELLING CYLINDER

Tools required:
- 1 hook spanner (for ring nuts)
- 1 4mm Allen key

5 4
6
2

12
10
11
10

9
7
8

DISASSEMBLY
70

Unscrew the head (Ref. 1) using a hook spanner by dislodging the tab on the rim of the jacket that is
staked into a corresponding location on the head.
Remove from the rod assembly cylinder jacket (Ref. 2) + piston (Ref. 3) assembly.
Remove the Allen screw (Ref. 4) (4mm Allen key) of the piston.
Attention: screw locked with loctite (see "Application of threadlock" chapter).
Unscrew the piston (Ref. 3) of the cylinder using a hook spanner, remove the piston (Ref. 3) of the cylinder
and the head piece (Ref. 1) from the rod.
Remove the gasket (Ref. 5) and the sealed gaskets (Ref. 6) of the piston, remove the gaskets (Ref. 7-8-9),
the guide rings (Ref. 10) and the gaskets (Ref. 11 and 12) of the head piece.
Check the condition of the valve, the valve seat and spring; change the gaskets and the components
if necessary.
Attention to the direction of reassembly.

REASSEMBLY

Operation reverse to that for disassembly.

Note: The outer tab of the jacket must be staked into the corresponding location on the head to prevent
the head from working loose.
Loctite threadlock must be used for fitting the Allen screw.
Smear hydraulic fluid on the gaskets.
When assembling the set of watertight gaskets (Ref. 6) " Avoid alinging the cuts of the anti-extrusion
rings" (Shift by one third of the circumference).
70-04-M205EN (25/06/2012)
 CHECKING AND ADJUSTING THE
HYDRAULIC SYSTEM 21

ADJUSTING THE TURRET ROTATION BRAKE

MRT 1850 / 2150

Rotate the valve cock (clockwise) to close the valve (Photo 01).
Successively, for correct adjustment, turn the valve cock (counterclockwise) through 2 turns and tighten
the grub screw (Photo 02).

MRT 2540

Rotate the valve cock (clockwise) to close the valve (Photo 01).
Successively, for correct adjustment, turn the valve cock (counterclockwise) through 1 and 3/4 turns and
tighten the grub screw (Photo 02).

PHOTO 1 PHOTO 2

70

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 CHECKING AND ADJUSTING THE
22 HYDRAULIC SYSTEM
70

70-04-M205EN (25/06/2012)
 REMOVING THE HYDRAULIC COMPONENTS

page

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
REMOVING THE HYDRAULIC FLUID TANK AND FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . 3
REMOVING THE DIRECTIONAL CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REMOVING THE CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
–– REMOVING THE STABILIZERS EXTENSION CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
–– REMOVING THE STABILIZERS ASCENT AND DESCENT CYLINDERS . . . . . . . . . . . . . . . . . 9
–– REMOVING THE BOOM LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

70
–– REMOVING THE COMPENSATION CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
–– REMOVING THE SLEWING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
–– REMOVING THE BOOM EXTENSION CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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 REMOVING THE HYDRAULIC
2 COMPONENTS
70

GENERAL INFORMATION

Mark all the hydraulic pipes and electrical connections with a marker pen, before disassembling, to
ensure correct positioning in the reassembly phase .

b Discharge pressure from the hydraulic circuit before disconnecting the tubes. Plug all the
hydraulic pipes and orifices to prevent impurities from contaminating the hydraulic circuit.

PREPARATION AND SAFETY INSTRUCTIONS

Park the vehicle on a horizontal surface and switch off the I .C . engine .

Specific tools:
– Crane for lifting (5000 kg . minimum) .
– Jack

70-06-M205EN (11/09/2012)
 REMOVING THE HYDRAULIC
COMPONENTS 3

REMOVING THE HYDRAULIC FLUID TANK AND

FUEL TANK

1
Place containers of suitable size to hold the quantity of fluid to
be collected under the drainage cap (Ref. 1).
Remove the cap (Ref. 1) and drain out the oil.

To speed up draining of the tank, remove the filler cap (Ref. 2).

70
2

Remove cover (Ref. e), remove the three steps (Ref. 4) of the
ladder, remove the front guard (Ref. 5).

4
5

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 REMOVING THE HYDRAULIC
4 COMPONENTS

Disconnect the fuel suction and return pipes (Ref. 6) fitted on

the level indicator, disconnect the electric connection (Ref. 7)
10 of the fuel level indicator.
11
Unscrew the venting filter (Ref. 8) and screw an eyelet on the
8
tank to secure the tank to an overhead crane or elevator.
7 Disconnect the electric sockets (Ref. 9) and the support (Ref.
9
10) on the tank and unscrew the clamp (Ref. 11) which holds
together the electric cables, from the chassis.
6

Unscrew the oil return manifold (Ref. 12) fitted on the exhaust
12
13 filter (Ref. 13), removing the relays box after unscrewing the
screws (Ref. 14).

14
14

Slacken the screws (Ref. 15) fixing the manifold to the chassis,
remove the vacuum indicator (Ref. 16).
70

15

16

24
Disconnect the hydraulic fluid suction pipes (Ref. 17, 18, 19, 20)
fitted on the tank.
25 23
21
Note: the tube (Ref. 20) is present only in the models equipped
with air conditioning.
17 Disconnect the hydraulic suction pipes (Ref. 21) on the transmission
18 oil filter (Ref. 22).
19
22 Disconnect the hydraulic tube (Ref. 23) for oil return from the
20
radiator, disconnect the hydraulic drainage pipe of the rotation
motor (Ref. 24) and the hydraulic pipe (Ref. 25) for oil return
from the hydrostatic pump.

70-06-M205EN (11/09/2012)
 REMOVING THE HYDRAULIC
COMPONENTS 5

Slacken the screws (Ref. 26) on the front of the tank.

26

26

Slacken the screws (Ref. 27) on the rear of the tank.

27

27

Slacken the screws (Ref. 28) on the inner side of the tank to the
chassis.

70
Remove the tank from the vehicle.

28

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 REMOVING THE HYDRAULIC
6 COMPONENTS

REMOVING THE DIRECTIONAL CONTROL VALVE

3
1
Disconnect all the electrical connections (Ref. 1) and the hydraulic
pipes (Ref. 2) from the directional control valve (Ref. 3).

Disconnect the tube (Ref. 4) from the accumulator (Ref. 5).

70

Remove the accumulator (Ref. 5) from the turret support bracket.

Secure the directional control valve (3) to an overhead crane,
3
slacken the screws (Ref. 6) and the washers (Ref. 7) which fix it
5
to the turret and remove it from the vehicle.
7 6

70-06-M205EN (11/09/2012)
 REMOVING THE HYDRAULIC
COMPONENTS 7

REMOVING THE CYLINDERS

REMOVING THE STABILIZERS EXTENSION CYLINDERS

Lower the stabilizers so that it is possible to act on the pins

1 (Ref . 1) .
Acting on the commands concerned, extend the stabilizers
extension arm so that it is possible to work on the pins (Ref . 2) .
2

If it is found to be impossible to remove the boom, unscrew the

stop screw (Ref . 3) and the nut (Ref . 4), remove the pin (Ref . 5)
and then the foot (Ref . 6) .

70
3

4
5 6

Slacken the screws (Ref . 7) and the washers (Ref . 8) and remove
the valve cover plate (Ref . 9) .

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 REMOVING THE HYDRAULIC
8 COMPONENTS

If necessary, slacken the screws (Ref. 10), remove the valve

12 (Ref. 11)
12
from the bottom of the cylinder and disconnect the two hydraulic
tubes (Ref. 12)
di alimentazione.

10
11

Slacken the stop screw (Ref. 13) and the nut (Ref. 14) and remove
the pin (Ref. 15).
13

14
15
70

Slacken the stop screw (Ref. 16) and the nut (Ref. 17) and remove
the pin (Ref. 18).

16

18
17

19
Remove the stabilizers extension cylinder (Ref. 19) from the
20
side of the bottom plate (Ref. 20).

70-06-M205EN (11/09/2012)
 REMOVING THE HYDRAULIC
COMPONENTS 9

REMOVING THE STABILIZERS ASCENT AND DESCENT

CYLINDERS

1 To disassemble the LH front or RH rear inclination cylinder,

3 remove the mudguard to avoid accidental breakage .
Hook up the stabilizer arm on the foot side by means of an
2
overhead crane or elevator, unscrew the stop screw (Ref . 1),
the nut (Ref . 2) and remove the pin (Ref . 3) .
Rest the foot end of the stabilizers arm (Ref . 4) on the ground .
4

Secure the cylinder to an overhead crane or elevator by means

5
of a belt .
Slacken the stop screw (Ref . 5) and the nut (Ref . 6) and remove

70
7
the pin (Ref . 7) .
6

Disconnect the hydraulic pipes (Ref . 8) from the block valve of

the cylinders .

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 REMOVING THE HYDRAULIC
10 COMPONENTS

9
Remove the cylinder (Ref. 9) from its seat.
70

70-06-M205EN (11/09/2012)
 REMOVING THE HYDRAULIC
COMPONENTS 11

REMOVING THE BOOM LIFT CYLINDER

Activate the boom lift command to bring the boom above the
cab (Ref. 1) dimensions, to allow for easy access to the rod-boom
side lift cylinder hinge pin from both sides.

Secure the boom to an overhead crane or an elevator by means

of the eyelets provided for the purpose (Ref. 2) in the upper
part of the boom.

70
2
2 Secure the lift cylinder to a support.

Unscrew the stop screw (Ref. 3) and remove the hinge pin of
the lift cylinder on the rod-boom side (Ref. 4).

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 REMOVING THE HYDRAULIC
12 COMPONENTS

Place the lift cylinder on the turret, resting it on a wooden beam

(Ref. 5) and retract the rod using the control in the cab.

Disconnect the hydraulic pipes (Ref. 6) from the block valve of

the cylinder.

Slacken the screw (Ref. 7) and the nut (Ref. 8) and remove the
pin (Ref. 9) locking the lift cylinder through the slot provided
70

on the turret.
7

With the help of ropes and an overhead crane, remove the lift
cylinder (Ref. 10) from the vehicle.

10

70-06-M205EN (11/09/2012)
 REMOVING THE HYDRAULIC
COMPONENTS 13

REMOVING THE COMPENSATION CYLINDER

Lift the boom enough to be able to access the upper locking

pin (Ref . 1) of the compensation cylinder .
2 Secure the compensation cylinder to the overhead crane .
3 Unscrew the screw and retainer nut (Ref . 2 and 3) and remove
1
the lower hinge pin (Ref . 1)
7 of the compensation cylinder using an extractor if necessary .

Unscrew the screw and retainer nut (Ref . 4 and 5) and remove
the lower hinge pin (Ref . 6)

70
of the compensation cylinder using an extractor if necessary .
4

Remove the compensation cylinder (Ref . 7) from the vehicle

6 with the help of an overhead crane .

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 REMOVING THE HYDRAULIC
14 COMPONENTS

REMOVING THE SLEWING CYLINDER

Unscrew the ring nut (Ref. 1) which blocks the pin (Ref. 2).

4
Secure the quick-release coupling (Ref. 3) to an overhead crane.
Remove the pin (Ref. 2) from the quick-release coupling (Ref.
70

3), and from the slewing cylinder (Ref. 4).

Disconnect the hydraulic pipes (Ref. 5) from the block valve of

the cylinder.

70-06-M205EN (11/09/2012)
 REMOVING THE HYDRAULIC
COMPONENTS 15

Secure the cylinder to a suitable jack.

Slacken the screw (Ref. 6) and unscrew the nut (Ref. 7) and
7
remove the pin (Ref. 8) to free the slewing cylinder (Ref. 4).

With the help of ropes, an overhead crane and a jack, remove

the slewing cylinder (Ref. 4) from the top of the boom.

70
4

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 REMOVING THE HYDRAULIC
16 COMPONENTS

REMOVING THE BOOM EXTENSION CYLINDER

1 With the boom extended by about 25-30cm, unscrew the lock

nuts and nuts on the tierods for the booms extension chains
2
(Ref. 1 and 2) up to the split pins.
2

Unscrew the lock nuts and nuts (Ref. 3) of the tierods for the
chains for extraction of the II extension boom up to the split pins.
70

Unscrew the lock nuts and nuts (Ref. 4) of the tierods for the
chains for retraction of the III extension boom up to the split pins.

70-06-M205EN (11/09/2012)
 REMOVING THE HYDRAULIC
COMPONENTS 17

Remove the screws (Ref. 5) blocking the extension cylinder

hinge pins to the I extension boom.
5
5

Using an extractor, remove the hinge pins (Ref. 6) connecting

the extension cylinder to the I extension boom.

7
Remove the Seeger rings (Ref. 7) and remove the hinge pin (Ref.
8) between the extension cylinder and the outer arm.

70
8

Using an overhead crane or elevator, remove the extension

cylinder (Ref. 9) from the boom.

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 REMOVING THE HYDRAULIC
18 COMPONENTS
70

70-06-M205EN (11/09/2012)
 REINSERTING THE HYDRAULIC COMPONENTS

page

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
REINSERTING THE CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– REINSERTING THE EXTENSION CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– REINSERTING THE SLEWING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
–– REINSERTING THE COMPENSATION CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
–– REINSERTING THE BOOM LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
–– REINSERTING THE STABILIZERS ASCENT AND DESCENT CYLINDERS . . . . . . . . . . . . . . 11

70
–– REINSERTING THE STABILIZERS EXTENSION CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REINSERTING THE DIRECTIONAL CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
REINSERTING THE HYDRAULIC FLUID AND FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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 REINSERTING THE HYDRAULIC
2 COMPONENTS
70

GENERAL INFORMATION

Reposition all the pipes and connections correctly according to the markings made with a marker pen
during the disassembly .

PREPARATION AND SAFETY INSTRUCTIONS

Park the vehicle on a horizontal surface and switch off the I .C . engine .

Specific tools:
– Crane for lifting (5000 kg . minimum) .
– Jack

70-07-M205EN (11/09/2012)
 REINSERTING THE HYDRAULIC
COMPONENTS 3

REINSERTING THE CYLINDERS

REINSERTING THE EXTENSION CYLINDER

2 Clean the bushes of the booms extension cylinder.

Check to make sure the rollers (Ref. 1) and slide (Ref. 2) are fitted
correctly on the cylinder.

Check to make sure the valve block (Ref. 3) is mounted correctly

3 on the extension cylinder.

70

Fit two eccentric bushes (Ref. 4) (one on each side), on the

extension cylinder, on the rod side, with the holes for assembly
(Ref. 5) facing outwards.

4
5

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 REINSERTING THE HYDRAULIC
4 COMPONENTS

Using an overhead crane or elevator, insert the extension

cylinder (Ref. 9) into the boom, keeping the valves block (Ref.
3) facing downwards.

Align the holes of the bushes present on the I extension boom

with the seats of the pins on the extension cylinder jacket.

Insert the two hinge pins (Ref. 7) between the extension cylinder
and I extension boom, keeping the two holes (Ref. 8) on the
70

pin perpendicular.
8

Fix the pins (Ref. 7) to the cylinder by means of the pins.

Insert the screws upwards from below and lock by means of
the nuts (Ref. 10).
9 9

10 10

70-07-M205EN (11/09/2012)
 REINSERTING THE HYDRAULIC
COMPONENTS 5

Align the holes of the bushes present on the I extension boom

with the seats of the pins on the extension cylinder jacket.

Fit the two grub screws (Ref. 11) on the cylinder rod to block
the eccentric bushes.
Insert the hinge pin (Ref. 12) between the extension cylinder
and the outer boom and fix by means of the seeger rings (Ref.
13), one on each side.

Note: If necessary, lift the extension cylinder using an overhead

11 11 crane or elevator, to align the hinge hole with the outer boom.
12 Grease the extension cylinder pin (see "Lubricants" Table in the
Operation and Maintenance Manual).

70
13

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 REINSERTING THE HYDRAULIC
6 COMPONENTS

REINSERTING THE SLEWING CYLINDER

1
With the help of ropes and an overhead crane, lift the slewing
cylinder (Ref. 1) and place it on a jack.

Position the bottom of the slewing cylinder (Ref. 1)

on the top of the boom, aligned with the hole for the pin.
70

Insert the hinge pin (Ref. 2) for the slewing cylinder in the hole
4 in the III extension boom.
Fit the screw (Ref. 3) and the locking nut (Ref. 4).
2

70-07-M205EN (11/09/2012)
 REINSERTING THE HYDRAULIC
COMPONENTS 7

Reconnect the hydraulic pipes (Ref. 5) on the cylinder valve.

Respect the ports on the valve.

Insert the pin (Ref. 6) for hinging the rod of the slewing cylinder
1
(Ref. 1) to the quick-release coupling (Ref. 7).

Lock the pin (Ref. 6) with the ring nut (Ref. 8).

70
6

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 REINSERTING THE HYDRAULIC
8 COMPONENTS

REINSERTING THE COMPENSATION CYLINDER

Reposition the compensation cylinder (Ref . 1) on the turret with

3 the help of an overhead crane .

Insert the cylinder bottom hinge pin (Ref . 2) in the hole provided
2
for the purpose and lock it using the screw (Ref . 3) and the nut
4
(Ref . 4) .

Lift the cylinder to align the rod with the hole provided on the
70

boom, insert the pin (Ref . 5) and block it using the screw (Ref .
6) and the nut (Ref . 7) .
6

7
5

70-07-M205EN (11/09/2012)
 REINSERTING THE HYDRAULIC
COMPONENTS 9

REINSERTING THE BOOM LIFT CYLINDER

Reposition the lift cylinder (Ref. 1) on the vehicle by means of

ropes and overhead crane.
1

Insert the lift cylinder locking pin in the hole provided in the
turret and hold it in place by tightening the screw (Ref. 3) and

70
the nut (Ref. 4).

Reconnect the hydraulic pipes (Ref. 5) on the cylinder block valve.

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 REINSERTING THE HYDRAULIC
10 COMPONENTS

Raise the lift cylinder (Ref. 1) from the turret (Ref. 6), until the
rod gets inserted in its seat on the boom

Insert the lift cylinder hinge pin (Ref. 7) of the rod-boom side,
blocking it by means of the screw (Ref. 8).

Remove the overhead crane or elevator from the eyelets (Ref.

8) present in the upper part of the boom.

Remove the support from the lift cylinder.

70

9 9

70-07-M205EN (11/09/2012)
 REINSERTING THE HYDRAULIC
COMPONENTS 11

1
REINSERTING THE STABILIZERS ASCENT AND DESCENT
CYLINDERS

Reposition the cylinder (Ref . 1) on the stabilizer arms by means

of an overhead crane or an elevator using a belt .

3
Insert the pin (Ref . 2) in the hole and lock by tightening the
screw (Ref . 3)

70
2
and the nut (Ref . 4) .
4
Refit all the hydraulic pipes on the stabilizers inclination cylinder
valve .

Reposition the stabilizers boom on the foot side (Ref . 5) using

an overhead crane or an elevator, insert the pin (Ref . 6), locking
7 it using the screw (Ref . 7) and the nut (Ref . 8) .
6
The mudguards can now be refitted near the LH front and RH
8 rear inclination cylinders .

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 REINSERTING THE HYDRAULIC
12 COMPONENTS

Reconnect the hydraulic pipes (Ref. 9) on the cylinder block valve.

9
70

70-07-M205EN (11/09/2012)
 REINSERTING THE HYDRAULIC
COMPONENTS 13

REINSERTING THE STABILIZERS EXTENSION CYLINDERS

1 Reposition the stabilizers extension cylinder (Ref . 1) inserting it

2 in the foot (Ref . 2) from the side of the bottom plate .

Insert the pin (Ref . 3) in the hole concerned and lock by means
of the screw (Ref . 4) and the nut (Ref . 5) .

70
4

3
5

Insert the pin (Ref . 6) and lock by means of the screw (Ref . 7)
and the nut (Ref . 8) .

8
6

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 REINSERTING THE HYDRAULIC
14 COMPONENTS

Refit the valve (Ref. 9), that may have been removed earlier,
11 at the bottom of the cylinder, using the screws (Ref. 10) and
11
reconnect the two hydraulic feed pipes (Ref. 11).
Respect the inlet ports on the valve (Ref. 9).

10
9

Refit the valve cover plate (Ref. 12) by means of the screws (Ref.
13) and washers (Ref. 14).

14

12

13

Refit the foot (Ref. 15), dismantled earlier, inserting the pin
(Ref. 16) and block by means of the screws (Ref. 17) and the
70

nut (Ref. 18).

17

18
16 15

70-07-M205EN (11/09/2012)
 REINSERTING THE HYDRAULIC
COMPONENTS 15

REINSERTING THE DIRECTIONAL CONTROL

1
VALVE
4

3 2 Reposition the directional control valve (Ref. 1) on the vehicle

with the help of an overhead crane.
Fix to the chassis by means of the screws and washers (Ref. 2
and 3).
Refit the accumulator (Ref. 4) on the turret support bracket.

1 Reconnect all the electrical connections (Ref. 5) and the hydraulic

5
pipes (Ref. 6) on the directional control valve (Ref. 1).

6
70

Reconnect the tube (Ref. 7) on the accumulator (Ref. 4).

(11/09/2012) 70-07-M205EN
 REINSERTING THE HYDRAULIC
16 COMPONENTS

REINSERTING THE HYDRAULIC FLUID AND FUEL

TANK

Reposition the tank on the vehicle using an overhead crane,

tighten the screw (Ref. 1) on the inner side of the tank to the
chassis.

Slacken the screws (Ref. 2) on the rear of the tank.

70

Tighten the screws (Ref. 3) on the front of the tank.

70-07-M205EN (11/09/2012)
 REINSERTING THE HYDRAULIC
COMPONENTS 17

5 Reconnect the hydraulic tube (Ref. 4) for oil return from the
hydrostatic pump, the hydraulic drainage pipe of the rotation
motor (Ref. 5) and the hydraulic pipe (Ref. 6) for oil return from
6
4 7 the radiator.
Reconnect the hydraulic suction pipes (Ref. 7) on the transmission
9
oil filter (Ref. 8).
10
Reconnect the hydraulic fluid suction pipes (Ref. 9, 10, 11, 12)
8
11 fitted on the tank.
12 Note: the tube (Ref. 12) is present only in the models equipped
with air conditioning.

Tighten the screws (Ref. 13) fixing the manifold to the chassis,
refit the vacuum indicator (Ref. 14).

13

14

Refit the relays box by tightening the screws (Ref. 15), screw
16
17
the oil return manifold (Ref. 16) on the exhaust filter (Ref. 17).

70
15
15

Reconnect the fuel suction and return pipes (Ref. 18) fitted on
the level indicator, connect the electric connection (Ref. 19) of
22
23 the fuel level indicator.
Screw on the oil vent filter (Ref. 20) and remove the overhead
20
19
crane or the elevator used for removing the tank.
21 Reconnect the electric sockets (Ref. 21) and the support (Ref. 22)
on the tank and screw the clamp (Ref. 23), which holds together
18 the electric cables, on the chassis.

(11/09/2012) 70-07-M205EN
 REINSERTING THE HYDRAULIC
18 COMPONENTS

Refit the front guard (Ref. 24), refit the three steps (Ref. 25).
Refit the cover (Ref. 26).
26

25

25
24

25

Refit the drainage plug (Ref. 27)

27

Fill the tank with 210 litres of hydraulic fluid

70

70-07-M205EN (11/09/2012)
 SPECIAL TOOLS FOR THE HYDRAULIC SYSTEM

page

PRESSURE GAUGES STANDARD BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

DIGITAL PRESSURE GAUGE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– FUNCTIONS : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

70

(25/06/2012) 70-09-M205EN
 SPECIAL TOOLS FOR THE HYDRAULIC
2 SYSTEM

PRESSURE GAUGES STANDARD BOX

The box contains all the components necessary for measuring

the pressures on all Manitou products.

1 2 3 3 4 5 5 6
70

8 7

Pressure gauges standard box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549671

Consisting of:

1. 1 1/9 bar Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . 549882

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

70-09-M205EN (25/06/2012)
 SPECIAL TOOLS FOR THE HYDRAULIC
SYSTEM 3

DIGITAL PRESSURE GAUGE BOX

FUNCTIONS:

• Pressure gauge Function: the display makes all the following

options possible:

- Input temperature and pressure at +/- 2°C

- Input minimum and maximum pressure P1 (700 bar in Class 0.1)
- Output minimum and maximum pressure P2 (700 bar in Class 0.1)
- Differential pressure dP=P1-P

• Hold Function: the user can put the display on hold at any
moment to be able to take down notes.

• Unit Function: the user can change the unit of measurement

(bar, PSI, kPa, mCe) at any moment.

• Tare Function: allows zero offset.

• Leaks test function: makes if possible to measure pressure

variations in a predefined time.

• Save Function: up to a maximum of 16000 values can be

saved. The sampling frequency can be set.

70
• Zero Function: the zero setting is done on 2 sensors.

Digital Pressure gauge Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 662187

Consisting of:

1. 1 Digital pressure gauge Mano dP HP 700 bar

2. 1 Hose for measurement DN2 1215/1620, L = 1.5m, 630 bar
3. 2 Hoses for measurement DN2 1620/1620, L = 1.5m, 630 bar
4. 2 Adaptors for Pressure gauge 1620

(25/06/2012) 70-09-M205EN
 SPECIAL TOOLS FOR THE HYDRAULIC
4 SYSTEM
70

70-09-M205EN (25/06/2012)
 Electricity

- Electrical characteristics and

specifications

- Electrical schematic diagrams

- Electrical components location

- Electrical control and adjustment

- Electrical specific tooling

80
 ELECTRICAL FEATURES AND SPECIFICATIONS

page

SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SOFTWARE VERSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OPERATING LOGIC OF THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
VEHICLE WITH FORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
–– VEHICLE WITH FORKS ON TYRES OR STABILIZERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
–– VEHICLE WITH FORKS ON TYRES OR STABILIZERS IN TILTING CONDITION . . . . . . . . . 5
VEHICLE ON STABILIZERS WITH PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
MACHINE WITH FIXED/ORH PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
–– MACHINE ON STABILIZERS WITH FIXED/ORH PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . 8
–– VEHICLE ON STABILIZERS WITH FIXED/ORH PLATFORM IN TILTING CONDITION . . 9
–– VEHICLE ON TYRES WITH FIXED/ORH PLATFORM IN TILTING CONDITION . . . . . . . . . 11
–– MACHINE ON TYRES WITH FIXED/ORH PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

80
VEHICLE WITH OSCILLATING PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
–– VEHICLE ON TYRES WITH OSCILLATING/ORH PLATFORM IN TILTING CONDITION. . 14
–– VEHICLE ON TYRES WITH OSCILLATING PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
–– VEHICLE ON STABILIZERS WITH OSCILLATING PLATFORM IN TILTING CONDITION. . 17
–– VEHICLE ON STABILIZERS WITH OSCILLATING PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . 18
VEHICLE WITH RADIO CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
–– VEHICLE ON STABILIZERS WITH RADIO CONTROL IN TILTING CONDITION . . . . . . . . 22
–– VEHICLE ON STABILIZERS WITH RADIO CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Connectors wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
2 SPECIFICATIONS

SOFTWARE

SOFTWARE VERSION

The software version installed on the vehicle’s MC2M board is seen on the display in the cab when the
panel is switched on.
80

MNT_XXX_YYY

The first 7 alphanumeric characters (MNT_XXX) displayed identify the machine type, while the remaining
4 identify the number of the software version.
Further details regarding the software versions installed on the electronic control devices of the vehicle
are available in the advanced diagnostics pages that can be accessed by means of the F key.
To display these, press F5 on the display and then press F10.

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 3

OPERATING LOGIC OF THE VEHICLE

The software program inserted in the MC2M control unit limits the movements of the vehicle on the
basis of the:
–– accessory fitted;
–– state of the vehicle (or tyres or stabilizers)
–– position of the boom;
–– position of the cab;
–– type of command (from cab or by radio control).
The operating logics implemented in the vehicle software are described below.

80

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
4 SPECIFICATIONS

VEHICLE WITH FORKS

VEHICLE WITH FORKS ON TYRES OR STABILIZERS

MOVEMENTS ALLOWED FROM THE CAB

TURRET WITHIN +/-15° TURRET MORE THAN +/-15°
BOOM WITHIN 55° BOOM MORE THAN 55° NOTES
BOOM RETRACTED BOOM EXTENDED
STABILIZERS RAISED √

STABILIZERS LOWERED √ √

TURRET ROTATION √ √

SLEWING UPWARDS √ √

SLEWING DOWNWARDS √ √

BOOM ASCENT √ √

BOOM DESCENT √ √

BOOM RETRACTION √ √

BOOM EXTENSION √ √

OPTION 1 √ √

OPTION 2 √ √

LEVELLING FUNCTIONS ON FRONT, WITH BOOM < 3M

AXLE BLOCK BLOCKED (FLASHING INDICATOR LIGHT WITH TURRET ROTATED OR BOOM > 55°

ATTENTION: the MRT 2540 model cuts the rotation if the boom is > 55°, rotation allowed only within
+/- 5°.

ATTENTION: the stabilizers can only be lifted if the turret is positioned within +/-5°, the boom is retracted
and positioned within 55°.

MOVEMENTS ALLOWED FROM THE CAB WITH ROLLOVER PROTECTION EXCLUSION KEY ACTIVATED
TURRET WITHIN +/-15° TURRET MORE THAN +/-15°
80

BOOM WITHIN 55° BOOM MORE THAN 55° NOTES

BOOM RETRACTED BOOM EXTENDED
STABILIZERS RAISED √ √

STABILIZERS LOWERED √ √

TURRET ROTATION √ √

SLEWING UPWARDS √ √

SLEWING DOWNWARDS √ √

BOOM ASCENT √ √

BOOM DESCENT √ √

BOOM RETRACTION √ √

BOOM EXTENSION √ √

OPTION 1 √ √

OPTION 2 √ √

ATTENTION: the platform exclusion key has no effect on the above-mentioned functioning.
ATTENTION: the levelling is never recovered by the key.

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 5

VEHICLE WITH FORKS ON TYRES OR STABILIZERS IN TILTING CONDITION

MOVEMENTS ALLOWED FROM THE CAB

TURRET WITHIN +/-15° TURRET MORE THAN +/-15°
BOOM WITHIN 55° BOOM MORE THAN 55° NOTES
BOOM RETRACTED BOOM EXTENDED
STABILIZERS RAISED

STABILIZERS LOWERED √ √

The turret can be brought to the central

position only if 1 of the 2 proximity
TURRET ROTATION √ √
switches +/-5° is reading

SLEWING UPWARDS

SLEWING DOWNWARDS √ √

BOOM ASCENT

BOOM DESCENT

BOOM RETRACTION √ √

BOOM EXTENSION

OPTION 1 √ √

OPTION 2

LEVELLING ONLY WORKS WITH BOOM ANGLE < 20° ALSO WHEN EXTENDED

MOVEMENTS ALLOWED FROM THE CAB WITH ROLLOVER PROTECTION EXCLUSION KEY ACTIVATED
TURRET WITHIN +/-15° TURRET MORE THAN +/-15°
BOOM WITHIN 55° BOOM MORE THAN 55° NOTES
BOOM RETRACTED BOOM EXTENDED
STABILIZERS RAISED √ √

STABILIZERS LOWERED √ √

TURRET ROTATION √ √

80
SLEWING UPWARDS √ √

SLEWING DOWNWARDS √ √

BOOM ASCENT √ √

BOOM DESCENT √ √

BOOM RETRACTION √ √

BOOM EXTENSION √ √

OPTION 1 √ √

OPTION 2 √ √

LEVELLING ONLY WORKS WITH BOOM ANGLE < 20° ALSO WHEN EXTENDED

ATTENTION: the platform exclusion key has no effect on the above-mentioned functioning.

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
6 SPECIFICATIONS

VEHICLE ON STABILIZERS WITH PLATFORM

MOVEMENTS ALLOWED FROM PUSHBUTTON PANEL

BOOM BOOM BOOM BOOM
WITHIN H=3m WITHIN H=3m MORE THAN H=3m MORE THAN H=3m NOTES
BOOM RETRACTED BOOM EXTENDED BOOM RETRACTED BOOM EXTENDED
TURRET ROTATION √ √ √ √

SLEWING UPWARDS √ √ √ √

SLEWING
√ √ √ √
DOWNWARDS
BOOM ASCENT √ √ √ √

BOOM DESCENT √ √ √ √

BOOM RETRACTION √ √ √ √

BOOM EXTENSION √ √ √ √

OPTION 1 √ √ √ √

OPTION 2 √ √ √ √

MOVEMENTS ALLOWED FROM PUSHBUTTON PANEL IN VEHICLE TILTING CONDITIONS

BOOM BOOM BOOM BOOM
WITHIN H=3m WITHIN H=3m MORE THAN H=3m MORE THAN H=3m NOTES
BOOM RETRACTED BOOM EXTENDED BOOM RETRACTED BOOM EXTENDED
The turret can be brought to
the central position only if 1 of
TURRET ROTATION √ √ √ √
the 2 proximity switches +/-5°
is reading.
SLEWING UPWARDS

SLEWING DOWNWARDS √ √ √ √

√ √
BOOM ASCENT (even if more than H=3m) (even if more than H=3m)
√ √

BOOM DESCENT

BOOM RETRACTION √ √ √ √

BOOM EXTENSION

OPTION 1 √ √ √ √
80

OPTION 2

MOVEMENTS ALLOWED FROM PUSHBUTTON PANEL IN PLATFORM OVERLOAD CONDITION

BOOM BOOM BOOM BOOM
WITHIN H=3m WITHIN H=3m MORE THAN H=3m MORE THAN H=3m NOTES
BOOM RETRACTED BOOM EXTENDED BOOM RETRACTED BOOM EXTENDED
TURRET ROTATION

SLEWING UPWARDS

SLEWING DOWNWARDS

BOOM ASCENT

BOOM DESCENT

BOOM RETRACTION

BOOM EXTENSION

OPTION 1

OPTION 2

NOTE: the data given in the afore-mentioned tables are applicable for all positions of the turret.

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 7

MOVEMENTS ALLOWED FROM PUSHBUTTON PANEL IN VEHICLE TILTING AND PLATFORM OVERLOAD CONDITIONS
BOOM BOOM BOOM BOOM
WITHIN H=3m WITHIN H=3m MORE THAN H=3m MORE THAN H=3m NOTES
BOOM RETRACTED BOOM EXTENDED BOOM RETRACTED BOOM EXTENDED
TURRET ROTATION

SLEWING UPWARDS

SLEWING DOWNWARDS

BOOM ASCENT

BOOM DESCENT

BOOM RETRACTION

BOOM EXTENSION

OPTION 1

OPTION 2

MOVEMENTS ALLOWED FROM PUSHBUTTON PANEL IN PLATFORM WITH DOOR OPEN CONDITION
BOOM BOOM BOOM BOOM
WITHIN H=3m WITHIN H=3m MORE THAN H=3m MORE THAN H=3m NOTES
BOOM RETRACTED BOOM EXTENDED BOOM RETRACTED BOOM EXTENDED
TURRET ROTATION

SLEWING UPWARDS
SLEWING
DOWNWARDS
BOOM ASCENT

BOOM DESCENT

BOOM RETRACTION

BOOM EXTENSION

OPTION 1

OPTION 2

MOVEMENTS ALLOWED FROM PUSHBUTTON PANEL IN VEHICLE TILTING AND PLATFORM WITH DOOR OPEN CONDITIONS

80
BOOM BOOM BOOM BOOM
WITHIN H=3m WITHIN H=3m MORE THAN H=3m MORE THAN H=3m NOTES
BOOM RETRACTED BOOM EXTENDED BOOM RETRACTED BOOM EXTENDED
TURRET ROTATION

SLEWING UPWARDS

SLEWING DOWNWARDS

BOOM ASCENT

BOOM DESCENT

BOOM RETRACTION

BOOM EXTENSION

OPTION 1

OPTION 2

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
8 SPECIFICATIONS

MACHINE WITH FIXED/ORH PLATFORM

MACHINE ON STABILIZERS WITH FIXED/ORH PLATFORM

MOVEMENTS ALLOWED FROM THE CAB

BOOM BOOM BOOM BOOM
WITHIN H=3m WITHIN H=3m MORE THAN H=3m MORE THAN H=3m NOTES
BOOM RETRACTED BOOM EXTENDED BOOM RETRACTED BOOM EXTENDED
STABILIZERS RAISED √

STABILIZERS LOWERED √ √

TURRET ROTATION

SLEWING UPWARDS
SLEWING
DOWNWARDS
BOOM ASCENT When the vehicle is stabilized
BOOM DESCENT √ all the movements work with
speed limitation
BOOM RETRACTION

BOOM EXTENSION

OPTION 1

OPTION 2

MOVEMENTS ALLOWED FROM THE CAB WITH PLATFORM EXCLUSION KEY ACTIVATED
BOOM BOOM BOOM BOOM
WITHIN H=3m WITHIN H=3m MORE THAN H=3m MORE THAN H=3m NOTES
BOOM RETRACTED BOOM EXTENDED BOOM RETRACTED BOOM EXTENDED
STABILIZERS RAISED √

STABILIZERS LOWERED √ √

TURRET ROTATION √ √ √ √ With the platform exclusion

key activated, all commands
SLEWING UPWARDS √ √ √ √
from the pushbutton are
SLEWING DOWNWARDS √ √ √ √ lost, but if the enable button
80

in the pushbutton panel

√ √ is pressed, the save key is
BOOM ASCENT (even if more than H=3m) (even if more than H=3m)
√ √
obtained (enabling from the
BOOM DESCENT √ √ √ √ pushbutton panel has over
the key) and the commands
BOOM RETRACTION √ √ √ √ can be resumed from the
pushbutton panel. This is
BOOM EXTENSION √ √ √ √ because the person in the
OPTION 1 √ √ √ √ basket must be able to stop a
“dangerous” movement made
OPTION 2 √ √ √ √ by the operator in the cab.

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 9

MOVEMENTS ALLOWED FROM THE CAB WITH ROLLOVER PROTECTION EXCLUSION KEY ACTIVATED
BOOM BOOM BOOM BOOM
WITHIN H=3m WITHIN H=3m MORE THAN H=3m MORE THAN H=3m NOTES
BOOM RETRACTED BOOM EXTENDED BOOM RETRACTED BOOM EXTENDED
STABILIZERS RAISED √

STABILIZERS LOWERED √ √

TURRET ROTATION

SLEWING UPWARDS

SLEWING DOWNWARDS

BOOM ASCENT

BOOM DESCENT √

BOOM RETRACTION

BOOM EXTENSION

OPTION 1
Controlled by the rollover
OPTION 2
protection system

NOTE: the data given in the afore-mentioned tables are applicable for all positions of the turret.

VEHICLE ON STABILIZERS WITH FIXED/ORH PLATFORM IN TILTING CONDITION

MOVEMENTS ALLOWED FROM THE CAB

BOOM BOOM BOOM BOOM
WITHIN H=3m WITHIN H=3m MORE THAN H=3m MORE THAN H=3m NOTES
BOOM RETRACTED BOOM EXTENDED BOOM RETRACTED BOOM EXTENDED
STABILIZERS RAISED √

STABILIZERS LOWERED √ √

TURRET ROTATION

SLEWING UPWARDS

80
SLEWING DOWNWARDS

BOOM ASCENT

BOOM DESCENT

BOOM RETRACTION

BOOM EXTENSION

OPTION 1

OPTION 2

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
10 SPECIFICATIONS

MOVEMENTS ALLOWED FROM THE CAB WITH PLATFORM EXCLUSION KEY ACTIVATED
BOOM BOOM BOOM BOOM
WITHIN H=3m WITHIN H=3m MORE THAN H=3m MORE THAN H=3m NOTES
BOOM RETRACTED BOOM EXTENDED BOOM RETRACTED BOOM EXTENDED
STABILIZERS RAISED √

STABILIZERS LOWERED √ √

TURRET ROTATION √ √ Only for returning to the centre

SLEWING UPWARDS

SLEWING DOWNWARDS √ √ √ √

√ √ √ √
BOOM ASCENT (even if more than H=3m) (even if more than H=3m) (even if more than H=3m) (even if more than H=3m)

BOOM DESCENT

BOOM RETRACTION √ √ √ √

BOOM EXTENSION

OPTION 1 √ √ √ √

OPTION 2

MOVEMENTS ALLOWED FROM THE CAB WITH ROLLOVER PROTECTION EXCLUSION KEY ACTIVATED
BOOM BOOM BOOM BOOM
WITHIN H=3m WITHIN H=3m MORE THAN H=3m MORE THAN H=3m NOTES
BOOM RETRACTED BOOM EXTENDED BOOM RETRACTED BOOM EXTENDED
STABILIZERS RAISED √

STABILIZERS LOWERED √ √

TURRET ROTATION

SLEWING UPWARDS

SLEWING DOWNWARDS

BOOM ASCENT

BOOM DESCENT √

BOOM RETRACTION
80

BOOM EXTENSION

OPTION 1

OPTION 2

NOTE: the data given in the afore-mentioned tables are applicable for all positions of the turret.

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 11

VEHICLE ON TYRES WITH FIXED/ORH PLATFORM IN TILTING CONDITION

MOVEMENTS ALLOWED FROM THE CAB

BOOM BOOM BOOM BOOM
WITHIN H=3m WITHIN H=3m MORE THAN H=3m MORE THAN H=3m NOTES
BOOM RETRACTED BOOM EXTENDED BOOM RETRACTED BOOM EXTENDED
STABILIZERS RAISED √

STABILIZERS LOWERED √ √

TURRET ROTATION √ √ Only for returning to the centre

SLEWING UPWARDS

SLEWING DOWNWARDS √ √

√ √
BOOM ASCENT (only up to H=3m) (only up to H=3m)

BOOM DESCENT

BOOM RETRACTION √ √

BOOM EXTENSION

OPTION 1 √ √

OPTION 2

MOVEMENTS ALLOWED FROM THE CAB WITH PLATFORM EXCLUSION KEY ACTIVATED
BOOM BOOM BOOM BOOM
WITHIN H=3m WITHIN H=3m MORE THAN H=3m MORE THAN H=3m NOTES
BOOM RETRACTED BOOM EXTENDED BOOM RETRACTED BOOM EXTENDED
STABILIZERS RAISED √

STABILIZERS LOWERED √ √

TURRET ROTATION

SLEWING UPWARDS
SLEWING
√ √ √ √
DOWNWARDS
√ √
BOOM ASCENT (only up to H=3m) (only up to H=3m)

BOOM DESCENT

80
BOOM RETRACTION √ √ √ √

BOOM EXTENSION

OPTION 1 √ √ √ √

OPTION 2

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
12 SPECIFICATIONS

MOVEMENTS ALLOWED FROM THE CAB WITH ROLLOVER PROTECTION EXCLUSION KEY ACTIVATED
BOOM BOOM BOOM BOOM
WITHIN H=3m WITHIN H=3m MORE THAN H=3m MORE THAN H=3m NOTES
BOOM RETRACTED BOOM EXTENDED BOOM RETRACTED BOOM EXTENDED
STABILIZERS RAISED √

STABILIZERS LOWERED √ √

TURRET ROTATION √ √

SLEWING UPWARDS √ √

SLEWING DOWNWARDS √ √

√ √
BOOM ASCENT (only up to H=3m) (only up to H=3m)

BOOM DESCENT √ √ √ √

BOOM RETRACTION √ √

BOOM EXTENSION

OPTION 1 √ √

OPTION 2 √ √

NOTE: the data given in the afore-mentioned tables are applicable for all positions of the turret.

MACHINE ON TYRES WITH FIXED/ORH PLATFORM

MOVEMENTS ALLOWED FROM THE CAB

BOOM BOOM BOOM BOOM
WITHIN H=3m WITHIN H=3m MORE THAN H=3m MORE THAN H=3m NOTES
BOOM RETRACTED BOOM EXTENDED BOOM RETRACTED BOOM EXTENDED
STABILIZERS RAISED √

STABILIZERS LOWERED √ √

TURRET ROTATION √ √

SLEWING UPWARDS √ √
80

SLEWING DOWNWARDS √ √

√ √
BOOM ASCENT (only up to H=3m) (only up to H=3m)

BOOM DESCENT √ √ √ √

BOOM RETRACTION √ √

BOOM EXTENSION

OPTION 1 √ √

OPTION 2 √ √

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 13

MOVEMENTS ALLOWED FROM THE CAB WITH PLATFORM EXCLUSION KEY ACTIVATED
BOOM BOOM BOOM BOOM
WITHIN H=3m WITHIN H=3m MORE THAN H=3m MORE THAN H=3m NOTES
BOOM RETRACTED BOOM EXTENDED BOOM RETRACTED BOOM EXTENDED
STABILIZERS RAISED √

STABILIZERS LOWERED √ √

TURRET ROTATION √ √

SLEWING UPWARDS √ √

SLEWING DOWNWARDS √ √

√ √
BOOM ASCENT (only up to H=3m) (only up to H=3m)

BOOM DESCENT √ √ √ √

BOOM RETRACTION √ √

BOOM EXTENSION

OPTION 1 √ √

OPTION 2 √ √

MOVEMENTS ALLOWED FROM THE CAB WITH ROLLOVER PROTECTION EXCLUSION KEY ACTIVATED
BOOM BOOM BOOM BOOM
WITHIN H=3m WITHIN H=3m MORE THAN H=3m MORE THAN H=3m NOTES
BOOM RETRACTED BOOM EXTENDED BOOM RETRACTED BOOM EXTENDED
STABILIZERS RAISED √

STABILIZERS LOWERED √ √

TURRET ROTATION √ √

SLEWING UPWARDS √ √

SLEWING DOWNWARDS √ √

√ √
BOOM ASCENT (only up to H=3m) (only up to H=3m)

BOOM DESCENT √ √ √ √

BOOM RETRACTION √ √

BOOM EXTENSION

80
OPTION 1 √ √

OPTION 2 √ √

NOTE: the data given in the afore-mentioned tables are applicable for all positions of the turret.

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
14 SPECIFICATIONS

VEHICLE WITH OSCILLATING PLATFORM

VEHICLE ON TYRES WITH OSCILLATING/ORH PLATFORM IN TILTING CONDITION

MOVEMENTS ALLOWED FROM THE CAB

BOOM BOOM BOOM BOOM
WITHIN H=3m WITHIN H=3m MORE THAN H=3m MORE THAN H=3m NOTES
BOOM RETRACTED BOOM EXTENDED BOOM RETRACTED BOOM EXTENDED
Only with proximity switch on
STABILIZERS RAISED √
pendulum in reading mode
STABILIZERS LOWERED √ √

+/- 6° then returns to the

TURRET ROTATION
centre
SLEWING UPWARDS √ √

SLEWING DOWNWARDS
√ √
BOOM ASCENT (only up to H=3m) (only up to H=3m)

BOOM DESCENT

BOOM RETRACTION √ √

BOOM EXTENSION

OPTION 1 √ √

Controlled by the rollover

OPTION 2
protection system

MOVEMENTS ALLOWED FROM THE CAB WITH PLATFORM EXCLUSION KEY ACTIVATED
BOOM BOOM BOOM BOOM
WITHIN H=3m WITHIN H=3m MORE THAN H=3m MORE THAN H=3m NOTES
BOOM RETRACTED BOOM EXTENDED BOOM RETRACTED BOOM EXTENDED
Only with proximity switch on
STABILIZERS RAISED √
pendulum in reading mode
STABILIZERS LOWERED √ √

TURRET ROTATION
80

SLEWING UPWARDS

SLEWING DOWNWARDS √ √ √ √

√ √
BOOM ASCENT (only up to H=3m) (only up to H=3m)

BOOM DESCENT

BOOM RETRACTION √ √ √ √

BOOM EXTENSION

OPTION 1 √ √ √ √

Controlled by the rollover

OPTION 2
protection system

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 15

MOVEMENTS ALLOWED FROM THE CAB WITH ROLLOVER PROTECTION EXCLUSION KEY ACTIVATED
BOOM BOOM BOOM BOOM
WITHIN H=3m WITHIN H=3m MORE THAN H=3m MORE THAN H=3m NOTES
BOOM RETRACTED BOOM EXTENDED BOOM RETRACTED BOOM EXTENDED
Only with proximity switch on
STABILIZERS RAISED √
pendulum in reading mode
STABILIZERS LOWERED √ √

TURRET ROTATION √ √

SLEWING UPWARDS √ √ √ √

SLEWING DOWNWARDS
√ √
BOOM ASCENT (only up to H=3m) (only up to H=3m)

BOOM DESCENT √ √ √ √

BOOM RETRACTION √ √

BOOM EXTENSION

OPTION 1 √ √ √ √

Controlled by the rollover

OPTION 2
protection system

NOTE: the data given in the afore-mentioned tables are applicable for all positions of the turret.

VEHICLE ON TYRES WITH OSCILLATING PLATFORM

MOVEMENTS ALLOWED FROM THE CAB

BOOM BOOM BOOM BOOM
WITHIN H=3m WITHIN H=3m MORE THAN H=3m MORE THAN H=3m NOTES
BOOM RETRACTED BOOM EXTENDED BOOM RETRACTED BOOM EXTENDED
Only with proximity switch on
STABILIZERS RAISED √
pendulum in reading mode
STABILIZERS LOWERED √ √

TURRET ROTATION √ √ Within +/- 5°

80
SLEWING UPWARDS √ √ √ √

SLEWING DOWNWARDS
√ √
BOOM ASCENT (only up to H=3m) (only up to H=3m)

BOOM DESCENT √ √ √ √

BOOM RETRACTION √ √

BOOM EXTENSION
√ √ √ √
OPTION 1 (cylinders retraction+LH (cylinders retraction+LH (cylinders retraction+LH (cylinders retraction+LH
rot.) rot.) rot.) rot.)

OPTION 2

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
16 SPECIFICATIONS

MOVEMENTS ALLOWED FROM THE CAB WITH PLATFORM EXCLUSION KEY ACTIVATED
BOOM BOOM BOOM BOOM
WITHIN H=3m WITHIN H=3m MORE THAN H=3m MORE THAN H=3m NOTES
BOOM RETRACTED BOOM EXTENDED BOOM RETRACTED BOOM EXTENDED
Only with proximity switch on
STABILIZERS RAISED √
pendulum in reading mode
STABILIZERS LOWERED √ √

TURRET ROTATION √ √ Within +/- 5°

SLEWING UPWARDS √ √

SLEWING DOWNWARDS √ √

√ √
BOOM ASCENT (only up to H=3m) (only up to H=3m)

BOOM DESCENT √ √ √ √

BOOM RETRACTION √ √

BOOM EXTENSION √ √ √ √

OPTION 1 √ √

OPTION 2 √ √

MOVEMENTS ALLOWED FROM THE CAB WITH ROLLOVER PROTECTION EXCLUSION KEY ACTIVATED
BOOM BOOM BOOM BOOM
WITHIN H=3m WITHIN H=3m MORE THAN H=3m MORE THAN H=3m NOTES
BOOM RETRACTED BOOM EXTENDED BOOM RETRACTED BOOM EXTENDED
Only with proximity switch on
STABILIZERS RAISED √
pendulum in reading mode
STABILIZERS LOWERED √ √

TURRET ROTATION √ √

SLEWING UPWARDS √ √ √ √

SLEWING DOWNWARDS
√ √
BOOM ASCENT (only up to H=3m) (only up to H=3m)

BOOM DESCENT √ √ √ √
80

BOOM RETRACTION √ √

BOOM EXTENSION
√ √ √ √
OPTION 1 (cylinders retraction+LH (cylinders retraction+LH (cylinders retraction+LH (cylinders retraction+LH
rot.) rot.) rot.) rot.)

OPTION 2

NOTE: the data given in the afore-mentioned tables are applicable for all positions of the turret.

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 17

VEHICLE ON STABILIZERS WITH OSCILLATING PLATFORM IN TILTING CONDITION

MOVEMENTS ALLOWED FROM THE CAB

BOOM BOOM BOOM BOOM
WITHIN H=3m WITHIN H=3m MORE THAN H=3m MORE THAN H=3m NOTES
BOOM RETRACTED BOOM EXTENDED BOOM RETRACTED BOOM EXTENDED
Only with proximity switch on
STABILIZERS RAISED √
pendulum in reading mode
STABILIZERS LOWERED √ √

TURRET ROTATION

SLEWING UPWARDS

SLEWING DOWNWARDS

BOOM ASCENT

BOOM DESCENT

BOOM RETRACTION

BOOM EXTENSION

OPTION 1

OPTION 2

MOVEMENTS ALLOWED FROM THE CAB WITH PLATFORM EXCLUSION KEY ACTIVATED
BOOM BOOM BOOM BOOM
WITHIN H=3m WITHIN H=3m MORE THAN H=3m MORE THAN H=3m NOTES
BOOM RETRACTED BOOM EXTENDED BOOM RETRACTED BOOM EXTENDED
Only with proximity switch on
STABILIZERS RAISED √
pendulum in reading mode
STABILIZERS LOWERED √ √

TURRET ROTATION

SLEWING UPWARDS

SLEWING DOWNWARDS √ √ √ √

√ √
BOOM ASCENT (also more than H=3m) (also more than H=3m)
√ √

BOOM DESCENT

80
BOOM RETRACTION √ √ √ √

BOOM EXTENSION

OPTION 1 √ √ √ √

OPTION 2

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
18 SPECIFICATIONS

MOVEMENTS ALLOWED FROM THE CAB WITH ROLLOVER PROTECTION EXCLUSION KEY ACTIVATED
BOOM BOOM BOOM BOOM
WITHIN H=3m WITHIN H=3m MORE THAN H=3m MORE THAN H=3m NOTES
BOOM RETRACTED BOOM EXTENDED BOOM RETRACTED BOOM EXTENDED
Only with proximity switch on
STABILIZERS RAISED √
pendulum in reading mode
STABILIZERS LOWERED √ √

TURRET ROTATION

SLEWING UPWARDS

SLEWING DOWNWARDS

BOOM ASCENT

BOOM DESCENT

BOOM RETRACTION

BOOM EXTENSION

OPTION 1

OPTION 2

NOTE: the data given in the afore-mentioned tables are applicable for all positions of the turret.

VEHICLE ON STABILIZERS WITH OSCILLATING PLATFORM

MOVEMENTS ALLOWED FROM THE CAB

BOOM BOOM BOOM BOOM
WITHIN H=3m WITHIN H=3m MORE THAN H=3m MORE THAN H=3m NOTES
BOOM RETRACTED BOOM EXTENDED BOOM RETRACTED BOOM EXTENDED
Only with proximity switch on
STABILIZERS RAISED √
pendulum in reading mode
STABILIZERS LOWERED √ √

TURRET ROTATION

SLEWING UPWARDS
80

SLEWING DOWNWARDS

BOOM ASCENT

BOOM DESCENT

BOOM RETRACTION

BOOM EXTENSION

OPTION 1

OPTION 2

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 19

MOVEMENTS ALLOWED FROM THE CAB WITH PLATFORM EXCLUSION KEY ACTIVATED
BOOM BOOM BOOM BOOM
WITHIN H=3m WITHIN H=3m MORE THAN H=3m MORE THAN H=3m NOTES
BOOM RETRACTED BOOM EXTENDED BOOM RETRACTED BOOM EXTENDED
Only with proximity switch on
STABILIZERS RAISED √
pendulum in reading mode
STABILIZERS LOWERED √ √

TURRET ROTATION √ √ √ √

SLEWING UPWARDS √ √ √ √

SLEWING DOWNWARDS √ √ √ √

√ √
BOOM ASCENT (also more than H=3m) (also more than H=3m)
√ √

BOOM DESCENT √ √ √ √

BOOM RETRACTION √ √ √ √

BOOM EXTENSION √ √ √ √

OPTION 1 √ √ √ √

OPTION 2 √ √ √ √

MOVEMENTS ALLOWED FROM THE CAB WITH ROLLOVER PROTECTION EXCLUSION KEY ACTIVATED
BOOM BOOM BOOM BOOM
WITHIN H=3m WITHIN H=3m MORE THAN H=3m MORE THAN H=3m NOTES
BOOM RETRACTED BOOM EXTENDED BOOM RETRACTED BOOM EXTENDED
Only with proximity switch on
STABILIZERS RAISED √
pendulum in reading mode
STABILIZERS LOWERED √ √

TURRET ROTATION

SLEWING UPWARDS

SLEWING DOWNWARDS

BOOM ASCENT

BOOM DESCENT

BOOM RETRACTION

80
BOOM EXTENSION

OPTION 1

OPTION 2

NOTE: the data given in the afore-mentioned tables are applicable for all positions of the turret.

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
20 SPECIFICATIONS

VEHICLE WITH RADIO CONTROL

VEHICLE ON STABILIZERS: MOVEMENTS ALLOWED FROM THE CAB

BOOM BOOM BOOM BOOM
WITHIN H=3m WITHIN H=3m MORE THAN H=3m MORE THAN H=3m NOTES
BOOM RETRACTED BOOM EXTENDED BOOM RETRACTED BOOM EXTENDED
STABILIZERS RAISED √

STABILIZERS LOWERED √ √

TURRET ROTATION

SLEWING UPWARDS

SLEWING DOWNWARDS

BOOM ASCENT
Because it is considered as
BOOM DESCENT √
platform
BOOM RETRACTION

BOOM EXTENSION

OPTION 1

OPTION 2

VEHICLE ON TYRES: MOVEMENTS ALLOWED FROM THE CAB

BOOM BOOM BOOM BOOM
WITHIN H=3m WITHIN H=3m MORE THAN H=3m MORE THAN H=3m NOTES
BOOM RETRACTED BOOM EXTENDED BOOM RETRACTED BOOM EXTENDED
STABILIZERS RAISED √

STABILIZERS LOWERED √ √

TURRET ROTATION √ √

SLEWING UPWARDS √ √

SLEWING DOWNWARDS √ √

√ √
BOOM ASCENT (only up to H=3m) (only up to H=3m)
80

BOOM DESCENT √ √ √ √

BOOM RETRACTION √ √

BOOM EXTENSION

OPTION 1 √ √

OPTION 2 √ √

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 21

VEHICLE ON STABILIZERS: MOVEMENTS ALLOWED FROM THE CAB WITH PLATFORM EXCLUSION KEY ACTIVATED
BOOM BOOM BOOM BOOM
WITHIN H=3m WITHIN H=3m MORE THAN H=3m MORE THAN H=3m NOTES
BOOM RETRACTED BOOM EXTENDED BOOM RETRACTED BOOM EXTENDED
STABILIZERS RAISED √

STABILIZERS LOWERED √ √

TURRET ROTATION √ √ √ √

SLEWING UPWARDS √ √ √ √

SLEWING DOWNWARDS √ √ √ √

√ √ √ √
BOOM ASCENT (also more than H=3m) (also more than H=3m) (also more than H=3m) (also more than H=3m)

BOOM DESCENT √ √ √ √

BOOM RETRACTION √ √ √ √

BOOM EXTENSION √ √ √ √

OPTION 1 √ √ √ √

OPTION 2 √ √ √ √

VEHICLE ON STABILIZERS: MOVEMENTS ALLOWED FROM THE CAB WITH ROLLOVER PROTECTION EXCLUSION KEY ACTIVATED
BOOM BOOM BOOM BOOM
WITHIN H=3m WITHIN H=3m MORE THAN H=3m MORE THAN H=3m NOTES
BOOM RETRACTED BOOM EXTENDED BOOM RETRACTED BOOM EXTENDED
STABILIZERS RAISED √

STABILIZERS LOWERED √ √

TURRET ROTATION

SLEWING UPWARDS

SLEWING DOWNWARDS

BOOM ASCENT

BOOM DESCENT √

BOOM RETRACTION

80
BOOM EXTENSION

OPTION 1

OPTION 2

NOTE: the data given in the afore-mentioned tables are applicable for all positions of the turret.

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
22 SPECIFICATIONS

VEHICLE ON STABILIZERS WITH RADIO CONTROL IN TILTING CONDITION

MOVEMENTS ALLOWED FROM THE CAB

BOOM BOOM BOOM BOOM
WITHIN H=3m WITHIN H=3m MORE THAN H=3m MORE THAN H=3m NOTES
BOOM RETRACTED BOOM EXTENDED BOOM RETRACTED BOOM EXTENDED
STABILIZERS RAISED √

STABILIZERS LOWERED √ √ √

The turret can be brought to

the central position only if 1 of
TURRET ROTATION √ √ √
the 2 proximity switches +/-5°
is reading.
SLEWING UPWARDS

SLEWING DOWNWARDS

BOOM ASCENT

BOOM DESCENT

BOOM RETRACTION

BOOM EXTENSION

OPTION 1

OPTION 2

MOVEMENTS ALLOWED FROM THE CAB WITH PLATFORM EXCLUSION KEY ACTIVATED
BOOM BOOM BOOM BOOM
WITHIN H=3m WITHIN H=3m MORE THAN H=3m MORE THAN H=3m NOTES
BOOM RETRACTED BOOM EXTENDED BOOM RETRACTED BOOM EXTENDED
STABILIZERS RAISED √

STABILIZERS LOWERED √ √

The turret can be brought to

the central position only if 1 of
TURRET ROTATION √ √ √ √
the 2 proximity switches +/-5°
is reading.
SLEWING UPWARDS

SLEWING DOWNWARDS √ √ √ √
80

BOOM ASCENT

BOOM DESCENT

BOOM RETRACTION √ √ √ √

BOOM EXTENSION

OPTION 1 √ √ √ √

OPTION 2

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 23

MOVEMENTS ALLOWED FROM THE CAB WITH ROLLOVER PROTECTION EXCLUSION KEY ACTIVATED
BOOM BOOM BOOM BOOM
WITHIN H=3m WITHIN H=3m MORE THAN H=3m MORE THAN H=3m NOTES
BOOM RETRACTED BOOM EXTENDED BOOM RETRACTED BOOM EXTENDED
STABILIZERS RAISED √

STABILIZERS LOWERED √ √ √

The turret can be brought to

the central position only if 1 of
TURRET ROTATION √ √ √
the 2 proximity switches +/-5°
is reading.
SLEWING UPWARDS

SLEWING DOWNWARDS

BOOM ASCENT

BOOM DESCENT √

BOOM RETRACTION

BOOM EXTENSION

OPTION 1

OPTION 2

NOTE: the data given in the afore-mentioned tables are applicable for all positions of the turret.

80

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
24 SPECIFICATIONS

VEHICLE ON STABILIZERS WITH RADIO CONTROL

MOVEMENTS ALLOWED FROM RADIO CONTROL PUSHBUTTON PANEL

BOOM BOOM BOOM BOOM
WITHIN H=3m WITHIN H=3m MORE THAN H=3m MORE THAN H=3m NOTES
BOOM RETRACTED BOOM EXTENDED BOOM RETRACTED BOOM EXTENDED
TURRET ROTATION √ √ √ √

SLEWING UPWARDS √ √ √ √

SLEWING DOWNWARDS √ √ √ √

BOOM ASCENT √ √ √ √

BOOM DESCENT √ √ √ √

BOOM RETRACTION √ √ √ √

BOOM EXTENSION √ √ √ √

OPTION 1 √ √ √ √

Controlled by the rollover

OPTION 2 √ √ √ √
protection system

MOVEMENTS ALLOWED FROM RADIO CONTROL PUSHBUTTON PANEL IN VEHICLE TILTING CONDITIONS
BOOM BOOM BOOM BOOM
WITHIN H=3m WITHIN H=3m MORE THAN H=3m MORE THAN H=3m NOTES
BOOM RETRACTED BOOM EXTENDED BOOM RETRACTED BOOM EXTENDED
The turret can be brought to
the central position only if 1 of
TURRET ROTATION √ √ √ √
the 2 proximity switches +/-5°
is reading.
SLEWING UPWARDS

SLEWING DOWNWARDS √ √ √ √

BOOM ASCENT

BOOM DESCENT

BOOM RETRACTION √ √ √ √

BOOM EXTENSION
80

OPTION 1 √ √ √ √

Controlled by the rollover

OPTION 2
protection system

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 25

CONNECTORS WIRING

Connectors wiring
Ref. Pin Wire colour Section Destination Image

Black 1 GND
A1 1
Black-Blue 1 MC2M- CABIN/R16

Light blue-Yellow 1,5 X18-F/10

Light blue-Yellow 1 X13/2
1
A2 Light blue-Yellow 1 X10/3(FPDX) 1
Light blue-Yellow 1 X6/3(FPSX) 2
2 Black-Yellow 1 CC3/2

1 Purple-Red 1 I51/21

A4-F

2 Black 1 GND

1 Red 1 A27098/+

A4-M

2 Black 1 A27098/-

I9/1

1 Pink-Grey 1

A6-F X21-M/4

2 Black 1 GND

80
1 Red 1 A27102/+

A6-M

2 Black 1 A27102/-

1 Brown-Green 1 CC2/8

BPD 1
2
2 Black 1 GND

MC2M CHASSIS/S7
1 Brown 0,5 X16-M/27
X501-F/2
CAN MC2M CHASSIS/S26
2 White 0,5 X16-M/28
X501-F/1
3 Shield - MC2M CHASSIS/S27

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
26 SPECIFICATIONS

Connectors wiring
Ref. Pin Wire colour Section Destination Image
1 Black 1,5 GND
2 Red-White 1,5 X18-F/13
I43/1
3 Grey-Red 1
CC1 X19-M/S
4 Grey-Black 1 I43/2
Grey-Blue 1 X19-M/R
5
Grey-Blue 1 I43/3
1 White-Blue 1 X16-M/14
3 Yellow-Blue 1 X99/1
5 Black-Red 1 X16-M/15
6 Black-White 1 X16-M/16
CC2 7 White-Yellow 1 X16-M/13
8 Brown-Green 1 BPD/1
9 Black-Purple 1 X32-M/4
10 Brown-Purple 1 X32-M/3
11 Yellow-Black 1 MC2M CHASSIS/R21

1 Brown-Grey 1 X18-F/9

CC3
2
2 Black-Yellow 1 A2/2
1

1(58) Yellow-Red 1,5 X16-M/4

Blue 1 X21-F/28
2(R)
Blue 1,5 X16-M/9
Blue-Black 1 X21-F/27
3(L)
Blue-Black 1,5 X16-M/8
4(56a) Pink-Red 1 X21-F/21
DL/9(30/1)
DL 5(30) Pink-Black 1
F44
R79/C
6(C) Pink-Yellow 1
80

X20-F/L
7(56b) Pink-Green 1 X21-F/20
8(49) Purple 1 X21-F/8
DL/5
9(30/1) Pink-Black 1
F44
5 Light blue-Orange 1 X37-F/4
7 Pink 1 F34
DM
8 Pink-Brown 1 X21-F/23
9 Pink-Blue 1 X21-F/24

IN Blue 1 R4/87

F1

OUT White-Green 1 X18-M/16

IN Blue 1 R4/87

F10

OUT Grey-Purple 1 X18-M/18

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 27

Connectors wiring
Ref. Pin Wire colour Section Destination Image

IN Blue 1,5 R4/87

F11
Orange 1,5 R10/30
OUT
Orange 1,5 R12/30

IN Blue 1,5 R4/87

F12
Purple 1,5 R11/30
OUT
Purple 1,5 R13/30

IN Blue 1,5 R4/87

F13
R7/30
OUT Pink 1,5
R7/86
Red-Black 1,5 X18-M/17
X17-M/10
IN Red-Black 2,5
F14 X17-M/8
Red-Black 4 R3/87
OUT Red-White 1,5 X18-M/13

IN Blue 4 R4/87
F15
X18-M/25
OUT Light blue-Red 1,5
X18-M/26

IN Red 4 X18-M/1/2/3/4
F16

OUT Brown-Red 4 X17-M/18

IN Red 4 X18-M/1/2/3/4
F17

OUT Red 4 R3/30

80
IN Red 6 X18-M/1/2/3/4
F18

OUT Red 6 R4/30

IN Red 2,5 X18-M/1/2/3/4

F19

OUT Green 2,5 R1/30

IN Blue 1 R4/87
F2

OUT Green-Red 1 X18-M/15

IN Red 2,5 X18-M/1/2/3/4

F20

OUT Green-Black 2,5 R2/30

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
28 SPECIFICATIONS

Connectors wiring
Ref. Pin Wire colour Section Destination Image

IN Blue 1,5 R4/87

F3

OUT Light blue 1,5 R6/30

IN Red-Black 1,5 R78/87

I20/10
I56/10
I66/10
F33
OUT Red-Green3 1 I68/10
I7/10
X20-F/G
X7D-F/P

IN Brown 1 R35/87
F34

OUT Pink 1 DM/7

IN Brown 2,5 R35/87

F35
R75/30
OUT Yellow-Black 2,5
R83/30

IN Red 1 KEY/1
F36

OUT Orange-White 1 X20-F/F

IN Blue 1,5 R74/87

Blue-Yellow 1 X21-F/10
Blue-Yellow 1 X32-F/1
F37
OUT X107-F/1
Blue-Yellow 1
X107-F/10
Blue-Yellow 1 X42-F/5
80

IN White-Red 1,5 KEY/6

F38

OUT Grey-Green 1,5 X16-M/1

IN White-Red 1 KEY/1
F39
MA-F/2
OUT White-Red 1
X22-F/25

IN Yellow-Red 1,5 X18-M/5

F4
X18-M/7
OUT Yellow-Black 1,5
X22-F/25

IN Red 1,5 KEY/1

F40

OUT Orange-White 1,5 X7D-F/D

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 29

Connectors wiring
Ref. Pin Wire colour Section Destination Image

IN Red-Black 1 R78/87
F41
TV-F/1
OUT Blue-Red 1
X7D-F/T

IN Blue 1,5 R74/87

F42

OUT Blue-Red 1,5 XAC-F/K

IN Brown 2,5 R35/87

I56/3
F43 Brown-White 1
OUT I56/4
Brown-White 1,5 M8-F/6

IN Brown 1,5 R35/87

F44
DL/5
OUT Pink-Black 1
DL/9

IN Blue 1,5 R74/87

F45

OUT Brown-Purple 1,5 I68/3

IN Brown 1,5 R35/87

F46
OBD2-F/1
OUT Red-Green 1
XDM-F/2

IN White-Red 1 KEY/6
F47

OUT White-Red 1 I22/31

IN Brown 2,5 R35/87

80
Green-White 1 X20-F/N
F48
OUT
Green-White 1 XS1-F/6

IN Red 1,5 KEY/1

X20-F/C
F49 Red
OUT 1 X23-F/9
Red X37-F/1

IN Yellow-Red 1,5 X18-M/5

F5
OUT Yellow 1,5 X18-M/6

IN White-Red 1,5 KEY/6

F50 R76/30
OUT Pink-Red 1
X22-F/8

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
30 SPECIFICATIONS

Connectors wiring
Ref. Pin Wire colour Section Destination Image

IN Brown 1,5 R35/87

F51

OUT Yellow-Black 1,5 X7D-F/A

IN Red-Black 1,5 R78/87

F52

OUT Red-Green 1,5 X22-F/21

IN White-Red 1,5 KEY/6

F53

OUT Yellow-Black 1,5 X22-F/22

IN Brown 1,5 R35/87

F54

OUT Yellow-Purple 1,5 X7D-F/B

IN Brown 1,5 R35/87

F55

OUT Purple-Black 1,5 X7D-F/E

IN Brown 1,5 R35/87

F56

OUT Purple-Black 1,5 X7D-F/F

IN Red-Black 1,5 R78/87

I66/1
I66/3
Orange-Yellow 1,5
I66/4
F57 X20-F/E
OUT
80

I66/1
Orange-Yellow 1 I66/3
I66/4
Orange-Yellow 2,5 X20-F/E

IN White-Red 2,5 KEY/6

F58

OUT Grey-Black 2,5 X23-F/6

IN White-Red 2,5 KEY/6

F58

OUT Grey-Black 2,5 X23-F/6

IN Brown 1,5 R35/87

F59

OUT White-Green 1,5 X21-F/11

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 31

Connectors wiring
Ref. Pin Wire colour Section Destination Image

IN Blue 1 R4/87
F6
R8/30
OUT Blue 1
R8/86

IN Red 1 KEY/1
F60

OUT Orange-Red 1 X21-F/9

IN Red 2,5 KEY/1

OBD2-F/16
F61
OUT Orange-Green 1 XDM-F/3
XM4-F/1
Red-Black 1 R78/87
Red-Black 1,5 R78/87
IN
Red-Black 1 R78/87
Red-Black 1 R78/87
F62
Orange-Blue 1 X40/4
Orange-Blue 1,5 I7/1
OUT
Orange-Blue 1 I20/5
Orange-Blue 1 X22-F/10

IN White-Red 2,5 KEY/6

F63
Blue 1 X37-F/8
OUT
Blue 1 X20-F/A

IN Brown 1,5 R35/87

F64

OUT Pink 1,5 R77/87

IN Blue 1,5 R74/87

80
F65

OUT Red-Brown 1,5 X22-F/23

IN Brown 2,5 R35/87

F66

OUT Blue 2,5 X7D-F/1

IN Brown 1,5 R35/87

F67

OUT Yellow 1,5 X7D-F/N

IN Brown 1,5 R35/87

F68

OUT Yellow-Red 1,5 X7D-F/L

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
32 SPECIFICATIONS

Connectors wiring
Ref. Pin Wire colour Section Destination Image

IN Brown 1,5 R35/87

F69

OUT Yellow-Red 1,5 X7D-F/L

IN Blue 1,5 R4/87

F7
Red-Green 1 X19-F/A
OUT
Red-Green 1 X18-M/20

IN Red 4 KEY/1
F70
Green 1 X107-F/11
OUT
Green 4 X12-F/1

IN Brown 1,5 R35/87

F71

OUT Yellow-Red 1,5 X7D-F/L

IN Brown 6 R35/87
F72

OUT Blue 6 X40-F/2

IN Red 35 B1
F75
Red 16 X35-B-D-E
OUT
Red 25 X1-1

IN Blue 1 R4/87
F8

OUT Pink-Red 1 R9/30

80

IN Blue 1,5 R4/87

F9

OUT Orange 1,5 X18-M/8

1 Grey 1 X35-C
G1

/ Red 25 M1/F75

CARRIAGE
SYSTEM LINE / Black 35 Black
GND

MERCEDES
ENGINE PART / Black 4 Black
LINE GND

/ Black 16 Black
DASHBOARD
LINE GND / Black 25 Black

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 33

Connectors wiring
Ref. Pin Wire colour Section Destination Image

TURRET
POSTERIOR LINE / Black 35 GND
GND

STABILIZERS
SOLENOID
/ Black 10 GND
VALVES RIGHT
LINE GND

STABILIZERS
SOLENOID
/ Black 10 GND
VALVES LEFT
LINE GND

2 Black-Blue 1 I1/9
5 Orange-Yellow 1 X20-M/E
I1 6 Black 1 GND
7 Purple-White 1 STR3-F/14
10 Red-Green3 1 X20-M/G
11 Green-Black 1 X21-M/18
14 Orange-Yellow 1 X20-M/E
I10 21 White 1 I73/24
X21-M/25
24 Brown-Blue 1
X70-F/2
I71/1
1 Orange-Blue 1
X22-M/10
I15
2 Black 1 GND
3 Brown-Black 1 MC2M-CABIN/L35
1 Light blue-White 1 STR2/9
3 Orange-Yellow 1 X20-M/E
I2 7 Light blue 1 STR2/10
9 Black 1 GND
10 Red-Green3 1 X20-M/G
1 Yellow-Red 1 X20-F/P
Orange-Blue 1,5 I7/1

80
Orange-Blue 1 F62
5
I20 Orange-Blue 1 X22F/10
Orange-Blue 1 X40-F/4
9 Black 1 GND
10 Red-Green3 1 F33
11 Light blue-Green 1 X22-F/16
12 Light blue 1 R76/87
I22
31 White-Red 1 F47
32 Brown 1 X37-F/3

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
34 SPECIFICATIONS

Connectors wiring
Ref. Pin Wire colour Section Destination Image
2 Green-White 1 STR2/1
I24/4
Orange-Yellow 1
3 I24/6
Orange-Yellow 2,5 X20-M/E
I24/3
Orange-Yellow 1
4 I24/6
I24 Orange-Yellow 2,5 X20-M/E
I24/3
Orange-Yellow 1
6 I24/4
Orange-Yellow 2,5 X20-M/E
8 Green-Grey 1 STR2/2
9 Black 1 GND
10 Red-Green3 1 X20-M/G
I26/7
I28/1
1 Blue-Green 1 I29/1
I30/1
I31/1
L31/1
2 Brown-Green 1
X21-M/3
I26
I26/4
3 Orange-Yellow 1
X20-M/E
I26/3
4 Orange-Yellow 1
X20-M/E
L30/1
8 Brown-Red 1 X21-M/2
X55-F/1
1 Orange-Yellow 1 X20-M/E
2 White-Black 1 L28-F/1
STR3-F/5
I27 5 White 1
X55-F/2
6 Red-Green3 1 X20-M/G
80

8 White-Blue 1 L29-F/1
I26/1
I26/7
1 Blue-Green 1 I29/1
I30/1
I28
I31/1
5 White-Orange 1 STR3-F/6
9 Black 1 GND
10 Red-Green3 1 X20-M/G
I26/1
I26/7
1 Blue-Green 1 I28/1
I30/1
I29
I31/1
5 White-Grey 1 STR3-F/7
9 Black 1 GND
10 Red-Green3 1 X20-M/G

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 35

Connectors wiring
Ref. Pin Wire colour Section Destination Image
I26/1
I26/7
1 Blue-Green 1 I28/1
I29/1
I30
I31/1
5 White-Blue 1 STR3-F/8
9 Black 1 GND
10 Red-Green3 1 X20-M/G
I26/1
I26/7
1 Blue-Green 1 I28/1
I29/1
I31
I30/1
5 White-Green 1 STR3-F/9
9 Black 1 GND
10 Red-Green3 1 X20-M/G
1 Purple-Red 1 X21-M/16
3 Black 1 GND
I35 7 Purple-Yellow 1 X21-M/15
9 Black 1 GND
10 Red-Green3 1 X20-M/G
1 Orange-Yellow 1 X20-M/E
5 Yellow-Green 1 STR2-F/5
I4
9 Black 1 GND
10 Red-Green3 1 X20-M/G

1 White-Red 1 X9-M/T
I41
2
2 Pink-Yellow 1 X9-M/L 1

CC1/3
1 Grey-Red 1
X19-M/S

80
I43 2 Grey-Black 1 CC1/4
Grey-Blue 1 X19-M/R
3
Grey-Blue 1 CC1/5
11 Grey-Black 1 X21-M/19
14 Orange-Yellow 1 X20-M/E
I51
21 Purple-Red 1 A4/1
24 Orange-Yellow 1 X20-M/E
1 Green-White 1 X20-M/N
I53/4
2 Yellow-Red 1
X20-M/M
3 Orange-White 1 X20-M/F
I53 I53/2
4 Yellow-Red 1
X20-M/M
5 Pink-Yellow 1 X20-M/L
6 Blue-Black 1 X21-M/27
7 Blue 1 X21-M/28

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
36 SPECIFICATIONS

Connectors wiring
Ref. Pin Wire colour Section Destination Image
1 White-Green 1,5 X21-M/11
5 Light blue-Green 1,5 X21-M/7
I54
9 Black 1 GND
10 Red-Green3 1 X20-M/G
I56/6
1 Pink-Grey 1
M8-F/5
2 White-Yellow 1 X7D-F/R
I56/4
Brown-White 1
3 M8-F/6
Brown-White 1,5 F43
I56/3
I56 Brown-White 1
4 M8-F/6
Brown-White 1,5 F43
I56/1
6 Pink-Grey 1
M8-F/5
8 Pink-White 1 M8-F/3
9 Black 1 GND
10 Red-Green3 1 F33
Green-Red 1 X18-F/15
1
Green-Red 1 X32-M/1
I6
2 Black 1 GND
3 Pink-White 1 MC2M CHASSIS/L22
I66/3
Orange-Yellow 1
I66/4
1
Orange-Yellow 1,5 F57
Orange-Yellow 2,5 X20-F/E
2 Green-Red 1 X21-F/22
I66/1
Orange-Yellow 1
I66/4
3
Orange-Yellow 1,5 F57
I66
Orange-Yellow 2,5 X20-F/E
I66/1
80

Orange-Yellow 1
I66/3
4
Orange-Yellow 1,5 F57
Orange-Yellow 2,5 X20-F/E
5 Purple-Black 1 X21-F/6
9 Black 1 GND
10 Red-Green3 1 F33
1 Brown-Grey 1,5 M10-F/A
3 Brown-Purple 1,5 F45
I68 5 Brown-Green 1,5 M10-F/B
9 Black 1 GND
10 Red-Green3 1 F33
11 Brown-Grey 1 STR2-F/4
14 Orange-Yellow 1 X20-M/E
I69
21 Brown-White 1 STR2-F/3
24 Orange-Yellow 1 X20-M/E

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 37

Connectors wiring
Ref. Pin Wire colour Section Destination Image
F62
Orange-Blue 1
I20/5
1
Orange-Blue 1 X22-F/10
I7 Orange-Blue 1 X40-F/4
5 Grey-Black 1,5 X22-F/11
9 Black 1 GND
10 Red-Green3 1 F33
STR2-F/21
1 Purple-Yellow 1
X20-M/U
5 Orange-Yellow 1 X20-M/E
6 Purple-White 1 X20-M/V
I70 I73/21
8 Brown 1 X21-M/26
X70-F/1
9 Black 1 GND
10 Red-Green3 1 X20-M/G
I15/1
1 Orange-Blue 1
X22-M/10
I71
2 Black 1 GND
3 Brown-White 1 MC2M-CABIN/L36
11 Red-Black 1 X21-M/17
14 Orange-Yellow 1 X20-M/E
I70/8
I73
21 Brown 1 X21-M/26
X70-F/1
24 White 1 I10/21
1 Orange-Yellow 1 X20-M/E
5 Blue-Black 1 STR3/16
I76
9 Black 1 GND
10 Red-Green3 1 X20-M/G
I77/3

80
1 Orange-Yellow 1 I77/4
X20-M/E
2 Orange-Purple 1 STR3-F/17
I77/1
3 Orange-Yellow 1 I77/4
I77 X20-M/E
I77/1
4 Orange-Yellow 1 I77/3
X20-M/E
5 Orange-Green 1 STR3-F/13
9 Black 1 GND
10 Red-Green3 1 X20-M/G
1 Orange-Yellow 1 X20-M/E
5 Brown-Pink 1 X21-M/5
I78
9 Black 1 GND
10 Red-Green3 1 X20-M/G

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
38 SPECIFICATIONS

Connectors wiring
Ref. Pin Wire colour Section Destination Image
1 Orange-Yellow 1 X20-M/E
5 Grey-Red 1 X20-M/H
I79
9 Black 1 GND
10 Red-Green3 1 X20-M/G
1 Green-Red 1 X32-F/1

I8 2 Black 1 GND

3 Pink-Yellow 1 X32-F/2

A6-F/1
1 Pink-Grey 1
X21-M/4
I9 5 Orange-Yellow 1 X20-M/E
9 Black 1 GND
10 Red-Green3 1 X20-M/G
Red-Brown 1 XMS/2
X14-M/C
Red-Brown 1,5
ISR 1 X76-F/1
LSR/1
Red-Yellow 1
XSR/1

1 Brown 0,5 X21-M/12

J1939 1

2 White 0,5 X21-M/13 2

F36
F60
Red 1
XAC/A
XAC/B
F40
Red 1,5
F49
F61
Red 2,5
1(30) R80/30
F70
80

Red 4 XAC/1
XAC/2
5
R74/30 6
Red 6
R78/30 7
KEY 8
Red 10 R35/30
9
Red 25 X1-M/1 10
F39
F47
White-Red 1
R80/86
R81/87
6(15/54) F38
White-Red 1,5 F50
F53
F58
White-Red 2,5
F63
Grey-Purple 1 X22-F/17
7(50)
Grey-Purple 1,5 X16-M/3

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 39

Connectors wiring
Ref. Pin Wire colour Section Destination Image

1 White-Black 1 I27/2
L28
2 Black 1 GND

1 White-Blue 1 I27/8
L29
2 Black 1 GND

I26/8
1 Brown-Red 1 X21-M/2
L30
X55-F/1
2 Black 1 GND
I26/2
1 Brown-Green 1
L31 X21-M/3
2 Black 1 GND
Black 1 GND
LSR 1 ISR/1
Red-Yellow 1
XSR/1

Red 25 G1/F75
M1 /
Grey-Red 1,5 X35-F

A Brown-Grey 1,5 I68-1

M10-F B Brown-Green 1,5 I68-5 A

C
B
C Black 1,5 GND

1 Green 1,5 X22-M/24

M11

2 Black 1,5 GND

80
Black 1,5 GND
M12 1
Brown-Yellow 1,5 X76-F/7

1 Black 1 GND
M4/2
2 Yellow-Black 1
X14-M/B
M4/3
3 Brown 0,5
X14-M/U
M4/4
4 White 0,5
M3 X14-M/V
M4/5
5 Shield -
X14-M/W
15 White-Green 1 X14-M/K
16 White-Red 1 X14-M/H
17 White 1 X14-M/F
18 White-Pink 1 X14-M/M

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
40 SPECIFICATIONS

Connectors wiring
Ref. Pin Wire colour Section Destination Image
1 Black 1 GND
M3/2
2 Yellow-Black 1
X14-M/B
M3/3
3 Brown 0,5
X14-M/U
M3/4
4 White 0,5
M4 X14-M/V
M3/5
5 Shield -
X14-M/W
15 White-Blue 1 X14-M/L
16 White-Yellow 1 X14-M/J
17 White-Black 1 X14-M/G
18 White-Orange 1 X14-M/N
2 Black 1,5 GND
3 Pink-White 1 I56/8
4 Pink 1 SV
I56/1 6
M8-F 5 Pink-Grey 1 5
I56/6 4
1
I56/3 2
3
Brown-White 1
6 I56/4
Brown-White 1,5 F43

1 Brown-Pink 1 X23-F/11
6
MA-F 5
F39 4
1
2 White-Red 1 3
2
X22-F/25

Blue 1,5 X30/2(FADX)

MC2M CHASSIS L40 Blue 1 X10/4(FPDX)

Blue 1 X13/1
L1 Brown-Purple 1 X11-F/24
L10 Brown-Red 1 X22-M/26
L11 Brown-Green 1 X22-M/27
80

L12 White-Blue 1 X14-F/L

L13 Pink-Grey 1 X23-M/4
L14 White-Pink 1 X14-F/M
L17 Orange-Brown 1 X22-M/9
L18 Green-Black 1 X22-M/13
L19 Black-Blue 1 X10/13
L2 Yellow-Green 1 X14-F/R
MC2M-CABIN L20 Black-Purple 1 X10/11
L21 Orange-White 1 XRD/K2
L22 White-Red 1 X14-F/H
L23 Blue 1 X11-F/12
L24 White 1 X14-F/F
L25 Black-Green 1 XRD/F2
L26 Red-Black 1 X22-M/14
Brown 1 X23-M/2
L28
Brown 1 XRD/J1
L29 Pink-Yellow 1 X9-F/L
L3 Grey-Purple 1 X22-M/17

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 41

Connectors wiring
Ref. Pin Wire colour Section Destination Image
L30 Green 1 X11-F/11
L31 Green-White 1 X14-F/O
L32 White-Yellow 1 X14-F/J
L33 White-Black 1 X14-F/G
L34 White-Green 1 X14-F/K
L35 Brown-Black 1 I15/3
L36 Brown-White 1 I71/3
L37 Purple-Red 1 XRD/G1
X10-7
L4 Brown-Pink 1
X23-M/11
L5 Light blue-Black 1 X22-M/1
MDCP/33
L8 Grey-Black 1
X22-M/12
L9 Grey-Red 1 X23-M/3
R13 Blue-Black 1,5 X11-F/26
R14 Grey-Red 1 X22-M/2
XRD/H2
R15 Red-Yellow 1
XRD/H3
R16 Black-Blue 1 A1/1
R17 Orange-Purple 1 X86-F/1
R19 Orange-Black 1 X14-F/S
MC2M-CABIN
R20 Orange-Green 1 X14-F/T
R23 White-Orange 1 X14-F/N
R24 Brown-Black 1 X11-F/13
R26 Orange-Green 1 X11-F/17
R27 Black-Yellow 1 X11-F/15
R28 Black-White 1 X11-F/16
R30 Brown-Green 1 X11-F/14
R38 Green-Red 1 X14-F/P
R39 Green-Grey 1 X14-F/Q
R4 Grey-Green 1 X22-M/18
R40 Pink-Green 1 X11-F/19

80
R5 Yellow-Grey 1 X22-M/7
MDCP/13
Red-Black 1
S1 MDCP/16
Red-Black 1,5 X23-M/10
S13 Black-Yellow 1 X10-F/15
S14 Black-White 1 X10-F/17
S17 Light blue-Red 1 X14-F/X
S19 Pink-White 1 X22-M/28
S20 Pink-Yellow 1 X22-M/29
S21 Black 1 GND

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
42 SPECIFICATIONS

Connectors wiring
Ref. Pin Wire colour Section Destination Image
MDCP/20
X11-F/20
X14-F/V
X15-M/5
S23 White 0,5 X23-M/17
X88-M/4
X88-M/9
X9-F/Q
XRD/C2
X14-F/W
X15-M/6
X23-M/18
S24 Shield - X88-M/10
X88-M/5
X9-F/R
XRD/B1
MDCP/19
X11-F/18
X14-F/U
MC2M-CABIN X15-M/4
S25 Brown 0,5 X23-M/16
X88-M/3
X88-M/8
X9-F/P
XRD/C1
MDCP/18
S26 White 0,5
X23-M/14
MC2M-CABIN/S29
S27 Shield -
X23-M/15
S28 Brown 0,5 X11-F/27
MC2M-CABIN/S27
S29 Shield -
X23-M/15
80

S3 Blue-Red 1,5 X11-F/21

S30 White 0,5 X11-F/29
S4 Blue-Yellow 1,5 X11-F/22
S5 Blue-Green 1,5 X11-F/25
S6 Grey 1 X23-M/10
MDCP/17
S7 Brown 0,5
X23-M/13
L1 Grey-Red 1 X27C/2
L10 Grey-White 1 X27A/4
L11 Blue-White 1 X7A/4
L12 Purple-White 1 X5A/4
L13 Brown-Red 1 X29C/2
MC2M CHASSIS L14 Orange-Red 1 X12A/1
L19 Purple-Blue 1 X19-M/U
L2 Blue-Red 1 X7C/2
L21 Pink-Yellow 1 X32-M/2
L22 Pink-White 1 I6/3
L23 Pink 1 X22/2

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 43

Connectors wiring
Ref. Pin Wire colour Section Destination Image
L24 Grey-Blue 1 X35-M/S
L3 Purple-Red 1 X5C/2
X16-M/19
L34 Light blue-Orange 1
X18-F/29
X16-M/4
L37 Yellow-Red 1,5
X18-F/5
Blue-Black 1,5 X25/2(FASX)
Blue-Black 1 X6/4(FPSX)
L39
Blue-Black 1,5 X16-M/8
Blue-Black 1 X13/4
L4 Orange 1 T1/2
L40 Blue 1,5 X16-M/9
L6 Black-Red 1 X28/C
L9 Brown-White 1 X29A/4
R10 Pink-Grey 1 X17-F/3
R13 Light blue-White 1 X32-M/5
R14 Light blue-Green 1 X32-M/6
R15 Light blue-Yellow 1 X32-M/8
R16 Light blue-Black 1 X32-M/7
R17 Orange-White 1 X33-F/2
R18 Orange-Green 1 X33-F/3
R19 Orange-Yellow 1 X33-F/5
R20 Orange-Black 1 X33-F/4
R21 Yellow-Black 1 CC2/11
R22 Green-Blue 1 XSC2-F/8
MC2M CHASSIS
R23 Brown-Green 1 X29B/4
R24 Grey-Green 1 X27B/4
R25 Blue-Green 1 X7B/4
R26 Purple-Green 1 X5B/4
R28 Brown-Yellow 1 X29/2
R29 Grey-Yellow 1 X27/2
Grey-Purple 1,5 X16-M/3

80
R3
Grey-Purple 1 X17-F/1
R33 White-Blue 1 X11A/3
R34 White-Grey 1 X4A/3
R38 Blue-Yellow 1 X7A/2
R39 Purple-Yellow 1 X5/2
R4 White-Blue 1 X32-M/9
R40 Black-Purple 1 X34/1
R5 White-Green 1 X32-M/10
R7 Light blue 1 X33-F/1
R8 Orange-Blue 1 X11B/1
R9 Orange-Grey 1 X4/1
Red-Black 1 X18-F/28
S1
Red-Black 1,5 X16-M/5
X33-F/8
S13 Red-Purple 1
X34/2
X33-F/9
S14 Red-Green 1
X34/3
S15 Grey-Yellow 1 XSC-F/12

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
44 SPECIFICATIONS

Connectors wiring
Ref. Pin Wire colour Section Destination Image
S16 Grey-Blue 1 XSC1-F/3
S17 Pink-Blue 1 X17-F/13
S18 Purple-Blue 1 X17-F/15
S19 White-Pink 1 X17-F/9
S2 Brown-Green 1 X28/B
S20 White-Black 1 X17-F/11
S21 Black 1 GND
X16-M/26
S23 White 0,5 X500-F/1
X71/C
S24 Shield - X16-M/21
X16-M/25
S25 Brown 0,5 X500-F/2
MC2M CHASSIS
X71/D
CAN/2
S26 White 0,5 X16-M/28
X501-F/1
S27 Shield - CAN/3
S4 Red-Grey 1 X33-F/7
S5 Red-Blue 1 X33-F/6
S6 Green-Black 1 X33-F/10
CAN/1
S7 Brown 0,5 X16-M/27
X501-F/2
S8 Blue-Pink 1 X17-F/5
S9 Blue-Black 1 X17-F/7
Red-Black 1,5 MDCP/3
MC2M-1 CABIN/2
1 Red-Black 2,5
MC2M-1 CABIN/3
Red-Black 6 X23-M/1
Red-Black 1,5 MDCP/3
MC2M-1 CABIN/1
80

2 Red-Black 2,5
MC2M-1 CABIN MC2M-1 CABIN/3
Red-Black 6 X23-M/1
Red-Black 1,5 MDCP/3
MC2M-1 CABIN/1
3 Red-Black 2,5
MC2M-1 CABIN/2
Red-Black 6 X23-M/1
4 Black 2,5 GND

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 45

Connectors wiring
Ref. Pin Wire colour Section Destination Image
Red-Black 1,5 X18-F/17
MC2M-1 CHASSIS/2
1 MC2M-1 CHASSIS/3
Red-Black 2,5
X17-F/10
X17-F/8
Red-Black 1,5 X18-F/17
MC2M-1 CHASSIS/1
2 MC2M-1 CHASSIS/3
MC2M-1 CHASSIS Red-Black 2,5
X17-F/10
X17-F/8
Red-Black 1,5 X18-F/17
MC2M-1 CHASSIS/1
3 MC2M-1 CHASSIS/2
Red-Black 2,5
X17-F/10
X17-F/8
4 Black 2,5 GND
1 Black 1 GND
MC2M-1 CABIN/1
Red-Black 2,5 MC2M-1 CABIN/2
3
MC2M-1 CABIN/3
Red-Black 6 X23-M/1
4 Light blue-Yellow 1 X22-M/15
MC2M-CABIN/S1
Red-Black 1
13 MDCP/16
Red-Black 1,5 X23-M/10
14 Red-Yellow 1 MDCP/14
MC2M-CABIN/S1
Red-Black 1
16 MDCP/13
Red-Black 1,5 X23-M/10
MDCP
MC2M-CABIN/S7
17 Brown 0,5
X23-M/13
MC2M-CABIN/S26

80
18 White 0,5
X23-M/14
MC2M-CABIN/S25
X11-F/18
X14-F/U
X15-M/4
19 Brown 0,5 X23-M/16
X88-M/3
X88-M/8
X9-F/P
XRD/C1

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
46 SPECIFICATIONS

Connectors wiring
Ref. Pin Wire colour Section Destination Image
MC2M-CABIN/S23
X11-F/20
X14-F/V
X15-M/5
20 White 0,5 X23-M/17
X88-M/4
X88-M/9
X9-F/Q
XRD/C2
MDCP 24 Grey-Pink 1 X9-F/N
25 Grey-Yellow 1 X9-F/D
26 Grey-Blue 1 X9-F/E
27 Orange-Purple 1 X9-F/O
28 Orange-Yellow 1 X9-F/G
29 Brown-Blue 1 X9-F/H
30 Brown-Grey 1 X9-F/J
31 White-Grey 1 X9-F/K
MC2M-CABIN/L8
33 Grey-Black 1
X22-M/12
F46
1 Red-Green 1
XDM-F/2
X16-M/27
X21-F/12
X23-F/13
3 Brown 0,5
X504-F/2
XM4-F/19
XS1-F/7
5 Black 1 GND
STR4/7
X16-M/25
6 Brown 0,5 X21-/33
OBD2-F X23-F/16
80

X503-F/2
XDM-F/14
7 Brown-Blue 1
XM1-F/2
X16-M/18
8 Pink-Red 1
XDM-F/5
X16-M/28
X21-F/13
11 White 0,5 X23-F/14
X504-F/1
XM4-F/21
12 Brown 0,75 X20-F/K
13 Blue 0,75 X20-F/J

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 47

Connectors wiring
Ref. Pin Wire colour Section Destination Image
STR4/8
X16-M/26
14 White 0,5 X21-F/34
X23-F/17
OBD2-F
X503-F/1
F61
16 Orange-Green 1 XDM-F/3
XM4-F/1
30 Green 2,5 F19
R2/85
85 Black-Yellow 1
R1 X18-M/14
86 Pink-Blue 1 X17-M/13
87 White-Red 2,5 X17-M/14
30 Orange 1,5 F11
85 Black 1 GND
R10
86 Blue-Pink 1 X17-M/5
87 Grey 1,5 X17-M/6
30 Purple 1,5 F12
85 Black 1 GND
R11
86 Blue-Black 1 X17-M/7
87 Green 1,5 X17-M/17
30 Orange 1,5 F11
85 Black 1 GND
R12
86 White-Pink 1 X17-M/9
87 Grey-Black 1,5 X18-M/22
30 Purple 1,5 F12
85 Black 1 GND
R13
86 White-Black 1 X17-M/11
87 Green-Black 1,5 X17-M/19
30 Red 1,5 X18-M/1/2/3/4
85 Light blue-Orange 1 X18-29
R14
86 Grey-Purple 1 X17-M/1

80
87 Yellow-Purple 1,5 X17-M/2
30 Light blue 1,5 X19-F/D
85 Black-White 1 X19-F/B
R15 86 Light blue-White 1 X19-F/C
87 Light blue-Red 1,5 X19-F/F
87a Light blue-Grey 1 X19-F/E
30 White 1 X19-F/J
85 Black-Yellow 1 X19-F/G
R16 86 Light blue-Yellow 1 X19-F/H
87 White-Red 1 X19-F/L
87a White-Grey 1 X19-F/K
30 Orange 1 X19-F/O
85 Black 1 X19-F/M
R17 86 Light blue 1 X19-F/N
87 Orange-Red 1 X19-F/Q
87a Orange-Grey 1 X19-F/P

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
48 SPECIFICATIONS

Connectors wiring
Ref. Pin Wire colour Section Destination Image
30 Green-Black 2,5 F20
R1/85
85 Black-Yellow 1
R2 X18-M/14
86 Purple-Blue 1 X17-M/15
87 White-Green 2,5 X17-M/16
30 Red 4 F17
85 Black 1 GND
86 Red-Black 1 X18-M/28
R3 Red-Black 1,5 X18-M/17
X17-M/10
87 Red-Black 2,5
X17-M/8
Red-Black 1,5 F14
30 Red 10 KEY/1
85 Black 1 GND
Green-Red 1 R74/86
86
Green-Red 1 R81/30
Brown 1 F34
F44
F46
F51
F54
F55
Brown 1,5
R35 F56
F59
87 F64
F67
F68
F35
F43
Brown 2,5 F48
F66
F69
80

Brown 6 F72
30 Red 6 F18
85 Black 1 GND
86 Grey-Green 1 X18-M/19
Blue 1 F1
Blue 1 F8
F10
Blue 4
F6
R4 Blue 1 F15
Blue 1 F11
87
Blue 1 F12
Blue 1,5 F9
Blue 1,5 F2
Blue 1 F13
Blue 1 F7
Blue 1 F3

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 49

Connectors wiring
Ref. Pin Wire colour Section Destination Image
30 Red 1,5 X18-M/1/2/3/4
85 Black 1 GND
R5
86 Red-Yellow 1 X18-M/27
87 Grey-Red 1,5 X18-M/21
30 Light blue 1,5 F3
85 Black 1 GND
R6
86 Brown-Grey 1 X18-M/9
87 Light blue-Yellow 1,5 X18-M/10
30 Pink 1,5 R7/30
85 Brown-Black 1 X18-11
R7
86 Pink 1 F13
87 Pink-Black 1,5 X18-M/12
30 Red 6 KEY/1
85 Black 1 GND
Green-Red 1 R35/86
86
Green-Red 1 R81/30
R74
Blue 1,5 F42
Blue 1,5 F37
87
Blue 1,5 F65
Blue 1,5 F45
F35
30 Yellow-Black 2,5
R83/30
85 Black 1 GND
R75
86 Pink-White 1 X22-F/28
Blue-Green 1 X22-F/6
87
Blue-Green 1,5 X22-F/5
F50
30 Pink-Red 1
X22-F/8
R76 85 Black 1 GND
86 Light blue-Yellow 1 X22-F/15
87 Light blue 1 I22/12
30 Pink-Black 1,5 X22-F/19

80
85 Black 1 GND
R77
86 Grey-Green 1 X22-F/18
87 Pink 1,5 F64
30 Red 6 KEY/1
85 Black 1 GND
Red-Black 1,5 X23-F/10
Red-Black 1,5 X21-F/14
86 Red-Black 1 STR4/6
Red-Black 1,5 X16-M/5
R78 Red-Black 2,5 R80/87
Red-Black 1,5 F57
F33
F41
87
Red-Black 1,5 F52
F62
F71

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
50 SPECIFICATIONS

Connectors wiring
Ref. Pin Wire colour Section Destination Image

31 Black 1 GND

R79 + Red-Yellow 1,5 X20-F/M

DL/6(C)
C Pink-Yellow 1
X20-F/L
F6
30 Blue 1
R8/86
85 Pink-Brown 1 X18-M/24
R8
F6
86 Blue 1
R8/30
87 Black-Blue 1 X18-M/23
30 Red 2,5 KEY/1
85 Black 1 GND
86 White-Red 1 KEY/6
Red-Black 1,5 X23-F/10
R80
Red-Black 1,5 X21-F/14
87 Red-Black 1 STR4/6
Red-Black 1 R78/86
Red-Black 1,5 X16-M/5
Green-Red 1 R74/86
30
Green-Red 1 R35/86
85 Black 1 GND
Brown 1 XM4-F/2
R81
Brown 1 X21-F/26
86
Brown 1 X23-F/2
Brown 1 X16-M/6
87 White-Red 1 KEY/6
30 Black 1 GND
85 Black 1 GND
X21-F/1
R82 86 White-Orange 1
X37-F/5
80

Light blue-Orange 1 XM2-F/1

87
Light blue-Orange 1 X16-M/19
Yellow-Black 1 F35
30
Yellow-Black 2,5 R75/30
85 Black 1 GND
R83
86 Pink-Yellow 1 X22-F/29
Blue-Pink 1 X22-F/4
87
Blue-Pink 2,5 X22-F/3
30 Pink-Red 1 F8
85 Black 1 GND
R9
86 Pink-Grey 1 X17-M/3
87 Pink-Green 1 X17-M/4

1 Blue 0,75 X20-M/J

RS232 1
2 Brown 0,75 X20-M/K 2

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 51

Connectors wiring
Ref. Pin Wire colour Section Destination Image

1 Light blue-White 1 X32-F/5

S11 1
2 Black 1 GND 2

1 Light blue-Green 1 X32-F/6

S12 1
2 Black 1 GND 2

1 Light blue-Black 1 X32-F/7

S13 1
2 Black 1 GND 2

1 Light blue-Yellow 1 X32-F/8

S14 1
2 Black 1 GND 2

1 Light blue 1 X33-M/1

S15 1
2 Black 1 GND 2

1 Orange-White 1 X33-M/2
S16 1
2 Black 1 GND 2

1 Orange-Green 1 X33-M/3
S17 1
2 Black 1 GND 2

1 Orange-Black 1 X33-M/4
S18 1
2 Black 1 GND 2

80
1 Orange-Yellow 1 X33-M/5
S19 1
2 Black 1 GND 2

1 White-Blue 1 X32-F/9
S24 1
2 Black 1 GND 2

1 White-Green 1 X32-F/10
S25 1
2 Black 1 GND 2

1 Red-Blue 1 X33-M/6
S27 1
2 Black 1 GND 2

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
52 SPECIFICATIONS

Connectors wiring
Ref. Pin Wire colour Section Destination Image

1 Red-Grey 1 X33-M/7
S28 1
2 Black 1 GND 2

1 Red-Purple 1 X33-M/8
S35 1
2 Black 1 GND 2

1 Red-Green 1 X33-M/9
S36 1
2 Black 1 GND 2

A Green-Black 1 X33-M/10

S6 B Grey-Purple 1 X33-M/11 1
2
C Black 1 GND

1 Brown-Purple 1 X32-F/3
S8 1
2 Black-Purple 1 X32-F/4 2

1 Green-White 1 I24/2
2 Green-Grey 1 I24/8
3 Brown-White 1 I69/21
4 Brown-Grey 1 I69/11
5 Yellow-Green 1 I4/5
VIEW/6
6 White 0,5
X21-M/34
8 Red-Black 1,5 X21-M/14
9 Light blue-White 1 I2/1
10 Light blue 1 I2/7
11 Pink-Green 1 X21-M/20
STR2
80

12 Pink-Red 1 X21-M/21
VIEW/5
14 Brown 0,5
X21-M/33
16 White-Orange 1 X21-M/1
17 Pink-Brown 1 X21-M/23
18 Pink-Blue 1 X21-M/24
I70/1
21 Purple-Yellow 1
X20-M/U
22 Purple 1 X21-M/8
Black 1 GND
23
Black 1 GND

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 53

Connectors wiring
Ref. Pin Wire colour Section Destination Image
3 Purple-Black 1 X21-M/6
4 Green-Red 1 X21-M/22
I27/5
5 White 1
X55-F/2
6 White-Orange 1 I28/5
7 White-Grey 1 I29/5
STR3 8 White-Blue 1 I30/5
9 White-Green 1 I31/5
13 Orange-Green 1 I77/5
14 Purple-White 1 I1/7
15 Yellow-Red 1 X20-M/P
16 Blue-Black 1 I76/5
17 Orange-Purple 1 I77/2
1 Green-Brown 1 X16-/11
2 Green-Grey 1 X16-M/10
3 Green-Black 1 X16-M/17
4 Green-Yellow 1 X16-M/20
5 Black 1 GND
R78/86
Red-Black 1
R80/87
6 X16-M/5
Red-Black 1,5 X21-F/14
1
X23-F/10 2
STR4
OBD2/6 3
4 8
X16-F/25 7
7 Brown 0,5 X21-F/33 6
5
X23-F/16
X503-F/2
OBD2/14
X16-M/26
8 White 0,5 X21-F/34
X23-F/17

80
X503-F/1

SV-F 1 Pink 1 M8/4

2 Orange 1 MC2M CHASSIS/L4

T1
3 Black 1 GND

1 Light blue-Red 2,5 X35-H/J 1

2

T41
1
2 Black 2,5 GND 2

F41
1 Blue-Red 1
X7D-F/T
TV-F 1
2 Black 1 GND 2

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
54 SPECIFICATIONS

Connectors wiring
Ref. Pin Wire colour Section Destination Image
1 Blue 1,5 X20-M/A
4 Shield - X21-M/35
STR2/14
5 Brown 0,5
X21-M/33
VIEW STR2/6
6 White 0,5
X21-M/34
7 Black 1 GND
13 Red 1 X20-M/C
24 Black 1,5 GND
X10-2
Blue-Green 1
1 X22-M/6
Blue-Green 1,5 X22-M/5
Blue-Green 1 X22-M/6
2 X10-1
Blue-Green 1,5
X22-M/5
X10-4
Blue-Pink 1
3 X22-M/4
Blue-Pink 1,5 X22-M/3
Blue-Pink 1 X22-M/4
4 X10-3
Blue-Pink 1,5
X22-M/3
5 Grey 1,5 X22-M/11
X11-F/23
6 White-Red 1 X22-M/25
X9-F/T
MC2M-CABIN/L4
7 Brown-Pink 1
X23-M/11
Blue 1 X10/9
X10
8 Blue 2,5 X10/10
Blue 6 X23-M/8
X10/10
Blue 2,5
9 X10/8
80

Blue 6 X23-M/8
Blue 1 X10/9
10 Blue 2,5 X10/8
Blue 6 X23-M/8
11 Black-Purple 1 MC2M-CABIN/L20
12 Black 2,5 GND
13 Black-Blue 1 MC2M-CABIN/L19
14 Black 2,5 GND
15 Black-Yellow 1 MC2M-CABIN/S13
16 Black 2,5 GND
17 Black-White 1 MC2M-CABIN/S14
18 White 2,5 X23-M/7
X15-M/2
19 Red 1 X23-M/9
X46/B

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 55

Connectors wiring
Ref. Pin Wire colour Section Destination Image
1 Black 1 GND
Yellow-Black 1 X10A/1
Yellow-Black 1 X13/7
2
Yellow-Black 1,5 X25/3(FASX)
Yellow-Black 1,5 X18-F/7
Light blue-Yellow 1,5 X18-F/10
Light blue-Yellow 1 A2/1
3
Light blue-Yellow 1 X13/2
X10(FPDX)
Light blue-Yellow 1 X6/3(FPSX)
Blue 1 X10/4(FPDX)
Blue 1 X13/1
4
Blue 1 MC2M CHASSIS/L40
Blue 1,5 X16-M/9
Pink-Black 1,5 X18-F/12
5 Pink-Black 1 X6/5 (FPSX)
Pink-Black 1 X13/6

X107-F/2

X101-F 1 Yellow 1 X12-F/4

X32-F/2

X102-F/4
1 Black-White 1
X16-M/16
X102-F/5
2 Black-Red 1
X16-M/15
6
3 White-Yellow 1 X16-M/13
X102-F 5
X102-F/1 4
4 Black-White 1 1
X16-M/16 2
3
X102-F/2
5 Black-Red 1
X16-M/15
6 White-Blue 1 X16-M/14
X107-F/6

80
1 Grey-Red 1 X12-F/7
X32-F/4
X107-F/9
X103-F
X12-F/6
2 Brown-White 1 X32-F/3
X32-F/5
X33-M/2
X106/1
1 Pink-Black 1 X107A/1
X9-M/B A
X105
2 Black 1 GND
C
3 Brown 0,5 X9-M/P B
4 White 0,5 X9-M/Q

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
56 SPECIFICATIONS

Connectors wiring
Ref. Pin Wire colour Section Destination Image
X107-F/6
1 Grey-Red 1 X12-F/7
X32-F/4
X107-F/9
X103-F
X12-F/6
2 Brown-White 1 X32-F/3
X32-F/5
X33-M/2
X106/1
1 Pink-Black 1 X107A/1
X9-M/B A
X105
2 Black 1 GND
C
3 Brown 0,5 X9-M/P B
4 White 0,5 X9-M/Q
X105/1
1 Pink-Black 1 X107A/1
X9-M/B
X106
2 Black 1 GND
3 Orange-Purple 1 X9-M/O
4 Brown-Grey 1 X9-M/J
X105/1
1 Pink-Black 1 X106/1
X9-M/B
X107A
2 Black 1 GND
3 Grey-Blue 1 X9-M/E
4 White-Grey 1 X9-M/K
Blue-Yellow 1 X21-F/10
Blue-Yellow 1 X42-F/5
1 Blue-Yellow 1 X32-F/1
F37
Blue-Yellow 1
X107-F/10
Yellow 1 X101-F/1
80

2 Yellow 1 X12-F/4
Yellow 1 X32-F/2
4 Black 1 GND
X107-F Grey-Red 1 X103-F/1
6 Grey-Red 1 X12-F/7
Grey-Red 1 X32-F/4
X12-F/8
8 Blue-White 1
X42-F/3
X103-F/2
X12-F/6
9 Brown-White 1 X32-F/3
X32-F/5
X33-M/2

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 57

Connectors wiring
Ref. Pin Wire colour Section Destination Image
Blue-Yellow 1 X21-F/10
Blue-Yellow 1 X42-F/5
10 Blue-Yellow 1 X32-F/1
F37
X107-F Blue-Yellow 1
X107-F/1
F70
11 Green 1
X12-F/1
12 Black 1 GND
X109/1
1 Pink-Black 1
X9-A
X108 2 Black 1 GND
3 Grey-Yellow 1 X9-M/D
4 Orange-Yellow 1 X9-M/G
X108/1
1 Pink-Black 1
X9-M/A
X109 2 Black 1 GND
3 Grey-Pink 1 X9-M/N
4 Brown-Blue 1 X9-M/H
Yellow-Black 1,5 X25/3(FASX)
Yellow-Black 1,5 X18-F/7
1
X10A Yellow-Black 1 X10/2(FPDX) 1
Yellow-Black 1 X13/7 2
2 Black 1 GND
White-Green 1 X18-F/16
1
White-Green 1 X4A/1
X11A 1
2 Black 1 GND
2
3 White-Blue 1 MC2M CHASSIS/R33

1 Orange-Blue 1 MC2M CHASSIS/R8

X11B 1
2 Black 1 GND 2

1 Grey-Black 2,5 X23-M/6

80
2 Black 2,5 GND
3 Purple-Yellow 1 X22-M/31
4 Purple-White 1 X22-M/30
5 Green-Brown 1 XRD-C3
6 Green-Grey 1 XRD/D1
7 Green-Yellow 1 XRD/D2
8 Green-White 1 XRD/D3
X11-F 9 Grey-Red 1 XRD/E2
10 Grey-Black 1 XRD/E3
11 Green 1 MC2M-CABIN/L30
12 Blue 1 MC2M-CABIN/L23
13 Brown-Black 1 MC2M-CABIN/R24
14 Brown-Green 1 MC2M-CABIN/R30
15 Black-Yellow 1 MC2M-CABIN/R27
16 Black-White 1 MC2M-CABIN/R28
17 Orange-Green 1 MC2M-CABIN/R26

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
58 SPECIFICATIONS

Connectors wiring
Ref. Pin Wire colour Section Destination Image
MC2M-CABIN/S25
MDCP/19
X14-F/U
X15-M/4
18 Brown 0,5 X23-M/16
X88-M/3
X88-M/8
X9-F/P
XRD/C1
19 Pink-Green 1 MC2M-CABIN/R40
MC2M-CABIN/S23
MDCP/20
X14-F/V
X15-M/5
20 White 0,5 X23-M/17
X11-F X88-M/4
X88-M/9
X9-F/Q
XRD/C2
21 Blue-Red 1,5 MC2M-CABIN/S3
22 Blue-Yellow 1,5 MC2M-CABIN/S4
X10-F/6
23 White-Red 1 X22-M/25
X9-F/T
24 Brown-Purple 1 MC2M-CABIN/L1
25 Blue-Green 1,5 MC2M-CABIN/S5
26 Blue-Black 1,5 MC2M-CABIN/R13
27 Brown 0,5 MC2M-CABIN/S28
X22-M/20
28 Brown-Blue 1
XRD/K1
29 White 0,5 MC2M-CABIN/S30
80

Black 1 GND
X12A 1
Orange-Red 1 MC2M CHASSIS/L14

Green 1 X107-F/11
1
Green 4 F70
Yellow 1 X101-F/1
4 Yellow 1 X32-F/2
Yellow 1 X107-F/2
5 Green 1,5 X22-F/24
X103-F/2
X12-F
X107-F/9
6 Brown-White 1 X32-F/3
X32-F/5
X33-M/2
Grey-Red 1 X103-F/1
7 Grey-Red 1 X32-F/4
Grey-Red 1 X107-F/6

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 59

Connectors wiring
Ref. Pin Wire colour Section Destination Image
X107-F/8
8 Blue-White 1
X42-F/3
X12-F
10 Black 4 GND
12 Grey 1 X33-M/1
Blue 1 X30/2(FADX)
Blue 1 X10/4(FPDX)
1
Blue 1 MC2M CHASSIS/L40
Blue 1,5 X16-M/9
Light blue-Yellow 1,5 X18-F/10
Light blue-Yellow 1 A2/1
2
Light blue-Yellow 1 X10/3(FPDX)
Light blue-Yellow 1 X6/3(FPSX)
3 Black 1 GND
Blue-Black 1,5 X25/2(FASX)
Blue-Black 1 X6/4(FPSX)
4 1
Blue-Black 1 MC2M CHASSIS/L39 2
X13
Blue-Black 1,5 X16-M/8 3
4 8
Yellow 1 X6A/1 7
Yellow 1 X30/3(FADX) 6
5 5
Yellow 1,5 X18-F/6
Yellow 1 X6(FPSX)
Pink-Black 1,5 X18-F/12
6 Pink-Black 1 X10/5(FPDX)
Pink-Black 1 X6/5 (FPSX)
Yellow-Black 1 X10A/1
Yellow-Black 1,5 X25/3(FASX)
7
Yellow-Black 1,5 X18-F/7
Yellow-Black 1 X10/2(FPDX)
Red-Green 1,5 X22-M/21
A XRD/F1
Red-Green 1
XRD/H1
B Yellow-Black 1,5 X22-M/22

80
X22-M/23
C Red-Brown 1,5
X46-A
D Black 1,5 GND
E Black 1,5 GND
F White 1 MC2M-CABIN/L24
G White-Black 1 MC2M-CABIN/L33
H White-Red 1 MC2M-CABIN/L22
X14-F
J White-Yellow 1 MC2M-CABIN/L32
K White-Green 1 MC2M-CABIN/L34
L White-Blue 1 MC2M-CABIN/L12
M White-Pink 1 MC2M-CABIN/L14
N White-Orange 1 MC2M-CABIN/R23
O Green-White 1 MC2M-CABIN/L31
P Green-Red 1 MC2M-CABIN/R38
Q Green-Grey 1 MC2M-CABIN/R39
R Yellow-Green 1 MC2M-CABIN/L2
S Orange-Black 1 MC2M-CABIN/R19
T Orange-Green 1 MC2M-CABIN/R20

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
60 SPECIFICATIONS

Connectors wiring
Ref. Pin Wire colour Section Destination Image
MC2M-CABIN/S25
MDCP/19
X11-F/18
X15-M/4
U Brown 0,5 X23-M/16
X88-M/3
X88-M/8
X9-F/P
XRD/C1
MC2M-CABIN/S23
MDCP/20
X11-F/20
X15-M/5
X14-F
V White 0,5 X23-M/17
X88-M/4
X88-M/9
X9-F/Q
XRD/C2
MC2M-CABIN/S24
X15-M/6
X23-M/18
W Shield - X88-M/10
X88-M/5
X9-F/R
XRD/B1
X Light blue-Red 1 MC2M-CABIN/S17
X51/2
X51/5
A Red-Green 1
X53/1
X53/3
M3/2
B Yellow-Black 1
M4/2
80

ISR/1
Red-Brown 1
C XMS/2
Red-Brown 1,5 X76-F/1
D Black 1,5 GND
E Black 1,5 GND
F White 1 M3/17
X14-M
G White-Black 1 M4/17
H White-Red 1 M3/16
J White-Yellow 1 M4/16
K White-Green 1 M3/15
L White-Blue 1 M4/15
M White-Pink 1 M3/18
N White-Orange 1 M4/18
O Green-White 1 X53/2
P Green-Red 1 X51/3
Q Green-Grey 1 X51/4
R Yellow-Green 1 XMS/1
S Orange-Black 1 X75-4

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 61

Connectors wiring
Ref. Pin Wire colour Section Destination Image
T Orange-Green 1 X75/2
M3/3
U Brown 0,5
M4/3
M3/4
X14-M V White 0,5
M4/4
M3/5
W Shield -
M4/5
X Light blue-Red 1 XSP/1

1 Brown-Black 1 X18-F/11
X15A 1
2 Black 1 GND 2

1 Light blue-Green 1 X22-M/16

X10-19
2 Red 1 X23-M/9
X46-B
3 Black 1 GND
MC2M-CABIN/S25
MDCP/19
X11-F/18
X14-F/U
4 Brown 0,5 X23-M/16
X88-M/3
X88-M/8
X9-F/P
XRD/C1
MC2M-CABIN/S23
X15-M
MDCP/20
X11-F/20
X14-F/V
5 White 0,5 X23-M/17
X88-M/4

80
X88-M/9
X9-F/Q
XRD/C2
MC2M-CABIN/S24
X14-F/W
X23-M/18
6 Shield - X88-M/10
X88-M/5
X9-F/R
XRD/B1

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
62 SPECIFICATIONS

Connectors wiring
Ref. Pin Wire colour Section Destination Image
X18-F/19
Grey-Green 1 X26/C
1
X71/A
Grey-Green 1,5 F38
Black 1 GND
2
Black 1,5 GND
Grey-Purple 1 X17-F/1
KEY
3 Grey-Purple 1,5
X22-F/17
Grey-Purple 1 MC2M CHASSIS/R3
Yellow-Red 1 MC2M CHASSIS/L37
4 DL/1
Yellow-Red 1,5
X18-F/5
Red-Black 1,5 X23-F/10
Red-Black 1,5 X21-F/14
MC2M CHASSIS/S1
Red-Black 1 STR4/6
X18-F/28
5
MC2M CHASSIS/S1
R78-86
Red-Black 1
R80-87
X18-F/28
Red-Black 2,5 R80-87
Brown 1 XM4/2
X16-M Brown 1 X21-F/26
6 Brown 1 X23-F/2
R81-86
Brown 1
X35-M/K
X18-F/24
7 Pink-Brown 1
XM2-F/9
Blue-Black 1,5 X25/2(FASX)
Blue-Black 1 X6/4(FPSX)
80

Blue-Black 1 X13/4
8
Blue-Black 1 MC2M CHASSIS/L39
Blue-Black 1 X21-F/27
Blue-Black 1,5 DL/3
Blue 1 X10/4(FPDX)
Blue 1 X13/1
MC2M CHASSIS/L40
9 Blue 1
X21-F/28
DL/2
Blue 1,5
X30/2(FADX)
STR4/2
10 Green-Grey 1
XSC-F/3
STR4/1
11 Green-Brown 1
XSC-F/4
Yellow-Purple 1 XM1-F/1
12 X17-F/2
Yellow-Purple 1,5
X35-M/L

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 63

Connectors wiring
Ref. Pin Wire colour Section Destination Image
White-Yellow 1 CC2/7
13
White-Yellow 1 X102-F/3
White-Blue 1 X102-F/6
14
White-Blue 1 CC2/1
CC2/5
15 Black-Red 1 X102-F/2
X102-F/5
CC2/6
16 Black-White 1 X102-F/1
X102-F/4
STR4/-3
17 Green-Black 1
XSC-F/5
OBD2-F/8
18 Pink-Red 1 X35-M/R
XDM-F/5
X18-F/29
Light blue-Orange 1
XM2-F/1
19
MC2M CHASSIS/L34
Light blue-Orange 1
R82-87
STR/4
20 Green-Yellow 1
XSC-F/6
MC2M CHASSIS/S24
21 Shield - X21-F/35
X23-F/18
X16-M X35-M/X
22 Brown 0,34 XDM-F/8
XM2-F/14
X35-M/V
23 Yellow 0,34 XDM-F/6
XM2-F/13
X35-M/W
24 White 0,34 XDM-F/7

80
XM2-F/15
MC2M CHASSIS/S25
OBD2-F/6
STR4/7
X21-F/33
25 Brown 0,5
X23-F/16
X500-F/2
X503-F/2
X71/D
MC2M CHASSIS/S23
OBD2-F/14
STR4/8
X21-F/34
26 White 0,5
X23-F/17
X500-F/1
X503-F/1
X71/C

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
64 SPECIFICATIONS

Connectors wiring
Ref. Pin Wire colour Section Destination Image
OBD2-F/3
X21-F/12
X23-F/13
27 Brown 0,5
X504-F/2
XM4-F/19
XS1-F/7
X16-M
OBD2-F/11
X21-F/13
X23-F/14
28 White 0,5
X504-F/1
XM4-F/21
XS1-F/8
Grey-Purple 1,5 X16-M/3
1
Grey-Purple 1 MC2M CHASSIS/R3
Yellow-Purple 1,5 X16-M/12
2
Yellow-Purple 1,5 X35-M/L
3 Pink-Grey 1 MC2M CHASSIS/R10
4 Pink-Green 1 X9/1(E35)
5 Blue-Pink 1 MC2M CHASSIS/S8
6 Grey 1,5 X30/5(FADX)
7 Blue-Black 1 MC2M CHASSIS/S9
Red-Black 1,5 X18-F/17
MC2M-1 CHASSIS/1
8 MC2M-1 CHASSIS/2
Red-Black 2,5
MC2M-1 CHASSIS/3
X17-F/10
X17-F 9 White-Pink 1 MC2M CHASSIS/S19
Red-Black 1,5 X18-F/17
MC2M-1 CHASSIS/1
10 MC2M-1 CHASSIS/2
Red-Black 2,5
MC2M-1 CHASSIS/3
X17-F/8
80

11 White-Black 1 MC2M CHASSIS/S20

12 Black 4 GND
13 Pink-Blue 1 MC2M CHASSIS/S17
14 White-Red 2,5 X23/A
15 Purple-Blue 1 MC2M CHASSIS/S18
16 White-Green 2,5 X24/A
17 Green 1,5 X30/4(FADX)
18 Brown-Red 4 X35-M/G
19 Green-Black 1,5 X25/4(FASX)

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 65

Connectors wiring
Ref. Pin Wire colour Section Destination Image
1 Grey-Purple 1 R14/86
2 Yellow-Purple 1,5 R14/87
3 Pink-Grey 1 R9/86
4 Pink-Green 1 R9/87
5 Blue-Pink 1 R10/86
6 Grey 1,5 R10/87
7 Blue-Black 1 R11/86
X17-M/10
Red-Black 2,5
X18-M/7
8
Red-Black 4 R3/87
Red-Black 1,5 F14
9 White-Pink 1 R12/86
X17-M X17-M/8
Red-Black 2,5
X18-M/17
10
Red-Black 4 R3/87
Red-Black 1,5 F14
11 White-Black 1 R13/86
12 Black 4 GND
13 Pink-Blue 1 R1/86
14 White-Red 2,5 R1/87
15 Purple-Blue 1 R2/86
16 White-Green 2,5 R2/87
17 Green 1,5 R11/87
18 Brown-Red 4 F16
19 Green-Black 1,5 R13/87
Red 1 X26/B
X18-F/2
X18-F/3
Red 4
1 X18-F/4
X35-M/B
X35-M/D
Red 6
X35-M/E

80
Red 1 X26/B
X18-F/1
X18-F/3
Red 4
X18-F 2 X18-F/4
X35-M/B
X35-M/D
Red 6
X35-M/E
Red 1 X26/B
X18-F/1
X18-F/2
Red 4
3 X18-F/4
X35-M/B
X35-M/D
Red 6
X35-M/E

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
66 SPECIFICATIONS

Connectors wiring
Ref. Pin Wire colour Section Destination Image
Red 1 X26/B
X18-F/1
X18-F/2
Red 4
4 X18-F/3
X35-M/B
X35-M/D
Red 6
X35-M/E
Yellow-Red 1 MC2M CHASSIS/L37
5
Yellow-Red 1,5 X16-M/4
Yellow 1 X6A/1
Yellow 1 X13/5
6
Yellow 1,5 X30/3(FADX)
Yellow 1 X6(FPSX)
Yellow-Black 1 X10A/1
Yellow-Black 1 X13/7
7
Yellow-Black 1,5 X25/3(FASX)
Yellow-Black 1 X10/2(FPDX)
X27/1
X27A/3
X27B/3
X27C/1
X29/1
X29A/3
X29B/3
X18-F X29C/1
8 Orange 1
X5/1
X5A/3
X5B/3
X5C/1
X7/1
X7A/3
X7B/3
80

X7C/1
9 Brown-Grey 1 CC3/1
Light blue-Yellow 1 A2/1
Light blue-Yellow 1 X13/2
10
Light blue-Yellow 1 X10/3(FPDX)
Light blue-Yellow 1 X6/3(FPSX)
11 Brown-Black 1 X15A/1
Pink-Black 1 X10/5(FPDX)
12 Pink-Black 1 X6/5 (FPSX)
Pink-Black 1 X13/6
13 Red-White 1,5 CC1/2
X20-F/1
14 Black-Yellow 1
X35-M/T
Green-Red 1 I6/1
15
Green-Red 1 X32-M/1
X11A/1
16 White-Green 1
X4A/1

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 67

Connectors wiring
Ref. Pin Wire colour Section Destination Image
Red-Black 1,5 MC2M-1 CHASSI/S3
MC2M-1 CHASSIS/1
17 MC2M-1 CHASSIS/2
Red-Black 2,5
X17-F/10
X17-F/8
1 X32-M/11
18 Grey-Purple
X33-F/11
X16-M/1
19 Grey-Green 1 X26/C
X71/A
20 Red-Green 1 X22/1
21 Grey-Red 1,5 X35-M/F
22 Grey-Black 1,5 X25/5(FASX)
X18-F 23 Black-Blue 1 X35-M/U
24 Pink-Brown 1 X16-M/7
X18-F/26
25 Light blue-Red 1,5 X35-M/H
X35-M/J
X18-F/25
26 Light blue-Red 1,5 X35-M/H
X35-M/J
27 Red-Yellow 1 X35-M/A
MC2M CHASSIS/S1
28 Red-Black 1 MC2M-1 CHASSI/S1
X16-M/5
MC2M CHASSI/L34
29 Light blue-Orange 1
X16-M/19
R14/30
Red 1,5
R5/30
F19
Red 2,5
F20
F16

80
1
F17
Red 4 X18-M/2
X18-M/3
X18-M/4
Red 6 F18
X18-M
R14/30
Red 1,5
R5/30
F19
Red 2,5
F20
F16
2
F17
Red 4 X18-M/1
X18-M/3
X18-M/4
Red 6 F18

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
68 SPECIFICATIONS

Connectors wiring
Ref. Pin Wire colour Section Destination Image
R14/30
Red 1,5
R5/30
F19
Red 2,5
F20
F16
3
F17
Red 4 X18-M/1
X18-M/2
X18-M/4
Red 6 F18
R14/30
Red 1,5
R5/30
F19
Red 2,5
F20
F16
4
F17
Red 4 X18-M/1
X18-M/2
X18-M/3
Red 6 F18
5 Yellow-Red 1,5 F4/F5
6 Yellow 1,5 F5
7 Yellow-Black 1,5 F4
8 Orange 1,5 F9
9 Brown-Grey 1 R6/86
X18-M
10 Light blue-Yellow 1,5 R6/87
11 Brown-Black 1 R7/85
12 Pink-Black 1,5 R7/87
13 Red-White 1,5 F14
R1/85
14 Black-Yellow 1
R2/85
15 Green-Red 1 F2
80

16 White-Green 1 F1
Red-Black 1,5 R3/87
X17-M/10
17 Red-Black 2,5
X17-M/8
Red-Black 1,5 F14
18 Grey-Purple 1 F10
19 Grey-Green 1 R4/86
Red-Green 1 X19-F/A
20
Red-Green 1 F7
21 Grey-Red 1,5 R5/87
22 Grey-Black 1,5 R12/87
23 Black-Blue 1 R8/87
24 Pink-Brown 1 R8/85
25 Light blue-Red 1,5 F15
26 Light blue-Red 1,5 F15
27 Red-Yellow 1 R5/86
28 Red-Black 1 R3/86
29 Light blue-Orange 1 R14/85

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 69

Connectors wiring
Ref. Pin Wire colour Section Destination Image
F7
A Red-Green 1
X18-M/20
B Black-White 1 R15/85
C Light blue-White 1 R15/86
D Light blue 1,5 R15/30
E Light blue-Grey 1 R15/87a
F Light blue-Red 1,5 R15/87
G Black-Yellow 1 R16/85
H Light blue-Yellow 1 R16/86
J White 1 R16/30
X19-F K White-Grey 1 R16/87a
L White-Red 1 R16/87
M Black 1 R17/85
N Light blue 1 R17/86
O Orange 1 R17/30
P Orange-Grey 1 R17/87a
Q Orange-Red 1 R17/87
R Grey-Blue 1 XRS-1
S Grey-Red 1 XRS-2
T Grey 1 XD+-1
U Purple-Blue 1 XD+-2
XSC1-F/1
A Red-Green 1 XSC2-F/1
XSC-F/2
B Black-White 1 XSC-F/7
C Light blue-White 1 XSC-F/8
D Light blue 1,5 XSC-F/9
E Light blue-Grey 1 XSC-F/10
F Light blue-Red 1,5 XSC-F/11
G Black-Yellow 1 XSC2-F/3
H Light blue-Yellow 1 XSC2-F/4
J White 1 XSC2-F/5

80
K White-Grey 1 XSC2-F/6
X19-M
L White-Red 1 XSC2-F/7
M Black-Blue 1 XSC1-F/8
N Light blue 1 XSC1-F/7
O Orange 1 XSC1-F/6
P Orange-Grey 1 XSC1-F/5
Q Orange-Red 1 XSC1-F/5
Grey-Blue 1 I43/3
R
Grey-Blue 1 CC1/5
CC1/3
S Grey-Red 1
I43/1
T Grey 1 X35-M/C
U Purple-Blue 1 MC2M CHASSIS/L19

X1-M 1 Red 25 KEY/1

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
70 SPECIFICATIONS

Connectors wiring
Ref. Pin Wire colour Section Destination Image
X18-F/14
1 Black-Yellow 1
X35-M/T
2 Black 1 GND
F63
Blue 1
A X37-F/8
Blue 1,5 F63
B White 2,5 F69
F49
C Red 1 X23-F/9
X37-F/1
D Black 4 GND
I66/1
Orange-Yellow 1 I66/3
E
I66/4
Orange-Yellow 1,5 F57
F Orange-White 1 F36
X20-F G Red-Green3 1 F33 1
H Grey-Red 1 X23-F/3 2
J Blue 0,75 OBD2-F/13
K Brown 0,75 OBD2-F/12
DL/6(C)
L Pink-Yellow 1
R79/C
M Yellow-Red 1 R79/+
Green-White 1 F48
N
Green-White 1 XS1-F/6
P Yellow-Red 1 I20/1
R Orange-Purple 1 XS1-F/1
S Orange-Black 1 XS1-F/2
T Orange-Blue 1 XS1-F/3
U Purple-Yellow 1 X22-F/31
V Purple-White 1 X22-F/30
W Black 1 GND
80

X Black 1 GND
1 White 1 X20-M/2
2 White 1 X20-M/1
A Blue 1,5 VIEW/1
B White 2,5 XAS/2
C Red 1 VIEW/13
D Black 4 GND
I24/3
Orange-Yellow 1 I24/4
X20-M I24/6
I10/14 2

Orange-Yellow 1 I70/5 1

E I73/14
I1/5
I2/3
Orange-Yellow 1,5 I26/3
I26/4
I27/1

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 71

Connectors wiring
Ref. Pin Wire colour Section Destination Image
I4/1
I51/14
I51/24
I69/14
I69/24
I76/1
E Orange-Yellow 1,5
I77/1
I77/3
I77/4
I78/1
I79/1
I9/5
F Orange-White 1 I53/3
I1/10
I2/10
I24/10
I27/6
I28/10
I29/10
I30/10
I31/10
I35/10
G Red-Green3 1
I4/10
X20-M I54/10
I70/10 2

I76/10 1

I77/10
I78/10
I79/10
I9/10
XAS/1
H Grey-Red 1 I79/5

80
J Blue 0,75 RS232/1
K Brown 0,75 RS232/2
L Pink-Yellow 1 I53/5
I53/2
M Yellow-Red 1
I53/4
N Green-White 1 I53/1
P Yellow-Red 1 STR3/15
R Orange-Purple 1 X98/A
S Orange-Black 1 X98/B
T Orange-Blue 1 X98/C
I701
U Purple-Yellow 1
STR2/21
V Purple-White 1 I70/6
W Black 1 GND
X Black 1 GND

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
72 SPECIFICATIONS

Connectors wiring
Ref. Pin Wire colour Section Destination Image
CAN/1
27 Brown 0,5 MC2M CHASSIS/S7
X501-F/2
X216-M
CAN/2
28 White 0,5 MC2M CHASSIS/S26
X501-F/1
R82/86
1 White-Orange 1
X37-F/5
2 Brown-Red 1 X22-F/26
3 Brown-Green 1 X22-F/27
4 Pink-Grey 1 X23-F/4
5 Brown-Pink 1 X22-F/9
6 Purple-Black 1 I66/5
7 Light blue 1,5 X7D-F/C
8 Purple 1 DL/8
9 Orange-Red 1 F60
Blue-Yellow 1 F37
Blue-Yellow 1 X32-F/1
10 X107-F/1
Blue-Yellow 1
X107-F/10
Blue-Yellow 1 X42-F/5
11 White-Green 1,5 F59
OBD2-F/3
X16-M/27
X23-F/13
12 Brown 0,5
X504-F/2
XM4-F/19
X21-F XS1-F/7
OBD2-F/11
X16-M/28
X23-F/14
13 White 0,5
X504-F/1
80

XM4-F/21
XS1-F/8
Red-Black 1 X23-F/10
Red-Black 1 STR4/6
14 Red-Black 1 R78/86
Red-Black 1,5 X16-M/5
Red-Black 2,5 R80/87
15 Purple-Yellow 1 XM3-F/4
16 Purple-Red 1 XM3-F/5
17 Red-Black 1 X22-F/14
18 Green-Black 1 X22-F/13
19 Grey-Black 1 X22-F/12
20 Pink-Green 1 DL/7
21 Pink-Red 1 DL/4
22 Green-Red 1 I66/2
23 Pink-Brown 1 DM/8
24 Pink-Blue 1 DM/9

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 73

Connectors wiring
Ref. Pin Wire colour Section Destination Image
X22-F/20
25 Brown-Blue 1
X37-F/6
Brown 1 XM4-F/2
Brown 1 X23-F/2
26
R81/86
Brown 1
X16-M/6
Blue-Black 1 DL/3
27
Blue-Black 1,5 X16-M/8
DL/2
28 Blue 1,5
X16-M/9
29 Black-Yellow 1 X7D-F/K
30 Red-Grey 1 X7D-F/J
31 Black-White 1 X7D-F/H
X21-F
32 Red-White 1 X7D-F/G
OBD2-F/6
STR4/7
33 Brown 0,5 X16-M/25
X23-F/16
X503-F/2
OBD2/14
STR4/8
34 White 0,5 X16-M/26
X23-F/17
X503-F/1
X16-M/21
35 Shield -
X23-F/18

X21M 8 Purple 1 STR2/22

1 White-Orange 1 STR2/16

80
I26/8
2 Brown-Red 1 L30/1
X55-F/1
I26/2
3 Brown-Green 1
L31/1
A6-F/1
4 Pink-Grey 1
I9/1
5 Brown-Pink 1 I78/5
6 Purple-Black 1 STR3/3
X21-M
7 Light blue-Green 1,5 I54/5
X38/7
9 Orange-Red 1
XCD/4
X38/4
10 Blue-Yellow 1
XCD/7
11 White-Green 1,5 I54/1
12 Brown 0,5 J1939/1
13 White 0,5 J1939/2
14 Red-Black 1,5 STR2/8
15 Purple-Yellow 1 I35/7

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
74 SPECIFICATIONS

Connectors wiring
Ref. Pin Wire colour Section Destination Image
16 Purple-Red 1 I35/1
17 Red-Black 1 I73/11
18 Green-Black 1 I10/11
19 Grey-Black 1 I51/11
20 Pink-Green 1 STR2/11
21 Pink-Red 1 STR2/12
22 Green-Red 1 STR3/4
23 Pink-Brown 1 STR2/17
24 Pink-Blue 1 STR2/18
I10/24
25 Brown-Blue 1
X70/F/2
I70/8
X21-M 26 Brown 1 I73/21
X70-F/1
27 Blue-Black 1 I53/6
28 Blue 1 I53/7
29 Black-Yellow 1 X39A/6
30 Red-Grey 1 X39A/5
31 Black-White 1 X39A/4
32 Red-White 1 X39A/3
STR2/14
33 Brown 0,5
VIEW/5
STR2/6
34 White 0,5
VIEW/6
35 Shield - VIEW/4

1 Red-Green 1 X18-F/20
X22 1
2 Pink 1 MC2M CHASSIS/L23 2

1 Light blue-Black 1 X7-F/S

2 Grey-Red 1 XS1-F/4
80

Blue-Pink 2,5 R83-87

3
Blue-Pink 1 X22-F/4
Blue-Pink 2,5 R83/87
4
Blue-Pink 1 X22-F/3
Blue-Green 2,5 R75/87
5
Blue-Green 1 X22-F/6
Blue-Green 2,5 R75/87
6
Blue-Green 1 X22-F/5
X22-F 7 Yellow-Grey 1 X7D-F/M
F50
8 Pink-Red 1
R76/30
9 Brown-Pink 1 X21-F/5
Orange-Blue 1,5 I7/1
Orange-Blue 1 I20/5
10
Orange-Blue 1 F62
Orange-Blue 1 X40-F/4
11 Grey 1,5 I7/5
12 Grey-Black 1 X21-F/19
13 Green-Black 1 X21-F/18

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 75

Connectors wiring
Ref. Pin Wire colour Section Destination Image
14 Red-Black 1 X21-F/17
15 Light blue-Yellow 1 R76/86
16 Light blue-Green 1 I22/11
Grey-Purple 1,5 X16-M/3
17
Grey-Purple 2,5 KEY/7
18 Grey-Green 1 R77/86
19 Pink-Black 1,5 R77/30
X21-F/25
20 Brown-Blue 1
X37-F/6
21 Red-Green 1,5 F52
X22-F 22 Yellow-Black 1,5 F53
23 Red-Brown 1,5 F65
24 Green 1,5 X12-F/5
F39
25 White-Red 1
MA-F/2
26 Brown-Red 1 X21-F/2
27 Brown-Green 1 X21-F/3
28 Pink-White 1 R75/86
29 Pink-Yellow 1 R83/86
30 Purple-White 1 X20-F/V
31 Purple-Yellow 1 X20-F/U
1 Light blue-Black 1 MC2M-CABIN/L5
2 Grey-Red 1 MC2M-CABIN/R14
X10/4
Blue-Pink 1
3 X22-M/4
Blue-Pink 1,5 X10-/3
Blue-Pink 1 X10/4
4 X10-/3
Blue-Pink 1,5
X22-M/3
Blue-Green 1 X10-2
5 Blue-Green 1,5 X10-1
Blue-Green 1 X22-M/6

80
Blue-Green 1 X10-2
6 Blue-Green 1,5 X10-1
Blue-Green 1,5 X22-M/5
X22-M 7 Yellow-Grey 1 MC2M-CABIN/R5
X88-M/1
8 Pink-Red 1
X88-M/6
9 Orange-Brown 1 MC2M-CABIN/L17
I15/1
10 Orange-Blue 1
I71/1
11 Grey 1,5 X10-5
MC2M-CABIN/L8
12 Grey-Black 1
MDCP/33
13 Green-Black 1 MC2M-CABIN/L18
14 Red-Black 1 MC2M-CABIN/L26
15 Light blue-Yellow 1 MDCP/4
16 Light blue-Green 1 X15-M/1
17 Grey-Purple 1 MC2M-CABIN/L3
18 Grey-Green 1 MC2M-CABIN/R4

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
76 SPECIFICATIONS

Connectors wiring
Ref. Pin Wire colour Section Destination Image
X9-F/A
19 Pink-Black 1,5
X9-F/B
X11-F/28
20 Brown-Blue 1
XRD/K1
X14-F/A
21 Red-Green 1,5 XRD/F1
XRD/H1
22 Yellow-Black 1,5 X14-F/B
X14-F/C
23 Red-Brown 1,5
X46/A
X22-M
24 Green 1,5 M11/1
X10/6
25 White-Red 1 X11-F/23
X9-F/T
26 Brown-Red 1 MC2M-CABIN/L10
27 Brown-Green 1 MC2M-CABIN/L11
28 Pink-White 1 MC2M-CABIN/S19
29 Pink-Yellow 1 MC2M-CABIN/S20
30 Purple-White 1 X11-F/4
31 Purple-Yellow 1 X11-F/3

A White-Red 2,5 X17-F/14

X23
B Black 2,5 GND

1 Red-Black 6 F71
Brown 1 XM4-F/2
Brown 1 X21-F/26
2
R81/86
Brown 1
X16-M/6
3 Grey-Red 1 X20-F/H
4 Pink-Grey 1 X21-F/4
5 Grey 1 XS1-F/5
80

6 Grey-Black 2,5 F58

7 White 2,5 X7D-F/2
8 Blue 6 X40-F/1
F49
9 Red 1 X20-F/C
X23-F X37-F/1
Red-Black 1 STR4/6
Red-Black 1,5 X21-F/14
10 Red-Black 1 R78/86
Red-Black 1,5 X16-M/5
Red-Black 2,5 R80/87
11 Brown-Pink 1 MA-F/1
12 Black 1 GND
OBD2-F/3
X16-M/27
X21-F/12
13 Brown 0,5
X504-F/2
XM4-F/19
XS1-F/7
80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 77

Connectors wiring
Ref. Pin Wire colour Section Destination Image
OBD2-F/11
X16-M/28
X21-F/13
14 White 0,5
X504-F/1
XM4-F/21
XS1-F/8
15 Shield - XM4-F/20
OBD2-F/6
X23-F STR4/7
16 Brown 0,5 X16-M/25
X21-F/33
X503-F/2
OBD2-F/14
STR4/8
17 White 0,5 X16-M/26
X21-F/34
X503-F/1
X16-M/21

X23-F/18 18 Shield -
X21-F/35

Red-Black 1,5 MDCP/3

MC2M-1 CABIN/1
1
Red-Black 2,5 MC2M-1 CABIN/2
MC2M-1 CABIN/3
Brown 1 MC2M-CABIN/L28
2
Brown 1 XRD/J1
3 Grey-Red 1 MC2M-CABIN/L9
4 Pink-Grey 1 MC2M-CABIN/L13
5 Grey 1 MC2M-CABIN/S6
6 Grey-Black 2,5 X11-F/1

80
7 White 2,5 X10/18
Blue 1 X10/9
8 X10/10
Blue 2,5
X23-M X10/8
X10/19
9 Red 1 X15-M/2
X46/B
MC2M-CABIN/S1
10 Red-Black 1 MDCP/13
MDCP/16
MC2M-CABIN/L4
11 Brown-Pink 1
X10/7
12 Black 1 GND
MC2M-CABIN/S7
13 Brown 0,5
MDCP/17
MC2M-CABIN/S26
14 White 0,5
MDCP/18

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
78 SPECIFICATIONS

Connectors wiring
Ref. Pin Wire colour Section Destination Image
MC2M-CABIN/S27
15 Shield -
MC2M-CABIN/S29
MC2M-CABIN/S25
MDCP/19
X11-F/18
X14-F/U
16 Brown 0,5 X15-M/4
X88-M/3
X88-M/8
X9-F/P
XRD/C1
"MC2M-CABIN/S23"
MDCP/20
X23-M X11-F/20
X14-F/V
17 White 0,5 X15-M/5
X88-M/4
X88-M/9
X9-F/P
XRD/C2
MC2M-CABIN/S24
X14-F/W
X15-M/6
18 Shield - X88-M/10
X88-M/5
X9-F/R
XRD/B1

A White-Green 2,5 X17-F/16

X24
B Black 2,5 GND

Blue-Black 1 X13/4
80

Blue-Black 1 X6/4(FPSX)
2
Blue-Black 1 MC2M CHASSIS/L39
Blue-Black 1,5 X16-M/8
Yellow-Black 1 X10A/1 6
X25(FASX) Yellow-Black 1 X13/7 5
3 4
Yellow-Black 1,5 X18-F/7 1
2
Yellow-Black 1 X10/2(FPDX) 3
4 Green-Black 1,5 X17-F/19
5 Grey-Black 1,5 X18-F/22
6 Black 1,5 GND

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 79

Connectors wiring
Ref. Pin Wire colour Section Destination Image
A Black 1 GND
X18-F/1
X18-F/2
Red 4 X18-F/3
B X18-F/4
A
X26 X35-M/B
X35-M/D C
Red 6 B
X35-M/E
X16-M/1
C Grey-Green 1 X18-F/19
X71/A
X18-F/8
X27A/3
X27B/3
X27C/1
X29/1
X29A/3
X29B/3
X29C/1
1 Orange 1 A
X27 X5/1
X5A/3 C
B
X5B/3
X5C/1
X7/1
X7A/3
X7B/3
X7C/1
2 Grey-Yellow 1 MC2M CHASSIS/R29
X18-F/8
X27/1
X27B/3
X27C/1

80
X29/1
X29A/3
X29B/3
X29C/1
3 Orange 1 A
X27A X5/1
X5A/3 C
B
X5B/3
X5C/1
X7/1
X7A/3
X7B/3
X7C/1
4 Grey-White 1 MC2M CHASSIS/L10

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
80 SPECIFICATIONS

Connectors wiring
Ref. Pin Wire colour Section Destination Image
X18-F/8
X27/1
X27A/3
X27C/1
X29/1
X29A/3
X29B/3
X29C/1
3 Orange 1 A
X27B X5/1
X5A/3 C
B
X5B/3
X5C/1
X7/1
X7A/3
X7B/3
X7C/1
4 Grey-Green 1 MC2M CHASSIS/R24
X18-F/8
X27/1
X27A/3
X27B/3
X29/1
X29A/3
X29B/3
X29C/1
1 Orange 1 A
X27C X5/1
X5A/3 C
B
X5B/3
X5C/1
X7/1
X7A/3
X7B/3
80

X7C/1
2 Grey-Red 1 MC2M CHASSIS/L1

A Black 1 GND

A
X28 B Brown-Green 1 MC2M CHASSIS/S2
C
B
C Black-Red 1 MC2M CHASSIS/L6

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 81

Connectors wiring
Ref. Pin Wire colour Section Destination Image
X27/1
X27A/3
X27B/3
X27C/1
X29A/3
X29B/3
X29C/1
Orange 1 X5/1
1 A
X29 X5A/3
X5B/3 C
B
X5C/1
X7/1
X7A/3
X7B/3
X7C/1
Orange 1,5 X18-F/7
2 Brown-Yellow 1 MC2M CHASSIS/R28
X27/1
X27A/3
X27B/3
X27C/1
X29/1
X29B/3
X29C/1
Orange 1 X5/1
3 A
X29A X5A/3
X5B/3 C
B
X5C/1
X7/1
X7A/3
X7B/3
X7C/1

80
Orange 1,5 X18-F/7
4 Brown-White 1 MC2M CHASSIS/L9

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
82 SPECIFICATIONS

Connectors wiring
Ref. Pin Wire colour Section Destination Image
X27/1
X27A/3
X27B/3
X27C/1
X29/1
X29A/3
X29C/1
Orange 1 X5/1
3 A
X29B X5A/3
X5B/3 C
B
X5C/1
X7/1
X7A/3
X7B/3
X7C/1
Orange 1,5 X18-F/7
4 Brown-Green 1 MC2M CHASSIS/R23
X27/1
X27A/3
X27B/3
X27C/1
X29/1
X29A/3
X29B/3
Orange 1 X5/1
1 A
X29C X5A/3
X5B/3 C
B
X5C/1
X7/1
X7A/3
X7B/3
X7C/1
80

Orange 1,5 X18-F/7

2 Brown-Red 1 MC2M CHASSIS/L13
Blue 1 X10/4(FPDX)
Blue 1 X13/1
2
Blue 1 MC2M CHASSIS/L40
Blue 1,5 X16-M/9
Yellow 1 X6A/1 6
X30(FADX) Yellow 1 X13/5 5
3 4
Yellow 1,5 X18-F/6 1
2
Yellow 1 X6(FPSX) 3
4 Green 1,5 X17-F/17
5 Grey 1,5 X17-F/6
6 Black 1,5 GND

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 83

Connectors wiring
Ref. Pin Wire colour Section Destination Image
Green-Red 1 I8/1
F37
X107-F/1
1
Blue-Yellow 1 X107-F/10
X21-F/10
X42-F/5
X101-F/1
Yellow 1 X107-F/2
2
X12-F/4
Pink-Yellow 1 I8/3
X32-F
Brown-Purple 1 S8/1
X103-F/2
X107-F/9
3
Brown-White 1 X12-F/6
X32-F/5
X33-M/2
X103-F/1
Grey-Red 1 X107-F/6
4
X12-F/7
Black-Purple 1 S8/2
Light blue-White 1 S11/1
X103-F/2
X107-F/9
5
Brown-White 1 X12-F/6
X32-F/3
X33-M/2
X32-F 6 Light blue-Green 1 S12/1
7 Light blue-Black 11 S13/1
8 Light blue-Yellow 1 S14/1
9 White-Blue 1 S24/1
10 White-Green 1 S25/1
11 Grey-Purple 1 X81/1

80
12 Black 1,5 GND
Green-Red 1 I6/1
1
Green-Red 1 X18-F/15
2 Pink-Yellow 1 MC2M CHASSIS/L21
3 Brown-Purple 1 CC2/10
4 Black-Purple 1 CC2/9
5 Light blue-White 1 MC2M CHASSIS/R13
6 Light blue-Green 1 MC2M CHASSIS/R14
X32-M
7 Light blue-Black 1 MC2M CHASSIS/R16
8 Light blue-Yellow 1 MC2M CHASSIS/R15
9 White-Blue 1 MC2M CHASSIS/R4
10 White-Green 1 MC2M CHASSIS/R5
X18-F/18
11 Grey-Purple 1
X33-F/11
12 Black 1,5 GND

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
84 SPECIFICATIONS

Connectors wiring
Ref. Pin Wire colour Section Destination Image
1 Light blue 1 MC2M CHASSIS/R7
2 Orange-White 1 MC2M CHASSIS/R17
3 Orange-Green 1 MC2M CHASSIS/R18
4 Orange-Black 1 MC2M CHASSIS/R20
5 Orange-Yellow 1 MC2M CHASSIS/R19
6 Red-Blue 1 MC2M CHASSIS/S5
7 Red-Grey 1 MC2M CHASSIS/S4
X33-F MC2M CHASSIS/S13
8 Red-Purple 1
X34/2
MC2M CHASSIS/S14
9 Red-Green 1
X34/3
10 Green-Black 1 MC2M CHASSIS/S6
X18-F/18
11 Grey-Purple 1
X32-M/11
12 Black 1,5 GND
Light blue 1 S15/1
1
Grey 1 X12-F/12
Orange-White 1 S16/1
X103-F/2
X107-F/9
2
Brown-White 1 X12-F/6
X32-F/3
X32-F/5
3 Orange-Green 1 S17/1
X33-M 1
4 Orange-Black 1 S18/1
2
5 Orange-Yellow 1 S19/1
6 Red-Blue 1 S27/1
7 Red-Grey 1 S28/1
8 Red-Purple 1 S35/1
9 Red-Green 1 S36/1
10 Green-Black 1 S6/A
11 Grey-Purple 1 S6/B
80

12 Black 1,5 GND

1 Black-Purple 1 MC2M CHASSIS/R40
MC2M CHASSIS/S13
2 Red-Purple 1
X33-F/8 A
X34
MC2M CHASSIS/S14
3 Red-Green 1 C
X33-F/9 B

4 Black 1 GND

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 85

Connectors wiring
Ref. Pin Wire colour Section Destination Image
A Red-Yellow 1 X36-12
Red 4 F75
B X35-F/D
Red 6
X35-F/E
C Grey 1 G1
Red 4 X35-F/B
D F75
Red 6
X35-F/E
Red 4 X35-F/B
E F75
Red 6
X35-F/D
X35-F F Grey-Red 1,5 M1
G Brown-Red 4 X36-5/6
H Light blue-Red 1,5 T41-1
J Light blue-Red 1,5 T41-1
Brown 1,5 X37-1
K
Brown 1,5 X36-15
L Yellow-Purple 1,5 X36-8
M Black 1,5 X36-9/11
N Black 1,5 X36-9/11
P Black 1 X36-9/11
R Pink-Red 1 X36-13
S Grey-Blue 1 P39-1
T Black-Yellow 1 P39-2
U Black-Blue 1 X38-1
X35-F V Yellow 0,34 X36-1
W Light blue 0,34 X36-2
X Brown 0,34 X36-3/4

80

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
86 SPECIFICATIONS

Connectors wiring
Ref. Pin Wire colour Section Destination Image
A Red-Yellow 1 X18-F/27
Red 1 X26/B
X18-F/1
X18-F/2
Red 4
B X18-F/3
X18-F/4
X35-M/D
Red 6
X35-M/E
C Grey 1 X19-M/T
Red 1 X26/B
X18-F/1
X18-F/2
D Red 4 X18-F/3
X18-F/4
X35-M/B
Red 6 X35-M/E
Red 1 X26/B
X18-F/1
X18-F/2
E Red 4 X18-F/3
X18-F/4
X35-M/B
X35-M Red 6 X35-M/D
F Grey-Red 1,5 X18-F/21
G Brown-Red 4 X17-F/18
X18-F/25
H Light blue-Red 1,5 X18-F/26
X35-M/J
X18-F/25
J Light blue-Red 1,5 X18-F/26
X35-M/H
K Brown 1,5 X16-M/6
80

X16-M/12
L Yellow-Purple 1,5
X17-F/2
M Black 1,5 GND
N Black 1,5 GND
P Black 1 GND
R Pink-Red 1 X16-M/18
S Grey-Blue 1 MC2M CHASSIS/L24
X18-F/14
T Black-Yellow 1
X20-F/1
U Black-Blue 1 X18-F/23
V Yellow 0,34 X16-M/23
W White 0,34 X16-M/24
X Brown 0,34 X16-M/22

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 87

Connectors wiring
Ref. Pin Wire colour Section Destination Image
1 Yellow 1 X35-V
2 Light blue 1 X35-W
3 Brown-Red 1 X35-X
4 Brown-Grey 1 X35-X
5 Brown-Red 1,5 X35-G
6 Brown-Red 1,5 X35-G
X36
8 Yellow-Purple 1,5 X35-L
9 Black 1,5 X35-M/N/P
11 Black 1,5 X35-M/N/P
12 Red-Yellow 1 X35-A
13 Pink-Red 1 X35-R
15 Brown 1,5 X35-K

X37 1 Brown 1,5 X36-15

Red 1 X20-F/C
1 Red 1 F49
Red 1,5 X23-F/9
2 Black 1 GND
3 Brown 1 I22/32
1
4 Light blue-Orange 1 DM/5 2
X37-F
R82/86 3
5 White-Orange 1 4 8
X21-F/1 7
X21-F/25 6
6 Brown-Blue 1 5
X22-F/20
Blue 1,5 X20-F/A
8
Blue 1 F63

3 White 1,5 X37-M/6

4 White 1 X37-M/5
5 White 1 X37-M/4 1
X37-M 2

80
6 White 1,5 X37-M/3 3
4 8
7 White 1 X37-M/8 7
6
5
8 White 1 X37-M/7
1 Black-Blue 1 X35-U
2 Black 1 GND
X21-M/10
4 Blue-Yellow 1
X38 XCD/7 1
X21-M/9 2
7 Orange-Red 1
XCD/4
8 Black 1 GND

1 Black-Yellow 1 X35-T
X39
2 Grey-Blue 1 X35-S

3 Red-White 1 X21-M/32
4 Black-White 1 X21-M/31
X39A
5 Red-Grey 1 X21-M/30
6 Black-Yellow 1 X21-M/29

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
88 SPECIFICATIONS

Connectors wiring
Ref. Pin Wire colour Section Destination Image

1 Orange-Grey 1 "MC2M CHASSIS/R9"

X4 1
2 Black 1 GND 2

1 Blue 6 X23-F/8
2 Blue 6 F72
3 Black 1 GND
X40-F Orange-Blue 1 F62 2
Orange-Blue 1,5 I7/1 4
4 1
3
Orange-Blue 1 I20/5
Orange-Blue 1 X22-F/10

1 White 6 X40-M/2
X40-M
2 White 6 X40-M/1

1 Black 1 GND
X107-F/8
3 Blue-White 1
X12-F/8 2
1
F37 3
X42-F
X107-F/1 6
5
5 Blue-Yellow 1 X107-F/10 4

X21-F/10
X32-F/1
X14-F/C
A Red-Brown 1,5
X22-M/23
X10/19 A
X46
B Red 1 X15-M/2
C
X23-M/9 B

C Black 1 GND

1 White-Red 1 X11-M/23
X47 1
80

2 Brown-Purple 1 X11-M/24 2

X11A/1
1 White-Green 1
X18-F/16 A
X4A
2 Black 1 GND C
B
3 White-Grey 1 MC2M CHASSIS/R34

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 89

Connectors wiring
Ref. Pin Wire colour Section Destination Image
X18-F/8
X27/1
X27A/3
X27B/3
X27C/1
X29/1
X29A/3
X29B/3
1 Orange 1 A
X5 X29C/1
X5A/3 C
B
X5B/3
X5C/1
X7/1
X7A/3
X7B/3
X7C/1
2 Purple-Yellow 1 MC2M CHASSIS/R39
MC2M CHASSIS/S23
1 White 0,5 X16-M/26
X71/C
X500-F 1
MC2M CHASSIS/S25
2
2 Brown 0,5 X16-M/25
X71/D
CAN/2
1 White 0,5 MC2M CHASSIS/S26
X16-M/28
X501-F 1
CAN/1
2
2 Brown 0,5 MC2M CHASSIS/S7
X16-M/27
OBD2-F/14
STR4-F/8
1 White 0,4 X16-M/26

80
X21-F/34
X23-F/17
X503-F 1
OBD2-F/6
2
STR4-F/7
2 Brown 0,4 X16-M/25
X21-F/33
X23-F/16

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
90 SPECIFICATIONS

Connectors wiring
Ref. Pin Wire colour Section Destination Image
OBD2-F/11
X16-M/28
X21-F/13
1 White 0,4
X23-F/14
XM4-F/21
XS1-F/8
X504-F 1
OBD2-F/3
2
X16-M/27
X21-F/12
2 Brown 0,4
X23-F/12
XM4-F/19
XS1-F/7
1 Black 1 GND
X51/5
Red-Green 1 X53/1
2
X53/3
Red-Green 1,5 X14-M/A 6
X51 3 Green-Red 1 X14-M/P 5
4
4 Green-Grey 1 X14-M/Q 1
2
X51/2 3
Red-Green 1 X53/1
5
X53/3
Red-Green 1,5 X14-M/A
X51/2
Red-Green 1 X51/5
1
X53/3
Red-Green 1,5 X14-M/A
2 Green-White 1 X14-M/O A
X53
X51/2
C
Red-Green 1 X51/5 B
3
X53/1
Red-Green 1,5 X14-M/A
80

4 Black 1 GND
I26/8
1 Brown-Red 1 L30/1
X55-F X21-M/2 1
I27/5 2
2 White 1
STR3/5

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 91

Connectors wiring
Ref. Pin Wire colour Section Destination Image
X18-F/8
X27/1
X27A/3
X27B/3
X27C/1
X29/1
X29A/3
X29B/3
3 Orange 1 A
X5A X29C/1
X5/1 C
B
X5B/3
X5C/1
X7/1
X7A/3
X7B/3
X7C/1
4 Purple-White 1 MC2M CHASSIS/L12
X18-F/8
X27/1
X27A/3
X27B/3
X27C/1
X29/1
X29A/3
X29B/3
3 Orange 1 A
X5B X29C/1
X5/1 C
B
X5A/3
X5C/1
X7/1
X7A/3
X7B/3

80
X7C/1
4 Purple-Green 1 MC2M CHASSIS/R26

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 ELECTRICAL FEATURES AND
92 SPECIFICATIONS

Connectors wiring
Ref. Pin Wire colour Section Destination Image
X18-F/8
X27/1
X27A/3
X27B/3
X27C/1
X29/1
X29A/3
X29B/3
1 Orange 1 A
X5C X29C/1
X5/1 C
B
X5A/3
X5B/3
X7/1
X7A/3
X7B/3
X7C/1
2 Purple-Red 1 MC2M CHASSIS/L3
1 Black 1 GND
Yellow 1 X6A/1
Yellow 1 X13/5
2
Yellow 1 X30/3(FADX)
Yellow 1,5 X18-F/6
Light blue-Yellow 1 A2/1
Light blue-Yellow 1 X10/3(FPDX)
3
Light blue-Yellow 1 X13/2
X6(FPSX)
Light blue-Yellow 1 X18-F/10
Blue-Black 1,5 X25/2(FASX)
Blue-Black 1,5 X16-M/8
4
Blue-Black 1 MC2M CHASSIS/L39
Blue-Black 1 X13/4
Pink-Black 1,5 X18-F/12
5 Pink-Black 1 X10/5(FPDX)
80

Pink-Black 1 X13/6
Yellow 1 X13/5
Yellow 1,5 X30/3(FADX)
1
X6A Yellow 1,5 X18-F/6 1
Yellow 1 X6(FPSX) 2
2 Black 1 GND

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 93

Connectors wiring
Ref. Pin Wire colour Section Destination Image
X18-F/8
X27/1
X27A/3
X27B/3
X27C/1
X29/1
X29A/3
X29B/3
1 Orange 1 A
X7 X29C/1
X5/1 C
B
X5A/3
X5B/3
X5C/1
X7A/3
X7B/3
X7C/1
2 Blue-Yellow 1 MC2M CHASSIS/R38
I70/8
1 Brown 1 I73/21
X70-F X21-M/26 1
I10/24 2
2 Brown-Blue 1
X21-M/25

1 White 1 X70-M/2
X70-M
2
2 White 1 X70-M/1 1

X16-M/1
A Grey-Green 1 X18-F/19
X26/C
B Black 1 GND
MC2M CHASSIS/S23
X71

80
C White 0,5 X16-M/26
X500-F/1
MC2M CHASSIS/S25
D Brown 0,5 X16-M/25
X500-F/2
1 Blue-Yellow 1 X76-F/3
2 Orange-Green 1 X14-M/T
6
3 Blue-White 1 X76-F/4
X75 5
4 Orange-Black 1 X14-M/S 4
1
5 Blue-Green 1 X76-F/6 2
3
6 Blue-Pink 1 X76-F/5

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
94 SPECIFICATIONS

Connectors wiring
Ref. Pin Wire colour Section Destination Image
Red-Brown 1 ISR/1
1 XMS/2
Red-Brown 1,5 X14-M/C
2 Black 1 GND
X76-F 3 Blue-Yellow 1 X75/1
4 Blue-White 1 X75/3
5 Blue-Pink 1 X75/6
6 Blue-Green 1 X75/5
7 Brown-Yellow 1,5 M12/1

1 White 1,5 X76-M/7

X76-M
7 White 1,5 X76-M/1

X18-F/8
X27/1
X27A/3
X27B/3
X27C/1
X29/1
X29A/3
X29B/3
3 Orange 1 A
X7A X29C/1
X5/1 C
B
X5A/3
X5B/3
X5C/1
X7/1
X7B/3
X7C/1
4 Blue-White 1 MC2M CHASSIS/L11
X18-F/8
80

X27/1
X27A/3
X27B/3
X27C/1
X29/1
X29A/3
X29B/3
3 Orange 1 A
X7B X29C/1
X5/1 C
B
X5A/3
X5B/3
X5C/1
X7/1
X7A/3
X7C/1
4 Blue-Green 1 MC2M CHASSIS/R25

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 95

Connectors wiring
Ref. Pin Wire colour Section Destination Image
X18-F/8
X27/1
X27A/3
X27B/3
X27C/1
X29/1
X29A/3
X29B/3
1 Orange 1 A
X7C X29C/1
X5/1 C
B
X5A/3
X5B/3
X5C/1
X7/1
X7A/3
X7B/3
2 Blue-Red 1 MC2M CHASSIS/L2
1 Blue 2,5 F66
2 White 2,5 X23-F/7
A Yellow-Black 1,5 F51
B Yellow-Purple 1,5 F54
C Light blue 1,5 X21-F/7
D Orange-White 1,5 F40
E Purple-Black 1,5 F55
F Purple 1,5 F56
G Red-White 1 X21-F/32
H Black-White 1 X21-F/31
X7D-F
J Red-Grey 1 X21-F/30
K Black-Yellow 1 X21-F/29
L Yellow-Red 1,5 F68
M Yellow-Grey 1 X22-F/7
N Yellow 1,5 F67

80
P Red-Green3 1 F33
R White-Yellow 1 I56/2
S Light blue-Black 1 X22-F/1
Blue-Red 1 TV-F/1
T
Blue-Red 1 F41

1 Grey-Purple 1 X32-F/11
X81 1
2 Black 1 GND 2

1 Orange-Purple 1 MC2M-CABIN/R17
X86-F 1
2 Black 1 GND 2

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
96 SPECIFICATIONS

Connectors wiring
Ref. Pin Wire colour Section Destination Image
X22-M/8
1 Pink-Red 1
X88-M/6
2 Black 1 GND
MC2M-CABIN/S25
MDCP/19
X11-F/18
X14-F/U
3 Brown 0,5 X15-M/4
X23-M/16
X88-M/8
X9-F/P
XRD/C1
MC2M-CABIN/S23
MDCP/20
X11-F/19
X14-F/V
4 White 0,5 X15-M/5
X23-M/17
X88-M/9
X9-F/Q
XRD/C2
MC2M-CABIN/S24
X14-F/W
X15-M/6
X88-M 5 Shield - X23-M/18
X88-M/10
X9-F/R
XRD/B1
X22-M/8
6 Pink-Red 1
X88-M/1
7 Black 1 GND
MC2M-CABIN/S25
80

MDCP/19
X11-F/18
X14-F/U
8 Brown 0,5 X15-M/4
X23-M/16
X88-M/3
X9-F/P
XRD/C1
MC2M-CABIN/S23
MDCP/20
X11-F/19
X14-F/V
9 White 0,5 X15-M/5
X23-M/17
X88-M/4
X9-F/Q
XRD/C2

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 97

Connectors wiring
Ref. Pin Wire colour Section Destination Image
MC2M-CABIN/S24
X14-F/W
X15-M/6
X88-M 10 Shield - X23-M/18
X88-M/5
X9-F/R
XRD/B1

Black 1 GND
X9(E35) 1
Pink-Green 1 X17-F/4

1 Red-Yellow 1 X9-M/M
X90 1
2 Black 1 GND 2

A Orange-Purple 1 X20-M/R

A
X98 B Orange-Black 1 X20-M/S
C
B
C Orange-Blue 1 X20-M/T

1 Yellow-Blue 1 CC2/3
X99 1
2 Black 1 GND 2

Pink-Black 1 X9-F/B
A
Pink-Black 1,5 X22-M/19
Pink-Black 1 X9-F/B
B
Pink-Black 1,5 X22-M/19
C Black 1,5 GND
D Grey-Yellow 1 MDCP/25
E Grey-Blue 1 MDCP/26
F Black 1,5 GND

80
G Orange-Yellow 1 MDCP/28
H Brown-Blue 1 MDCP/29
J Brown-Grey 1 MDCP/30
K White-Grey 1 MDCP/31
X9-F L Pink-Yellow 1 MC2M-CABIN/L29
M Red-Yellow 1 MDCP/14
N Grey-Pink 1 MDCP/24
O Orange-Purple 1 MDCP/27
MC2M-CABIN/S25
MDCP/19
X11-F/18
X14-F/U
P Brown 0,5 X15-M/4
X23-M/16
X88-M/3
X88-M/8
XRD/C1

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
98 SPECIFICATIONS

Connectors wiring
Ref. Pin Wire colour Section Destination Image
MC2M-CABIN/S23
MDCP/20
X11-F/20
X14-F/V
Q White 0,5 X15-M/5
X23-M/17
X88-M/4
X88-M/9
XRD/C2
MC2M-CABIN/S24
X9-F
X14-F/W
X15-M/6
R Shield - X23-M/18
X88-M/10
X88-M/5
XRD/B1
S Black 1 GND
X10-F/6
T White-Red 1 X11-F/23
X22-M/25
X108/1
A Pink-Black 1
X109/1
X105/1
B Pink-Black 1 X106/1
X107A/1
C Black 1,5 GND
D Grey-Yellow 1 X108/3
E Grey-Blue 1 X107A-3
F Black 1,5 GND
G Orange-Yellow 1 X108/4
H Brown-Blue 1 X109/4
X9-M
J Brown-Grey 1 X106/4
80

K White-Grey 1 X107A-4
L Pink-Yellow 1 I41/2
M Red-Yellow 1 X90/1
N Grey-Pink 1 X109/3
O Orange-Purple 1 X106/3
P Brown 0,5 X105/3
Q White 0,5 X105/4
R Shield - “CAN-OPEN Line cable shield”
S Black 1 GND
T White-Red 1 I41/1

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 99

Connectors wiring
Ref. Pin Wire colour Section Destination Image
1 Red 4 KEY/1
2 Red 4 KEY/1
A Red 1 KEY/1
B Red 1 KEY/1
C Black 1 GND
D Black 1 GND
XAC
E Black 1 GND
F Black 1 GND
G Black 1 GND
H Black 1 GND
J Black 1 GND
K Blue-Red 1,5 F42
Black 2,5 GND
1
Red-Green3 1 X20-M/G
XAS
2 White 2,5 X20-M/B

X21-M/9
4 Orange-Red 1
X38/7
X21-M/10
XCD
7 Blue-Yellow 1 X21-M10
X38/4
8 Black 1 GND

1 Grey 1 X19-F/T
XD+ 1
2 Purple-Blue 1 X19-F/U 2

1 Black 1 GND
F46
2 Red-Green 1
OBD2-F/1
F61
3 Orange-Green 1 OBD2-F/16
XM4/1

80
OBD2-F/8
5 Pink-Red 1
X16-M/18
XDM-F
X16-M/23
6 Yellow 0,34
XM2-F/13
X16-M/24
7 White 0,34
XM2-F/15
X16-M/22
8 Brown 0,34
XM2-F/14
OBD2-F/7
14 Brown-Blue 1
XM1-F/2

1 Yellow-Purple 1 X16-M/12
XM1-F
OBD2-F/7
2 Brown-Blue 1
XDM/14

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
100 SPECIFICATIONS

Connectors wiring
Ref. Pin Wire colour Section Destination Image
R82/87
1 Light blue-Orange 1
X16-M/19
XPA-M/5
5 Green 1
XPA-M/6
9 Pink-Brown 1 X16-M/7
XM2-F X16-M/23
13 Yellow 0,34
XDM-F/6
X16-M/22
14 Brown 0,34
XDM-F/8
X16-M/24
15 White 0,34
XDM-F/7

4 Purple-Yellow 1 X21-F/15

XM3-F 5 Purple-Red 1 X21-F/16

6 Black 1 GND

OBD2-F/16
Orange-Green 1
1 XDM/3
Orange-Green 1 F61
Brown 1 X23-F/2
Brown 1 X21-F/26
2
R81-86
Brown 1
X16-M/6
3 Black 1 GND
12 Green-Black 1 XPA-M/2
13 Green-Brown 1 XPA-M/4
XPA-M/1
14 Green-White 1
XPA-M/3
XM4-F OBD2-F/3
X16-M/27
Brown 0,5 X23-F/13
19
X504-F/2
80

XS1-F/7
Brown 0,5 X21-F/12
20 Shield - X23-F/15
OBD2-F/11
X16-M/28
X21-F/13
21 White 0,5
X23-F/14
X504-F/1
XS1-F/8
1 Yellow-Green 1 X14-M/R
ISR/1
XMS Red-Brown 1 1
2 X14-M/C
2
Red-Brown 1,5 X76-F/1

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 101

Connectors wiring
Ref. Pin Wire colour Section Destination Image
XM4-F/14
1 Green-White 1
XPA-M/3
2 Green-Black 1 XM4-F/12
XM4-F/14
3 Green-White 1
XPA-M/1
XPA-M
4 Green-Brown 1 XM4-F/13
XM2-F/5
5 Green 1
XPA-M/6
XM2-F/5
6 Green 1
XPA-M/6
MC2M-CABIN/S24
X14-F/W
X15-M/6
B1 Shield - X23-M/18
X88-M/10
X88-M/5
X9-F/R
MC2M-CABIN/S25
MDCP/19
X11-F/18
X14-F/U
C1 Brown 0,5 X15-M/4
X23-M/16
X88-M/3
X88-M/8
X9-F/P
MC2M-CABIN/S23
MDCP/20
X11-F/20
XRD
X14-F/V
C2 White 0,5 X15-M/5
X23-M/17

80
X88-M/4
X88-M/9
X9-F/Q
C3 Green-Brown 1 X11-F/5
D1 Green-Grey 1 X11-F/6
D2 Green-Yellow 1 X11-F/7
D3 Green-White 1 X11-F/8
E2 Grey-Red 1 X11-F/9
E3 Grey-Black 1 X11-F/10
Red-Green 1 XRD-H1
F1 X14-F/A
Red-Green 1,5
X22-M/21
F2 Black-Green 1 MC2M-CABIN/L25
G1 Purple-Red 1 MC2M-CABIN/L37
G2 Black 1 GND
G3 Black 1 GND

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
102 SPECIFICATIONS

Connectors wiring
Ref. Pin Wire colour Section Destination Image
XRD-F1
Red-Green 1
XRD-H1
H1
X14-F/A
Red-Green 1,5
X22-M/21
MC2M-CABIN/R15
H2 Red-Yellow 1
XRD/H3
MC2M-CABIN/R15
H3 Red-Yellow 1
XRD XRD/H2
MC2M-CABIN/L28
J1 Brown 1
X23-M/2
J2 Black 1 GND
J3 Black 1 GND
X11-F/28
K1 Brown-Blue 1
X22-M/20
K2 Orange-White 1 MC2M-CABIN/L21

1 Grey-Blue 1 X19-F/R
XRS 1
2 Grey-Red 1 X19-F/S 2

1 Orange-Purple 1 X20-F/R
2 Orange-Black 1 X20-F/S
3 Orange-Blue 1 X20-F/T
4 Grey-Red 1 X22-F/2
5 Grey 1 X23-F/5
F48
6 Green-White 1
X20-F/N
OBD2-F/3
X16-M/27 1
2
XS1-F X21-F/12
7 Brown 0,4 3
X23-F/13 4 8
X504-F/2 7
6
5
80

XM4-F/19
OBD2-F/11
X16-M/28
X21-F/13
8 White 0,4
X23-F/14
X504-F/1
XM4-F/21
X19-M/A
1 Red-Green 1 XSC2-F/1
XSC-F/2
2 Black 1 GND
1
3 Grey-Blue 1 MC2M CHASSIS/S16 2
XSC1-F
4 Orange-Red 1 X19-M/Q 3
4 8
5 Orange-Grey 1 X19-M/P 7
6 Orange 1 X19-M/O 6
5
7 Light blue 1 X19-M/N
8 Black-Blue 1 X19-M/M

80-01-M205EN (05/02/2013)
 ELECTRICAL FEATURES AND
SPECIFICATIONS 103

Connectors wiring
Ref. Pin Wire colour Section Destination Image
X19-M/A
1 Red-Green 1 XSC1-F/1
XSC-F/2
2 Black 1 GND
1
3 Black-Yellow 1 X19-M/G 2
XSC2-F
4 Light blue-Yellow 1 X19-M/H 3
4 8
5 White 1 X19-M/J 7
6 White-Grey 1 X19-M/K 6
5
7 White-Red 1 X19-M/L
8 Green-Blue 1 MC2M CHASSIS/R22
1 Black 1 GND
X19-M/A
2 Red-Green 1 XSC1-F/1
XSC2-F/1
3 Green-Grey 1 X16-M/10
4 Green-Brown 1 X16-M/11
5 Green-Black 1 X16-M/17
XSC-F
6 Green-Yellow 1 X16-M/20
7 Black-White 1 X19-M/B
8 Light blue-White 1 X19-M/C
9 Light blue-White 1,5 X19-M/D
10 Light blue-Grey 1 X19-M/E
11 Light blue-Red 1,5 X19-M/F
12 Grey-Yellow 1 MC2M CHASSIS/S15

1 Light blue-Red 1 X14-M/X

XSP 1
2 Black 1 GND 2

Red-Yellow 1 ISR/1
1
XSR LSR/1
2 Black 1 GND

80

(05/02/2013) 80-01-M205EN
 ELECTRICAL FEATURES AND
104 SPECIFICATIONS
80

80-01-M205EN (05/02/2013)
 WIRING DIAGRAMS

page

FUSE BLOCKS AND RELAYS IN CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

FUSE BLOCKS AND RELAYS ON CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
CAN-BUS LINE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

POSITION OF THE COMPONENTS ON THE DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

WIRING DIAGRAMS BY FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
– 1 – SWITCHING ON - SWITCHING OFF ENGINE/GEAR SHIFT LEVER/STEERING . . . . . 12
– 2 – HYDRAULIC MOVEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
– 3 – DANFOSS MOVEMENTS TRANSMISSION AND DIRECTIONAL CONTROL VALVE. . 16
– 4 – CAB - ADM2 - MR2 - RADIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
– 5 – OPTIONAL BOOM - SENSORS AND TRANSDUCERS 3B6 -
SET-UP CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

80
– 6 – LIGHTS SENSORS/PROXIMITY SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
– 7 – HEATING AND AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
– 8/1 – CONTROL UNITS AND CAN-BUS CIRCUIT POWER SUPPLIES . . . . . . . . . . . . . . . . . 26
– 8/2 – CONTROL UNITS AND CAN-BUS CIRCUIT POWER SUPPLIES . . . . . . . . . . . . . . . . . 28

(25/06/2012) 80-02-M205EN
 2 WIRING DIAGRAMS

FUSE BLOCKS AND RELAYS IN CAB

Ref. Description Position on the diagram
F33 Switches indicator lights fuse (7.5A) C6
F34 Gearshift lever power supply fuse (7.5A) C7
F35 Boom head output third relay fuse (7.5A) C8
F36 Fuse on positive from battery for four direction indicator lights (7.5A) C9
F37 Vehicle radio/heating power supply "15" fuse (7.5A) C10
F38 Start up switch auxiliary power supply fuse (7.5A) C11
F39 Boom limit stop fuse (7.5A) C11
F40 Ceiling light fuse (7.5A) C12
F41 Cab door limit stop fuse (7.5A) C13
F42 Air conditioning fuse (7.5A) C14
F43 Windscreen wiper pump fuse (10A) E6
F44 Stalk lights switch and horn power supply fuse (10A) E7
F45 Heating fan power supply fuse (10A) E8
F46 Diagnostics power supply fuse (10A) E9
F47 Engine stop emergency button fuse (10A) E10
F48 Fuse for positive from key for four direction indicator lights (10A) E11
F49 Positive “30” / Danfoss / 3B6 fuse (10A) E11
F50 Positive “15” / Danfoss directional control valve (10A) E12
F51 Front work lights fuse (10A) E13
F52 Driver's seat/radio control unit internal power supply fuse (10A) E14
F53 Joystick “15” positive fuse (10A) G6
F54 Rear work lights fuse (10A) G7
F55 “15” upper windscreen wiper fuse (10A) G8
F56 “15” rear windscreen wiper fuse (10A) G9
F57 Switches “15” positive fuse (15A) G10
F58 Platform functions power supply fuse (15A) G6
F59 Rotary beacon fuse (15A) G7
F60 Vehicle radio power supply fuse (15A) G8
F61 Diagnostics power supply fuse (15A) G9
F62 Tower alignment/small mixer bucket proximity switch power supply fuse (15A) G10
F63 Anti-theft/instrument power supply fuse (15A) I6
80

F64 3B6 transducers fuse (15A) I7

F65 Pneumatic seat fuse (15A) I8
F66 Boom head work lights fuse (15A) I9
F67 "15" electric windows fuse (15A) I10
F68 Heated rear window fuse (20A) K6
F69 "30" Cigarette lighter fuse (20A) K7
F70 Heating power supply fuse (20A) K8
F71 Cab section MC2M power supply fuse (25A) K9
F72 Big mixer bucket fuse (25A) K10
R74 Radio and heater relay G13
R75 Boom head output second relay M8
R76 Danfoss directional control valve enabling relay Q8
R77 3B6 transducers power supply relay Q11
R78 3B6 control units power positives relay I13
R79 Direction indicators flasher relay M12
R80 3B6 control units electronic positives relay Q14
R81 Relay for cutting power supply from emergency mushroom switch O8
R82 Neutral position negative signal relay O11
R83 Boom head output third relay O14
80-02-M205EN (25/06/2012)
 A

S
C

Q
O
G

M
1
2

(25/06/2012)
3
4
5
6

F68 F63 F58 F53 F43 F33

20A 15A 15A 10A 10A 7.5A
7

F69 F64 F59 F54 F44 F34

20A 15A 15A 10A 10A 7.5A
8

F70 F65 F60 F55 F45 F35

R76
R81
20A 15A 15A 10A 10A 7.5A

R75
F71 F66 F61 F56 F46 F36
9

25A 15A 15A 10A 10A 7.5A

F72 F67 F62 F57 F47 F37

25A 15A 15A 15A 10A 7.5A
10

F48 F38
10A 7.5A
11

R77
R82
F49 F39
10A 7.5A
12

R79
F50 F40
10A 7.5A

R78
R74
13

F51 F41
10A 7.5A

R80
R83
14

F52 F42
10A 7.5A
15
16
17
18
WIRING DIAGRAMS

19

80-02-M205EN
3

80
 4 WIRING DIAGRAMS

FUSE BLOCKS AND RELAYS ON CHASSIS

Ref. Description Position on the diagram
F1 Rear axle block fuse (7.5A) I5
F2 Axle alignment sensors fuse (7.5A) I5
F3 Reversing lights fuse (7,5A) I5
F4 LH position lights fuse (7.5A) I5
F5 RH position lights fuse (7.5A) I5
F6 Spark plugs power supply fuse (7.5A) I6
F7 Gear change micro switch fuse (10A) I6
F8 Emergency pump relay power supply fuse (10A) I6
F9 Micro switch power supply fuse (10A) I6
F10 Set-up fuse (10A) I6
F11 Dipped beams fuse (15A) O5
F12 High beams fuse (15A) O6
F13 Stop lights fuse (15A) O7
F14 Danfoss control unit fuse (15A) O7 / O8
F15 Fuel oil filter heater fuse (20A) O8
F16 Mercedes control unit power supply fuse (25A) O9
F17 Chassis section MC2M power supply fuse (25A) O10
F18 Chassis primaries power supplies relay fuse (30A) O10 / O11
F19 Oil cooling fan fuse (25A) G15
F20 Oil cooling fan fuse (25A) O15
R1 Oil cooling fan 1 relay K5
R2 Oil cooling fan 2 relay K8
R3 Chassis section MC2M power supply relay I8
R4 Chassis primaries power supplies relay K10
R5 Start-up relay I10
R6 Reversing lights relay K12
R7 Stop lights relay K12
R8 Spark plugs preheating relay I12
R9 Emergency pump activation relay K13
R10 RH dipped beam relay K13 / K14
R11 RH high beam relay I13 / I14
80

R12 LH dipped beam relay K15

R13 LH high beam relay K15
R14 Relay for start up control by ADM-2 I15
R15 Set-up relay K16
R16 Set-up relay K16
R17 Set-up relay I16

80-02-M205EN (25/06/2012)
 WIRING DIAGRAMS 5

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

F19
25A

F1 7.5A F6 7.5A

F2 7.5A F7 10A

I F3 7.5A F8 10A R8 R11 R14 R17

R3 R5
F4 7.5A F9 10A

F5 7.5A F1010A

R7 R10 R13 R16

K
R1 R2 R4

R6 R9 R12 R15

80
M

F11 F12 F13 F14 F15 F16 F17 F18

F20
15

15

15

15

20

25

25

30

25A

O
15

15

15

15

20

25

25

30

(25/06/2012) 80-02-M205EN
 6 WIRING DIAGRAMS
80

80-02-M205EN (25/06/2012)
 WIRING DIAGRAMS 7
CAN-BUS LINE CIRCUIT

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

CAN BUS OPEN

CABIN CAN BUS OPEN-1
A SWITCH A
CAN BUS J1939
CHAINS WORK LAMPS
BROKEN WIPER BASKET ISO K-LINE
ROTARY LAMPS PREDISPOSITION
SWITCH STANDARD WIRES

C C
3B6
AIR CONDITIONING MC2M SAUER SAUER 3B6 SAUER AUTEC
BOOM 3B6 THROTTLE
GROUP DANFOSS DANFOSS DANFOSS RADIO CONTROL CORE
LEFT JOYSTICK RIGHT JOYSTICK EXTENSOMETER DISTRIBUTOR RECEIVER VIEW FOOT
PEDAL

E MERCEDES E
ADM2
UNIT BOX

3B6
BOOM 3B6
PRESSURE MIDAC-PLUS
G TRANSDUCER UNIT BOX G

INCHING
PEDAL
ATTACHMENT
BOOM
I RECOGNITION ENCODER I

ROTARY
COLLETTOR
WITH
ENCODER

K K

80
M M

BLINKERS INDICATOR SAUER

DANFOSS MERCEDES
PETROL AUTOMATIC 3B6 ENGINE
O HEADLIGHTS LEVELING H1 O
LEVELING MC2M AXIAL PISTON MR2
LIGHTS BULL UNIT BOX
SENSOR PUMP

ENABLE
BACKWARD
Q & FORWARD Q
HYDRAULIC BRAKES LEVELING STEERING AXLES BLOCK OUTRIGGERS GEAR POSITION
OIL FAN SYSTEM SYSTEMS SYSTEMS SYSTEMS SYSTEMS
VALVE & BULB

ENGINE SPEED FAST & SLOW

S SENSORS SENSORS GEAR SELECTION S

(25/06/2012) 80-02-M205EN
 8 WIRING DIAGRAMS

POSITION OF THE COMPONENTS ON THE DIAGRAMS Component Diagram 1 Diagram 2 Diagram 3 Diagram 4 Diagram 5 Diagram 6 Diagram 7
Diagram Diagram
8/1 8/2
Component Diagram 1 Diagram 2 Diagram 3 Diagram 4 Diagram 5 Diagram 6 Diagram 7 Diagram 8/1 Diagram 8/2 F40 √
A1 √
F41 √ √
A2 √ √
F42 √
A4 √
F43 √
A6 √
F44 √
B1 √
F45 √
BDP √
F46 √
C1 √
F47 √ √
C2 √
F48 √
CAN √ √
F49 √ √ √
CC1 √ √
F50 √ √
CC2 √
F51 √
CC3 √ √
F52 √ √ √
DL √
F53 √
DM √
F54 √
E35 √
F55 √
F1 √
F56 √
F2 √
F57 √ √ √
F3 √ √
F58 √
F4 √
F59 √
F5 √
F60 √
F6 √
F61 √ √
F7 √ √
F62 √ √
F8 √
F63 √ √ √
F9 √
F64 √
F10 √
F65 √
F11 √
F66 √
F12
80

√
F67 √
F13 √
F68 √
F14 √ √
F69 √
F15 √
F70 √
F16 √
F71 √ √
F17 √ √ √ √
F72 √
F18 √ √
F75 √
F19 √
FADX √
F20 √
FASX √
F33 √ √ √ √ √ √
FPDX √
F34 √
FPSX √
F35 √
G √
F36 √
I2 √
F37 √ √
I4 √
F38 √ √
I6 √
F39 √ √ √
I7 √
F40 √
I8 √
80-02-M205EN (25/06/2012)
 WIRING DIAGRAMS 9

Diagram Diagram Diagram Diagram

Component Diagram 1 Diagram 2 Diagram 3 Diagram 4 Diagram 5 Diagram 6 Diagram 7 Component Diagram 1 Diagram 2 Diagram 3 Diagram 4 Diagram 5 Diagram 6 Diagram 7
8/1 8/2 8/1 8/2
I9 √ PSC √

I10 √ √ R1 √

I15 √ R2 √

I22 √ √ √ √ R3 √ √ √

I24 √ R4 √ √

I26 √ R5 √

I27 √ R6 √ √

I28 √ R7 √

I29 √ R8 √

I30 √ R9 √

I31 √ R10 √

I35 √ R11 √

I41 √ √ R12 √

I43 √ R13 √

I51 √ R14 √

I53 √ R15 √

I54 √ R16 √

I56 √ R17 √

I68 √ R35 √ √

I69 √ R74 √

I70 √ R75 √

I71 √ R76 √ √

I73 √ R77 √

I77 √ R78 √

I78 √ R79 √

I79 √ R80 √ √ √ √ √

J1939 √ √ √ R81 √ √ √

80
KEY √ R82 √

L28 √ R83 √

L29 √ RS232 √

L30 √ S6 √

L31 √ S8 √

M1 √ S11 √

M10 √ S12 √

M11 √ S13 √

M3 √ √ S14 √

M4 √ √ S15 √

MA √ √ S16 √

MC2M CABIN √ √ √ √ √ √ √ S17 √

MC2M CHASSIS √ √ √ √ √ √ S18 √

MDCP √ √ √ S19 √

MIDAC PLUS √ S24 √

MP √ S25 √

OBD2 √ √ S27 √
(25/06/2012) 80-02-M205EN
 10 WIRING DIAGRAMS

Diagram Diagram Diagram Diagram

Component Diagram 1 Diagram 2 Diagram 3 Diagram 4 Diagram 5 Diagram 6 Diagram 7 Component Diagram 1 Diagram 2 Diagram 3 Diagram 4 Diagram 5 Diagram 6 Diagram 7
8/1 8/2 8/1 8/2
S28 √ X29C √

S35 √ X32 √

S36 √ X33 √

SQ √ X34 √

STR2 √ √ √ √ √ X36 √ √ √

STR3 √ √ X37 √

STR4 √ X38 √

T1 √ X39 √

T41 √ X39A √

TERA-7 √ X40 √

VIEW √ X41 √

X2 √ X42 √

X4 √ X47 √

X4A √ X55 √

X5 √ X70 √

X5A √ X71 √

X5B √ X76 √

X5C √ X81 √

X6A √ X88 √ √

X7 √ X99 √

X7A √ X101 √

X7B √ X102 √

X7C √ X103 √

X7D √ X105 √ √

X10 √ X106 √

X10A √ X107 √

X11 √ X107A √
80

X11A √ X108 √

X11B √ X109 √

X12 √ X500 √

X12A √ X501 √

X13 √ X503 √

X15 √ √ √ X504 √

X15A √ XAC √

X20 √ XAS √

X23 √ XCD √

X24 √ XD+ √

X27 √ XDM √ √

X27A √ XM1 √ √ √

X27B √ XM2 √ √

X27C √ XM3 √ √

X29 √ XM4 √ √ √

X29A √ XPA √

X29B √ XRD √ √

80-02-M205EN (25/06/2012)
 WIRING DIAGRAMS 11

Diagram Diagram
Component Diagram 1 Diagram 2 Diagram 3 Diagram 4 Diagram 5 Diagram 6 Diagram 7
8/1 8/2
XRS √

XSC √

XSC1 √

XSC2 √

80
(25/06/2012) 80-02-M205EN
 12 WIRING DIAGRAMS
WIRING DIAGRAMS BY FUNCTIONS

1 – SWITCHING ON - SWITCHING OFF ENGINE/GEAR SHIFT LEVER/STEERING

Connectors Fuses and relays

Position on the Hydraulic
Type of wiring Ref. Description Ref. Description Position on the diagram
diagram equivalent

X11 Boom/platform functions interface connector S24 F16 Mercedes control unit power supply fuse K36
X36 Mercedes engine MR2 control unit K39 F33 Switches indicator lights fuse M13
X37 Anti-theft device connector G35 F34 Gearshift lever power supply fuse E10
X70 Radio control switch by-pass Q20 F47 Engine stop emergency button fuse E7
XD+ "d+"alternator signal by-pass Q22 F49 Positive “30” / Danfoss / 3B6 fuse G30
XM1 ADM2 connector A40 F52 Driver's seat/radio control unit internal power supply fuse K34
XM4 ADM2 connector A34 F57 Switches "15" positive fuse K7
XRD Radio control unit connector S31 F58 Platform functions power supply fuse O24
F63 Anti-theft/instrument power supply fuse I36
F75 Main fuse E3
R5 Start-up relay G20
Components
R14 Relay for start up control by ADM-2 G11
Ref. Description Position on the diagram Hydraulic equivalent R35 Cab section power supplies remote control switch G24
R78 3B6 control units power positives relay I5
B1 12VDC battery E4
R80 3B6 control units electronic positives relay K5
DM Gearshift lever set-up E35
R81 Relay for cutting power supply from emergency mushroom switch G28
G Alternator Q7
R82 Neutral position negative signal relay G16
I10 Platform exclusion key O15
I22 Emergency mushroom-shaped button G7
I24 Steering selection switch K19
I70 Radio control switch O10
I73 Start up enabling with I10 activated O18
KEY Start-up panel A4
M1 Starter motor O5
MC2M CABIN Cab section inputs/outputs 3B6 control unit A16 / A27
MC2M CHASSIS Chassis section inputs/outputs 3B6 control unit E39
80

S24 Crab steering solenoid valve I28

S25 Concentric steering solenoid valve I29
STR2 3B6 primary instrument inputs/outputs O39

80-02-M205EN (25/06/2012)
 WIRING DIAGRAMS 13
DIAGRAM 1

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

MC2M-CABIN MC2M-CABIN XM4

INPUT/OUTPUT SIGNALS INPUT/OUTPUT SIGNALS
A MERCEDES ADM2
A

L34 Gear lever neutral position input

XM1

L28 Emergency pusch button

MERCEDES ADM2

2 Emergency pusch button

L19 D+ Alternator signal
KEY

HZ2.5
GZ

BR4
1 Starting engine
KEY SWITCH
2

X16-3
P 0 1 2 3 10 3 3
5 6 8 7 4

L40

L40
L1

L1

21
4

L33
L34

L33
L21
L22

L24
L25

L27

L32

L21
L22

L24
L25

L27
L28

L32
L29

L31

L35

L29

L31

L35
L26

L36
L37

L26

L36
L37
L20

L23

L38

L20

L23

L38
L30

L30
L18

L18
L19

L39

L39
L17

L17
L11
L12

L16

L11
L12

L16
L10

L10
L14
L15

L14
L15
L13

L13

1
L7
L8
L9

L7
L8
L9

20
18
19
17
L6

L6
L4
L5

L4
L5

11
12

16
10
L2
L3

L2
L3

14
15
13
7
8
9
6
4
5
3
5

3
6

X16-3
7

AC
M

M
ZL
C 1 2 8 C
9
R6

10
11
12
X35-B-D-E X18-1-2-3-4

MC2M-CHASSIS
INPUT/OUTPUT SIGNALS
X1-1
F47

R1
125A
F75

10A

E HZ
R2
R3 Key starting engine
E
F34 BL R4 Crab steering valve
BV R5 Concentric steering valve
DM

X23-2
7,5A
B1 GEAR LEVER PREDISPOSITION
R6
X21-1

X17-1

R7
12V BATTERY R8
1 1 R9
BR1.5

2 2
I22

N1.5
R10

R1.5

R1.5

R10
R14 R82 R5 R35 R81 3 3

BR
R11
4 4
AC B R12
HZ 86 30 BC 86 30 RG 86 30 VR 86 30 M 86 30 5 5
R13

X18-27
6 6 R14
S B

F49
7 7

10A
G SL
8 8
R15
R16
G
SM 9 9
M

EMERGENCY R17

X35-A
BUTTON AC 85 N 85 N 85 N 85 N 85 R18
87 87a 87 87a 87 87a 87 87a 87 87a
KEY STARTING NEUTRAL KEY STARTING CABIN MAIN EMERGENCY SWITCH X37 R19
R20

M10
HR1.5

VR
ANTITHEFT

AC1.5
CUTS FEEDING
GZ1.5

ENGINE RELAY POSITION ENGINE RELAY AUXILIARY FEEDING R21

TELERUPTOR RELAY
R22
X18-29

B1.5

B1.5
R23

R78

B
B
R24
R6

X17-2

X32-9 R25

2
3
4
5
6
7
RN 86 30
X16-19 X16-19 X32-10 R26

1 1

88
19 R27

CG

CG
VH
I I

2
3
4
5
6
7
R28
X35-L
R29
4 8 3 7 10
S24 S25

BV
BL

ML
N
M

BC
AC

H
L
R
1 R30
2
X16-12

0
R31
N 85
87 87a R32
R33

F63
KEY POWER SUPPLY R34

15A
RN6

12

CRAB CONCENTRIC

N
I24 STEERING STEERING R35
X16-12

2 6 1 5 9 VALVE VALVE R36

STEERING

N
CG
VB
MODE SWITCH R37
R38
R39
F57 R40

K K
R2.5

15A
R80
BR 86 30 X36
MERCEDES MR2

F52

F16
10A

25A
1
2
N 85 3
87 87a 4

80
X17-18 MR1.5
X35-G 5

X22-21
KEY POWER SUPPLY MR1.5
RN2.5

6
7
GZ1.5
M 8 Key starting engine input M
9
10
X21-25

11
X20-E

F33

RG
7,5A

12 Starting engine output

13
X16-6 X16-6 X35-K 14
X20-G

6
M1.5 15 Stop engine

X22-31
X19-U
STR2

F58
15A
RV Nr°13

I/O CORE DIGITAL INPUT/OUTPUT

X21-26
X18-21

O VB O

X22-30
CG

I70
ZB

1 Crab steering mode

I10 I73
ML

VH
ML

ZL
B

2 Concentric steering mode

H

5 6 10 3
M1
X35-F

X21-23
1 0

X21-24
4

X20-U
N70

STARTING ENGINE 5
X22-6
2
1

2
1

30 6
X19-T

7
2
1

2
1

X22-20
X20-V
8
G BASKET 9
M

START
B

ALTERNATOR 1 7 2 8 9 EXCLUSION BUTTON 10

KEY AVAILABLE 11
B
B

B
B

RADIO
R25

TOI10
M

N
ZG

SWITCH 12
HR1.5

13
Q
50
X70 BY-PASS
RADIO
SWITCH
XD+ 14 Q
X35-C 15

HN
ML

ZG

ML
ZB

RV

RV
H BC

M
N

N
N

N
N
16 Gear lever neutral position output
X16-17 X16-17 SM 17 Gear lever forward
17 SL

11
16
15

13
12

10
21

17

Radio control power supply H1

27

14

G1
7
6

D1
8

Eergency push button K1

28

25
26

19

F1
24
23
22

18

Eergency push button J1

H2

C1
E1
20

GND G2
H3
4

GND G3

D2
D3

A2
B1
F2

A3
F3
GND J2

C2
E2
GND J3

C3
K2

E3

B2
B3
18 Gear lever backward

A1
1
29

K3
GND
Radio control switch
Radio control switch
19

Power supply basket

Eergency push button

Radio control power supply

N25

20
ZG
N70

21 Radio control switch input

0
'

22
BR4
R25
R25

M1
RN

23

S X11 XRD S
BASKET INTERFACE CONNECTOR AUTEC RADIO CONTROL

(25/06/2012) 80-02-M205EN
 14 WIRING DIAGRAMS
2 – HYDRAULIC MOVEMENTS

Connectors Components
Position on the Hydraulic
Type of wiring Ref. Description Ref. Description Position on the diagram Hydraulic equivalent
diagram equivalent

X5 1st LH rear micro switch for stabilizer on ground A4 MC2M CABIN Cab section inputs/outputs 3B6 control unit S26
X5A 2nd LH rear micro switch for stabilizer on ground M20 MC2M CHASSIS Chassis section inputs/outputs 3B6 control unit S9/ S17 / S35
X5B 1st LH rear beam micro switch A5 / A6 MIDAC PLUS Cab section inputs/outputs 3B6 control unit G3 / G4
X5C 2nd LH rear beam micro switch M22 MP Emergency pump I11
X7 1st RH rear micro switch for stabilizer on ground A7 S11 RH front beam solenoid valve M16
X7A 2nd RH rear micro switch for stabilizer on ground M23 S12 LH front beam solenoid valve M17
X7B 1st RH rear beam micro switch A9 S13 LH rear beam solenoid valve M17 / M18
X7C 2nd RH rear beam micro switch M24 / M25 S14 RH rear beam solenoid valve M18
X15 Danfoss directional control valve connector M3 S15 Stabilizers retraction/ascent solenoid valve M8
X27 1st LH front micro switch for stabilizer on ground C4 S16 RH front stabilizer solenoid valve M9
X27A 2nd LH front micro switch for stabilizer on ground M26 S17 LH front stabilizer solenoid valve M10
X27B 1st LH front beam micro switch C5 / C6 S18 LH rear stabilizer solenoid valve M11
X27C 2nd LH front beam micro switch M27 S19 RH rear stabilizer solenoid valve M12
X29 1st RH front micro switch for stabilizer on ground C7 S35 RH levelling solenoid valve M13
X29A 2nd RH front micro switch for stabilizer on ground M28 / M29 S36 LH levelling solenoid valve M15
X29B 1st RH front beam micro switch C9 SQ Cab door limit stop I17
X29C 2nd RH front beam micro switch M30 STR2 3B6 primary instrument inputs/outputs K40 / K41
X34 Stabilizers block optional kit C41 STR3 3B6 primary instrument inputs/outputs O40 / O41
X55 Folding stabilizers configuration C40 VIEW 3B6 main instrument power supply E40 / E41

Components Fuses and relays

Ref. Description Position on the diagram Hydraulic equivalent Ref. Description Position on the diagram

A4 Rollover protection exclusion buzzer I21 F8 Emergency pump relay power supply fuse E14
A6 Emergency pump active buzzer I8 / I9 F9 Micro switch power supply fuse E14
80

E35 Emergency pump remote control switch coil I9 F18 Chassis primaries power supplies relay fuse E6
I4 Speed reset switch I21 F33 Switches indicator lights fuse G33
I9 Emergency pump switch I13 F38 Start-up panel auxiliary power supply E17
I22 Emergency mushroom-shaped button M31 F39 Boom limit stop fuse G18
I26 Beams in/out or stabilizers up/down switch C26 F41 Cab door limit stop fuse G17
I27 Beams and stabilizers selection switch C36 F49 Positive “30” / Danfoss / 3B6 fuse G28
I28 RH front beam/stabilizer switch C18 F50 Positive “15” / Danfoss directional control valve G31
I29 LH front beam/stabilizer switch C20 F57 Switches "15" positive fuse G32
I30 RH rear beam/stabilizer switch C23 F63 Anti-theft/instrument power supply fuse E35
I31 LH rear beam/stabilizer switch C29 / C30 R4 Chassis primaries power supplies relay I15
I41 Boom ascent maximum limit stop I19 R9 Emergency pump activation relay G12
I51 Rollover protection exclusion key I15 R76 Danfoss directional control valve enabling relay I31
I69 Levelling joystick A14 R80 3B6 control units electronic positives relay K26
I78 Sideshift by-pass switch I24
I79 Automatic levelling switch C11
L28 Selected beams indicator C38
L29 Selected stabilizers indicator C39
L30 Stabilizers feet beams/descent extension indicator C33
L31 Stabilizers feet beams/descent retraction indicator C31
80-02-M205EN (25/06/2012)
 WIRING DIAGRAMS 15
DIAGRAM 2

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

5’
6
4

5
RN
BR

R2
R2

A A

RV nr°13

RV nr°13

RV nr°13

RV nr°13

RV nr°13
X5 X5B
ZG

X7 X7B

LG
ZV

LV

CG
CG
CG
I69

CG

CG

CG

BN
LV

LV

LV

LV

BL

MR
MV

MR

BN

NZ
BL

RV
RZ
N
B
1 10 1 10 1 10 1 10 3 4 10 1 10 1 7 2 8 10
1 0 1 0 1 0 1 0 1 0 2 1 0 1 1 1 0 1 1

1ST REAR 1ST REAR

3
2
LEFT EARTH 1ST REAR RIGHT EARTH 1ST REAR

2
1

1
LEFT BEAM RIGHT BEAM
OUTRIGGERS
SWITCH SWITCH
OUTRIGGERS
SWITCH SWITCH I79 5 9 5 9 5 9 5 9 7 2 8 9 5 9
2 2 5 6 9
2 2

L28 L29 X55

1
X34

N
C AUTOMATIC LEVELING
L31 L30 C

N
I28 I29 I30 I31 I27

N
HR

B
MV

RV nr°13
BL
BC

LV

LV
BH

MR

BV
I26

MH
MB
LEVELING COMPASS BLOCK
BEAMS BEAMS OUTRIGGERS OUTRIGGERS
FRONT RIGHT FRONT LEFT REAR RIGHT RETR./EXT. REAR LEFT RETRACTION EXTENSION OUTRIGGER/BEAM
OUTRIGGER/BEAM OUTRIGGER/BEAM OUTRIGGER/BEAM OUTRIGGER/BEAM SELECTION SWITCH CONFIGURATION CONNECTOR
BEAM LOW/RISE
X27 X27B X29 X29B SELECTION SWITCH SELECTION SWITCH SELECTION SWITCH SELECTION SWITCH
PILOT/OUTRIG. PILOT/OUTRIG.
C

C
OUTRIGGER RISING RISING

5
N2
I/O CORE
POWER SUPPLY
1ST FRONT 1ST FRONT F63 X20-A
LEFT EARTH 1ST FRONT RIGHT EARTH 1ST FRONT L1.5 1 Key switch power supply
OUTRIGGERS LEFT BEAM OUTRIGGERS RIGHT BEAM 15A 2
SWITCH SWITCH SWITCH SWITCH
VIEW

X18-8
3
SCH*
MV
MG
HV
HG

F9 M*
4 Can-open GND line
C1.5 L1.5 5 Can-open HIGH line
E 10A B* 6 Can-open LOW line E
N
F8 F38 7 GND
8
10A 7,5A 9
10
F18

X20-G
X20-E
11
12
30A R
13 Battery power supply
14
15
EMERGENCY PUMP CHASSIS MAIN
R9

R6
SR
16
PILOT RELAY AUXILIARY FEEDING

RV nr°13

RV nr°13
X17-3 17
SH 86 30 HV 86 30 18
G G

CG

CG
MIDAC-PLUS 19

F49

F50

F57

F33
7,5A
RN

10A

10A

15A
20

BR
INPUT/OUTPUT SIGNALS 1 10 1 10
X16-2 1 0 1 0 21
X23-12
GND direct to battery 1 N* 22

F39
F41
2

7,5A

7,5A
N 85 N 85 23

SR
2 X16-2 N1.5
87 87a 87 87a 24 GND
3 X22-15 30
AG AG
R4 I4 5 9
I78 5 9 86 25

L6
Midac plus power sup. consent 4

X22-25
SV

26

CM
X17-4

GV
5 X16-1 X16-1 RESET BY-PASS
TRANSLATION

X20-H
27

X21-3
6 1 GEAR

R2.5
7 28
R25

X7-T

X9-T
29
RV nr°13

8
E35 30
SV

9 BR 86 30 N 85
I I9 I51 SQ I41 31 I
CG

10 EMERGENCY PUMP 87 87a

CG

CG

BR
LR
REMOTE CONTROL 32
11
MP
N

5 6
R76

A
10 33
A6

X23-3
12

X22-27
Electronic power supply 13
RN
SH
1 0 SAFETY
SYSTEM DOOR
A4 CONSENT
34
14 MAXIMUM SAFETY SYSTEM HYDRAULIC 35
EXCLUSION SWITCH RISING EXCLUSION BUZZER N 85 DISTRIBUTOR
15 N KEY SWITCH
RN 87 87a
Electronic power supply 16
1 7 2 8 9 N ZR I/O CORE DIGITAL INPUT/OUTPUT
3B6 BOX UNIT

RN2.5
17 EMERGENCY X20-C
EMERGENCY
R80
N
SH

ELECTRONIC
STR2
N25

PUMP EMERGENCY PUMP

AN
HN

SG
18 X23-16 BUZZER
PUMP
SWITCH SUPPLY 1
Can-open HIGH line 19
M*
2
Can-open LOW line 20 B* MB 3 Leveling switch right side
21 X23-17 MH 4 Leveling switch left side
X7-S

X9-L
22 X23-18 X22-12 X21-19 GV 5 Reset gear
K 23
X23-9
X22-26 X21-2
B* 6 Can-open LOW line K
24 7
25 X23-10 X16-26 X16-26 8
26 5 9
27
X22-1
10

A
28 11
X21-4

29 12

C
N

30 13
31
M*
14 Can-open HIGH line

80
32 S15 S16 S17 S18 S19 S35 S36 S11 S12 S13 S14 15
Safety system exclusion key 33
HN 2ND REAR 2ND REAR 2ND REAR 2ND REAR 2ND FRONT 2ND FRONT 2ND FRONT 2ND FRONT 16
OUTRIGGERS FRONT RIGHT FRONT LEFT REAR LEFT REAR RIGHT LEVELING RIGHT LEVELING LEFT FRONT RIGHT FRONT LEFT REAR RIGHT REAR LEFT LEFT EARTH LEFT BEAM RIGHT EARTH LEFT EARTH LEFT BEAM RIGHT EARTH
RETRACTION OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER SIDE VALVE SIDE VALVE BEAM VALVE BEAM VALVE BEAM VALVE BEAM VALVE RIGHT BEAM RIGHT BEAM
34 17
I22

AV
SWITCH OUTRIGGERS SWITCH OUTRIGGERS
A

OUTRIGGERS SWITCH OUTRIGGERS SWITCH

AB
CN

CG
CV
CB

RZ

RV

/RISING VALVE VALVE VALVE VALVE VALVE

AV

M M
AN

AG

35 SWITCH SWITCH SWITCH SWITCH 18

X23-4

X22-16
X33-1

X33-2

X33-3

X33-4

X33-5

X33-8

X33-9

X32-5

EMERGENCY
X32-6

X32-7

X32-8

19
BUTTON
X15 X5A X5C X7A X7C X27A X27C X29A X29C 20

MR
MB
ZB

HB
LB
ZR

HR
LR
21
Key switch power supply 1 AV 22
Battery power supply 2 R N
X16-25 X16-25 23 GND

GND 3
N 25
Can-open HIGH line 4
M*
B* X16-21 X16-21
Can-open LOW line 5 21 I/O CORE DIGITAL INPUT/OUTPUT
Can-open GND line 6
SCH*
7
X16-26
26
X16-26
2
1
STR3
8
3
SAUER-DANFOSS 4
O HYDRAULIC DISTRIBUTOR B 5 Outriggers & beams selection sw. O
BC 6 Front right outrigger & beam sel.sw.
BH 7 Front left outrigger & beam sel.sw.
BL 8 Rear right outrigger & beam sel.sw.
BV 9 Rear left outrigger & beam sel.sw.
10
11
12
13
X22-9 X21-5 14
15
16
Q 17
Q
SCH*
MG

AN
MV

MV
MR
HN
HG
AN

CM
AG

CN

MB

MR
CG

HV

NZ
ZG

HR
AV

M*
AB
SH

CV

RN
CB

LG
ZV

HB
HR
RV
LV

SH
RZ

SG
N*

ZB
ZR

LB
18
B*

LR
A

19
20
L7
Safety system exclusion key L8
Automatic leveling L9

L33
L34
S9
S8
S7

S5
S4
S3

L20
L21
L22

L24
L25

L27
L28

L32
L29

L31
S6

S2

L6

Beams retract/outrig. rising L11

L12

L18

L26

L36
L37
L4
Door switch L5

Beams extens./outrig. lower L10

L17

L23
L19

L30

L35
L16
L2
L3

Emergency pump switch L13

L14
L15

L38
S39
S38
S37
S36
S35
S34
S33
S32
S31
S30
S29
S28
S27
S26
Can-open HIGH line S25
Can-open GND line S24
Can-open LOW line S23
S22
GND direct to battery S21
S20
S19
S18
S17
S16
S15
Leveling left side valve S14
Leveling right side valve S13
S12
S11
S10

L17
L18
L39

L21

L23
L19
L20

L22
L16

L31
L32
L33
L24
L25

L28
L11
L12
L13

L27
L14
L15

L29
L30

L34
L35
L26
R11
R2
R3

R8
R9

L10

L36
L37
L38
L39
R21

R33
Emergency pump pilot relay R10

R12

1ST front left earth outriggers micro R29

R30

R34
R4
R5
R6
Outrig. retraction & rising valve R7

Rear left outrigger valve R20

Front right beam valve R13

1ST rear right beam micro R25

R31
R32

R35
Rear right outrigger valve R19

R22

1ST Front left beam micro R24

R27
1ST Front right earth outrig. micro R28

R36
1ST rear left beam micro R26

R37

L2
L3
L4
L5
L6
L7
Front right outrigger valve R17
Front left outrigger valve R18
Front left beam valve R14

Rear left beam valve R16

R38
Rear right beam valve R15

1ST Front right earth outrig. micro R23

L8
L9
1ST rear left earth outriggers micro R39

Electronic power supply S1

S40
R1

L1
L1

L40
Optional block leveling R40

L40
21
By-pass translation switch

Rear right second beam switch

Rear left second beam switch

Rear left second outrigger switch

Front right second beam switch
Rear right second outrigger switch
Front right second outrigger switch
Front left second outrigger switch
Maximum rising switch
1ST rear right earth outriggers micro

Front left second beam switch

22
23
4
6

5’
5
BR
RN
R2
R2

S S
MC2M-CHASSIS MC2M-CHASSIS MC2M-CABIN MC2M-CHASSIS
INPUT/OUTPUT SIGNALS INPUT/OUTPUT SIGNALS INPUT/OUTPUT SIGNALS INPUT/OUTPUT SIGNALS

(25/06/2012) 80-02-M205EN
 16 WIRING DIAGRAMS
3 – DANFOSS MOVEMENTS TRANSMISSION AND DIRECTIONAL CONTROL VALVE

Connectors Fuses and relays

Position on the Hydraulic
Type of wiring Ref. Description Ref. Description Position on the diagram
diagram equivalent

X15 Danfoss directional control valve connector A29 F3 Reversing lights fuse E31
X88 Encoder-manifold connector A5 F14 Danfoss control unit fuse G6
X99 Motor displacement O17 F17 Chassis section MC2M power supply fuse I36
X102 Brake pedal S5 F33 Switches indicator lights fuse G3
XRS Universal shaft sensor pull-up resistance M17 F50 Positive “15” / Danfoss directional control valve G5
F53 Joystick "15" positive fuse G4
F57 Switches "15" positive fuse G4
Components F71 Cab section MC2M power supply fuse I37
R3 Chassis section MC2M power supply relay G38
Ref. Description Position on the diagram Hydraulic equivalent
R6 Reversing lights relay G29
A2 Reversing buzzer G7 R76 Danfoss directional control valve enabling relay G34
BDP BDP Sauer Danfoss S9 / S10
C1 Forward movement solenoid valve K5
C2 Reversing solenoid valve K4
CAN CAN line S8 / S9
CC1 Transmission control Danfoss control unit S14
CC2 Transmission control Danfoss control unit S11
CC3 Transmission control Danfoss control unit S7 / S8
I2 Slow-fast speed switch G20
I22 Emergency mushroom-shaped button G9
I43 Danfoss control unit sensor S6 / S7
I77 Sauer Danfoss mode switch G16
J1939 Line can bus J1939 S25 / S26
M3 Seat LH side joystick S16
M4 Seat RH side joystick S21
MC2M CABIN Cab section inputs/outputs 3B6 control unit A22 / O37 / S34
80

MC2M CHASSIS Chassis section inputs/outputs 3B6 control unit A10 / A16 / O33
MDCP Midak-plus connector A32
PSC Danfoss connector S4
S8 Parking brake solenoid valve K10
S27 High speed solenoid valve K6
S28 Low speed solenoid valve K7
STR2 3B6 primary instrument inputs/outputs S31
STR3 3B6 primary instrument inputs/outputs S27

80-02-M205EN (25/06/2012)
 A

S
C

Q
O
G

M
1
R2
5’
BR R2
4 5’
2

(25/06/2012)
R2 BR
5 4
RN R2
6 5
DIAGRAM 3

RN
3

6
Negative C1 6
F33
Negative C2 5 7,5A
Digital output A2 4

GEAR
VALVE
Digital output A1 3

C2
F57

REVERSE
4

Reversa gear 2

PSC
Forward gear 1 15A

DANFOSS CONNECTOR
F53
12

GEAR
VALVE
NR NR

C1
10A

DANFOSS connection provided

2 2
11
5

X88

FORWARD
BG 3 3 BG
NB
F50 SCH*
1 1 NB 10 Can-open GND line
NR NR

X102
5 5 X33-6 10A B* 9 Can-open LOW line

INCHING PEDAL
BL BL
6 6
NB NB M* Can-open HIGH line
4 4 F14 8
6

VALVE
N 7 GND

S27
HL 30A

FAST GEAR
Signal sensor 3
HN SR “15” Positive ENDCODER
Negative sensor 2 X33-7 6
ENCODER COLLECTOR CONNECTOR

I43
Positive sensor 1 HR SCH* 5 Can-open GND line

RPM SENSOR
7

B* 4 Can-open LOW line

VALVE
M*

S28
MH 3 Can-open HIGH line

A2

SLOW GEAR
Negative signal buzzer 1
NG NG N 2 GND
Rear lights and buzzer 2

CC3
SR
8

1 “15” Positive ENDCODER

GEAR
X23-16

BUZZER
REVERSE

X18-9
SCH*

X22-22
Can-J1939 GND line 3
Can-J1939 LOW line 2 B*
Can-J1939 HIGH line 1
M*

BUTTON
9

I22
1

X16-14
X16-15
X16-16
X16-13
EMERGENCY

X14-B
RN S1 Positive to control box relay
A AV

X18-13
N S2
X23-17

2
GND 2 S3
X23-18

RH

DANFOSS TRANSMISSION BOX UNIT

14
15
16
13
MV S4 Slow gear valve
BDP Signal 1 RL

VALVE
S5 Fast gear valve

CAN BDP
S8
S6
10

MC2M

M*
S7 Can-J1939 HIGH line
S8

X32-4
X32-3

X16-14
X16-15
X16-16
X16-13
PARKING BRAKE
12 S9
GN S10
Mode switch "A" CC2 11
MZ S11
Parking brake valve 10 S12
X16-26
X16-25
X16-21

NZ

CC2
Parking brake negative valve
11

9 S13
Signal BPD
MV S14
8
2
BG S15
Signal sensor Inching-1 7 S16
26
25
21

NB 1
CHASSIS

Inching GND 6 S17

Inching supply 5 NR S18
0
INPUTS/OUTPUTS CHASSIS 3B6 CONTROL BOX

4 S19
12

Signal motor displac. 3 GL S20

S21
2 S22
X16-26
X16-25
X16-21

BL CZ CG B*
Signal sensor Inching-2 1 SCH* S23 Can-open LOW line
2
4

DANFOSS TRANSMISSION BOX UNIT

S24 Can-open GND line
M* S25 Can-open HIGH line
B*

X16-5
X16-27
X16-28
S26 Can-J1939 LOW line
13

SCH* S27 Can-J1939 GND line

12 S28
6

11 S29

5
27
28
S30
8

10
X20-E
S31
9 S32
CG CG S33
8
14

CC1
3

S34

X16-5
7

X16-28

X16-27
S35
6

SAUER DANFOSS ELECTRONIC TRANSMISSION BOX

HL S36
Signal sensor cardan 5 S37
Negative sensor cardan 4 HN CV S38
HR
5

Positive sensor cardan 3 S39

X20-G

S40
15

RB1.5
7

Positive control box 2

N1.5 X21-13
GND 1

X21-12

X23-10

DANFOSS TRANSMISSION BOX UNIT

X19-S
X19-R
N RVnr.13 R1
R2
9
10

R3
R4
16

R5
Spare analog input
BS R6
18
X18-28

M3
MC2M

N
R7

HR
HL
B
I77

Roller optional signal

17
BR R8
Rotation boom signal 16 R9
BV R10
MODE SWITCH

Telescoping boom signal 15

X99
XRS
R11
SAUER DANFOSS
17

14 R12

LEFT ARM REST LEVER

2
1
13 R13

2 2
1 1
R14
12 R15

X14-M
11 R16

MOTOR DISPLACEMENT
R17
CHASSIS

10
18

R18
R19
INPUTS/OUTPUTS CHASSIS 3B6 CONTROL BOX

X14-F
3,3KOHM
GN R20
8 R21 "OUT32"Predisposition
1

X14-H
7 R22
R23

PULL-UP SENSOR RESISTANCE CARDAN

6
0

R24

X14-K
19

5 R25
Can-open LOW line 4
B* R26
M*
AB R27
1

Can-open HIGH line 3 R28

GN CG R29
Key switch power supply 2
3

N A R30
GND 1 R31
20

R32
R33
I2

R34
2

BC R35
4

Spare analog input

SLOW/FAST

18 R36
GEAR SWITCH

BN R37

M4
Spare analog input
8

17 R38
21

BG
Luffing boom signal 16 R39
Rising boom signal 15
BL N RVnr.13 R40
9
10

14
13 L1

RIGHT ARM REST LEVER

12 L2
22

L3
X14-J

X14-G
X14-L

X14-N
11 L4
10 L5
L6
9 X14-U
MC2M

L7
8 L8
L9
23

7
L10
6 L11
BL L12 Rising boom signal
5
Can-open LOW line 4 B* BS L13
L14 Spare analog input
CABIN

Can-open HIGH line 3 M* L15

24

Key switch power supply 2 GN L16

L17
GND 1 N L18
X14-V
INPUTS/OUTPUTS CABIN 3B6 CONTROL BOX

L19
L20
BR L21
L22 Rotation boom signal
25

B L23
L24
L25
Can-J1939 LOW line 2 B* L26
M* L27
Can-J1939 HIGH line 1 L28
L29
26

J1939
CAN LINE J1939
L30
BG L31
L32 Luffing boom signal
BN L33 Spare analog input
BV L34 Telescoping boom signal
23 L35
22 L36
27

21 L37
20 L38
STR3 19 L39
18 L40
Sauer Danfoss mode switch 17
CZ BC R23 Spare analog input
16
15
28

14
Sauer Danfoss mode switch 13
CV
12 X22-16
11 AV Key switch power supply
MH

1
N

10
9 R 2 Battery power supply
8
X15
29

86

85

7 X23-9 N 3 GND
R6

INPUTS/OUTPUTS CABIN 3B6 CORE VIEW

6
5 M* 4 Can-open HIGH line
4
LIGHTS RELAY

B* Can-open LOW line

REVERSE GEAR

3 5
2 SCH*
SAUER DANFOSS DISTRIBUTOR

1 6 Can-open GND line

30

X18-10 7
87

GND 23
N AG1.5
F3 8
22 A1.5
21
87a
30

20 7,5A
31

19
STR2

18
17
16 1
15
X21-33
M*
Can-open HIGH line 14 2
13
32

12 X22-15 3
11 A
AG Midac plus power supply consent
Fast gear switch 10
4
AB
MDCP

Slow gear switch 9 5

Positive to control box relay 8 RN
7 X21-14 6
B*
INPUTS/OUTPUTS CABIN 3B6 CORE VIEW

Can-open LOW line 6

7
33

5
MIDAK-PLUS CONNECTOR

AG

4
X21-34
3
8
X18-17
86

2
85

9
1
RN2.5 X17-8 10
1
RN2.5 11
34

2 X17-10
R76

S40 RN2.5 12
3
S39 RN
CONSENT DANFOSS

Positive to control box relay

DISTRIBUTOR RELAY

S38 4
N2.5 13
S37 14
S36
87

S35
A X22-8 15
35

MC2M

SR
POWER SUPPLY MC2M CHASSIS

S34 RN 16 Positive to control box relay

87a

S33 X23-13
30

S32 M* 17 Can-J1939 HIGH line

MC2M-CHASSIS

S31
S30 F17 B* 18 Can-J1939 LOW line
S29 M*
X23-14 19 Can-open HIGH line
S28
36

25A B*
S27 20 Can-open LOW line
CABIN

S26
S25 21
S24
S23
22
S22
RN

INPUTS/OUTPUTS CHASSIS 3B6 CONTROL BOX

X23-1 F71 23
37

S21 RN2.5
S20 1 24
86

85

S19 2 RN2.5 25A

S18 25
S17 3
RN2.5
26
S16 N2.5
R3

4
S15 27
38

S14
S13 28
POWER SUPPLY MC2M CABIN

S12 29
MC2M CHASSIS RELAY

MC2M-CABIN

S11
S10 30
87

S9
RN4
S8 R4 31
39

87a

S7
30

32
S6
S5 33
S4
S3 34
S2
Positive to control box relay S1
RN 35
40
41
WIRING DIAGRAMS

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 18 WIRING DIAGRAMS
4 – CAB - ADM2 - MR2 - RADIO

Connectors Fuses and relays

Position on the Hydraulic
Type of wiring Ref. Description Ref. Description Position on the diagram
diagram equivalent

RS232 Connector XRS232 K39 F6 Spark plugs power supply fuse G28
X7D Cab connector A6 F33 Switches indicator lights fuse G10
X36 Mercedes engine MR2 control unit I33 F37 "15" Radio/heating power supply G14
X38 Engine air preheating connector (Optional) E39 F40 Ceiling light fuse G5
X38A Vehicle radio power supply connector S6 F41 Cab door limit stop fuse G11
X39A Radio speakers connector S8 F43 Windscreen wiper pump fuse G16
XAS Cigarette lighter connector E26 F46 Diagnostics power supply fuse G18
XCD Power supply connector for radio with CD S4 F51 Front work lights fuse G4
XDM Diagnostics connector A18 F52 Driver's seat/radio control unit internal power supply fuse G15
XM1 ADM connector S27 F54 Rear work lights fuse G4
XM2 ADM connector S22 F55 "15" Upper windscreen wiper G5
XM3 ADM connector S17 F56 "15" Rear windscreen wiper G8
XM4 ADM connector S10 F59 Rotary beacon fuse G12
XPA Accelerator pedal S36 F60 Radio power supply fuse G17
F61 Diagnostics power supply fuse G18
F66 Boom head work lights fuse G12
F67 "15" Electric windows G8
Components F68 Heated rear window fuse G6
F69 "30" cigarette lighter fuse G19
Ref. Description Position on the diagram Hydraulic equivalent
R8 Spark plugs preheating relay E31
I10 Platform exclusion key K5
I35 RPM switch I28
I54 Rotary beacon switch K11
I56 Windscreen wiper pump switch K16
J1939 CAN line J1939 M4
MC2M CABIN Cab section inputs/outputs 3B6 control unit A24 / A31
80

OBD2 Diagnostics connector S30

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BR
4
RN
DIAGRAM 4

5 4 6 0
6
M

R2 BR RN M1 L6
3

10
L6

GND
N F51
8
“15” Radio CD positive
LG 15A
7
4

XCD
6 F54

OPTIONAL

CAR RADIO CD
5

J1939
CR 10A
“30” Radio CD positive 4

Can-J1939 LOW line

Can-J1939 HIGH line

3 F40

I10
5

1
2
X21-10
2 7.5A
1 F55
X21-9
GND 8 N 15A
CR ML
6

B*
“30” Radio TAPE positive 7

M*
F68

BASKET EXLUSION KEY

6 GN1.5
X7D

15A A Positive front working light

X38A
5

X21-12

CAR RADIO TAPE

LG GZ1.5 B Positive rear working light
“15” Radio TAPE positive 4 X21-7
CABIN CONNECTOR

A1.5

X21-13
Rotating lamp
7

3 C
2 CB1.5 D Positive lamp
1 ZN1.5 E “15” Upper windscreen wiper
F67 F56 Z1.5
8 F “15” Rear windscreen wiper
8

7 20A 20A X21-32 RB G Front right speaker positive

Left front speaker negative 6
NG
X21-31 NB
RH H Front right speaker negative

X39A
Left front speaker positive 5 X21-30
Front right speaker negative 4
NB RH J Left front speaker positive
X21-29
9

CAR RADIO SPEAKERS

Front right speaker positive 3
RB NG K Left front speaker negative
2 GR1.5 L “15” Rear window heating
1 X22-7
GH
M Red rotating lamp
B* G1.5 N Electric window positive
10

Can-J1939 GND line 21 F33 RVnr.13

P Power indicator switchs fuse

1
20
7.5A

XM4
M* BG R Front windscreen wiper pump
Can-J1939 HIGH line 19 X22-1
AN Door micro

0
S
18
11

F41 LR

ADM2/21 CONNECTOR
T Door micro positive

SWITCH PREDISPOSITION
ROTATING LAMP
17

I54
10A
U
16 X21-11 F59
BV1.5 V
15

1
25A
12

AV1.5 W
Throttle pedal by ADM2 14
VB

5
F66 aa
VM
Throttle pedal by ADM2 13
X20-G 10A bb
Throttle pedal by ADM2 12
VN N RVnr.13
cc
13

9
10
11
dd
10
F37 ee
9
7.5A ff
14

8
gg
7 M8-3 hh
Return windscreen wiper
6 L2.5 1 “15” Positive working lights head arm
X22-21 F52 X10-18 X23-7
15

5 B2.5
OPTIONAL 2 Working lights head arm

2
4 10A
3
N

1
GND 3
F43 4
Emergency button pushed 2
M

0
16

7.5A

First speed windscreen wiper

CV

1
“30” Diagnostic supply 1

SWITCH PUMP
WIPER

M8-5
I56
SH F60
18

1
MB
17

15A
17
3

16 N

XM3
1 GND
15 F46 10A RV 2 “15” Diagnostic supply
14
13 CV “30” Diagnostic supply
18

ADM2/18 CONNECTOR
XDM

12
F61 15A 4
11
10
SR
5

5 Diagnostic MR2 unit box

7

F69
9 G* Can-K HIGH line
6
19

DIAGNOSTIC CONNECTOR

8 20A A* 7 Can-K LOW line

7 BG
GND 6
N MR* Can-K GND line
2

MB 8
5
ZR
4

ZG 9
Signal switch to reduce RPM 4
20

3 10
2
11
1
12
21

SH SB 13
Can-K LOW line 15
B*
6
8

ML 14 Diagnostic ADM2 unit box

Can-K GND line 14
M*
15
Can-K HIGH line
G*
13
16
22

N RVnr.13

XM2
12
X20-B

9
10

11
X21-16
X21-15

10

ADM2/15 CONNECTOR
23

Activation glow plug relay 9

SM

8 L1
L2
7 L3
GH L4
24

R5 Red rotating lamp

6 L6
V L7
Throttle pedal by ADM2 5 L8
L9
4 L10
L11
25

3 L12
L13
2 L14
MC2M-CABIN

RG R15 Radio control activation

X16-7 X16-7 L16
1 7 L17
RVnr.13
INPUTS/OUTPUTS CABIN 3B6 CONTROL BOX

1 L18
26

L19
1

L20
LIGHTER
XAS

N2.5 CB L21 Safety radio signal negative

1
0

L22
X16-22
X16-22
X16-24
X16-23

L23
2

12 B2.5 NV L24
2 L25 Safety radio control signal positive
27

11 L26
18
24

22
23

XM1
10 M L27
L28 Emergency button pushed
9 F6 L29
8 L30
1

7.5A L31
I35

7
ADM2/12 CONNECTOR
L32
28

6
X16-22
X16-22
X16-24
X16-23

L33
3

RPM SWITCH

5 L34
L35
4 L36
7

ZR
X35-R
X35-X
X35-V

X35-W

3 L37 MC2M Emergency button signal

ML L38
Diagnostic ADM2 unit box ZR
29

2 L39
“50” Starting
GZ AN L40
1
2

L5 Door micro
N
4

CV
X16-12

“30” Diagnostic supply 16 ZG

X18-24
30

15
12
L

14
SM

OBD2

RX RS232 13 L* N RVnr.13 A1
86

85

9
10

M* A2
R8
31

TX RS232 12
DIAGNOSTIC CONNECTOR

B* A3
X16-12

Can-J1939 LOW line 11

B1 GND can-open line
ACTIVATION REMOTE

10
SWITCH GLOW RELAY

B2
X35-L

9
32

X18-23 B3
87

Diagnostic engine control box MR2 8

SR NL
C1 Can-open HIGH line
L
MC2M-CABIN

ML
87a

Diagnostic ADM2 unit box 7 C2 Can-open LOW line

30
REMOTE CONTROL SISTEM CONNECTOR

X11-5 VM
6 G* 1 Can-K HIGH line C3 Wired remote control signal
X11-6
33

N VH D1 A485 communication data

GND 5 A* 2 Can-K LOW line
X36

X11-7 VG
4 MR* D2 B485 communication data
3 Can-K GND line X11-8 VB D3 GND communication data
Can-J1939 HIGH line 3 M* MH* 4 Can-K GND line
E1
34

2 X11-9 HR
5 E2 PWR + radio control signal
“15” Diagnostic supply 1
RV X11-10 HN
6 E3 PWR - radio control signal
RV F1 Positive safety radio control
7
NV F2 Safety radio control signal positive
35

GZ1.5 8 Key starting signal

MERCEDES MOTOR CONNECTOR

F3
9 ZR
X35-U

9 G1 MC2M Emergency button signal

10 N G2
N
36

8 11 G3
XPA

RV H1 Positive safety radio control

12
7 RG H2 Radio control activation
SR 13 Diagnostic MR2 unit box RG H3 Radio control activation
Throttle pedal by ADM2 V 14 X23-2
37

6 M Emergency button pushed

J1
THROTTLE PEDAL BY ADM2

15 X21-25 X22-20
N J2 GND
Throttle pedal by ADM2 5 V
N J3 GND
X11-28 ML
VM K1 Emergency button signal
Throttle pedal by ADM2 4
38

CB K2 Safety radio signal negative

Throttle pedal by ADM2 VB X20-J L* K3

3
1
NL
1
Throttle pedal by ADM2 2
VN X20-K M*
39

2
X38

N
2
RS232

Throttle pedal by ADM2 1

VB
GLOW PLUGS

RS232 CONNECTOR
40

OPTIONAL
OPTIONAL

N2
5
41
WIRING DIAGRAMS

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 20 WIRING DIAGRAMS
5 – OPTIONAL BOOM - SENSORS AND TRANSDUCERS 3B6 - SET-UP CONNECTORS

Connectors Fuses and relays

Position on the Hydraulic
Type of wiring Ref. Description Ref. Description Position on the diagram
diagram equivalent

X10 Optional connector S5 F7 Gear micro switch fuse E5

X40 Big mixer bucket connector S21 F10 Set-up fuse I7
X76 Pneumatic seat set-up connector G39 F17 Chassis section MC2M power supply fuse G7
X81 Set-up connector G12 F33 Switches indicator lights fuse C6
X105 Cable reel 3B6 S19 F35 Boom head output third relay fuse C5
X106 Bottom plate-compensation S22 / S23 F39 Boom limit stop fuse C4
X107A Rod-compensation S24 / S25 F62 Tower alignment/small mixer bucket proximity switch power supply fuse C5
X108 Bottom plate-lift S26 F64 3B6 transducers fuse C6
X109 Rod-lift S28 F65 Pneumatic seat fuse C7
XSC Set-up connector A37 F72 Big mixer bucket fuse C4
XSC1 Set-up connector A34 R3 Chassis section MC2M power supply relay G21
XSC2 Set-up connector A40 R15 Set-up relay G26
R16 Set-up relay G30
R17 Set-up relay G34
Components
R75 Boom head output second relay A12
Ref. Description Position on the diagram Hydraulic equivalent R77 3B6 transducers power supply relay A9
R80 3B6 control unit +VE power supply relay G16
I7 Small mixer bucket switch A19
R83 Boom head output third relay A16
MA Winch micro switch M13
MC2M CABIN Cab section inputs/outputs 3B6 control unit A22 / S13 / S39
MC2M CHASSIS Chassis section inputs/outputs 3B6 control unit A28/ E39 / S36
MDCP Midak-plus connector S30
S6 Set-up connector G13
STR4 3B6 primary instrument inputs/outputs S16
80

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R2
M 5
10 BR ’
4
DIAGRAM 5

RN
6 M
L6 10
3

RN
R2 6
5 L6
R2
F39 5
4

L6
7.5A ’
F72
25A
R X23-9
Positive 12 Vdc direct to battery 19 F62
5

X23-7 X7-2

X10
Head boom working lights
B2.5 15A
18
F35
Predisposition output 17 NB

BOOM OPTIONALS
7.5A

F7 10A
GND 16
N2.5 F64
6

NG 15A
Spare digital I/O 15 F33
GND
N2.5 15A
14
F65

25A

10A
NL

F10
F17
Spare digital I/O 13
7

15A
GND 12
N2.5

Predisposition input
NZ
11
L2.5 X23-8
8

Big bucket 10

Big bucket 9
L
HV

Big bucket 8
L2.5
86

85
9

X23-11
3B6 RELAY

Winch switch 7
MS
R77

BR X22-25
Positive winch microswitch 6
X22-18
H1.5 X22-11
Little bucket signal
ENABLE TRANSDUCERS

X18-18
5
10

LS S1.5
Third head boom signal output logic 4
SN1.5
87 87a
30

Third head boom signal output logic 3 LS1.5

LV X22-5-6
Second head boom signal output logic 2
11

Second head boom signal output logic 1 LV1.5

X32-11
HZ
SB

1
N
2

X81
86

85
12

SPARE
EXIT RELAY

X22-28

SUPPLY
R75

X22-3-4

X33-10
X33-11

MS
R40 VN A
BOOM HEAD SECOND

R7 HZ
B
13

S6
N

CONTROL BOX
R6 C LV2.5

R1 1Kohm
GN2.5
R5
87 87a
30

SPARE

R2 1Kohm
SUPPLY
Enable relay for 3B6 transducer R4
HV
14

INPUTS/OUTPUTS CABIN 3B6

R3

OPTIONAL
R2

MC2M-CABIN
MA WINCH MICROSWITCH
BR
R1
N
SGnr.1
15

86

85

BR

N
EXIT RELAY

Can-open LOW line 8

B*
86

85

Can-open HIGH line 7 M*

R83
16

BOOM HEAD THIRD

RN
R80

Positive 12 Vdc
X22-29

STR4
3B6 UNIT BOX

GND 5 N LS2.5
+VE POWER RELAY

VG GN2.5
Predisposition 4
87 87a
30

RN2.5
17

Predisposition 3 VN
R2.5
87 87a
1

VH
30

Predisposition 2

Predisposition 1
VM

INPUTS/OUTPUTS CABIN 3B6 CORE VIEW

0
18

SWITCH

X9-Q
X16-26

Can-open LOW line 4

B*
CL1.5
LITTLE BUCKET

M* X9-P
1

Can-open HIGH line 3 H1.5

19

GND
N

X105
2
I7

Pos. extensometer sensor 1

SN
X16-26

BOOM EXTENSOMETER
N RVnr.13
20

X23-16
10

X23-10
X18-28

CL1.5
4 4
N
RN

3 3
B6 2 2
L6
21

X40
86

85

B6 L6 RN
S1 Positive 12 Vdc
R3

1 1 S2
S3

BIG BUCKET CONNECTOR

S4
MC2M RELAY

S5
X9-J S6
X23-17
MC2M
22

Bottom compens.cylin.-2 4 MH S7
X9-O S8
Bottom compensation cylinder-1 3 CZ RN4 S9
R4 S10
N S11
87 87a

GND 2
30

X106
NG S12
SN X9-B S13 Spare digital I/O
Positive bottom sensor
23

1 NB S14 Spare digital I/O

CABIN

X22-19 S15
S16

BOTTOM-COMPENSATION
S17
X9-K SB S18
Stem compensn.cylin.-2 4 BH S19 Abilitation relay 2 output boom head
SG S20 Abilitation relay 3 output boom head
INPUTS/OUTPUTS CHASSIS 3B6 CONTROL BOX
24

HL X9-E X19-B S21

Stem compensation cylinder-1 3
B* S22
N X19-C S23 Can-open LOW line
GND 2
M* S24

X107A
S25 Can-open HIGH line
AB

SN
NB

Positive stem sensor 1 S26

S27
25

86

85

S28
S29
S30
X9-G S31
X18-17

Bottom lifting cylinder-2 4

SPARE RELAY

S32
HG X9-D S33
Bottom lifting cylinder-1 3
R15

S34
26

N S35

X108
GND 2 S36

STEM-COMPENSATION RAISING-BOTTOM
SN X9-A AR1.5 S37
Positive bottom sensor 1 A1.5 X19-D S38
87 87a

AH S39
30

S40
27

X9-H X19-E
Stem lifting cylinder-2 4
ML
HS X9-N X19-F
Stem lifting cylinder-1 3 S1
S2
GND 2
N S3
28

S4
X109

Positive stem sensor

SN X19-G S5
1 VN S6 Spare digital I/O
MC2M

X19-H S7
LIFTING STEM CYLINDER

S8
S9
AG

NG

S10
29

35 S11
34 S12
86

85

S13
33 HG S14
32 S15 Spare digital I/O
BH HL S16 Spare digital I/O
X17-10

Stand compensation cylinder-2 31

R16

SPARE RELAY

S17
30

CHASSIS

Base compensation cylinder-2 30

MH
S18
X19-A

Stand lifting cylinder-2 29 ML S19

INPUTS/OUTPUTS CHASSIS 3B6 CONTROL BOX

MDCP

Base lifting cylinder-2 28

CG S20
CZ S21
Base compensation cylinder-1 27 BR S22
HL B X19-J
Stand compensation cylinder-1 26 S23
87 87a

HG S24
31

BH
30

MIDAK-PLUS CONNECTOR

Base lifting cylinder-1 25

HS S25
Stand lifting cylinder-1 24 S26
23 S27
X19-K S28
22 S29
21 X19-L S30
B*
32

Can-open LOW line 20 S31

M* S32
Can-open HIGH line 19 X19-M S33
18 S34
17 X19-N S35
Positive 12 Vdc 16
RN S36
S37
33

15 S38
A

14 S39
NL

Positive 12 Vdc 13
RN S40
12
86

85
X17-8

11
10 RV Positive 12 Vdc
34

1
R17

9 N
SPARE RELAY

2 GND
8 HL
3 Spare digital I/O
XSC1

7 X19-Q CR 4 Predisposition R7 Pin:87

6
PREDISPOSITION-1

CR CH 5 Predisposition R7 Pin:87a
5 X19-O
35

4 C C Predisposition R7 Pin:30
6
87 87a

CH
30

3 A 7 Predisposition R7 Pin:86
2 NL
8 Predisposition R7 Pin:85
1 X19-P
36

N 1 GND
R40
RV 2 Positive 12 Vdc
R39 X22-23 X14-C X16-10 X16-10 VH
10 3 Predisposition
X16-11 X16-11 VM
CONTROL BOX

R24 11 4 Predisposition
XSC
37

MC2M

X16-20 X16-20 VN
R23 20 5 Predisposition
X16-17 X16-17 VG
17 6 Predisposition
PREDISPOSITION

Spare digital I/O R22 VL

NB Predisposition
7
R3 AB Predisposition
8
INPUTS/OUTPUTS CHASSIS 3B6

A1.5
38

9 Predisposition
R2 AH
10 Predisposition
R1 AR1.5 Predisposition
11
HG Spare digital I/O
12
N
MR1.5
N2.5
RN2.5
RN2.5
RN2.5

NL
NZ
MS
39

X76

RV
CONNECTOR

Positive
9
8
7
6
5
4
3
2

1
3
2

10

N 2 GND
PREDISPOSITION
PNEUMATIC SEAT
1 1

11 11
3B6 CONTROL BOX

L9
L8
L7
L6
L5
L3
L2

NG 3 Predisposition
L39
L38
L37
L36
L35
L34
L33
L32
L31
L30
L29
L28
L27
L26
L25
L24
L23
L22
L21
L18
L17
L16
L15
L14
L13
L12
L11
L10
1 GND

L1
10
9
8
7
6
5
4
3
2

L40

AG Predisposition
CHASSIS MC2M

4
POWER SUPPLY CHASSIS
40

Positive 12 Vdc
Positive 12 Vdc

B 5 Predisposition
1 Positive 12 Vdc
XSC2

BH Predisposition
B1.5
B1.5

6
L4 Winch switch

BR
PREDISPOSITION-2

L20 Spare digital I/O

L19 Spare digital I/O

7 Predisposition
MC2M CHASSIS

VL 8 Spare digital I/O

41

CABIN

N2
5
INPUTS/OUTPUTS CABIN 3B6 CONTROL BOX
WIRING DIAGRAMS

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6 – LIGHTS SENSORS/PROXIMITY SWITCHES

Connectors Fuses and relays

Position on the Hydraulic
Type of wiring Ref. Description Ref. Description Position on the diagram
diagram equivalent

X2 Gear engaged limit stop K14 F1 Rear axle block fuse M25
X4 LH rear axle block solenoid valve O35 F2 Axle alignment sensors fuse M16
X4A LH rear axle block micro switch S34 F3 Reversing lights fuse M28
X6A LH rear side lights Q35 F4 LH position lights fuse M23
X10A RH rear side lights Q34 / Q35 F5 RH position lights fuse M19
X11A RH rear axle block micro switch S33 F7 Gear micro switch fuse K7
X11B RH rear axle block solenoid valve O33 F11 Dipped beams fuse E22
X12A Air filter pressure switch G12 F12 High beams fuse E30
X13 Trailer lights S36 F13 Stop lights fuse E19
X15A Stop lights pressure switch G18 F15 Fuel oil filter heater fuse C8
X20 Hydraulic fluid temperature bulb I14 F18 Chassis primaries power supplies relay fuse E6
X23 Fan-1 oil cooling S5 F19 Oil cooling fan fuse K11
X24 Fan-2 oil cooling S8 F20 Oil cooling fan fuse K15
X39 Oil filter pressure switch I12 F36 Fuse for positive from battery for four direction indicator lights G27
X41 Winch micro switch on boom M4 F38 Start-up panel auxiliary power supply C8
X47 Boom chains breakage limit stop O5 F39 Boom limit stop fuse O6
F44 Stalk lights switch and horn power supply fuse E16
F47 Engine stop emergency button fuse E5
Components F48 Fuse for positive from key for four direction indicator lights E27
F62 Tower alignment/small mixer bucket proximity switch power supply fuse M18
Ref. Description Position on the diagram Hydraulic equivalent
R1 Oil cooling fan -1 relay M10
A1 Horn S31 / S32 R2 Oil cooling fan -2 relay M13
A2 Reversing buzzer O31 R4 Chassis primaries power supplies relay G5
CC3 Transmission control Danfoss control unit C39 R6 Reversing lights relay M27
DL Stalk lights switch I21 R7 Stop lights relay I23
FADX RH side front optical unit S20
80

R10 RH dipped beam relay G21

FASX LH side front optical unit S23 / S24 R11 RH high beam relay G29
FPDX RH side rear optical unit S27 R12 LH dipped beam relay G25
FPSX LH side rear optical unit S30 / S31 R13 LH high beam relay G33
I6 Rear axle alignment proximity switches S10 R35 Cab section power supplies remote control switch I5
I8 Front axle alignment proximity switches S12 R79 Direction indicators flasher K33
I15 Turret alignment proximity switch S14 R81 Relay for cutting power supply from emergency mushroom switch K5
I22 Emergency mushroom-shaped button E6
I41 Boom ascent maximum limit stop I11
I53 Emergency direction lights switch K27
I71 Blocked cab proximity switch S16
MA Winch micro switch O7
MC2M CABIN Cab section inputs/outputs 3B6 control unit A20
MC2M CHASSIS Chassis section inputs/outputs 3B6 control unit A29 / E38 / K38
STR2 3B6 primary instrument inputs/outputs A15
T1 Fuel level sensor G10
T41 Fuel oil filter heater A13

80-02-M205EN (25/06/2012)
 WIRING DIAGRAMS 23
DIAGRAM 6

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
STR2 MC2M-CABIN MC2M-CHASSIS
I/O CORE DIGITAL INPUT/OUTPUT INPUT/OUTPUT SIGNALS INPUT/OUTPUT SIGNALS
T41

L37 Position ligths switched on

L35 Turret alignament proxim.
10

HEATING OIL FILTER

5
4

6
5’

L14 Air filter pressure switch

L24 Oil filter pressure switch

L29 Maximum rising switch

5
R2

L36 Loked cabin proximity

BR

RN
R2

L21 Front axel alignament

N2
L22 Rear axel alignament
12 High beam switched on
11 Low beam switched on

L1 Boom chains switch

L4 Boom back hoist sw.

L4 Fuel level gauge

L23 Gear switch

22 Horn

L40

L40
23

L1
L10
L11
L12
L13
L14
L15
L16
L17
L18
L19
L20
L21
L22
L23
L24
L25
L26
L27
L28

L30
L31
L32
L33
L34

L37
L38
L39

L10
L11
L12
L13

L15
L16
L17
L18
L19
L20

L25
L26
L27
L28
L29
L30
L31
L32
L33
L34
L35
L36

L38
L39
1

L5
L6
L7
L8
L9

L5
L6
L7
L8
L9
L2
L3

L2
L3
10

13
14
15
16
17
18
19
20
21
4
5
6
7
8
9
2
3
F15
CC3

AR1.5+AR1.5

N1.5+N1.5
C 20A C

Z
SV
SR

MZ

MN
MB
MS

HL
C
SG

SG

GR
SB
CR

S
F38 DANFOSS TRANSMISSION BOX UNIT

7,5A NG
X18-26-25 X35-H-J 1 Reverse gear buzzer
MH 2 Reverse gear light

MC2M-CHASSIS
F47

F18
10A

30A

INPUT/OUTPUT SIGNALS

E R1
E
BR

R2

F44

F13

F11

F48

F12
10A

15A

15A

10A

15A
R3
I22
EMERGENCY
R4
R5
BUTTON
R6
R7
M

CL

CR
R8 Right rear axle block valve
C

CH R9 Left rear axle block valve

X18-11

X17-11
X17-5

X17-9

X17-7

Z1.5
C1.5
R4

Z1.5
R10

C1.5
R6

R10 R12 R11 R13 R11

MN
HV 86 30

NG
R12
LS 86 30 BS 86 30 LN 86 30 BN 86 30

N
G R13
R14
G
N

T1 X12A NL

F36
7,5A
R15 Horn
FUEL TANK AIR FILTER R16

2
1
SENSOR PRESSURE
N 85 SWITCH
R17
N N N N

2
1
87 87a 85 85 85 85 R18
X15A

N
87 87a 87 87a 87 87a 87 87a R19
CHASSIS MAIN
L6

AUXILIARY STOP CIRCUIT RIGHT LEFT RIGHT LEFT R20

H1.5

V1.5
HN1.5
FEEDING RELAY

VN1.5
PRESSURE LOW BEAM LOW BEAM HIGH BEAM HIGH BEAM R21
X35-T
X35-S

LIGHT RELAY LIGHT RELAY LIGHT RELAY LIGHT RELAY

X9-L

B
B
SWITCH
R22
X16-1 X16-1 R23
X20
SG

HL

1 R24

X20-N

X20-F
HYDRAULIC OIL R25
X39 TEMPERATURE
R10

R26
I R35 SWITCH I

S1.5
OIL FILTER R27
R7

LN
CB
VB
PRESSURE R28
VR 86 30
SWITCH

RG
R29
S 86 30 1 3 6
NG
BR

R30
X9-T I41
MAXIMUM
C R L 56a 56b 58 30 49 0 1
+ R31

LN
SG

SV
DL R32

SR

SN1.5
Z
N

GR1.5
RISING 31 R BL
S

SWITCH R33 Right rear axle block switch

F7
10A

N 85 LIGHTS BH
SWITCH C R34 Left rear axle block switch
87 87a
X2 I53
X21-21
X21-8

X16-4
4 2 5 7 R35
CABIN MAIN MN 85
M10

GEAR

SG
WARNING R36
R79

GR

GR

SG
L
AUXILIARY FEEDING 87 87a
SWITCH LIGHT SWITCH
TELERUPTOR R37
STOP

X21-27
FLASHING

SN1.5
4

X20-L
X21-20

LIGHT RELAY R38

TURN LIGHT
RV

R39

X16-4
K X18-20 X20-M R40 K
R81
BR

M 86 30 MC2M-CHASSIS
INPUT/OUTPUT SIGNALS
S1
F19

F20
25A

25A

S2
S3
N S4

X18-9
85 X18-14
87 87a S5

80
S6
VN2.5

EMERGENCY
VR

SWITCH CUTS S7
LS
FEEDING RELAY
R2 S8 Low beam right relay
X18-5

LN
M X17-15
ZL 86 30 S9 High beam right relay
M
S10
X17-13

S11
X23-11

F62
X10-7

F3
7,5A

7,5A
15A
V2.5

F2

S12
R1 S13
30 S14
X41 SL
MS
MS

86
7,5A

7,5A

A1.5
F4

F1
F5

7,5A
NG 85
R6 S15
R1 1Kohm
OPTIONAL

MA X11B X4 S16

CH
87 87a

CL
SL
A2
R2 1Kohm

X22-10

86 30

NG
OIL COOLING MH S17 1° Hydraulic cooling fan
ZL
BV2.5

X16-9

X16-8
WINCH FAN-2 RELAY S18 2° Hydraulic cooling fan
MICROSWITCH BS
S19 Low beam left relay
NG 85 BN S20 High beam left relay
BR

BOOM BACK
BR

87 87a 8 S21
9

HOIST SWITCH

AG
REVERSE
O O
X17-16

X18-15

X17-17

X18-22

X17-19

X18-12

X18-16
OIL COOLING S22
X17-6

X18-6

X18-7
X22-25
BR2.5

N 85
X16-9

X16-8

GEAR BUZZER

N
FAN-1 RELAY REAR RIGHT AXLE REAR LEFT AXLE S23
87 87a BLOCK VALVE BLOCK VALVE
X11-23

S24
REVERSE GEAR

AG1.5
F39

S25
7,5A

LIGHT RELAY
X17-14

S26
X47
BR

S27

X18-10
BOOM CHAINS S28
SWITCH S29
S30
S31
S32
MZ

S33
S34
S35
X32-2

X32-1

Q X11-24
Q

GN
N

N
G
S36
BV2.5
BR2.5

N2.5

N2.5

S37
HN1.5

S38
VN1.5
MN

MB

GN

AG
BH

SN
NL

LN
SG

BV

BV
VR

VR

H1.5
CL

CL
SB

BL
V1.5

N
G
S39

L
GN

GN
AG

AG
SN

SN
LN

LN
G

G
L

S40

2
1

2
1
RIGHT FRONT LIGHT LEFT FRONT LIGHT RIGHT REAR LIGHT LEFT REAR LIGHT

X10A X6A

6
5
4
7

3
2
LOW BEAM HIGH BEAM TURN LIGHT POSITION LOW BEAM HIGH BEAM TURN LIGHT POSITION REVERSE STOP TURN LIGHT POSITION REVERSE STOP TURN LIGHT POSITION RIGHT REAR LEFT REAR

1
N
SIDE LIGHT SIDE LIGHT
N

N
FADX FASX FPDX FPSX A1
N

N
X23 OIL COOLING
FAN-1 X24 OIL COOLING
FAN-2
I6
REAR AXLE
ALIGNMENT
PROXIMITY I8
FRONT AXLE
ALIGNMENT
PROXIMITY I15
TURRET
ALIGNMENT
PROXIMITY I71 LOCKED CABIN
PROXIMITY
FRONT RIGHT FRONT LEFT REAR RIGHT REAR LEFT HORN X11A
RIGHT REAR AXLE
X4A X13
TRAILER SYSTEM LIGHTS
LIGHTS SYSTEM LIGHTS SYSTEM LIGHTS SYSTEM LIGHTS SYSTEM LEFT REAR AXLE
BLOCK SWITCH BLOCK SWITCH
’

0
R25

6
BR4
R25

M1
RN

S S

(25/06/2012) 80-02-M205EN
 24 WIRING DIAGRAMS
7 – HEATING AND AIR CONDITIONING

Connectors Fuses and relays

Position on the Hydraulic
Type of wiring Ref. Description Ref. Description Position on the diagram
diagram equivalent

X12 Heating O17 F33 Switches indicator lights fuse E23

X32 Thermostat C25 F37 "15" Radio/heating power supply E20
X33 Ambient thermostat G24 F42 Air conditioning fuse E22
X42 Heater diagnostic connecrtor G18 F45 Heating fan power supply fuse E19
X101 Air conditioning set-up O11 F70 Heating power supply fuse E21
X103 Switch heating fan predisposition O13 R74 Radio and heater relay G9
X107 Heating timer set-up O23 R81 Relay for cutting power supply from emergency mushroom switch I6
XAC Air conditioning set-up S30

Components

Ref. Description Position on the diagram Hydraulic equivalent

I68 Heating fan switch C9

M10 Heating fan I15
M11 Heater pump O8
80

80-02-M205EN (25/06/2012)
 WIRING DIAGRAMS 25
DIAGRAM 7

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

13
M BR4 nr. 6
5
6
L6

N
R2
RN

RV

C C

RVnr.13
MZ1.5
I68
4 8 3 7 10
1 X32
0

F45

F37

F42

F33
F70
10A

7.5A

7.5A
7.5A

20A
THERMOSTAT

1
3
2
5
4
E E

G
MB

MB
HR

LG
2 6 1 5 9

N
MH1.5

MV1.5
FAN HEATER SWITCH

G G
R74
RADIO AND
R6

HEATER RELAY
X33

H
VR 86 30
X42
HEATER
MH1.5

MV1.5
DIAGNOSTIC
N 85 M10 1 N
87 87a
2

MB
AMBIENT
L6

I 3
LB THERMOSTAT I
4

R81 5 LG
VR

M 86 30 6

HEATER FAN
N1.5

N 85
87 87a
K K
EMERGENCY SWITCH
BR

CUTS SUPPLY RELAY

80
M M
V1.5
X22-24

MB

MB
HR

HR
N4

LG

LG
V4
LB

LB
MB
HR

N
H

G
V
G
V1.5

3
2

2
4

4
7

5
9

8
10

10
11

11
M11 X101 X103
1
1
1

O O
1

1
12

12

X12
1

1
1

HEATING SYSTEM X107

M TIMER HEATING SYSTEM PREDISPOSITION
12

12
1

1
DIESEL
10

10
11

11
3

3
2

2
4

4
7

5
9

8
HEATER PUMP
MB

HR
LG

LG
LB
V1.5

G
V
MB
HR
N4

V4
LB
N1.5

LR1.5
R4

R4
SWITCH A/C SWITCH HEATING

N
R

R
FAN PREDISPOSITION FAN PREDISPOSITION
Q Q

H
G

M
D
A

K
C
2

L
J
1

3
6

1
5

HEATING SYSTEM
’

4
RN
L6
L6

nr.
R2

M
BR
RV
TIMER HEATING SYSTEM PREDISPOSITION
XAC AIR CONDITIONING
GROUP PREDISPOSITION
S S

(25/06/2012) 80-02-M205EN
 26 WIRING DIAGRAMS
8/1 – CONTROL UNITS AND CAN-BUS CIRCUIT POWER SUPPLIES

Connectors Fuses and relays

Position on the Hydraulic
Type of wiring Ref. Description Ref. Description Position on the diagram
diagram equivalent

X71 Planarity sensor (electronic level gauge) A32 F17 Chassis section MC2M power supply fuse G14
X88 Encoder-manifold connector A26 F49 Positive “30” / Danfoss / 3B6 fuse K6
X500 Terminals with 120 Ohm resistance (CAN-BUS) Q31 F52 Driver's seat/radio control unit internal power supply fuse G14
X503 A37 F63 Anti-theft/instrument power supply fuse K10
X504 Terminals with 120 Ohm resistance (CAN-BUS) A34 F71 Cab section MC2M power supply fuse K12
XRD Radio control unit connector A14 R80 3B6 control units electronic positives relay E26

Components

Ref. Description Position on the diagram Hydraulic equivalent

J1939 Line can bus J1939 Q33

MC2M-CABIN Cab section inputs/outputs 3B6 control unit Q11 / Q14
MDCP Midak-plus connector E35
STR2 3B6 primary instrument inputs/outputs A5
TERA-7 Tera-7 display inputs/outputs Q4 / Q5
80

80-02-M205EN (25/06/2012)
 E
A

S
K
C

Q
O
G

M
BR
1
4
2

(25/06/2012)
BR
RN
6 4
RN
R2
5 6
3
DIAGRAM 8/1

R2
R2 5
5’
R2
5’
4

35 1
25 2
N

TERA-7
5

GND 24 3
STR2

15 4

14 5

CORE VIEW CONTROL BOX

6

R F49 B*
Main power supply 13 6 Can-open LOW line
10A
10 7
9 RN 8 +VE power supply
7

8 9
GND 7 N 10
INPUTS/OUTPUTS CABIN 3B6 CORE VIEW TERA-7

B*
8

Can-open LOW line 6 11

Can-open HIGH line 5 M* 12
GND can-open line
SCH*
4 13
9

Can-open HIGH line 3 M* 14 Can-open HIGH line

Can-open LOW line 2 15

L F63
+VE power supply 1 16
10

15A
17
18
11

19
RN2.5 20
Main power supply 1
RN2.5 F71
Main power supply 2 21
12

RN2.5 25A
Main power supply 3 22
N2.5 N
GND 4 23 GND
13

MC2M-CABIN
I/O CHASSIS 3B6 CONTROL BOX
A1
25A
10A

F17
F52
14

XRD

S40 A2

S39 A3

S38 SCH* B1 GND can-open line

15

S37 B2

S36 B3
16

MC2M-CABIN
S35 M* C1 Can-open HIGH line
AUTEC RADIO-CONTROL UNIT BOX

I/O CHASSIS 3B6 CONTROL BOX

S34 B* C2 Can-open LOW line

S33 C3
17

S32 D1

S31 D2
18

S30 D3

S29 E1

S28 E2
19

GND can-J1939 line

SCH*
S27 E3
Can-open LOW line B* RV F1 Main power supply
S26
Can-open HIGH line S25 M* F2
20

GND can-open line

SCH*
S24 F3
Can-J1939 LOW line
B* G1
S23
N
21

S22 G2 GND
N N
GND S21 G3 GND
RV H1 Main power supply
S20
22

S19 H2

S18 H3
23

S17 J1
N
S16 J2 GND
N
S15 J3 GND
24

S14 K1
S13 K2
S12 K3
25

S11
N
BR

S10
85
86
26

S9 1
R80
X88

S8 2
+VE UNIT BOX

Can-J1939 HIGH line

M* M*
S7 3 Can-open HIGH line
27

87

S6 RN2.5 B* 4 Can-open LOW line

R2.5
87a

S5 SCH*
30

5 GND can-open line

28

S4 6
ENCODER POSITION ROTATION

S3 7
S2 M* Can-open HIGH line
8
29

+VE power supply S1 RN B* Can-open LOW line

9
SCH* 10 GND can-open line
11
30

12
Can-open HIGH line 2 M*

B*
31

Can-open LOW line 1

X500

B
32

X71

B*
C Can-open LOW line
LEVELING SENSOR

M* D Can-open HIGH line

Can-J1939 LOW line 2 B*
33

Can-J1939 HIGH line 1 M*

J1939
34

B*
1 Can J1939 LOW line
X504

M* 2 Can J1939 HIGH line

35

RN
RN

M*
M*

B*
B*
RN1.5
N*
MDCP
36

5
4

7
6
2

9
8
3

34
33
29
28
27
26
16
15
14

32
31
30
25
24
23
22
19
17
13
12
11
10

20
21
18
1

35
GND

B*
37

1 Can-open LOW line

X503

M*
+VE power supply
+VE power supply

2 Can-open HIGH line

+VE power supply

Can-open LOW line

Can-J1939 LOW line

Can-open HIGH line

Can-J1939 HIGH line
38

INPUTS/OUTPUTS CHASSIS 3B6 CONTROL BOX

Can
J19
3 9L
Can OW
J19 line
3
39

9H
GN IGH
Dc line B*
an-
ope
Can
-op n li
ne
M
en *
LOW
Can line SC
-op H
40

en
HIG
H li B*
ne
M
*
41

N2
5
WIRING DIAGRAMS

80-02-M205EN
42

E
A

S
K
C

Q
O
G

M
27

80
 28 WIRING DIAGRAMS
8/2 – CONTROL UNITS AND CAN-BUS CIRCUIT POWER SUPPLIES

Connectors Fuses and relays

Position on the Hydraulic
Type of wiring Ref. Description Ref. Description Position on the diagram
diagram equivalent

X15 Danfoss directional control valve connector A17 F14 Danfoss control unit fuse I7
X36 Mercedes engine MR2 control unit E3 F17 Chassis section MC2M power supply fuse I19
X105 Cable reel 3B6 A14 F61 Diagnostics power supply fuse I34
X501 CAN_BUS set-up A5 R3 Chassis section MC2M power supply relay I17
XDM Diagnostics connector O3 R80 3B6 control units electronic positives relay I11
XM1 ADM2 Mercedes 12-pin female connector E36
XM2 ADM2 connector I36
XM3 ADM2 connector M36
XM4 ADM2 Mercedes 21-pin female connector S27

Components

Ref. Description Position on the diagram Hydraulic equivalent

CAN CAN line A12 / A13

CC1 Transmission control Danfoss control unit A7
M3 Seat LH side joystick A20
M4 Seat RH side joystick A27
MC2M-CHASSIS Chassis section inputs/outputs 3B6 control unit S7 / S10
OBD2 Diagnostics connector A35
80

80-02-M205EN (25/06/2012)
 A

S
C

Q
O
G

M
1
BR
4
BR
4

2
SC
H

(25/06/2012)
B*
M
*
3

R2
5
DIAGRAM 8/2

X36
CAN OPEN

XDM
R2
5
B* ’
M
*
4

GND
Can-K HIGH line

GND can-K line

Can-K LOW line
GND can-K line
GND can-K line

Can-K LOW line

Can-K HIGH line

16
16

1
1
CAN J1939

10
14
10
14

4
8
9
11
12
13
15
4
8
9
11
12
13
15

2
3
5
6
7
2
3
5
6
7
B*
5

1 Can-J1939 LOW line

M* 2 Can-J1939 HIGH line

N
B*
X501

B*

G*
G*
M*

M*
M*

DIAGNOSTIC CONNECTOR
6

MR2 MERCEDES ENGINE UNIT BOX

RN2.5 N1.5
7

Main power supply 1 1 GND

F14
CC1

Main power supply 2 RN2.5 RB1.5 2 Main power supply

30A
Main power supply 3 RN2.5 3
8

GND 4 N2.5 4
5

MC2M-CHASSIS
6
9

I/O CHASSIS 3B6 CONTROL BOX

7

8
DANFOSS TRANSMISSION BOX UNIT
10

S40 9
S39 10

BR

N
S38 11

85
86
11

S37 12

R80
S36

3B6 UNIT BOX

S35
12

M*
1 Can-J1939 HIGH line

+VE POWER RELAY

MC2M-CHASSIS
87
S34 RN2.5 B* Can-J1939 LOW line
R2.5 2

I/O CHASSIS 3B6 CONTROL BOX

87a
S33

30
CAN

SCH*
CAN BUS

3 GND can J1939 line

DANFOSS
13

S32

S31

S30 1
14

S29 2
X105

M*
3B6 BOOM

S28 3 Can-open HIGH line

SCH* B* Can-open LOW line

15

Can-J1939 LOW line 4

EXTENSOMETER

S27
Can-J1939 LOW line
B*
S26
M*
Can-open HIGH line S25
1
16

SCH*
GND can-open line S24
2
Can-open LOW line B*
S23
3
RN

S22
17

M* 4 Can-open HIGH line

85
86

N*
GND
X15

S21
R3

B* 5 Can-open LOW line

S20 SCH
6 GND can-open line
18

MC2M RELAY

S19
ACTUATOR PVED-CX
ELECTROHYDRAULIC

7
87

S18 RN4
R4
F17 8
87a

S17
30
19

25A
S16
1
S15
2
M3
20

S14 M* 3 Can-open HIGH line

S13
B* 4 Can-open LOW line
S12 SCH* 5 GND can-open line
21

S11
6
S10
7
S9
22

8
S8
9
M*
Can-J1939 HIGH line S7
10
23

S6
DANFOSS JS7000 LEFT AND RIGHT HANDLE

11
S5
12
S4
24

13
S3
14
S2
15
25

RN
+VE power supply S1
16

17
26

18
Can-J1939 LOW line 21 B*

SCH*
Can-J1939 LOW line 20 1
M4
27

XM4
Can-J1939 HIGH line 19 M* 2

18 M* 3 Can-open HIGH line

B* 4 Can-open LOW line

28

17
16 SCH* 5 GND can-open line

15 6
29

14 7
13 8
12 9
30

11 10
DANFOSS JS7000 LEFT AND RIGHT HANDLE

10 11
31

9 12
8 13

7 14
32

6 15
5 16
33

4 17
GND 3 N
18
2
F61
34

+VE power supply 1 CV 1

15A
2
M* Can-J1939 HIGH line
3
35

4
OBD2

5
M*
36

6 Can-open HIGH line

DIAGNOSTIC CONNECTOR

B*
M*
G*

XM3
XM2
XM1

8
37

9
9
2

9
8
2
9
8
2
8
7
6
3

4
4

7
6
5
3
7
6
5
3
10

10
10
11

17
16
14
13
12
11
14
13
12
11

15
1
1
1

15

18
12

10
GND

B*
38

11 Can-J1939 LOW line

12
GND can-K line
Can-K HIGH line

Can-K LOW line

13
39

B*
MERCEDES ADM2 UNIT BOX
MERCEDES ADM2 UNIT BOX
MERCEDES ADM2 UNIT BOX

14 Can-open LOW line

15
16
40

N2
5
41
42

S
C

Q
O
G

M
WIRING DIAGRAMS

80-02-M205EN
X

X
X
29

80
 30 WIRING DIAGRAMS
80

80-02-M205EN (25/06/2012)
 POSITION OF THE ELECTRICAL COMPONENTS

page

POSITION OF THE ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A2

– POSITION OF ELECTRICAL COMPONENTS UP TO VEHICLE 22725 - 758856

– CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5
– GROUNDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8
– POSITION OF THE ELECTRICAL COMPONENTS STARTING WITH THE VEHICLE 22756 - 758886
– CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11
– GROUNDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A14

80

(25/01/2013) 80-03-M205EN
 POSITION OF THE ELECTRICAL
2 COMPONENTS

POSITION OF THE ELECTRICAL COMPONENTS

Position on the diagram

Ref. Description
LH of vehicle RH of vehicle
MC2M-1 CABIN Cab section inputs/outputs 3B6 control unit E31
MC2M-2 CABIN Cab section inputs/outputs 3B6 control unit E31 / E32
MC2M-3 CABIN Cab section inputs/outputs 3B6 control unit E33
MC2M-1 CHASSIS Chassis section inputs/outputs 3B6 control unit G12
MC2M-2 CHASSIS Chassis section inputs/outputs 3B6 control unit G13
MC2M-3 CHASSIS Chassis section inputs/outputs 3B6 control unit E15
OBD2 Diagnostics connector E15
X1 C28
X2 Gear engaged limit stop C28
X7 Cab connector C23 / C24
X9 C39
X10 Optional connector C36
X11 Boom/platform functions interface connector E39
X14 C24
X15 Danfoss directional control valve connector E36
X16 I14 C27 / C21
X17 Q25
X18 Q26
X19 Q24 / Q25
X22 Chassis section inputs/outputs 3B6 control unit C26
X23 Fan-1 oil cooling C25
X35 I36
X36 Mercedes engine MR2 control unit M26 / M27
X88 Encoder-manifold connector C26 / C27
XA I8
XA/C Air conditioning set-up E27 / E28
XB K8
XDM Diagnostics connector C15
XM1 ADM2 Mercedes 12-pin female connector A21
80

XM2 ADM connector A22

XM3 ADM2 connector A23
XM4 ADM2 Mercedes 21-pin female connector A24
XSC Set-up connector E21

80-03-M205EN (25/01/2013)
 POSITION OF THE ELECTRICAL
COMPONENTS 3
POSITION OF ELECTRICAL COMPONENTS ON RH SIDE OF VEHICLE
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

XM4
XM2 XM3
XM1

C C

ADM2 CENTRAL BOX UNDER THE

MAIN DASHBOARD IN THE CABIN
XDM

OBD2

E E

G G

MAIN DASHBOARD

X16 X35

I I

K K

80
M M

X36

O PLD CENTRAL BOX ON O

THE TOP OF THE ENGINE

Q Q

S S

(25/01/2013) 80-03-M205EN
 POSITION OF THE ELECTRICAL
4 COMPONENTS
POSITION OF ELECTRICAL COMPONENTS ON LH SIDE OF VEHICLE
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

C
X7 X14 X23 X22 X16 X1 C
X16 X2
X88
X10 X9
MC2M-3
XA/C
XSC MC2M-2
MC2M-1 X15 X11
E E
MC2M-3

MC2M-2
MC2M-1

G G

I I
Xa
Xb

K K
80

M M

O O

Q Q

X19 X17 X18

S S

80-03-M205EN (25/01/2013)
 POSITION OF THE ELECTRICAL
COMPONENTS 5

CONNECTORS POSITION

Position on the
Type of wiring Ref. Description diagrams Observations
Diagram 1 Diagram 2
Rear of turret A1 Horn I18
Chassis primary A2 Reversing buzzer K6
Rear of turret A4 Rollover protection exclusion buzzer I12
Dashboard A6 Emergency pump active buzzer O35
Chassis primary B- 12VDC battery K5
Chassis primary BDP BDP Sauer Danfoss K21
Chassis primary CAN CAN line K18
Chassis primary CC1 Transmission control Danfoss control unit K18
Chassis primary CC2 Transmission control Danfoss control unit K19
Chassis primary CC3 Transmission control Danfoss control unit K19
Dashboard DL Stalk lights switch G15
Dashboard DM Gearshift lever set-up G17 OPTIONAL
Engine F40 Ceiling light fuse M20
Engine G Alternator M17
Dashboard I1 G29
Dashboard I2 Slow-fast speed switch G30
Dashboard I4 Speed reset switch G30
Chassis primary I6 Rear axle alignment proximity switches K8
Dashboard I7 Small mixer bucket switch G5 OPTIONAL
Solenoid valves I8 Front axle alignment proximity switches K24
Dashboard I9 Emergency pump switch E28
Dashboard I10 Platform exclusion key K31
Rear of turret I15 Turret alignment proximity switch I14
Dashboard I20 G7 OPTIONAL
Dashboard I21 G8 OPTIONAL
Dashboard I22 Emergency mushroom-shaped button G4
Dashboard I24 Steering selection switch I30
Dashboard I26 Beams in/out or stabilizers up/down switch G33
Dashboard I27 Beams and stabilizers selection switch I33

80
Dashboard I28 RH front beam/stabilizer switch G32
Dashboard I29 LH front beam/stabilizer switch G31
Dashboard I30 RH rear beam/stabilizer switch I32
Dashboard I31 LH rear beam/stabilizer switch I31
Dashboard I35 RPM switch E30 OPTIONAL
Safety device I41 Boom ascent maximum limit stop I4
Chassis primary I43 Danfoss control unit sensor K22
Dashboard I51 Rollover protection exclusion key K29
Dashboard I53 Emergency direction lights switch C26
Dashboard I54 Rotary beacon switch I29 OPTIONAL
Dashboard I56 Windscreen wiper pump switch E6
Dashboard I66 G6 OPTIONAL
Dashboard I68 Heating fan switch E9 OPTIONAL
Dashboard I69 Levelling joystick G33
Dashboard I70 Radio control switch E29
Rear of turret I71 Blocked can proximity switch I15
Dashboard I73 Start up enabling with I10 activated K32
Dashboard I76 E32 OPTIONAL
Dashboard I77 Sauer Danfoss mode switch E30
(25/01/2013) 80-03-M205EN
 POSITION OF THE ELECTRICAL
6 COMPONENTS

Position on the
Type of wiring Ref. Description diagrams Observations
Diagram 1 Diagram 2
Dashboard I78 Sideshift by-pass switch I30 OPTIONAL
Dashboard I79 Automatic levelling switch E31 OPTIONAL
Driver's seat ISR G20 OPTIONAL
Dashboard J1939 Line can bus J1939 E30
Dashboard KEY Start-up panel C33
Dashboard L28 Selected beams indicator I34
Dashboard L29 Selected stabilizers indicator I34
Dashboard L30 Stabilizers feed beams/descent extension indicator G34
Dashboard L31 Stabilizers feed beams/descent retraction indicator G34
Driver's seat LSR G20 OPTIONAL
Engine M1 Starter motor M16
Driver's seat M3 Seat LH side joystick G20
Driver's seat M4 Seat RH side joystick G19
Dashboard M8 Q39
Dashboard M10 Heating fan O37 OPTIONAL
Rear of turret M11 Heater pump I12
Driver's seat M12 G19 OPTIONAL
Dashboard MA Winch micro switch Q38
Rear of turret MC2M-1 Cab part inputs/outputs 3B6 control unit G12
Rear of turret MC2M-2 Cab part inputs/outputs 3B6 control unit G12
Rear of turret MC2M-3 Cab part inputs/outputs 3B6 control unit G12
Chassis primary MC2M-1 Carriage part inputs/outputs 3B6 control unit G17
Chassis primary MC2M-2 Chassis section inputs/outputs 3B6 control unit G17
Chassis primary MC2M-3 Chassis section inputs/outputs 3B6 control unit G17
Rear of turret MDCP Midak-plus connector G12
Dashboard OBD2 Diagnostics connector O35
Dashboard R35 Emergency pump remote control switch coil Q38
Dashboard RS232 Connector XRS232 C27
Solenoid valves S6 Set-up connector K25 OPTIONAL
Solenoid valves S8 Parking brake solenoid valve I22
Solenoid valves S11 RH front beam solenoid valve K22
80

Solenoid valves S12 LH front beam solenoid valve K22

Solenoid valves S13 LH rear beam solenoid valve K23
Solenoid valves S14 RH rear beam solenoid valve K24
Solenoid valves S15 Stabilizers retraction/ascent solenoid valve K25
Solenoid valves S16 RH front stabilizer solenoid valve K26
Solenoid valves S17 LH front stabilizer solenoid valve K26
Solenoid valves S18 LH rear stabilizer solenoid valve K26
Solenoid valves S19 RH rear stabilizer solenoid valve I26
Solenoid valves S24 Crab steering solenoid valve K22
Solenoid valves S25 Concentric steering solenoid valve K23
Solenoid valves S27 High speed solenoid valve K26
Solenoid valves S28 Low speed solenoid valve K26
Solenoid valves S35 RH levelling solenoid valve K26
Solenoid valves S36 LH levelling solenoid valve K26
Dashboard STR2 3B6 main instrument inputs/outputs E28 / E29
Dashboard STR3 3B6 main instrument inputs/outputs E29
Dashboard SV E6
Chassis primary T1 Fuel level sensor E16

80-03-M205EN (25/01/2013)
 POSITION OF THE ELECTRICAL
COMPONENTS 7

Position on the
Type of wiring Ref. Description diagrams Observations
Diagram 1 Diagram 2
Engine T41 Fuel oil filter heater M19
Dashboard TLM E27
Dashboard VIEW 3B6 main instrument power supply E27 / E28
Dashboard X1 O27
Dashboard X2 Gear engaged limit stop O27
Chassis primary X4 LH rear axle block solenoid valve I7
Chassis primary X4A LH rear axle block micro switch G7
Chassis primary X5 1st LH rear micro switch for stabilizer on ground E3
Chassis primary X5A 2nd LH rear micro switch for stabilizer on ground G3
Chassis primary X5B 1st LH rear beam micro switch G3
Chassis primary X5C 2nd LH rear beam micro switch G3
Chassis primary X6 E4
Chassis primary X6A LH rear side lights E5
Chassis primary X7 1st RH rear micro switch for stabilizer on ground M4
Chassis primary X7A 2nd RH rear micro switch for stabilizer on ground M4
Chassis primary X7B 1st RH rear beam micro switch M4
Chassis primary X7C 2nd RH rear beam micro switch M4
Chassis/Dashboard primary X7D Cab connector E13 O27
Chassis/Rear of the turret/
X9 I6 / I10
Safety device primary
Rear of turret X10 Optional connector O4 / I10
Chassis primary X10A RH rear side lights O5
Rear of turret X11 Boom/platform functions interface connector I11
Chassis primary X11A RH rear axle block micro switch M7
Chassis primary X11B RH rear axle block solenoid valve K7
Dashboard X12 Heating Q39
Chassis primary X12A Air filter pressure switch K11
Chassis primary X13 Trailer lights I4 OPTIONAL
Rear of turret X14 G14
Rear of turret X15 Danfoss directional control valve connector I11
Chassis primary X15A Stop lights pressure switch K7

80
Chassis/Dashboard primary X16 G16 O27
Chassis primary X17 E19
Chassis primary X18 E18
Chassis primary X19 E20
Chassis/Dashboard primary X20 Hydraulic fluid temperature bulb K18 O38
Dashboard X21 O38
Rear of the turret/Dashboard X22 K22 O27
Chassis primary X22 G13
Rear of the turret/Dashboard X23 G13 O27
Chassis primary X23 Fan-1 oil cooling I27
Chassis primary X24 Fan-2 oil cooling I27
Chassis primary X25 E28
Chassis primary X25A E27
Chassis primary X26 I28 OPTIONAL
Chassis primary X28 I28 OPTIONAL
Chassis primary X27 1st LH front micro switch for stabilizer on ground G28
Chassis primary X27A 2nd LH front micro switch for stabilizer on ground G28
Chassis primary X27B 1st LH front beam micro switch G28
Chassis primary X27C 2nd LH front beam micro switch G28

(25/01/2013) 80-03-M205EN
 POSITION OF THE ELECTRICAL
8 COMPONENTS

Position on the
Type of wiring Ref. Description diagrams Observations
Diagram 1 Diagram 2
Chassis primary X29 1st RH front micro switch for stabilizer on ground M29
Chassis primary X29A 2nd RH front micro switch for stabilizer on ground M29
Chassis primary X29B 1st RH front beam micro switch M29
Chassis primary X29C 2nd RH front beam micro switch M29
Chassis primary X30 M28
Chassis primary X30A M27
Solenoid valves/Chassis
X32 Thermostat I24 E15
primary/Dashboard
Solenoid valves/Chassis
X33 Ambient thermostat I25 E16
primary/Dashboard
Chassis primary X34 Stabilizers block optional kit I22
Engine/Chassis primary X35 M19
Engine X36 Mercedes engine MR2 control unit M18
Engine/Dashboard X37 Anti-theft device connector M18 O37
Engine X38 Engine air preheating connector M18 OPTIONAL
Dashboard X38A Vehicle radio power supply connector I31
Engine X39 Oil filter pressure switch M17
Dashboard X39A Radio speakers connector I32
Dashboard X40 Big mixer bucket connector O38 OPTIONAL
Dashboard X42 Heater diagnostic connecrtor O36
Rear of turret X46 I11 OPTIONAL
Driver's seat X51 G19
Driver's seat X53 G19
Dashboard X55 Folding stabilizers configuration O38 OPTIONAL
Dashboard X70 Radio control switch by-pass E27
Chassis primary X71 Planarity sensor (electronic level gauge) I21
Driver's seat X75 G19 OPTIONAL
Driver's seat X76 Pneumatic seat set-up connector G19 OPTIONAL
Solenoid valves X81 Set-up connector K24 OPTIONAL
Safety device X86 I10 OPTIONAL
Rear of turret X88 Encoder-manifold connector G14
Safety device X90 I5 OPTIONAL
80

Chassis primary X99 Motor displacement K21

Dashboard X101 Air conditioning set-up E16 OPTIONAL
Dashboard X102 Brake pedal O36
Cruscotto X103 Switch heating fan predisposition E15
Safety device X105 Cable reel 3B6 K9
Safety device X106 Bottom plate-compensation K10
Dashboard X107 Heating timer set-up E15
Safety device X107A Rod-compensation K10
Safety device X108 Bottom plate-lift I10
Safety device X109 Rod-lift I10
Chassis primary X500 Terminals with 120 Ohm resistance (CAN-BUS) G17
Chassis primary X501 CAN-BUS set-up G16
Dashboard X503 Q37 OPTIONAL
Dashboard X504 Terminals with 120 Ohm resistance (CAN-BUS) Q37
Rear of turret X505 G12
Dashboard XAC Air conditioning set-up Q27 OPTIONAL
Dashboard XAS Cigarette lighter connector C25
Dashboard XCD Power supply connector for radio with CD I29
Dashboard XDM Diagnostics connector O35
80-03-M205EN (25/01/2013)
 POSITION OF THE ELECTRICAL
COMPONENTS 9

Position on the
Type of wiring Ref. Description diagrams Observations
Diagram 1 Diagram 2
Dashboard XDK O35
Dashboard XM1 ADM2 Mercedes 12-pin female connector Q35
Dashboard XM2 ADM connector Q36
Dashboard XM3 ADM2 connector Q36
Dashboard XM4 ADM2 Mercedes 21-pin female connector Q34
Driver's seat XMS G20 / G21
Dashboard XPA Accelerator pedal I17
Rear of turret XRD Radio control unit connector G12
Chassis primary XSC Set-up connector G16 OPTIONAL
Dashboard XS1 Q38
Driver's seat XSP G19 OPTIONAL
Driver's seat XSR G20 / G21 OPTIONAL
Dashboard XTV Q38 OPTIONAL
Dashboard XVR E30

80

(25/01/2013) 80-03-M205EN
 POSITION OF THE ELECTRICAL
10 COMPONENTS

GROUNDS

Position on the
Type of wiring Ref. Description diagrams Observations
Diagram 1 Diagram 2
Solenoid valves Ground Ground I23 / i25
Chassis primary Ground Chassis ground I25
Back of turret Ground Chassis ground I13
Engine Ground Engine ground M17
Dashboard Ground Dashboard ground Q37
80

80-03-M205EN (25/01/2013)
 POSITION OF THE ELECTRICAL
COMPONENTS 11
DIAGRAM 1
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 Legend: A

Front wiring

Rear wiring

Turret rear wiring

C C
Engine wiring

Driver's seat wiring

Platform wiring

Connection between wirings

E X18 X17 X19 E

FUSE AND RELAY

BOX CHASSIS
X6 X7D
X5 X6A MC2M-1 T1 X25

MC2M CABIN
X53 M3 XSR X25A
X14
MC2M-2 X27
X5A

MC2M CHASSIS
X23
MC2M-3 MC2M-1 M12 XMS
X5B X75 X27A
X22
X505 MC2M-2
X5C X76 X27B
XSP
G MDCP G
AND RELAY BOX
MC2M-3
A/C INSTRUM.
BOARD-FUSE XSC X27C
X88 X51
XRD M4 LSR ISR
X501 X500
X16
X4A

X4 Ground
X9 X10 X11 X15 I15 I71 A1
X13 X34 Ground
X23 X26
A4
X86 X46 M11
X24 X28
I I
X9 X108 X71 X32 X33
X90
X109
Ground Ground
I41 S8 S19
X106
B- A2 X15A I6 ELECTRIC S11 S18
X107A
X105 MANIFOLD X20
S12 S13 S14 S15 S16 S17

S24 S25 X81 S6 S27 S28

K X12A CAN CC1 CC2 CC3 S35 K

BPD X99 I43 S36
I8
X22
X11B
Ground

X7C X11A X38 X35 F40

X7B

80
M1 X37 T41 X29C
X7A
M X29B M
X7 X36
X29A

X30A X29
G X39 X30
X10A
X10

O O

Q Q

S S

(25/01/2013) 80-03-M205EN
 POSITION OF THE ELECTRICAL
12 COMPONENTS
DIAGRAM 2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

A
Legend: A
Cab wiring

I53

C KEY C

XAS

RS232
VIEW
SV
STR2
I68 STR3
I56 J1939
X32 TLM
E XVR E
X107 X33

X103 X101
X70
I9 I70 I35 I77 I79 I76
I7 I66 I20 I21
STOP I69
Mode

DL DM
I22

G G
I1 I4 I2 I29 I28 I26 L30

RESET L31
P
XPA

L28
I54 I24 I78 I31 I30 I27

L29

I I

XCD X38A X39A

K K
I73
I51 I10
80

M M

X1 XDK
X2
A6

MC2M CABIN
X7D
XDM OBD2 X102 X37 M10 X40
O X23 O
X42 X55
X22

FUSE BOX
X21
X16

AND RELAY BOX

A/C INSTRUM.
X20

BOARD-FUSE
XA/C

CLUSTER
XTV

XS1

MA
Q X503
M8
Q
X504 R35
X12
XM4 XM1 XM3 XM2 Ground

ELECTRIC
S MANIFOLD S

80-03-M205EN (25/01/2013)
 ELECTRICAL CONTROL AND ADJUSTMENT

pag.

OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
MACHINE LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OPERATOR PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DIAGNOSTIC AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
ALARM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
ALARMS DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
DIAGNOSTIC PROCEDURES WITH TEXT DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
STATUS PAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
CALIBRATION PROCEDURES WITH TEXT DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
TRANSDUCERS CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
LMI CALIBRATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

80

(15/02/2013) 80-04-M205EN
 2 Electrical control and adjustment

OVERVIEW

The MNT_007 system is a global machine management based on Can Bus technology developed for
the MANITOU MRT PREMIUM & EASY

Main features:

1 - Full electronic control with MULTIPLEX TECHNOLOGY based on CAN BUS

2 - Boom control from the cabin
3 - Boom control from Basket
4 - Boom control from radio remote control
5 - Redundant LMI in according ISO13000 and EN280
6 - Automatic attachment selection
7 - Black box management with up to 500 events
80

80-04-M205EN (15/02/2013)
 Electrical control and adjustment 3

MACHINE LAYOUT

Cobo/3b6 supplying:

Ref Description Cobo Code

Machine and motion
1 MC2M T
management
2 Midac Plus Lmi management

80
4 redundant pressure
3 Pressure transducers
transducer
Cable Reel with redundant
4 Acq length and angle sensor (
main boom)
In Cabin display Tera 7 with
5 TERA 7
extend IoCore Unit
6 MC2M C Chassis Management
7 ASACBO Chassis angle sensor

(15/02/2013) 80-04-M205EN
 4 Electrical control and adjustment

FUNCTIONAL DESCRIPTION

MC2M T (Turret)

Is the master unit that Manages the Machine movement.

The main functions are:
Read input and control output;
• Capture e manage signals from other unit of machine;
• Capture joysticks and command movement;
• Capture engine data from canbus;
• Interface with transmission;
• Interface with distributor;
• Interface with recognition attachments
• Interface with display TERA7

MC2M C (Chassis)

Is a slave unit Useful to read and active output.

The main functions are:
• Read input and control output;
• Communicate with other unit of machine;
• Interface with display TERA7

IO-CORE (TERA 7)

Is a slave unit Useful to read and active output.

The main functions are:
• Read input and control output;
• Communicate with other unit of machine;
• Interface with display TERA7
80

MIDAC PLUS (LMI)

Is a slave unit Useful to read and active output.

The main functions are:
• Read input and control output;
• Capture e manage signals from other unit of machine;
• Interface with display TERA7
• Interface with distributor;
• LMI function

80-04-M205EN (15/02/2013)
 Electrical control and adjustment 5

OPERATOR PANEL

The operator panel is shown in follow picture:

1 2

Ref. Descriprion Function

Press F1,F2,..F5 key to activate the following graphic interfaces:

80
F1: Page “Driving”
F2: Page Load Limiter
1 Function button
F3: Page Working Space Limiter ( ISAAC )
F4: Page Detent
F5: Page Alarm

2 Function button

3 Arrow Keys and ENTER These keys are used to move through the menu and confirm the selections.

(15/02/2013) 80-04-M205EN
 6 Electrical control and adjustment

PAGE ON ROAD (DRIVE MODE)

2
7
7
5
1

1 - Water temperature gauge

2 - Fuel level gauge
3 - Engine RPM gauge
4 - Hour counter and time
5 - Km counter
6 - Actual gear and direction
80

7 - On Road function lamps. (On the left and on the right)

In this page is possible, with the Home Key, the zeroing of partial hours of work.

80-04-M205EN (15/02/2013)
 Electrical control and adjustment 7

LOAD LIMITER PAGE

2 5
2

2
2
2 2

3 6

Ref. Description Function

LCD bar showing the lifted load in percentage to the maximum admitted load in that
working condition.

1 Percentage Bar. Green reference: Safe Zone

Amber reference: Alarm Zone (Lifted load higher than 90% of maximum admitted load).
Red reference: Cut-off Zone ( Lifted load higher than 100% of maximum admitted load).

80
According to display icons:
–– Height
–– Boom Angle
–– Boom Length
2 Lmi Imformations
–– Radium
–– Actual load
–– Maximum Load allowed at current position
–– Turret Angle (if it is present level)
3 Stability Area See Stability paragraph
4 Messages area Generic text area used for diagnostic and during calibration.
In according with display icons:
–– Outrigger out
–– Stabilizer on ground
–– Turret centred
5 Generic lamps in “crane “ mode
–– Turret blocked
–– Vertical control
–– Horizontal control

Shows an icon with the selected attachment and the code of operative mode as per
6 Crane configuration
machine’ manual.

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 8 Electrical control and adjustment

ISAAC PAGE (WORKING SPACE LIMITER)

6
2

Fields 1 to 5 indicate the value of programmed limit. With icon lit the limit is overcame and the relatives
movements blocked.
Indication “---,--“ appear when the limit is not programmed.

1 - Limit on height
2 - Limit on Left side
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3 - Limit on Right side

4 - Limit in clockwise direction
5 - Limit on count clockwise direction
6 - Current values

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 Electrical control and adjustment 9

DETENT PAGE

Through right joystick and keys you can set 4 detents for each movement.

Descriprion Function

Press F6,F7,..F10 key to Select the type of detent (speed) :

F6: Detent 1

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F7: Detent 2
Function button
F8: Detent 3
F9: Detent 4
F10: max speed

Setting detent movement procedure :

bb To setting of the detent, do not move the boom or turret of the machine.

1 - Press red button on right joystick;

2 - Move joystick (joystick and direction according to the desired movement) and leave red button;

The movement carried out in step 3 is now stored in the system.

To erase one detent , select the proper row and keep pressed red button for 10 seconds.

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 10 Electrical control and adjustment

DIAGNOSTIC PAGE

1 6

2 7
11 14

3 8
12 15

4 9
13

10
5

16

Lamps lighting means fault or error in component or unit.

1 - Display Tera 7
2 - Mc2m Turret
3 - Midac Plus
4 - Turret rotation sensor
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5 - Joystick left
6 - Attachment identification
7 - Mc2m Chassis
8 - Cable-reel on main boom
9 - Radio remote control
10 - Joystick Right
11 - Engine
12 - Hydraulics
13 - Maintenance
14 - Pressure switch transducers
15 - Transmission
16 - Allarm display area

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 Electrical control and adjustment 11

In Diagnostic page ,with F6 key, you can show the Sauer Page, useful to Sauer components maintenance,
while through the F7 is possible to see Black Box page. (these pages are under password)

Motion Control

Motion control is performed by means of two independent channels.

• The system samples and computes the electric signals, CAN BUS or ANALOG, coming from Joystick
and drives proportionally the movement taking into account all safety logic
• The presence of the operator is necessary for the system to operate. This means that in case of failure
of any component, the system stops all movements.

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 12 Electrical control and adjustment

SAUER PAGE

This page is useful to maintenance of the Sauer devices.

There are 3 functions:

–– Setting Module ID;

–– Setting Module Neighbor:
–– Assist function.
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Descriprion Function
Press F6,F7,..F10 key to start the function pressed :

F6:
F7: function to set Sauer node Id
Function button F8: function to set Sauer neighbor
F9: Assist function
F10:

Enter : to unlock the possibility to select the Module

: to move and select the module

Arrow Keys and ENTER
: to move and select the module
Esc : to back in the Detent Page

After selection of module, press one of these commands.

In the bottom of Page there is a description of process state

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 Electrical control and adjustment 13

BLACK BOX PAGE

To Read the events stored, there is Black Box page .

Descriprion Function
Press F6,F7,..F9 key to scroll events or pages:

F6: move up Events

F7: move down Events

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Function button F8: Skip pages
F9: Skip pages
F10:

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 14 Electrical control and adjustment

ELECTRONIC CONTROL

Picture shows electronic control scheme

Cabin command.
The Movement commands from cabin are able with 2 can bus joysticks. The main channel is read by
can bus, while the redundant channel is read through analog signal 0 – 5 V.

MC2M unit reads both signals, normalizes them in a scale from -1000 to +1000 and then verifies the
congruency, there is a fault if the value differs by 10%.

Each joystick has deadman signal, that allows the movement.

After, the joystick command is ramped, and sent to logic block that allows the movement.

Basket command
The basket commands are made with the radio module, for safety reasons must be connected through
cable.
MC2M reads from can bus command signals, normalizes them and adjusts the signals.

Radio Command
From radio transmitter can be controlled movements such as basket commands.
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 Electrical control and adjustment 15

SPEED CONTROL FROM CABIN

The speed of each movement can be adjusted within a percentage from 0-100%
The value of 100% means the maximum command to the valve. Lower values proportionally reduces
the speed.

Note : The speed value is proportional to the spool stroke and not to the speed of the controlled boom,
because this is depending by the sections, the load and available flow from the pump.

In order to ad just the speeds from the cabin, the parameters in the table below have to be modified.
In order to calibrate the speed, it is enough to set the required value.
The right column shows example values recorded on a prototype machine.

Movement Associated Parameter Default value

Boom Up P100
Boom Down P101
Rotate Right P102
Rotate Left P103
Forks Up P104
Forks Down P105
NA P106
NA P107
Tele Boom Out P108
Tele Boom In P109
Attachment 1 P110
Attachment 2 P111
Winch Up P112
Winch Down P113

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 16 ELECTRICAL CONTROL AND ADJUSTMENT

SPEED CONTROL FROM BASKET

When basket control is available, each movement is defined with Fast/Slow speed selected by remote
control switch.

Note : 1000 = 100%

Movements from basket High Speed Low Speed Actual speed (live)
Boom Up P141 P143 P140
Boom Down P142 P144 P140
Tele Boom Out P146 P148 P145
Tele Boom In P147 P149 P145
Rotate Right P151 P153 P150
Rotate Left P152 P154 P150
Forks Up P156 P158 P155
Forks Down P157 P159 P155
Attachment 1 P161 P163 P160
Attachment 2 P162 P164 P160
Winch Up P166 P168 P165
Winch Down P167 P169 P166
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SPEED CONTROL FROM REMOTE RADIO

When radio control is available, each movement is defined with Fast/Slow speed selected by remote
control switch.

Note : 1000 = 100%

Movements from basket High Speed Low Speed Actual speed (live)
Boom Up P201 P203 P200
Boom Down P202 P204 P200
Tele Boom Out P206 P208 P205
Tele Boom In P207 P209 P205
Rotate Right P211 P213 P210
Rotate Left P212 P214 P210
Forks Up P216 P218 P215
Forks Down P217 P219 P215
Attachment 1 P221 P223 P220
Attachment 2 P222 P224 P220
Winch Up P226 P228 P225
Winch Down P227 P229 P225

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 18 Electrical control and adjustment

MOTION CONTROL

Motion controls are performer from MC2M_Turret unit.

Joystick

The cabin joysticks are redundant: the channels A are can bus and Channels B are analogic. The Master
unit read and adjust both and set a correct values for motion control.

Right Joystick

Left Joystick
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 Electrical control and adjustment 19

Joystick values from radio

The radio Joysticks are single channel with directional switch.

Interface with radio receive is can bus.

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 20 Electrical control and adjustment

RAMPS

Each movement can be optimised by means of acceleration ramps (start) and deceleration ramps (stop).
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 Electrical control and adjustment 21

This value sets acceleration to get the requested speed. The higher is the value, the higher is the
acceleration (and smaller is the time to reach the requested speed).
“Acceleration time” is calculates as T= 1000 / Ramp (tenth of seconds). The range is 0 – 1000 values
smaller than 100 (1 second)are normally not used.

Value Acceleration Time (sec) Note

1000 0,1 Ramp disabile
500 0,2
333 0,3
250 0,4
200 0,5
167 0,6
142 0,7

80
125 0,8
111 0,9
100 1 Ramp 1 second.
90 1,1
83 1,2
76 1,3
71 1,4
66 1,5
50 2 Ramp 2 seconds
40 2,5
33 3

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 22 Electrical control and adjustment

Associated parameter:

Movement Output Input Accel. positive Decel. positive Accel. negative Decel. negative
Boom Up/ Boom Down P706 P707 P708 P709 P710 P711
Telescopic boom P726 P727 P728 P729 P730 P731
Forks
Slewing P766 P767 P768 P769 P770 P771
Options P786 P787 P788 P789 P790 P791
Winch P806 P807 P808 P809 P810 P811

The values of ramps depends on the helm. (cabin/radio or basket).

If there is a cabin command, the ramp values take the values from Cabin table. (Look table below)

Winscope pages of ramps parameters are in the motion page of each movement.

The ramps of cabin and basket are divided in two block:

Cabin or radio ramps:

Movement Accel. positive Decel. positive Accel. negative Decel. negative

Boom Up/ Boom Down P1500 P1501 P1502 P1503
Telescopic boom P1505 P1506 P1507 P1508
Forks
Slewing P1515 P1516 P1517 P1518
Options P1520 P1521 P1522 P1523

Basket ramps:

Movement Accel. positive Decel. positive Accel. negative Decel. negative

Boom Up/ Boom Down P1530 P1531 P1532 P1533
Telescopic boom P1535 P1536 P1537 P1538
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Forks
Slewing P1545 P1546 P1547 P1548
Options P1550 P1551 P1552 P1553

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 Electrical control and adjustment 23

VALVES CONTROL

Hydraulic valve conditioning block, aligns Joystick signal and safety control in proper signal to drive
the proportional valve.

80

Input Joystick signal conditioned by previous controls ( range – 1000/ + 1000)

Output Signal to be sent to A/D converter on ARM unit ( range 0 - 255)
Bias Fixes the value to center the proportional valve. 0
Dead Band A Dead band compensation 400
Dead Band B Dead band compensation 400
Max A Set the maximum value to pilot the valve in PA-BT position Normally 75% 1600
Max B Set the maximum value to pilot the valve in PB-AT position Normally 25% 1600

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 24 Electrical control and adjustment

The next table shows the parameters index for each movement
Movement Ouput Input Bias Max A MaxB Dead band A Dead band B
Boom Up / Down P712 P713 P714 P715 P716 P717 P718
Slewing P732 P733 P734 P735 P736 P737 P738
Forks P752 P753 P754 P755 P756 P757 P758
Boom Extension P772 P773 P774 P775 P776 P777 P778
Attachment P792 P793 P794 P795 P796 P797 P798
Winch P812 P813 P814 P815 P816 P817 P818

Winscope pages of ramps parameters are in the motion page of each movement.

Example of winscope page for Boom lift movement

SUMMARY OF MOTION VALUE

80

The following winscope page shows a summary of motion value of all movements.

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 Electrical control and adjustment 25

SLOW MOTIONS

Some position close to dead end of the motion of the machine boom is reached only with slow
movements, in order to have safe and smooth reaction of the manoeuvres.

The following diagram shows slow motion condition:

X - Reference quote, depends on selected movement. Boom angle or boom length, for example.
Y - Actual Joystick Speed. For example 50% means the commanded speed from the system is only the
half the Joystick.
1 - Area where slow motion is still off. The maximum speed is allowed.
2 - Quote ( angle or length) where slow motion starts

80
3 - Area where slow motion is active. For the same position of the joystick, speed reduces while
approaching the dead end of the motion.
4 - Electronically programmed slow motion end. When this point overcome, the maximum speed
allowed is equal to the value of point 5.
5 - Maximum allowed speed at the end of the slow motion area. Set 0 to stop the movement. Set a
value higher than Dead Band value in order to have the minimum speed.

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 26 Electrical control and adjustment

Slow Motion depending from boom position.

From Cabin or radio:

Movement Boom Lift Boom lower Boom Extension Rotation Cw Rotation CCw
Actual Slowdown Value (Live) P920 P925 P930 P940 P945
Percentage at slow motion End (5) P921 P926 P931 P941 P946
Boom Length at slow motion start (2) P922 P927 P932 P942 P947
Boom Length at slow motion End (4) P923 P928 P933 P943 P948
Actual Boom length (Live) P924 P929 P934 P944 P949
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 Electrical control and adjustment 27

From Basket:

Movement Boom Lift Boom lower Boom Extension Rotation Cw Rotation CCw
Actual Slowdown Value (Live) P960 P965 P970 P980 P985
Percentage at slow motion End (5) P961 P966 P971 P981 P986
Boom Length at slow motion start (2) P962 P967 P972 P982 P987
Boom Length at slow motion End (4) P963 P968 P973 P983 P988
Actual Boom length (Live) P964 P969 P974 P984 P989

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 28 Electrical control and adjustment

DIAGNOSTIC AND TROUBLESHOOTING

The control performs an self-diagnostics system to recognize transducers and unit faults, broken cables,
and various errors from the machine.
On recognition of error or fault the control put itself in safety conditions disabling all the dangerous
commands and at the same time showing a message on the display.
On the basis of alarm code it is possible identifier the failure or fault.
The codes are describe in the “Alarm codes” paragraph with possible causes and suggestions to restore
the correct functioning (troubleshooting).
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WARNING LIST

The warning code is used to inform why a command can’t be executed.

Code Description
IDS_WARNING1 Machine not stopped
IDS_WARNING2 Not Used
IDS_WARNING3 Hardware Fault or machine alarm
IDS_WARNING4 Need Dead man switch
IDS_WARNING5 Cut off from LMI
IDS_WARNING6 Basket overload
IDS_WARNING7 Angle major of 55 degree
IDS_WARNING8 W8
IDS_WARNING9 W9
IDS_WARNING10 Not allowed ( generic conditions)
IDS_WARNING11 End of stroke slowdown
IDS_WARNING12 LMI Slowdown
IDS_WARNING13 Turret unblocked
IDS_WARNING14 Stabilize on ground
IDS_WARNING15 Angle major 10 degree
IDS_WARNING16 Vertical lift stop due max length
IDS_WARNING17 Vertical lift stop due min length
IDS_WARNING18 Machine on road
IDS_WARNING19 On Basket
IDS_WARNING20 Turret not unblocked
IDS_WARNING21 Horizontal movement stop due max length
IDS_WARNING22 Horizontal movement stop due min length
IDS_WARNING23 Turret not in frontal position
IDS_WARNING24 Height major than 3 meter
IDS_WARNING25 Machine not on weels
IDS_WARNING26 Stop for max angle
IDS_WARNING27 Stop for boom not close

80
IDS_WARNING28 Turret not in frontal position (+/- 15 degree)
IDS_WARNING29 Stop from ISAC ( area managements)
IDS_WARNING30 Seat-switch missing
IDS_WARNING31 Error in basket decode
IDS_WARNING32 Basket door open
IDS_WARNING33 Option excluded
IDS_WARNING34 Cabin door open
IDS_WARNING35 Error on Basket decode
IDS_WARNING36 Basket connect but not selected
IDS_WARNING38 A2B winch limit up
IDS_WARNING39 Rope overload
IDS_WARNING40 Not used
IDS_WARNING41 Boom not close in areal jib
IDS_WARNING42 Limit on tipping back
IDS_WARNING43 Outrigger not closed
IDS_WARNING44 Brake pedal missing
IDS_WARNING45 Not in neutral
IDS_WARNING46 Boom not under 3 m
IDS_WARNING47 Park brake enable missing

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 30 Electrical control and adjustment

Code Description
IDS_WARNING48 Generic enable missing
IDS_WARNING49 Attachment not confirmed
IDS_WARNING50 Attachment not locked
IDS_WARNING51 Radio with machine not stabilized
IDS_WARNING52 Boom not under 3 m
IDS_WARNING53 Gear not engage
IDS_WARNING54 Right limit
IDS_WARNING55 Left limit
IDS_WARNING56 High Speed
IDS_WARNING57 TCU limited state
IDS_WARNING58 TCU safe state
IDS_WARNING59 Tag not present in loadcharts
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ALARM LIST
Code Description
IDS_ALARM1 MCT: E2Prom Alarm
IDS_ALARM2 MCT: Crc Error in program Flash
IDS_ALARM10 MCT: can bus timeout from radio [1]
IDS_ALARM11 MCT: can bus timeout from radio [2]
IDS_ALARM19 MCT: can bus timeout cabin right joystick [1]
IDS_ALARM20 MCT: can bus timeout cabin right joystick [2]
IDS_ALARM21 MCT: can bus timeout cabin right joystick [3]
IDS_ALARM22 MCT: can bus timeout cabin right joystick [4]
IDS_ALARM23 MCT: can bus timeout cabin left joystick [1]
IDS_ALARM24 MCT: can bus timeout cabin left joystick [2]
IDS_ALARM25 MCT: can bus timeout cabin left joystick [3]
IDS_ALARM26 MCT: can bus timeout cabin left joystick [4]
IDS_ALARM28 MCT: can bus timeout MC2M chassis [1]
IDS_ALARM29 MCT: can bus timeout MC2M chassis [2]
IDS_ALARM32 MCT: Fault found in Tera7/IoCore
IDS_ALARM33 MCT: can bus timeout from Tera7/IoCore [1]
IDS_ALARM34 MCT: can bus timeout from Tera7/IoCore [2]
IDS_ALARM37 MCT: can bus timeout from Lmi [1]
IDS_ALARM38 MCT: can bus timeout from Lmi [2]
IDS_ALARM39 MCT: can bus timeout from Lmi [3]
IDS_ALARM40 MCT: can bus timeout from Lmi [4]
IDS_ALARM41 MCT: can bus timeout from Lmi [5]
IDS_ALARM46 can bus timeout from Tools Recognition
IDS_ALARM55 can bus timeout from level angle transducer
IDS_ALARM64 MCT: Fault on Lmi bypass key
IDS_ALARM65 MCT: Fault on traveling byapss button
IDS_ALARM66 MCT: Fault on basket bypass key
IDS_ALARM67 MCT: Fault on frontal proximity switch
IDS_ALARM68 MCT: Fault on Emergency
IDS_ALARM69 MCT: Fault on Emergency radio
IDS_ALARM73 MCT: congruency [Radio safety]

80
IDS_ALARM74 MCT: congruency [Basket connected]
IDS_ALARM75 MCT: congruency [Basket overload switch]
IDS_ALARM76 MCT: congruency [Basket lock switch]
IDS_ALARM82 Fault [MCT Pin R4: Power transducers]
IDS_ALARM83 Fault [MCT Pin R5: Cabin red lamp]
IDS_ALARM84 Fault [MCT Pin R6: External buzzer]
IDS_ALARM85 Fault [MCT Pin R13: Pendulum activation valves]
IDS_ALARM86 Fault [MCT Pin R15: Power to radio unit]
IDS_ALARM87 Fault [MCT Pin R16: Claxson]
IDS_ALARM88 Fault [MCT Pin R17: EV boom suspension]
IDS_ALARM91 Fault [MCT Pin R19: EV seat forward]
IDS_ALARM92 Fault [MCT Pin R20: EV seat backward]
IDS_ALARM93 Fault [MCT Pin S3: EV rotation basket 3D]
IDS_ALARM94 Fault [MCT Pin S4: EV lift basket 3D]
IDS_ALARM95 Fault [MCT Pin S5: EV inclination Basket 3D]
IDS_ALARM96 Fault [MCT Pin S19: EV1 Optional]
IDS_ALARM97 Fault [MCT Pin S20: EV2 Optional]
IDS_ALARM100 MCT:Fault from distributor [Pvsk]
IDS_ALARM101 MCT:Fault from distributor [Boom Lift]

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Code Description
IDS_ALARM102 MCT:Fault from distributor [Boom Extend]
IDS_ALARM103 MCT:Fault from distributor [Rotation]
IDS_ALARM104 MCT:Fault from distributor [Fork]
IDS_ALARM105 MCT:Fault from distributor [Optional]
IDS_ALARM107 MCT:Fault condition Transmission unit
IDS_ALARM109 Fault from Cabin Joystick [Boom lift A]
IDS_ALARM110 Fault from Cabin Joystick [Boom lift B]
IDS_ALARM111 Fault from Cabin Joystick [Forks A]
IDS_ALARM112 Fault from Cabin Joystick [Forks B]
IDS_ALARM113 Fault from Cabin Joystick [Rotation A]
IDS_ALARM114 Fault from Cabin Joystick [Rotation B]
IDS_ALARM115 Fault from Cabin Joystick [Boom Extention A]
IDS_ALARM116 Fault from Cabin Joystick [Boom Extention B]
IDS_ALARM118 Fault condition from Cabin Joystick [ Optional A]
IDS_ALARM119 Fault condition from Cabin Joystick [ Optional B]
IDS_ALARM121 Congruency Cabin Joystick [Boom Lift]
IDS_ALARM122 Congruency Cabin Joystick [Fork]
IDS_ALARM123 Congruency Cabin Joystick [Rotation]
IDS_ALARM124 Congruency Cabin Joystick [Boom Extention]
IDS_ALARM125 Congruency Cabin Joystick [Optional]
IDS_ALARM127 Congruency [ Unlocked valve rear axle right ]
IDS_ALARM128 Congruency [ Unlocked valve rear axle left ]
IDS_ALARM136 Can bus time out [ Pvsk module ]
IDS_ALARM137 Can bus time out [ Boom lift module ]
IDS_ALARM138 Can bus time out [ Forks module ]
IDS_ALARM139 Can bus time out [ Boom extention module ]
IDS_ALARM140 Can bus time out [ Boom rotation module ]
IDS_ALARM141 Can bus time out [ Boom optional module ]
IDS_ALARM145 Error on feedback of Pvsk valve
IDS_ALARM146 Error on feedback of Boom lift valve
IDS_ALARM147 Error on feedback of Folks valve
IDS_ALARM148 Error on feedback of Boom extention valve
IDS_ALARM149 Error on feedback of Rotation valve
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IDS_ALARM150 Error on feedback of Option valve

IDS_ALARM163 Tcu_Error: Watchdog
IDS_ALARM164 Tcu_Error: DSP Reference Voltage
IDS_ALARM165 Tcu_Error: Injection Channel
IDS_ALARM166 Tcu_Error: Battery Voltage
IDS_ALARM167 Tcu_Error: Sensor Voltage
IDS_ALARM172 Tcu_Error: FNR switch
IDS_ALARM173 Tcu_Error: Inching Sensor
IDS_ALARM174 Tcu_Error: Driving Sensor
IDS_ALARM175 Tcu_Error: Pump Rpm Status
IDS_ALARM176 Tcu_Error: Pump Angle Sensor
IDS_ALARM177 Tcu_Error: Mode Switch2
IDS_ALARM178 Tcu_Error: Motor Rpm Sensor
IDS_ALARM179 Tcu_Error: Motor Direction Sensor
IDS_ALARM181 Tcu_Error: Pump Valve FWD
IDS_ALARM182 Tcu_Error: Pump Valve REV
IDS_ALARM183 Tcu_Error: Motor Prop Valve
IDS_ALARM184 Tcu_Error: COR Valve

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Code Description
IDS_ALARM185 Tcu_Error: BB Valve
IDS_ALARM186 Tcu_Error: BDP Valve
IDS_ALARM201 E2Prom Alarm [MC2M Chassis]
IDS_ALARM202 Crc Error in program Flash [MC2M Chassis]
IDS_ALARM210 Fault [MCC Pin R3: Start Engine]
IDS_ALARM211 Fault [MCC Pin R4: Ev Crab]
IDS_ALARM212 Fault [MCC Pin R5: Ev Concentric]
IDS_ALARM213 Fault [MCC Pin R7: EV Stab Up / Outrigger In]
IDS_ALARM214 Fault [MCC Pin R8: EV Unlocking rear axle right]
IDS_ALARM215 Fault [MCC Pin R9: EV Unlocking rear axle left]
IDS_ALARM216 Fault [MCC Pin R10: Emergency pump]
IDS_ALARM219 Fault [MCC Pin R13: Outrigger front right]
IDS_ALARM220 Fault [MCC Pin R14: Outrigger front left]
IDS_ALARM221 Fault [MCC Pin R15: Outrigger rear]
IDS_ALARM222 Fault [MCC Pin R16: Outrigger rear left]
IDS_ALARM223 Fault [MCC Pin R17: Stabilize front right]
IDS_ALARM224 Fault [MCC Pin R18: Stabilize front left]
IDS_ALARM225 Fault [MCC Pin R19: Stabilize rear right]
IDS_ALARM226 Fault [MCC Pin R20: Stabilize rear left]
IDS_ALARM229 Fault [MCC Pin S2: Hydraulic brake]
IDS_ALARM230 Fault [MCC Pin S3: Parking brake]
IDS_ALARM231 Fault [MCC Pin S4: Gear slow]
IDS_ALARM232 Fault [MCC Pin S5: Gear fast]
IDS_ALARM233 Fault [MCC Pin S13: Ev Levelling right]
IDS_ALARM234 Fault [MCC Pin S14: EV levelling left]
IDS_ALARM237 Fault [MCC Pin S17: EV1 radiator]
IDS_ALARM238 Fault [MCC Pin S18: EV2 radiator]
IDS_ALARM240 Fault [MCC Pin S8: Low beam light right]
IDS_ALARM241 Fault [MCC Pin S9: Beam light right]
IDS_ALARM242 Fault [MCC Pin S19: Low beam light left]
IDS_ALARM243 Fault [MCC Pin S20: Beam light left]
IDS_ALARM244 Fault [MCC Pin S10: Park Brake Reset]
IDS_ALARM401 E2Prom Alarm [LMI ]

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IDS_ALARM402 Crc Error in program Flash [LMI]
IDS_ALARM403 Crc Error in load chart Flash [LMI]
IDS_ALARM410 Fault on external device [Acq1A E2prom Alarm ]
IDS_ALARM411 Fault on external device [Acq1A Acceletrometer 1 ]
IDS_ALARM412 Fault on external device [Acq1A Acceletrometer 2 ]
IDS_ALARM413 Fault on external device [Wdo ]
IDS_ALARM414 Can bus time out from external device [Acq1A ]
IDS_ALARM419 Fault on device [Acq1B E2prom Alarm]
IDS_ALARM420 Fault on device [Acq1B Acceletrometer 1]
IDS_ALARM421 Fault on device [Acq1B Acceletrometer 2]
IDS_ALARM422 Fault on external device [Wdo]
IDS_ALARM423 Can bus time out from device [Acq1B]
IDS_ALARM428 Can bus time out from sensor [Turret Angle A]
IDS_ALARM429 Can bus time out from sensor [Turret Angle B]
IDS_ALARM430 Congruency error form sensor [Turret Angle]
IDS_ALARM431 Cross point error form sensor [Turret Angle]
IDS_ALARM437 Can bus time out from device [MCC_Stab A]
IDS_ALARM438 Can bus time out from device [MCC_Stab B]

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Code Description
IDS_ALARM439 Can bus time out from device [MCT]
IDS_ALARM446 Boom Angle A: Min Value
IDS_ALARM447 Boom Angle A: Max Value
IDS_ALARM448 Boom Angle B: Min Value
IDS_ALARM449 Boom Angle B: Max Value
IDS_ALARM450 Boom Angle: Congruency A-B
IDS_ALARM455 Boom Length A: Min Raw value
IDS_ALARM456 Boom Length A: Max Raw Value
IDS_ALARM457 Boom Length A: Min Value
IDS_ALARM458 Boom Length A: Max Value
IDS_ALARM459 Boom Length B: Min Raw value
IDS_ALARM460 Boom Length B: Max Raw Value
IDS_ALARM461 Boom Length B: Min Value
IDS_ALARM462 Boom Length B: Max Value
IDS_ALARM464 Boom Length: Congruency A-B
IDS_ALARM473 Pressure Low chamber main cylinder A: Min
IDS_ALARM474 Pressure Low chamber main cylinder A: Max
IDS_ALARM475 Pressure Low chamber main cylinder B: Min
IDS_ALARM476 Pressure Low chamber main cylinder B: Max
IDS_ALARM477 Pressure Low chamber main cylinder : Congruency A-B
IDS_ALARM482 Pressure High chamber main cylinder A: Min
IDS_ALARM483 Pressure High chamber main cylinder A: Max
IDS_ALARM484 Pressure High chamber main cylinder B: Min
IDS_ALARM485 Pressure High chamber main cylinder B: Max
IDS_ALARM486 Pressure High chamber main cylinder : Congruency A-B
IDS_ALARM491 Pressure Low chamber compensation A: Min
IDS_ALARM492 Pressure Low chamber compensation A: Max
IDS_ALARM493 Pressure Low chamber compensation B: Min
IDS_ALARM494 Pressure Low chamber compensation B: Max
IDS_ALARM495 Pressure Low chamber compensation : Congruency A-B
IDS_ALARM500 Pressure High chamber compensation A: Min
IDS_ALARM501 Pressure High chamber compensation A: Max
IDS_ALARM502 Pressure High chamber compensation B: Min
80

IDS_ALARM503 Pressure High chamber compensation B: Max

IDS_ALARM504 Pressure High chamber compensation : Congruency A-B
IDS_ALARM518 Switch err. Stabilize front right:Congruency
IDS_ALARM519 Switch err. Stabilize front left:Congruency
IDS_ALARM520 Switch err. Stabilize rear right:Congruency
IDS_ALARM521 Switch err. Stabilize rear left:Congruency
IDS_ALARM522 Switch err. Outrigger front right: Congruency
IDS_ALARM523 Switch err. Outrigger front left:Congruency
IDS_ALARM524 Switch err. Outrigger rear right:Congruency
IDS_ALARM525 Switch err. Outrigger rear left:Congruency
IDS_ALARM527 Overload condition 1
IDS_ALARM528 Overload condition 1
IDS_ALARM529 Overload condition 1
IDS_ALARM530 Fault condition output Pin [Pin - Extra CutOff]
IDS_ALARM531 Extra CutOff From LMI
IDS_ALARM536 Can bus time out from Tools Recognition
IDS_ALARM537 Fault from Tools Recognition: Blk
IDS_ALARM538 Fault from Tools Recognition: Error Code

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ALARMS DESCRIPTIONS

MC2M ALARM

This alarm detects corrupted data in MC2M board

Possible reasons are:
• System not yet programmed
• Machine attempted to Start with battery low
• Attachment activated but not programmed.

What to do:
• Reboot system
• In case alarm occurs after new attachment activated, simply calibrate load and save
• Reload the original calibration file or recalibrate the machine

This alarm disable (watchdog) WDO, since a faulty parameter generates potential danger.

PRESSURE TRANSDUCERS ALARMS

Pressure transducers used in the system sends signal from 4 to 20 mA

System checks the signal to be within this range.
Normally 2 alarms are possible

• Value lower than minimum (3,5 mA)

• Value over the maximum (22 mA)

For lifting cylinder only alarm on minimum value is available, since in case of very high load on the forks,
pressure may exceed the nominal one. Anyhow, safety system still is operating correctly.

Possible reasons about this failure are:

• Cable cutter
• Short Circuit on the cable

80
• Pressure transducer damaged
• Main Unit Damaged

What to do:
• If alarm occurs while boom movements, check the cable in the area close to articulations and extensions
• Check if corrosion occur in the connector plug.
• Check sensor power supply and connection integrity.
• Check that cable shield is completely isolated by the other conductors
• Eventually, replace the pressure transducer
• Main Unit fault is very rare. Before to replace the main unit, check function by inverting the transducers

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POTENTIOMETRIC TRANSDUCER ALARMS

Potentiometric transducer sends a valid signal in the range from 0,25 to 4,75 V
The program converts the input voltage and by means of special procedures, display the following data:
• Centimeter for length
• Tenth of degrees for angles
• Kg * 10 for weighing function

4 alarm level are available for each sensor:

1 - Unconverted signal less than 0,25V
2 - Unconverted signal higher than 4,75v
3 - Converted value lower than the minimum preset
4 - Converted value higher than the maximum preset

Alarm 1 and 2 allows to identify mechanical sensors calibration.

Example :
a machine has a minimum extension of 5 meters and a maximum of 15.
Alarm 3 occurs if the measured length is lower than 4,7 meters
Alarm 4 occurs if the measured length is 15,3 meters
Tolerance for this alarms is 0,3 meters for length measurement and 5° for angle
1 second delay is included for each alarm

Note :
Depending from the applications for some transducer the voltage thresholds for alarm 1 and 2 could
be different from above values.
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The following pictures shows alarms point of activation for length transducers.

LEGENDA :

X - A/D sampling (bit)

Y - Transducer value after conversion
1 - Minimum value set point 0,25 v ( 50 bit ) (Alarm 1 ON)
2 - Length corresponding to Alarm 3
3 - Length at calibration point 1 (minimum lenght)
4 - Reading of the converter at point 1 of calibration (minimum lenght)
5 - Reading of the converter at point of calibration 2 (maximum lenght)
6 - Lengt at calibration point 2 (maximum lenght)
7 - Length corresponding to Alarm 4
8 - Reading of the converter corresponding to 4,75 V (Alarm 2)
9 - Converter full scale
10 - Zone of intervention of alarm 1
11 - Zone of intervention of alarm 3
12 - Working Area
13 - Zone where transducers are out of range but not yet in alarm

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14 - Zone of intervention of alarm 4
15 - Zone of intervention of alarm 2
P1 - Calibration point 1 ( Min)
P2 - Calibration point 2 (Max)

Reasons:

Power supply missing

Cursor not connected
Alarm 1
Short circuit between cable shiled and cursor
Transducer damaged
Ground connection missing
Alarm 2
Transducer Damaged
Calibration missing
Transducer with mechanical offset
Alarm 3
Transducer not calibrated
Transducer damaged
Calibration missing
Transducer with mechanical offset
Alarm 4
Transducer not calibrated
Transducer damaged
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DIGITAL SIGNAL CONGRUENCY ALARM

For safety reasons some “important” signal is sampled by means of 2 separate digital input. When
possible, the signal are sampled by two different units, in order to avoid “common mode” errors.
If the signal read by the two inputs are discordant an alarm is created.

The following signals are read by two inputs of the system:

• Extension of outrigger
• Turret/Carrier alignment
• Stabilize on Ground

Alarm is created when the 2 signals are different for at least one second.

Reasons:
• The redundancy of sensors is used to check the function of the input channel in case of malfunction
possible reasons are the main unit or the wirings.

What to do:
• Check the sensor, then the wiring of connection between the sensor and the unit…

CONGRUENCY ALARMS OF LOAD MOMENT INDICATOR

For safety reasons length and angle sensors are read by a couple of sensors. The values of this couple
of sensors are compared in order to control their congruency.
Alarms occurs if the difference between the values are greater than:
• 0,3 meters for length
• 5° for angles

Alarm is created when there is difference for at least one second

Reasons:
80

• Transducer fails
• Wirings failed,
• Misalignments of the transducers (mechanical position)

What to do:
• Same as potentiometric sensors.
• Eventually, calibrate once again the sensors

ALARMS ON OUTPUT FEEDBACK

For safety reasons, some “important” output is feed back to the main unit to check congruency between
command and output.
Depending on the safety importance, control can be performed by on POST (Power On STartup) or
cyclic mode, every 0,1 seconds.
Alarm is generated if the input is not corresponding to the controlled Output. One second delay is
included before alarm activated.

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CRC LOAD CHARTS DATA INTEGRITY ALARM

Load charts are stored in particular area of the FLASH memory together to control fields, used to check
their integrity.
During the prepare phase of the Load Chart, CRC is calculated and stored in the specific field of the
FLASH memory.
During the normal functioning, program the program performs the opposite calculation, that is to
recalculate CRC and compare it with the one resident in the FLASH. In case two values are different
alarm is activated.

Attachments load chart are stored in several pages. Verified load chart is only the one in use.
Since the calculation is long, alarm can be activated even after few minutes after accessory selection.

Reasons:
• If this alarm, attend after the flashing download, the source file is corrupted or have a wrong CRC.
• Data inside the memory are corrupted

In both cases it is necessary to reload the file or change the FLASH EPROM

CRC PROGRAM ALARM

Same as per CRC Load Charts. In this case, all pages for the program are checked at the same time.
Therefore one error in one page stops the machine to work.

CAN BUS DEVICES ALARMS

The system can detect 2 different alarms per each device connected.

Timeout alarm.
the unit had no messages from the remote device for more than a certain time. Possible reasons are:
• Wirings
• Device damaged or power off

80
If all devices connected on the same line has the same alarm, check electric connections.
If only one device has alarm, pay attention to this device only, included wirings.

Devices in Alarm conditions

The remote device has detected an alarm and send it to the main unit.
Actions depends on alarm type and gender.
Typically reasons are :

• Device Data memory error

• Device un-calibrated
• Fault detected on the device

In all this conditions, you should replace the device.

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F.A.Q.

DISPLAY IS BACKLIT BUT NO INDICATIONS APPEARS (BLANK).

Commands for display indication are send by serial line from Main Unit (HEAD)
If there are no indication on the display, it is not possible to read eventual error codes.
The following steps are recommended:

• Disconnect the unit called ARM located at BOOM SIDE connector: in this way, only the main unit an
the display are connected to the CAN BUS line
• Connect the main unit called HEAD to the TEST BENCH
• Check the power supply +VE. (Pin 49,50 (+Vb) with 51)
• Check +5V out from pin 4
• Check +15 out from pin 43
• Check power supply out +VP ( Pin 53,54,55,56 = Vb)
• Check RS232
• Check CAN BUS line
• Check Wirings between the display and main unit

HOW TO CHECK THE SERIAL LINE BETWEEN IDR TYPE DISPLAY AND HEAD TYPE MAIN UNIT.

Use multimeter, set to VOLTS:

• Check the voltage of the pin TX of HEAD unit (Pin 46).
• It must be within the range of –4 and –8 volts.
• In case of transmission, voltage decrease progressively each second.
• If this behaviour can not be identified, the main unit HEAD is not sending messages or RX TX cables
are inverted or IDR display is damaged.
• Disconnect IDR display and repeat the test
• Check the voltage on pin 45 of main unit RX:
• it must be within the range of –4 and –8 volts.
• 0 volts means that TX signal from IDR display is not transmitted.
• Check the connection. By pressing one button, a light voltage drop must be noticed.
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HOW TO CHECK CAN BUS LINE

Use multimeter, set to OHM or VOLTS:

• Switch off all system.

• Check resistance between pin 48 (CAN H) and 47 (CAN L) of the main unit (HEAD).
• The good value is 60 ohm. System may work also with values between 40 and 150 Ohm.
• If resistance is ∞, the system may not function
• Switch on the system
• Check the voltages between CANH and GND
• The good value have to be within 2,5 - 2,6 volts
• If the values are between 3.5 –4 Vdc, there is the possibility to have a condition of “Heavy Bus”:
wirings are wrong or can bus resistance is missing
• If value is lower than 2,4 Vdc, CANH and CANL may be inverted in some other peripheral as
sensor or other devices connected on the BUS

• If the voltage is:

• < 1 Vdc possible short circuit in the BUS
• > 5 Vdc, possible errors on the BUS.
• Y11 IPEH-2021 CAN DONGLE troubleshooting
• CAN DONGLE is an instrument that enables a normal WINDOWS ® operated PC to analyse the
CAN BUS line. It is composed by a program running onto a PC and an USB Probe, to be connected
to the CAN BUS line The following picture shows the PCAN explorer program connected to the
main unit:

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The presence of several messages running means the CAN LINE ok

In case CAN LINE is not working:

• Disconnect all the units and devices from the BUS

80

• Double check all CAN BUS wirings and in particolar check that the lines CANH and CANL are not
crossed in some point
• Check the presence of the “END LINE RESISTANCES”
• Connect one device per time on the BUS and check its activity with the PCAN Explorer software.
• Consider that a unit may work in not proper way even if OK by the Hardware point of view.

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ANNEX A

DIAGNOSTIC PROCEDURES WITH TEXT DISPLAY

DIAGNOSTICS PAGES

The diagnostics page are always available without passwords

From LMI main screen, press ENTER button to go into diagnostic mode. Then scroll with arrow keys to
select desire page.

In order to simplify the research on changing page, the page numbers and identifications text are
shown for few seconds.
In the follow table the first column is indicating the messages display in field [4] “Message Area” of display.

P01 : Allarmi
AAAA : Alarm or fault from LMI
Alarm AAAA BBBB BBBB: Alarm or Fault from Machine
Warning CCCC DDDD CCCC: Warning from LMI
DDDD: Warning From Machine

P02 : LMI
P = Differential Pressure inside the lifting cylinder
W = Load ( t)
M = Max Load allowed in the actual position
A = Boom Angle
L = Boom Length
R = Radius from turret centre

x = Type of Max Load in use in according to the following list:

- s = From load chart
P100 W 4.1xM5.0 - r = From static stability
A 45oL 8.5 R6.0 - d = From dynamic stability
- m = From max load nominal
- z = Cut from minimum Load

o = Boom length indication

80
e = actual Extension
r = actual Retracting
v = Empty corrections centred
c = Laden correction centered
x = Empty and Laden corrections centered

P03 : Pressures
Upper row: Main Cylinder
P = Differential pressure
L: Pressure piston side
H: Pressure rod side
P100 L:xxx H:xxx
P 40 l:xxx h:xxxx
Lower row: Compensation cylinder
p = Differential pressure
l: Pressure piston side
h: Pressure rod side

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P04 : Boom
Angles and boom lengths from LMI and Machine unit

Upper row:
AA.A : Angle from Lmi
BB.B: Angle from Machine
a AA.A BB.B CC.C CC.C: Angle difference between Lmi and Machine
l DD.D EE.E FF.F
Lower row:
DD.D Length from Lmi
EE.E Length from Machine
FF.F: Length difference between Lmi and Machine

P05 : Outriggers
Outriggers percentages

Stb AAA BBB AAA: Forward left

CCC DDD BBB: Forward right
CCC: backward left
DDD: backward right

P06 : Rotax
AAAA: Turret angle
BBBB: Error code from rotax
Rot AAAA BBBB
CCCC: Angle 1 from rotax
CCCC DDDD EEEE
DDDD: Angle 2 from rotax
EEEE: Angle difference from rotax (Angle 1- Angle 2)

P07 : Levelling”
Chassis inclinations

Liv T:XXXX T: Transversal

SXX E:XX L:XXXX L: Longitudinal
S: Status
E: Error

P09 :
N/U Not Used

P10 : Boom Lift Main Boom rising Motion

80

111: Joystick sampling 0 +/- 1000

So 111 222 333 222: Percentage of the speed settled by Joystick
333: Command to Danfoss (0 – 1024)

P11 : Telescopic Telescopic Boom Motion

111: Joystick sampling 0 +/- 1000
Sf 111 222 333 222: Percentage of the speed settled by Joystick
333: Command to Danfoss (0 – 1024)

P12 : Forks Fork motion

111: Joystick sampling 0 +/- 1000
Fo 111 222 333 222: Percentage of the speed settled by Joystick
333: Command to Danfoss (0 – 1024)

P13 : Slewing Slewing motion

111: Joystick sampling 0 +/- 1000
Ro 111 222 333 222: Percentage of the speed settled by Joystick
333: Command to Danfoss (0 – 1024)

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P14 : Option Option motion

111: Joystick sampling 0 +/- 1000
Au 111 222 333 222: Percentage of the speed settled by Joystick
333: Command to Danfoss (0 – 1024)

P15 : Winch Winch motion

111: Joystick sampling 0 +/- 1000
Ar 111 222 333 222: Percentage of the speed settled by Joystick
333: Command to Danfoss (0 – 1024)

P16 : Press.Transd Pressure Transducers

Analog Channels 0-3 from View

0 B111 2 B222 0: Pressure transducer Ram side

1 B333 3 xxxx 1: Pressure transducer Rod side
2: Pressure transducer Ram side compensation cylinder
3: Pressure transducer Ram side compensation cylinder

P17 : Lmi Status

* Lmi Status
M IIII: VVVV (See below)

P18 : Mach. Status

* Machine status
M IIII: VVVV (See below)

P19 :
Not Used

P20 : Act1A Main boom cable-reel: ACT 1A

ACT1A A:aaaa Main Boom Cable Reel: Left Hand Transducer
ccc Eee L:ssss See also Angle Calibration

P21 : Act1B Main boom cable-reel: ACT 1B

ACT1B A:aaaa Right Hand Transducer
ccc Eee L:ssss See also Angle Calibration

P22 : Rotax Turret angle reading

80
A Angle 1 from Rotax
Rotax A:aaaa B Angle 2 from Rotax
ccc Eee B:ssss E Fault code from Rotax
CCC Incoming message counter

P23 : CCT Stb FR Length transducer outrigger Forward right CCT

A Length 1
CctFR A:aaaa B Length 2
ccc Eee B:ssss E Fault code
CCC Incoming message counter

P24 : CCT Stb FL Length transducer outrigger Forward left CCT

A Length 1
CctFL A:aaaa B Length 2
ccc Eee B:ssss E Fault code
CCC Incoming message counter

P25 : CCT Stb BR Length transducer outrigger Backward right CCT

A Length 1
CctBR A:aaaa B Length 2
ccc Eee B:ssss E Fault code
CCC Incoming message counter

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P26 : CCT Sbt BL Length transducer outrigger Backward Left CCT

A Length 1
CctBL A:aaaa B Length 2
ccc Eee B:ssss E Fault code
CCC Incoming message counter

P27 : AsaC Chassis levelling sensors

X: truck roll angle value
AsaC X:aaaa Y: truck pitch angle value
ccc Eee Y:ssss Ccc : message counter
Eee: planarity sensor error

STATUS PAGES

From display cabin it is possible ( without password) check status and conditions of all machine units.
Setting a password with adequate level, with same form it is possible to modify all parameters.
That should be useful for diagnostic, calibration and in general for machine setup.

The pages are the following:

P09 : Lmi Status

*
Lmi status
M IIII: VVVV

P10 : Mac.Status
*
Machine status
M IIII: VVVV
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VARIABLES, PARAMETERS, CONDITIONS

The program manages the following type of data:

I: Digital inputs
Represents signals such as buttons, switches, proximity from machine. The conditions are ON (“1”
Conctac close) or OFF (“0” Contact open)

O: Digital ouputs
Represents the output signal from the unit to typically valves, lamps, relays.
Conditions:
OFF (“0”) = Output not activated
ON (“1”) = Output activated

M: Internal memory or Flags

They are the image of internal memories used by program and like previous use two conditions: true
and false.
Should be used for general image of conditions or other.

Q: Variable
They are the numeric variables used by program. The range is -30000 to +30000

S: System variables.
They are other variables used specially for system management

P: Parameters
They are data that can be set and saved in E2PROM memory. Typically are used for calibration and
configuration,

The meaning of all variables depends of the program.

HOW READ A DATA VALUE

The following example will clarify the procedure.

80
The example describes how to visualise the variables 10 of LMI Unit.

P09 : Lmi Status From Main menu display this page

*
After 1-2 seconds display show the figure with the value of the first variable avoidable. In the example is show FLAG 0.
M 0: OFF
*
With ESC button move the cursor above “M”
M 0: OFF
*
With arrow key change the value until “Q” ( variables) is displayed
Q 0: 0
With ESC move the cursor above index field.
With arrow key change the value until 10.
*
In this case the right number ( 123) indicate the value of variable 10.
Q 10: 123
Press ENTER to exit from Setting Mode or use arrow key to select a other data.

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Other example: Set the parameter 100 of machine to value 95.

On power in make sure to set the correct password.

P10 : Mac.Status
From main menu display this page.
* After 1-2 seconds the display shows the figure with the value of the first variable avoidable.
M 0: OFF In the example is shown FLAG 0.
*
With ESC button move the cursor above “M”
M 0: OFF
*
With arrow key change the value until “P” ( parameters) is shown
P 0: 0

With ESC move the cursor above index field.

*
With arrow key change the value until 100.
P 100: 123
In this case the right number ( 123) indicate the value of variable 10
With Esc move the cursor to value field.
With Arrow key change the value until 95 ( or other desidered value) is displayed.
*
Press ENTER to exit from Setting Mode or use arrow key to select a other data.
P 100: 95
Of course it is necessary save the changing ( With “01 Save”) before shut down.
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ANNEX B

CALIBRATION PROCEDURES WITH TEXT DISPLAY

CALIBRATION MENU

Calibrations are available only if the good password level has been inserted.
From Main Page, to use “+” to enter calibration mode
Scroll pages until the desired page is selected

*** Main Page.

WW.W MM.M RR.R OM Enter password and press “+” to access programming mode
Machine configuration.
The following parameters are available:
CONFIGURATION • language
32 Config • Units (metric or imperial)
• Password 1
• Password 2
CONFIGURATION Attachments or Accessories
33 Tools Press “Page” to activate or deactivate the available accessories/attachments
Axx Lxx.x Wxx.x
Main Boom length and angle calibration in the “completely closed” position
12 Trasd Min
Axx Lxx.x Wxx.x
Main Boom length calibration in the “completely open” position
13 Trasd Max
Axx Lxx.x Wxx.x
Save Calibrations
01 Save
STABILITY
Outrigger In calibration
55 Outrigger In
STABILITY
Outrigger Out calibration
56 Outrigger Out
STABILITY
Turret rotation calibration ( Rotax)
57 Rotax
STABILITY
Turret levelling
58 Levelling
STABILITY
Save settings
01 Save

80
SOSPENSION
Sospension calibration down
35 Sosp. Down
SOSPENSION
Suspensions calibration Up
36 Sosp. Up
STABILITY
Save settings
01 Save

Axx Lxx.x Wxx.x

LMI Empty calibration
20 Empty
Axx Lxx.x Wxx.x
Setting of the known weight used for machine calibration
21 LadenAct xx.x
Axx Lxx.x Wxx.x
Load calibration
22 Laden
Axx Lxx.x Wxx.x
Dynamic zero load calibration (calibration of “load zero” while moving)
23 Empty Dynamic
Axx Lxx.x Wxx.x
Dynamic Load calibration (calibration of the load using the known value while moving)
24 Laden Dynamic
Axx Lxx.x Wxx.x
Copy the load of the forks to all other attachments
25 Save To All
Axx Lxx.x Wxx.x
Init of the weighing of the selected attachment
26 Init Weight

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Axx Lxx.x Wxx.x

Save Calibrations
01 Save

LMI Visualisation or calibration of all LMI parameters

30 Parameters See “Parameter List” for details
MACHINE Visualisation or calibration of all Machine (Logic and motions) parameters
40 Parameters See “Parameter List” for details

OPTIONS
Calibration of empty moment chart
31 Empty Moment
OPTIONS
System initialization
10 Initialise

OPTIONS
Black Box management
50 BlackBox
OPTIONS
Black Box Initialize
51 Init BlackBox
OPTIONS
Time and Date setting
52 Time Setting

MACHINE CONFIGURATION
Machine Configuration.
The following options are available:
CONFIGURATION • Language
32 Config • Unit (metric or imperial)
• Password 1
• Password 2
CONFIGURATION Set the language of the messages.
Language 0 4 languages are available.
Set Unit of working.
CONFIGURATION
0 = Metric
Eng.Unit 0
1 = Imperial
CONFIGURATION Set first level password
PW1 xxx It is active only if a password greater or equal to second level is active
CONFIGURATION Set second level password
PW2 xxx It is active only if a password greater or equal to third level is active

ATTACHMENT OPENING (ACTIVATE AN ATTACHMENT)

80

CONFIGURATION
Set second level password, then select the Tool Page by means of “+” and “-”
33 Tools
Press ENTER to display the first attachment of the list.
The first attachment is always Forks and it is always on.
TOOLS
Press “+” e “-“ buttons to select other attachments.
Forche 1
0 = Attachment OFF
1 = Attachment ON
TOOLS
Press ENTER to enable
ARGANO 3T 0
*
A star is shown above the digit to be modified.
ARGANO 3T 0
*
Press INDEX to move the star above the first digit at right as shown.
ARGANO 3T 0

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TRANSDUCERS CALIBRATION

The machine calibration is performed directly from cabin display.

The calibration procedures is accessible only setting the password with correct level.
That’s not indicate in the description, general and repetitive operations that are describe in an other
part of the manual.
The procedure to verify all the components are illustrate in the “Operator Panel” chapter.

OUTRIGGER CALIBRATION

Each outrigger have a CAN-BUS length transducer that must be calibrated in its close and open positions.
The picture show the pages from “calibration menu list” with the required commands

STABILITY
Calibration with outrigger fully closed
55 Outrigger In
STABILITY
Calibration with outrigger fully open
56 Outrigger Out

To acquire the fully closed position:

• Close completely the outriggers
• Display the page 55
• Push ENTER button to memorize the outriggers close position

To acquire the fully open position:

• Open completely the outriggers
• Display the page 56
• Push ENTER button to acquire the outriggers open position

ENCODER CALIBRATION

80
Task of Rotax is measure the angular rotation of the turret. It don’t require any calibration but only a
zeroing of positions.

STABILITY
57 Rotax

To acquire the zero position:

• Display page 57
• Align the turret and put in the pin
• Push ENTER to acquire the zero position

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CHASSIS LEVELLING SENSOR CALIBRATION

Task of levelling sensors ( ASA-CBO) is measure the inclination of the chassis in both directions longitudinal
and transversal. It is supplied already calibrated and the machine installation require only its zeroing.

STABILITY
58 Levelling

To acquire the zero position:

• Display page 58
• Move chassis in horizontal in both transversal and longitudinal directions.
• Push ENTER to acquire the zero position

ANGLE AND LENGHT CALIBRATION

On boom there is a cable-reel with double CAN-BUScard to read boom angle and length .
Angle necessitate only a zeroing. The Length require instead calibration in fully close and fully open
position,

TRANSDUCER
Boom length and angle calibrations with machine close.
12 Trasd Min
TRANSDUCER
Boom length calibration with machine open
13 Trasd Max

To set the machine close position:

• Close the boom and move it completely down.
• Display page 12
• Push ENTER to acquire the close position calibration

To set the machine open position:

• Open the boom and move it completely Up at the and of cylinder stroke,
• Display page 13
• Push ENTER to acquire the open position calibration
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LMI CALIBRATION PROCEDURE

This chapter describes the LMI calibration procedure of a machine that could be needed, after proper
verification, when a better accuracy is requested or when a pre-programmed accessory load table must
be activated.
The calibration is performed directly from the machine display.

In order the calibration steps are the following:

• Client configuration setting (language and Measure system)
• Attachments activation
• Transducer calibrations.
• Initialisation of Load Calibration
• Weight Corrections “no load applied”
• Weight corrections “under load.”

MECHANICAL ALIGNMENT OF ANGLE AND EXTENSION SENSORS

We suppose the mechanical alignment already done during movement calibration. Otherwise the
machine can’t move.

You can check angle and length transducers in the following pages:

Main Boom Cable Reel: Left Hand Transducer

P15 : Act1A Braccio Principale: ACT 1A

Main Boom Cable Reel: Left Hand Transducer
ACT1A A:aaaa A: angle transducer
ccc Eee L:ssss L: Length transducer
E: Error code from ACT1A

Main Boom Cable Reel: Right Hand Transducer

P16 : Act1B Braccio Principale: ACT 1B

80
Main Boom Cable Reel: Left Hand Transducer
ACT1B A:aaaa A: angle transducer
ccc Eee L:ssss L: Length transducer
E: Error code from ACT1B

(15/02/2013) 80-04-M205EN
 54 Electrical control and adjustment

Following a list of angle and length values in some control point.

Boom Angles ACT 1A ACT1B

Boom Close 0° 1800 1800
Boom Open 80°

Boom Length ACT 1A ACT1B

Boom Close
Boom Open

Jib Angle ACT 2A

Boom Close 0°
Boom Open 80°

Jib Length ACT 2A

Boom Close
Boom Open

EXTENSION AND ANGLE CALIBRATION

This operation consists in the automatic self calibration extension and angle sensors in boom in IN/
OUT and UP/DOWN conditions.

SENSORS SELF CALIBRATION AT CLOSED MACHINE CONDITIONS

Position the machine with boom and jib totally retracted.

By means of “+” and “-” keys look for the page indicated here
A00 S 6.8 W.0
Press ENTER and INDEX to confirm the calibration at “Machine closed” condition.
12 Trasd. Min
Check that the displayed angle and extension values are correct.
Afterwards, proceed to self calibration of sensors at “Open machine” condition.

SENSORS SELF CALIBRATION AT OPEN MACHINE CONDITIONS

Extend totally boom and Jib making sure that the two cylinders of raising and extension are at the end of their stroke. In
A00 S 6.8 W.0
this conditions angle and extension readings might correspond to the memorised ones. By means of “+” and “-” keys look
80

13 Trasd. Max
for the page indicated here. Press ENTER and INDEX to confirm the calibration at “Machine open” condition.

CALIBRATION PROCEDURE INITIALISATION

Following the load table activation of the accessory to be used, perform first of all a check of the
correspondence of the load weight reading on the display to some lifted loads with known weight.
If readings exceed the 10% tolerance, it is suggested to refine the calibration starting from this “Initialisation”:

A00 S 6.8 W.0 By means of + and – keys scroll on the menu here indicated.
26 INIT WEIGHT Press ENTER to enter the accessory configuration
A00 S 6.8 W.0
Press INDEX to confirm Initialisation = deleting of preceding calibration
Index to Confirm

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 Electrical control and adjustment 55

WEIGHT CALIBRATION WITH NO LOAD (Empty mode)

It is now recommended to check the load weight measurement and displaying with no load applied,
and, if out of allowed tolerance, perform a “refined calibration”.

Fourches
Install the accessory with outriggers on ground and turret centred. Select its relevant load table from the main page.
Stab. Frontale
Confirm by pressing the ENTER button

Calibration With Closed / Midde / Open Boom

A00 S 6.8 W.0
Display the command “20 Empty Static” and activate the procedure with ENTER
20 Empty
For Each boom Length position:
P100 W 5.0 M 5.0 position the boom completely lowered and look for correct angle calibration position indicated by “Ac” on display.
Ac 00 L20.3 R15.1
Press ENTER to perform the calibration
The indications shown are:
• W: current load.
Lft W .0 z XX • A: Angle.
A-5 L 6.8 s 0 • L: Boom length.
• Z: Correction empty.
• S: Correction under load.
P100 W 5.0 M 5.0 Move the boom to next correction point ( ie Ac 15, 30 a.s.o. degrees) .
Ac 15 L20.3 R15.1 For each point push ENTER key to perform calibration.

WEIGHT CALIBRATION WITH LOAD APPLIED

The weight under load can now be calibrated. At least 2 sample weights are needed, one near the
maximum value (e.g. 4 ton) and one which can be lifted with the boom almost completely extended
(e.g. 1 ton).

Setting the Known Load

A00 S 6.8 W 3.8
Display the command “21 Laden Act” and set the value of the known load
21 LadenAct 4.00
*
To set the value as normal, press ENTER to display the asterisk, then with INDEX position it on the
21 LadenAct 4.00
Calibration With Closed / Midde / Open Boom

80
A00 S 6.8 W 3.8
Display the command “22 Laden Static” and activate the procedure with ENTER
22 Laden
For Each boom Length position:
P100 W 4.0 M 5.0 position the boom completely lowered and look for correct angle calibration position indicated by “Ac” on display.
Ac 00 L 6.8 R15.1
Press ENTER to perform the calibration
The indications shown are:
• W: current load.
Lft W .0 z 00 • A: Angle.
A-5 L 6.8 s XX • L: Boom length.
• Z: Correction empty.
• S: Correction under load.
P100 W 4.0 M 5.0 Move the boom to next correction point ( ie Ac 15, 30 ecc degree) .
Ac 15 L 6.8 R15.1 For each point push ENTER key to perform calibration.

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 56 Electrical control and adjustment

DYNAMIC CORRECTIONS WITH NO LOAD APPLIED

The load will be corrected during the lifting and lowering movement to compensate for the increase
or the reduction of the weight in dynamic conditions respectively.

A 0 L 6.8 W0.0
Display this page and press ENTER
23 Empty Dynamic
A XX W XX.X
For correction up select the figure page and enable the correction with ENTER
Lifting XXX
W = current weight
A = current angle
“u” = (Up) up movement in progress
“d” = (Down) down movement in progress
AuXX WXX.X *
“c“ = (Centred) fixed angle points (*)
Lifting XXX
XXX = current correction
* = digit to be modified
Experimentally modify the value up or down until a good compromise is reached then confirm with ENTER.
Press ENTER to acquire the datum
A XX W XX.X
Proceed with the correction down (“+” and “-“ keys).Select the figure page and press ENTER
Lowering XXX
W = current weight
A = current angle
“u” = (Up) up movement in progress
“d” = (Down) down movement in progress
A XX WXX.X * “c“ = (Centred) fixed angle points (*)
Lowering XXX XXX = current correction
* = digit to be modified

Experimentally modify the value up or down until a good compromise is reached then confirm with ENTER.
Press ENTER to acquire the datum

DYNAMIC CORRECTIONS WITH LOAD APPLIED

With boom closed lift a known weight load and follow the following procedure which is equal to the
previous one (No load applied).

A 0 L 6.8 W0.0 Display this page and press ENTER

24 Laden Dynamic Procede as Empty dynamic procedure to perform corrections
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80-04-M205EN (15/02/2013)
 SPECIAL TOOLS FOR THE ELECTRICAL SYSTEM

page

DIAGNOSTICS KIT CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

WORKSHOP TROLLEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

80

(25/06/2012) 80-09-M205EN
 SPECIAL TOOLS FOR THE ELECTRICAL
2 SYSTEM

DIAGNOSTICS KIT CASE

80

80-09-M205EN (25/06/2012)
 SPECIAL TOOLS FOR THE ELECTRICAL
SYSTEM 3

12
11

10

5
9
13

6 8

7
1

3 4

80
Diagnostic kit case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 746120

Consisting of:

1. 1 Power cable with connector for cigarette lighter . . . . . . . . . . . . . . . . . . 745240

2. 1 Cable for red battery pliers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745241
3. 1 Cable for black battery pliers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745242
4. 1 Power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745243
5. 1 Cable for portable VCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745244
6. 1 Cable Diag OBD Manitou . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745245
7. 1 Cable Diag RC2/RC4 Manitou . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745246
8. 1 Mains cable CE standard L : 3m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745247
9. 1 Local power source Diag 3G 60W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745251
10. 1 Battery LI-ION 7.4V / 9.6AH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745367
11. 1 PAD (set PC for industrial use + case) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745438
12. 1 VCI (Vehicle Interface Communication/PAD) . . . . . . . . . . . . . . . . . . . . . . 745439
13. Styluses (set of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745368
(25/06/2012) 80-09-M205EN
 SPECIAL TOOLS FOR THE ELECTRICAL
4 SYSTEM

Docking station

Docking station (battery charger) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745236

WORKSHOP TROLLEY
80

Workshop trolley (trolley + station set) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745235

80-09-M205EN (25/06/2012)
 Driver's CAB

- Driver’s cab removal

- Driver’s cab refit

- Driver’s cab troubleshooting

85
 REMOVING THE DRIVER'S SEAT

page

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
REMOVING THE CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– REMOVING THE CAB GUARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– DISCONNECT THE CAB ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
–– REMOVING THE DISPLAY FROM THE DASHBOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
–– DISCONNECT THE CAB HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
–– REMOVING THE CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DISCONNECT THE AIR CONDITIONING FROM THE CAB (OPTIONAL) . . . . . . . . . . . . . . . . . 9

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 2 REMOVING THE DRIVER'S SEAT

REMOVING THE CAB

GENERAL INFORMATION

The sequence for disassembly operations must be followed to access the various components .
Mark all the hydraulic pipes and electrical connections with a marker pen, before disassembling, to
ensure correct positioning in the reassembly phase .

b
85

Plug all the hydraulic pipes and orifices to prevent impurities from contaminating the hydraulic
circuit.

PREPARATION AND SAFETY INSTRUCTIONS

Park the vehicle on a horizontal surface, resting the stabilizers on the ground to ensure utmost stability
and safety .

Specific tools:
– Crane for lifting (5000 kg . minimum) .

85-06-M205EN (03/09/2012)
 REMOVING THE DRIVER'S SEAT 3

4 REMOVING THE CAB

5
5

1
REMOVING THE CAB GUARD
3 2

Open the hood (ref. 1) on the back of the cab, slacken the screw
(Ref. 2) and the nut (Ref. 3) to free the tierods (Ref. 4).
Unscrew the screws which block the hood (Ref. 1) to the hinges
(Ref. 5) and remove the hood (Ref. 1) from the vehicle.

Remove the objects that obstruct access to the guard (Ref. 6),
step ladder, box and radio control.

Remove the guard (Ref. 6) from the vehicle after unscrewing

the fixing screws (Ref. 7) and the knob (Ref. 8).

8 6

7
7
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 4 REMOVING THE DRIVER'S SEAT

Remove the guard on the compartment from under the cab (Ref . 9), the guard on the power steering
(Ref . 10) and the front guard (Ref . 11) .

11
9

10

12
Disconnect the rotary beacon and emergency lamp (Ref . 12
and 13) from the cab .
13
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85-06-M205EN (03/09/2012)
 REMOVING THE DRIVER'S SEAT 5

DISCONNECT THE CAB ELECTRICAL SYSTEM

Disconnect all the connectors from control unit MC2M.

Disconnect the electrical bulkhead connectors under the cab

and disconnect the ground cable (Ref. 14).
Disconnect the connectors from the logic box.

14

Disconnect the electric connectors for connection to the chassis

line.

85

Remove all the clamps (Ref. 15) which secure the cables and
15 tubes of the electrical and hydraulic systems of the cab.

15

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 6 REMOVING THE DRIVER'S SEAT

REMOVING THE DISPLAY FROM THE DASHBOARD

Remove the display (Ref. 16) from the vehicle dashboard after
unscrewing the screws.

16

Disconnect the connectors (Ref. 17) from the back of the display.

17

DISCONNECT THE CAB HYDRAULIC SYSTEM

Disconnect the hydraulic pipes (Ref. 18) of the power steering.

18
85

Disconnect the hydraulic pipes (Ref. 19) from the brakes pump.

19

19 19

19

85-06-M205EN (03/09/2012)
 REMOVING THE DRIVER'S SEAT 7

Disconnect the hydraulic tube (Ref. 20) and the coils (Ref. 21)
of the slow/fast gear change solenoid valve.
21

21
20

Remove the cables of the brakes pump through the opening

in the power steering guard from under the cab.

REMOVING THE CAB

22
Fit the eyebolts (Ref. 22) on the cab and secure it to an overhead
crane by means of ropes and chains.

85

24
Disconnect the cable connector lug (Ref. 23) from the lever of
the rotation blocking pin (Ref. 24) from inside the cab.

23

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 8 REMOVING THE DRIVER'S SEAT

25

26

Remove the plastic guard (Rif. 25) on the back of the seat, to
access the nuts locking the rear cab supports, remove the mat
(Ref. 26) to access the nut which blocks the LH front cab support.
It may be necessary to remove or shift the burner duct (Ref.
27) or its bracket, to access the nut which blocks the RH front
cab support.

27

Unscrew the nuts (Ref. 28) and remove the vibration damper
supports (Ref. 29).

28
28

29 29
85

Unscrew the screws (Ref. 30) and remove the vibration damper
supports (Ref. 31).

31

30

85-06-M205EN (03/09/2012)
 REMOVING THE DRIVER'S SEAT 9

Disconnect the fuel oil pipe (Ref . 32) of the heater from the back
of the support plate .

32

Lift the cab slightly with the help of an overhead crane, check
to make sure no cables or hydraulic pipes are still connected
(disconnect these), then remove the cab from the vehicle and
place it on a horizontal surface or on a firm support that can
bear the cab weight .

1
2 DISCONNECT THE AIR CONDITIONING FROM THE
CAB (OPTIONAL)
3

If an air conditioning system is present on the vehicle, remove

it before dismantling the cab . Remove the rotary beacon and
the emergency lamp (Ref . 1 and 2), remove the guard (Ref . 3) of
the air conditioning radiators and the RH rear raceway (Ref . 4) .

4
85

Connect a station for emptying the gas system of the air

conditioning to the connectors (Ref . 5) .

5
5

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 10 REMOVING THE DRIVER'S SEAT

Disconnect the pipes (Ref . 6 and 7) from the air conditioner

radiators unit .

Remove the air conditioner unit (Ref . 8) .

The cab can now be removed .

8
85

85-06-M205EN (03/09/2012)
 REINSERTING THE DRIVER'S SEAT

page

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
REINSERTING THE CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– REPOSITIONING THE CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– RECONNECT THE CAB HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
–– RECONNECT THE CAB ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
–– REASSEMBLING THE CAB GUARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CONNECT THE AIR CONDITIONING ON THE CAB (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . 9

85

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 2 REINSERTING THE DRIVER'S SEAT

REINSERTING THE CAB

GENERAL INFORMATION

The sequence for disassembly operations must be followed to access the various components .
Reposition all the pipes and connections correctly according to the markings made with a marker pen
during the disassembly .

PREPARATION AND SAFETY INSTRUCTIONS

85

Park the vehicle on a horizontal surface, resting the stabilizers on the ground to ensure utmost stability
and safety .

Specific tools:
– Crane for lifting (5000 kg . minimum) .

85-07-M205EN (04/09/2012)
 REINSERTING THE DRIVER'S SEAT 3

REINSERTING THE CAB

REPOSITIONING THE CAB

Use chains and an overhead crane to reposition the cab on the

vehicle.

Connect the fuel oil pipe (Ref. 1) of the heater from the back of
the support plate on the outer front part of the cab.

85
Fit the vibration damper supports (Ref. 2) by tightening the
screws (Ref. 3).

(04/09/2012) 85-07-M205EN
 4 REINSERTING THE DRIVER'S SEAT

Fit the vibration damper supports (Ref. 4) using the nuts (Ref. 5).

5
5

4 4

Refit the burner duct (Ref. 6) or its bracket, which may have
been shifted in the assembly phase to access the nut locking
the RH front cab support.
Refit the plastic guard (Ref. 7) and the mat (Ref. 8).

8
85

Reconnect the cable connector lug (Ref. 9) on the lever of the

10 rotation blocking pin (Ref. 10) inside the cab.

85-07-M205EN (04/09/2012)
 REINSERTING THE DRIVER'S SEAT 5

Remove the eyebolts (Ref. 11) from the cab.

11

RECONNECT THE CAB HYDRAULIC SYSTEM

Insert the cables in the braking hydraulic system from under the
cab and draw them out through the opening of the guard on the
power steering from the front of the cab to the brakes pump.

Reconnect the hydraulic tube (Ref. 12) and the coils (Ref. 13)
on the slow/fast gear change solenoid valve.
13

13
12

85

Reconnect the hydraulic pipes (Ref. 14) on the brakes pump.

Proceed with bleeding the brakes:

14
(. 40 - BRAKES)
14 14

14

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 6 REINSERTING THE DRIVER'S SEAT

Reconnect the hydraulic pipes (Ref. 15) to the power steering.

15

RECONNECT THE CAB ELECTRICAL SYSTEM

Reconnect all the connectors (Ref. 16) on the back of the display
(Ref. 17).

16

Refit the display (Ref. 17) on the vehicle dashboard.

17
85

Reconnect the electric connectors for connection to the chassis

line.

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 REINSERTING THE DRIVER'S SEAT 7

Reconnect the electrical bulkhead connectors under the cab

and reconnect the ground cable (Ref . 18) .

18

Reconnect all the connectors of the control unit MC2M .

Gather all the electric cables and hydraulic pipes in groups,

securing them by means of clamps (Ref . 19) to make sure they
19 do not obstruct the rotation of the turret or get damaged during
the movements .

19

85

20

21 REASSEMBLING THE CAB GUARDS

Reconnect the rotary beacon and the emergency lamp (Ref . 20

and 21) on the cab .

(04/09/2012) 85-07-M205EN
 8 REINSERTING THE DRIVER'S SEAT

Refit the guard on the compartment under the cab (Ref. 22), the guard (Ref. 23) on the power steering
and the front guard (Ref. 24).
di copertura frontale.

22 24

23

Refit the guard (Ref. 25) fixing it in position by means of the

screws (Ref. 26) and the knob (Ref. 27).

27 25

26

26
26

Put the step ladder, box and radio control back in the housing
at the back of the cab.
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 REINSERTING THE DRIVER'S SEAT 9

Reposition the hood (Ref . 28) on the vehicle, fixing it by means

30
29
of the screws to the hinges (Ref . 29) .
29 Block the tierods (Ref . 30) on the hood by means of the screw
28 (Ref . 31) and the nut (Ref . 32) .
32 31

CONNECT THE AIR CONDITIONING ON THE CAB

(OPTIONAL)

1 After fitting the cab on the vehicle, reposition the air conditioning
unit (Ref . 1) on the cab with the help of an overhead crane .

Reconnect the pipes (Ref . 2 and 3) on the air conditioner radiators

unit .

3 85

6
7 Refit the guard (Ref . 4) of the air conditioner radiators and the RH
rear raceway (Ref . 5), refit the rotary beacon and the emergency
4 lamp (Ref . 6 and 7) .

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 10 REINSERTING THE DRIVER'S SEAT

Connect a station for filling the air conditioning gas system to

the connectors provided (Ref. 8) and fill the system with the
gas concerned:
8
8 ( . 110 - OPTIONAL - ACCESSORIES)
85

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 TROUBLESHOOTING IN THE DRIVER'S SEAT

page

HEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– UNIVERSAL CONNECTION TO DIAGNOSIS TESTER FOR ALL EBERSPÄCHER . . . . . . .
VERSIONI „C“-„C COMPACT“ - AIRTRONIC E HYDRONIC HEATERS . . . . . . . . . . . . . . . . . . . 4
–– AIR HEATERS FAULTS CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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 2 TROUBLESHOOTING IN THE DRIVER'S SEAT

HEATING

OPERATING INSTRUCTIONS

Order Number: Manitou Code 711231

The faults diagnosis equipment can be used for all Eberspächer AIRTRONIC e HYDRONIC heater
models including models “C”, “C compact” and “P” marketed earlier.

1 - Cancellation of faults saved in memory 6

2 - Cancellation of faults saved in memory
3 - Diagnosis request
4 - Back, faults F5 – F1, current (AF)
5 - Forwards, current fault (AF), F1 – F5
6 - Display

1 2 3 4 5

Display, after the connection

= intermittent flashing signal

After pressing the "D" key, the display shows

= intermittent flashing signal, and after about 8 seconds

= no fault present, or
85

= current fault (example: flame sensor interruption), or

= diagnosis not possible (incorrect connection or heater not

on)

85-08-M205EN (04/09/2012)
 TROUBLESHOOTING IN THE DRIVER'S SEAT 3

• SAVING THE FAULTS IN MEMORY

The control unit can save up to 5 faults in memory which are read by the diagnosis equipment and
then displayed. The current fault is saved in memory space F1. The faults saved previously in memory
are shifted to F5. If all the memory spaces are occupied, the memory space F5 will be overwritten.
• OVERHEATING
When 3 overheating faults occur in succession - fault 12/13 - AF 15 appears on the display; this
means the control unit is blocked.
• TOO MANY SWITCHING ON ATTEMPTS
When the heater makes 10 switching on attempts in succession - fault 52 - AF 50 appears on the
display; this means the control unit is blocked.
• CANCELLING THE FAULTS FROM MEMORY AND UNLOCKING THE CONTROL UNIT
Press the 2 keys "L" "L" simultaneously until the displays appears as shown below:

The control unit is unlocked and the faults saved in memory by F1 to F5 are cancelled.

NOTE_ The automatic block is not present in all the control units.

85

(04/09/2012) 85-08-M205EN
 4 TROUBLESHOOTING IN THE DRIVER'S SEAT

UNIVERSAL CONNECTION TO DIAGNOSIS TESTER FOR ALL EBERSPÄCHER

VERSIONI „C“-„C COMPACT“ - AIRTRONIC E HYDRONIC HEATERS

Connect 3 cables to 6-pin connector of diagnosis equipment (see Figure):

a) contact 1 (brown wire) - to negative

a) contact 5 (red wire) - to positive
c) contact 3 (blue/white wire) - to blue/white wire free of cable clamp (*)

(*) In models where the blue/white wire is connected to the control device, disconnect this wire from
the command and connect it to contact 3.
NOTE No fault is indicated if the wire is found to be connected to the control device as well as to contact
3 of the diagnosis equipment.

• SWITCH ON THE HEATER

When the "D" button is pressed the diagnosis tester display shows the current fault, consisting of
2 digits.

Blue-white (diagnosis)
Red
Brown
5
(negative)
Blue-White 3 1

Brown

Red + (positive)
85

85-08-M205EN (04/09/2012)
 TROUBLESHOOTING IN THE DRIVER'S SEAT 5

AIR HEATERS FAULTS CODES

Fault Fault description Causes/Remedies
000 Operation without faults. .....................
001 Overload. Overload problems, check regulator.
002 Undervoltage. Undervoltage problems, charge battery.
004 Fresh air signal output short circuit warning. Eliminate short circuit/overload.
005 Anti-theft system output short circuit warning. Eliminate short circuit/overload.
009 ADR switched off by means of D+ or PTO Check the ADR connecting cables.
Check the regulator.
010 Switched off because of overvoltage.
Check the alternator.
Check regulator and battery.
011 Switched off because of undervoltage.
Check the alternator.
012 Check for obstructions in the fresh air intake and hot air
Overheating - interruption to dosing pump.
013 outlet. Check the supply to the dosing pump and heating
Temperature on heat exchanger too high.
014 switch/sensor.
Excessive overheating. Eliminate the cause and unlock the
015 Operation block.
control unit by means of the diagnosis equipment.
017 Overheating (2a detection threshold). Check overheating sensor.
020 Spark plug interruption. Check, if necessary replace spark plug and/or spark
plug heating element, check the connecting cables and
contacts, check the connection to the spark plug relay.
021 Spark plug overload or short circuit. Check and replace the spark plug if necessary.
Defective spark plug relay.
022 Check and replace the spark plug relay, if necessary.
Short circuit on spark plug relay.
Check the connecting cables and contacts, check the
023 Voltage regulator: interruption on coil connection.
connection to the spark plug and then replace the voltage
024 Voltage regulator: short circuit to coil connection.
regulator, if necessary.
025 Exit from diagnosis system short circuit. Check connection at output from diagnosis system.
029/030 Electric motor does not work. Check the motor rpm, replace if necessary.
031/032 Relay for rpm variation not working. Check the relay for rpm variation and the printed circuit.
033 Irregularoties in motor rpm (outside tolerance limit). Check the connections to the electric motor.
035 Relay for reduced power, interruption to coil. Check/Replay relay.
036 Relay for reduced power, coil short circuit. Check cables and contacts.
038 Interruption of vehicle fan command relay. Check the cables and contacts, check the relay and replace,
039 Vehicle fan command relay short circuit. if necessary.
043 External components/dosing pump output short circuit. Eliminate short circuit/overload.
047 Dosing pump short circuit. Check and/or replace the dosing pump;
048 Dosing pump interruption. check the dosing pump and electric power supply.
The number of switching on attempts possible has been
exceeded. Check the fuel supply, exhaust pipe and suction
050 Operation block. pipe. Check the spark plug and replace, if necessary.
Unlock the control unit by means of the diagnosis
equipment.
Acknowledgement of flame defective already when lighted.
051 Check and replace the flame sensor if necessary.
Defective flame sensor.
85
No start up. Check fuel supply, suction and exhaust gases pipes; check
052
Safety time exceeded. and replace the spark plug if necessary.
Flame interruption: The heater is switched on (flame acknowledged) and
053 in the "power" phase signals flame interruption in one of the phases.
054 at "maximum" power Check fuel quantity/power supply and engine rpm.
055 at "medium" power If the combustion is OK, check and/or replace the flame
056 at "minimum" power sensor.
057 Flame sensor short circuit or connection inverted. Check the cable and contact to flame sensor.
058 Flame during washing. Check flame sensor.
Check the temperature sensor connector, check the
060 Temperature sensor interruption.
temperature sensor on the printed circuit and on the
061 Temperature sensor short circuit.
control unit and the supplementary one, if any.
062 Interruption at command device. Check the cable and contacts to the control device, replace
063 Command device short circuit. if necessary.

(04/09/2012) 85-08-M205EN
 6 TROUBLESHOOTING IN THE DRIVER'S SEAT

Fault Fault description Causes/Remedies

064 Flame sensor interruption. Check the connector on the flame sensor wiring.
065 Flame sensor short circuit. Check the flame sensor, replace, if necessary.
071 Interruption at overheating sensor. Check overheating sensor, replace, if necessary. Check the
072 Overheating sensor short circuit. connecting cables.
090 Occasional internal disturbance. Replace the control unit.
091 External voltage disturbances. Eliminate the cause.
092/093
Control unit defective. Replace the control unit.
094/097
Replace the control unit or use the supplementary
096 Control unit (internal temperature detection sensor defective).
temperature sensor.
255 Faults memory cancelled. ...................
85

85-08-M205EN (04/09/2012)
 Frame - Body

- Body removal

- Body refit

90
 REMOVING FROM THE CHASSIS

page

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
REMOVING THE TURRET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– DISCONNECT THE TURRET HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– DISASSEMBLING THE TURRET SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
–– REMOVING THE TURRET FROM THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REMOVING THE SLEWING RING BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

90

(04/09/2012) 90-06-M205EN
 2 REMOVING FROM THE CHASSIS

REMOVING THE TURRET AND SLEWING RING BEARING

GENERAL INFORMATION

The sequence for disassembly operations must be followed to access the various components.
Mark all the hydraulic pipes and electrical connections with a marker pen, before disassembling, to
ensure correct positioning in the reassembly phase.

bb Plug all the hydraulic pipes and orifices to prevent impurities from contaminating the hydraulic
circuit.

PREPARATION AND SAFETY INSTRUCTIONS

90

Park the vehicle on a horizontal surface, resting the stabilizers on the ground to ensure utmost stability
and safety.

Specific tools:
–– Crane for lifting (5000 kg. minimum).
–– Hydraulic control unit.

90-06-M205EN (04/09/2012)
 REMOVING FROM THE CHASSIS 3

REMOVING THE TURRET

Remove the boom from the vehicle: ( 50 - BOOM).

Remove the lift cylinders and compensation cylinders from the

turret: ( 70 - HYDRAULICS).

2 Remove the cab from the vehicle: ( 85 - DRIVER'S SEAT).

DISCONNECT THE TURRET HYDRAULIC SYSTEM

1
Disconnect the fuel oil pipe (Ref. 1) or, if necessary, remove the
tank (Ref. 2) from the bracket that supports it.

Unscrew the screws and nuts (Ref. 3 and 4) and remove the
plate (Ref. 5) which blocks the tubes bundle (Ref. 6).
4

4
3

Slacken the screws (Ref. 7) and remove the collars (Ref. 8).
90

7 7

8
8

(04/09/2012) 90-06-M205EN
 4 REMOVING FROM THE CHASSIS

Remove the connectors (Ref. 9) of the cylinder.

Disconnect the tubes (Ref. 10 and 11).

10

10

11

Disconnect all the hydraulic pipes from the directional control

valve, taking care to mark them with a marker pen before
disconnecting, to make reassembly easier.

Remove the pipes through the slot on the turret.

90

90-06-M205EN (04/09/2012)
 REMOVING FROM THE CHASSIS 5

DISASSEMBLING THE TURRET SENSORS

Slacken the screw and nut (Ref. 12 and 13) and remove the
12
bracket (Ref. 14)
which supports the slewing ring bearing centring sensor (Ref. 15).

13

15
14

Remove the micro switch (Rif. 16) for slewing ring bearing
locking pin presence.

16

Slacken the screw (Ref. 17) and remove the horn (Ref. 18).
17

18

20

Remove the support (Ref. 19) and the micro switch (Ref. 20) for
90

boom maximum ascent.

19

(04/09/2012) 90-06-M205EN
 6 REMOVING FROM THE CHASSIS

REMOVING THE TURRET FROM THE VEHICLE

Secure the turret to an overhead crane.

Slacken the screws (Ref. 21), from both sides of the shaft, and
remove the universal shaft (Ref. 22) from under the vehicle.

21

22

Remove the bracket (Ref. 23) to release the silencer (Ref. 24).

23

24

Remove the silencer (Ref. 24) from the vehicle.

24

Unscrew the lock nuts (Ref. 25) and nuts (Ref. 26).
90

25

26

90-06-M205EN (04/09/2012)
 REMOVING FROM THE CHASSIS 7

Using a hydraulic control unit, circulate oil inside the circuit,

to allow rotation of the reduction gear hub and thereby the
27
rotation of the slewing ring bearing.
28
Unscrew the screws (Ref. 28) which block the chassis to the
slewing ring bearing, through the hole provided (Ref. 27) on
the chassis; by means of the control unit, rotate the chassis just
enough to remove all the screws one at a time.

With the help of an overhead crane, remove the turret (Ref. 29)
from the vehicle, resting it on a horizontal surface, or on safe
supports capable of holding the weight.

29

90

(04/09/2012) 90-06-M205EN
 8 REMOVING FROM THE CHASSIS

REMOVING THE SLEWING RING BEARING

1
Slacken the screws (Ref. 1) which block the slewing ring bearing
(Ref. 2) to the vehicle chassis.

Insert two eyebolts (Ref. 3) on two holes, aligned at approximately

3 180°, of the slewing ring bearing (Rif. 2).
2

Lift the slewing ring bearing (Ref. 2) with the help of an overhead
crane and remove it from the chassis.
90

90-06-M205EN (04/09/2012)
 REINSERTION ON THE CHASSIS

page

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
REINSERTING THE SLEWING RING BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REINSERTING THE TURRET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
–– REINSERTING THE TURRET ON THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
–– REASSEMBLING THE TURRET SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
–– RECONNECT THE TURRET HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

90

(04/09/2012) 90-07-M205EN
 2 REINSERTION ON THE CHASSIS

REINSERTING THE TURRET AND SLEWING RING BEARING

GENERAL INFORMATION

The sequence for disassembly operations must be followed to access the various components.
Reposition all the pipes and connections correctly according to the markings made with a marker pen
during the disassembly.

PREPARATION AND SAFETY INSTRUCTIONS

Park the vehicle on a horizontal surface, resting the stabilizers on the ground to ensure utmost stability
and safety.
90

Specific tools:
–– Crane for lifting (5000 kg. minimum).
–– Hydraulic control unit.

90-07-M205EN (04/09/2012)
 REINSERTION ON THE CHASSIS 3

REINSERTING THE SLEWING RING BEARING

Clean the seat on the vehicle in which the new slewing ring
bearing is to be fitted.

Go over the threads of the holes for the slewing ring bearing
locking screws with a tap (Rif. 1).
1

Check to make sure the lower surface of the new slewing ring
bearing (Ref. 2) is clean and position the slewing ring bearing
on the vehicle with the help of an overhead crane.
90

(04/09/2012) 90-07-M205EN
 4 REINSERTION ON THE CHASSIS

While positioning the slewing ring bearing on the vehicle, take

care to ensure that the sides of the slewing ring bearing on
3 which the grease nipples (Ref. 3) are mounted, are to the RH
and LH of the base, to leave the grease nipples easily accessible.

The slewing ring bearing gear (Ref. 2) has three coloured

2
reference teeth (Ref. 4) which have greater tolerance and must
be inserted on the pinion (Ref. 5) of the rotation gear.
4

6 Remove the eyebolts (Ref. 6) from the slewing ring bearing.

2

Apply threadlocker Loctite on the screws (Ref. 7) and tighten

these by applying a 346 Nm tightening torque.
90

90-07-M205EN (04/09/2012)
 REINSERTION ON THE CHASSIS 5

The sequence for tightening the screws is cross-wise in relation

to the centre of the slewing ring bearing, which means one screw
must be tightened followed by that diametrically opposite, to
ensure that the slewing ring bearing is screwed uniformly on
the base.

90

(04/09/2012) 90-07-M205EN
 6 REINSERTION ON THE CHASSIS

REINSERTING THE TURRET

REINSERTING THE TURRET ON THE VEHICLE

Place the turret (Ref. 1) on the vehicle using ropes and an

overhead crane.

Refit the screws (Ref. 2) through the hole under the chassis.
Using a hydraulic control unit, rotate the chassis enough to be
2
able to access all the screws through the hole, one at a time.

Screw the nuts (Ref. 3) and the lock nuts (Ref. 4) to block the
screws (Ref. 2).
90

90-07-M205EN (04/09/2012)
 REINSERTION ON THE CHASSIS 7

Refit the silencer (Ref. 5) on the vehicle.

Refit the bracket (Ref. 6) to lock the silencer (Ref. 5).

Remove the ropes and free the turret from the overhead crane.
Refit the universal shaft (Ref. 7) under the vehicle, tightening
the screws (Ref. 8) on both sides.

7
90

(04/09/2012) 90-07-M205EN
 8 REINSERTION ON THE CHASSIS

REASSEMBLING THE TURRET SENSORS

10

Refit the support (Ref. 9) and the micro switch (Ref. 10) for boom
maximum ascent.
9

Refit the horn (Ref. 11) using the screw (Ref. 12).

12

11

Refit the slewing ring bearing locking pin presence sensor

"171" (Ref. 13).

13

Fit the slewing ring bearing centering sensor "151" (Ref. 14) on
the bracket (Ref. 15) and block the latter on the vehicle.
90

14

15

90-07-M205EN (04/09/2012)
 REINSERTION ON THE CHASSIS 9

RECONNECT THE TURRET HYDRAULIC SYSTEM

Insert the hydraulic pipes in the slot on the turret.

Reconnect all the hydraulic pipes on the directional control

valve, according to the markings made in the disassembly phase.

Reconnect the tubes (Ref. 16 and 17).

16

16

17

Refit the connectors (Ref. 18).

18
90

(04/09/2012) 90-07-M205EN
 10 REINSERTION ON THE CHASSIS

Refit the collars (Ref. 19) and tighten the screws (Ref. 20).

20
20

19
19

Block the tubes bundle (Ref. 21) with the plate (Ref. 22) by means
of the screws and nuts (Ref. 23 and 24).
24

23

21

22

23
24

Reconnect the fuel oil pipe (Ref. 25) on the tank (Ref. 26) or, if
the tank was removed, refit it on the bracket.

Refit the cab on the vehicle: ( 85 - DRIVER'S SEAT).

26
Refit the lift cylinders and compensation cylinders on the turret:
( 70 - HYDRAULICS).

Refit the boom on the vehicle: ( 50 - BOOM).

25
90

90-07-M205EN (04/09/2012)
 Options - Attachments

- Options - attachments
characteristics and specifications

- Options - attachments schematic

diagrams

- Options - attachments components

location

- Options - attachments control and

adjustment

110
 FEATURES AND TECHNICAL SPECIFICATIONS OF
OPTIONALS - ACCESSORIES

page

OPERATING PRINCIPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
DESCRIPTION OF THE WORKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FLUID CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DESCRIPTION OF THE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

110

(19/12/2012) 110-01-M205EN
 FEATURES AND TECHNICAL SPECIFICATIONS
2 OF OPTIONALS - ACCESSORIES

AIR CONDITIONER

OPERATING PRINCIPLE

OUTSIDE THE VEHICLE

(high pressure circuit)

Outside air
The
fluid is liquified

CONDENSER

Hot outside air High

temperature
FILTER
Purifies
and absorbs the liquid
COMPRESSOR

REGULATOR Suction
and compression

Outside air or recirculation air

EVAPORATOR

Expansion
of fluid and drop in The
temperature liquid evaporates

Cooled and dehumidified air

INSIDE THE VEHICLE CAB

(low pressure circuit)
110

110-01-M205EN (19/12/2012)
 Features and technical specifications
of optionals - accessories 3

DESCRIPTION OF THE WORKING

The air conditioning system reduces the ambient temperature inside the vehicle cab, removing and
dispersing the heat from inside towards the outside.
This heat exchange is made possible by using a coolant R134a, the properties of which make it possible
to obtain very low temperatures at low pressure in expansion and the other way around, very high
temperatures at medium pressure, by means of the compression process.

The properties of the fluid are used by following the cycle in a closed circuit the principle of which is:

Step 1: Compression
The fluid, in gaseous state at low pressure and low temperature, is sucked in and compressed by the
compressor (Ref. 1) which sends it, at high pressure and high temperature, to the condenser.

Step 2: Condensation
The fluid passes through the condenser (Ref. 2) to transmit its heat, by means of a fan, outside the vehicle.
When passing through the condenser, the fluid is liquified, maintaining a high temperature and high
pressure. It is then filtered in a dehydrator (or drier) (Ref. 3).

Step 3: Release
The fluid enters an expansion valve (Ref. 4) in which it is subjected to very great reduction of the pressure
and temperature, preserving the liquid state.

Step 4: Evaporation
The fluid flows through the evaporator (Ref. 5) to absorb heat from the air in the cab and vapourizes
while at the same time maintaining a low pressure and temperature.
The air from the cab, pushed by the engine fan, cools and loses humidity in contact with the evaporator.
The condensate from the air is then drained and discharged outside the vehicle.

The high and low pressure circuit is controlled by means of a HP and LP pressure switch (Ref. 6) fitted
directly on the drier filter.
Its safety functions are as follows:
Complete stop of the air conditioner if the pressure drops below 2 bar or exceeds 27 bar.

110

(19/12/2012) 110-01-M205EN
 FEATURES AND TECHNICAL SPECIFICATIONS
4 OF OPTIONALS - ACCESSORIES

FLUID CIRCUIT

5
4

– Fluid in gaseous state at high pressure and high temperature.

– Fluid in liquid state at high pressure and high temperature.
– Fluid in liquid state at low pressure and low temperature.
110

110-01-M205EN (19/12/2012)
 Features and technical specifications
of optionals - accessories 5

DESCRIPTION OF THE COMPONENTS

The compressor
The compressor (Ref. 1) is the organ which makes it possible to:
• convey the fluid through the suction circuit, in a gaseous state, from the evaporator at low pressure
and low temperature.
• compress the fluid and transmit it at high pressure and high temperature to the condenser.

The condenser
The condenser (Ref. 2) is a heat exchanger which transmits the heat recovered by the evaporator by
means of the fan to the outside and causes condensation of the fluid at high pressure.

The receiver (or drier) filter

The filter (Ref. 3) is the main protective element of the system. Its functions are as follows:
• To filter out solid particles, if any, carried by the fluid, as they could damage the compressor or block
the regulator.
• Dehumidify the fluid oil and protect the circuit elements from:
⇒⇒ corrosive agents,
⇒⇒ freezing of the moisture at the regulator outlet to prevent blocking of the system.
• Keep the fluid in the liquid state thereby forming a buffer tank to compensate for pressure variations,
if any. It thus contributes to absorbing pressure variation that may be generated by the compressor.

The “binary” pressure switch (Ref. 6)

Connected to the receiver filter, it is the safety element of the plant, and is sensitive to pressure variations.
It ensures safety of the system against very low pressure values or very high pressure values by acting
directly on the compressor clutch:
• Action against low pressures (<2 bar) because of lack of coolant, a leak or a block in the circuit downline.
• Action against high pressures (> 27 bar) because of incorrect cooling of the condenser, excess coolant
or a block in the circuit upline.

The expansion valve

The expansion valve (Ref. 4) is connected to the evaporator inlet.
• Expansion causes the pressure and temperature of the fluid to fall, thus cooling the air passing
through the evaporator.
• The flow is regulated in such a manner as to calibrate the amount of fluid to make sure it is completely
vapourized on coming out of the evaporator.

The evaporator
The evaporator (Ref. 5) is a heat exchanger provided with a valve and a fan.
The fan sucks in air (cold) through the evaporator, the moisture in the air condenses on the evaporator
fins, cools the air and pushes it out.
This heat exchange allows the coolant to evaporate at low pressure.

The antifreeze thermostat

The electric thermostat is connected to a probe fitted between two fins of the evaporator.
A temperature variation of the evaporator causes a variation in the thermostat setting resistance which
110

acts on the compressor clutch relay.

(19/12/2012) 110-01-M205EN
 Features and technical specifications
6 of optionals - accessories
110

110-01-M205EN (19/12/2012)
 OPTIONALS - ACCESSORIES DIAGRAMS

page

AIR CONDITIONING WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

–– FUSE BOX AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
POSITION OF THE COMPONENTS ON THE DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
WIRING DIAGRAMS BY FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
–– 1 - FUSE BOX AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
–– 2 - AIR CONDITIONING ELECTRIC WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

110

(18/12/2012) 110-02-M205EN
 2 OPTIONALS - ACCESSORIES DIAGRAMS

AIR CONDITIONING WIRING DIAGRAMS

FUSE BOX AND RELAYS

COMPONENTS
Ref. Description Position on the diagram
F1 Cab fan third speed fuse (30 A) G13
F2 Condenser fan 2 fuse (20 A) G12
F3 Condenser fan 1 fuse (20 A) G11
F4 Cab fan switch fuse (20A) G10
F5 Compressor solenoid valve fuse (7.5A) Q14
R1 Cab fan third speed relay (70 A) Q8
R2 Condenser fan 2 relay (40 A) O12
R3 Condenser fan 1 relay (40 A) K9
R4 Cab fan power supply disconnect relay (40 A) K12
R5 Air door relay (25 A) I13
R6 Cab fan switch relay (25 A) I10
R7 Compressor solenoid valve relay (25 A) I8
XA Fuse box connector A10
110

110-02-M205EN (18/12/2012)
 OPTIONALS - ACCESSORIES DIAGRAMS 3

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

XA
A

mm 400
C

20A

20A

20A

30A
F4

F3

F2

F1
G

I
R7 R6 R5

R3 R4

R2

O
F5 7.5A

R1
Q
110

(18/12/2012) 110-02-M205EN
 4 OPTIONALS - ACCESSORIES DIAGRAMS
110

110-02-M205EN (18/12/2012)
 OPTIONALS - ACCESSORIES DIAGRAMS 5

POSITION OF THE COMPONENTS ON THE DIAGRAMS

Component Diagram 1 Diagram 2
A/C √

EV1 √

EV2 √

EVC √

F1 √

F2 √

F3 √

F4 √

F5 √

IV √

PR √

PRT √

R1 √

R2 √

R3 √

R4 √

R5 √

R6 √

R7 √

RISC √

V1/2 √

V3 √

XA √ √

XB √

110

(18/12/2012) 110-02-M205EN
 6 OPTIONALS - ACCESSORIES DIAGRAMS

WIRING DIAGRAMS BY FUNCTIONS

1 - FUSE BOX AND RELAYS

COMPONENTS
Ref. Description Position on the diagram
F1 Cab fan third speed fuse (30 A) M8
F2 Condenser fan 2 fuse (20 A) M8
F3 Condenser fan 1 fuse (20 A) M7
F4 Cab fan switch fuse (20A) M6
F5 Compressor solenoid valve fuse (7.5A) M5
R1 Cab fan third speed relay (70 A) E16
R2 Condenser fan 2 relay (40 A) G16
R3 Condenser fan 1 relay (40 A) I16
R4 Cab fan power supply disconnect relay (40 A) O16
R5 Air door relay (25 A) M16
R6 Cab fan switch relay (25 A) K16
R7 Compressor solenoid valve relay (25 A) Q16
XA Fuse box connector A3
110

110-02-M205EN (18/12/2012)
 OPTIONALS - ACCESSORIES DIAGRAMS 7
DIAGRAM 1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

A XA
1

L
10
11
12
13
14
15
16
17
18
19

H
G
A

C
B

K
2
3
4
5
6
7
8
9

E
F

J
I
GN1.5
MN1.5

CR
S
SG
RH
N1.5

ZR
LG1.5

LR
Z

L4
V2.5

H2.5
R2.5
R2.5
R2.5
R2.5

A2.5
C

RH

L4
86 87a 87
R1
70 AMP.

85 30

L4nr1
N

MN1.5
G

LG
86 87a 87
R2
40 AMP.

85 30

M1.5
N

GN1.5
LG
I 86 87a 87
R3
40 AMP.

85 30
G1.5
N

V2.5
LG

86 87a 87
R6
25 AMP.
K

85 30
VN2.5
N
R2.5

R2.5

R2.5

R4
R

ZR
SG

86 87a 87
R5
7.5A

20A

20A

20A

30A

25 AMP.
F5

F4

F3

F2

F1

M
85 30
L4nr1
M1.5
G1.5
VN2.5
C

LR
H2.5
SG

86 87a 87
R4
40 AMP.

O 85 30
N

A2.5
C
S

86 87a 87
R7
25 AMP.

85 30
N

CR

Q
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 8 OPTIONALS - ACCESSORIES DIAGRAMS

2 - AIR CONDITIONING ELECTRIC WIRING

COMPONENTS
Ref. Description Position on the diagram
A/C Air conditioning switch I2
EV1 Electric fan 1 K2
EV2 Electric fan 2 M2
EVC Compressor solenoid valve A2
IV Fan switch G2
PR Pressure switch C2
PRT Air door C2
RISC Heater signal E2
V1/2 Cab fan second and third speed O4
V3 Cab fan third speed M4
XA Fuse box connector S15
XB Power supply connector S8
110

110-02-M205EN (18/12/2012)
 OPTIONALS - ACCESSORIES DIAGRAMS 9
DIAGRAM 2

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

N
A 2
EVC 1 CR

S
PR
2
1 SN

3 Z

PRT 1
2 N
ZR

RISC 1 SG

LR
10
N
9
8
A1.5
7
IV 6
5
RG1.5
RV1.5
4 A1.5
G 3
2 RH
1

LR
10
N
9
8
7
I H2.5
A/C 6
5 LR1.5
4
3
2 V2.5
LG1.5
1

N1.5
EV1
2
1 GN1.5

N1.5
EV2 2
1 MN1.5

L4
V3 A
B N4

O 1 LG
RV1.5
V1/2 2
3 RG1.5
SN
4

Q
MN1.5
GN1.5
LG1.5
LR1.5

LR1.5

N1.5
H2.5
A2.5
V2.5
R2.5
R2.5
R2.5
R2.5

110
RH
SG
CR

ZR
R4
R4

L4
N
N
N
N
N
N
N

Z
S
R
R
G

D
H

E
F

K
M
L

A
J

3
2
2

4
K

B
C

9
8

6
5
19
18
17
16
15
14
13
12
11
10
J

A
D
H
I

B
C
E
F

1
L
1
N

S XB XA

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 10 OPTIONALS - ACCESSORIES DIAGRAMS
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COMPONENTS

page

POSITION OF AIR CONDITIONING COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

POSITION OF AIR CONDITIONING CONNECTORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
– POSITION OF AIR CONDITIONING CONNECTORS ON DIAGRAM . . . . . . . . . . . . . . . . . . 5

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2 ACCESSORIES COMPONENTS
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 POSITION OF THE OPTIONALS -
ACCESSORIES COMPONENTS 3
POSITION OF AIR CONDITIONING COMPONENTS

90°

90°

Hydraulic
pump
Condenser kit

Compressor

Relief valve
Heater

Evaporator

Pump
reduction gear
Hydraulic
pump

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 POSITION OF THE OPTIONALS -
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POSITION OF AIR CONDITIONING CONNECTORS

COMPONENTS
Ref. Description Position on the diagram
A/C Air conditioning switch O7
EV1 Electric fan 1 E33
EV2 Electric fan 2 G36
EVC Compressor solenoid valve G25
IV Fan switch M7
PR Pressure switch G37
PRT Air door G7
RISC Heater signal Q7
V1/2 Cab fan second and third speed K4
V3 Cab fan third speed I4
XA Fuse box connector M18
XB Power supply connector M25
110

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 POSITION OF THE OPTIONALS -
ACCESSORIES COMPONENTS 5
POSITION OF AIR CONDITIONING CONNECTORS ON DIAGRAM

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

C C

E EV1 E

EV2
PRT

G G
EVC
PR

V3
I I

V1/2

K K

IV

M M

XA XB

O O
A/C

RISC

Q Q

110
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page

INSTRUCTIONS FOR ASSEMBLING THE AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . 2

FEATURES OF COOLANT R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PRECAUTIONS FOR HANDLING R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FILLING COOLANT IN THE AIR CONDITIONING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FILLING METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CHECKING THE WORKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
–– AIR CONDITIONER CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
–– ADJUSTING THE AIR CONDITIONING PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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AIR CONDITIONER

INSTRUCTIONS FOR ASSEMBLING THE AIR CONDITIONER

Carry out the assembling operations in a dry, dust-free area. Use PAG ISO 100 SP 20 COMPRESSOR oil
for lubricating all the gaskets and sealing surfaces before assembly.

Description Type Tightening torque

Condenser outlet - filter inlet pipe M6 16 N.m
Filter outlet - expansion valve inlet pipe M6 16 N.m
Compressor outlet - cab inlet pipe M8 25 N.m
Cab outlet - condenser inlet pipe M8 25 N.m
Expansion valve outlet - cab inlet pipe M10 33 N.m
Cab outlet - compressor inlet pipe M10 33 N.m

Compressor connection:

Legend:

1 - Compressor
2 - Cab outlet/compressor inlet pipe
3
3 - Compressor outlet/cab inlet pipe

1
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Connection to mixer valve:

Legend:

1 - Feed pipe
2 - Mixer valve
3 - Return pipe

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FEATURES OF COOLANT R134a

Description Hydrofluorocarbon
Use Coolant
Chemical features Tetrafluoroethane 134a
Chemical formula CH2F-CF3
Physical state Liquified gas
Colour Colourless
Odour Slightly ethereal
Boiling point (at atmospheric pressure) - 26.5 ℃
Melting point - 101 °C
Density at 25°C 1.21 kg/l
Critical pressure 40.7 bar
Critical temperature + 101 °C
Weight in vapour state 5 times heavier than air
1 kg in liquid state less than 1 bar 200 l in gaseous state
Solubility of water in product 0.097% in weight
Thermal decomposition Starting from 110 °C
Hazardous decomposition products Halides of hydrogen and traces of carbonyl halides
Hazardous reactions With alkaline metals and alkaline-earth metal salts in powder form (Al-Zn-
Be …)
Flash point Non-flammable (very stable)
Ignition temperature Above 75 °C
Explosiveness limit less than or more than none
Ozone depletion potential None, ODP=0

PRECAUTIONS FOR HANDLING R134a

1 - Personal protection: Safety goggles and rubber gloves.

2 - First aid: In case of inhalation remove immediately to fresh air, administer oxygen and give artificial
respiration depending on the degree of the emergency (do not administer drugs). Get medical
attention. In case of contact with eyes, flush eyes with plenty of water for 15 minutes and get
medical attention. In case of contact with the skin, flush with plenty of clean water and remove
contaminated clothing.

3 - Storage conditions: Store the R134a liquid in a cool, dry well-ventilated place.

4 - Handling: Only in well-ventilated places.

5 - Accidental release measures: In case of exposure of liquid R134a to fire, wear breathing apparatus.
110

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FILLING COOLANT IN THE AIR CONDITIONING SYSTEM

Coolant: R134a
Refilling equipment: Refilling station
Quantity of fluid: 1000 gr ± 50 gr
PAG ISO 100 SP20 Oil: No oil must be added. Just check to make sure the compressor
contains 135 ml of oil.

FILLING METHOD

Before using a filling station, consult the relevant user handbook for the device.

Filling liquid in the circuit for the first time (duration 56 minutes)

1 - Connection of station to circuit (about 1 minute).

2 - Generation of vacuum in fluid circuit (minimum 45 minutes).
• Reach vacuum pressure - 0.75 bar in 10 minutes at the most,
• Maintain the vacuum pressure - 0.99 bar max dehumidification for at least 30 minutes,
• Checking for leaks, at least 5 minutes.
3 - Filling operation (maximum 10 minutes).

Filling liquid after an operation (duration 90 minutes)

1 - Preparation (approx. 15 minutes).

• Connect the station to the circuit.
• Run the engine at 800 to 1200rpm.
• At the same time start up the air conditioner at maximum speed.
• Switch the vehicle off after 10 or 15 minutes.
2 - Recovery (approx. 15 minutes).
Has the purpose of recovering and recycling gas, oil and impurities present in the circuit.
Carry out the fluid recovery cycle from the station.
3 - Wait for 3 to 4 minutes to allow recovery of micro-freezing of oil and moisture.
4 - Bleed the recovered oil (about 1 minute).
5 - Steps 1, 2 and 3 can be repeated if pressure formation is noticed during steps 2 and 3.
6 - Generation of vacuum in fluid circuit (minimum 45 minutes).
• Reach vacuum pressure - -0.75 bar in 10 minutes or less,
• Maintain the vacuum pressure - 0.99 bar max dehumidification for at least 30 minutes,
• Checking for leaks, at least 5 minutes.
7 - Filling operation (maximum 10 minutes).
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Excess liquids (duration 15 minutes) with the vehicle engine running

1 - Preparation (approx. 10 minutes).

–– Connect the station to the circuit.
–– Run the engine at 800 to 1200rpm.
–– At the same time start up the air conditioner at maximum speed.
2 - Additional filling (approx. 5 minutes).

bb In the open air, liquid R134a is a colourless odourless gas heavier than air and in certain conditions
it can be hazardous for humans. Always recover the coolant from the refilling station.

CHECKING THE WORKING

The following checks must be performed with the vehicle engine switched on.

AIR CONDITIONER CONTROLS

bb The air conditioner works only when the telescopic lift is started up. With the air conditioner
running, always work with the doors and windows closed.
In winter: To ensure the correct working and complete efficacy of the air conditioning system,
start up the compressor once a week, even if it is only for short periods, to allow lubrication of
the internal gaskets. At low temperatures: Heat the engine before starting up the
compressor to allow the coolant in the liquid state, collected at the bottom of the compressor
circuit, to get transformed into gas under the action of the heat given out by the engine; in the
liquid state the coolant can damage the compressor.

bb If the air conditioner is not working properly, have it checked by your dealer (see: 3 - MAINTENANCE:
F - EVERY 2000 HOURS OF OPERATION). Never attempt to repair faults yourself.
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A - Control unit

A Legend of functions:

1 - Decrease internal temperature

2 - Increase internal temperature
3 - Temperature indicator setting
4 - Indicator for 1a fan speed
5 - Indicator for 2a fan speed
6 - Indicator for 3a fan speed
3
7 - Fan speed increase command
8 - Fan speed decrease command
2 7 9 - Internal air temperature sensor
10 - °C / °F conversion and vice versa
1 8 11 - External temperature reading command
4 5 6
12 - Recirculation command
9
13 - Compressor exclusion
14 - Automatic function reset

14 13 12 11 10

To switch off the unit, press the «Fan speed reduction command» button (Ref. 8) to deactivate the fan
completely; to switch it back on again, press the «Fan speed increase command» button (Ref. 7).

ERROR CODES

In case of a fault that affects the automatic regulation, the control unit displays an error code consisting
of the letter E followed by a number which identifies the type of fault according to the following Table::

E 1 external air temperature sensor (E.T.) interrupted.

E 2 external air temperature sensor (E.T.) short circuit.
E 3 cab air temperature sensor (I.T.) interrupted.
E 4 cab air temperature sensor (I.T.) short circuit.
E 5 mixed air temperature sensor (M.T.) interrupted.
E 6 mixed air temperature sensor (M.T.) short circuit.

Since automatic regulation is not possible, the keys for increasing and decreasing the internal temperature
are used to change the position of the mixer, while the fan speed is fixed at the 2a speed.

If the error is solved, the control unit resumes normal operation only after resetting the + key.
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AIRCONDITIONING PLANT – CHECKING THE WORKING

Electronic control of the temperature (E.AC.C.)

To check to ensure the correct working of the heating and cooling system, make sure the engine is
started up with the hoods closed, at ambient temperature between +15°C and 30°C and the engine
cooling fluid sufficiently hot.
If the ambient temperature is higher or lower than these values, the system automatically adjusts itself
in the maximum cooling or maximum heating conditions.

1 - Checking the water regulator valve

Press the cab internal temperature increase/decrease button, the water regulator valve shifts to the
maximum heating HI or maximum cooling LO condition.
Make sure the mixed air temperature changes accordingly.

2 - Checking the mixed air temperature sensor

If the sensor is defective, the following error codes appear on the display:
E5 = Mixed air temperature sensor (MT) open.
E6 = Mixed air temperature sensor (MT) short circuit.

3 - Checking the cab internal air temperature sensor

If the sensor is defective, the following error codes appear on the display:
E3 = Internal air temperature sensor (IT) open.
E4 = Internal air temperature sensor (IT) short circuit.

4 - Operating the compressor

On pressing the ECON button, the relative LED lights up and switches off alternately and the compressor
is activated and deactivated, respectively, by means of the electromagnetic clutch.

5 - External air inlet and recirculation command

On pressing the Recirculation button, the relative LED lights up indicating the condition of ventilation
with recirculating air. On pressing the recirculation button again, the LED switches off indicating the
condition of ventilation with external air inlet.

6 - Fan speed command

The cab ventilation can be adjusted at three fan speeds: minimum, medium and maximum.

7 - °C and °F selection
When the relative LED is Off, the temperature is indicated in °C , when the LED is On the temperature
is read in °F (Fahrenheit).
The maximum cab temperature value setting is 37°C or 99°F.

8 - External temperature sensor connector

On pressing the external temperature button (Ref. 11), the external temperature value appears on the
display.
If the sensor is defective, the following error codes appear on the display:
E1 = External air temperature sensor (ET) open.
E2 = External air temperature sensor (ET) short circuit.
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ADJUSTING THE AIR CONDITIONING PRESSURES

Remove the caps (Ref. 1 and 2) on the compressor connections

3
(Ref. 3).
1
Connect the high pressure and low pressure pipes of the refilling
station on the compressor (Ref. 3).

• Start up the vehicle engine.

• Switch on the air conditioner as follows:
–– Select air diffusion speed "I" by means of the fan knob.
–– Press the air conditioning switch so that the LED lights up.
–– Adjust the temperature regulation knob to maximum cold
–– Open all the diffuser spouts.
–– Set minimum speed (approx. 800 rpm)
–– Wait for at least 5 minutes to allow the circuit to stabilize.
–– Check the low pressure LP and high pressure HP values of the circuit to make sure they are
between:

• 0.5 bar and 2 bar in low pressure LP,

• 6 bar and 20 bar in high pressure HP,

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Examples:

LP=0.8 bar and HP=12.5 bar.

LP=1.4 bar and HP=15 bar.

Note:
These values are indicative and may change according to the ambient temperature and the type of
vehicle.
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page

ASSEMBLING THE AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

–– GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– ASSEMBLING THE AIR CONDITIONING IN THE CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– ASSEMBLING THE AIR CONDITIONING DRIVE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
–– ASSEMBLING THE AIR CONDITIONING HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . 6
–– INSPECTIONS AND CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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ASSEMBLING THE AIR CONDITIONING

90°

90°

GENERAL INFORMATION

The sequence for disassembly operations must be followed to access the various components .

PREPARATION AND SAFETY INSTRUCTIONS

Park the vehicle on a horizontal surface, resting the stabilizers on the ground to ensure utmost stability
and safety .
110

Specific tools:
- Crane for lifting (5000 kg . minimum) .

110-07-M205EN (19/12/2012)
 REINSERTING THE OPTIONALS -
ACCESSORIES 3

ASSEMBLING THE AIR CONDITIONING IN THE CAB

Fit the heater (Ref. 1) on its support (Ref. 2).

2

Fit the 3-way duct (Ref. 3) on the support (Ref. 2) using the
screws (Ref. 4).
6 Fit the air pipe (Ref. 5) on the heater (Ref. 1) and on the 3-way
duct (Ref. 3), blocking it using the clamps (Ref. 6).

3
4

6
1

Fix the evaporator support (Ref. 7) on the vehicle cab using the
screws and washers (Ref. 8, 9 and 10).

9
10
8

Fit the edge trim seal (Ref. 11) on the support (Ref. 7).
11
Fit the evaporator (Ref. 12) on the support (Ref. 7) by means of
the screws and washers (Ref. 13 and 14) and the nut (Ref. 15).

12
110

15
13
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Fit the air pipe (Ref. 16) on the evaporator (Ref. 12) and on the
17
3-way duct (Ref. 3), blocking it by means of the clamps
(Ref. 17).

16

3 17 12

Fit the hydraulic pipe (Ref. 18) on the pump (Ref. 19).
19

18

Fit the LH (Ref. 20) and RH (Ref. 21) supports on the condenser
kit (Ref. 22) by means of the screws and washers (Ref. 23 and 24).
27 Fit the kit (Ref. 22) on the top of the cab, blocking it by means
26
25 of the screws and washers (Ref. 25, 26 and 27).

24

23
20 21

22

Fit the bottom grille (Ref. 28) using the screws and washers
(Ref. 29 and 30), fit the LH spotlight cover (Ref. 31) and RH
35
31 spotlight cover (Ref. 32) by means of the screws and washers
36
(Ref. 33 and 34).
37 30 33
38
29
34
Fit the upper hood (Ref. 35) using the screws and washers
(Rif. 36, 37 and 38).
32
110

28

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43 44
Fit the support for the electric sockets (Ref. 39) on the vehicle
by means of the screw (Ref. 40), the washer (Ref. 41) and the
nut (Ref. 42).
Fit the rotary beacon (Ref. 43) and the emergency lamp
39 (Ref. 44), connect the electric sockets (Ref. 45).
45 40
41
42

46
Connect the electric cables (Ref. 46).

49 Fit the raceway (Ref. 47) on the support (Ref. 48) by means of
48 the screws and washers (Ref. 49 and 50).
50

47

1
ASSEMBLING THE AIR CONDITIONING DRIVE
UNIT

Fit the compressor pump gearmotor on the base by means of

the screws and washers (Ref. 2 and 3).
110

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Fit the compressor (Ref. 4) on the reduction gear (Ref. 1) blocking

it by means of the screws (Ref. 5) and the washers (Ref. 6) and
the hydraulic pump (Ref. 7)
by means of the screws (Ref. 8).
1

4 5 6 7

Fix the solenoid valve (Ref. 9) on the reduction gear (Ref. 1) by

9
means of the screws and washers (Ref. 10 and 11).
10

11

2
1 ASSEMBLING THE AIR CONDITIONING
HYDRAULIC SYSTEM
3

Fit on the exhaust manifold (Ref. 1), the washer (Ref. 2) and the
reducer (Ref. 3), fitting the hose-connector
4
5
6 (Ref. 4) on which the tube (Ref. 5) will be fitted; secure the tube
by means of the clamp (Ref. 6).

8 Fit the edge trim seal (Ref. 7) on the base to avoid wear of the
tube due to rubbing on the base.
Secure the tube on the motor by means of the clamp (Ref. 8)
9 and the screw (Ref. 9).
7
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11 Fit connectors (Ref. 11, 12, 13, 14 and 15) on the exhaust valve
12
(Ref. 10).
Block the hose (Ref. 16) on the base by means of the clamp
10 (Ref. 17)
13
the screws and washers (Ref. 18 and 19).
14

18 19
15

17
16

24 26 23
25 Fit the exhaust valve (Ref. 10) on the support (Ref. 23) locking it
20 by means of the screws and washers (Ref. 20, 21 and 22).
10
21
22 Fit the support (Ref. 23) on the base by means of the screws
and washers (Ref. 24, 25 and 26).

Fit the connector (Ref. 27) on the exhaust manifold (Ref. 28).

28

27

31 Fit the connectors (Ref. 29 and 30) on the hydraulic manifold

29 (Ref. 31).
110

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Connect the tubes (Ref. 32) on the condenser kit and (Ref. 33)
on the condenser filter.

33

32

Connect the pipes (Ref. 34 and 35) on the evaporator.

35

34

Connect all the hydraulic pipes (Ref. 36) on the hydraulic pump
and on the solenoid valve.

36 36

36

36

Connect the tubes on the compressor connectors (Ref. 13).

37

37
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INSPECTIONS AND CHECKS

After the kit assembly operations are complete, proceed as follows:

1. Carry out the operations for filling and topping up oil in the compressor of the system by following
the indications given below:

The quantity of R134a gas required for filling the systems is 1000 g.
Simultaneously with the filling operation, add to the system circuit 134 ml. of oil specially meant for
the SANDEN compressor installed.
Oil code: PAG SP20 - to be obtained from DELPHY products dealers and sales outlets.

2. Checking the hydraulic circuit pressure and the number of compressor rotations:

The hydraulic circuit pressure at maximum I.C. engine speed must be 200 bar (the pressure can be
adjusted by means of the VLP valve by connecting a pressure guage to the pressure plug present on
the “T” union of the valve).
Check the compressor rotation to make sure that, at the minimum I.C. engine speed, it is between 900
- 1000 rpm (check the rpm by means of the speed counter).
Optimum working of the air conditioning system is obtained with a compressor rotation of 3500 rpm
with the I.C. engine running at maximum speed, with a hydraulic circuit pressure of 170 bar.

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(19/12/2012) 110-07-M205EN
 REINSERTING THE OPTIONALS -
10 ACCESSORIES
110

110-07-M205EN (19/12/2012)