REPAIR MANUAL

MANUEL DE RÉPARATION
REPARATURANLEITUNG
MANUAL DE REPARACIÓN
MANUALE RIPARAZIONE

This document has been printed from my e doc

MANITOU BF
Head office: 430, Rue de l’Aubinière
44150 Ancenis - FRANCE
Share capital: 39,548,949 euros
857 802 508 RCS Nantes
Tel: +33 (0)2 40 09 10 11
www.manitou.com
La présente brochure n’est fournie qu’à titre consultatif, toute reproduction, copie, représentation, captation, cession, distribution, ou
autre, partiellement ou en totalité, sous quelque format que ce soit est interdite. Les schémas, les dessins, les vues, les commentaires
les indications, l’organisation même du document qui sont rapportés dans la présente documentation, sont la propriété intellectuelle
de MANITOU BF. Toute infraction à ce qui précède est susceptible d’entraîner des condamnations civiles et pénales. Les logos ainsi que
l’identité visuelle de l’entreprise sont la propriété de MANITOU BF et ne peuvent être utilisés sans autorisation exprès et formelle. Tous
droits réservés.

This manual is for information purposes only. Any reproduction, copy, representation, recording, transfer, distribution, or other, in part
or in whole, in any format is prohibited. The plans, designs, views, commentaries and instructions, even the document organization
that are found in this document, are the intellectual property of MANITOU BF. Any violation of the aforementioned may lead to civil
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diritti sono riservati.
 Contents

GENERAL INSTRUCTIONS AND SAFETY NOTICE

Group 00 (General characteristics and safety) 1-1

ENGINE
Group 10 (Engine) 2-1

OPTIONS - ACCESSORIES
Group 110 (Options - Attachments) 3-1

TRANSMISSION
Group 20 (Transmission) 4-1

AXLE ASSEMBLY - AXLE

Group 30 (Axle) 5-1

BRAKE
Group 40 (Brake) 6-1

TELESCOPIC BOOM
Group 50 (Boom) 7-1

HYDRAULIC
Group 70 (Hydraulic) 8-1

ELECTRICITY
Group 80 (Electricity) 9-1
 00
GENERAL

- GENERAL INSTRUCTIONS AND SAFETY

NOTICE
 00
GENERAL INSTRUCTIONS AND SAFETY NOTICE

pages

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

(11/06/2011) 00-M153EN
 2 General instructions and safety notice
00

PREAMBLE

This chapter deals with the general instructions and safety notice during inspection and mainte-
nance 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.
There is a manual in each truck
- Follow the safety manual instructions.
- Use the adequate tools for all work.
- 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 instruc-
tions 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-M153EN (11/06/2011)
 General instructions and safety notice 3

00
MAINTENANCE POSITION

2 4

1 3

Before any repair:

1 – Place the machine on a flat surface and block the wheels.
2 – Turn the engine off and take the key out of the ignition switch.
3 – Let the machine cool down.
4 – Take all the pressure out of the circuits concerned.

(11/06/2011) 00-M153EN
 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.

2 Before carrying out any operation on an electrically powered

component, activate the battery cut-off. If the forklift truck
is not equipped with battery cut-off, disconnect the battery
connectors and gather them.

Before carrying out any welding operations, think of

disconnecting computers.

ECU

A machine operating in a contaminated environment should be

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

00-M153EN (11/06/2011)
 General instructions and safety notice 5

00
Never step on a part of the machine that has not been desi-
gned 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 ob-

ject, make sure it is securitized.

When changing, or draining oils or fuel, or any other opera-

tion with liquids, solids, gases that are harmful to the envi-
ronment, make sure the necessary precautions are taken to
avoid contaminating the environment.

(11/06/2011) 00-M153EN
 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 positio-
ned 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.
Never adjust a component to over the maximum capacity indi-
cated by the manufacturer.
MAX

MIN
00-M153EN (11/06/2011)
 ENGINE

10
- ENGINE CHARACTERISTICS AND
SPECIFICATIONS

- ENGINE CONTROL AND ADJUSTEMENT

M
R
- ENGINE CHARACTERISTICS AND 647016EN
SPECIFICATIONS
(Engine 1104 D Euro 3
- ENGINE CONTROL AND ADJUSTEMENT 80 & 100 CV )
M
R
647017EN

(Engine 1104 D Euro 3

120 CV)
 10
ENGINE CHARACTERISTICS AND
SPECIFICATIONS

pages
ELECTRONIC CONTROL MODULE ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– DEFINITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– REAR CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– ELECTRICAL SUPPLY AND PIN-OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SENSOR AND PROBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ENGINE EARTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
LOW PRESSURE FUEL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
HIGH PRESSURE FUEL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

(26/05/2011) 10-01-M153EN
 2 Engine characteristics and
specifications

ELECTRONIC CONTROL MODULE ECM

DEFINITION
10

The electronic control module (ECM) (1) is the regulator and computer for the fuel circuit. The ECM
receives signals from the sensors to control the engine’s tuning and operating mode.
The electronic circuit is made up of the ECM, sensors on the engine and inputs from the whole
of the machine. The ECM is the computer. The personalization module is the computer software.
The personalization module contains the performance curves.

The performance curves define the following characteristics of the engine:

• Engine power
• Torque curves
• Engine speed (rpm)
• Engine noise
• Exhaust and emissions

Electronic control module (ECM)

J1

J2

REAR CONNECTOR

25 26 27 28 29 30 31 32 57 58 59 60 61 62 63 64

7mm
17 18 19 20 21 22 23 24 49 50 51 52 53 54 55 56
9 10 11 12 13 14 15 16 41 42 43 44 45 46 47 48

1 2 3 4 5 6 7 8 33 34 35 36 37 38 39 40

10-01-M153EN (26/05/2011)
 Engine characteristics and 3
specifications

10

(26/05/2011) 10-01-M153EN
 (26/05/2011)
R10
A5

canale analogique 28 27
1
+ ep:5
p
8
1K
K 4
19 11
- 2
9
canale IVS 6 ep:4
p
- N

Y18
Y16

Y21
Y19
Y17
5

B11
B7

B8
+

31
ep:2
p + 3
22 23 21 24 20 20
A4
F34

32 33 34 35 30 29
7 8 15 16 43 45 33 54 41 62 22 20 21 46 55 38 48 51 40 47 56 39 35 57 7 63 8 64 34 58 19 17
51 Bat+ Bat+ Bat+ Bat+ +8V val 0V sig +5V phm CAN S CAN H CAN L 5V p air m 5V p comb m 5V p hui m m inj 1 m inj 2 m inj 3 m inj 4 m dech

J1

J2
M1

Bat- Bat- Bat- Bat- Bat- + ap cont prech ent sort ent stop war prech t∞ eau alim t∞ air v mot 8V vit pompe inj sol m J1939+
+J1939- cdl- cdl+ batt- batt+
1 2 3 9 10 40 57 44 35 38 60 59 63 43 37 42 52 10 53 25 26 24 23 20 21 45 18
19
37 38 41 39 40 26 52 50 35 43 18 14 12 W
G1 T T W A
N N N C C
Engine characteristics and

ep:3
p
W
P 21 6 24
W C
ELECTRICAL SUPPLY AND PIN-OUT

36

Y20
Z Z Z

S32

B10
W

S24
D

B9
-
4 5 17 16 25 49
W E
specifications

ep:1

S5
K16
N N N 2
W F
N 44
225 10 22 11 N 48
ep:6
p

R9

V18
V16

V17
J

10-01-M153EN
4
10
 Engine characteristics and 5
specifications

KEY

- Negative power supply

10
+ Positive power supply
A5 Power control sensor
MCS module
B7 Air pressure sensor
B8 Fuel pressure sensor
B9 Primary speed sensor (engine flywheel)
B10 Secondary speed sensor (injection pump)
B11 Oil pressure sensor
K16 Preheating
R9 Water in diesel fuel sensor
S5 Air filter clogging
S24 Air temperature sensor
S32 Water temperature sensor
V16 Red engine fault warning led
V17 Orange engine fault warning led
V18 Orange engine pre-heating indicator led
Y16 Electronic injector 1
Y17 Electronic injector 2
Y18 Electronic injector 3
Y19 Electronic injector 4
Y20 Injection pump solenoid
Y21 Discharge electronic valve

(26/05/2011) 10-01-M153EN
 6 Engine characteristics and
specifications

SENSOR AND PROBE

10

2 3
1

8 7

1 ECM Moteur
J2
1 46 5V Power
Alimentation 5V supply

2 38 Weight
Masse

3 55 Signal
Signal

10-01-M153EN (26/05/2011)
 Engine characteristics and 7
specifications

2
ECM Moteur
J1

10
1 57
Control
Commande relais
relay

3
ECM Moteur
J2
1 42 Signal
Signal

2 37 Power supply
Alimentation

4 ECM Moteur
J2
1 48 Alimentation
5V Power 5V supply

2 40 Weight
Masse

3 51 Signal
Signal

ECM Moteur
J2
1 10 8V Power
Alimentation 8V supply

2 52 Signal
Signal

(26/05/2011) 10-01-M153EN
 8 Engine characteristics and
specifications

6
ECM Moteur
J2
10

1 10 Alimentation
8V Power8Vsupply
2 53 Signal
Signal

7 ECM Moteur
J2
1 47 5V Power
Alimentation 5V supply

2 39 Weight
Masse

3 56 Signal
Signal

8
ECM Moteur
J2
1 43 Signal
Temperature signal
2 37 Power supply
Alimentation

9 A5
canal analogique
1
+ 1K 4

- 2

canal IVS 6
-
5

+ 3

22 23 21 24 20

43 45 33 54 41
+8V val 0V sig +5V

J1

10-01-M153EN (26/05/2011)
 Engine characteristics and 9
specifications

10
ECM Moteur
J1

10
38 Signal
Signal
35 Weight
Retour

11 ECM Moteur
J1
1 44 Signal
Signal

2 33 Weight
Masse

3 43 +8V Power
Alimentation 5V supply

ENGINE EARTH

Earthing
GroundPoint
Point Earthing
Ground Point
Point
Option
Option 11 Option 22
Option

Earthing
GroundPoint
PointOption
Option 33

(26/05/2011) 10-01-M153EN
 10 Engine characteristics and
specifications

LOW PRESSURE FUEL CIRCUIT

10

Key:

(1) Primary fuel filter

(2) Water separator
(3) Diesel injection pump
(4) Fuel-cooled ECM.
(5) Fuel cooler (option)
(6) Secondary fuel filter
(7) Injection pump
(A) High pressure fuel feed to high pressure fuel collector
(B) Pressure release valve (PRV) return to high pressure fuel collector
(C) Return to fuel tank
(D) Electronic unit injector return
(E) Fuel feed from fuel tank

10-01-M153EN (26/05/2011)
 Engine characteristics and 11
specifications

HIGH PRESSURE FUEL CIRCUIT

10
Key:

(1) Electronic Unit Injector

(2) High pressure fuel collector
(3) Fuel level sensor
(4) Fuel pressure relief valve
(5) Fuel pump
(6) Injection pump solenoid
(7) Injection pump

(26/05/2011) 10-01-M153EN
 12 Engine characteristics and
specifications
10

10-01-M153EN (26/05/2011)
 10
ENGINE CONTROL AND ADJUSTMENT

pages
Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– Silentbloc motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– Cooling circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fuel circuit - 120ps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Adjusting procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
– Fuel gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

(24/05/2011) 10-04-M153EN
 2
Engine control and adjustment

TIGHTENING TORQUE

SILENTBLOC MOTOR
10

110 N.m ±± 10%

110 N.m 10%

70 N.m±±10%
70 N.m 10%

70 N.m ±± 10%
70 N.m 10%

70 N.m ±±10%
70 N.m 10%

COOLING CIRCUIT

20 N.m
20 ± 10%
N.m ± 10%

10-04-M153EN (24/05/2011)
 3
Engine control and adjustment

FUEL CIRCUIT - 120PS

10
26 N.m ±± 10%
26N.m 10%

(24/05/2011) 10-04-M153EN
 4
Engine control and adjustment

ADJUSTING PROCEDURE
Fig. B
FUEL GAUGE
10

Fig. A A

1
- Position the gauge (Item 1) (Fig. A) in the tank so that the
spring (Item 2) (Fig. C) enters the housing (Item 3) (Fig. A)
provided for this purpose at the bottom of the tank.

NOTE: To guide you, you can empty the tank and insert
a light through the drain hole 4 (Fig. A).

- A 12 to 14 mm gap A (Fig. B) between the top of the

gauge and the tank indicates that the gauge is correctly
3
positioned. If not, reposition the gauge.
4

Fig. C

- Position the top of the gauge to align the fixing holes with
the tappings on the tank. (The gauge can only be fitted
one way round as the holes are not equidistantly spaced)
2
(Fig. D).
- If necessary remove the remnants of gasket sealant from
the fixing screws.
- Place a copper washer (Ref. 48 499) under the head
of each of the five screws (Item 1) (Fig. D), then fix the
assembly to the tank.
Fig. D
- Connect the harness.
- If removed earlier, re-fit the drain plug, and then re-fill the
tank.
1

1
1

1
1

10-04-M153EN (24/05/2011)
OPTIONS - ATTACHMENTS

Pages

– OPTION FORCED OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1

– CRC OPTION: BOOM SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . .B1
– CLEANFIX OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C1
– ECS. (EASY CONNECTING SYSTEM) OPTION . . . . . . . . . . . . . . . . . . . .D1

110
 OPTION FORCED OPERATION

pages

FORCED OPERATION WORKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3

– FLOW LIMITING FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3
– FORCED OPERATION FUNCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4
FORCED OPERATION SCHEMATICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5
– SCHEMATIC WITH FORCED OPERATION OPTION . . . . . . . . . . . . . . . . . . . . . . . A7
– SCHEMATIC WITHOUT FORCED OPERATION OPTION . . . . . . . . . . . . . . . . . . . . A8
FORCED OPERATION COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9
– LOCATIONS OF COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9
FITTING PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11
LOADING THE PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13
FORCED OPERATION PROGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A14
– INPUT/OUTPUT LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A14

110

(10/09/2010) 110-M153A-EN
 A2
Option forced operation

Détail position de la commande

de marche forcée Masse cabine

1 - Press-button and indicator light wiring

2 - Forced operation/flow limitation wiring
3 - Base P150 wiring option LSU

Ne pas brancher

Sur borne 16

ACCESS
TELESCOPE
Relais coupure
télescope

Rouge Vert/Jaune 2
3
A B

Gris
C
1
Détail branchements
Vu coté arrivée des fils

bleu bleu

2 1 j j
3 4

rouge jaune Porte fusible LSU

5A

Faisceau principal

MLT630-120 LSU 1
MLT634T LSU 1
MLT634-120 LSU 1
MLT634-120 LSU PS 1
P150 RESTYLING MLT731T LSU 1
P150 Euro 3 MLT731-120 LSU 1
MLT731-120 LSU PS 1
MLT741-120 LSU 1
MLT741-120 LSU PS 1
MLT742 HT LSU 1
110

110-M153A-EN (10/09/2010)
 A3
Option forced operation

FORCED OPERATION WORKING

This option allows two functions:

1 - Controlling the maximum flow on accessories (flow limiting)

2 - Command and control of a CONTINUOUS hydraulic operation for an accessory
(forced operation)

FLOW LIMITING FUNCTION

Fig. 1 In “normal” operation (no forced operation) the purpose of

the potentiometer C (Fig. 3) is to limit the maximum flow on
the accessory line.
A

- Set the potentiometer C to the desired position.

- Turn thumbwheel A: Fig. 1 (SWF hand control) or Fig 2.

(JSM joystick) to activate a movement. The maximum
flow will be automatically limited, due to the action of the
potentiometer.

Fig. 2

Fig. 3

C
110

(10/09/2010) 110-M153A-EN
 A4
Option forced operation

FORCED OPERATION FUNCTION

This OPTION must only be used with an attachment requiring continuous hydraulic movement
of type: brush, feeder bucket, mixer, spray etc. It is strictly forbidden in handling operations
and at all other uses (winch, crane jib, crane jib with winch, hook, etc.).

ACTUATING CONTINUOUS HYDRAULIC ACCESSORY OPERATION

- Make sure the potentiometer C (Fig. 3) is set to 0%.

- Turn and hold thumbwheel A (Fig. 1) up or down (Fig. 2), forwards or backwards (depending on
the accessory fitted), press button B (Fig. 3) and release button A (Fig. 1 or Fig. 2). The flashing
red indicator lamp 1 (Fig. 3.) indicates that the option has been activated.
- Control the flow necessary with the potentiometer C (Fig. 3).

STOP

- To stop continuous hydraulic movement of the attachment, move switch A forwards or backwards
or press button B. Indicator 1 goes out.
- Set potentiometer C to 0%.

Never leave the driver’s cab without first resetting the potentiometer C to 0%. Before
starting the telehandler, make sure the potentiometer is set to 0%.
110

110-M153A-EN (10/09/2010)
 A5
Option forced operation

FORCED OPERATION SCHEMATICS

-
+
f 32 (5A)

Main boom Main accessory

extension wiring wiring

3 4 4 3 3 4 4 3
2 1 1 2 2 1 1 2

1 + + 1
2 2
signal
Signal 3 3 Signal
signal

4 4
potentiometer B B
C C
50% A A
25% 75% J4 J5
0% 100%
N° 2 47174

C Pre-set
Consigne
adjustment
B connector
A + J2 J3
8

1
1 2
3 4

3 4
2 1
16
8

1 +
14

2 switch Switch
signal
1

Signal
9

N° 247175

J1
3 +

+ 1 4 ++ 5 volt
5 Volt.
3 4 4 3
2 1 1 2
2 3 Signal
signal

Button + indicator light Signal 3

signal 2
++55volt
Volt.
4 1 +

3 4 4 3 3 4 4 3
2 1 1 2 2 1 1 2
110

Boom Boom
extension EMS extension EMS

(10/09/2010) 110-M153A-EN
 A6
Option forced operation

J4
- Batt + Batt-P
Max.
- Batt - Batt
pressure AU Fil 1
M1/S5
solenoid AU Fil 2 CAN low
valve COMMUN + COMMUN +
option CAN high

M1/S4
J5

PROGRAMME

**********

- battery
g1 CAN high boom extension
g2 CAN low M1/S3 bl
12V
_
5V
S valve
g3 - Batt - Batt j/vt

g4 COMMUN + M1/S6a M

M1/S1 bl _
12V
5V
S accessory valve
J3
To M1/E18
bc (J2-13) input
Boom extension
J2 signal
- battery j/vt - Batt To M1/E16
r + Batt (J2-11) input
+ battery - Batt M1/S2 Accessory signal
FUS 1
+ Batt + Batt-P r
- Batt

Accessory M1/E15 M1/E5

r Machine
handling r + Batt-P overload shunt
M1/E11
signal
J
M1/E16 M1/E4

M1/E12 M1/E10
g
4 3
M1/E17a M1/E3
J Pre-wiring accessory
Accessory cut-off “seat switch”
M1/E13 M1/E9
forced
operation M1/E18 M1/E2

signal M1/E14 M1/E8

v AU Fil 1
M1/E7
Accessory
forced AU Fil 2
operation
low pressure M1/E6

M1/E1
Silage bucket pre-wiring
J1
1 - Batt
2
MODULE E18/S6 MEM E15
3
E17a
4
50696445
5 + Batt
6 E14
7 E12
110

110-M153A-EN (10/09/2010)
 A7
Option forced operation

SCHEMATIC WITH FORCED OPERATION OPTION

F 32 (5A)

Telehandler harness
+

4 3 2 1

1 2 3 4

J2-8 + J2-1
0 to 12V J2-2

Forced operation option interface

B
signal
C
J2-12
Pre-set J2-11
Acc. signal

A Telesc. signal
J2-13
J2-4 +
+ J3-1
1 2
J2-14
switch signal
4
J3-3
Acc. signal
J2-3

J1-16 + + J3-2
3
J3-4

EMS harness
1 2 3 4 4 3 2 1

+ sign 5V 5V sign +

EMS Telescope EMS Accessory

110

(10/09/2010) 110-M153A-EN
 A8
Option forced operation

SCHEMATIC WITHOUT FORCED OPERATION OPTION

F 32 (5A)

Telehandler harness
+

4 3 2 1

1 2 3 4

EMS harness
1 2 3 4 4 3 2 1

+ sign 5V 5V sign +

EMS Telescope EMS Accessory

110

110-M153A-EN (10/09/2010)
 A9
Option forced operation

FORCED OPERATION COMPONENT LAYOUT

LOCATIONS OF COMPONENTS

EMS Modules

ECU

APPLICATION:

This option must only be used with accessories that need continuous hydraulic operation, such as
sweepers, feeder buckets, sprays etc.

The hydraulic movement of the accessory is adjustable from 0 to 100 liters per minute
(potentiometer).
- Easy operation
- Reduced demand on components
110

(10/09/2010) 110-M153A-EN
 A10
Option forced operation

FORCED OPERATION COMPONENTS

Parts required:

Complete kit: 698 418 - MLT 6 and 7

698 486 - MLT 8 and 9
50%

25% 75%

0% 100%
N° 247175
N° 2 47174

1st fitting

2nd fitting
110

110-M153A-EN (10/09/2010)
 A11
Option forced operation

FITTING PROCEDURE

- Remove the right hand trim panel A (Fig. 1).

Fig. 1
- Drill one 10.5 mm and one 16 mm hole in the positions
shown (Fig. 2).
Ø 16

Ø 10,5 - Fit the module 1 on its bracket 2 (Fig. 3).

40

- Fix the assembly in place with the screws B (Fig. 4) on the

70

right hand cab panel (1st fitting) or on the bracket 13 on

the joystick mounting flange (2nd fitting).

- Connect the harness 7 between the control block and the

module 1 following the instructions (Fig. 3).
Fig. 2

Connect the brown wire to

terminal 16 on the connector 7

16

attachment
1

After-sales test port.

control valve Do not connect
2

telescope
110

Fig. 3
(10/09/2010) 110-M153A-EN
 A12
Option forced operation

2 1

Fig. 4 Fig. 5

- Affix the sticker 11 to the trim panel (Fig. 6).

8
A - Connect the push-button with integral indicator light
8 and the potentiometer 9 to the harness 7 (Fig. 7),
then fit them to the trim panel A (Fig. 6).
11
10
- Affix the sticker 10 (Fig. 6).

9 NOTE: Adjust the minimum position of the potentiometer

9 to match the sticker 11 (Fig. 6).
Fig. 6
- Re-fit the fixing screws on the trim panel A (Fig. 6).

- Open the fuse and relay compartment cover to the right

of the pedals.
9
8
- Fit fuse 12 (5A) in place of the fuse (3A) (Fig. 8).

- Replace the cover on the fuse and relay compartment.

Fig. 7

12
110

Fig. 8
110-M153A-EN (10/09/2010)
 A13
Option forced operation

LOADING THE PROGRAM

- Ensure the module is not powered.

New sticker
- Locate the microprocessor 1 in its socket with the key
facing outwards.

- Switch on the ignition.

key
- Loading is automatic (indicated by a lit red LED).
key
- When loading is complete the LED will flash once
a second. Switch off the ignition at this point.

- Remove the microprocessor.

- Affix the new sticker.

Program 256499 - Check for correct operation.

Date

110

(10/09/2010) 110-M153A-EN
 A14
Option forced operation

FORCED OPERATION PROGRAM

INPUT/OUTPUT LIST

Inputs Connection FUNCTION

E1 J1-1 Not used
E2 J1-4 Not used
E3 J1-5 Accessory cut-off
E4 J1-6 Not used
E5 J1-7 Machine overload
E6 J1-9 Forced operation low pressure overload
E7 J2-14 Forced operation accessory low pressure
E8 J1-11 Boom retraction detection
E9 J1-12 Not used
E10 J1-13 Not used
E11 J1-14 Not used
E12 J2-5 Silage bucket direction 2
E13 J2-6 Not used
E14 J2-7 Silage bucket direction 1
E15 J2-10 Silage bucket presence
E16 J2-11 Joystick accessory signal
E17a J2-12 Accessory signal from potentiometer
E18 J2-13 Joystick boom extension signal

Outputs Connection FUNCTION

S1 J3-1 EMS accessory supply
S2 J1-16 Accessory forced operation indicator
S3 J3-4 EMS boom extension supply
S4 J4-8 Movement cut-off
S5 J4-2 Pressure relief solenoid valve
S6 J3-3 Accessory signal
110

110-M153A-EN (10/09/2010)
 CRC OPTION: BOOM SUSPENSION

pages

Operating principles of the “CRC” kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3

Schematic diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4
– LSU telehandler hydraulics schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4
– Non-LSU telehandler hydraulics schematics . . . . . . . . . . . . . . . . . . . . . . . . . . B5
– Electrical schematic diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6
Operating logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7
Cut-away drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B8
– Hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B8
– LSU electrical circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B9
– Non-LSU electrical circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B10
Location of components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B11
– MLT - LSU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B11
– MLT - non LSU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B12
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B13
– Setting the position contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B13
– CRC balancing valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B14
110

(10/09/2010) 110-M153B-EN
 B2
CRC option
110

110-M153B-EN (10/09/2010)
 B3
CRC option

OPERATING PRINCIPLES OF THE “CRC” KIT

The jib is suspended to reduce shaking of the lift truck on

rough ground (e.g. handling straw in a field).

A2 Applications are:
- 70%: movements on road and in fields.
A
- 30%: others, floating for mucking out animal housing, snow
clearing.
A1
Optimal efficiency: 1500 kg (or 3 bigball bales)
- Comfortable operation
- Less demand on components
- Optimized security

Functioning

- Set the forks or attachment on the ground and relieve the front wheels a few centimeters only.
- Press switch A in position A1, the visual indicator comes on indicating that jib suspension is
activated.
- Press switch A in position A2, the visual indicator goes out indicating that jib suspension is
deactivated.

Jib suspension is enabled up to a lift height of fork clamps 3 meters above ground level with
the boom retracted. When you operate beyond this height or perform another hydraulic
movement (crowding, boom extension, attachment), jib suspension is immediately
deactivated and the indicator light A goes out.

When the I.C. engine is off, jib suspension is automatically deactivated.

110

(10/09/2010) 110-M153B-EN
 B4
CRC option

SCHEMATIC DIAGRAMS

LSU TELEHANDLER HYDRAULIC SCHEMATICS

VL

35
PS
34
1 2

C2 C1
PX
30b EV(S1)
1,5L
40
ACC P

EV(S2)
300b M

60 cm3/tr
V
V1 T L1
V2

V1 V2
R
CSP

70b
C1 C2

To joystick

b2 B2 A2
40 ACC - Accumulator
CSP - Counterbalance valve
D - 4 or 5 (optional) element control block
EL - Lifting element
EV (S1) - Electrically operated valve (solenoid 1)
EV (S2) - Electrically operated valve (solenoid 2)
R - Hydraulic reservoir
D 34 V - Suspension valve
VL - Lifting cylinder
P - Equipment pump
EL 35 PS - Pressostat
M - Perkins diesel engine
110

280b
EL
a2

To joystick

110-M153B-EN (10/09/2010)
 B5
CRC option

NON-LSU TELEHANDLER HYDRAULIC SCHEMATICS

VL

PS
1 2

3
C2 C1
PX
30b EV(S1)
1,5L

ACC

EV(S2)
300b

V
V1 T
V2

A2 B2

280b

ACC - Accumulator
D - 4 or 5 (optional) element
control block
EL - Lifting element
EV (S1) - Electrically operated valve
(solenoid 1)
D EV (S2) - Electrically operated valve
(solenoid 2)
R - Hydraulic reservoir
V - Suspension valve
VL - Lifting cylinder
PS - Pressostat
110

EL
(10/09/2010) 110-M153B-EN
 B6
CRC option

ELECTRICAL SCHEMATIC DIAGRAM

Aggravating movements
cut-off
+12V

F22

r r

ro 1 0 2 1 7 2 8 10

S1
S7
3 6 9

r
S3 bl
S8
K11
S2
S4 j
S9

vi
S5
vt
K12 K10

vi S10 m

K20

ro ro o or or

K12 K10 K11

EV (S1) EV (S2)

S1: Boom suspension on/off switch

S2: Boom position Pressostat
S3: Boom lowering contact or Pressostat
S4: Crowd backwards contact or Pressostat
S5: Crowd forwards contact or Pressostat
S7: Boom extension contact or Pressostat
S8: Accessory contact or Pressostat
S9: Accessory contact or Pressostat
S10: Boom position contact < 3 meters
K10: Boom suspensions cut-off relay
110

K11: Boom suspension supply relay

K12: Aggravating movement cut-off relay
K20: DASL (Longitudinal stability alarm device)
EV (S1): Boom suspension solenoid valve 1
EV (S2): Boom suspension solenoid valve 2
110-M153B-EN (10/09/2010)
 B7
CRC option

OPERATING LOGIC

Diesel engine
Operational flow chart - boom
running
suspension (with aggravating
movements cut-off option) no hydraulic
movements

Press switch S1 to switch

suspension on

Aggravating movements cut-off Jib

Boom on
(simplified) the ground
Boom suspension not
switched on

Jib

Boom suspension
Machine at activated
capacity limit
K11=1

Hydraulic
movement:
boom extension Supply to EV (S1) EV
or accessory (S2) + indicator
(+ or -).

Hydraulic movement:
lowering, crowd forward. TS pivot point height >

Movement cut-off
activated Cut-off of EV (S1) EV
(S2) + indicator

Movement stop
Hydraulic movement
TS pivot point height >
stop

(normal operation)
Movement cut-off
de-activated
Press switch S1: engine stop
Suspension stop
Hydraulic movement
110

Supply cut-off K10=0

Normal machine
operation Boom suspension in
stop position

(10/09/2010) 110-M153B-EN
 B8
CRC option

CUT-AWAY DRAWINGS

HYDRAULIC CIRCUIT

S2

Px

V1 S1

T ACC

V2

LSU
NON LSU
110

110-M153B-EN (10/09/2010)
 B9
CRC option

LSU ELECTRIC CIRCUIT

K10 K11 r
3 4

m j 1 2
3

3
3 4
j 5 6
5

5
7 8

4
4

1
1

2
2

o o vi bl
9 10 r
vi

j/vt j/vt j/vt

P
vt vt 2
bl
ro T
m j/vt 1

I
K0 K1

H
5
K2 K3 K4
1

G
1
8 8
E

F
K5 K6

1
1 6
K7 K8 K9
F13 F14 F15
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12
30A
7.5A
7.5A
7.5A

10A
15A

15A

10A
5A

5A

F30
F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 F28 F29
25A
7.5A
7.5A
7.5A
7.5A
10A

15A
15A
15A
C
B
A

10A (F22)

110

(10/09/2010) 110-M153B-EN
 B10
CRC option

NON-LSU ELECTRIC CIRCUIT

MLT 630 T / 731 T Non-LSU (without aggravating movement cut-off option)

r
K10 K12 K11
m j 1 2

3
3 4
j 5 6

5 4

5 4

5 4
7 8

1
1

2
2
o o vi vi bl 9 10 r
j/vt j/vt vt j/vt
bl vt
ro m j/vt

I
K0 K1

H
5
K2 K3 K4

G
1 1
8 8

F
K5 K6
1
1 6
K7 K8 K9 F13 F14 F15
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12

30A
7.5A
7.5A
7.5A

10A
15A

15A

10A
5A

5A

D
F30
F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 F28 F29

25A
7.5A
7.5A
7.5A
7.5A
10A

15A
15A
15A
C
A

B
10A (F22)

MLT 630 T / 731 T Non-LSU (with aggravating movement cut-off option)

r
K10 K12 K11

j 1 2
m
3

3 4
j 5 6
5

7 8
4

4
4

1
1

2
2

o o vi bl
9 10 r
vi

j/vt j/vt j/vt

vt vt
bl
ro
j/vt
m

8
I

K0 K1
H

K2 K3 K4

1
G

1
8 8
E

K5 K6

1
1 6
K7 K8 K9
F13 F14 F15
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12
30A
7.5A
7.5A
7.5A

10A
15A

15A

10A
5A

5A

F30
F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 F28 F29
25A
7.5A
7.5A
7.5A
7.5A
10A

15A
15A
15A
C
B
A

10A (F22)
110

110-M153B-EN (10/09/2010)
 B11
CRC option

LOCATION OF COMPONENTS

MLT - LSU

1
K1
2
K1
0
K1

3 4

2 P
1 T

K11
K12
K10

110

(10/09/2010) 110-M153B-EN
 B12
CRC option

MLT - NON-LSU

1
K1
2
K1
0
K1

K11
K12
K10
110

110-M153B-EN (10/09/2010)
 B13
CRC option

ADJUSTMENTS

SETTING THE POSITION CONTACT

- Position the boom as indicated (Fig. A). The

fork clamp pivot should be at least 3 meters
off the ground.

- Adjust the position contact 32 (Fig. B) so

that it triggers in this configuration.
3m

- To check adjustment press switch 4 (Fig. C).

The switch light should light. It should go out
when you position the boom below 3 meters
(Fig. A).
Fig. A
- Adjust if necessary.

32 - Re-fit the boom rear cover plate.

Fig. B

Fig. C
110

(10/09/2010) 110-M153B-EN
 B14
CRC option

CRC BALANCING VALVE

Tightening torque: 27 +/- 3 N.m

110

110-M153B-EN (10/09/2010)
 B15
CRC option

Jet

Tightening torque: 50 +/- 5 N.m

2,2 mm = 80 l/min (operation flow rate)

Tightening torque:
4 +/- 2 N.m

The purpose of the parachute valve is

to avoid a load being dropped should a
break occur in the connection between
the valve and the accumulator.
Solenoid valves S1 and S2 should be
excited when the vehicle exceeds 3
kph in order to allow the suspension
function via the accumulator.
110

PORTS
V1-V2 = M22x1,5
T = M16x1,5
ACC. = M18x1,5
PX = G1/4
C1-C2 = Ø 11,5

(10/09/2010) 110-M153B-EN
 B16
CRC option

Boom suspension valve

Pilot pressure: 110 bar

Pilot pressure: 32,5 bar
Safety valve rated at 320 bar
Safety valve rated at 55 bar
110

110-M153B-EN (10/09/2010)
 CLEANFIX OPTION

pages

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C2
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3
Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4
Repair kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C6

110

(10/09/2010) 110-M153C-EN
 C2
CleanFix Option

INTRODUCTION

I
K0 K1

H
5
K2 K3 K4

G
1 1
8 8

F
K5 K6
2 1
1
6
K7 K8 K9 F13 F14 F15
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12

30A
7.5A
7.5A
7.5A

10A
15A

15A

10A
5A

5A

D
F30
F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 F28 F29

25A
7.5A
7.5A
7.5A
7.5A
10A

15A
15A
15A
C
A

B
KIT DE REPARATION
REPARATURSATZ KIT
KIT DI RIPARAZIONE
KIT OF REPAIR
KIT EQUIPO REPARACIÃN
110

110-M153C-EN (10/09/2010)
 C3
CleanFix Option

OPERATION

“Clean Fix” is a reversible flow fan:

- which draws air in and blows it out
- on an automatic cycle

Adjustable blades

It allows the direction of the fan blades to change, to create

a powerful airflow which cleans the radiator honeycomb and
grille (15 s/3 min).

Cooling

Cleaning
110

(10/09/2010) 110-M153C-EN
 C4
CleanFix Option

SCHEMATIC DIAGRAM

+ batt 12 V
C: Compressor

Y1: By-pass

Cleanfix
unit

Y1
batt. earth

Stage 1: Having rocked the switch, By-pass closes.

Stage 2: Compressor is powered for 15 to 25 seconds (blade orientation and hold)
Stage 3: Compressor and By-pass switched off (springs move blades back into position)
110

110-M153C-EN (10/09/2010)
 C5
CleanFix Option

REPAIR KIT

If one of the CleanFix fan blades breaks, blades

must be changed in sets of three, to stop the fan
going out of balance.

- Remove the fan from your machine.

- Remove the nine (M8-80) bolts (A) to the front.

- Remove the cover B behind.
- Replace the damaged blade as well as the two
B
blades at 120° from it.
- Refit the fan and check for smooth operation.

- Blade repair kit Ref. 787966.

- It is obligatory to change blades in sets of three
(120°).

- Repair kit for air intake pipework and 1 spring

Ref. 786994
110

(10/09/2010) 110-M153C-EN
 C6
CleanFix Option

MAINTENANCE

Filter change every 500 hours.

Ref.: 781443
1

1
110

110-M153C-EN (10/09/2010)
 ECS. (EASY CONNECTING SYSTEM) OPTION

pages

Depressurizing the accessory line (ECS option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3

– Operating principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3
Schematics Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D4
– Hydraulics for non-LSU telehandler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D4
– Electrics for non-LSU telehandler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D4
– Hydraulics for LSU telehandler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D5
– Electrics for LSU telehandler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D5
Location of components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6
– For non-LSU telehandler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6
– For LSU telehandler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D7

110

(10/09/2010) 110-M153D-EN
 D2
ECS option
110

110-M153D-EN (10/09/2010)
 D3
ECS option

DEPRESSURIZING THE ACCESSORY LINE (ECS OPTION)

OPERATING PRINCIPLE

Objective: Quicker disconnection and connection of

accessories.

- Using the ECS, the operator leaves the telehandler with the
engine running, and stands at the fork clamp. He presses
A
the protected push-button A located at the left front of
the chassis and, thanks to the independent solenoid
valves controlled for return to the tank, he releases the
hydraulic circuit pressure in the accessory lines. He can
then disconnect the hydraulic connectors and very easily
connect a new accessory.

110

(10/09/2010) 110-M153D-EN
 D4
ECS option

SCHEMATIC DIAGRAMS

HYDRAULICS FOR NON-LSU TELEHANDLER

Boom head coupler S51

F15

Y17

Y18

Tank

Control Valve

Attachment component

ELECTRICS FOR NON-LSU TELEHANDLER

+ F15: Motor stop and Easy Connect
System option fuse
F15
S51: ECS accessory depressurization
A
switch

Y17: ECS accessory line

j g depressurization solenoid valve

Y18: ECS accessory line

M M depressurization solenoid valve

S51
110

Y17 Y18

110-M153D-EN (10/09/2010)
 D5
ECS option

HYDRAULICS FOR LSU TELEHANDLER

Boom head coupler S51

F15

Y17

Y18

Tank

Control Valve

Attachment component

ELECTRICS FOR LSU TELEHANDLER

+ F15: Motor stop and Easy Connect
System option fuse
F15
S51: ECS accessory depressurization
A
switch

Y17: ECS accessory line

j g depressurization solenoid valve

Y18: ECS accessory line

M M depressurization solenoid valve

S51
110

Y17 Y18

(10/09/2010) 110-M153D-EN
 D6
ECS option

LOCATION OF COMPONENTS

FOR NON-LSU TELEHANDLER

Push button 2 must be located and

3
centered in the chassis drilling.
1
NOTE: Butt 2 must be fitted on the
lid of housing 1.

10A fuse in
F15. 39
I
H

Power Right hand cab

supply in D3 earth
Left front of
chassis

13
Fuse and relay carrier

2
2

1 3
12

Horn to be
re-fitted using the
bracket 3.

Protect the wiring with heat-

shrink or other (silicone etc.)
110

110-M153D-EN (10/09/2010)
 D7
ECS option

FOR LSU TELEHANDLER

Push button 2 must be located and

3
centered in the chassis drilling.
1
NOTE: Butt 2 must be fitted on the
lid of housing 1.

10A fuse in
F15. 33
I
H

Power Right hand cab

supply in D3 earth
Left front of
chassis

13
Fuse and relay carrier

2
2

3
12 1

Horn to be
re-fitted using the
bracket 3.

Protect the wiring with heat-

shrink or other (silicone etc.)
110

(10/09/2010) 110-M153D-EN
 D8
ECS option
110

110-M153D-EN (10/09/2010)
 TRANSMISSION

- TRANSMISSION COMPONENTS LOCATION

20
- TRANSMISSION CONTROL AND
ADJUSTEMENT

- TRANSMISSION REMOVAL

- TRANSMISSION TROUBLESHOOTING

M
- TRANSMISSION CONTROL AND

R
647058EN
ADJUSTEMENT
(Renvoi d’angles
15930-15932)

- TRANSMISSION CHARACTERISTICS AND

M

647020EN
R

SPECIFICATIONS
(Boite de vitesses
- TRANSMISSION CONTROL AND Compact Plus)
ADJUSTEMENT
M

647027EN
R

- TRANSMISSION SECTIONS AND

(Boite de vitesses
DIAGRAMS
PG 115)
- SPECIFIC TRANSMISSION TOOLING
M
R

647030DE/EN
- TRANSMISSION CONTROL AND (Pompe A4VG)
ADJUSTEMENT
M
R

647031FR/EN
(Moteur A6VM)
 TRANSMISSION COMPONENTS LOCATION

20
pages
PG 115 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– SHAFTS AND CLUTCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– OPERATING LOGIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
– POWER FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
– PRESSURE PORTS LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
– ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

(24/05/2011) 20-03-M153EN
 2
Transmission components location

PG 115 GEARBOX

COMPONENTS

1 2
LP FL
R 6
20

LP FH
3 4

12
7
11
9
8

10

KEY

1 Dip stick
2 Main L.P. = 15 bar
3 Converter L.P. = 6 bar
4 Filler hole
5 Control solenoid-operated valves unit
6 Speed sensor
7 Hand brake mechanism
8 Transmission filter
9 Cold start valve = 26 bar
10 Pump suction strainer
11 Converter
12 Transmission pump

20-03-M153EN (24/05/2011)
 3
Transmission components location

SHAFTS AND CLUTCHES

Clutch, forward, Clutch, forward,

high speed FH low speed FL

20
Clutch No. 1

Lay-shaft

Front axle output

shaft

Clutch No. 3
Clutch No. 2

Rear axle output

shaft

GEARS

Clutch, forward,
low speed FL T7

Clutch, forward,
high speed FH
T9
T8
Clutch No. 1

T6
Clutch, reversing
Clutch No. 2

T10

T4

Clutch No. 3

(24/05/2011) 20-03-M153EN
 4
Transmission components location

OPERATING LOGIC

Gears FORWARD gear REVERSE gear

Clutch Maximum Clutch Maximum
speed speed
1st FL+1 5,8 R+1 5,8
20

2nd FH+1 9,4 R+2 12,4

3rd FL+2 12,4 R+3 24
4th FH+2 19,7
5th FL+3
6th FH+3 38,1

POWER FLOW

R R

24 24

42 42
42 42
FH FL FH FL

24 24
32 32
46 46
44 38 1 44 38 1

19 19
32 48 32 48
37 37
3 2 3 2
28 28
26 26

25 25

Forward 1st gear 2nd gear

20-03-M153EN (24/05/2011)
 5
Transmission components location

R R

24 24

42 42
42 42
FH FL FH FL

20
24 24
32 32
46 46
44 38 1 44 38 1

19 19
32 48 32 48
37 37
3 2 3 2
28 28
26 26

25 25

Forward 3rd gear 4th gear

R R

24 24

42 42
42 42
FH FL FH FL

24 24
32 32
46 46
44 38 1 44 38 1

19 19
32 48 32 48
37 37
3 2 3 2
28 28
26 26

25 25

Forward 5th gear 6th gear

(24/05/2011) 20-03-M153EN
 6
Transmission components location

PRESSURE PORTS LOCATIONS

20

T5 T7 T9 T11 T10 T4 T2 T1 T3 T8 T6

T1: Converter pressure T7: Forward slow FL pressure

T2: Not in use T8: Reverse gear clutch pressure
T3: Pump pressure T9: Forward high speed FH pressure
T4: 3rd gear clutch pressure T10: 2nd gear clutch pressure
T5: Lubrication pressure T11: Not in use
T6: 1st gear clutch pressure

20-03-M153EN (24/05/2011)
 7
Transmission components location

ECU

The ECU (Electronic Control Unit) is a transmission management controller

It controls various gearbox functions:
- Gear changes
- Kick down
- Solenoid-operated valve wiring harness diagnostics

20
- Input diagnostics

The ECU flow diagram is as follows:

- Data coming from
from the shuttle lever
from the hand brake/transmission cut-out
from the crawler gear switch/5th gear lock
from the gear sensor

25
1

24

26
2

23

27
3

22
Solenoid operated
28
4

21

29
valve supply
5

20

30
6

19

31
7

18

Output to dashboard
32
8

17
9

33

display
16
10

34

UE
15
11

35

NIQ
14

O
12

36

R .U.
13

T
E LEC IT E.C
R UN
ITIE
BO TROL
N
CO

ECU unit

(24/05/2011) 20-03-M153EN
 8
Transmission components location
20

20-03-M153EN (24/05/2011)
 TRANSMISSION CONTROL AND ADJUSTMENT

20
pages
Transmission tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

(24/05/2011) 20-04-M153EN
 2
Transmission control and adjustment

TRANSMISSION TIGHTENING TORQUE

70 N.m ± 10%

170 N.m ± 10%

30 N.m ± 10% 37 N.m ± 10%

± 10% 60 N.m ± 10%

20

41 N.m

70 N.m ± 10% 70 N.m ± 10%

170 N.m ± 10%

37 N.m ± 10%

37 N.m ± 10%

60 N.m ± 10%

60 N.m ± 10%

Standard torque settings to be used when no specific mention is made in dismantling and
re-assembly.

Torque expressed in N.m (*)

Thread Class 5.6 Class 5.8 Class 8.8 Class 10.9 Class 12.9
diameter
M3 0,54 0,76 1,16 1,7 2
M4 1,24 1,74 2,66 3,91 4,57
M5 2,47 3,46 5,2 7,7 9
M6 4,29 6 9,1 13,4 15,7
M8 10,4 14,6 22 32 38
M10 20 28 44 64 75
M12 35 49 76 111 130
M14 57 79 121 178 209
M16 88 124 189 278 325
M18 122 171 261 384 449
M20 173 243 370 544 637
M22 238 334 509 748 875
M24 298 418 637 936 1095
M27 442 619 944 1386 1622
M30 600 840 1280 1880 2200
(*) - Tightening torques are given for black or zinc-plated fasteners with light lubrication.
- Tightening torques are given for automatic slip and reset torque wrenches and direct read
dial torque wrenches.
- For more information consult French Standard NF E25-030.

20-04-M153EN (24/05/2011)
 TRANSMISSION REMOVAL

20
pages
MLT 634/731/735/741/1035 T + LSU + 120 LSU . . . . . . . . . . . . . . . . . . . . . . . . . 2
Gearbox and angle drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– Removal of gearbox, leaving angle drive in place . . . . . . . . . . . . . . . . . . . . . . 2
– Removal of complete transmission (Gearbox and angle drive) . . . . . . . . . . . . . 9

MLT 634/735/741 120 LSU PS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Gearbox and angle drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
– Removal of complete transmission (Gearbox and angle drive) . . . . . . . . . . . . . 15

(10/09/2010) 20-06-M153EN
 2
Transmission removal

MLT 634/731/735/741/1035 T + LSU + 120 LSU

GEARBOX AND ANGLE DRIVE ASSEMBLY

gearbox
20

angle drive

REMOVAL OF GEARBOX, LEAVING ANGLE DRIVE IN PLACE

NOTE: The angle drive cannot be removed on its own.

- Place the telehandler on horizontal ground, with the

handbrake off and in neutral.

- Chock the lift truck.

- Raise the boom and support it with a prop.

Required equipment
- 1 Lifting bracket Ref.: 227820
- 1 Hex-head bolt, M12x25 Ref.: 44807
- 1 Hex-head bolt M12x35 Ref.: 58546
- 2 Washers M12 Ref.: 61676

20-06-M153EN (10/09/2010)
 3
Transmission removal

Remove the rear axle drive shaft

- Remove the two clamps 1, one each side of the drive
shaft.
1

20
Remove the front axle drive shaft
- Remove the two clamps 1 at the front axle end.
- Remove the fixing bolts 2 at the gearbox end.

1
2

- Remove the protection plate 1 above the transmission and

its bracket 2.

- Remove the parking brake cable and unfasten it at the

telehandler end.

(10/09/2010) 20-06-M153EN
 4
Transmission removal

- Remove the fixing bolt 1 and then the gear lever 2.

3
2

- Disconnect the transmission oil pressure switch 3 and

temperature sensor 4.
20

- Unfasten the accelerator cable at the pedal end then

remove it towards the engine.

- Disconnect the two connectors on the gearbox control

solenoid valve.

- Remove the engine bay cover plate.

20-06-M153EN (10/09/2010)
 5
Transmission removal

- Place a recipient under the gearbox and unfasten the lower

gearbox oil cooling hose 1.

20
- Unfasten the upper oil cooling hose 2.
- Plug the openings in the hoses and the gearbox.

- Remove the flexible support plate 1 under the gearbox.

- Pass the two oil-cooling hoses into the engine bay under
the radiator.

- Mount and fix the lifting bracket (227820) as shown onto

the gearbox.

(10/09/2010) 20-06-M153EN
 6
Transmission removal

- With a chain hoist and webbing,

sling the gearbox.

20

Take the weight of the gearbox on the hoist.

Drain the torque converter

- Remove the torque converter inspection cover.

- Place a recipient under the torque converter, remove the

plug 1 and drain.
- Separate the torque converter by removing the six bolts 2.

2
1

20-06-M153EN (10/09/2010)
 7
Transmission removal

- Remove ten of the twelve fixing bolts 1 between the gearbox

1
and the angle drive, leaving one bolt on each side to keep
the assembly together.

20
- Support the angle drive to keep it in place while removing
the remaining bolts.

- Completely remove the right hand gearbox mounting.

- Remove the four fixing bolts 1 from the left hand gearbox
mounting.
1 - Loosen the bolt 2.
- Swivel the mounting and secure it to the chassis.

(10/09/2010) 20-06-M153EN
 8
Transmission removal

IMPORTANT
Ensure the area around the gearbox is free of possible snags (cables, harnesses, hoses etc.)
to avoid anything catching when the gearbox is removed.

- Slightly lift the gearbox, moving it towards the front of the telehandler in order to disengage it
from the angle drive.

As the disengagement takes place, ensure that the torque converter remains securely on
20

the gearbox.

- Lower the gearbox onto a dolly and chock it to ensure it does not tip.
- Unhook the sling.
- Prop the front axle, then remove the left front wheel.
- Remove the gearbox between the cab and the front axle.

20-06-M153EN (10/09/2010)
 9
Transmission removal

REMOVAL OF COMPLETE TRANSMISSION (GEARBOX AND ANGLE DRIVE)

- Place the telehandler on horizontal ground, with the

handbrake off and in neutral.
- Chock the lift truck.

- Raise the boom and support it with a prop.

20
REQUIRED EQUIPMENT
- 1 lifting bracket for the
227819 227820 angle drive Ref.: 227819
. 2 hex-head bolts M12x25 Ref.: 44807
. 2 M12 washers Ref.: 61676

- 1 gearbox lifting bracket Ref.: 227820

. 1 hex-head bolt M12x25 Ref.: 44807
. 1 hex-head bolt M12x35 Ref.: 58546
. 2 M12 washers Ref.: 61676

- Remove the rear axle drive shaft

- Remove the two clamps 1, one each side of the drive
shaft.
1

- Remove the front axle drive shaft

- Remove the two clamps 1 at the front axle end.
- Remove the fixing bolts 2 at the gearbox end.

1
2

(10/09/2010) 20-06-M153EN
 10
Transmission removal

- Remove the fixing bolts 1 from the transmission shaft

at the angle drive end.
- Disengage the shaft and support it up
20

- Remove the protection plate 1 above the transmission and

its bracket 2.

- Remove the parking brake cable and unfasten it at the

telehandler end.

- Remove the fixing bolt 1 and then the gear lever 2.

3
2

- Disconnect the transmission oil pressure switch 3 and

1 temperature sensor 4.

20-06-M153EN (10/09/2010)
 11
Transmission removal

- Unfasten the accelerator cable at the pedal end then

remove it towards the engine.

20
- Disconnect the two connectors on the gearbox control
solenoid valve.

- Remove the engine bay cover plate.

- Place a recipient under the gearbox and unfasten the lower

gearbox oil cooling hose 1.

(10/09/2010) 20-06-M153EN
 12
Transmission removal

- Unfasten the upper oil cooling hose 2.

- Plug the openings in the hoses and the gearbox.

2
20

- Remove the flexible support plate 1 under the gearbox.

- Pass the two oil-cooling hoses into the engine bay under
the radiator.

- Remove the two hydraulic pump hoses 1.

- Plug the openings.
- Remove the two fixing bolts 2 from the hydraulic pump.

- Disengage then support the pump towards the rear of the

2
1 telehandler.

- For models equipped with a trailer braking circuit, disconnect

the two hoses 1 and 2 and the pipe 3.
3 - For standard models, disconnect the hose 2 mounted on
4 the connector block 4.
5
- Remove the support bracket 5 screws then move the
assembly towards the cab.
1
2 8
- Remove the support clamp 6 from the main harness and
from the hose 2.
- Remove the pipe 7 from the braking circuit.
6
7 - Remove the oil filter mounting assembly 8.
- Protect the oil filter bracket opening on the gearbox.

20-06-M153EN (10/09/2010)
 13
Transmission removal

- Fit and secure the lifting bracket onto the right hand side
of the angle drive.

20
- Fit and secure the lifting bracket as shown onto the
gearbox.

- Using a chain hoist and sling, sling the transmission.

- Take the weight of the transmission on the hoist.

(10/09/2010) 20-06-M153EN
 14
Transmission removal

- Remove the two fixing bolts 1 from the angle drive.

1 1 - Completely remove the right hand gearbox mounting.

- Remove the four fixing bolts 1 from the left hand gearbox
20

mounting.
- Loosen the bolt 2.
- Swivel the mounting and secure it to the chassis.

right-hand mounting left-hand mounting

IMPORTANT
Ensure the area around the transmission is free of possible snags (cables, harnesses,
hoses etc.) to avoid anything catching when the transmission is removed.

- Slightly raise the transmission and move it towards the front of the telehandler in order to
disengage the back of the angle drive from the top of the hydraulic oil container.

- Lower the transmission onto a dolly and chock it to stop it tipping.

- Unhook the slings.
- Prop the front axle, then remove the left front wheel.
- Remove the transmission between the cab and the front axle.

20-06-M153EN (10/09/2010)
 15
Transmission removal

MLT 634/735/741 120 LSU PS

GEARBOX AND ANGLE DRIVE ASSEMBLY

gearbox

20
angle drive

REMOVAL OF COMPLETE TRANSMISSION (GEARBOX AND ANGLE DRIVE)

- Position the front wheels of the telehandler on appropriate

supports 30 cm high.
- Raise the boom to its maximum elevation and secure it in
place with, for example, a hoist.
30 cm

REQUIRED EQUIPMENT
1 - 1 bracket 1
3 Ref.: 229 035
2 2
- 3 hex-head bolts M12x30
Ref.: 63 547
- 2 special bolts 2
Ref.: 229 034
- 1 special bolt 3
Ref.: 229 033

(10/09/2010) 20-06-M153EN
 16
Transmission removal

- Remove the transmission protection plate 1 and its

bracket 2.

1
20

Remove the front axle drive shaft

- Remove the two clamps 1 at the front axle end.
- Remove the fixing bolts 2 at the gearbox end.

1
2

Remove the rear axle drive shaft

- Remove the two clamps 1 on each side of the drive shaft.

- Remove the fixing bolts 1 from the transmission shaft

at the angle drive end.
- Disengage the drive shaft and support it up.

20-06-M153EN (10/09/2010)
 17
Transmission removal

- Remove the hand-brake cable end fork 1.

- Loosen the lock-nut 2 and put the cable to one side under
the left hand side of the telehandler.

20
- Remove the accelerator cable 1 at the pedal end then
disengage it at the engine end.

- Remove the engine bay cover plate 1.

- Place a recipient under the gearbox and disconnect the

lower oil cooling hose 1.

(10/09/2010) 20-06-M153EN
 18
Transmission removal

- Unfasten the upper oil cooling hose 2.

- Plug the openings in the hoses and the gearbox.

2
20

- Remove the hose support bracket 1 under the gearbox.

- Pass the two oil-cooling hoses into the engine bay under
the radiator.

7
9
3

5 4

2 6
1
8

- Disconnect the hose 6.

- Plug all hoses and unions.
- Remove the heater hoses clamp 7 fastener.
- Remove the oil filter mounting assembly 8.
- Disconnect wiring harness plug 9.

- For models equipped with a trailer braking circuit, disconnect the two hoses 1 and 2 and the
pipe 3.
- For standard models disconnect the hose 2 mounted on the connecting block 4.
- Remove the bracket 5 fixing bolt then remove the assembly towards the cab.

20-06-M153EN (10/09/2010)
 19
Transmission removal

- Position an engine hoist above the transmission.

20
- On the gearbox, remove the plug 1 with the spring, leaving
the ball in place.
2
2
- Remove the two plugs 2.
- In their place fit the special bolts.

- Fit the lifting bracket 1 with two M12 bolts.

- Take the weight of the transmission on the hoist.

- Remove the four fixing bolts from the main pump 1.

- Remove the two fixing bolts 2 from the angle drive.
3 - Remove the mounting assembly 3 from the angle drive.

(10/09/2010) 20-06-M153EN
 20
Transmission removal

- Completely remove the right hand gearbox mounting.

20

- Remove the four fixing bolts 1 from the left hand gearbox
mounting.
2 - Slightly loosen the bolt 2.
- Swivel the mounting towards the outward side of the
1 chassis.

IMPORTANT
Ensure the area around the transmission is free of possible snags (cables, harnesses,
hoses etc.) to avoid anything catching when the transmission is removed.

- Slightly lower the transmission and move it towards the front of the telehandler to disengage the
hydraulic pump from the angle drive.
- Disengage the back of the angle drive from the hydraulic oil tank.
- Lower the transmission onto a dolly and chock it to stop it tipping.
- Unhook the sling.
- Remove the transmission via the front of the telehandler.

20-06-M153EN (10/09/2010)
 TRANSMISSION TROUBLESHOOTING

20
pages
PG 115 Transmission - 5-speed + JSM (diagnostic mode) . . . . . . . . . . . . . . . . . . . . . 2
– Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– ECU monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– Diagnostic mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– Output monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– Input monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PG 115 6-speed transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
– Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
– ECU monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
– Output monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
– Input monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

(24/05/2011) 20-08-M153EN
 2
Transmission troubleshooting

PG 115 TRANSMISSION - 5-SPEED + JSM (DIAGNOSTIC MODE)

DESCRIPTION
20

Shuttle control

ECU MONITORING

As soon as the ignition is switched on the ECU checks the output wiring (ECU to solenoid valves)
and input wiring (from shuttle control to ECU) in order to detect short circuits or breakages in the
wiring loom.

The ECU first checks the output wiring and only checks the input wiring if the output wiring passes
testing.

ECU output wiring harness

When the ignition is switched on, if no problems are detected in the wiring looms the display
shows the letter “n”, corresponding to the neutral position on the shuttle control.

If there is a fault in the output wiring, the display shows the letter “E” (Error) for 2 seconds then
reverts to showing “n”.

It is possible to identify the defective harness by holding down the Kick Down button, then switching
the ignition off, then on again. The display will then show the letter “E” followed by a number
indicating which harness is faulty.

DIAGNOSTIC MODE

To enter diagnostic mode:

- Locate the empty connector next to the brake fluid
reservoir.
- Put a jumper across the two connections of this
connector.
This jumper has the same effect as the Kick Down
button, just for entering diagnostic mode.

20-08-M153EN (24/05/2011)
 3
Transmission troubleshooting

OUTPUT MONITORING

Example:

then:

20
Error codes:
Low speed forward solenoid valve fault FL

High speed forward solenoid valve fault FH

Reverse gear solenoid valve fault

ECU memory fault

No. 1 solenoid valve fault

No. 2 solenoid valve fault

No. 3 solenoid valve fault

Crawler speed solenoid valve fault

INPUT MONITORING

Input diagnostic codes:

Transmission cut-off switch Shuttle control 3rd gear switch

Shuttle control reverse gear switch Shuttle control 4th gear switch

Shuttle control forward gear switch Shuttle control neutral switch

Shuttle control 1st gear switch Shuttle control 5th gear lock-out switch

Shuttle control 2nd gear switch

(24/05/2011) 20-08-M153EN
 4
Transmission troubleshooting

PG 115 6-SPEED TRANSMISSION

DESCRIPTION

Gear display
20

Gear selector

JSM

ECU MONITORING

As soon as the ignition is switched on the ECU checks the output wiring (ECU to solenoid valves)
and input wiring (from shuttle control to ECU) in order to detect short circuits or breakages in the
wiring loom.

The ECU first checks the output wiring and only checks the input wiring if the output wiring passes
testing.

ECU output wiring harness

When the ignition is switched on, if no problems are detected in the wiring looms the display
shows the number “8”, and then the letter “n” corresponding to the neutral position on the shuttle
control.

In the event of an output fault, the display shows the number “6” for 1 second, then “1” for
1 second, then “8” for 1 second, then “E” (error) for 2 seconds before reverting to “n”.

It is possible to identify the defective harness by holding down the “-” button on the JSM gear
selector, then switching the ignition off, then on again. The display will then show the letter “E”
followed by a number indicating which harness is faulty.

20-08-M153EN (24/05/2011)
 5
Transmission troubleshooting

OUTPUT MONITORING

Example:

then:

20
Error codes:
Low speed forward solenoid valve fault FL

High speed forward solenoid valve fault FH

Reverse gear solenoid valve fault

ECU memory fault

No. 1 solenoid valve fault

No. 2 solenoid valve fault

No. 3 solenoid valve fault

INPUT MONITORING

Procedure:

While holding the “-” button down on the JSM gear selector, switch the ignition back on.

Input diagnostic codes:

Parking brake switch Transmission cut-off switch

Shuttle control reverse gear switch Driver presence switch

Shuttle control forward gear switch 6th gear lock-out switch

Gear change up switch Shuttle control neutral switch

(24/05/2011) 20-08-M153EN
 6
Transmission troubleshooting

ECU software development facilitates gear changes from 5th to 6th.

Old software No. 265433:

Change up from 5th to 6th at 21,25 kph (very close to maximum speed of 22,4 kph).
Coef. 1448 Hz.
Change down from 6th to 5th at 19,7 kph. Coef. 1341 Hz.

New software No. 265433 E.S. or 287423: (from No. 585753)

20

The new software makes it possible to change from 5th to 6th at 19,5 kph. Coef. 1340 Hz.
Change down from 6th to 5th at 18,3 kph. Coef. 1246 Hz.

20-08-M153EN (24/05/2011)
 AXLE

- AXLE CONTROL AND ADJUSTEMENT

- AXLE REMOVAL

30
- AXLE CONTROL AND ADJUSTEMENT

M
547983

R
- AXLE TROUBLESHOOTING (Axle 212)
- SPECIFIC AXLE TOOLING
 AXLE CONTROL AND ADJUSTMENT

30
pages
Axle tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

(24/05/2011) 30-04-M153EN
 2
Axle control and adjustment

AXLE TIGHTENING TORQUES

MLT 1035 LT LSU

340 N.m ± 10%

340 N.m ± 10%
340 N.m ± 10%

480 N.m ± 10%

63 N.m ± 15%
30

63 N.m ± 15%

Standard torque settings to be used when no specific mention is made in dismantling

and re-assembly.
Torque expressed in N.m (*)
Thread Class 5.6 Class 5.8 Class 8.8 Class 10.9 Class 12.9
diameter
M3 0,54 0,76 1,16 1,7 2
M4 1,24 1,74 2,66 3,91 4,57
M5 2,47 3,46 5,2 7,7 9
M6 4,29 6 9,1 13,4 15,7
M8 10,4 14,6 22 32 38
M10 20 28 44 64 75
M12 35 49 76 111 130
M14 57 79 121 178 209
M16 88 124 189 278 325
M18 122 171 261 384 449
M20 173 243 370 544 637
M22 238 334 509 748 875
M24 298 418 637 936 1095
M27 442 619 944 1386 1622
M30 600 840 1280 1880 2200
(*) - Tightening torques are given for black or zinc-plated fasteners with light lubrication.
- Tightening torques are given for automatic slip and reset torque wrenches and direct read
dial torque wrenches.
- For more information, refer to Standard NF E25-030.

30-04-M153EN (24/05/2011)
 AXLE REMOVAL

30
pages
Axle assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Front axle removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– Re-fitting front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal of rear axle with removable axle rocker beam . . . . . . . . . . . . . . . . . . . . . . . 5
– Rear axle re-fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Rear axle rocker beam removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
– Rear axle rocker beam removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
– Re-fitting rear axle rocker beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Integral articulation rear axle remova . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
– Rear axle re-fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

(24/05/2011) 30-06-M153EN
 2
Axle removal

AXLE ASSEMBLY
MLT 1035 LT LSU

340 N.m ± 10%

340 N.m ± 10%
340 N.m ± 10%

480 N.m ± 10%

30

63 N.m ± 15%

63 N.m ± 15%

FRONT AXLE REMOVAL

- Raise the boom and support it with a prop.

30-06-M153EN (24/05/2011)
 3
Axle removal

- Remove the two fixing clamps 1 at the axle end of the drive
shaft.

- Disconnect the two hoses 1 from the steering ram.

30
1

- Remove the forward chassis cover plate 1.

- Disconnect the brake fluid supply pipe 1.

- Plug the pipe and the union.
- Disconnect the wheel direction sensor wiring 2.

2 1

(24/05/2011) 30-06-M153EN
 4
Axle removal

- Using a jack, raise the front of the chassis sufficiently to

allow the axle to pass underneath.
- Place the assembly on a support beam 1 (approx. 800 mm
in length) supported by two stands.

Be careful with hoses and wiring underneath the

chassis.
1

- Remove the axle plate fixing bolts 1.

30

1 1

- Wheel the axle forwards under the chassis.

Be careful not to let the axle rotate about the

wheels.

RE-FITTING FRONT AXLE

- Re-fitting is by reversing the operations described in “REMOVAL OF FRONT AXLE”.

- Tighten all fasteners to the torques shown in “TIGHTENING TORQUE SETTINGS”.

30-06-M153EN (24/05/2011)
 5
Axle removal

REMOVAL OF REAR AXLE WITH REMOVABLE AXLE ROCKER BEAM

- Position the telehandler on horizontal ground, handbrake

on and shuttle control and gear lever in neutral.
- Chock the telehandler and lower the boom.

30
Remove the rear axle drive shaft
- Remove the two clamps 1, one each side of the drive shaft.

- Disconnect the two hoses 1 from the steering ram.

2
- Plug hoses and unions.
- Disconnect the wheel direction switch wiring 2.

1
1

- Disconnect the flexible brake hose 1.

- Plug the hose and the union.
- Put the hose to one side above the rear axle.

(24/05/2011) 30-06-M153EN
 6
Axle removal

- Remove the strain gauge cover 1.

- Remove the two mounting screws 1.

30

- Remove the strain gauge and secure in such a way that

it will not be subject to load or shock.

1 1

- Raise the rear of the telehandler using a jack and place

two stands and a support beam 1 under the chassis at the
strong points.

- Remove the two rear wheels.

- Remove the mudguard brackets 1.
1

30-06-M153EN (24/05/2011)
 7
Axle removal

- Arrange a lifting beam 1 above the telehandler.

- Secure slings to each side of the axle.
- Remove the fixing bolts 2 on each side of the rear axle.
1

30
2
2

- Lower the axle onto a pallet.

- Remove the assembly using a fork lift truck or a pallet truck.

REAR AXLE RE-FITTING

- Re-fitting is by reversing the operations described in “REAR AXLE REMOVAL”.

- Tighten all fasteners to the torques shown in “TIGHTENING TORQUE SETTINGS”.

When the axle is re-fitted, fit the strain gauge using torque settings shown on page 16 and
adjust the safety system (see group 80 - ELECTRICITY).

(24/05/2011) 30-06-M153EN
 8
Axle removal

REAR AXLE ROCKER BEAM REMOVAL

- Remove the rear axle before removing the rear axle rocker beam.

REAR AXLE ROCKER BEAM REMOVAL

- For MLT Series 1 and Turbo, remove the hook fitted to the
1 telehandler and the cover plate 1.
- Projecting hitch
30

- Coupling ladder
1

1 - Hydraulic hitch

30-06-M153EN (24/05/2011)
 9
Axle removal

- For other models remove only the hook fitted to the

telehandler and leave the counter-weight in place.
- Coupling ladder

- Hydraulic hitch

30
- Remove the greasing pipes from the swivel point of the
rear axle rocker beam.
- Secure a lifting eye 1 at each end of the rocker beam.
- Fit a sling to each lifting eye.
1

Ø 90
ép. 5 mm - Lifting eye diagram.
Ø 45

Vis HM 12x30

(24/05/2011) 30-06-M153EN
 10
Axle removal

- Remove the fixing bolt 1 from the swivel point of the rear
axle rocker beam.

- Remove the swivel axle 1 using a slide hammer.

30

Take care not to let the rocker beam rock.

1

- Remove the rear axle rocker beam.

RE-FITTING REAR AXLE ROCKER BEAM

- Re-fitting is by reversing the operations described in “REAR AXLE ROCKER BEAM REMOVAL”
- Tighten all fasteners to the torques shown in “TIGHTENING TORQUE SETTINGS”.

30-06-M153EN (24/05/2011)
 11
Axle removal

INTEGRAL ARTICULATION REAR AXLE REMOVAL

- Position the telehandler on horizontal ground, handbrake

on and shuttle control and gear lever in neutral.
- Chock the telehandler and lower the boom.

30
Remove the rear axle drive shaft
- Remove the two clamps 1, one each side of the drive shaft.

- Disconnect the two hoses 1 from the steering ram

(one on each side).
- Plug hoses and unions.

- Disconnect the flexible brake hose 1.

- Plug the hose and the union.
- Put the hose to one side above the rear axle.
2
2
- Disconnect the two greasing pipes 2.
1

(24/05/2011) 30-06-M153EN
 12
Axle removal

- Remove the strain gauge cover 1.

- Remove the two mounting bolts 2.

30

- Remove the strain gauge and secure in such a way that

it will not be subject to load or shock.
2 2

- Disconnect the wiring 1 from the wheel direction switch.

- Remove the fixing bolts 2 from the swivel point of the rear
1
axle.

- For the MLT 629 Series 1 and Turbo, remove the hook
1
fitted to the telehandler and the cover plate 1.
- Projecting hitch

30-06-M153EN (24/05/2011)
 13
Axle removal

- Coupling ladder
1

- Hydraulic hitch

30
1

- For other models remove only the hook fitted to the

telehandler and leave the counter-weight in place.
- Coupling ladder

- Hydraulic hitch

(24/05/2011) 30-06-M153EN
 14
Axle removal

- Raise the rear of the telehandler using a jack and place

two stands and a support beam 1 under the chassis at the
strong points.

- Remove the two rear wheels.

30

- Remove the mudguard brackets 1.

1

- Arrange a lifting beam 1 above the telehandler.

- Secure slings to each side of the axle.

30-06-M153EN (24/05/2011)
 15
Axle removal

- Remove the swivel axle 1 using a slide hammer.

30
- Lower the axle onto a pallet.
- Remove the assembly using a fork lift truck or a pallet truck.

REAR AXLE RE-FITTING

- Re-fitting is by reversing the operations described in “REAR AXLE REMOVAL”.

- Tighten all fasteners to the torques shown in “TIGHTENING TORQUE SETTINGS”.

When the axle is re-fitted, fit the strain gauge using torque settings shown on page 16 and
adjust the safety system (see group 80 - ELECTRICITY).

(24/05/2011) 30-06-M153EN
 16
Axle removal
30

30-06-M153EN (24/05/2011)
 BRAKE

- BRAKE CHARACTERISTICS AND

SPECIFICATIONS

- BRAKE COMPONENTS LOCATION

- BRAKE CONTROL AND ADJUSTEMENT

- SPECIFIC BRAKE TOOLS

40
 BRAKE CHARACTERISTICS AND
SPECIFICATIONS

pages

40
MT BRAKE CIRCUIT CHARACTERISTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– MT 732
– MT 932
– MT 1030 S
– MT 1030 ST
MT HYDROSTATIC BRAKE CIRCUIT CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . 4
– MT 1033 H L
MLT BRAKE CIRCUIT CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
– MLT 630 T
– MLT 634 T LSU
– MLT 634 120 LSU + PS
– MLT 731 T + LSU
– MLT 735 T LSU
– MLT 735 120 LSU + PS
– MLT 741 120 LSU + PS
– MLT 742 T
– MLT 1035 LT LSU
MLT HYDROSTATIC BRAKE CIRCUIT CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . 6
– MLT 742 H T LSU

(03/05/2011) 40-01-M153EN
 2
Brake characteristics and specifications
40

40-01-M153EN (03/05/2011)
MT BRAKE CIRCUIT CHARACTERISTICS 3
Brake characteristics and specifications

Disc brake:
Brake fluid L.H.M S8 214 B SHELL V=0,75L Number of discs per wheel 1
Braking surface per disc side 30,8 cm2
Total braking surface 61,6 cm2
Friction material Asbestos-free
Master cylinder ø1’1/8
(CARLISLE CORP.)
Cubic capacity: 20,2 cm3
Dynamic Friction Coefficient 0,2
Static friction coefficient 0,4
Static application:
* Maximum permissible force at brake linkage (Fmax) 1890 N
* Average friction radius (Rmoy) 81 mm
* Max torque (Cmax= 0,014 x Fmax x Rmoy) 2143 N.m
Make TURNER POWERTRAIN
Disc diameter 203,8 mm
Disc thickness 9,5 mm
Wear adjustment mechanical

40
Braking ratio:
245/61 = 4,016

Towards rear drive axle

(same as front drive axle)

Planetary reducer
R = 1/6

Oil back brake disc:

Number of discs per wheel 4
Braking surface per disc side 146,85 cm2
Total braking surface (front axle only) 2350 cm2
Total telehandler braking surface 4699 cm2
Pressure of use advised 70 to 80 bar
Friction material WELLMAN No.266
Dynamic Friction Coefficient 0,115
Static friction coefficient 0,095
Make DANA
Disc diameter 201,5 mm
Disc thickness 4,75 - 4,85 mm
Scope of action 88 mm
Number of receiver cylinders 1
Slave cylinder surface 41,88 cm2
Wear compensation Auto

SERVICE BRAKE Track width 26,75 mm PARKING BRAKE

(04/05/2011) 40-01-M153EN
 4 MT HYDROSTATIC BRAKE CIRCUIT CHARACTERISTICS
Brake characteristics and specifications

(25) 190
66
Brake fluid L.H.M S8 214 B SHELL

Master cylinder ø1’1/8

Cubic capacity: 20,2 cm3
MAX

25
8

40
40

Braking ratio:
190x80/66x8 = 28,79

Braking ratio:
258/40 = 6,45

80
8
Planetary reducer
R = 1/6

Oil back brake disc:

Number of discs per wheel 4
Braking surface per disc side 146,85 cm2
Total braking surface (front axle only) 2350 cm2
Pressure of use advised 70 to 80 bar
Friction material WELLMAN No.266
Dynamic Friction Coefficient 0,115
Static friction coefficient 0,095
Make DANA
Disc diameter 201,5 mm
Disc thickness 4,75 - 4,85 mm
Scope of action 88 mm
Number of receiver cylinders 1
Slave cylinder surface 41,88 cm2
Wear compensation Auto
SERVICE BRAKE Track width 26,75 mm
PARKING BRAKE

40-01-M153EN (04/05/2011)
MLT BRAKE CHARACTERISTICS 5
Brake characteristics and specifications

Disc brake:
Brake fluid L.H.M S8 214 B SHELL V=0,75L Number of discs per wheel 1
Braking surface per disc side 30,8 cm2
Oil re
turn Master cylinder ø31,75 mm Total braking surface 61,6 cm2
Cubic capacity: 31,4 cm3 Friction material Asbestos-free
Oil s (CARLISLE CORP.)
upply
Dynamic Friction Coefficient 0,2
Static friction coefficient 0,4
Static application:
* Maximum permissible force at brake linkage (Fmax) 1890 N
* Average friction radius (Rmoy) 81 mm
* Max torque (Cmax= 0,014 x Fmax x Rmoy) 2143 N.m
Make TURNER POWERTRAIN
Disc diameter 203,8 mm
Disc thickness 9,5 mm
Wear adjustment mechanical

40
Braking ratio:
193/58 = 3,327

To rear axle
(idem. front axle)

Planetary reducer
R = 1/6

Oil back brake disc:

Number of discs per wheel 4
Braking surface per disc side 146,85 cm2
Total braking surface (front axle only) 2350 cm2
Total telehandler braking surface 4 699 cm2
Pressure of use advised 70 to 80 bar
Friction material WELLMAN No.266
Dynamic Friction Coefficient 0,115
Static friction coefficient 0,095
Make DANA
Disc diameter 201,5 mm
Disc thickness 4,75 - 4,85 mm
Scope of action 88 mm
Number of receiver cylinders 1
Slave cylinder surface 41,88 cm2
Wear compensation Auto

SERVICE BRAKE Track width 26,75 mm PARKING BRAKE

(04/05/2011) 40-01-M153EN
 6 MLT HYDROSTATIC BRAKE CIRCUIT CHARACTERISTICS
Brake characteristics and specifications

Brake fluid L.H.M S8 214 B SHELL V=0,75L

Master cylinder ø31,75 mm

Cubic capacity: 31,4 cm3
40

Braking ratio: 190x80/

66x8 = 28,79

Braking ratio:
193/45 = 4,3

Towards rear drive axle

(same as front drive axle)

Planetary reducer
Oil back brake disc:
R = 1/6
Number of discs per wheel 4
Braking surface per disc side 146,85 cm2
Total braking surface (front axle only) 2350 cm2
Total telehandler braking surface 4 699 cm2
Total braking surface, parking brake (front axle) 2350 cm2
Pressure of use advised 70 to 80 bar
Friction material WELLMAN No.266
Dynamic Friction Coefficient 0,115
Static friction coefficient 0,095
Make DANA
Disc diameter 201,5 mm
Disc thickness 4,75 - 4,85 mm
Scope of action 88 mm
Number of receiver cylinders 1
Slave cylinder surface 41,88 cm2
Wear compensation Auto
Track width 26,75 mm
SERVICE BRAKE PARKING BRAKE

40-01-M153EN (04/05/2011)
 BRAKE COMPONENTS LOCATION

pages

40
HYDRAULIC BRAKING CIRCUIT DIAGRAM KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
MT HYDRAULIC BRAKING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– MT 732
– MT 932
– MT 1030 S
– MT 1030 ST
HYDRAULIC BRAKING CIRCUIT - MT HYDROSTATIC . . . . . . . . . . . . . . . . . . . . . . . . . 4
– MT 1033 H L
MLT HYDRAULIC BRAKING CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
– MLT 630 T
– MLT 634 T LSU
– MLT 634 120 LSU + PS
– MLT 731 T + LSU
– MLT 735 T LSU
– MLT 735 120 LSU + PS
– MLT 741 120 LSU + PS
– MLT 742 T
– MLT 1035 LT LSU
HYDRAULIC BRAKING CIRCUIT - MT HYDROSTATIC . . . . . . . . . . . . . . . . . . . . . . . . . 6
– MLT 742 H T LSU

(04/05/2011) 40-03-M153EN
 2
Brake components location

HYDRAULIC BRAKING CIRCUIT KEY

Item Designation
BA Feed block + accumulator
MC Master cylinder
P Pump equipment
PD Steering pump
PFR(O) Trailer brake plug integrated in the vafr (option)
RLF Brake fluid tank
SC Circuit selector
SCFR(O) Circuit selector (trailer brake option)
T/R Tank
VACM Movement cut-off valve
VAFR Trailer brake valve
VAFR(O) Trailer brake valve (option)
40

40-03-M153EN (04/05/2011)
MT BRAKE CIRCUIT LOCATIONS 3
Brake components location

V
A

PD
V2 S P
V1
SCFR

40
RLF

B2

MC
B1

T Y

LS
P
VAFR
OP
TIO
MT 732 NM
T1
MT 932 03
0S
MT 1030 S T PFR
MT 1030 ST
(04/05/2011) 40-03-M153EN
 4 MT HYDROSTATIC BRAKE CIRCUIT LOCATIONS
Brake components location

V
A
40

RLF

B2 MC
B1

MT 1033 H L T
40-03-M153EN (04/05/2011)
MLT BRAKE CIRCUIT LOCATIONS 5
Brake components location

V
A

PD

V2 S D
SC V1
RLF V1 V2
SCFR
S
D
BA

40
VACM U

BL B1 MC
N S2F
R
L
B

N
P L MLT
63
MLT 0 T
P

731
T
MLT
742
U T

BA
Serie D - Serie 4
MLT 630 T SER
IE
MLT 634 T LSU OP D - S
MLT 634 120 LSU + PS T E
OP ION RIE
MLT 731 T + LSU SER TIO MLT 4
MLT 735 120 LSU + PS IE E N M 731
- S LT 74 T
MLT 741 120 LSU + PS ER 2 T
IE5
MLT 742 T
MLT 1035 LT LSU Y
LS T
Serie E - Serie 5
MLT 634 T LSU R P
VAFR
MLT 634 120 LSU + PS
MLT 731 T
MLT 735 T LSU
MLT 735 120 LSU + PS
MLT 741 120 LSU + PS PFR
MLT 1035 LT LSU
(04/05/2011) 40-03-M153EN
 6 MLT HYDROSTATIC BRAKE CIRCUIT LOCATIONS
Brake components location

V
A

RLF
PD
V2 S D
V1
SCFR
40

N B2
A A
L B
N
MC
L
P P
T A

PH

T Y

LS
P
VAFR
OP
TIO
N

PFR
MLT 742 H T LSU
40-03-M153EN (04/05/2011)
 BRAKE CONTROL AND ADJUSTMENT

pages

40
Brake circuit bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Trailer braking circuit bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Parking brake pad removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Re-fitting parking brake pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Checking and adjusting parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
MLT and MT service brake pedal height adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 8
Service brake pedal height adjustment, MLT hydrostatic. . . . . . . . . . . . . . . . . . . . . . 9
MT hydrostatic service brake pedal height adjustment . . . . . . . . . . . . . . . . . . . . . . . 10

(13/05/2011) 40-04-M153EN
 2
Brake control and adjustment

Brake circuit bleeding

REQUIRED EQUIPMENT: 1 pressurized brake bleeder
(pressure 1 to 1,2 bar) Ref. 554 019.

- Raise the jib.

- Remove the forward cover plat (Item 1).
1
40

- Remove the lower left dashboard cover (Item 2).

Behind the brake pedal, position the bridle at the hole

(Item L) furthest away from the swivel point, in the “Long”:
brake bleeding position. (Except MT)

40-04-M153EN (13/05/2011)
 3
Brake control and adjustment

- Take the top off the brake fluid reservoir and fit the brake
bleeder adapter (Item 3).

3
- Operate the bleed valve.

- Place a transparent brake bleeding hose on the left hand bleed

nipple (Item 5) on the rear axle (except MT 1033 H L).
4

- Loosen the vent screw, then when the brake fluid flows without
5
air bubbles, retighten the vent screw.

40
- Repeat the operation on the right hand bleed nipple (Item 6)
on the rear axle (except MT 1033 H L).

As a general rule, when bleeding the brake circuit start with the
most distant bleed point and work towards the nearest.

- Carry out the same procedure on the right hand, then left hand
bleed nipples (Item 7) on the front axle and then bleed the
master cylinder if necessary.

- Top up the brake fluid tank level.

Fluid to be used: See “CHARACTERISTICS” in chapter
“O - GENERAL POINTS”.

When bleeding is complete re-fit the bridle in its service position

(Item C), position “short”. (Except MT)

(13/05/2011) 40-04-M153EN
 4
Brake control and adjustment

Trailer braking circuit bleeding

REQUIRED EQUIPMENT: 1 pressurized brake bleeder
(pressure 1 to 1,2 bar) Ref. 554 019.

- Raise the jib.

- Remove the transmission cover plate (Item 1).
40

- Remove the lower left hand instrument panel cover

(Item 2).

- Take the top off the brake fluid reservoir and fit the brake
bleeder adapter (Item 3).

40-04-M153EN (13/05/2011)
 5
Brake control and adjustment

- Place a transparent brake bleeding tube on the trailer

braking valve bleed nipple (Item 4).
4
- Operate the bleed valve.

- Loosen the vent screw, then when the brake fluid flows
without air bubbles, retighten the vent screw.

- Top up the brake fluid tank level.

Fluid to be used: See “CHARACTERISTICS” in chapter
“O - GENERAL POINTS”.

40

(13/05/2011) 40-04-M153EN
 6
Brake control and adjustment

Parking brake pad removal

- Place the telehandler on horizontal ground, with the handbrake off and in neutral.
- Chock the lift truck.

- Remove the parking brake cable (Item 1).

- Remove the caliper upper mounting bolt (Item 2).
- Swivel the caliper around the lower bolt (Item 3).
1

3
40

- Compress the spring (Item 4) using two screwdrivers.

- Remove the pads (Item 5).
5

Re-fitting parking brake pads

- Re-fitting is the reverse of the operations described in the chapter “PARKING BRAKE PAD
REMOVAL”.
- Check and adjust the parking brake.

40-04-M153EN (13/05/2011)
 7
Brake control and adjustment

Checking and adjusting the parking brake

A
B

For public highway certified telehandlers

- Place the lift truck on level ground with the rated load in the transport position.

40
- Check braking by locking the parking brake (Item 1) in position A.
- Pull on the lift truck rear towing pin with a minimum force of 3500 daN. The wheels of the lift truck
must not rotate.
- Carry out adjustments if necessary:
- Progressively tighten the end of the lever (Item 1) and recheck braking.
- Repeat the operation until the correct braking adjustment is obtained.

For non HRT approved lift truck

- Place the lift truck on a slope less than 15% with the rated load in the transport position.
- Check braking by locking the parking brake (Item 1) in position A.
- The adjustment is correct when the lift truck is held stationary on a slope.
- Carry out adjustments if necessary:
- Press the service brake pedal, then release the parking brake moving the lever (Item 1)
to position B.
- Progressively tighten the end of the lever (Item 1) and recheck braking.
- Repeat the operation until the correct braking adjustment is obtained.

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 8
Brake control and adjustment

MLT and MT service brake pedal height adjustment

1) - BRAKE PEDAL

- Adjust the height of the pedal (Item A) from the cab floor without mats, to 140 mm for MLT and
155 mm for MT, using the stop (Item B).
- Tighten the locknut (Item E).
- Adjust the pedal free play (Item A) (3 to 4 mm) by turning the pushrod (Item C).
- Tighten the locknut (Item D).

2) - TRANSMISSION CUT-OFF SWITCH

- Pedal in its rest position, against the stop (Item B).

- Adjust the switch position (Item F) so that the transmission cut-off activates when the pedal is
125 mm high for MLT and 130 mm high for MT measured from the cab floor (see diagram).
40

B
C E
D

Pedal free play

3 to 4 mm

F
MT
130 mm
155 mm
125 mm
140 mm

MLT

40-04-M153EN (13/05/2011)
 9
Brake control and adjustment

Service brake pedal height adjustment, MLT hydrostatic

1) - TH7 AND BRAKE PEDAL

- Adjust the height of the brake pedal (Item A) measured from the floor without mats to 140 mm.
- Adjust the TH7 (Item B) using the screw (Item C).
- Tighten the locknut (Item D).
- Check the adjustment of the TH7 (Item E) protection screw and the tightness of the locknut (Item F).
- Ensure the lug (Item G) is touching the pedal bracket and adjust the master cylinder by turning
the pushrod (Item H).
- Tighten the locknut (Item I).
- Adjust the brake pedal free play (Item A) (3 to 4 mm) using the lug (Item G) adjustment screw
(Item J).
- Tighten the locknut (Item K).

2) - TRANSMISSION CUT-OFF SWITCH

40
- With the pedal at rest, touching the TH7 screw (Item C).
- Adjust the switch (Item L) position so that transmission cut-off is activated when the pedal is
125 mm from the cab floor (see diagram).

Pedal free play

3 to 4 mm

Pedal in rest
position

Pedal position at the start

of transmission cut-off

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 10
Brake control and adjustment

MT hydrostatic service brake pedal height adjustment

1) - BRAKE PEDAL

- Adjust the height of the brake pedal (Item A) to 160 mm above the cab floor (without mats) using
the stop (Item B).
- Tighten the locknut (Item C).
- Adjust the brake pedal free play (Item A) (3 to 4 mm) by turning the pushrod (Item D).
- Tighten the locknut (Item E).

2) - TH7 VALVE ADJUSTMENT

- Pedal in its rest position, resting on the stop (Item B).

- Place a 0,5 mm to 1 mm shim; between the screw head (Item F) and the TH7 pushrod.
- Adjust the stop position (Item F).
- Tighten the locknut (Item G).
40

NOTE: The pedal switch must change state (passnt) as soon as the TH7 pushrod is free to move,
that is at the very start of braking.

Pedal in rest position

Pedal free play

3 to 4 mm

40-04-M153EN (13/05/2011)
 SPECIFIC BRAKE TOOLING

pages

40
HYDRAULIC BRAKE BLEED VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

(11/05/2011) 40-09-M153EN
 2
Specific brake tooling

HYDRAULIC BRAKE BLEED VALVE

Bleed valve supplied with all the components required

for bleeding the hydraulic brake circuits of all Manitou
products.
40

MANITOU Reference

Hydraulic brake bleed valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 554019

Spare parts:
Top manometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 719980
Bottom manometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 719981
Membrane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 661913
Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 661914

40-09-M153EN (11/05/2011)
 BOOM

- BOOM CONTROL AND ADJUSTEMENT

- BOOM REMOVAL

50
 BOOM CONTROL AND ADJUSTMENT

pages

MLT 1035 LT LSU - Complete boom exploded diagram . . . . . . . . . . . . . . . . . . . . . . . 3

Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
– Bleeding and filling boom extension cylinders . . . . . . . . . . . . . . . . . . . . . . . . . 6

50
– Hose mounting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
– Instructions for mounting slide pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
– Instructions for slide pad greasing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
– Instructions for pivot greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
– Instructions for greasing the boom interior . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal of crowd and accessory circuit hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
– Re-fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
– Checking the coiling of hoses inside the boom . . . . . . . . . . . . . . . . . . . . . . . . 14
Removal of intermediate boom cylinder hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
– Re-fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
– Checking the coiling of hoses inside the boom . . . . . . . . . . . . . . . . . . . . . . . . 18
Crowd cylinder removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
– Re-fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Inner boom extension cylinder removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
– Re-fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
– Checking the coiling of hoses inside the boom . . . . . . . . . . . . . . . . . . . . . . . . 28
Removal of intermediate boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
– Re-fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Clamp fork removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
– Re-fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

(11/05/2011) 50-04-M153EN
 Inner boom removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
– Re-fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Intermediate boom removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
– Re-fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Complete boom removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
– Re-fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

MLT 634, MLT 731, MLT 735, MLT 741

Adjusting and shimming the boom slide pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Removal of twin hoses from the boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
– Removal of twin hoses from the boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
– Re-fitting twin hoses in the boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Crowd cylinder removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
– Crowd cylinder removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
– Crowd cylinder re-fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Clamp fork removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
– Clamp fork removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
50

– Fork clamp re-fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Boom extension cylinder removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
– Boom extension cylinder removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
– Boom extension cylinder re-fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Boom removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
– Boom removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
– Re-fitting the boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

50-04-M153EN (11/05/2011)
 3
Boom control and adjustment

MLT 1035 LT LSU - COMPLETE BOOM EXPLODED DIAGRAM

50
HYDRAULIQUE (Circuit flèche)
HYDRAULIK (Auslegerkreis)
HIDRAULICO (Circuito aguilón)
HYDRAULIC (Jib circuit)
IDRAULICO (Circuito bracci telescopici)

A
B
D C

B A

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Boom control and adjustment

HYDRAULIQUE (Circuit levage - Télescopage)

HYDRAULIK (Aufwinden - Zusammenstroll kreis)
HIDRAULICO (Circuito levantamiento -Teleccopaje)
HYDRAULIC (Lifting - Teslescope circuit)
IDRAULICO (Circuito sollevamento - braccio)
ION
AT
AR
EP
ER ION
ED AC
S AIR SATZ EPAR
S
CE TUR E R
NE ARA IO D
P R
RE ESA IT NE
C K
NE AIR RAZIO
E P PA
R RE
K IT

ION
AT
AR
EP
ER ION
IR E D Z RAC
A T A
SS SA EP
CE TUR E R
NE ARA IO D
P R
RE ESA IT NE
C K
NE AIR RAZIO
P
RE REPA
KIT
50

HYDRAULIQUE (Circuit télescopage)

HYDRAULIK (Zusammenstroll kreis)
HIDRAULICO (Circuito teleccopaje)
HYDRAULIC (Teslescope circuit)
IDRAULICO (Circuito braccio)

N
TIO
RA
PA
RE N
E DE ACIO
AIR TZ AR
SS SA EP 36
CE TUR E R
NE ARA IO D
P R
RE ESA IT 36
C NE
K
NE AIR RAZIO
P
35
RE REPA
KIT
35 34
34
36
36
ION
AT
AR
EP
DER IO N
E AC
AIR TZ AR
SS SA EP
CE TUR E R
NE ARA IO D
P R
RE ESA IT NE
C K
NE AIR RAZIO
P
RE REPA
KIT

50-04-M153EN (11/05/2011)
 5
Boom control and adjustment

HYDRAULIQUE (Circuit compensation - alimentation flèche)

HYDRAULIK (Kompensation - Ausleger zuschiebung kreis)
HIDRAULICO (Circuito compensación - alimentación aguilon)
HYDRAULIC (Compensation - jib feed circuit)
IDRAULICO (Circuito compensazione - Alimentazione bracci telescopici)

50

(11/05/2011) 50-04-M153EN
 6
Boom control and adjustment

RECOMMENDATIONS

BLEEDING AND FILLING BOOM EXTENSION CYLINDERS

- This operation is to be carried out when one of the boom extension cylinders has been removed
or disconnected from its hydraulic oil supply.
- Start the engine and completely retract the boom while maintaining pressure on the control block
lever in order to fill the cylinders. Then slightly extend the boom, then retract it again.

NOTE: To ensure correct simultaneous extension, you must regularly completely retract the boom.

HOSE MOUNTING INSTRUCTIONS

- When you re-fit or replace a hose, you must always allow it

to follow its natural coiling direction. Connections must be
made without twisting or strain, so that the hose uncoils
inside the boom without excessive twisting.

NOTE: The markings stamped on the hose ends must be

positioned to the outside of the coiling direction
50

Marking

Marking

50-04-M153EN (11/05/2011)
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Boom control and adjustment

INSTRUCTIONS FOR MOUNTING SLIDE PADS

- When selecting bolts, ensure a minimum of 9 mm protrudes

beyond the nut.
- Apply normal Loctite to the stud/insert and nut/stud on all
slide pad fittings that are inaccessible from the outside of the
Shim boom.
Slide pad - Screw the stud 1 by hand to the end of the thread on the insert 2.
3 2
1 - Fit the nut 3.
- Shim, then tighten the nut to a torque of 92,6 N.m ± 25%.
9 mm
- After shimming, play should be between 0 and 0,5 mm for all
minimum
slide pads.

Clearance

50
NOTE: For fitting side slide pads special tool Ref. 552 829 should be used.

INSTRUCTIONS FOR SLIDE PAD GREASING

This must be done when new slide pads are fitted to the boom.

NOTE: To be done every 10 hours for the first 50 hours then one last time after 250 service
hours.

- Extend the jib completely.

- Using a paintbrush, apply grease to all 4 sides of the boom sections.
- Extend and retract the jib several times in order to spread the coat of grease evenly.
- Remove the surplus of grease.

Recommended grease: MANITOU multi-purpose NLGI Grease Ref. 161 590.

If the telehandler is used in an abrasive atmosphere (dust, sand, coal) use an anti-friction
coating (MANITOU Ref.: 483 536) available from your Manitou dealer.

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Boom control and adjustment

INSTRUCTIONS FOR PIVOT GREASING

Greasing bushed pivots:

- For new parts, fill all hollows or holes in the bushings with grease.
- Apply a thin film of grease to the pin eyes.
- Check for correct operation, then re-grease.

Greasing pivots without bushings:

- Apply a thin film of grease to the pin eye in unbushed bearings.

Recommended grease: MANITOU Multi-purpose HD NLGI 2 Grease Ref. 554 973.

INSTRUCTIONS FOR GREASING THE BOOM INTERIOR

To be carried out after:

- Fitting new hoses.
- Fitting a new outer boom.
- Outer boom cleaning.
50

- Completely extend the boom sections and grease the lower part of the outer boom over its entire
length and width to ease the movement of hoses inside the boom.

Recommended grease: MANITOU multi-purpose NLGI Grease Ref. 161 590.

50-04-M153EN (11/05/2011)
 9
Boom control and adjustment

REMOVAL OF CROWD AND ACCESSORY CIRCUIT HOSES

NOTE: The procedure below describes how to change the

accessory circuit hoses; the procedure is identical for
the crowd circuit.

- Remove the two covers 1 at the back of the boom.

1

- Remove the two pads 1 only for 1st and 2nd generation
machines.
- Remove the hose guide 2.

50
1 1

- Remove the upper hose bracket 1.

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 10
Boom control and adjustment

- Extend the crowd cylinder 1 rod to half its length.

- Remove the inner boom cover plate 1.

1
50

- Depressurise the hydraulic circuit.

- Disconnect and plug the accessory circuit hoses 1.

- Remove the hoses 1 through the back of the boom.

50-04-M153EN (11/05/2011)
 11
Boom control and adjustment

- To make it easier to remove the hoses and brackets under

the boom, disconnect and plug the intermediate boom
2 extension cylinder feed hoses 1 and remove the clamps 2.
- Have a recipient ready to catch the oil.
- Remove the hose bracket 3 and recover the brackets from
1
inside the boom.
- Disconnect the two hoses 4.
3

1 4 4

- Take out the two hoses 1 passing them

underneath the boom.

50
RE-FITTING

- Re-fit the hoses 1 in the outer boom and connect them to

the metal pipes.
- Re-fit the hose bracket 2 with the clamps to the inside of
the boom.

NOTE:
1 2
- Bent or mis-shaped brackets should be changed.
1 - Hoses 3 should be clamped in their original locations.
3

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 12
Boom control and adjustment

2 NOTE: When re-fitting the bracket 1,

ensure it does not overlap the
1
clamp 2.
Good
- Re-connect the two boom extension
cylinder hoses 1, then re-fit the the two
2 1 2
clamps 2.
1

Bad

- Pull the hoses through the back of the boom and lay them
totally flat and aligned with the telehandler.

- Take the hoses one by one (ensuring they are not twisted)
and put them in the boom head. When resistance is felt
twist them to pass them above the crowd cylinder, then
release.

- Connect the hoses at the inner boom.

50

- Re-fit but do not tighten the bracket 1.

NOTE:
Bent or mis-shaped brackets must be changed.
1

- Start the engine and move the accessory and crowd circuit
lever. (Under pressure, the hoses go automatically to the
right places).
- Stop the engine, then depressurize the hydraulic circuits.

50-04-M153EN (11/05/2011)
 13
Boom control and adjustment

1st fitting

Boom extension 135 Crowd/accessory

hoses
125
hoses

2nd fitting

Boom extension 148 Crowd/accessory 138

hoses hoses

50
- Checking boom extension hose clearances.
- Adjust the crowd and accessory cylinder hose clearance to that shown.

NOTE:
• Clearances are measured between the back of the cylinder and the back of the hose. This is the
MAXIMUM clearance.
• 1st GENERATION: The back of the cylinder is a machined part.
• 2nd GENERATION: The back of the cylinder is a cast part.

- Tighten the bracket 1 without bending it.

- Re-fit the hose guide 2.

- Re-fit the two blocks 1 if applicable.

BLEED THE CIRCUIT: See “Bleeding and filling boom extension cylinders”.

GREASING: See “Instructions for greasing the inside of the boom”.

- Check the hydraulic oil level.

- Put the fork clamp through its complete range of movement several times.
- Check that all hoses are correctly located.
- Check for leaks.

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 14
Boom control and adjustment

CHECKING THE COILING OF HOSES INSIDE THE BOOM

- Extend the boom to its full extent.

- Retract the boom sections, checking that hoses coil
correctly.
- The hoses must roll up while remaining vertical.
- If you note that one or more hoses twists to the side as it
rolls, re-check the orientation of the hose ends.
- Repeat the operation until hoses roll up correctly.

- Re-fit the two covers 1 at the back of the boom.

GOOD
50

BAD

50-04-M153EN (11/05/2011)
 15
Boom control and adjustment

REMOVAL OF INTERMEDIATE BOOM CYLINDER HOSES

- Remove the two covers 1 at the back of the boom.

2 - Depressurize the boom hydraulic circuit.

- Remove the clamps 1on each side of the boom base
2
section.
- Disconnect and plug the hoses 2 from the boom extension
cylinder.
- Have a recipient ready to catch the oil.

50
1

- Remove the hose bracket 1 and recover the clamps inside

the boom.
- In case of difficulty removing the clamps from inside the
boom, disconnect the U-bend 2.

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 16
Boom control and adjustment

- Disconnect and plug the hoses 1 from the boom extension

cylinder.
- Remove the hoses.

RE-FITTING

- If you are fitting new hoses place a reference mark A (using adhesive tape) at the distance from
the end of the hose shown below.
- If you are re-fitting existing hoses, check and if necessary reposition a reference mark at the right
distance from the end of the hose

NOTE: The hose reference number is marked on one of its end fittings.
50

3530 mm (2nd generation hose - Ref.: 243 821 lg 4500)

3470 mm (1st generation hose - Ref.: 232 004 lg 4420)

- Fit the hoses 1 in the boom and connect them to the back of
the cylinder, following their roll direction, see “Instructions
for fitting hoses”.
- Re-fit the hose bracket 1 with the clamps inside the boom.
- Place mark A on the hose (see above) in the intermediate
1 1
of the interior clamp 1.
- Tighten the hose clamps (do this before reconnecting the
hoses 2 to avoid them twisting inside the boom).

NOTE:
Bent or deformed brackets must be replaced.

50-04-M153EN (11/05/2011)
 17
Boom control and adjustment

2 NOTE: When re-fitting the bracket 1,

ensure it does not overlap the
1
clamp 2.
Good

2 1 2
1

Bad

ø 16 mm
- Re-connect the boom extension cylinder hoses 2.
1

NOTE: Befor reconnecting the hoses to the boom

extension cylinder, check the sealing rings on the pipes 1
2
are in good condition and change them if necessary.
Ref. Sealing rings: 169 438

- Re-fit the two clamps 1.

2

50
BLEED THE CIRCUIT: See “Bleeding and filling boom extension cylinders”.

GREASING: See “Instructions for greasing the inside of the boom”.

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Boom control and adjustment

CHECKING THE COILING OF HOSES INSIDE THE BOOM

- Extend the boom to its full extent.

- Retract the boom sections, checking that hoses coil
correctly.
- The hoses must roll up while remaining vertical.
- If you note that one or more hoses twists to the side as it
rolls, re-check the orientation of the hose ends.
- Repeat the operation until hoses roll up correctly.

- Re-fit the two covers 1 at the back of the boom.

GOOD
50

BAD

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Boom control and adjustment

CROWD CYLINDER REMOVAL

- Remove the inner boom cover plate 1.

- Depressurise the hydraulic circuit.

- Disconnect and plug the crowd cylinder 1 hoses.
1

50
- Extend the boom sections by about one metre to improve
accessibility.
- Extend the crowd cylinder cylinder rod to half its length.
- Remove the crowd cylinder head clevis pin 1.
- Use a metal bar 2 to stop the clamp fork from rotating.

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Boom control and adjustment

- Put a metal bar 1 through the cylinder rod end.

2
- Secure a chain on each side.
- Remove the clevis pin 2 from the base of the cylinder.
- Place a pallet under the cylinder.
- Slowly lower the cylinder.

- Lay the cylinder 1 flat on the pallet.

The cylinder is heavy. Take care when

50

1
laying it flat.

RE-FITTING

- Re-fit the cylinder, takin care not to knock the rod or valve.

NOTE:
The crowd and accessory circuit hoses must pass above the base of the cylinder.

- Re-fit the clevis pins and their locking devices.

- Re-connect the hoses to the cylinder.
- Re-fit the cover plate 1.

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Boom control and adjustment

INNER BOOM EXTENSION CYLINDER REMOVAL

- Ensure there is clear space 3 m in front and 4 m behind

the telehandler.
- Remove the two covers 1 at the back of the boom.

- Raise the boom to its maximum elevation.

- Remove the two circlips from the boom extension cylinder 1
clevis pin.
- Put the boom in its horizontal position.

50
- Remove the inner boom cover plate 1.

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Boom control and adjustment

- Depressurize the boom hydraulic circuit.

1
- Disconnect and plug the crowd circuit 1 hoses and, if fitted,
the accessory circuit 2 hoses.

- Remove the hose bracket 1 from the back of the boom

head.
2
3 - Put to one side the crowd circuit hoses 2 and, if fitted, the
accessory circuit hoses, 3 through the back of the boom.
1
50

- Extend the boom sections by 60 cm approx.

- Remove the inner boom extension cylinder clevis pin 1.
- Retract the intermediate boom.

1 - Disconnect and plug the hoses 1 from the boom extension

1
cylinder.
- Have a recipient ready to catch the oil.

NOTE: The aim of this procedure is to avoid hydraulic oil

being sprayed inside the boom when you disconnect
the hoses from the back of the boom head extension
cylinder.

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Boom control and adjustment

- Remove the optional movement cut-off switch 1 if your

telehandler is so equipped.

- Disconnect and plug the two boom extension cylinder

supply hoses 1.
1 1 - Plug the two unions on the cylinder valve.
- Remove the two blocks 2 only for 1st and 2nd generation
machines.
- Remove the hose guide 3.
3

2 2

50
- Remove the left hand rear light bracket 1.

- From the left, drive the clevis pin 1 out from the base of the
cylinder, so that it exits through the hole 2 in the chassis.
- Remove the clevis pin 1.

2 1

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Boom control and adjustment

- Slightly raise the boom (max. 5°).

- Lever the extension cylinder 1 towards the back.
- Use a bar 2 to lock the cylinder in place at the back of the
boom base section (to stop the cylinder moving into the
2
boom when the intermediate boom section is extended).

- Remove the clevis pin 1 from the head of

the intermediate boom section cylinder.
1 - Extend the boom head 2 by 2 m.
3 2
- Extend the intermediate boom 3 by 0,70 m.
50

- Continue by removing the boom extension cylinder 1 through

the back of the machine.
- If you notice resistance, place a bar 2 through the foot of the
cylinder and use rotary movements to pass the guides of
the cylinder head A over the inner boom slide pad fixings.

2 1

- Sling the cylinder and completely

remove it.
1

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Boom control and adjustment

RE-FITTING

1st GENERATION NOTE: Before re-fitting the boom extension cylinder,

check the head orientation.

- Re-fit the cylinder in the boom.

- When resistance is felt, place a bar 2 through the foot

of the cylinder and use rotary movements to insert the
A GOOD A BAD
cylinder head into the boom head and then to pass the
guides of the cylinder head A (1st model cylinder) over
2nd GENERATION
the inner boom slide pad fixings.

GOOD BAD

- Stop any backwards motion by the cylinder using a bar 1.

- Retract the intermediate boom 3.

50
- Re-fit the intermediate boom cylinder head clevis pin 1.
- Retract the inner boom 1.
- Re-fit the clevis pin 1, carefully centring it in the intermediate
1
boom section.

- Re-fit the hose guide 3.

- Re-fit the two slide pads 2, if applicable.
- Re-connect the hoses 1 to the back of the cylinder.

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Boom control and adjustment

- Position the crowd cylinder 1 and accessory circuit

2 hoses (if present) totally flat and aligned with with the
1
2
telehandler.
- Take the hoses one by one (ensuring they are not twisted)
3 and put them in the inner boom. When resistance is felt
twist them to pass them above the crowd cylinder, then
release.
- Re-fit but do not tighten the clamp 3.
- Re-connect the hoses in the inner boom.
- Re-connect the hoses 1 to the boom extension cylinder

BLEED THE CURCUIT

- Start the telehandler.

- Extend the intermediate boom section 20 cm.
- Retract the intermediate boom and maintain pressure for approximately ten seconds.

- Extend the inner boom (using a hoist or other lifting equipment).

- Re-fit the boom extension cylinder head clevis pin 1 and its circlips.
- Raise the boom to its maximum elevation and re-fit the boom extension cylinder base clevis pin 1
50

circlips.
- Lower the boom.
- Move the accessory and crowd circuit lever (under pressure the hoses will automatically take up
the correct position).
- Stop the engine, then decompress the hydraulic circuits.

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Boom control and adjustment

1st fitting

Boom extension 135 Crowd/accessory

hoses
125
hoses

2nd fitting

Boom extension 148 Crowd/accessory 138

hoses hoses

50
- Checking boom extension hose clearances.
- Adjust the crowd and accessory cylinder hose clearance to that shown.

NOTE:
• Clearances are measured between the back of the cylinder and the back of the hose. This is the
MAXIMUM clearance.
• 1st GENERATION: The back of the cylinder is a machined part.
• 2nd GENERATION: The back of the cylinder is a cast part.

- Tighten the clamp 3 without mis-shaping it.

- Re-fit the hose guide 3.
- Re-fit the two blocks 2.

- If applicable re-fit the switch 1.

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Boom control and adjustment

CHECKING THE COILING OF HOSES INSIDE THE BOOM

- Extend the boom to its full extent.

- Retract the boom sections, checking that hoses coil
correctly.
- The hoses must roll up while remaining vertical.
- If you note that one or more hoses twists to the side as it
rolls, re-check the orientation of the hose ends.
- Repeat the operation until hoses roll up correctly.

- Re-fit the two covers 1 at the back of the boom.

GOOD
50

BAD

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Boom control and adjustment

REMOVAL OF INTERMEDIATE BOOM

- Sling the cylinder 1.

- Depressurize the boom hydraulic circuit.

- Disconnect the two hoses 2.
2
4 - Remove the clevis pin 3 from the cylinder head.
- Remove the U clamp 4.
2 3

50
- Disconnect the two cylinder supply hoses 5.
- Remove the cylinder base clevis pin 6.
- Remove the intermediate boom 1.
5 5

RE-FITTING

- Carry out the operations described above in reverse order.

BLEED THE CIRCUIT: See “Bleeding and filling boom extension cylinders”.

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Boom control and adjustment

CLAMP FORK REMOVAL

- Remove the crowd cylinder head clevis pin 1.

- Sling the clamp fork 2.
- Remove the clamp fork pivot pin 3.
- Remove the clamp fork 2.

The clamp fork is heavy. Take appropriate

precautions when removing it.

RE-FITTING

- Carry out the operations described above in reverse order.

GREASING: See “Instructions for pivot greasing”.

50

50-04-M153EN (11/05/2011)
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Boom control and adjustment

INNER BOOM REMOVAL

- Remove the fork clamp; see chapter “Fork clamp removal”.

- Remove the crowd cylinder, see chapter “Crowd cylinder removal”.

The operations described below are only to be undertaken when the inner boom is to be
replaced.

- Remove the boom extension cylinder from the inner boom, see chapter “Boom Head Extension
Cylinder Removal”.
- Remove the bracket mounting 1.
1 - Remove the fixings from the side 2 and upper 3 slide pads.
- Take note of and recover spacers and slide pads.
3 3

2 2

50
- Take note of and remove side and upper 1 slide pads and
1 spacers from the intermediate boom section.
- Sling the boom and slightly lift it, then take note of and
1
remove the slide pads and spacers 2.

2
2

- Sling the boom head, then remove it.

- The centre of gravity of the bare boom is

approximately 1000 mm from the attachment
point of the base of the crowd cylinder.

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Boom control and adjustment

- The centre of gravity of the boom with

fork clamp and crowd cylinder fitted
is approximately 470 mm from the
attachment point of the base of the
crowd cylinder.

RE-FITTING

- Re-fit the lower slide pads 1 and spacers (if fitted).

3 - Re-fit the side slide pads 2 and upper slide pads 3 without
3
spacers.

NOTE: The final shimming of the upper and side slide pads
2
is carried out with the inner boom in place in the
2
intermediate boom.
50

1
1

- Fit the inner head in the intermediate boom.

- Shim the slide pads at the back of the boom, see “Instructions for fitting slide pads”.
- Re-fit the bracket mounting 1.

- Re-fit the slide pads and spacers to the head of the intermediate boom, see “Instructions for
fitting slide pads”.

- Re-fit the boom head extension cylinder, see chapter “Boom head extension cylinder removal”.

If applicable:
- Re-fit the crowd cylinder, see chapter “Crowd cylinder removal”.
- Re-fit the clamp fork, see chapter “Clamp fork removal”.

GREASING: see the chapter “Instructions for slide pad greasing”.

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Boom control and adjustment

INTERMEDIATE BOOM REMOVAL

- Remove the inner boom, see chapter “Inner boom

2 2 removal”.

1 1
- Remove the side 1 and upper 2 slide pad fixings.
- Take note of and recover spacers and slide pads.

- Remove and take note of the side and upper 1

2 slide pads and spacers at the outer boom.
1 1
1
- Sling the intermediate boom 2, raise it slightly,
then remove the slide pads and spacers 3.

NOTE: To facilitate the removal of the alignment

1

50
4 collars 4 use a piece of 19 mm diameter
rod between the guide and the intermediate
boom.
3
3

- Remove the fixing clamps from the hoses 1 on both sides

of the boom.
- Disconnect the U-bend 2 under the base of the boom.
1
3
1 - Remove the brackets 3 to avoid any possible interference
with the intermediate boom lower slide pads.
3

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Boom control and adjustment

- Sling the intermediate boom and then

remove it.

NOTE: The centre of gravity of the

intermediate boom is approximately
1620 mm from the lower tapping 1.

RE-FITTING

1st and 2nd generations 1st and 2nd generations:

3
3 - Re-fit the lower slide pads 1 and spacers (if fitted).
50

2
- Re-fit the side 2 and upper 3 slide pads, without spacers.
2 - Re-fit the two slide pads 4.

1
1

3rd generation
3rd generation:

3
- Re-fit the lower slide pads and spacers 1.
3 - Re-fit the side 2 and upper 3 slide pads, without spacers.

2 NOTE: Final upper and side slide pad spacing is carried out
2
when the intermediate boom section is in place in
the outer boom.

1 1 - Fit the intermediate boom in the base of the boom.

1 1

50-04-M153EN (11/05/2011)
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Boom control and adjustment

2 - Position the clamps 1.

1
NOTE: When re-fitting the upper bracket 1
4 4
Good ensure that it does not overlap the
clamp 2.
1 1
2
- Re-connect the U-bend 3.
2 1
3 - Tighten the clamps 1.
- Re-fit the hose 4 clamps on both sides
of the boom.
Bad

- Shim the slide pads at the back of the intermediate boom section. See chapter “Slide pad fitting
instructions”.

- Re-fit the slide pads and spacers at the head of the boom base. See chapter “Slide pad fitting
Instructions”.

- Re-fit the inner boom. See chapter “Inner boom removal”.

50
GREASING: see chapter “Instructions for greasing slide pads”.

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Boom control and adjustment

COMPLETE BOOM REMOVAL

- Raise the boom sufficiently to gain access to the

2 compensating cylinder 1.
- Depressurize the boom hydraulic circuit.
2
- Disconnect and plug the two hoses 2 from the extension
cylinder.
3 - Remove the clamps 3.
- Disconnect and plug the two or four (as fitted) hoses 4 from
the accessory and crowd circuit.
4
- Remove the compensating cylinder pivot pin 1.
1 - Retract the compensating cylinder rod then swivel the
4
cylinder towards the back of the chassis.

- Position the boom 1 as shown.

- Sling the boom using the forward eyes 2 provided
for this purpose.

1
50

- Position a block 1 under the elevating cylinder 2.

- Remove the elevating cylinder 3 pivot pin.
3
- Retract the elevating cylinder rod.

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Boom control and adjustment

- Remove the boom pivot pin 1.

- Lift the complete boom away, taking care not to knock it
against the cab or chassis.

RE-FITTING

Carry out the operations described above in reverse order.

GREASING: see “Instructions for greasing pivots”.

GREASING: see “Instructions for greasing the inside of the boom”.

50

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Boom control and adjustment

MLT 634, MLT 731, MLT 735, MLT 741

ADJUSTMENT AND SHIMMING OF BOOM SLIDE PADS

- Place the telehandler on horizontal ground, handbrake on, shuttle control and gear lever in
neutral.
- Put the boom in the horizontal position.

FORWARD SLIDE PADS

- Extend about 200 mm and measure
the play on the lower, upper and
side slide pads (Permissible play:
0 to 0,5 mm).

0 to 0,5 mm
50

1
- If necessary, fit spacers.
- Completely unscrew the nuts 1.
1
- Add spacers as necessary, balancing the thicknesses on
both sides of the boom.

NOTE:
Spacers are available in the following sizes: 0,5; 1; 2 and 4 mm.
1

1 1

NOTE:
For side slide pads use MANITOU tool Ref. 552829.

50-04-M153EN (11/05/2011)
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Boom control and adjustment

2 - Ensure that the studs 1 are well tightened to the bottom

1 of the thread.
- Re-fit the nuts 2 and tighten to 92,6 N.m ± 25%.
2
1

1
2

1 1
2 2

REAR SLIDE PADS

- Remove the rear cover plate.

- Completely retract the boom and measure the

play on the lower, upper and side slide pads.
(Permissible play: 0 to 0,5 mm).

50
0 to 0,5 mm

- If necessary, fit spacers.

- Completely unscrew the nuts 1.
- Add spacers as necessary, balancing the thicknesses on
1 both sides of the boom.

1 NOTE:
1
Spacers are available in the following sizes: 0,5; 1; 2 and 4 mm.
1

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Boom control and adjustment

NOTE:
For side slide pads use MANITOU tool Ref. 552829.

- Ensure that the studs 1 are well tightened to the bottom

of the thread.
1 - Apply thread locking compound MANITOU Ref. 187526 to
2 the nuts 2 and tighten to 92,6 N.m ± 25%.

1 2
2

2 1
1
- Re-fit rear cover.
50

50-04-M153EN (11/05/2011)
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Boom control and adjustment

REMOVAL OF TWIN HOSES FROM THE BOOM

REMOVAL OF TWIN HOSES FROM THE BOOM

- Place the telehandler on horizontal ground, handbrake on, shuttle control and gear lever in
neutral.
- Place the boom in its horizontal position and extend it 130 mm.
- Switch on the telehandler ignition and remove the pressure in the crowd and accessory circuits
by repeatedly activating the hydraulic controls.

- Overview of twin hose location.

50
- Remove the rear cover plate.

- Put the lower back plate to one side.

- Place a recipient under the twin hoses.

- Remove the fixing clamps 1, take note of the hose
connections then disconnect them and plug the openings.

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Boom control and adjustment

- Take note of the accessory 1 and crowd circuit 2 twin hose

connections, disconnect them and plug the openings.

2
50

- Use adhesive tape to tightly tape the hoses together.

- Pull the hoses towards the front by the U-bends and

completely remove them in a controlled manner.

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Boom control and adjustment

RE-FITTING TWIN HOSES IN THE BOOM

- Re-fitting is by carrying out the operations described in the chapter “Removal of twin hoses from
the boom” in reverse order, paying attention to the following points.

- Place the hoses in front of the boom with the U-bends pointing downwards:
- the longer hoses are for the accessory circuit,
- the shorter hoses are for the crowd circuit.

- Tightly tape the twin hoses together at the end with the straight fitting 1, using adhesive tape.

NOTE: When replacing old twin hoses with new ones, take note of the hydraulic connections of the

50
old twin hoses and use this as a reference for fitting the new ones.

- Insert the twin hoses from underneath, as far as the back

of the boom.

- Working at the back of the boom, slide the hoses into the
1 upper guide 1 and continue to insert them.

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Boom control and adjustment

- At the inner boom, recover the hoses, remove the adhesive

tape and re-connect them.

- Check the clearance between the hoses and the boom

extension cylinder pin.
- Test the boom for correct operation.
50

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Boom control and adjustment

CROWD CYLINDER REMOVAL

CROWD CYLINDER REMOVAL

- Place the telehandler on horizontal ground, handbrake on, shuttle control and gear lever in
neutral.
- Put the boom in its horizontal position.
- Switch on the telehandler ignition and depressurize the crowd circuit by repeatedly activating the
hydraulic control.

Do not extend the crowd cylinder rod more than

300 mm so that it can be disengaged from the boom
300 mm head.

- Take note of the crowd circuit twin hose connections, then

50
disconnect them and plug the openings.

- Remove the electric cable reel bracket 1 if fitted.

- Remove the crowd cylinder base pin 2.
1

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Boom control and adjustment

- Lash the crowd cylinder to the boom head.

- Using a hoist, for example, tilt the fork clamp in the crowd
backward direction so that the crowd cylinder comes away
from the boom head and place it on a block.

Take care with the weight of the crowd cylinder.

50

- Block the crowd cylinder under its rod.

- Remove the cylinder head clevis pin and disengage the
cylinder.

Take care with linkages moving when the crowd

cylinder head clevis pin is removed.

50-04-M153EN (11/05/2011)
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Boom control and adjustment

CROWD CYLINDER RE-FITTING

- Re-fitting is by carrying out the operations described in the chapter “Crowd cylinder removal” in
reverse order, paying attention to the following points:

- Test the crowd cylinder for correct operation.

2
1 - Before re-fitting pivot and clevis pins 1, clean them and
apply a thin coat of grease.
See chapter: “Telehandler characteristics” in section
2
“0 - General Points”.

2 - Also clean and grease the pivots 2 with the same grease.
1

50

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Boom control and adjustment

CLAMP FORK REMOVAL

CLAMP FORK REMOVAL

- Remove the crowd cylinder before removing the fork clamp.

- Disconnect the hydraulic locking cylinder hoses at the

solenoid valve and at the valve (optional).

- Sling the form clamp and remove the pivot pin.

50

- Remove the fork clamp.

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Boom control and adjustment

FORK CLAMP RE-FITTING

- Re-fitting is by carrying out the operations described in the chapter “Fork clamp removal” in
reverse order, paying attention to the following points.

1
2

- Before re-fitting the pivot pin 1, clean it and apply a thin coating of grease.
See chapter: “Telehandler characteristics” in section “0 - General Points”.

- Also clean and grease the pivots 2 with the same grease.

50

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Boom control and adjustment

BOOM EXTENSION CYLINDER REMOVAL

BOOM EXTENSION CYLINDER REMOVAL

- Place the telehandler on horizontal ground, handbrake on, shuttle control and gear lever in
neutral.
- Put the boom in the horizontal position.

- Extend the boom sufficiently to gain access to the head of

the boom extension cylinder.
- Switch the telehandler ignition on and depressurize the
boom extension circuit by repeatedly activating the hydraulic
control.
- Remove the circlip and remove the boom extension cylinder
head pin.

- Remove the rear cover plate.

50

- Put the lower back plate to one side.

- Remove the hydraulic pipe clamps.

- Unscrew the hydraulic pipes from the extension cylinder.

- Line the cylinder base pin up with the opening in the plate.

- Remove the circlip and remove the extension cylinder

base pin.

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Boom control and adjustment

- Pull the extension cylinder out about 1 m and sling it with

a strap.

- Completely remove the extension cylinder ensuring it is

appropriately slung at its centre of gravity and that it is
carefully removed.

50
BOOM EXTENSION CYLINDER RE-FITTING

- Re-fitting is by carrying out the operations described in the chapter “Boom extension cylinder
removal” in reverse order, paying attention to the following points:

- Test the extension boom

for correct operation.

1
2

- Before re-fitting the pivot pins 1, clean them and apply a thin coating of grease (see chapter:
“Telehandler characteristics” in section “0 - General Points”).
- Also clean and grease the pivots 2 with the same grease.

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Boom control and adjustment

BOOM REMOVAL

BOOM REMOVAL

- Before removing the boom carry out the following operations:

• Remove the boom twin hoses.
• Remove the crowd cylinder.
• Remove the fork clamp.
• Remove the extension cylinder.

- Disconnet the wiring from the reel at the solenoid valve in

the boom head and put it to one side (option).
50

- Remove the wiring bracket (option).

- Hold the by-pass return hose, remove it and guide it round

its reel (option).

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Boom control and adjustment

- Remove the electrical and hydraulic reel (option).

- Put a bar through the opening in the head of the extension

cylinder, for example, and extend the boom until the rear
slide pads just butt up against the front ones.

50
- Sling the boom, paying attention to distance “A”, depending
on the options fitted to the telehandler.

6 m boom
- Bare boom.
A = mm
- Boom with jib head solenoid valve.
A = 780 mm

7 m boom
- Bare boom.
A = mm
- Boom with jib head solenoid valve.
A = mm

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Boom control and adjustment

- Remove all slide pads and spacers on the inner boom,

taking careful note of their positions for re-fitting.

- Take the section

completely out and
remove it.
50

- Remove all slide pads and spacers from the base of the
section, taking careful note of their positions for re-fitting.

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Boom control and adjustment

RE-FITTING THE BOOM

- Re-fitting is by carrying out the operations described in the chapter “Boom removal” in reverse
order, paying attention to the following points:

STUD - Cross-section of all boom slide pads fitting.

NUT
SPACER

INSERT

SLIDE PAD

Rear boom slide pads:

- Apply MANITOU thread locking compound Ref. 187526 to
1 the end of the studs 1 and screw them to the bottom of
2 the thread.
1 - Apply MANITOU thread locking compound Ref. 187526 to
2
2 the nuts 2 and tighten them to torque 92,6 N.m ± 25%.

50
2 1

Front slide pads on outer boom:

- For the side slide pads us MANITOU tool Ref. 552829.

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Boom control and adjustment

- Screw the stud 1 in to the bottom of the thread.

2
1 - Tighten the nuts 2 to 92,6 N.m ± 25%.
2

1
2

1
1
2
2

- Pre-load the reel with one and half turns before reconnecting
the by-pass return hose.
50

- After re-fitting all boom components, adjust and shim the boom slide pads and verify the correct
operation of the boom.

50-04-M153EN (11/05/2011)
 BOOM REMOVAL

pages

Complete boom removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

– Complete boom removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

50
– Re-fitting the whole boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

(21/04/2010) 50-06-M153EN
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Boom removal

COMPLETE BOOM REMOVAL

COMPLETE BOOM REMOVAL

- Place the telehandler on horizontal ground, handbrake on, shuttle control and gear lever
in neutral.
- Completely retract the boom.
- If an accessory is mounted on the clamp fork, remove it.

NOTE: The removal shown is for a 6 m boom, but the procedure is identical for a 7 m boom.

- Switch on the telehandler ignition and depressurize the

crowd, boom extension and accessory circuits by repeatedly
activating the hydraulic controls.

1
50

- Raise the boom sufficiently to gain access to the

compensation cylinder head pin 1 and the elevation cylinder
head pin 2.

1 - Sling the boom using the ring nearest the jib.

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Boom removal

- If fitted, disconnect the electric reel at the jib, cut the

plastic clips along the boom and put the wiring to one side
towards the rear.

- If fitted, remove the hydraulic reel hose from the jib, cut
the clips along the boom and put it to one side towards
the rear.

- Remove the rear cover plate.

- Unscrew the hydraulic pipes from the extension cylinder.

50
- Disconnect the four crowd and accessory circuit hoses and
move them aside.

- Lash the elevating cylinder to the boom, remove the circlip

and remove the cylinder head clevis pin using a slide
hammer.

- Securely chock the cylinder in place and remove the

lashing.

(21/04/2010) 50-06-M153EN
 4
Boom removal

- Remove the compensation cylinder head clevis pin using a slide hammer.

- Support the boom under the fork clamp using a crane, to avoid it tipping when the boom pivot pin
is removed.

- Remove the boom pivot pin. Take note of the positioning of spacers (if fitted) on each side of the
boom, then remove them.

- Carefully remove the whole boom.

50

50-06-M153EN (21/04/2010)
 5
Boom removal

RE-FITTING THE WHOLE BOOM

To re-fit the boom carry out the operations described in the chapter “WHOLE BOOM REMOVAL”,
paying attention to the following points.

1 1
2
2
1
2 2
2 2

- Before re-fitting pivot pins 1, clean them and lightly grease them (See chapter: TELEHANDLER
CHARACTERISTICS in group 0 - GENERAL POINTS).

- Also clean and grease the pivots 2 with the same grease.

50
- Re-fit the spacers 3 if fitted and re-fit the pivot pin.

(21/04/2010) 50-06-M153EN
 6
Boom removal

STANDARD TIGHTENING TORQUE TO BE USED WHEN NOT SPECIFICALLY MENTIONED IN REMOVAL

AND RE-FITTING PROCEDURES.

TIGHTENING TORQUE (*)

Thread Class 5.6 Class 5.8 Class 8.8 Class 10.9 Class 12.9
diameter
M3 0,54 0,76 1,16 1,7 2
M4 1,24 1,74 2,66 3,91 4,57
M5 2,47 3,46 5,2 7,7 9
M6 4,29 6 9,1 13,4 15,7
M8 10,4 14,6 22 32 38
M10 20 28 44 64 75
M12 35 49 76 111 130
M14 57 79 121 178 209
M16 88 124 189 278 325
M18 122 171 261 384 449
M20 173 243 370 544 637
M22 238 334 509 748 875
M24 298 418 637 936 1095
M27 442 619 944 1386 1622
50

M30 600 840 1280 1880 2200

(*) - Tightening torques are given for black or zinc-plated fasteners with light lubrication.
- Tightening torques are given for automatic slip and reset torque wrenches and direct read
dial torque wrenches.
- For more information consult French Standard NF E25-030.

50-06-M153EN (21/04/2010)
 HYDRAULICS

- HYDRAULIC CHARACTERISTICS AND

SPECIFICATIONS

- HYDRAULIC SCHEMATIC DIAGRAMS

- HYDRAULIC COMPONENTS LOCATION

- HYDRAULIC CONTROL AND

ADJUSTEMENT

- HYDRAULIC SPECIFIC TOOLING

70
 HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS

HYDRAULIC COMPONENTS DATA SHEETS

– STEERING PUMP
– COUNTER BALANCE VALVE
– SLOPE CORRECTION VALVE
– DOUBLE EXTENSION BALANCING VALVE
– DISCHARGE VALVE

70

(24/05/2011) 70-01-M153EN
70

70-01-M153EN (24/05/2011)
 Hydraulic characteristics and 1
specifications

STEERING PUMP/DIRECTIONAL BLOCK OSPC 200 LS

Values for information purposes only.

T
P
Role:
L - Direct and dose the flow in order to supply the
steering circuit.
R
- It is a rotating valve.

LS

R L

1. Secondary relief valve.

1 2. Pump valve.

2 3. Main pressure relief valve.

70
200 cm³/tr

LS - P : Pressure.
- T : Return to tank.
- R : Exit towards the right side.
- L : Exit towards the left side.
- LS : Pilot line.
T P

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________

(03/09/2008) F70-3-0003EN
 2 Hydraulic characteristics and
specifications

Values for information purposes only.

R L

When the driver turns the steering wheel towards the right, he
passes the flowrate from P to R and sends pilot pressure towards
the divisor to get priority.
LS

T P

R L

When there is an impact on a wheel, the pressure increases in the

line. This pressure opens the valve which enables the resulting
pressure to be evacuated and therefore protects the hydraulic
and mechanical steering components.
LS

T P

R L
70

When the wheels are locked to a maximum, the steering circuit

increases in pressure, the LS line activates the relief valve and
enables flow to the tank.
LS

T P

What use do the two valves that are located opposite each other on the top part of the diagram
have?

What is the maximum pressure permitted in the steering circuit?

What is the LS line, without actions, connected to on the steering wheel?

F70-3-0003EN (03/09/2008)
 Hydraulic characteristics and 1
specifications

COUNTER BALANCE VALVE d1

Values for information purposes only.

Role:
- Insulates the cylinder in case of hose breakage.

- Cylinder movement requires the starting of the I.C.

V1 engine.

- Limits max. pressure due to impacts.

V2

70
C1 C2
1 3
1. Temporization screws.
2
2. By-pass valve.
4
3. Slide with max. adjustment screw.

V1 V2 4. Non-return valve.

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(03/09/2008) F70-3-0008EN
 2 Hydraulic characteristics and
specifications

Values for information purposes only.

C1 C2

V1 V2

Return control during cylinder descent.

C1 C2

V1 V2
70

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

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

C1 C2

V1 V2

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

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
F70-3-0008EN (03/09/2008)
 Hydraulic characteristics and 3
specifications

Values for information purposes only.

What is the valve opening pressure on the diagram?

What happens when the non-return valve starts to leak?

70
If the temporization screw is either screwed or unscrewed, what effect does it have
on movement?

(03/09/2008) F70-3-0008EN
 4 Hydraulic characteristics and
specifications
70

F70-3-0008EN (03/09/2008)
 Hydraulic characteristics and 1
specifications

DUMP CORRECTION VALVE

Values for information purposes only.

V2

V1

C2 C1

V2 V1

70

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(03/09/2008) F70-3-0009EN
 2 Hydraulic characteristics and
specifications

Values for information purposes only.

70

F70-3-0009EN (03/09/2008)
 Hydraulic characteristics and 1
specifications

DOUBLE EXTENSION BALANCING VALVE bf2,3

Values for information purposes only.

Role:

- Insulates the cylinder in case of hose breakage.

C1

C2 - Cylinder movement requires the starting of the I.C.

engine.

V1 - Limits max. pressure due to impacts.

V2

70
C1 C2
300b 1 1 300b 1. Balancing valve.

2. By-pass ring.
2 2

3 3. Temporization screws.
V1 3 V2

Maximum pressure (bar) 350

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(01/02/2011) F70-3-0015EN
 2 Hydraulic characteristics and
specifications
70

F70-3-0015EN (01/02/2011)
 Hydraulic characteristics and 1
specifications

DISCHARGE VALVE Bf1

Values for information purposes only.

c Role:
- Discharge or accumulative flow from two different
hydraulic lines.
T
P

1. Non-return valve

70
2. Tank slide.

3. Pilot electrovalve.
3
C VD

Ø0,7

P T
2
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(03/05/2011) F70-3-0044EN
 2 Hydraulic characteristics and
specifications
70

F70-3-0044EN (03/05/2011)
 HYDRAULIC SCHEMATIC DIAGRAMS

Pages
Series D - Series 4:
– MLT 630/731 T Series D-E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– MLT 634 120 LSU + PS Series D-E3
– MLT 735/741 120 LSU + PS Series 4-E3 . . . . . . . . . . . . . . . . . . . . . . . 6
– MLT 634/731 T LSU Series D-E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
– MLT 742 T Series 4-E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
– MT 732/932 Series D-E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
– MT 1030 S/ST Series 4-E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

70
– MLT 1035 LT LSU Series 4-E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
– MLT 742 H T LSU Series 4-E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
– MT 1033 H L Series 4-E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Series E - Series 5:
– MLT 731 T Series E-E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
– MLT 634 -120 LSU + PS Series E-E3
MLT 735 -120 LSU + PS Series E-E3
MLT 741 -120 LSU + PS Series 5-E3 . . . . . . . . . . . . . . . . . . . . . . . . . 24
– MLT 634 T LSU Series E-E3
MLT 735 T LSU Series 5-E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
– MLT 1035 LT LSU Series 5-E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

(16/05/2011) 70-02-M153EN
 2
Hydraulic schematic diagrams
70

70-02-M153EN (16/05/2011)
 3
MLT 630 T Series D-E3 Hydraulic schematic diagrams
MLT 731 T Series D-E3

Keys and diagrams

HYDRAULIC DIAGRAM KEY

Position on
Item Designation Characteristics (Options)
diagram
BA Feed block + accumulator E21
CA Suction strainer S6
CSP Counterbalance valve K27/I27/M40
CR(O) Trailer hook (option) I40
D 4 or 5 component valve (option) S38
EE Inlet section S25
EA(O) Attachment component (option) S27
EL Lifting component S29
EI Tilt component S31
EA Optional equipment component S33
ET Telescoping component S36
EF Closing component S38
D3 3 position steering valve A14
Position 1: short steering
Position 2: front wheel steering
Position 3: crab position
EVTF(O) Boom head electrovalve (option) E30
FDAV Front disc brake 3
FDAR Rear disc brake K15
FR Return filter Q13
M Turbo i.c. engine Q7 1104d-44ta
Idle speed 930 rpm
Nominal loaded speed 2200 rpm

70
Full speed unladen 2400 rpm
MC Master cylinder C6
N Level S4
P Pump equipment Q4
PAAV Front attachment plug C28
PAAV(O) Front attachment plug (option) E27
PAAR(O) Rear attachment plug (option) G38
PD Steering pump C13
PP Pressure port O21
PFR(O) Trailer brake plug integrated in the VAFR (option) G10
PRF(O) Leakage return plug (option) A27
R Hydraulic tank S5
RLF Brake fluid tank A3
SC Circuit selector n°1 C10
SCFR(O) Circuit selector n° 2 (trailer brake option) E9
S2F Selector 2 functions K20
VC Compensation cylinder DE K29 100x50 c310
VI Tilt cylinder DE I29 120x60 c445/130x65 c380
VDAV Front steering cylinder DE K5 90x45 c80x2
VD Discharge valve O9
VDAR Rear steering cylinder DE K13 90x45 c80x2
VL Lifting cylinder DE I25 130x70 c720/140x70 c720

(16/05/2011) 70-02-M153EN
 4
Hydraulic schematic diagrams MLT 630 T Series D-E3
MLT 731 T Series D-E3

HYDRAULIC DIAGRAM KEY

Position on
Item Designation Characteristics (Options)
diagram
VT DE telescoping cylinder K39 70x50 c2100/70x50 c2750
VAFR(O) Trailer brake valve (option) G9
VVT(O) Ts locking cylinder DE (option) A29 60x45 c183
VAI Insulation valve A33
VACM(O) Movement cut-off valve (option) Q19

NOTE: 1- The calibration pressures of the main relief valves, on the inlet sections, are given for maximum engine
speed.
2- The calibration pressures of the secondary relief valves are at an engine speed of 1000 rpm.
3- The pressure relief valves should be adjusted at an oil temperature of 50°C.
70

70-02-M153EN (16/05/2011)
 5
MLT 630 T Series D-E3 Hydraulic schematic diagrams
MLT 731 T Series D-E3
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

PRF
BL L 2
3 1
RLF N A B T
A A
AV AR 3 2 1 VVT(O)
3 2 1
D3
B1 P VAI
MC R L
P
PD 200b 200b

C C

200 cm3 /tr

PAAV

SC
V1 V2 C2
C4
LS 140b PAAV(O)
S C1 C3
SCFR(O)
V1 V2 0,7 L.
E T P E
13 b
Ø1 S P1
35b
BA
U EVTF(O)
P T P1 P2
45±5B

Y
VAFR(O)
G N LS P2 T G
PFR Ø 0.7
B OPTION FREINAGE REMORQUE
PAAR(O)
(1 ou 2 PRISES)
T P
M4 S2F

TELESCOPAGE
M2
VI CR(O)
S2
B1
I VL I
A1
S1
C1 C2
M3 CSP 315b +15
0
M1

ACCESSOIRES
S2
B2
110b
A2 V1 V2 VT

70
S1
K FDAV VDAV FDAR K
VDAR
VC
C1 C2
335b CSP
ES. AR.
ES. AV.

C1 C2
335b CSP
30b
M V1 V2 M

N°226111
30b
V1 V2

O O
P P A1 B1 A2 B2 A3 B3 X1 A4 B4 X2 A5 B5 T
C VD 280b 280b 190b 190b

EF CF OUT P1 PP
FR
6b
5b
BA
LS
Q M VACM(O) M3 M4 Q
P
21.99 cm3/tr IN 10 μm absolu 1ère monte
21.99 cm3/tr 15 μm absolu PR.
P T
M1 M2
250b
CA
Niveau moyen: N 125 μm
S 104L absolu EE EA(O) EL EI EA ET EF S

R Capacité 128 litres Réserve direction

Y1 Y2 D

(16/05/2011) 70-02-M153EN
 6
Hydraulic schematic diagrams MLT 634 120 LSU + PS
Series D-E3
MLT 735 120 LSU + PS
MLT 741 120 LSU + PS
Series 4-E3
HYDRAULIC DIAGRAM KEY HYDRAULIC DIAGRAM KEY
Position on Position on
Item Designation Characteristics (Options) Item Designation Characteristics (Options)
diagram diagram
BA Feed block + accumulator E17 VAI Isolation valve A21
CA Breather filter S11 VAFR(O) Trailer brake valve (option) I10
CR(O) Trailer hook (option) C41 VC Compensation cylinder DE C26 110x55 c310
CSP Counterbalance valve A26/C33/E30 VDAR Rear steering cylinder E8
D Control Valve K18 VDAV Front steering cylinder E4
EE Inlet section K20 VI Tilt cylinder DE A28 140x70 c388
EA Attachment component K23 VL Lifting cylinder DE A31 150x70 c716
EA(O) Attachment component (option) K35 VT DE telescoping cylinder A24 75x55 c2700
EL Lifting component K32 VVT(O) Carriage locking cylinder (option) DE A17 60x45 c183
EI Tilt component K29
ET Telescoping section K25
EF Closing component K37
D3 3 position steering valve A10
Position 1: short steering NOTE: 1- The calibration pressures of the main relief valves, on the inlet sections, are given for maximum engine
speed.
Position 2: front wheel steering
2- The calibration pressures of the secondary relief valves are at an engine speed of 1000 rpm.
Position 3: crab steering
3- The pressure relief valves should be adjusted at an oil temperature of 50°C.
EVAA(O) Rear attachment electrovalve (option) E38
EVTF(O) Jib head electrovalve (option) E20
EV5E(O) 5th component electrovalve (option) M34
FDAR Rear brake disc E9
FDAV Front brake E2
FEMS Ems head filter M20
FR Return filter O17
M Turbo i.c. engine Q12 1104d-e44ta
70

Idle speed 930 rpm +20/0

Nominal loaded speed 2200 rpm
Full speed unladen 2360 rpm
MA Manipulator O20
MC Master cylinder M9
N Level S5
P Pump equipment Q8
PAAV Front attachment plug A16
PAAV(O) Front attachment plug (option) C16
PAAR(O) Rear attachment plug (option) A39/C39
PCR Cooler circuit pump Q3
PD Steering pump E13
PFR(O) Trailer brake plug integrated in the VAFR (option) K11
PP Pressure port G19
PRF(O) Leakage return plug (option) C16
R Hydraulic tank S7
RF Cooler O5
RLF Brake fluid tank K8
SC Circuit selector G9
SCFR(O) Trailer brake circuit selector (option) G8
VACM(O) Movement cut-off valve (option) K18

70-02-M153EN (16/05/2011)
 7
MLT 634 120 LSU + PS Series D-E3 Hydraulic schematic diagrams
MLT 735/741/120 LSU + PS Series 4-E3
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

VVT(O) VT VI VL x
VAI
1
A 2 A B T PAAR(O) A
3 1 (1 ou 2 PRISES)
2
3 2 1 C1 C2 C1 C2
PAAV 335b CSP 300b CSP
AV AR D3 3
3 2 1 PAAR(O)
P
4 (2 PRISES)
C2 30b
C4 V1 V2
PAAV(O) V1 V2 C1 C2 CR(O)
C C1 C3 335b CSP C
VC
PRF(O)
C3
30b C2

ES. AR.
ES. AV.

V1 V2

x
EVTF(O) P1 P2
EVAA(O)
0,7 L. C4 C1
E FDAV VDAV VDAR FDAR R L 13 b E
200b 200b PD P1
BA
35b CSP M
U C1 C2

x
200 cm3/tr 45±5b
P2 P1
200b
SC

x
V1 V2
V1 V2 P2 T
G LS 140b G
S
PP
SCFR(O)

x
V1 V2 T P
M LS D B1 A1 B2 A2 b B3 A3 b B4 A4 b B5 A5
S
DLS

OPTION FREINAGE REMORQUE

I P T I
P

Y
VAFR(O) 22,5 bar
N LS
PFR
B 270 bar
T

70
K T T T T T K
B B A B
EE EA ET 200 bar 190b 280b EI 280 bar EL EA(O) EF
RLF D
Y pst a a a
VACM(O)
B2 L N
2 4

M MC M
P FEMS EV5E(O)
10 μm 3 1

MA P T

O O
B 1 3 2 4

RF FR
6b
5b
P 63 cm3/tr M
PCR 10 μm absolu
Q 14 cm3/tr (1ère monte) MA Q
15 μm absolu
L L1 L2 S (pièce rechange)

CA
N Niveau moyen :
125 μm
absolu
S 104 litres S

R Capacité 128 litres Réserve direction

(16/05/2011) 70-02-M153EN
 8
Hydraulic schematic diagrams MLT 634 T LSU Series D-E3
MLT 731 T LSU Series D-E3

HYDRAULIC DIAGRAM KEY HYDRAULIC DIAGRAM KEY

Position on Position on
Item Designation Characteristics (Options) Item Designation Characteristics (Options)
diagram diagram
BA Feed block + accumulator E20 VDAR Rear steering cylinder DE K13 90x45 c80x2
CA Suction strainer S6 VL Lifting cylinder DE I33 130x70 c720
CSP Counterbalance valve E27/K30/M33 VT DE telescoping cylinder I29 70x50 c2100/140x70 c720
CR(O) Trailer hook (option) C41 VAFR(O) Trailer brake valve (option) DE G9 70x50 c2700
D 4 or 5 component valve (option) O38 VVT(O) Ts locking cylinder DE (option) A32 60x45 c183
EE Inlet section S24 VAI Insulation valve A36
EA(O) Attachment component (option) S35 VACM(O) Movement cut-off valve (option) E24
EL Lifting component S34
EI Tilt component S32
EA Optional equipment component S27
ET Telescoping component S29
EF Closing component S37
D3 3 position steering valve C13
NOTE: 1- The calibration pressures of the main relief valves, on the inlet sections, are given for maximum engine
speed.
Position 1: short steering
2- The calibration pressures of the secondary relief valves are at an engine speed of 1000 rpm.
Position 2: front wheel steering 3- The pressure relief valves should be adjusted at an oil temperature of 50°C.
Position 3: crab position
EVHAR(O) Electrovalve (rear hydraulic option) K18
EVTF(O) Boom head electrovalve (option) E33
FDAV Front disc brake K5
FDAR Rear disc brake K15
FEMS ems head filter G20
FR Return filter Q11
70

M Turbo i.c. engine Q7 1104d-44ta

Idle speed 930 rpm
Nominal loaded speed 2200 rpm
Full speed unladen 2400 rpm
MA Manipulator G21/G24
MC Master cylinder C5
N Level S4
P Pump equipment Q4
PAAV Front attachment plug C31
PAAV(O) Front attachment plug (option) C31
PAAR(O) Rear attachment plug (option) C40
PD Steering pump C12
PFR(O) Trailer brake plug integrated in the vafr (option) I10
PP Pressure port O19
PRF(O) Leakage return plug (option) A23
R Hydraulic tank S5
RLF Brake fluid tank A2
SC Circuit selector E10
SCFR(O) Circuit selector (trailer brake option) E9
SCHAR(O) Circuit selector (rear hydraulic option) K39
VC Compensation cylinder DE E28 100x50 c310
VI Tilt cylinder DE C28 120x60 c445
VDAV Front steering cylinder DE K7 90x45 c80x2/130x65 c380

70-02-M153EN (16/05/2011)
 9
MLT 634 T LSU Series D-E3 Hydraulic schematic diagrams
MLT 731 T LSU Series D-E3
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

VVT(O)
B L
RLF
N PRF(O)
A VAI A

2 A B T
3 1

B1
3 2 1 2
MC AV AR
PAAV PAAR(O)
D3 1 (1 ou 2 PRISES)
3 2 1
P P
C C2
C
C4
R L VI PAAV(O)
PD 200b 200b 0,7 L. C1 C3
13 b
CR(O)
P1
35b BA VACM C1 C2
200 cm3/tr U CSP 300b
SC 45±5b EVTF(O)
E V1 V2 P1 P2
E
LS 140b
V1 V2
S
P2 T
3 4
SCFR(O)
V1 V2 VC
T P

S FEMS
MA
OPTION 10 μm
G FREINAGE G
REMORQUE
P T
P T

Y
MA
VAFR(O) 2 C4
N LS
PFR 1 C1
B 1 2 3 4 C2
VL
C3
I I

VT

SCHAR(O)
P1 P2

70
K
FDAV FDAR K
VDAV VDAR C1 C2 C1 C2
335b CSP CSP 335b
EVHAR(O)
ES. AR.
ES. AV.

3 2
30b 30b
1 4 V1 V2 V1 V2
M C1
M
C2
CSP 70b

V1 V2
PP

O P O
X

M LS D B1 A1 B2 A2 b B3 A3 b B4 A4 b B5 A5
D
B FR DLS
6b b b
5b

Q P Q
P 45 cm3/tr M
10 μm absolu 1ère monte 22,5 b
15 μm absolu PR.
LS a a
L L1 L2 S

T T T
T 270 b T B B A B
EI
CA EE EA ET 200 b 190 b 280 b 280 b EL EA(O) EF
Niveau moyen: N 125 μm y pst a a a
S 104L absolu S

R Réserve direction

(16/05/2011) 70-02-M153EN
 10
Hydraulic schematic diagrams MLT 742 T Series 4-E3

HYDRAULIC DIAGRAM KEY HYDRAULIC DIAGRAM KEY

Position on Position on
Item Designation Characteristics (Options) Item Designation Characteristics (Options)
diagram diagram
BA Feed block + accumulator G20 VAFR(O) Trailer brake valve (option) I8
CA Suction strainer S6 VVT(O) Ts locking cylinder DE (option) A26 60x45 c183
CSP Counterbalance valve M22/I25/M41 VAI Insulation valve A30
CR(O) Trailer hook (option) I38 VACM(O) Movement cut-off valve (option) O18
D 4 or 5 component valve (option) S35
EE Inlet section S22
EA(O) Attachment component (option) S24
EL Lifting component S26
EI Tilt component S28
EA Optional equipment component S30
ET Telescoping component S33
EF Closing component S35
D3 3 position steering valve C13
Position 1: short steering
Position 2: front wheel steering NOTE: 1- The calibration pressures of the main relief valves, on the inlet sections, are given for maximum engine
speed.
Position 3: crab position
2- The calibration pressures of the secondary relief valves are at an engine speed of 1000 rpm.
EVTF(O) Boom head electrovalve (option) E27
3- The pressure relief valves should be adjusted at an oil temperature of 50°C.
FDAV Front disc brake K3
FDAR Rear disc brake K15
FR Return filter O13
M Turbo i.c. engine Q6 1104d-44ta
Idle speed 930 rpm
Nominal loaded speed 2200 rpm
Full speed unladen 2400 rpm
70

MC Master cylinder C5
N Level S3
P Pump equipment Q3
PAAV Front attachment plug C25
PAAV(O) Front attachment plug (option) C24
PAAR(O) Rear attachment plug (option) G36
PD Steering pump C12
PP Pressure port O21
PFR(O) Trailer brake plug integrated in the vafr (option) I9
PRF(O) Leakage return plug (option) A23
R Hydraulic tank S4
RLF Brake fluid tank A3
SC Circuit selector n°1 E9
SCFR(O) Circuit selector n°2 (trailer brake option) G8
VC Compensation cylinder DE K26 110x55 c310
VI Tilt cylinder DE I26 140x70 c388
VD Discharge valve O9
VDAV Front steering cylinder DE K5 90x45 c80x2
VDAR Rear steering cylinder DE K13 90x45 c80x2
VL Lifting cylinder DE I23 150x70 c716
VT DE telescoping cylinder K40 75x55 c2700

70-02-M153EN (16/05/2011)
 11
Hydraulic schematic diagrams
MLT 742 T Series 4-E3

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

B L VVT(O)
A RLF N PRF A
VAI

2 A B T
3 1
B1
3 2 1
MC
AV AR D3
P PAAV
3 2 1
C P C

C2
R L C4
PD PAAV(O)
200b 200b
C1 C3

200 cm3/tr
E E
SC EVTF(O)
V1 V2 P1 P2
LS 140b
S
SCFR(O)
V1 V2 T P 0,7L.
13 b
S P1
Ø1
G OPTION 35b BA G
FREINAGE U
REMORQUE
P T
45±5b
PAAR(O)
(1 ou 2 PRISES)
Y
VAFR(O) P2 T
N LS VI CR(O)
PFR Ø 0.7
I B I

C1 C2
VL 315b +15
0
CSP
110b
V1 V2 VT

70
FDAV VDAV FDAR
K VDAR VC K

C1 C2
ES. AR.

CSP
ES. AV.

315b +15
0
C1 C2
335b CSP
110b
M V1 V2 M

30b
V1 V2

O O
C P

P1
VD VACM(O)
EF CF OUT
PP P A1 B1 A2 B2 A3 B3 A4 B4 A5 B5 T
FR 280b 280b 190b 190b
6b
5b
LS
M
P
Q IN
Q
21.99 cm3/tr 10 μm absolu 1ère monte
21.99 cm3/tr 15 μm absolu PR.
P T

CA
Niveau moyen: N 125 μm
104L 270b
S absolu S
EE EA(O) EL EI EA ET EF
R Capacité 128 litres Réserve direction
D

(16/05/2011) 70-02-M153EN
 12
Hydraulic schematic diagrams MT 732 Series D-E3
MT 932 Series D-E3

HYDRAULIC DIAGRAM KEY

Position on
Item Designation Characteristics (Options)
diagram
CA Suction strainer S6
CSP Counterbalance valve I24/I34/G37
CSD Double counter balance valve K37
D 4 component valve O35
EE Inlet section S24
EA(O) Attachment component S25
EL Lifting component S28
EI Tilt component S30
ET Telescoping component S32
EF Closing component S34
D3 3 position steering valve A12
Position 1: short steering
Position 2: front wheel steering
Position 3: crab position
FDAV Front disc brake K3
FR Return filter O15
M Turbo i.c. engine Q7 1104d-44t/1104d-44ta
Idle speed 930 rpm
Nominal loaded speed 2200 rpm
Full speed unladen 2380 rpm (1104d-44t)
Full speed unladen 2400 rpm (1104d-44 ta)
MC Master cylinder E4
N Level S4
P Pump equipment Q4
70

PAAV(O) Front attachment plug (option) E22

PD Steering pump C11
PP Pressure port O24
R Hydraulic tank S5
RLF Brake fluid tank A5
VC Compensation cylinder DE I28 110x55 c310 (mt 7 and 9)
VI Tilt cylinder DE E28 120x60 c416 (mt 7 and 9)
VD Discharge valve O10
VDAV Front steering cylinder DE K5 90x45 c80x2
VDAR Rear steering cylinder DE K11 90x45 c80x2
VL Lifting cylinder DE G24 140x70 c720 (mt 7 and 9)
VT DE telescoping cylinder I33 70x50 c2700 (mt 7)
VT1 DE telescoping cylinder I38 100x60 c2600 (mt 9)
VT2 DE telescoping cylinder G38 80x50 c2600 (mt 9)
VACM Movement cut-off valve Q18

NOTE: 1- The calibration pressures of the main relief valves, on the inlet sections, are given for maximum engine
speed.
2- The calibration pressures of the secondary relief valves are at an engine speed of 1000 rpm.
3- The pressure relief valves should be adjusted at an oil temperature of 50°C.

70-02-M153EN (16/05/2011)
 13
MT 732 Series D-E3 Hydraulic schematic diagrams
MT 932 Series D-E3
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

2 A B T
A 3 1 A

3 2 1
RLF AV AR
D3
3 2 1
P

R L
C B2 B1 PD 200b 200b C

200 cm3/tr
MC

LS 140b
E E

T P
VI
PAAV(O)
VT2
C1 C2
VL CSP 315b +15
0
G G
C1 C2
110b CSP 315b +15
0
V1 V2

110b
VC VT V1 V2

I C1 C2 VT1 I
CSP 335b
C1 C2
335b CSP
C1 C2
FDAV VDAV VDAR CSD
30b 300b 300b
V1 V2

70
K 30b K
V1 V2 V1 V2
ES. AR.
ES. AV.

Télescopage MT 7 Télescopage MT 9

M M

En série pour MT 728 / 928

En option pour MT 732 / 932 T (A)

PP
C P A1 B1 A2 B2 A3 B3 A4 B4 T
O VD 280b 280b
190b 190b D O
EF CF OUT P1 FR
6b
5b

LS VACM
M
P 10 μm absolu 1ère monte
21.99 cm3/tr IN 15 μm absolu PR.
Q 21.99 cm3/tr Q
P T

250b

CA EE EA(O) EL EI ET EF
Niveau moyen: N 125 μm
104L absolu
S S
R Capacité 128 litres Réserve direction

(16/05/2011) 70-02-M153EN
 14
Hydraulic schematic diagrams MT 1030 S Series 4-E3
MT 1030 ST Series 4-E3

HYDRAULIC DIAGRAM KEY HYDRAULIC DIAGRAM KEY

Position on Position on
Item Designation Characteristics (Options) Item Designation Characteristics (Options)
diagram diagram
CA Suction strainer S9 VDAV Front steering cylinder DE K4 90x45 c80x2
CSP Counterbalance valve I32/C34/I39 VI Tilt cylinder DE A34 120x60 c416
CSD Double counter balance valve K38 VL Lifting cylinder DE G33 140x70 c720
CPD Double counterbalance valve I28 VSD Right stabilizer cylinder DE I26 125x60 c200
D 6 component valve O38 VSG Left stabilizer cylinder DE I30 125x60 c200
EE Inlet section S23 VT1 DE telescoping cylinder I40 100x60 c2850
EA Optional equipment component S25 VT2 DE telescoping cylinder G40 80x50 c2850
ESD Right stabilizer section S27 VVT(O) Ts locking cylinder DE (option) A22 60x45 c183
ESG Left stabilizer section S29
EL Lifting component S31
EI Tilt component S34
ET Telescoping component S36
EF Closing component S38
D3 3 position steering valve A13
Position 1: short steering NOTE: 1- The calibration pressures of the main relief valves, on the inlet sections, are given for maximum engine
speed.
Position 2: front wheel steering
2- The calibration pressures of the secondary relief valves are at an engine speed of 1000 rpm.
Position 3: crab position
3- The pressure relief valves should be adjusted at an oil temperature of 50°C.
EVTF(O) Boom head electrovalve (option) E23
FDAV Front disc brake K2
FDAR Rear disc brake K14
FR Return filter O15
M Turbo i.c. engine Q9 1104d-44t/1104d-44ta
Idle speed 930 rpm
Nominal loaded speed 2200 rpm
70

Full unladen speed (1104d-44t) 2380rpm

Full unladen speed (1104d-44ta) 2400 rpm
MC Master cylinder E3
N Level S6
P Pump equipment Q6
PAAV Front attachment plug C21
PAAV(O) Front attachment plug (option) C20
PD Steering pump C12
PFR(O) Trailer brake plug integrated in the vafr (option) G9
PRF(O) Leakage return plug (option) E17
PP Pressure port O22
R Hydraulic tank S7
RLF Brake fluid tank C4
SCFR(O) Circuit selector (trailer brake option) E8
VACM(O) Movement cut-off valve (option) O17
VAFR(O) Trailer brake valve (option) G8
VAI Insulation valve A26
VASS Stabilizer safety valve K28
VC Compensation cylinder DE E34 110x55 c310
VD Discharge valve O12
VDAR Rear steering cylinder DE K12 90x45 c80x2

70-02-M153EN (16/05/2011)
 15
MT 1030 S Series 4-E3 Hydraulic schematic diagrams
MT 1030 ST Series 4-E3
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

VVT(O)
2 A B T
3 1 VAI
A A
3 2 1 VI
AV AR
D3
3 2 1
P
C1 C2
PAAV
CSP 315b
+15
0
R L
PD 200b 200b
C C2 C
C4
110b
RLF PAAV(O)
C1 C3 V1 V2
200 cm3/tr
VC

LS 140b
B2 B1
SCFR(O) PRF(O) EVTF(O)
E P1 P2 E
V1 V2
T P
S
MC Ø1
OPTION
FREINAGE
REMORQUE P T

G Y VL VT2 G
VAFR(O)
N LS
PFR Ø 0.7
B C1 C2
CSP 315b +15
0

VSD VSG
C1 C2 C1 C2 C1 C2
110b
I 280b 100b 100b 280b CSP 335b I
V1 V2
CPD
V1 V2 V1 V2 VT1
VASS 30b
FDAV VDAV FDAR B B
VDAR V1 V2

70
A A C1 C2
K CSD 300b 300b K
ES. AR.
ES. AV.

V1 V2

M M

PP
C VD
O VACM(O) P A1 B1 A2 B2 A3 B3 A4 B4 A5 B5 A6 B6 T O
P1 FR D
280b 280b 190b 190b
EF CF OUT
6b
5b

LS
M 10 μm absolu 1ère monte
P
15 μm absolu PR.
IN
Q 21.99 cm3/tr Q
21.99 cm3/tr P T

250b

CA
Niveau moyen: N 125 μm EE EA ESD ESG EL EI ET EF
S 104L absolu S

R Capacité 128 litres Réserve direction

(16/05/2011) 70-02-M153EN
 16
Hydraulic schematic diagrams MLT 1035 LT LSU
Series 4-E3

HYDRAULIC DIAGRAM KEY HYDRAULIC DIAGRAM KEY

Position on Position on
Item Designation Characteristics (Options) Item Designation Characteristics (Options)
diagram diagram
BA Feed block + accumulator C19 VC Compensation cylinder DE E25 110x55 c310
CA Suction strainer S8 VCD Roll corrector cylinder C37 110 x 50 c165
CSD Double counter balance valve E37/M28 VI Tilt cylinder DE C25 120x60 c416
CSP Counterbalance valve C24/M32/K34 VDAV Front steering cylinder DE K5 90x45 c80x2
CR(O) Trailer hook (option) G39 VDAR Rear steering cylinder DE K12 90x45 c80x2
D 5 component valve O36 VL Lifting cylinder DE G32 140x70 c720
EE Inlet section S21 VT1 DE telescoping cylinder K26 100 x 60 c2850
ECD Slope control component S33 VT2 DE telescoping cylinder G26 80 x 50 c2850
EL Lifting component S31 VAFR(O) Trailer brake valve (option) I7
EI Tilt component S29 VVT(O) Ts locking cylinder A29
EA Optional equipment component S25 VAI Insulation valve A33
ET Telescoping component S26 VACM Movement cut-off valve C22
EF Closing component S34
D3 3 position steering valve C12
Position 1: short steering NOTE: 1- The calibration pressures of the main relief valves, on the inlet sections, are given for maximum engine
speed.
Position 2: front wheel steering
2- The calibration pressures of the secondary relief valves are at an engine speed of 1000 rpm.
Position 3: crab position
3- The pressure relief valves should be adjusted at an oil temperature of 50°C.
EVSC(O) Circuit selector electrovalve (option) K38
EVTF(O) Boom head electrovalve (option) E30
FDAV Front disc brake K2
FDAR Rear disc brake K14
FEMS Ems head filter E19
FR Return filter Q13
M Turbo i.c. engine Q9 1104d-44 ta
70

Idle speed 930 rpm

Nominal loaded speed 2200 rpm
Full speed unladen 2400 rpm
MA Manipulator G20
MC Master cylinder C4
N Level S4
P Pump equipment Q6
PAAV Front attachment plug C28
PAAV(O) Front attachment plug (option) C28
PAAR(O) Rear attachment plug (option) G37
PCR Cooling circuit pump Q2
PD Steering pump C11
PFR(O) Trailer brake plug integrated in the vafr (option) I8
PP Pressure port O18
PRF(O) Leakage return plug (option) A20
R Hydraulic tank S6
RF Cooler Q3
RLF Brake fluid tank A3
SC Circuit selector E8
SCFR(O) Circuit selector (trailer brake option) E7
S1F Selector 1 function K18

70-02-M153EN (16/05/2011)
 17
Hydraulic schematic diagrams
MLT 1035 L T LSU Series 4-E3

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

PRF(O) VVT(O)
B L
A RLF N A
VAI

2 A B T
3 1

3 2 1
VI
MC AV AR
D3 PAAV
3 2 1 0,7 L.
P P
C 13 b C
P1
C1 C2
VACM
C2 Gicleur VCD
R L 35b BA CSP 300b C4 Ø 0.9
U PAAV(O)
PD 200b 200b C1 C3
45±5B 1
2 V1 V2
3 Gicleur
200 cm3/tr Ø 0.9
P2 T
E SC E
EVTF(O) C2 C1
V1 V2 VC P1 P2 325b 325b
LS 140b
S FEMS
SCFR(O) CSD
10 μm V2 V1
V1 V2
T P

S P T PAAR(O) CR(O)
(1 ou 2 PRISES)
OPTION
MA
G G
FREINAGE
REMORQUE
P T
1 2 3 4 VT2 VL
Y
VAFR(O)
N LS
PFR C2 C1
B
I 315b +15
0
CSP I
C4

C2
110b
V2 V1 C1 C2 C1 C3
335b CSP

70
VT1
K K
FDAV VDAV VDAR FDAR 30b
V1 V2
EVSC(O)
P1 P2

S1F
C2 C1
M5 C1 C2
ES. AR.

DEVERS

CSD
ES. AV.

M6 300b 300b
S2
CSP 70b
3 2
M M
1 4
S1 V2 V1 V1 V2

MA
PP

P
O O
X
M LS D B1 A1 B2 A2 b B3 A3 b B4 A4 b B5 A5
D
DLS b b
B FR
6b
RF 5b
P
Q Q
22,5 bar
P 45 cm3/tr M
PCR a a
10 μm absolu 1ère monte LS
15 μm absolu PR.

N°272035
14 cm3/tr
L L1 L2 S T T
T
T EE 270b T T B B A B
EI 280 bar
200b
EA ET 190b 280b EL ECD EF
CA y pst a a a
Niveau moyen: N 125 μm
S 104L absolu S

R Capacité 128 litres Réserve direction

(16/05/2011) 70-02-M153EN
 18
Hydraulic schematic diagrams MLT 742 H T LSU Series 4-E3

HYDRAULIC DIAGRAM KEY HYDRAULIC DIAGRAM KEY

Position on Position on
Item Designation Characteristics (Options) Item Designation Characteristics (Options)
diagram diagram
A Accumulator I10 R Hydraulic tank S9
BT Transfer box E13 RF Cooler Q13
CA Breather filter S10 RAD Radiator O4
CAR Non-return valve O12/O15 RLF Brake fluid tank I17
CR(O) Towing hook C41 (OPTION) RPI Inching pressure reducer (th7) K20
CSP Counterbalance valve E31/E33/E36 SCFR(O) Trailer brake circuit selector G19 (OPTION)
D Control Valve I25 VACM(O) Movement cut-off valve K25 (OPTION)
EE Inlet section I27 VAI Isolation valve A28
EA Attachment component I29 VAFR(O) Trailer brake valve (option) I20
EA(O) Attachment component I37 (OPTION) VC Compensating cylinder E31 DE 100x55 C310
EL Lifting component I35 VDAR Rear steering cylinder I15
EI Tilt component I33 VDAV Front steering cylinder I4
ET Telescoping section I31 VI Tilting cylinder C32 DE 140x70 C388
EF Closing component I38 VL Lifting cylinder C35 DE 150x70 C716
D3 3 position steering valve E20 VPV Gear change cylinder I12
Position 1: short steering VT Telescoping cylinder C30 DE 75x55 C2700
Position 2: front wheel steering VVT(O) Carriage locking cylinder (option) A25 DE 60x45 C183
Position 3: crab steering
EVAA(O) Rear attachment electrovalve E39 (OPTION)
EVTF(O) Boom head electrovalve E27 (OPTION)
EV5E(O) 5th component electrovalve K37 (OPTION) NOTE: 1- The calibration pressures of the main relief valves, on the inlet sections, are given for maximum engine
speed.
EVPV Gear change solenoid valve K13
2- The calibration pressures of the secondary relief valves are at an engine speed of 1000 rpm.
FDAR Rear brake disc I16
3- The pressure relief valves should be adjusted at an oil temperature of 50°C.
FDAV Front brake I2
70

FEMS Ems head filter K26

FR Return filter O18
FT Transmission filter K6
M Perkins diesel engine M15 1104D-44T
Idle speed 930 rpm +20/0
Nominal loaded speed 2200 rpm
Full speed unladen 2400 rpm
MA Manipulator K27
MC Master cylinder K17
MH Hydrostatic motor E5
N Level S8
P Pump equipment M6
PAAV Front attachment plug C23
PAAV(O) Front attachment plug C23 (OPTION)
PAAR(O) Rear attachment plug A40 (OPTION)
PCR Cooler circuit pump Q11
PD Steering pump E20
PFR(O) Trailer brake plug integrated in the vafr I20 (OPTION)
PH Hydrostatic pump O15
PP Pressure port G26
PRF(O) Leak return plug E24 (OPTION)

70-02-M153EN (16/05/2011)
 19
Hydraulic schematic diagrams
MLT 742 H T LSU Series 4-E3

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

VVT(O) x
1
VAI PAAR(O)
2 (1 ou 2 PRISES)

3
VL PAAR(O)
4 (2 PRISES)
PAAV
C VT VI CR(O) C
C2
C4
PAAV(O)
C1 C3 C1 C2 C1 C2 C3
C1 C2

x
2 A B T 335b 300b 315b +15 C2
3 1
PRF(O)

x
0
3 2 1

AV AR D3 30b CSP CSP 110b CSP EVAA(O)

V1 V2 V1 V2 V1 V2 C4 C1
3 2 1 P P1 P2
E R L EVTF(O) VC E
M1 B T U BT CSP
PD 200b 200b
x

x
MH C1 C2 M

x
a P2 P1
200 cm3/tr 200b

x
OPTION V1 V2
FREINAGE REMORQUE
SCFR(O) LS 140b
b V1 V2 PP

x
G G
P M LS D B1 A1 B2 A2 b B3 A3 b B4 A4 b B5 A5
S T
DLS
x

T G X1 X3 A

ES. AR.
ES. AV.

P T P

Y 22,5
FDAV VDAV VDAR FDAR VAFR(O) bar
N LS
I PFR B T 270 bar I
VPV RLF T T T T T
B B A B
B2 L N D EE EA ET EI EL EA(O) EF
A

x
Y pst 200 bar a 190 bar 280 bar a 280 bar a
0,7 L A B
13 b Gicleur Ø1 VACM(O) 2 4
EVPV T P
MC
FT P T P
B A
RPI

70
A
FEMS EV5E(O)
K 15 μm 10μm 3 1 K
absolu
MA P T

X Y
1 3 2 4
MB Fe Fa Fa1 PS a b T1
B
x

M B
M

MA
P 63 cm3/tr M

L L1 L2 S PH
A
O O
x
x

MA Fs S MH G X2 X1 T2
CAR CAR FR
RAD 0.5 bar 2 bar 6b
5b
10 μm absolu (1ère monte)
15 μm absolu (pièce rechange)
RF

Q PCR 14 cm3/tr
Q

N CA
125 μm
Niveau moyen : absolu
104 litres
S S
R Capacité 128 litres Réserve direction

(16/05/2011) 70-02-M153EN
 20
Hydraulic schematic diagrams MT 1033 H L

HYDRAULIC DIAGRAM KEY HYDRAULIC DIAGRAM KEY

Position on Position on
Item Designation Characteristics (Options) Item Designation Characteristics (Options)
diagram diagram
BT Transfer box K12 VAI Insulation valve A30
CA Suction strainer S17 VAP Control valve E32
CAR Non-return valve Q24 VC Compensating cylinder C35 De 110x55 C310
CPD Double counterbalance valve E32 VCD Slope corrector cylinder C34 De 110x50 C165
CSD Double counter balance valve I37 VDAR Rear steering cylinder Q15 De 90x45 C80x2
CSP Counterbalance valve G37/G36/A34 VDAV Front steering cylinder Q6 De 90x45 C80x2
D 4 or 5 component valve K40 (Option) VI Tilting cylinder A35 De 120x60 C416
EE Inlet section M31 VL Lifting cylinder E34 De 140x70 C720
EA Optional equipment component M32 VPV Gear change cylinder Q11
ECD Slope corrector component M33 VT1 Telescoping cylinder G38 De 100x60 C2850
EL Lifting component M35 VT2 Telescoping cylinder E38 De 80x50 C2850
EI Tilt component M36 VVT(O) Ts locking cylinder A27 De 60x45 C183 (Optional)
ET Telescoping component M38
EF Closing component M39
D3 3 position steering valve C23
Position 1: short steering NOTE: 1- The calibration pressures of the main relief valves, on the inlet sections, are given for maximum engine
Position 2: front wheel steering
speed.
2- The calibration pressures of the secondary relief valves are at an engine speed of 1000 rpm.
Position 3: crab position
3- The pressure relief valves should be adjusted at an oil temperature of 50°C.
EVPV Gear change solenoid valve Q12
EVTF(O) Boom head electrovalve C28 (Option)
FDAV Front disc brake Q5
FR Return filter Q27
FT Transmission filter K18
M Perkins engine M24 1104d-44t
70

Idle speed 930 rpm (+20/0)

Nominal loaded speed 2380 rpm
Full speed unladen 2400 rpm
MC Master cylinder I26
MH Hydrostatic motor K4
N Level S15
P Pump equipment M16
PAAV Front attachment plug A27
PAAV(O) Front attachment plug C26 (Option)
PD Steering pump C22
PFR(O) Trailer brake connector G29 (Option)
PH Hydrostatic pump O23
PP Pressure port K30
PRF(O) By-pass return connector G29 (Option)
R Hydraulic tank S19
RH Hydraulic cooler S15
RLF Brake fluid tank G17
RPI Inching pressure reducer (th7) I18
SCFR(O) Circuit selector E21 Trailer brake option
VACM(O) Movement cut-off valve K28 (Option)
VAFR(O) Trailer brake valve G20 (Option)

70-02-M153EN (16/05/2011)
 21
MT 1033 H L Hydraulic schematic diagrams

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

2
3 1 VVT(O) VI

AV AR VAI
A 3 2 1 C1 C2 A
+15
315b 0
A B T

3 2 1 PAAV CSP 110b

D3 V1 V2
P C2
C4 VC
PAAV(O)
R L C1 C3
PD 200b 200b
VCD
C C

200 cm3/tr EVTF(O)

P1 P2 C1 C2
325b 325b
LS 140b
SCFR(O)
Gicleur Ø1 V1 V2
CPD
V1 V2
T P Ø1
S
E Gicleur Ø1
VL VT2 E

P T B
VAP C1 C2
+15
A 315b 0
Y
VAFR(O)
OPTION FREINAGE REMORQUE N B
PRF(O) CSP 110b
V1 V2
C1 C2
G RLF VT1 G
335b
PFR(O)
B2 B1
C1 C2
30b CSP 300b 300b
Gicleur Ø1 V1 V2

MC T P CSD
V1 V2

I I
RPI
A

PP
P A1 B1 A2 B2 A3 B3 A4 B4 A5 B5 T
D

70
190b 190b
K BT 280b 280b
K
M1 T B U VACM(O)
MH FT
a 15 μm Y
absolu

a b
MB Fe Fa1 Fa PS T1
LS CF EF B 250b
M b M
EE EA ECD EL EI ET EF

T G X1 X3 A P
43,77 cm3/tr M
PH
ES. AV.

A
O O
MA Fs S MH G X2 X1 T2
ES. AR.

FDAV VDAV VDAR

VPV CAR
2b

Q A B Q
EVPV
P T
FR
6b
5b

10 μm absolu (1ère monte)

RH 15 μm absolu (pièce rechange)

S N CA S
Niveau moyen : 125 μm
104 litres absolu
R Capacité 128 litres Réserve direction

(16/05/2011) 70-02-M153EN
 22
Hydraulic schematic diagrams
MLT 731 T Series E-E3

HYDRAULIC DIAGRAM KEY HYDRAULIC DIAGRAM KEY

Position on Position on
Item Designation Characteristics (Options) Item Designation Characteristics (Options)
diagram diagram
BA Feed block + accumulator E21 VT DE telescoping cylinder K39 70x50 c2100/70x50 c2750
CA Suction strainer S6 VAFR(O) Trailer brake valve (option) G9
CSP Counterbalance valve K27/I29/M40 VVT(O) Ts locking cylinder DE (option) A29 60x45 c183
CR(O) Trailer hook (option) I40 VAI Insulation valve A33
D 4 or 5 component valve (option) S38 VACM(O) Movement cut-off valve (option) Q19
EE Inlet section S25
EA(O) Attachment component (option) S27
EL Lifting component S29
EI Tilt component S31
EA Optional equipment component S33
ET Telescoping component S36
EF Closing component S38
D3 3 position steering valve A14
Position 1: short steering
Position 2: front wheel steering NOTE: 1- The calibration pressures of the main relief valves, on the inlet sections, are given for maximum engine
Position 3: crab position
speed.
2- The calibration pressures of the secondary relief valves are at an engine speed of 1000 rpm.
EVTF(O) Boom head electrovalve (option) E30
3- The pressure relief valves should be adjusted at an oil temperature of 50°C.
FDAV Front disc brake K3
FDAR Rear disc brake K15
FR Return filter Q13
M Turbo i.c. engine Q7 1104d-44ta
Idle speed 930 rpm
Nominal loaded speed 2200 rpm
Full speed unladen 2400 rpm
70

MC Master cylinder C6
N Level S4
P Pump equipment Q4
PAAV Front attachment plug C28
PAAV(O) Front attachment plug (option) E27
PAAR(O) Rear attachment plug (option) G38
PD Steering pump C13
PP Pressure port O21
PFR(O) Trailer brake plug integrated in the vafr (option) G10
PRF(O) Leakage return plug (option) A27
R Hydraulic tank S5
RLF Brake fluid tank A3
SC Circuit selector n°1 C10
SCFR(O) Circuit selector n°2 (trailer brake option) E9
S2F Selector 2 functions K20
VC Compensation cylinder DE K29 100x50 c310
VI Tilt cylinder DE I29 120x60 c445/130x65 c380
VDAV Front steering cylinder DE K5 90x45 c80x2
VD Discharge valve O9
VDAR Rear steering cylinder DE K13 90x45 c80x2
VL Lifting cylinder DE I25 130x70 c720/140x70 c720

70-02-M153EN (16/05/2011)
 23
Hydraulic schematic diagrams
MLT 731 T Series E-E3
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

PRF
BL L 2
3 1
RLF N A B T
A A
AV AR 3 2 1 VVT(O)
3 2 1
D3
B1 P VAI
MC R L
P
PD 200b 200b

C C

200 cm3 /tr

PAAV

SC
V1 V2 C2
C4
LS 140b PAAV(O)
S C1 C3
SCFR
V1 V2 0,7 L.
E T P E
13 b
Ø1 S P1
35b
BA
U EVTF(O)
P T P1 P2
45±5B
Y
VAFR
G N LS P2 T G
PFR Ø 0.7
B FREINAGE REMORQUE
PAAR(O)
(1 ou 2 PRISES)
T P
M4

TELESCOPAGE
M2
VI CR(O)
S2
B1
I VL I
A1
S1
C1 C2
M3 CSP 315b +15
0
M1

ACCESSOIRES
S2
B2
110b

S1
A2 V1 V2 VT
FDAR S2F

70
K FDAV VDAV VDAR K
VC
C1 C2
335b CSP
ES. AR.
ES. AV.

C1 C2
335b CSP
30b
M V1 V2 M

N°226111
30b
V1 V2

O O
P P A1 B1 A2 B2 A3 B3 X1 A4 B4 X2 A5 B5 T
C VD 280b 280b 190b 190b

EF CF OUT P1 PP
FR
6b
5b
BA
LS
Q M VACM(O) M3 M4 Q
P
21.99 cm3/tr IN 10 μm absolu 1ère monte
21.99 cm3/tr 15 μm absolu PR.
P T
M1 M2
250b
CA
Niveau moyen: N 125 μm
S 110L absolu EE EA(O) EL EI EA ET EF S

R Capacité 135 litres Réserve direction

Y1 Y2 D

(16/05/2011) 70-02-M153EN
 24
Hydraulic schematic diagrams MLT 634 -120 LSU + PS
Series E-E3
MLT 735 -120 LSU + PS
MLT 741 -120 LSU + PS
Series 5-E3
HYDRAULIC DIAGRAM KEY HYDRAULIC DIAGRAM KEY
Position on Position on
Item Designation Characteristics (Options) Item Designation Characteristics (Options)
diagram diagram
BA Feed block + accumulator E17 VACM(O) Movement cut-off valve (option) K18
CA Breather filter S11 VAI Isolation valve A21
CR(O) Trailer hook (option) C41 VAFR(O) Trailer brake valve (option) I10
CSP Counterbalance valve A26/A30/C33/ VC Compensation cylinder DE C26 110x55 c310
E30
VDAR Rear steering cylinder E8
D Control Valve K18
VDAV Front steering cylinder E4
EE Inlet section K20
VI Tilt cylinder DE A28 140x70 c388
EA Attachment component K23
VL Lifting cylinder DE A31 150x70 c716
EA(O) Attachment component (option) K35
VT DE telescoping cylinder A24 75x55 c2700
EL Lifting component K32
VVT(O) Carriage locking cylinder (option) DE A17 60x45 c183
EI Tilt component K29
ET Telescoping section K25
EF Closing component K37
D3 3 position steering valve A10
Position 1: short steering NOTE: 1- The calibration pressures of the main relief valves, on the inlet sections, are given for maximum engine
Position 2: front wheel steering speed.
Position 3: crab steering 2- The calibration pressures of the secondary relief valves are at an engine speed of 1000 rpm.
3- The pressure relief valves should be adjusted at an oil temperature of 50°C.
EVAA(O) Rear attachment electrovalve (option) E38
EVTF(O) Jib head electrovalve (option) E20
EV5E(O) 5th component electrovalve (option) M34
FDAR Rear brake disc E9
FDAV Front brake E2
FEMS Ems head filter M20
FR Return filter O17
70

M Turbo i.c. engine Q12 1104d-e44ta

Idle speed 930 rpm +20/0
Nominal loaded speed 2200 rpm
Full speed unladen 2360 rpm
MA Manipulator O20
MC Master cylinder M9
N Level S5
P Pump equipment Q8
PAAV Front attachment plug A16
PAAV(O) Front attachment plug (option) C16
PAAR(O) Rear attachment plug (option) A39/C39
PCR Cooler circuit pump Q3
PD Steering pump E13
PFR(O) Trailer brake plug integrated in the VAFR (option) K11
PP Pressure port G19
PRF(O) Leakage return plug (option) C16
R Hydraulic tank S7
RF Cooler O5
RLF Brake fluid tank K8
SC Circuit selector G9
SCFR(O) Trailer brake circuit selector (option) G8

70-02-M153EN (16/05/2011)
 25
MLT 634 -120 LSU + PS Series E-E3 Hydraulic schematic diagrams
MLT 735 -120 LSU + PS - MLT 741 -120 LSU + PS Series 5-E3
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

VVT(O) VT VI VL x
VAI
1
A 2 A B T PAAR(O) A
3 1 (1 ou 2 PRISES)
2
3 2 1 C1 C2 C1 C2
PAAV 335b CSP 300b CSP
AV AR D3 3
3 2 1 PAAR(O)
P
4 (2 PRISES)
C2 30b
C4 V1 V2
PAAV(O) V1 V2 C1 C2 CR(O)
C C1 C3 335b CSP C
VC
PRF(O)
C3
30b C2

ES. AR.
ES. AV.

V1 V2

x
EVTF(O) P1 P2
EVAA(O)
0,7 L. C4 C1
E FDAV VDAV VDAR FDAR R L 13 b E
200b 200b PD P1
BA
35b CSP M
U C1 C2

x
200 cm3/tr 45±5b
P2 P1
200b
SC

x
V1 V2
V1 V2 P2 T
G LS 140b G
S
PP
SCFR

x
V1 V2 T P
M LS D B1 A1 B2 A2 b B3 A3 b B4 A4 b B5 A5
S
DLS

FREINAGE REMORQUE
I P T I
P

Y
VAFR 22,5 bar
N LS
PFR
B 270 bar
T

70
K T T T T T K
B B A B
EE EA ET 200 bar 190b 280b EI 280 bar EL EA(O) EF
RLF D
Y pst a a a
VACM(O)
B2 L N
2 4

M MC M
P FEMS EV5E(O)
10 μm 3 1

MA P T

O O
B 1 3 2 4

RF FR
6b
5b
P 63 cm3/tr M
PCR 10 μm absolu
Q 14 cm3/tr (1ère monte) MA Q
15 μm absolu
L L1 L2 S (pièce rechange)

CA
N Niveau moyen :
125 μm
absolu
S 110 litres S

R Capacité 135 litres Réserve direction

(16/05/2011) 70-02-M153EN
 26
Hydraulic schematic diagrams
MLT 634 T LSU Series E-E3

MLT 735 T LSU Series 5-E3

HYDRAULIC DIAGRAM KEY HYDRAULIC DIAGRAM KEY

Position on Position on
Item Designation Characteristics (Options) Item Designation Characteristics (Options)
diagram diagram
BA Feed block + accumulator E20 VDAV Front steering cylinder DE K7 90x45 c80x2
CA Suction strainer S6 VDAR Rear steering cylinder DE K13 90x45 c80x2
CSP Counterbalance valve E27/K30/K32/ VL Lifting cylinder DE I33 130x70 c720/140x70 c720
M33
VT DE telescoping cylinder I29 70x50 c2100/70x50 c2700
CR(O) Trailer hook (option) C41
VAFR Trailer brake valve G9
D 4 or 5 component valve (option) O38
VVT(O) Ts locking cylinder DE (option) A32 60x45 c183
EE Inlet section S24 VAI Insulation valve A36
EA(O) Attachment component (option) S35 VACM(O) Movement cut-off valve (option) E24
EL Lifting component S34
EI Tilt component S32
EA Optional equipment component S27
ET Telescoping component S29
EF Closing component S37
D3 3 position steering valve C13 NOTE: 1- The calibration pressures of the main relief valves, on the inlet sections, are given for maximum engine
Position 1: short steering speed.
Position 2: front wheel steering 2- The calibration pressures of the secondary relief valves are at an engine speed of 1000 rpm.
3- The pressure relief valves should be adjusted at an oil temperature of 50°C.
Position 3: crab position
EVHAR(O) Electrovalve (rear hydraulic option) K18
EVTF(O) Boom head electrovalve (Option) E33
FDAV Front disc brake K5
FDAR Rear disc brake K15
FEMS Ems head filter G20
FR Return filter Q11
M Turbo i.c. engine Q7 1104d-44ta
70

Idle speed 930 rpm

Nominal loaded speed 2200 rpm
Full speed unladen 2400 rpm
MA Manipulator G21/G24
MC Master cylinder C5
N Level S3
P Pump equipment Q4
PAAV Front attachment plug C31
PAAV(O) Front attachment plug (option) C31
PAAR(O) Rear attachment plug (option) C40
PD Steering pump C12
PFR Trailer brake plug integrated in the vafr I10
PP Pressure port O19
PRF(O) Leakage return plug (option) A23
R Hydraulic tank S4
RLF Brake fluid tank A2
SC Circuit selector E10
SCFR Circuit selector E9
SCHAR(O) Circuit selector (rear hydraulic option) I39
VC Compensation cylinder DE E28 100x50 c310
VI Tilt cylinder DE C28 120x60 c445/130x65 c380

70-02-M153EN (16/05/2011)
 27
MLT 634 T LSU Series E-E3 Hydraulic schematic diagrams
MLT 735 T LSU Series 5-E3
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

VVT(O)
B L
RLF
N PRF(O)
A VAI A

2 A B T
3 1

B1
3 2 1 2
MC AV AR
PAAV PAAR(O)
D3 1 (1 ou 2 PRISES)
3 2 1
P P
C C2
C
C4
R L VI PAAV(O)
PD 200b 200b 0,7 L. C1 C3
13 b
CR(O)
P1
35b BA VACM C1 C2
200 cm3/tr U CSP 300b
SC 45±5b EVTF(O)
E V1 V2 P1 P2
E
LS 140b
V1 V2
S
P2 T
3 4
SCFR
V1 V2 VC
T P

S FEMS
MA
10 μm
G FREINAGE G
REMORQUE
P T
P T

Y
MA
VAFR C4
2
N LS
C1
PFR 4
1 C2
B 1 2 3
VL
C3
I SCHAR(O) I

VT

P1 P2

FDAR

70
K K
FDAV VDAV VDAR C1 C2 C1 C2
335b CSP CSP 335b
EVHAR(O)
ES. AR.
ES. AV.

3 2
30b 30b
1 4 V1 V2 V1 V2
M C1
M
C2
CSP 70b

V1 V2
PP

O P O
X

M LS D B1 A1 B2 A2 b B3 A3 b B4 A4 b B5 A5
D
B FR DLS
6b b b
5b

Q P Q
P 45 cm3/tr M
10 μm absolu 1ère monte 22,5 b
15 μm absolu PR.
LS a a
L L1 L2 S

T T T T
T 270 b T B B A B
EI
CA EE EA ET 200 b 190 b 280 b 280 b EL EA(O) EF
Niveau moyen: N 125 μm y pst a a a
S 110L absolu S

R Capacité 135 litres Réserve direction

(16/05/2011) 70-02-M153EN
 28
Hydraulic schematic diagrams
MLT 1035 LT LSU
Series 5-E3

HYDRAULIC DIAGRAM KEY HYDRAULIC DIAGRAM KEY

Position on Position on
Item Designation Characteristics (Options) Item Designation Characteristics (Options)
diagram diagram
BA Feed block + accumulator C19 S1F Selector 1 function K18
CA Suction strainer S8 VC Compensation cylinder DE E25 110x55 c310
CSD Double counter balance valve E37/M28 VCD Roll corrector cylinder C37 110 x 50 c165
CSP Counterbalance valve C24/I27/M32/ VI Tilt cylinder DE C25 120x60 c416
K34
VDAV Front steering cylinder DE K5 90x45 c80x2
CR(O) Trailer hook (option) G39
VDAR Rear steering cylinder DE K12 90x45 c80x2
D 5 component valve O36
VL Lifting cylinder DE G32 140x70 c720
EE Inlet section S21
VT1 DE telescoping cylinder K26 100 x 60 c2850
ECD Slope control component S33
VT2 DE telescoping cylinder G26 80 x 50 c2850
EL Lifting component S31
VAFR Trailer brake valve I7
EI Tilt component S29
VVT(O) Ts locking cylinder A29
EA Optional equipment component S25
VAI Insulation valve A33
ET Telescoping component S26
VACM Movement cut-off valve C22
EF Closing component S34
D3 3 position steering valve C12
Position 1: short steering NOTE: 1- The calibration pressures of the main relief valves, on the inlet sections, are given for maximum engine
Position 2: front wheel steering speed.
Position 3: crab position 2- The calibration pressures of the secondary relief valves are at an engine speed of 1000 rpm.
3- The pressure relief valves should be adjusted at an oil temperature of 50°C.
EVSC(O) Circuit selector electrovalve (option) K38
EVTF(O) Boom head electrovalve (option) E30
FDAV Front disc brake K2
FDAR Rear disc brake K14
FEMS Ems head filter E19
FR Return filter Q13
70

M Turbo i.c. engine Q9 1104d-44 ta

Idle speed 930 rpm
Nominal loaded speed 2200 rpm
Full speed unladen 2400 rpm
MA Manipulator G20
MC Master cylinder C4
N Level S4
P Pump equipment Q6
PAAV Front attachment plug C28
PAAV(O) Front attachment plug (option) C28
PAAR(O) Rear attachment plug (option) G37
PCR Cooling circuit pump Q2
PD Steering pump C11
PFR Trailer brake plug integrated within vaf I8
PP Pressure port O18
PRF(O) Leakage return plug (option) A20
R Hydraulic tank S6
RF Cooler Q3
RLF Brake fluid tank A3
SC Circuit selector E8
SCFR Circuit selector E7

70-02-M153EN (16/05/2011)
 29
MLT 1035 LT LSU Hydraulic schematic diagrams
Series 5-E3
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

PRF(O) VVT(O)
B L
A RLF N A
VAI

2 A B T
3 1

3 2 1
VI
MC AV AR
D3 PAAV
3 2 1 0,7 L.
P P
C 13 b C
P1
C1 C2
VACM
C2 Gicleur VCD
R L 35b BA CSP 300b C4 Ø 0.9
U PAAV(O)
PD 200b 200b C1 C3
45±5B 1
2 V1 V2
3 Gicleur
200 cm3/tr Ø 0.9
P2 T
E SC E
EVTF(O) C2 C1
V1 V2 VC P1 P2 325b 325b
LS 140b
S FEMS
SCFR CSD
10 μm V2 V1
V1 V2
T P

S P T PAAR(O) CR(O)
(1 ou 2 PRISES)
MA
G G
FREINAGE REMORQUE
P T
1 2 3 4 VT2 VL
Y
VAFR
N LS
PFR C2 C1
B
I 315b +15
0
CSP I
C4

C2
110b
V2 V1 C1 C2 C1 C3
335b CSP

VT1

70
K K
FDAV VDAV VDAR FDAR 30b
V1 V2
EVSC(O)
P1 P2

S1F
C2 C1
M5 C1 C2
ES. AR.

DEVERS
CSD
ES. AV.

M6 300b 300b
S2
CSP 70b
3 2
M M
1 4
S1 V2 V1 V1 V2

MA
PP

P
O O
X
M LS D B1 A1 B2 A2 b B3 A3 b B4 A4 b B5 A5
D
DLS b b
B FR
6b
RF 5b
P
Q Q
22,5 bar
P 45 cm3/tr M
PCR a a
10 μm absolu 1ère monte LS
15 μm absolu PR.

N°272035
14 cm3/tr
L L1 L2 S T T
T
T EE 270b T T B B A B
EI 280 bar
200b
EA ET 190b 280b EL ECD EF
CA y pst a a a
Niveau moyen: N 125 μm
S 110L absolu S

R Capacité 128 litres Réserve direction

(16/05/2011) 70-02-M153EN
 30
Hydraulic schematic diagrams
70

70-02-M153EN (16/05/2011)
 HYDRAULIC COMPONENTS LOCATION

pages
Hydraulic circuits key. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A2
1 - Main hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A3
2 - Telescoping lift hydraulic circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5
3 - Boom hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7
4 - Boom compensation hydraulic circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . .A9
5 - Slope correction hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A11
6 - Steering hydraulic circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A12

70

(26/05/2011) 70-03-M153EN
 A2
Hydraulic components location

HYDRAULIC CIRCUITS KEY

Hydraulic circuits:
1 - Main 4 - Jib supply compensation
2 - Telescoping lift 5 - Tilting corrector
3 - Jib 6 - Steering

Representation on circuit Electric

Item Designation code
1 2 3 4 5 6 equivalence
BA FEED BLOCK + ACCUMULATOR x x x
CA SUCTION STRAINER x
CPD DOUBLE PILOT VALVE (Slope corrector cylinder) x
CPD DOUBLE PILOT VALVE (Right hand and left hand x
stabilizer cylinders)
CSD DOUBLE COUNTER-BALANCE VALVE (VT1) x
CSP COUNTER BALANCE VALVE (Lift cylinder) x x
CSP COUNTER BALANCE VALVE (Tilt cylinder) x x
CSP COUNTER BALANCE VALVE (VT2) x x
D 7 COMPONENT VALVE x x x x x
D3 3 POSITION STEERING VALVE x
Fdar REAR BRAKE DISC
Fdav FRONT BRAKE
FP NEGATIVE BRAKE
FR RETURN FILTER x
JSM HYDRAULIC CONTROL LEVER x x
70

MC MASTER CYLINDER
MR COOLER MOTOR x x
P HYDRAULIC PUMP x x
PD STEERING PUMP x
R HYDRAULIC TANK x
RDU UNDIRECTIONAL FLOWRATE REDUCTOR GEAR
RF OIL COOLER x
RLF BRAKE FLUID TANK
VC COMPENSATING CYLINDER x x
VCD SLOPE CORRECTOR CYLINDER x
Vdar REAR STEERING CYLINDER x
Vdav FRONT STEERING CYLINDER x
VI TILT CYLINDER x x
VIC COMPENSATION INSULATION VALVE x
VL LIFT CYLINDER x
VSD RIGHT HAND STABILIZER CYLINDER x
VSG LEFT HAND STABILIZER CYLINDER x
VT1 1 TELESCOPING CYLINDER x
VT2 2 TELESCOPING CYLINDER x

70-03-M153EN (26/05/2011)
 A3
Hydraulic components location

1 - MAIN HYDRAULIC CIRCUIT

MLT 634-LSU Turbo S.E-E3 /MLT 735-LSU Turbo S.5-E3 /MLT 1035L-LSU Turbo S.5-E3
MLT 634-120LSU S.E-E3 /MLT 735-120LSU S.5-E3 /MLT 741-120LSU S.5-E3
MLT 634-120LSU PS S.E-E3 /MLT 735-120LSU PS S.5-E3 /MLT 741-120LSU PS S.5-E3

MA

MA

IN
T 4 T
1 P OU
2 3
FEMS

Pst

Y 2
1
VACM(O)
3

D U

BA

70
PP

P
LS

D
N

T
P1

BA

L1
X
P
B
R

S
CA

FR

(26/05/2011) 70-03-M153EN
 A4
Hydraulic components location

MLT 731 Turbo S.E-E3

B
A2 2
S2F T

B
A1 1

PP MA

D P

T P1

U
T

BA
70

PP C

D VD
N P

U P1
T

BA
OUT
LS
EF
F
C

P
IN

CA FR

70-03-M153EN (26/05/2011)
 A5
Hydraulic components location

2 - TELESCOPING LIFT HYDRAULIC CIRCUIT

MLT 731 Turbo S.E-E3

D B1
A1

B4
A4

VT

VL

V1
V1
V2 CSP
V2 CSP

MLT 634-LSU Turbo S.E-E3 /MLT 735-LSU Turbo S.5-E3

MLT 634-120LSU S.E-E3 /MLT 735-120LSU S.5-E3 /MLT 741-120LSU S.5-E3
MLT 634-120LSU PS S.E-E3 /MLT 735-120LSU PS S.5-E3 /MLT 741-120LSU PS S.5-E3

70
A2

B2

A4
D
B4

CSP V1

V1

V2

V2

VT

VL

V1
V1
V2
V2 CSP CSP

(26/05/2011) 70-03-M153EN
 A6
Hydraulic components location

MLT 1035L-LSU Turbo S.5-E3

V2 CSP VT1
V1

CSP VT2

V1

V2
70

B2

A2
D A4

B4

CSP
V1
V1
V2
V2

VT1

VL

V2

V1
V1

V2
CSP

70-03-M153EN (26/05/2011)
 A7
Hydraulic components location

3 - BOOM HYDRAULIC CIRCUIT

MLT 731 Turbo S.E-E3/MLT 735-LSU Turbo S.5-E3

MLT 735-120LSU S.5-E3/MLT 735-120LSU PS S.5-E3

PAAV

D C
VI

B1
A1

V1
B3
CSP
V2
A3

70
MLT 634-LSU Turbo S.E-E3/MLT 634-120LSU S.E-E3/MLT 634-120LSU PS S.E-E3

PAAV

D C

VI

V1
A
CSP V2
B1 B
A1

B3 A

A3

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 A8
Hydraulic components location

MLT 1035L-LSU Turbo S.5-E3

PAAV

A
B
D C
V1
B A
V2

B1
A1 CSP
VI

B3
A3
70

MLT 741-120LSU S.5-E3/MLT 741-120LSU PS S.5-E3

PAAV

D C
VI

B1
A1

V1
B3
CSP
V2
A3

70-03-M153EN (26/05/2011)
 A9
Hydraulic components location

4 - BOOM COMPENSATION HYDRAULIC CIRCUIT

MLT 731 Turbo S.E-E3

B3
A3
B1

D A1

B1 1
A

B3 3
A

VC

MLT 634-LSU Turbo S.E-E3 /MLT 735-LSU Turbo S.5-E3

MLT 634-120LSU S.E-E3 /MLT 735-120LSU S.5-E3 /MLT 741-120LSU S.5-E3

70
MLT 634-120LSU PS S.E-E3 /MLT 735-120LSU PS S.5-E3 /MLT 741-120LSU PS S.5-E3

A1

D B1

A3

B3
B1 1
A

B3 3
A

VC

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 A10
Hydraulic components location

MLT 1035L-LSU Turbo S.5-E3

A1

B1
A3

B3

B1 1
A

B3 3
A

VC
70

70-03-M153EN (26/05/2011)
 A11
Hydraulic components location

5 - SLOPE CORRECTION HYDRAULIC CIRCUIT

MLT 1035L-LSU Turbo S.5-E3

S1F
3

2
4
1

2
CSD

3
a D
VCD V1
VACM V2

T
U
A5

B5
BA
b

70

(26/05/2011) 70-03-M153EN
 A12
Hydraulic components location

6 - STEERING HYDRAULIC CIRCUIT

MLT 634-LSU Turbo S.E-E3/MLT 634-120LSU S.E-E3/MLT 634-120LSU PS S.E-E3

LS
PD L
R
T
ES. AV

A T

R P D3 VDAV

SC
S
V2
SCFR V2

VDAR D S
D

S
DL

ES. AR
70

MLT 731 Turbo S.E-E3

LS
PD
L

T
R
ES. AV

T
A

R P D3 VDAV

SC
S
SCFR V2
V2

VDAR
S
LS

ES. AR P

70-03-M153EN (26/05/2011)
 A13
Hydraulic components location

MLT 735-LSU Turbo S.5-E3/MLT 735-120LSU S.5-E3/MLT 735-120LSU PS S.5-E3

MLT 741-120LSU S.5-E3/MLT 741-120LSU PS S.5-E3

LS
PD L
R
T
ES. AV

T
A
B

R P D3 VDAV

SC
S
SCFR V2
V2

VDAR D S
D

S
DL

ES. AR

70
MLT 1035L-LSU Turbo S.5-E3

ES. AV

LS
PD
L
R
T

P
VDAV

T
A
B

R P D3

SC
S
SCFR V2
V2

D
VDAR S

S
DL

ES. AR

(26/05/2011) 70-03-M153EN
 A14
Hydraulic components location
70

70-03-M153EN (26/05/2011)
 HYDRAULIC CONTROL AND ADJUSTMENT

Pages

Hydraulic pressure control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3

EMS module operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1
Control block operation (DDIC system). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C1
Control block removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D1
Cylinder removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E1

70
KAPPA hydraulic pump removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F1
AA10VO hydraulic pump removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G1

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Hydraulic control and adjustment
70

70-04-M153EN (10/09/2010)
 A3
Hydraulic control and adjustment

HYDRAULIC PRESSURE CONTROL

Pages

Hydraulic pressure control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5

– 1 - Main circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5
– 2 - Steering circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7
– 3 - Power assisted braking circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8
LSU circuit hydraulic pressure control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9
– 1 - Main circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9

70
– 2 - Steering circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13
– 3 - Power assisted braking and joystick circuit . . . . . . . . . . . . . . . . . . . . . . . . A14

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Hydraulic control and adjustment
70

70-04-M153EN (10/09/2010)
 A5
Hydraulic control and adjustment

HYDRAULIC PRESSURE CONTROL

1 - MAIN CIRCUIT

Parts required

- 1 Manometer 0/400 bar 549 885

or 1 digital manometer (0-600 bar) 554 118
- 1 Connector 213 536
- 1 test hose 549 888
A
- 1 test plug 72 339

Procedure

- Check hydraulic oil level.

- Remove the trim panel 1 (Fig. A) to the rear of the cab to gain
access to the control block.
1
- Bring the oil up to operating temperature (50°C) by carrying out
hydraulic movements.

Checking and adjusting the pressure relief valve is carried out

with full flow and the engine at maximum revolutions.
Checking and adjusting the anti-shock valves is carried out with B
minimum flow and the engine operating at 1000 rpm.

70
Checking and adjusting the main pressure relief valve.

3
- Connect the pressure gauge to the test port.
- With the engine at maximum revolutions, activate the accessory 2
1
circuit control and read the pressure shown on the gauge. 4
- Main pressure relief valve: 240 bar (MT 732/932)
250 bar (MLT 630/731).

Checking and adjusting anti-shock valves.

- Prior to carrying out these procedures it is necessary to increase

the setting on the main limiter 4 (Fig. B) by 50 bar.
- Connect the pressure gauge to the pressure port.
- Keep the relevant cylinder at the end of its travel and read the pressure shown on the gauge
(See table of values).
- When adjustment operations have been completed, return the main limiter to:
240 bar (MT 732/932)
250 bar (MLT 630/731).

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 A6
Hydraulic control and adjustment

Table of values

Cylinder rod side

MT 732
Key hydraulic MT 932
MLT 630 Turbo
circuit diagram MLT 731 Turbo

Crowd compensation EI piston side 280 bar

anti-shock valve EI rod side 190 bar
Piston side Elevation anti-shock EL piston side 280 bar
valve
Boom extension ET piston side 190 bar
anti-shock valve
70

70-04-M153EN (10/09/2010)
 A7
Hydraulic control and adjustment

2 - STEERING CIRCUIT

Parts required

- 1 Manometer 0/400 bar 549 885

or 1 digital manometer (0-600 bar) 554 118
- 1 test hose 549 888
- 1 connector 173 567
- 1 test point 58 181 A

STEERING
Procedure PUMP

- Using a T connector connect the pressure

gauge to the pressure out pipe on the main
pump (port P).

- With the engine operating at maximum

revolutions, move the steering on to full
lock and, holding that position, read the
pressure on the pressure gauge.
- Steering pressure: 140 bar

70
MAIN PUMP

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 A8
Hydraulic control and adjustment

3 - POWER ASSISTED BRAKING CIRCUIT

A
Parts required MT ...

- 1 Manometer 0/60 bar 549 884

or 1 digital manometer (0-600 bar) 554 118
- 1 test hose 549 888
- 1 connector 211 689
- 1 test plug 58 181
MASTER CYLINDER

Procedure

- With the motor off, press the brake pedal approximately 20

times to depressurize the braking circuit.
- Using a T connector connect the pressure gauge to the feed
block outlet for MT models… (Fig. A) and between the feed
block and the valveblock for MLT…Turbo (Fig. B).
- Operate the engine at maximum revolutions.
- Turn the steering wheel in order to activate the pump spool.
- Adjust the screw on the feed block to 35 bar.

FEED BLOCK
70

Checking adjustment
B
- With the motor off, press the brake pedal approximately
20 times to depressurize the braking circuit. MLT ... Turbo
- Operate the engine at maximum revolutions.
- Turn the steering wheel.
- Brake power assistance pressure: 35 bar

Before removing the T-piece with the gauge, decompress the

circuit by pressing the brake pedal with the engine stopped. MASTER
CYLINDER

Checking the accumulator and the feed block non-return

valve.
VALVE
- After checking the brake power assistance circuit pressure, BLOCK
leave the pressure gauge and connector on the hydraulic
circuit.
- Stop the engine.
- There is then braking capacity for at least 5 presses on the
pedal before pressure drops to zero.
- If, on the other hand, the pressure drops to zero after the FEED
engine is stopped, either the accumulator or the non-return BLOCK
valve is faulty.
70-04-M153EN (10/09/2010)
 A9
Hydraulic control and adjustment

CHECKING LSU CIRCUIT PRESSURES

1 - MAIN CIRCUIT

Parts required

- 1 Digital manometer (0-600 bar) 554 118

- 1 test hose 549 888
- 1 Rev counter 490 165
A
Procedure
2
- Check hydraulic oil level.
- Remove the covers 1 and 2 (Fig. A).
- Remove control block cover plate 3 (Fig. B) inside the cab.
- Bring the oil up to operating temperature (50°C) by carrying out
hydraulic movements.
1

1-1 Checking and adjusting stand-by pressure (the same as B

adjusting the FR regulator)

- Connect the digital pressure gauge (0-600 bar) to the control block
test port (Fig. C).

70
- Connect the tachometer.
- Start the engine and leave it at idle.
- Without making any hydraulic movement, measure the stand-by
pressure : 19 bar ± 1.
- If the stand-by pressure is not correct turn the adjustment screw 3
FR 1 (Fig. D) on the main pump. Screw in to increase pressure
and screw out to decrease pressure. (Tip: 1 turn equals approx.
16 bar)

NOTE: If it proves impossible to correctly set the pressure using this

technique, refer to page 11.

- Using the tachometer ensure the engine is idling at 930 +20

0 rpm.
- Carry out adjustments if necessary.
C D

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 A10
Hydraulic control and adjustment

1-2 Checking the DR valve pressure (LS main pump maximum

pressure)

NOTE: In the DDIC system maximum hydraulic circuit pressure limiting

is carried out using the LS limiter on the SX14 control block.
Do not decalibrate the pump regulator DR.
H

- Connect the 0-600 bar pressure gauge to the test port (Fig. H).
- With the engine at maximum revolutions, activate the press button
(accessory circuit) on the joystick.
- Tighten the adjusting screw 1 (Fig. H) to over-rate the main control
block limiter.
- There must be 290 bar showing on the manometer.
- If not, turn the adjustment screw 2 (Fig. I) on the main pump. 1
- Screw in to increase the DR and screw out to decrease the DR. (Tip:
one turn equals approx. 50 bar)
- When finished, reset the main pressure relief valve 1 (Fig. H) to 270
bar ± 5. I

1-3 Checking and adjusting the control block anti-shock

valves

- Before commencing this procedure over-rate the main limiter 1

70

(Fig. H) to 290 bar, following the instructions below.

- Connect the 0-600 bar pressure gauge to the test port (Fig. H).
- With the engine at maximum revolutions, activate the press button
(accessory circuit) on the joystick.
- Set the pressure to 290 bar by tightening the adjustment screw on
the main control block 1 (Fig. H) limiter.
- Screw in to increase the DR and screw out to decrease the DR. (Tip:
one turn equals approx. 50 bar)

When over-rating is complete, check the anti-shock valves.

- Engine at 1500 rpm.

- Have the relevant cylinder at the end of its travel and read the
pressure on the gauge (see table of values) below.
- If the pressures are not correct, turn the anti-shock valve adjustment J
screw (Fig. J).
2
1 - Crowd anti-shock valve, rod side
2 - Crowd anti-shock valve, piston side
3 - Elevation anti-shock valve, piston side
4 - Boom extension anti-shock valve, piston side

- When operations are complete, re-set the pressure relief valve to

270 bar ± 5. 3
1
4
70-04-M153EN (10/09/2010)
 A11
Hydraulic control and adjustment

Table of values
Key hydraulic circuit MLT 630 120 LSU
Cylinder rod side MLT 634 Turbo LSU
diagram MLT 634 120 LSU
MLT 634 120 LSU POWERSHIFT
MLT 731 Turbo LSU

Crowd compensation EI piston side 280 bar

+9
0
anti-shock valve EI rod side 190 bar
+9
0

Elevation anti-shock EL piston side 280 bar +9

0
Piston side valve
Boom extension ET piston side 200 bar +9
0
anti-shock valve

1-4 Checking and adjusting the main limiter K

- Connect the 0-600 bar pressure gauge to the test port (Fig. K).
- With the engine at maximum revolutions, activate the press
button (accessory circuit) on the joystick and read the pressure
on the gauge.
- Main limiter pressure: 270 bar ± 5.

70
- If the pressure is not correct, turn the adjusting screw 1 (Fig. K)
on the main limiter.
1

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 A12
Hydraulic control and adjustment

Troubleshooting

STAND-BY PRESSURE IMPOSSIBLE TO SET CORRECTLY TO 19 BAR

± 1 (PAGE 8).
- Connect the pressure gauge to the main LS pump.

There are 2 possible solutions. (A or B)

K
A - Remove the plug 1 (Fig. K) and put in its place a test port (Ref.:
58 187) and then connect a pressure gauge.
- With the engine at idle and no hydraulic movement, check the
pressure.
- The pressure should be 0. If there is some residual pressure or
check the flow regulator 3 (Fig. L) for possible seize or
blockage.
2

B - Connect a T connector (Ref.: 211 689) between the two connectors

2 (Fig. K), fit a test port (Ref.: 58 181) and connect the pressure FR 1
gauge.
- With the engine at idle and no hydraulic movement, check the
L
pressure.
- The pressure should be 0. If there is some residual pressure
in the LS line check the flow regulator 3 (Fig. L) on the control 3
block.
70

NOTE:
- If stand-by pressure is 19 bar, the pump’s flow rate is at the
minimum of 2 liters per minute.
- If pressure is below 19 bar, the pump is pumping.
- If there is a leak between the pump outlet and the reservoir (e.g.
leaking anti-shock valve) the pump attempts to compensate the
leak and can cause an idling engine to stall.
- A lack of flow at the pump can be caused by a leak in the LS circuit
(loss of pressure in the LS line).

70-04-M153EN (10/09/2010)
 A13
Hydraulic control and adjustment

2 - STEERING CIRCUIT

Parts required

- 1 Manometer 0/400 bar 549 885

or 1 digital manometer (0-600 bar) 554 118
- 1 test hose 549 888

Procedure
A
- Remove the control block cover 1 (Fig. A).

B
- Connect the pressure gauge to the control block test port (Fig. B).

70
- With the engine operating at maximum revolutions, move the
steering on to full lock and, holding that position, read the pressure
on the pressure gauge.
- Steering pressure : 140 bar

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 A14
Hydraulic control and adjustment

3 - POWER ASSISTED BRAKING AND JOYSTICK CIRCUIT

Parts required

- 1 Manometer 0/60 bar 549 884

or 1 digital manometer (0-600 bar) 554 118
- 1 test hose 549 888
- 1 Connector 211 689
- 1 test point 58 181

Procedure
A
- With the engine switched off, press the brake pedal approximately
20 times to remove the accumulator pressure.
- Connect a pressure gauge with a T connector between the two
connectors 1 (Fig. A).
- Operate the engine at maximum revolutions. 1
- Turn the steering wheel in order to activate the pump spool.
- Read the pressure shown on the gauge.
- Power assisted braking circuit pressure : 35 bar.
70

- If pressure is not correct, remove the pressure reducer to check for

contamination and, if necessary, change the block and accumulator
assembly.

Before removing the T-piece and the pressure gauge, depressurize

the circuit by pressing the brake pedal with the engine stopped.

NOTE: If you find that pressure falls just after the engine is switched
off, refer to the “Troubleshooting” chapter.

70-04-M153EN (10/09/2010)
 B1
Hydraulic control and adjustment

EMS MODULE OPERATION

Pages

Overview of the EMS electrohydraulic control module . . . . . . . . . . . . . . . . . . . . . . . . B3

– 1 - Component positions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3
– 2 - Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4
Operation and cross-section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5
EMS as fitted to telehandler - hydraulic schematic . . . . . . . . . . . . . . . . . . . . . . . . . . B6
– 1 - Hydraulic characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6

70
– 2 - Hydraulic circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7
Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7
– 1 - Electrical characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B8
– 2 - Curve characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B8
Zero adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B9
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B10
Maintenance instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B11
– 1 - Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B11
– 2 - Proportional controller troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . B12
– 3 - Basic principles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B13
– 4 - Electrohydraulic controller removal and fitting . . . . . . . . . . . . . . . . . . . . . . B14
– 5 - Connection block and filter removal and fitting . . . . . . . . . . . . . . . . . . . . . . B20
– 6 - Neutral position setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B21
– 7 - Procedure for putting a new module into service . . . . . . . . . . . . . . . . . . . . B22

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Hydraulic control and adjustment
70

70-04-M153EN (10/09/2010)
 B3
Hydraulic control and adjustment

EMS ELECTROHYDRAULIC CONTROL MODULE OVERVIEW

1 - LOCATION OF COMPONENTS

EMS Modules

LS

P
T

70

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 B4
Hydraulic control and adjustment

2 - LAYOUT

T 4
1 P
2
70

Pilot pressure 35 bar

Interface
MA = 15 Nm
Control unit

Inlet block
MA = 10 Nm

MA = 11 Nm

Return Filter

70-04-M153EN (10/09/2010)
 B5
Hydraulic control and adjustment

OPERATION AND CROSS SECTION

5 3 7 12 8

14

1 2 11 4 6 10 9 13

The electrohydraulic control module is composed of an electronics unit (1), an electrohydraulic

transformation stage (2) and a mechanical interface (4).

The analog electronic card (5) modulates the current sent to the proportional electrohydraulic valves

70
(3) so that the position of the control piston (6) measured by the linear sensor (7) corresponds
to the control signal received. The sensor (7) is adjustable using a screw and LED (14) (see
page 11). Each electrohydraulic valve (3) is in contact with a control piston chamber (8). The
amount of hydraulic fluid it sends moves the control piston the amount required by the controller.
The pressure of the fluid in the control piston chamber (8) depends on the external force opposing
the movement of the piston (6).

The mechanical interface (4) connects the control module to the side of the hydraulic control block.
It is centered by the collar (9) and held in place by two fixing bolts. The transverse oil-way (11)
supplies hydraulic fluid to the electrohydraulic valves, the oil-way (12) provides system drainage.
A connection block on the side of the first module provides a means of connection for all the inter-
connected modules to the external low pressure source. The bolt (10) connects the control piston
(6) and the valve spool.

The return mechanism (13) ensures that all moving parts return to neutral.

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 B6
Hydraulic control and adjustment

EMS AS FITTED TO TELEHANDLER - HYDRAULIC SCHEMATIC

Analog
Input signal
microcontroller
5
Hall Effect position
PWM Driver sensor

8
SX14 13
10
SP
7
TP VPB V PA 9
6

3 3

Tp Pp

RPM
12 11

Pressure
reducer
70

1 - HYDRAULIC CHARACTERISTICS

Oil consumption:
at end of travel: 3,6 cc at 46 cSt

Maximum feed pressure: 35 bar

Maximum return pressure: 1,5 bar

Fluid temperature range: -20 to +80°C

Viscosity range: 10 to 380 mm2/sec

Maximum permitted fluid contamination: NAS1638 Class 9

Type of fluid: Manitou hydraulic ISO 46

70-04-M153EN (10/09/2010)
 B7
Hydraulic control and adjustment

2 - HYDRAULIC DIAGRAM

P Pump
A, B Cylinder
T Reservoir
LS Load Sensing
A
Pst Low pressure
B
Y Hydraulic control drain

Y
Pst

P LS T

CABLING

70
HALL
– +
EFFECT
Sensor
+5 – Telehandler + 12 V
battery
signal
blue
yellow/green
1
2
5V supply black 4

brown 3

0,5V - 4,5V signal

5V generator

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 B8
Hydraulic control and adjustment

1 - ELECTRICAL CHARACTERISTICS

Supply voltage: 12

Amperage: 0,6 A

Power used: 8W

Controller supply voltage: 5V

Controller amperage: 7 mA

Input impedance: 40 kOhm

Protection:
supply: Polarity inversion to ISO 7637
controller: Short circuit, open circuit, overvoltage

CEM: to ISO 7637

2 - CURVE CHARACTERISTICS

- Control block spool travel as a function of the signal sent by the Joystick thumb wheel
100% = 5 V
50% = 2,5 V
0% = 0 V
70

10

Maximum safety
4 threshold: protection
against short
2 circuits between the
regulated supply
Input voltage (%) Input voltage (%)
0 line and the control
0 10 20 30 40 50 60 70 80 90 100 line
-2

-4
Initial jump to
overcome spring
-6 resistance and
spool overlap
-8

-10

Neutral position dead zone

Minimum safety threshold:
protection against short circuits
between the signal line and earth

70-04-M153EN (10/09/2010)
 B9
Hydraulic control and adjustment

ZERO-SETTING

0 bar

Adjustment
screw

Green LED

This screw is adjusted to tell the electronic control card the

neutral position of the control block spool and, therefore,
the zero position of the status sensor

The zero position of the status sensor can be adjusted using

an adjustment screw.

Green LED Adjustment method: The LED situated next to the adjustment
screw must be lit when the spool is at neutral.

Caution: it is essential that the 35 bar supply pressure is

decompressed.

70
Essential precautions

Useful information:

Once zero-setting has been carried out the green LED will not necessarily illuminate every time
the spool returns to neutral. This is because the electronic precision of a return to neutral is
considerably more precise than that obtained with the mechanical return to neutral system.

Essential precautions:

- Never directly aim a jet wash at the EMS module.

- If electric welding is carried out, disconnect all electronic connections.
- Never handle the block by its electrohydraulic (EMS) modules.
- Protect the modules from any possible physical shock when handling them and when they are
in use.

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TROUBLESHOOTING

1 - Take note of the telehandler serial number.

2 - Take note of the control block serial number.
3 - Take note of the module serial number.
4 - Check if the LED is lit when the joystick is in its neutral (middle) position.
NB: The LED is used only for adjustment purposes.
5- If the LED is lit, go to 7 below.
6- If the LED is not lit:
- Disconnect the module power supply
- Slowly and carefully adjust the zero point until the LED lights up. Take note of the
number of turns needed.
7- Check the presence of 12 V battery voltage on the EMS terminals.
8- Check the regulated 5 V on the EMS module. In the case of no voltage, replace the module.
9- Check the minimum set voltage of 0,9 V on the EMS.
10 - Check the minimum set voltage of 2,5 V (half the regulated voltage) on the EMS when the
thumbwheel is at the end of travel in one direction.
11 - Check the minimum set voltage of 4,1 V at the EMS when the thumbwheel is at the end of
travel in the opposite direction.
12 - If any one of the three voltages (positions 9, 10, 11) replace the handle. If all is correct see
13 below.
13 - Check the supply pressure P to the EMS (35 bar max.).
14 - Check the return pressure Y from the EMS (1,5 bar max.).
15 - Check operation.
16 - If it is still inoperational:
70

- Remove the complete module and mechanically slide the SX14 spool in both
directions, testing operation speed in both directions.
- If spool speeds are correct when operated manually, change the module.

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Hydraulic control and adjustment

MAINTENANCE INSTRUCTIONS

1 - INTRODUCTION

1-1 Foreword

Only competent persons can install, connect

or maintain this device. All operations must
comply with current technical and cleanliness
standards specific to this type of installation.

To ensure optimal performance and safety

during maintenance operations, you are
strongly advised to READ THIS MANUAL
EMS electrohydraulic control module
WITH CLOSE ATTENTION.

All the information, illustrations and characteristics in this document are based on the most recent
information available at the time of publication. In order to assure the high quality of its products,
MANITOU reserves the right to make modifications to the conception or technical aspects of this
product without notice.

70
1-2 Safety Notice

Pay particular attention to the safety alert markers and special instructions markers in this
manual.

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2 - PROPORTIONAL CONTROL TROUBLESHOOTING

Problem(s) Likely cause Additional checks Solutions

No movement for any 1. Insufficient supply Check the minimum
proportional operation voltage supply voltage of 9 V
at the proportional
controller terminals.

2. Insufficient pilot Check the supply

pressure pressure in the
proportional controller
pilot circuit blocks
minimum 15 bar.
3. Proportional control Clean the filter. Remove the hydraulic
protection filter supply block filter.
blocked.

Absence of or faulty 1. Absence of proportional Check the signal from Check the wiring
movement on one control signal at the the joystick to the connections and loom
proportional operation. control block. proportional control between the proportional
units. control unit and the
Value = 2,5 V if the joystick.
joystick thumbwheel is If connections and wiring
at neutral. are good, change the
joystick.
2. Faulty proportional Check for a signal voltage If the value is out of range,
70

control signal at the of between 1 and 4 change the joystick.

control block. volts, using the joystick
thumbwheel.

3. Insufficient control Check for a 5 V control If the voltage is zero or

voltage at the control voltage from the insufficient, replace the
block proportional proportional control units proportional control unit.
control units. towards the joystick.

Untimely movement with Faulty signal from the Check the signal from Check the wiring
the joystick proportional joystick proportional the joystick to the connections and loom
controller at neutral. controls. proportional control between the proportional
units. control unit and the
Value = 2,5 V if the joystick.
joystick thumbwheel is If connections and wiring
at neutral. are good, change the
joystick.
Jerky or irregular Protection filter partially Clean the filter. Remove the hydraulic
movements on all blocked. supply block filter.
proportional operations.

Jerky or irregular Blockage or seizing of Replace the proportional

movements on one that proportional control control unit.
proportional operation. unit’s position sensor.

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Hydraulic control and adjustment

Problem(s) Likely cause Additional checks Solutions

Jerky or irregular Blockage or seizing of Replace the proportional
movement in one the pilot spool of the control unit.
direction only, on one proportional control unit
proportional operation. in question.
Asymmetric response Position sensor neutral Adjust the neutral
to control of one mis-calibrated. position on the position
proportional operation. sensor.
Oil leak between two Defective sealing in Change seals.
proportional control the pilot circuit oilways
units. between units.
Oil leak at electrohydraulic 1. Damaged seal. Change the seals.
and mechanical interface
on the proportional
control units. 2. Excessive pilot Check that the supply
pressure. pressure in the pilot
circuit does not exceed
35 bar.

3 - BASIC RULES

General points concerning the connection of the electrohydraulic control module

Hydraulic system

70
When removing the electrohydraulic control module, all openings must be immediately covered to
avoid any possible contamination of the hydraulic system.
Check the hydraulic system’s oil quality and filtration capacity as part of all repair and maintenance
tasks on the system.
When replacing the electrohydraulic control module, do not remove the plastic plugs on openings
and pipework until just before making connections.
Do not tighten connectors to a higher torque than that shown in the fitting instructions.
PTFE tape, hemp or jointing compound must not be used.
Hydraulic pipes and connectors must in no case be under any strain.

Electrical system

Throughout all operations, take care not to damage the cables and electrical connections.
Ensure that there is no residual voltage in the electrical cables and connections.

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4 - REMOVAL AND INSTALLATION OF THE ELECTROHYDRAULIC CONTROL MODULE

4-1 General recommendations

CAUTION: BEFORE REMOVING THE ELECTROHYDRAULIC CONTROL MODULE FROM THE

TELEHANDLER BOTH THE ECM ITSELF AND ITS SURROUNDINGS MUST BE CAREFULLY CLEANED.
(N.B. NEVER AIM HIGH PRESSURE LIQUID FROM A JET WASH DIRECTLY AT THE ECM).

THE HYDRAULIC SYSTEM MUST BE KEPT TOTALLY CLEAN OF ALL IMPURITIES. PLASTIC PLUGS
MUST BE FITTED ONTO OILWAYS AND OPENINGS AS SOON AS THEY ARE EXPOSED.

Be sure to wear appropriate protective clothing and to use correct equipment to avoid accidents,
particularly with hydraulic oil.

Use the lifting eyes and correct maintenance equipment.

Put all controls connected to the telehandler in neutral (on the ground, as low as they will go
etc.) to avoid possible accidents from uncontrolled movements of parts of the machine when the
hydraulic system is disconnected.

When the machine is stopped, remove all residual pressure from the system by working all the
distribution coils. For this, move the joystick in every direction.

4-2 Removal of a simple electrohydraulic control module

70

Telehandler switched off:

- Place all parts of the machine connected to the control unit into their rest position.
- Remove all accumulated pressure by activating all the coils. To do this, move the
joystick in every direction.

NOTE: Fit a vacuum pump to the hydraulic fluid reservoir to limit oil escapes when connections are
broken.
Fit protective plugs as soon as you have disconnected the hydraulic connections on
the electrohydraulic control module. Be sure to collect any oil spills in an appropriate
recipient.

Unscrew the fixing bolts with a M5 Allen key.

Re-fitting: torque to 15 ± 1 N.m

Pull the electrohydraulic control module

backwards, parallel to the coil, to free the piston.

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Hydraulic control and adjustment

Remove the cover from the pre-set return spool

system, on the opposite side from the coil.

Unscrew the positioning piston from the

distribution coil using a 19 mm spanner on the
piston side and a M5 Allen key on the spring
side.

Re-fitting: Apply 2 drops of Loctite 242 to the

piston thread.
Torque: 10 ± 1 N.m

70
Remove and replace the sealing ring between the
controller and the control valve.

Remove the alignment ring.

NOTE: Do not remove the coil from the control

valve.

To re-fit, carry out the above procedure in reverse

order.
Adjust the neutral position.
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4-3 Removal of one or more electrohydraulic control modules mounted together

Telehandler switched off:

- Place all parts of the machine connected to the control unit into their rest position.
- Remove all accumulated pressure by activating all the coils. To do this, move the
joystick in every direction.

NOTE: Fit a vacuum pump to the hydraulic fluid reservoir to limit oil escapes when connections are
broken.
Fit protective plugs as soon as you have disconnected the hydraulic connections on
the electrohydraulic control module. Be sure to collect any oil spills in an appropriate
recipient.

To remove either an intermediate or an end

electrohydraulic control module, it is necessary
to remove the entire module.

Remove all the fixing bolts from every

electrohydraulic control module using a M5 Allen
key (cf. § 4.2).

Re-fitting: torque to 15 ± 1 N.m

70

Pull the electrohydraulic control module

backwards, parallel to the coil, to free the piston.

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Hydraulic control and adjustment

Place the modules on a clean and uncluttered

surface to keep them separate one from
another.

Re-fitting:
- Remove and replace the connection pipes
between defective modules.
- Replace the defective electrohydraulic control
module.
- Replace all sealing rings between controls and
their control valve.
- Re-assembly is carried out in the reverse order.
- Adjust the neutral position.

70
4-4 Assembled electrohydraulic control module

Ensure that all mating surfaces are clean before re-assembling.

Re-fit any connecting pipes that have been removed.
Replace the O-ring between the electrohydraulic control module and the control valve component.
Re-fit the module following the instructions described in paragraphs 4.2 and 4.3 in reverse order.

Once it is installed the unit can be used:

- check the condition of all seals on hydraulic connectors
- check the condition of electric wiring
- make the hydraulic connections to the unit, following the connection diagram and tightening to
specified torques (see the table on the data sheet)
- ensure that pipes are not kinked and to not rub anywhere.

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4-5 Removal an Disassembly of control unit

NOTE: The electrohydraulic control module should not be removed for this operation.

Telehandler switched off:

- Place all parts of the machine connected to the control unit into their rest position.
- Remove all accumulated pressure by activating all the coils. To do this, move the
joystick in every direction.

NOTE: Fit a vacuum pump to the hydraulic fluid reservoir to limit oil escapes when connections are
broken.
Fit protective plugs as soon as you have disconnected the hydraulic connections on
the electrohydraulic control module. Be sure to collect any oil spills in an appropriate
recipient.

Remove the 4 mounting screws with a M3 Allen

key.

Re-fitting: torque to 3 to 3,5 N.m

70

Remove the electrohydraulic control module by

pulling it gently backwards, parallel to the coil,
until the position sensor stem is fully out.

NOTE: Removing the 4 mounting screws from

the control module releases the circuit
board protective cover. When carrying out
this operation be sure to avoid any risk of
contamination, damp or physical impact to
the electronic and hydraulic components.

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Hydraulic control and adjustment

Remove one or two electrohydraulic valves.

NOTE: This operation should only be carried out

if there is an externally visible oil leak
around the seal between the valve and its
housing.

Re-fitting:
- replace the external valve sealing rings
- put the valve(s) in its housing

Sealing rings

70
Replace the external sealing ring on the stem
(or the sensor O-ring).

NOTE: Before re-fitting, position the sensor O-ring

in its groove on the side of the mechanical
interface.

Re-fit the electrohydraulic control module by

following the instructions in reverse order.

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Hydraulic control and adjustment

5 - REMOVAL AND RE-FITTING OF THE CONNECTION BLOCK AND THE FILTER

Telehandler switched off:

- Place all parts of the machine connected to the control unit into their rest position.
- Remove all accumulated pressure by activating all the coils. To do this, move the
joystick in every direction.

NOTE: Fit a vacuum pump to the hydraulic fluid reservoir to limit oil escapes when connections are
broken.
Fit protective plugs as soon as you have disconnected the hydraulic connections on
the electrohydraulic control module. Be sure to collect any oil spills in an appropriate
recipient.

5-1 Removal and refitting of connection block

Remove the two fixing screws with a M5 Allen

key.

Re-fitting: torque to 11 ± 1 N.m

70

Remove the connection block. Pull the block

backwards, parallel to the bolt hole, in such a
way as to pull the connecting pipes out of their
corresponding sockets.

Re-fitting:
- Put the connecting pipes in position
- Re-fit the components in reverse order

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Hydraulic control and adjustment

5.2 - Replacement of the filter

Unscrew the filter from port P using a straight

screwdriver.

Re-fitting: screw the filter into port P by hand.

6 - NEUTRAL POSITION ADJUSTMENT

NOTE: To carry out this operation it is not necessary to remove either the control unit from the
telehandler or the electrohydraulic control module from the control valve.

Telehandler switched off:

- Place all parts of the machine connected to the control unit into their rest position.
- Remove all accumulated pressure by activating all the coils. To do this, move the
joystick in every direction.

70
Take note of and remove the inspection plug
located on the underside of the rear cover of the
control module.
Switch on the ignition.
It is absolutely essential that the 35 bar control
pressure is decompressed.

Note the internal adjustment device and the

green LED located underneath.
The green LED lights when the “mechanical zero
point” on the coil matches the “electrical zero
point” on the electronic installation.

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Hydraulic control and adjustment

Using a small straight screwdriver, turn the

adjustment screw clockwise or anti-clockwise
until the green LED lights.

7 - COMMISSIONING A NEW MODULE

Telehandler switched off:

- Place all parts of the machine connected to the control unit into their rest position.
- Remove accumulated pressure by activating all the coils.

Start the engine and load the accumulator by turning the steering wheel.

CAUTION

THE electrohydraulic PROPORTIONAL SYSTEM IS DESIGNED AND BUILT TO WORK DOWN TO -40°C.
FOR OIL TEMPERATURES LOWER THAN 15°C IT IS POSSIBLE THAT CONTROL MOVEMENTS MAY
INITIALLY BE SLOW AND JERKY. WE STRONGLY RECOMMEND YOU FOLLOW APPROPRIATE OIL
70

WARMING PROCEDURES WHEN STARTING IN COLD WEATHER.

Engage the joystick and slowly vary the control signals, checking that there are no obstacles in the
vicinity of the telehandler that could be struck if there is an accidental movement.

In response to a variable signal from the joystick, the selected function on the telehandler should
accelerate or slow down smoothly according to the signal, indicating good stability.

When just one joystick command is chosen, its corresponding function should be the only one to
respond and all other functions should remain at rest.

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Hydraulic control and adjustment

HYDRAULIC CONTROL BLOCK SYSTEM (DDIC SYSTEM)

Pages

Operation of the DDIC (Load independent flow distribution) system . . . . . . . . . . . . . . C3

– 1 - Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3
– 2 - Inlet component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4
– 3 - Distribution element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5
– 4 - End element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C7

70

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70

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Hydraulic control and adjustment

OPERATION OF THE DDIC SYSTEM

(LOAD INDEPENDENT FLOW DISTRIBUTION)

1 - INTRODUCTION

The Rexroth control block can control up to three

simultaneous movements.

The SX14 control block is made up of:

- An inlet/outlet element
- distribution elements
- an end element

Complete SX14 control block

R L
200b 200b PD

200 cm3/tr

V2
LS 140b
S

T P
M LS D B2 A2 b B3 A3 b B4 A4 b B5 A5
DLS

70
P T P

Y
VAFR 22,5 bar
N LS
PFR
B 270 bar
T

T T T T T
B B A B
EE ET 200 bar 190b 280b EI 280 bar EL EA(O) EF
D
a a a

Inlet component Distribution elements End

element

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Hydraulic control and adjustment

2 - INLET ELEMENT

The inlet element contains:

- a flow divider
The flow divider controls supply to the control block and to the steering system, with the
steering having priority.
- an LS pressure relief valve
The function of the LS pressure relief valve is to limit the maximum pressure in the circuit
by limiting the pump pilot pressure.
It pre-empts the action of the DR spool of the pump and reduces cavitation.
- a flow regulator
The flow regulator ensures the depressurization of the LS pilot line.

R L
200b 200b PD

200 cm3/tr

V2
LS 140b
S

T P
M LS D
DLS

P T P
70

Y
VAFR
N LS
PFR
B 270 bar
T

EE
D

T
P LS T P
LS

DLS M
LS
D

T
LS Pressure P
relief valve T
Flow regulator and
filter

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Hydraulic control and adjustment

3 - DISTRIBUTION ELEMENT

Each SX directional valve element is made up of a body 1, a spool 2, two load hold check valves 3,
a pressure compensator 4 and cavities for secondary relief and anti-cavitation valves 5.

B2 A2 b B3 A3 b B4 A4 b B5 A5

T T T T T
B B A B
ET 200 bar 190b 280b EI 280 bar EL EA(O)
a a a

A B
LS

70
T P T

Pressure compensator
Load hold check valve

Secondary or anti-cavitation valve

Main spool Hydraulic control

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Hydraulic control and adjustment

The maximum flow for each hydraulic function is determined by the shape of the spool:

Function PISTON side ROD side

Lifting 100 l/mm 100 l/mm
Tilting 100 l/mm 100 l/mm
Telescoping 90 l/mm 50 l/mm
Jib accessory 100 l/mm 100 l/mm
Double action rear accessory 100 l/mm 100 l/mm
Single action rear accessory 100 l/mm

Pressure compensator

- It ensures communication between the main pressure line through the control block and supply
to the actuator.
- It captures pressure information at the actuator and transmits it to the pump.

There is a priority between the actuator supply function and sending pressure information, so as
to prevent a rapid increase in pressure due to any delay in the compensator opening relative to
pump control.
70

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Hydraulic control and adjustment

4 - THE END ELEMENT

The end element contains a flushing valve whose function is

to prevent pressure spike phenomena due to the premature
closing of the main spool in one of the distribution elements
before the pump returns to minimum output.
22,5 bar

EF

Flushing valve

LS

70
End element

P
T

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70

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CONTROL BLOCK DIS-ASSEMBLY

Pages

1 - Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2
2 - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3
3 - Essential rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D4
4 - SX14 control block removal and replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . D5
5 - SX14 repair procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6

70
6 - Tightening torques MLT...LSU + MLT...120 LSU . . . . . . . . . . . . . . . . . . . . . . . . . . D12
7 - Tightening torque MLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D13
8 - Tightening torque MT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D14

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CONTROL BLOCK DIS-ASSEMBLY

1 - INTRODUCTION

1-1 Preface

This manual provides the instructions for servicing and

maintenance operations for the SX14 control block. For
the inspection and servicing operations associated with
the hydraulic system of the machine to which the block
is connected, it is essential to consult the corresponding
chapters in this manual.

The fitting, connecting and maintenance of this device must

be carried out only by a qualified technician, paying full
regard to current technical standards and the cleanliness
rules specific to this type of installation.

All information, illustrations, instructions and characteristics contained in this publication are based
on the latest product information available at the date of publication. Further to its aim to improve
quality, MANITOU reserves the right to make modifications at any time with no further notification or
obligation from its side.

1-2 Safety instructions

70

The safety instructions and important notes to which you must pay particular attention appear in
this manual in the following manner:

Instructions to be followed without fail in order to ensure your safety and avoid the risk of
material damage in the course of maintenance or repair operations.

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2 - TROUBLESHOOTING

Before working through any of these troubleshooting steps or removing the control block,
carry out a prior inspection of the telehandler’s hydraulic circuit in order to eliminate all
possible malfunctions arising from causes external to the SX14 control block.

Abnormal operation of the actuators connected to the control block.

Malfunction observed Probable cause Additional checks Solutions

Lack of power at all - LS pressure relief valve Take a pressure - Replace the LS pressure
actuators defective measurement relief valve (cf. § 5.1)
(see chapter 70 - 02) - Adjust the LS pressure
- LS pressure relief valve relief valve
out of adjustment
Lack of power on one - Secondary pressure - Re-set to nominal
actuator only relief or anticavitation pressure (see
valve out of adjustment chapter 70 - 02)
- Secondary pressure
relief valve jammed - Replace the secondary
“open” (return to tank) pressure relief valve
(cf. § 5.5)
Lack of speed in the Spool piloting fault Check control pressure Remedy
performance of one or all (see chapter 70 - 02)
movements

70
Lack of speed in just one - Spool stroke incorrect or Check piston movement If movement is incorrect,
movement spool not moving freely change housing and
- Individual compensator piston assembly
pressure blocked (cf. § 5.7 and 5.6).
Change housing and
pressure compensator
(cf. § 5.7)
Steering abnormally hard Flow divider adjustment - Adjusting piston sliding - Replace control sub-
problem freely system (cf. § 5.3)
- Adjusting piston - Replace housing and
jammed control sub-system
(cf. § 5.7 and 5.3)
Simultaneous - Individual compensator - Remove and clean
movement malfunction orifice blocked individual compensator
(cf. § 5.7)
- Individual compensator - Replace housing and
pressure blocked pressure compensator
assembly
- LS line leakage - Replace LS flow
regulator (cf. § 5.2)

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Abnormal machine operation.

Malfunction observed Probable cause Additional checks Solutions

Engine remains under Flow regulator blocked Check the ΔP at neutral Replace the flow regulator
load after spools have (see chapter 70 - 02) (cf. § 5.2)
returned to neutral

Abnormal control block operation.

Malfunction observed Probable cause Additional checks Solutions

Increased force on Control block assembly Check tightening torque Loosen and tighten to
controls or spool return tie rods too tight correct torque: (cf. § 6)
defective
Before commencing,
remove the control
block from its
mounting
Replace the spool seals
Spool seals worn out (cf. § 5.6)

Visual defects.

Malfunction observed Probable cause Additional checks Solutions

Spool leaking oil Spool seals defective Change spool seals
(cf. § 5.6)
70

Oil leaks at pressure Defective seals Remove the pressure

relief valves and plugs relief valve or plug and
replace the seals
Oil leakage between Defective seals between Remove the distribution
elements elements elements and change
the seals (cf. § 5.7)

3 - ESSENTIAL RULES

General points concerning the control block connection

- When the block is removed all openings must be plugged immediately to avoid any contamination
of the hydraulic circuit.
- When re-fitting the block remove the plastic plugs from openings just before re-making
connections.
- Do not tighten connectors to a torque greater than that specified in the assembly instructions.
- Check the quality of the hydraulic oil and the filtration capacity during all maintenance or repair
operations.
- The use of PTFE tape, hemp and jointing compound is forbidden.
- Hydraulic lines and connections must be under not strain of any kind.

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4 - SX14 CONTROL BLOCK REMOVAL AND RE-FITTING

4.1 General recommendations

Before removing the SX14 control block from the telehandler it is essential to thoroughly
clean the control block and its surroundings using a jet wash.
No impurity must enter the hydraulic circuit. Fit plastic plugs on all lines and openings as
soon as they are exposed.
Wear protective clothing and use suitable equipment to avoid any accident, particularly
with hydraulic fluid.
Use the lifting eyes and appropriate handling equipment.
Set all actuators attached to the control block in their rest position (on the ground, at
their lower limit etc.) to avoid accidents arising from uncontrolled movements when the
hydraulic circuit is disconnected.
With the machine switched off, release any pressure stored in the system by moving all
the distribution spools.

4.2 SX14 Control block removal

- Fit a vacuum pump to the tank to limit oil leakage when connections are broken.
- As soon as lines are disconnected from the control block, plug all openings.
- Be sure to catch any escaped oil in an appropriate recipient.
- Unscrew the mounting screws and remove the control block.

4.3 Re-fitting the SX 14 control block

70
- Ensure all mating faces are perfectly clean.
- Check the mating face onto the telehandler for flatness (Tolerance 0,5 mm).
- Check the condition of all seals on line connectors.
- Clean the block if it has been in prolonged storage.
- Correctly offer the block up to the telehandler and fix it in place with bolts.
- Connect the lines to the block as per the connecting diagram and the specified torques.
- Ensure that hoses are deployed so that are not twisted or rubbing on anything.
- When fitting has been correctly carried out the device can be put into use:
- Decalibrate the LS pressure relief valve before putting the telehandler into service.
- Move the distribution spools.
- Adjust the maximum pressure using the LS pressure relief valve while keeping one receiver
at the end of its stroke.

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Hydraulic control and adjustment

5 - SX14 CONTROL BLOCK REPAIR PROCEDURES

5.1 LS pressure relief valve replacement

NOTE: There is no need to remove the control block from

the telehandler for this operation.

Telehandler switched off:

- Place all actuators connected to the control block in
their rest position.
- Release stored pressures by moving all the distribution
spools.

NOTE : Collect any oil leaks in an appropriate recipient.

- On the inlet element, unscrew the LS pressure relief valve (17 mm spanner).

Reassembly: tightening torque: cf. § 6.

5.2 Flow regulator replacement

NOTE: There is no need to remove the control block from

the telehandler for this operation.
70

Telehandler switched off:

- Place all actuators connected to the control block in
their rest position.
- Release stored pressures by moving all the distribution
spools.

NOTE: Catch any escaped oil in an appropriate

container.

- On the inlet element, unscrew the flow regulator (22 mm spanner).

Reassembly: tightening torque: cf. § 6.

REMOVAL AND REPLACEMENT OF FILTER

- Using pliers, take the filter out of the flow regulator.

Strainer

Take care not to damage the O-ring at the end of

the regulator.

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Hydraulic control and adjustment

5.3 Flow divider sub-assembly dis-assembly

NOTE: It is not necessary to remove the control block from the telehandler for this operation.

Telehandler switched off:

- Place all actuators connected to the control block in their rest position.
- Release stored pressures by moving all the distribution spools.

NOTE:
- Fit a vacuum pump to the fluid reservoir in order to limit
any possible oil leaks during this operation.
- Catch any oil leaks in an appropriate recipient.

- Unscrew the plug (12 mm Allen key).

- Remove the stop and the spring.

Reassembly: tightening torque: cf. § 6.

- Replace any defective parts.

- Replace the O-rings on the plugs.
- Re-assembly is the reverse of dis-assembly.

Plug

70
Stop
Spring

Piston assembly

5.4 Flushing valve disassembly

NOTE: There is no need to remove the control block from

the telehandler for this operation.

Telehandler switched off:

- Place all actuators connected to the control
block in their rest position.
- Release stored pressures by moving all the
distribution spools.

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Hydraulic control and adjustment

- On the outlet element, unscrew the flushing valve plug

Plug (12 mm Allen key).

Re-fitting:
Shim
- Replace the plug O-ring.
- Tightening torque: cf. § 6.
Spring

- Remove: - the shim,

Ring
- the spring,
Piston - the ring,
- the piston.

- Re-assembly is the reverse of dis-assembly.

5.5 Replacement of secondary pressure relief valve

NOTE: There is no need to remove the control block

from the telehandler for this operation.
70

Telehandler switched off:

- Place all actuators connected to the control
block in their rest position.
- Release stored pressures by moving all the
distribution spools.

NOTE: Catch any escaped oil in an appropriate container.

On the distribution element in question, unscrew the secondary pressure relief valve (24 mm open
ended spanner).

Re-fitting:
- Set the pressure relief valve to the specified value.
- Fit the secondary pressure relief valve on the distribution element. For torque: cf. § 6.
- Fit a new appropriate locking cover.

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Hydraulic control and adjustment

5.6 Removal of a spool

NOTE: There is no need to remove the control block

from the telehandler for this operation.

Telehandler switched off:

- Place all actuators connected to the control
block in their rest position.
- Release stored pressures by moving all the
distribution spools.

NOTE:
- Fit a vacuum pump to the fluid reservoir in order to
limit any possible oil leaks during this operation.
- Catch any oil leaks in an appropriate recipient.

- Remove the cover fixing screws (5 mm Allen key).

Reassembly: tightening torque: cf. § 6.

70
- Remove the cup and spring.
- Remove the O-ring from the cover.
- Extract the spool from the distribution element.

Re-fitting: Grease new seals when fitting.

Spool fitting direction.

5.7 Dis-assembly and re-assembly of control block

PRELIMINARY OPERATIONS:

- Remove the control block from the telehandler (cf. § 4).

- Remove the 3 assembly nuts (13 mm socket).

Reassembly: tightening torque: cf. § 6.

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Hydraulic control and adjustment

- Remove the outlet element.

- Separate the distribution elements from the input
element.
- Replace the O-rings between the distribution
elements, the input element and the output element.
- If the input element is to be replaced, remove the
tie rods.
- Assembly is the opposite of dis-assembly, ensuring
that tie rods are torqued to the correct torque.
- Before commencing, ensure that mating faces on
the elements are clean.

Individual pressure compensator removal

- Unscrew the plug (7 mm Allen key).

70

- Remove the compensator piston.

- Clean the piston’s nozzle with compressed air.
- Check the condition of the bore in the body.

Re-assembly: replace the O-ring and the anti-extrusion

ring in the plug.

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Hydraulic control and adjustment

Disassembly of a load check valve

- Unscrew the plug (5 mm Allen key).

- Remove the spring and the poppet.

- Visually inspect the parts for condition.
- If necessary, replace any defective parts.

Re-fitting:
- Replace the plug O-ring.
- Tightening torque: cf. § 6.

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Hydraulic control and adjustment

6 - TIGHTENING TORQUE MLT...LSU + MLT...120 LSU

Torques given in N.m ± 10%.

ref. torque Nm ref. torque Nm

Input element:
1 LS pressure relief valve: 45 Distribution element:
2 LS flow regulator: 20 7 Non-return valve: 30
3 DLS/LS selector: 20 8 Pressure compensator plug: 60
4 Priority valve seat: 10 9 Secondary pressure relief valve: 70
5 Priority valve plug: 100 10 Hydraulic control unit: 10
6 Tie rods: 30 11 Return spring housing: 10
12 EMS control module control piston: 10
Output element: 13 EMS Module: 15
14 Flushing valve plug: 100
15 Tie rod nuts: 42

6 15 14

9
70

11

8
10
5
12

3
7

13

1
4

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Hydraulic control and adjustment

7 - TIGHTENING TORQUES MLT

F2

F1

C
H G D1
J D2
C
I
C K F

A
C

D
A

E2 E
E
C
E1

70
Ref Designation Number Size (mm) tightening torque
(N.m)
A M8 bolt 2 5 9,8
B M5X12 bolt 4 4 6,6
Change the seals M5X16 bolt 24 4 6,6
D Complete pressure relief valve 1 27 42
D1 1 27 42
Complete pressure relief valve (detail)
D2 1 13 24
E Poppet 2 24 42
E1 2 24 42
Complete pressure relief valve (detail)
E2 2 17 24
F Cartridge 2 24 42
F1 2 24 42
Complete pressure relief valve (detail)
F2 2 22 24
G Valve 4 8 24
H Plug 1 8 42
I Plug 2 12 42
J Bolt 1 6 24
K Bolt 1 6 24

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Hydraulic control and adjustment

8 - TIGHTENING TORQUES MT
N2 J1
J2

N1

R P O Q
M

J
N

B
A
Q H
B

A A G
K B D
N H
G

H D
C
G L
K2 E D
F

C I

K1
C
I
S

Ref Designation Number Size (mm) tightening torque

(N.m)
Shouldered bolt 3 5 24
70

A
B M10 nut 3 17 24
Change the seals Brake nut 5 13 24
D M12x20 bolt 3 18 24
E M5x12 screw 2 4 6,6
F M5x14 screw 8 4 6,6
G M5x18 screw 6 4 6,6
H M5x25 screw 3 4 6,6
I M8x25 screw 5 6 24
J Complete pressure relief valve 1 27 42
J1 1 27 42
Complete pressure relief valve (detail)
J2 1 13 24
K Complete pressure relief valve 2 24 42
K1 2 24 42
Complete pressure relief valve (detail)
K2 2 17 24
L M12x200 lever 2 19 42
M Cover screw 24 4 6,6
N Complete pressure relief valve 2 24 42
N1 2 24 42
Complete pressure relief valve (detail)
N2 2 22 24
O Valve 6 8 42
P Plug 1 8 42
Q Plug 2 12 42
R Bolt 6 6 24
S Lever 1 19 42
T Lever 1 19 42
70-04-M153EN (24/05/2011)
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Hydraulic control and adjustment

CYLINDER DISASSEMBLY

Pages

Cylinder disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3
– 1 - Hydraulic lifting systems standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3
– 2 - Dis-assembly and re-assembly of the complete rod . . . . . . . . . . . . . . . . . . E4
– 3 - Disassembly and re-assembly of piston and cylinder head . . . . . . . . . . . . . E7
– 4 - Dis-assembly and re-assembly of piston seals . . . . . . . . . . . . . . . . . . . . . . E9
– 5 - Dis-assembly and re-assembly of cylinder head seals. . . . . . . . . . . . . . . . . E10
– 6 - Application of thread locking compound . . . . . . . . . . . . . . . . . . . . . . . . . . E11

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70-04-M153EN (03/05/2010)
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Hydraulic control and adjustment

CYLINDER DISASSEMBLY

1 - HYDRAULIC LIFTING SYSTEMS STANDARDS

Extracts from Standard Pr EN 1459 - 1997

5.5.2 Hydraulic lifting system

5.5.2.1 Load retention

The lowering of a load due to a leak in the hydraulic system must not exceed 150mm
in 10 minutes with the boom positioned in its least favorable position and the oil at
its normal working temperature.

The average speed of tilt forward caused by oil leaks must not exceed half a degree
per minute.

6.3.3 Static load - leak test (elevation, tilt)

Load lowering measurements due to hydraulic leaks (see 5.5.2.1) must be carried
out with a test using the effective capacity, the telescoping boom completely
extended and the maximum elevation angle. Load lowering and fork clamp tilt must
be measured at the heel of the fork lift mast or close nearby.

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2 - DIS-ASSEMBLY AND RE-ASSEMBLY OF THE COMPLETE ROD

A1
Dis-assembly

- Place the cylinder in a vice fitted with soft jaws.

Rod 1 Body 3
- Tighten the vice moderately only to avoid deforming the
cylinder body.
- Loosen the cylinder head 2 (Fig. A1) with a hook wrench.
- If you have difficulty loosening the cylinder head consult the
paragraph “Dis-assembly” in chapter 6.
- Completely unscrew the cylinder head 2 (Fig. A1).
Cylinder head 2 Piston 4
- Remove the entire rod from the cylinder body.

NOTE: FOR LONG CYLINDERS

- Pull the rod out by 200 mm maximum.

A2
- Unscrew the cylinder head half of one turn (Carry out this
operation very progressively, without any abrupt movements).
- Pull the rod out by some 2500 mm.
- Support the rod by its end to reduce stress on the cylinder
head (Fig. A2).
- Continue to unscrew the cylinder head. If resistance is felt
raise and lower the rod to reduce friction.
70

Never force the cylinder head to unscrew it as this

might cause it to seize.

Inspection

- De-grease and clean the cylinder interior.

- Carry out a visual inspection of the cylinder body. It should be
free of scrapes, burrs, rust etc.

Re-fitting

- Use a brush to apply hydraulic oil to the piston seals.

- Replace the complete rod in the cylinder body 3 (Fig. A1).
- Take care not to damage the piston seals when taking them
past the thread on the piston body.

NOTE: Tightening the cylinder head is different depending on

if the cylinder body has a flange or not (Fig. A4). Follow
the following instructions.

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Hydraulic control and adjustment

CYLINDER WITHOUT FLANGE

A3
- Apply hydraulic oil to the external sealing rings of the cylinder
Thread head.
Cylinder locking - Apply Loctite 222 thread locking compound (see chapter 6)
head compound
Rod to the cylinder head (Fig. A3).
- Screw the cylinder head on.
- Tighten using a hook wrench and torque wrench (see
torque, Fig. A4) or use the procedure of tightening by angle
(Fig. A4).
- Turn the rod one rotation to ensure the seals are correctly in
place.
Seal
FLANGED CYLINDER

- Apply hydraulic oil to the seals and the thread of the cylinder
head.
- Screw the cylinder head on.
- Tighten using a hook wrench and torque wrench (see
torque, Fig. A4) or use the procedure of tightening by angle
(Fig. A4).
- Turn the rod one rotation to ensure the seals are correctly in
place.

Comments

70
- We recommend testing the cylinder before re-fitting it to the
telehandler.
- Move the rod in and out several times.

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Hydraulic control and adjustment

A4
A4-1
Procedure for tightening the cylinder head using the angle method.

- Tighten the cylinder head until it is in contact with the

cylinder body.
X - Put a mark 1 (Fig. A4-1) on the cylinder body and on the
cylinder head.
- Further tighten the cylinder head over the distance X (Fig. A4-2).
1 - Engage the flange with one of the nocks on the cylinder
1 head.

Tightening torques for cylinder head

flange
70

A4-2
THREAD A Ø BORE B Ø FLANGE C TIGHTENING TORQUE DISTANCE X
M43 x 200 40 51 200 to 250 N.m
M48 x 200 45 56 200 to 250 N.m
M53 x 200 50 61 200 to 250 N.m
M58 x 200 55 66 250 to 300 N.m
M63 x 200 60 72 250 to 300 N.m
M66 x 200 63 75 250 to 300 N.m
M68 x 200 65 78 250 to 300 N.m
M73 x 200 70 82 300 to 350 N.m
M78 x 200 75 89 300 to 350 N.m
M83 x 200 80 94 350 to 400 N.m
M88 x 200 85 99 350 to 400 N.m
M93 x 200 90 107 350 to 400 N.m
M98 x 200 95 109 400 to 450 N.m
M104 x 200 100 119 400 to 450 N.m
M109 x 200 105 124 400 to 450 N.m
M114 x 200 110 129 450 to 500 N.m
M124 x 200 120 139 450 to 500 N.m
M129 x 200 125 139 450 to 500 N.m
M134 x 200 130 149 450 to 500 N.m 8 to 9 mm
140 450 to 500 N.m 8,5 to 9,7 mm
150 450 to 500 N.m 9,2 to 10,5 mm
70-04-M153EN (03/05/2010)
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Hydraulic control and adjustment

3 - DISASSEMBLY AND RE-ASSEMBLY OF PISTON AND CYLINDER HEAD

B1 Dis-assembly
Cylinder head 2
Piston 7
- Place the rod in a vice fitted with soft jaws.
Rod 1 Piston 4 Set
Nut 5 screw 6
- Tighten sufficiently to stop the assembly rotating.
- Loosen the nut 5 (Fig. B1) and completely
unscrew it using a ring spanner. Or, depending
on model, remove the set screw 6 (Fig. 1) with an
Allen key.

NOTE: The set screw 6 (Fig. B1) is fitted with Loctite

and it is locked by striking it with a cold
B2 chisel.
Cylinder head 2
- Dis-assemble the piston 4 (Fig. B2) by pulling it
Rod 1 Piston 4
manually or, depending on model, by unscrewing
the piston 7 (Fig. B1) with a hook wrench.

B3

70
Cylinder head 2 - Remove the cylinder head 2 (Fig. B3) by sliding it
Rod 1
along the rod.

B4
Inspection

Cylinder head 2 - Check the rod for straightness using a dial gauge
Rod 1 along its entire length (Fig. B4).
- Check for flaking, corrosion or scraping on the rod.

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Hydraulic control and adjustment

Re-fitting
B5
- Re-fit the cylinder head 2 (Fig. B5) over the rod 1
Cylinder head 2 (Fig. B5).
- Re-fit the piston 4 (Fig. B1) onto the rod.
Rod 1
- Screw on and tighten the nut 5 (Fig. B1) using a
ring spanner and a torque wrench (Fig. B6). Or,
depending on model, re-screw the piston 7 (Fig. B1)
using a hook wrench (see torque Fig. B6) and secure
it with the set screw 6 (Fig. B1).

NOTE: B6
• The set screw must be secured with Loctite 243,
PISTON TIGHTENING TORQUE see chapter 6.
1400 • Set screw torque = 20 N.m.
1200 • Use a cold chisel to knock the metal back over the
1000
set screw.
Torque (N.m)

800

600

400

200

0
M20 M30 M40 M50 M60 M70
Thread
70

70-04-M153EN (03/05/2010)
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Hydraulic control and adjustment

4 - DIS-ASSEMBLY AND RE-ASSEMBLY OF PISTON SEALS

C1
NOTE:
Sealing rings Never use sharp or cutting tools (screwdrivers, blades etc.)
for fitting or removing seals. It is recommended to work on
workbenches free of swarf.

Dis-assembly

- Remove the piston seals (Fig. C1 or C2).

- Caution, ensure you do not damage the edges or bottom of
the seal grooves.
O-ring
Inspection

C2 - Degrease and clean the piston.

Seal
- Inspect bottoms and sides of the seal grooves for
smoothness and the absence of scrapes.
- The grooves must be clear of foreign bodies.

Re-fitting

- Position the seals as per Fig. C1 or C2.

- When fitting outside seals, expand them sufficiently to slide
them into their grooves, taking care not to break them.
- The inside seal must be fitted by hand.

70
O-ring

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Hydraulic control and adjustment

5 - DIS-ASSEMBLY AND RE-ASSEMBLY OF CYLINDER HEAD SEALS

D1
NOTE:
Anti-extrusion seal 2
O-ring 3 O-ring 1
Never use sharp or cutting tools (screwdrivers, blades etc.)
for fitting or removing seals. It is recommended to work on
workbenches free of swarf.

Dis-assembly

- Remove the seals from the cylinder head.

- Caution, ensure you do not damage the edges or bottom
Oil scraper 4 of the seal grooves.

Rod seal 5 Inspection

- Degrease and clean the cylinder head.

D2 - Inspect bottoms and sides of the seal grooves for
smoothness and the absence of scrapes.
Seal
- The grooves must be clear of foreign bodies.
- Slide the bare cylinder head over and along the piston
rod. Slide it all the way along the rod.
- The clearance should not be too great, but neither should
it jam.

Re-fitting
Plug 1
70

- Place the seals as per Fig. D1. The lips on the rod seal
should face the pressure side.
- When fitting the rod seal, start by engaging it in the
groove while holding it in place, possibly with your
D3 thumb or possibly with a plug 1 (Fig. D2) with no sharp
Drift 2 edges.
- Push it into its groove with the other hand or with a
smooth drift 2 (Fig. D3). If it proves difficult to fit, soak it
in hydraulic oil at 50°C before fitting.

Seal - Fit the oil scraper ring 4 (Fig. D1) using a mallet and a
pad. The O-rings 1 and 3 (Fig. D1) and the anti-extrusion
seal Ref. 2 (Fig. D1) are fitted by hand.

Plug 1

70-04-M153EN (03/05/2010)
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Hydraulic control and adjustment

6 - APPLICATION OF THREAD LOCKING COMPOUND

Characteristics

Loctite 222 low strength threadlocker

Application to cylinder head threads

No activator
Fixture time 10 - 30 min.
Cure time 3 - 6 hours
(Pressurizing the cylinder)
With Loctite N Activator
Fixture time 10 - 20 min.
Cure time 2 - 4 hours
(Pressurizing the cylinder)
Shear strength 1,5 - 4 N/mm2

Loctite 243 medium strength threadlocker

Applied to M8 bolts for securing pistons.

No activator
Fixture time 10 - 20 min.
Cure time 3 - 6 hours
(Pressurizing the cylinder)

70
With Loctite N Activator
Fixture time 5 - 15 min.
Cure time 2 - 4 hours
(Pressurizing the cylinder)
Shear strength 5 - 7,5 N/mm2

Dis-assembly

If parts fitted with threadlocker cannot be undone with normal tools, it is recommended to heat the
threadlocked zone to 250°C. For this a hot air gun is recommended, rather than a gas torch.

Note

If the temperature is close to 0°C when parts are fitted, it is recommended to use Loctite Activator.
This brings with it the added benefit of a reduction in cure time.

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Hydraulic control and adjustment
70

70-04-M153EN (03/05/2010)
 F1
Hydraulic control and adjustment

DIS-ASSEMBLY OF KAPPA HYDRAULIC PUMP

Pages

Dis-assembly of KAPPA main hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3

– 1 - General recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3
– 2 - Kappa 30 load sensing pump - replacement of seals . . . . . . . . . . . . . . . . . F4
– 3 - Main pump diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F12

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70

70-04-M153EN (10/09/2010)
 F3
Hydraulic control and adjustment

DIS-ASSEMBLY OF KAPPA MAIN HYDRAULIC PUMP

1 - GENERAL RECOMMENDATIONS

70
Check that components have not been damaged in transit. Always work in a clean environment.
Except for seals, clean all parts with solvent and blow them with clean dry air before re-assembling.
Take care not to damage seals. Avoid any careless handling or other damage to machined surfaces.
Components must be assembled without the use of force. If resistance is encountered, this means
incorrect assembly or the pieces which have been assembled are not perfectly aligned with other
components. If hand pressure is insufficient to completely position a component use a rubber
mallet. Never use a metal mallet or hammer. Be sure to use the correct tightening torques taken
from the values shown in the correct tables.

List of tools:

- Vice
- Special tool for installing the shaft seal
- Vertical press
- Special tool for protecting the shaft seal when fitting the front cover
- Special tool for carrying out pump rotation test after assembly
- Torque wrench
- Oil and grease
- Emery cloth

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Hydraulic control and adjustment

2 - KAPPA 30 LOAD SENSING PUMP - REPLACEMENT OF SEALS

- Fit soft jaws made of aluminum or similar to the vice

in order not to damage the machined surfaces of the
pump.

- Place the pump vertically with the end drive shaft facing
the floor, then tighten the vice. Be sure not to damage
machined parts when tightening.

- Mark the pump with a marker pen to help ensure correct

re-assembly.

- Remove the fixing bolts with a spanner.

70

- Remove the rear cover and the bolts.

- Remove the flexible seal.

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Hydraulic control and adjustment

- Remove the fixing bolts with a spanner.

- Remove the screws.

- Turn the pump round and place it in the vice with the end

70
drive shaft facing the ceiling.

- Remove the front cover with a rubber mallet.

- Mark the thrust plate and the body with a marker pen to
ensure correct re-assembly.

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Hydraulic control and adjustment

- Remove the thrust plate.

- Remove the drive gear and the driven gear.

- Remove the lower thrust plate and mark it and the body
70

with marker pen to ensure correct re-assembly.

- Remove the flexible seal.

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Hydraulic control and adjustment

- Remove the thrust plate and anti-extrusion seals and

replace with new ones, using grease, on both thrust
plates.

- Very carefully place the lower thrust plate in the body

until it is touching the body. The seal must be facing
down.

NOTE: The marker pen mark mad earlier on the thrust

plate and the body will be used at this point to
ensure the thrust plate is re-fitted in the correct
orientation with no possibility of error.

- Engage the drive gear and driven gear in the pump body,

70
until they are resting on the lower thrust plate.

- Take care not to inadvertently swap the gears round. Put

them back in their original positions.

- Very carefully place the upper thrust washer in the

body until it is touching the gears. The seal must face
upwards.

NOTE: The marker pen mark mad earlier on the thrust

plate and the body will be used at this point to
ensure the thrust plate is re-fitted in the correct
orientation with no possibility of error.

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Hydraulic control and adjustment

- Place the cover on the workbench and remove the ring

with pliers.

- Turn the cover over. Remove the shaft seal with a tool.
Take care not to damage machined parts.

- Apply a thin coating of grease to the shaft seal to ease

70

fitting. Now use the special shaft seal fitting tool and
push it into its housing until the ring seat is visible.

- Use pliers to engage the ring.

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Hydraulic control and adjustment

- Lubricate the tool for protecting the shaft seal when

fitting the front cover with clean grease or oil and engage
it in the drive gear.

- Fit the front cover without damaging the seal lip, ensuring
the guides are correctly housed.

- Place the pump vertically with the end drive shaft facing
the floor, then tighten the vice. Be sure not to damage
machined parts when tightening.

- Tighten the screws with a torque wrench set to a torque

of 140 N.m. Tighten the screws in diagonal sequence.

- Use grease to put the seal in place.

70
- Place the rear cover in the vice.

- Unscrew the plug with a spanner.

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Hydraulic control and adjustment

- Remove the sealing ring from the plug and fit a

new one.

- Using a torque wrench tighten the spring-carrier plug to

50 N.m.

- Unscrew the plug with a spanner.

70

- Remove the sealing ring from the plug and fit a

new one.

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Hydraulic control and adjustment

- Using a torque wrench tighten the plug to 50 N.m.

- Position the pump vertically with the drive shaft facing

downwards, then tighten the vice. Take care not to
damage the machined parts when tightening.

- Assemble by hand-tightening screws.

NOTE: The mark made earlier on the pump body and cover
will be used to ensure error-free assembly.

- Use a torque wrench to tighten the screws to a torque of

70
70 N.m, using a diagonal tightening sequence.

- Check the rotational torque by turning the drive gear,

ensuring that it moves freely and that no mistakes have
been made when assembling.

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Hydraulic control and adjustment

3 - MAIN PUMP DIAGRAM

1 – Plug
2 – Cup
3 – Reducer
4 – Valve spring
5 – Drive gear
6 – Cover
7 – Circlip
8 – Shaft seal
9 – Ring
10 – O-ring
11 – Thrust plate
12 – Driven gear
13 – O-ring
14 – Anti-extrusion ring
15 – Body
16 – Rear cover
17 – Screw
18 – Washer
19 – Screw
70

20 – Washer
21 – Sleeve
23 – Plug
24 – Screw
25 – O-ring
26 – Filter
27 – Plug
28 – Reducer
29 – Spool
30 – O-ring

70-04-M153EN (10/09/2010)
 G1
Hydraulic control and adjustment

DIS-ASSEMBLY OF THE AA10VO HYDRAULIC PUMP

Pages

Dis-assembly of the AA10VO main hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . . . G3

– 1 - Dis-assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G3
– 2 - Re-fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G8

70

(10/09/2010) 70-04-M153EN
 G2
Hydraulic control and adjustment
70

70-04-M153EN (10/09/2010)
 G3
Hydraulic control and adjustment

DIS-ASSEMBLY OF THE AA10VO MAIN HYDRAULIC PUMP

1 - DIS-ASSEMBLY

70
- Remove the regulator.

When re-assembling, ensure the regulator adjustable

throttle is correctly oriented, with the slot aligned
with the oil circulation drillings.

(10/09/2010) 70-04-M153EN
 G4
Hydraulic control and adjustment

- Position the pump vertically.

- Take a note of its position and remove the end cover.

- Remove the end cover, keeping the port plate in

position.

- Remove the sealing rings.

70

- Remove the taper roller bearing at the end of the shaft.

70-04-M153EN (10/09/2010)
 G5
Hydraulic control and adjustment

- Remove the shim.

- Place the pump horizontally.

- Remove the rotating group while keeping the pistons
and support plate in place.

- Remove the control piston end stop.

70
- Remove the piston from the control cylinder.
- Swivel the swashplate to facilitate the removal of the
piston.

(10/09/2010) 70-04-M153EN
 G6
Hydraulic control and adjustment

- Remove the control piston rod.

NOTE: As the head of the rod has a particular shape, it

may be necessary to manoeuver the swashplate
to remove the rod.

- Remove the swashplate.

- Remove the swashplate return spring.

70

- Remove the gear shaft and lower bearing assembly.

70-04-M153EN (10/09/2010)
 G7
Hydraulic control and adjustment

- Remove the swashplate shell bearings.

Grub
screws

- Remove the end circlip.

- Screw self-tapping screws through the shaft seal

70
recess.
- Remove the shaft seal by pulling on the screws using
pliers.

(10/09/2010) 70-04-M153EN
 G8
Hydraulic control and adjustment

2 - RE-FITTING

- Carry out the operations described above in reverse

order, incorporating the instructions given below:

- Use a spacer to fit a new shaft seal.

- Refit the end circlip.

- Ensure the port plate (cut-out) lines up correctly with the

end cover (tongue).

Cut-out
Tongue
70

- Carefully reposition the end cover seal.

- If the end cover position was not marked at the time of

dis-assembly, use the oil circulation drillings to correctly
align the end cover with the pump body.

70-04-M153EN (10/09/2010)
 G9
Hydraulic control and adjustment

- Ensure the control piston rod correctly engages in its

housing on the swashplate. Swivel the swashplate to
ensure the rod is correctly located.

- Bearing pre-load: This must be 0 to 0,05 mm.

- Use the shim 1 to ensure correct adjustment.

Fill the pump body with hydraulic oil after work is

done on it.

70

(10/09/2010) 70-04-M153EN
 G10
Hydraulic control and adjustment

STANDARD TIGHTENING TORQUE TO BE USED WHEN NOT SPECIFICALLY MENTIONED IN

REMOVAL AND RE-FITTING PROCEDURES.

TIGHTENING TORQUE IN N.m (*)

Thread Class 5.6 Class 5.8 Class 8.8 Class 10.9 Class 12.9
diameter
M3 0,54 0,76 1,16 1,7 2
M4 1,24 1,74 2,66 3,91 4,57
M5 2,47 3,46 5,2 7,7 9
M6 4,29 6 9,1 13,4 15,7
M8 10,4 14,6 22 32 38
M10 20 28 44 64 75
M12 35 49 76 111 130
M14 57 79 121 178 209
M16 88 124 189 278 325
M18 122 171 261 384 449
M20 173 243 370 544 637
M22 238 334 509 748 875
M24 298 418 637 936 1095
M27 442 619 944 1386 1622
M30 600 840 1280 1880 2200

(*) - Tightening torques are given for black or zinc-plated fasteners with light lubrication.
70

- Tightening torques are given for automatic slip and reset torque wrenches and direct read
dial torque wrenches.
- For more information consult French Standard NF E25-030.

DSR Valve

70-04-M153EN (10/09/2010)
 HYDRAULIC SPECIFIC TOOLING

pages

BASIC MANOMETER BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

DIGITAL MANOMETER BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

70

(11/05/2011) 70-09-M153EN
 2
Hydraulic specific tooling

BASIC MANOMETER BOX

This box contains all the components required for

measuring pressure on all Manitou products.

1 2 3 3 4 5 5 6
70

8 7

Basic manometer box .................................................................................549671

Consisting of:

1. 1 Manometer 1/9 bar ..............................................................549882

2. 1 Manometer 0/40 bar ............................................................549883
3. 2 Manometers 0/60 bar ..........................................................549884
4. 1 Manometer 0/400 bar ..........................................................549885
5. 2 Manometers 0/600 bar ........................................................549886
6. 4 Standard hoses ....................................................................549887
7. 2 Hoses for Maniscopic ...........................................................549888
8. 7 Manometer ports ..................................................................549889

70-09-M153EN (11/05/2011)
 3
Hydraulic specific tooling

DIGITAL MANOMETER BOX

FUNCTIONS:

• Mano Function: the following combinations can be

displayed:

- Temperature upstream to +/- 2°C

- Pressure upstream P1 with its min. and max. (700 bar
in class 0.1)
- Pressure downstream P2 with its min. and max. (700
bar in class 0.1)
- Differential pressure dP=P1-P

• Hold Function: the operator is able to freeze the display

panel so that he can take notes whenever he wishes

• Unit Function: the operator can change the measurement

unit whenever he wishes (bar, psi, kPa, mCe).

• Tare Function: enables offset to zero

• Leakage test Function: enables the pressure variation to

be measured over a programmed time period

• Recording Function: A max. of 16000 values may be

recorded. The sampling period can be configured.

70
• Zero Function: zero is carried out on 2 sensors

Digital Manometer box ...............................................................................662187

Consisting of:

1. 1 dP HP 700 bar Mano digital manometer

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

(11/05/2011) 70-09-M153EN
 4
Hydraulic specific tooling
70

70-09-M153EN (11/05/2011)
 ELECTRICITY

- ELECTRICAL CHARACTERISTICS AND

SPECIFICATIONS

- ELECTRICAL SCHEMATIC DIAGRAMS

- ELECTRICAL COMPONENTS LOCATION

- ELECTRICAL CONTROL AND

ADJUSTEMENT

- ELECTRICAL SPECIFIC TOOLING

80
 ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS

Pages

Fuses and relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

– Relay and fuse holder plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– Relay and fuse holder plate (details of FUSES) . . . . . . . . . . . . . . . . . . . . . . . . 3
ECM computer wiring connectors (120 LSU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

80

(23/05/2011) 80-01-M153EN
 2 Electrical characteristics and MLT 634 120 LSU (PS) Series E Euro 3
MLT 634/731 T (LSU) Series E Euro 3
specifications MLT 735/1035L T LSU Series 5 Euro 3
MLT 735/741 120 LSU (PS) Series 5 Euro 3

FUSES AND RELAYS

Relay and fuse holder plate

F34

F42 F40 k16

K17 + K18 - F31 + F32

F43 F41

3 3 21
5 5
1

4
2

4
2
1

1
K0
K1
3 3 3
7
5 5 5 I
G
5
4
2
4
2

4
2
1

1
K2
K3 K4
H
1
87
87 8 1
87a
8
85

87a
86

85

86

K5 E F
30

K6
30

85
87
3
1
87a 30 1
85

6
86

87a

87

K8 K9 86
30

K7
4
2
1

F13 F14 F15

80

F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12

25A
10A
30A

D
7.5A

7.5A
7.5A
10A

10A
10A

10A

15A
10A
10A
15A
5A

5A

F30
F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 F28 F29
25A
7.5A
7.5A
7.5A
7.5A

7.5A
10A
10A

10A
15A
15A

15A
15A
15A
10A

A B C 1

80-01-M153EN (23/05/2011)
MLT 634 120 LSU (PS) Series E Euro 3 Electrical characteristics and 3
MLT 634/731 T (LSU) Series E Euro 3
MLT 735/1035L T LSU Series 5 Euro 3
specifications
MLT 735/741 120 LSU (PS) Series 5 Euro 3

Relay and fuse holder plate (details of FUSES)

Section Item Current Designation

ELECTRONIC CONTROL UNIT SUPPLY
FUSES F1 7,5 A
OPTIONAL HYDRAULIC ACCESSORY LOCKING
F2 10 A WORKING TAIL LIGHT
7,5 A REAR WINDSCREEN WIPER
F3
10 A OPTIONAL SIDE AND ROOF SCREEN WIPERS
ENGINE STOP SOLENOID VALVE
F4 7,5 A
OPTIONAL HYDRAULIC ATTACHMENT EASY-CONNECT
F5 7,5 A ROTATING BEACON LIGHT

F6 5A WHEEL DIRECTION
LONGITUDINAL STABILITY ALARM DEVICE
TILTING CORRECTOR
F7 10 A
“SINGLE” HYDRAULIC MOVEMENT CUT-OFF
“AGGRAVATING” HYDRAULIC MOVEMENT CUT-OFF
FORWARD/NEUTRAL/REVERSE GEAR SELECTION
TRANSMISSION CUT-OFF
F8 15 A
REVERSING LIGHTS
OPTIONAL AUDIBLE REVERSE WARNING
F9 5A CONTROL PANEL
HORN
F10 15 A
STOP SWITCH
OPTION JIB HEAD LIGHT
F11 10 A
OPTIONAL FRONT AND REAR BLUE WORK LAMPS
F12 10 A TURN INDICATOR SUPPLY

F13 30 A HEATING

F14 10 A CIGARETTE LIGHTER

F15 25 A OPTIONAL OIL COOLER

F16 7,5 A AIR CONDITIONING OPTION

OPTION JIB HEAD ELECTROVALVE

80
OPTIONAL JIB SOLENOID VALVE AND ACCESSORY HYDRAULIC LOCKING
OPTION ELECTRICAL JIB PROVISION
OPTIONAL ANTI-THEFT PRE-WIRING
10 A OPTIONAL ANTI-THEFT SYSTEM
OPTIONAL IMMOBILIZER SYSTEM
OPTIONAL SELF-CLEANING FAN
OPTION HYDRAULIC TOWING HOOK
OPTIONAL SINGLE OR DOUBLE ACTING REAR HYDRAULIC PROVISION
F17 OPTIONAL PROVISION FOR TWO DOUBLE ACTING REAR HYDRAULIC
OPTIONAL HYDRAULIC TOWING HOOK AND SINGLE OR DOUBLE ACTION HYDRAULICS PRE-
WIRING
OPTIONAL DOUBLE ACTING REAR HYDRAULIC PROVISION + SINGLE ACTING REAR HYDRAULIC
PROVISION
OPTIONAL JIB HEAD SOLENOID VALVE AND SELF-CLEANING FAN
OPTIONAL PROVISION FOR TWO DOUBLE ACTING REAR HYDRAULIC
15 A OPTIONAL HYDRAULIC TOWING HOOK AND SINGLE OR DOUBLE ACTION HYDRAULICS PRE-
WIRING
OPTIONAL DOUBLE ACTION AND SINGLE ACTION REAR HYDRAULICS PRE-WIRING

F18 15 A FRONT WORK LAMP

F19 15 A OPTIONAL REAR WINDOW DEFROSTING

F20 10 A OPTION PNEUMATIC SEAT

F21 10 A FRONT WINDSCREEN WIPER AND WASHER

F22 10 A OPTION JIB SUSPENSION

(23/05/2011) 80-01-M153EN
 4 Electrical characteristics and MLT 634 120 LSU (PS) Series E Euro 3
MLT 634/731 T (LSU) Series E Euro 3
specifications MLT 735/1035L T LSU Series 5 Euro 3
MLT 735/741 120 LSU (PS) Series 5 Euro 3

Section Item Current Designation

RIGHT-HAND SIDELIGHT
SIDELIGHT ON WARNING LAMP
F23 7,5 A
CONTROL PANEL ILLUMINATION
OPTIONAL NUMBER PLATE ILLUMINATION
F24 7,5 A LEFT-HAND SIDELIGHT

F25 7,5 A RIGHT-HAND INDICATOR LIGHT

F26 7,5 A LEFT-HAND INDICATOR LIGHT

DIPPED BEAM HEADLIGHTS
F27 15 A DIPPED BEAM ON WARNING LAMP
REAR FOG LIGHT
MAIN BEAM HEADLIGHTS
F28 15 A
HEADLIGHTS WARNING LAMP
HAZARD WARNING LIGHTS
F29 15 A CEILING LIGHT
OPTION (+) PERMANENT
F30 25 A LIGHTING, HORN AND INDICATOR SWITCH

F31 25 A STARTER
3A ELECTRO-PROPORTIONAL HYDRAULIC CONTROL MODULES
5A OPTION JIB SUSPENSION
F32
“AGGRAVATING” HYDRAULIC MOVEMENT CUT-OFF
OPTION ATTACHMENT HYDRAULIC CONTROL FORCED OPERATION
F33 1A ELECTRONIC CONTROL UNIT

F34 30 A DIESEL ENGINE ELECTRONIC CONTROL MODULE

F35 5A DIAGNOSTIC CONNECTOR

F40 40 A TELEHANDLER ELECTRICAL EQUIPMENT

F41 40 A TELEHANDLER ELECTRICAL EQUIPMENT

F42 80 A DIESEL ENGINE PRE-HEATING

F43 80 A ALTERNATOR

F44 15 A OPTION DIESEL FUEL HEATER

K0 AIR CONDITIONING OPTION

K1 TRANSMISSION TO HYDRAULIC CONTROLS CUT-OFF RELAY

TRANSMISSION CUT-OFF RELAY
80

K2
FORWARD/REVERSE RELAY
K3 REVERSE GEAR RELAY

K4 FORWARD GEAR RELAY

K5 BUZZER
OPTION JIB HEAD ELECTROVALVE
K6 OPTION ELECTRICAL JIB PROVISION
OPTIONAL JIB HEAD SOLENOID VALVE AND HYDRAULIC ACCESSORY LOCKING

RELAY “SINGLE” HYDRAULIC MOVEMENT CUT-OFF

K7
“AGGRAVATING” HYDRAULIC MOVEMENT CUT-OFF
K8 STARTER SAFETY RELAY

K9 FLASHING UNIT

K10 OPTION JIB SUSPENSION

K11 OPTION JIB SUSPENSION

K12 OPTION

K15 PROPORTIONAL HYDRAULIC CONTROLS CUT-OFF RELAY

K16 ENGINE PRE-HEATING RELAY

K20 OPTIONAL DIESEL FUEL HEATER

80-01-M153EN (23/05/2011)
MLT 634 120 LSU (PS) Series E Euro 3 Electrical characteristics and 5
MLT 735/741 120 LSU (PS) Series 5 Euro 3
specifications

ECM (120 LSU) COMPUTER CONNECTORS

Air intake pressure sensor

J2 pin
Connector Pin connection Designation
connection
1 46 8V Power supply
B7 2 38 Weight
1 3 55 Signal
32

Fuel pressure sensor

J2 pin
Connector Pin connection Designation
connection
1 48 8V Power supply
B8 2 40 Weight
1
2 3 51 Signal
3

Primary speed sensor

J2 pin
Connector Pin connection Designation
connection
1 10 8V Power supply
B9

80
2 52 Signal

2
1

1
2
Secondary speed sensor

J2 pin
Connector Pin connection Designation
connection
1 10 8V Power supply
B10
2 53 Signal

(23/05/2011) 80-01-M153EN
 6 Electrical characteristics and MLT 634 120 LSU (PS) Series E Euro 3
MLT 735/741 120 LSU (PS) Series 5 Euro 3
specifications

Oil pressure sensor

12
3
J2 pin
Connector Pin connection Designation
connection
1 47 8V Power supply
B11 2 39 Weight
3 56 Signal

12
Air intake temperature sensor

J2 pin
Connector Pin connection Designation
connection
1 42 Signal
S24
2 37 Power supply

Coolant liquid temperature sensor

J2 pin
Connector Pin connection Designation
connection
1 1 43 Temperature signal
2
80

S32
2 37 Power supply

J2 connector

80-01-M153EN (23/05/2011)
 ELECTRICAL SCHEMATIC DIAGRAMS

Pages
– MLT 630/731 T Series D-E3
– MLT 742 T Series 4-E3
– MLT 731 T Series E-E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1

– MLT 634/731 T LSU Series D-E3

– MLT 634 T LSU Series E-E3
– MLT 735 T LSU Series 5-E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1

– MT 1030 S/ST Series 4-E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C1

– MLT 1035 LT LSU Series 4-E3

– MLT 1035 LT LSU Series 5-E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D1

80
– MLT 634 120 LSU PS Series D-E3
– MLT 735/741 120 LSU (PS) Series 4-E3
– MLT 634 120 LSU PS Series E-E3
– MLT 735/741 120 LSU PS Series 5-E3 . . . . . . . . . . . . . . . . . . . . . . .E1

– MLT 634 -120 LSU Series D-E3

– MLT 735/741 120 LSU Series 4-E3
– MLT 634 120 LSU Series E-E3
– MLT 735/741 120 LSU Series 5-E3 . . . . . . . . . . . . . . . . . . . . . . . . . .F1

– MT 732/932 Series D-E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G1

– MLT 742 H T LSU Series 4-E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H1

– MT 1033H L Series 4-E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1

(11/05/2011) 80-02-M153EN
 Electrical schematic diagrams MLT 630 T Series D-E3
MLT 731 T Series D-E3
MLT 742 T Series 4-E3
MLT 731 T Series E-E3
80

80-02-M153EN (11/05/2011)
 A1
MLT 630 T Series D-E3 Electrical schematic diagrams
MLT 731 T Series D-E3
MLT 742 T Series 4-E3
MLT 731 T Series E-E3

– Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A2
– Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7

80

(11/05/2011) 80-02-M153EN
 A2
Electrical schematic diagrams MLT 630 T Series D-E3
MLT 731 T Series D-E3
MLT 742 T Series 4-E3
MLT 731 T Series E-E3

Components
Item Type Designation Position on diagram
E1 E Rear right hand indicator light B30
E2 E Front right-hand indicator light B31
E3 E Rear left-hand indicator light B31
E4 E Front left-hand indicator light B32
E5 E Left hand brake light B29
E6 E Right hand brake light B29
E7 E Rear right hand side light B43
E8 E Front right hand side light B44
E9 E Rear left hand side light B45
E10 E Front left hand side light B45
E11 E Front left hand dipped headlight B45
E12 E Front right hand dipped headlight B46
E13 E Front left-hand headlight B47
E14 E Front right-hand headlight B47
E15 E Rear right-hand working light (option) C41
E16 E Rear left-hand working light (option) C41
E17 E Front left-hand working light (option) C40
E18 E Front right-hand working light (option) C41
E19 E Rotating beacon light B17
E20 E Left-hand reverse light (option) C25
E21 E Roof light C33
E22 E Right-hand reverse light (option) C25
E23 E Rear left-hand fog light (option) B46
E24 E Rear right-hand fog light (option) B47
E25 E Head jib left work light C39
E26 E Head jib right work light C40
E27 E License Plate light (option) B44
F1 Fuse Mono Ultra (7,5A) F10
80

F2 Fuse Rear working light (option) (15A) F41

F3 Fuse Windscreen / roof wipert (10A) F15
F4 Fuse Engine stop electrovalve (10A) F18
F5 Fuse Rotating beacon light (7,5A) F17
F6 Fuse Wheel alignment + trailer brake option (5A) F19
F7 Fuse Overload safety (10A) F21
F8 Fuse Reverser +transmission cut-off switch (15A) F23
F9 Fuse Power supply lights + modules (5A) F3
F10 Fuse Alarm / brake (15A) F29
F11 Fuse Working lights on boom (15A) F39
F12 Fuse Flashing lights (10A) F33
F13 Fuse Heating (30A) F34
F14 Fuse Cab cigarette lighter plug (25A) F36
F15 Fuse Diesel reheater (20A) F36
F16 Fuse Air conditioning (option) (7,5A) F34
F17 Fuse Boom head electrovalve (10A) F37
F18 Fuse Front working lights (15A) F40
F19 Fuse Rear window defrosting (option) (15A) F38

80-02-M153EN (11/05/2011)
 A3
MLT 630 T Series D-E3 Electrical schematic diagrams
MLT 731 T Series D-E3
MLT 742 T Series 4-E3
MLT 731 T Series E-E3

Components
Item Type Designation Position on diagram
F20 Fuse Pneumatic seat (10A) F37
F21 Fuse Front windscreen wiper / windscreen-washer (10A) F14
F22 Fuse Free (15A Max) F38
F23 Fuse Right hand side lights / dashboard (7,5A) D43
F24 Fuse Left-hand side lights (7,5A) D45
F25 Fuse Rear and front right hand indicator light (7,5A) D31
F26 Fuse Rear and front left hand indicator light (7,5A) D32
F27 Fuse Right and left dip lights+rear fog light+dip lights signal light (15A) D45
F28 Fuse Right and left hand headlights + headlight signal light (15A) D47
F29 Fuse Warning / ceiling light +(15A) F33
F30 Fuse Side light switch + dipped lights + headlights (25A) F45
F31 Fuse Starter (20A) E1
F40 Fuse Equipment (40A) D1
F41 Fuse Equipment (40A) D1
F42 Fuse Pre-heating (80A) C1
F43 Fuse Alternator (80A) C1
G1 G Battery C2
G2 G Alternator B4
H10 Indicator Warning lamp B32
H11 Indicator Front wheel alignment light C19
H14 Indicator Rear wheel alignment light C20
H15a Indicator Rev counter signal light, hour meter B42
H15b Indicator Rev counter signal light, hour meter B43
H16 Indicator Cooland temperature light B42
H17 Indicator Diesel gauge light B42
H19 Indicator Fan light B44
H20 Indicator Clock light B41

80
K0 Relay Air conditioning relay (option) B35/E35
K1 Relay Valve lever transmission cut-off relay B13/D28
K2 Relay Transmission cut-off relay E24/B27
K3 Relay Reverse gear relay B23/C25
K4 Relay Forward gear relay C24/B22/C9
K5 Relay Machine fault alarm E5
K6 Relay Free D48/B48
K7 Relay Movement cut-off (option) E21/B22
K8 Relay Starter safety relay D2/B23
K9 Relay Flashing / Warning unit C30
K10 Relay Overload safety module B21
K11 Relay Gradual control unit D10
K16 Relay Preheater relay B3/B1
K17 Relay Module relay lights B6/B5
K18 Relay Transmission cut-off module E26
M1 M Starter C2
M2 M Front screenwiper B15

(11/05/2011) 80-02-M153EN
 A4
Electrical schematic diagrams MLT 630 T Series D-E3
MLT 731 T Series D-E3
MLT 742 T Series 4-E3
MLT 731 T Series E-E3

Components
Item Type Designation Position on diagram
M3 M Windscreen washer B15
M4 M Roof windscreen wiper B16
M5 M Alarm B29
M6 M Fan B34
M7 M Reverse gear alarm (option) B26
M8 M Rear cab screen wiper B15
M9 M Diesel pump B19
M10 M Side windscreen wiper B17
M11 M Pneumatic seat compressor B38
P1 P Hour meter / Rotation counter B5
P2 P Fuel gauge B4
P3 P Engine coolant temperature B3
R1 R Preheating plugs B1
R2 R Fuel sensor D3
R3 R Sensor and thermo-switch for engine coolant temperature D3
R8 R Cigarette lighter resistance C36
S1 S Key switch F2
S2 S Reverse / forward gear reverser D23
S3 S Engine oil pressure switch B6
S4 S Brake fluid B7
S5 S Air filter clogging B7
S6 S Front wheel alignment detector C19
S7 S Brake switch B9/D25
S8 S Windscreen wiper switch / front windscreen washer / rear windscreen wiper E15
S9 S Alarm control D29
S10 S Wheel alignment switch E19
S11 S Warning light switch E32
S12 S Transmission oil pressure B9
80

S13a S Side light switch F43

S13b S Dipped light switch / headlight F44
S13c S Flashing switch F31
S14 S Gear lever transmission cut-off switch D27
S15 S Front / rear working light switch (option) E41
S16 S Stop switch E29
S17 S Transmission oil temperature B8
S18 S Front working light switch (option)
S19 S Rotating beacon switch D18
S20 S Side / roof wind screen wiper switch D17
S21 S Fan switch E34
S22 S Overload stress gauge E20
S23 S Clogging hydraulic filter B7
S24 S Valve lever transmission cut-off switch C13
S25 S Pedal transmission cut-off switch E27
S26 S Transmission cut-off switch F27
S27 S Rear wheel alignment detector C20

80-02-M153EN (11/05/2011)
 A5
MLT 630 T Series D-E3 Electrical schematic diagrams
MLT 731 T Series D-E3
MLT 742 T Series 4-E3
MLT 731 T Series E-E3

Components
Item Type Designation Position on diagram
S28 S Rear window defrost switch (option) E39
S29 S Rear fog light switch (option) D47
S31 S Attachment switch C11
S32 S Attachment switch C12
S33 S Telescope extension switch C12
S34 S Telescope retraction switch C13
S35 S Cold start switch B18
S36 S Seat switch D25
S37 S Neutralization of movements D22
S38 S Steering pressure B4
S39 S Pneumatic seat switch C38
S40 S Cigarette lighter time delay switch C36
S41 S Front working light switch on boom E40
V1 V Diode D6
V2 V Diode (only for TUV) D43
V3 V Diode (LED) battery charge lamp E6
V4 V Diode (LED) engine oil pressure lamp E6
V5 V Diode (LED) engine coolant temperature lamp E8
V6 V Diode (LED) air / oil clogging lamp E7
V7 V Diode (LED) transmission oil pressure lamp E9
V8 V Diode (LED) transmission oil temperature lamp E8
V9 V Diode (LED) brake fluid lamp E7
V10 V Diode (LED) brake lamp E9
V11 V Diode (LED) flashing / warning light lamp B30
V12 V Diode (LED) side signal light B43
V13 V Diode (LED) dipped lights light B46
V14 V Diode (LED) headlights light B48
V15 V Diode (LED) steering fault light D4
Y1 Electrovalve Engine stop electrovalve B18

80
Y2 Electrovalve Forward gear electrovalve B24
Y3 Electrovalve Reverse gear electrovalve B25
Y4 Electrovalve Cold start electrovalve B18
Y5 Electrovalve Attachment electrovalve B11
Y6 Electrovalve Attachment electrovalve B11
Y7 Electrovalve Telescope extension electrovalve B12
Y8 Electrovalve Telescope retraction electrovalve B12
Y9 Electrovalve Gradual electrovalve B10
Y10 Electrovalve Movement neutralization electrovalve B22
Y11 Electrovalve Discharge electrovalve D10
A Connector Fuse / relay panel (13 contact plug) X41
B Connector Fuse / relay panel (13 contact plug) X40
Change the Connector Fuse / relay panel (13 contact plug) X39
seals
D Connector Fuse / relay panel (6 contact plug) X37
E Connector Fuse / relay panel (8 contact plug)
F Connector Fuse / relay panel (8 contact plug)
G Connector Fuse / relay panel (21 contact plug) X44

(11/05/2011) 80-02-M153EN
 A6
Electrical schematic diagrams MLT 630 T Series D-E3
MLT 731 T Series D-E3
MLT 742 T Series 4-E3
MLT 731 T Series E-E3

Components
Item Type Designation Position on diagram
H Connector Fuse / relay panel (5 contact plug) X42
I Connector Fuse / relay panel (7 contact plug) X38
J Connector Fuse / relay panel (8 contact plug) X45
K Connector K1 X6 relay option provision
L Connector K0 X5 relay option provision
M Connector Provision option (8 contact plug + 1 contact plug) X4
N Connector Engine box X24
O Connector Rear plug option provision (8 contact plug) X19
Q Connector Fan heating X30
P Connector Switch
R Connector Option air conditioning X31
S Connector Cab (X26)
T Connector Front windscreen wiper X77
U Connector Strain gauge
V Connector Manipulator ON/OFF
W Connector Movement cut-off provision
X Connector Gradual control unit
Y Connector Windscreen wiper switch (X79-X80)
Z Connector 16 way plug (PCB Dashboard)
AA Connector Car radio X27; X53
AB Connector Windscreen wiper connector (9 ways + 2 ways) X79 ; X80
AC Connector Digicode connector X78
AD Connector Movement cut-off provision (1 contact plug) X43
80

80-02-M153EN (11/05/2011)
 A7
MLT 630 T Series D-E3/MLT 731 T Series D-E3 Electrical schematic diagrams
MLT 742 T Series 4-E3/MLT 731 T Series E-E3
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
F1
S1 F9 Fus.Therm. 2A E Z
G
155
J J J J M
B B B E Z
K5
I I I OP W r
30 30 17 17 50 19 19 54 15 58
64 63 Z Z V V V
92 65
V3 V4 V9 V6 V5 V8 V7 V10
C 4 1 5 bc bc bc bc bc C
82 66 Z Z Z Z Z Z Z
6 F X
67 V15 E F E E F E E X
16 12 13 7 X
F31 68 Z X
N N N N TEMPO X
N 1±0.5 SEC bl g o n vt v
15 r vt
8 6 3 11
V1 AF V1 V1 V1 V1 V1 V1 V1 m n V
V
B 21 V
V
2 3 K19 14 13 V
F40 F41 AF I B I I I I
E K8 R3
E
R2 3,5s K11
62 35
34 21 33 3 7 Y11
AG V1 19 55 17 8
B n 16 45
bc
S31 bc
S32 bc
S33 bc
S34 bc
S24
F42 F43 V1 V1 K4
14 M1 N N N V1 V1 g n n V
V
N 17 12 24 7 18 221 Ep18 B I V
G1 V
29 20 N N N M V
202
26 81 25 142 1 184 90 223 224
K16
13 23
S7
G
P3 P2 X G
N P P P P T P X
X K
10 24 K17 X
X 148
27 4 5 14 22 15 G2 K17 S3 S4 S5 S23 S17 S12 113
n J ro bl G
K16 141 73 P 9 Ep2 n
N N N N 72 S38 Ep7
P2 P1 74 222 56
R1 R1 R1 R1 225 10 11 22 28 140
91 205 258
91
jvt
Y9 Y5 Y6 Y7 Y8 K1
jvt
F
jvt
I I
J

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

+ perm
}
+ apc

K K

F3 F21 F5 F4 F6 F7 F8

A B 161
A A A B B S22 G G H
85 80
87 58 166
AB AB Ep4

80
76
S 157
S10 128 259
EG Lateral

M M
214
EG Toitl

SWF 521 243

+ Ep3 cab K7 242
S8 SWF 596 307 SWF 521 005
+
75
0 1 0 SWF 596 628 AC M S2
97 1 0 2 3 7 4 8 9 S37
5 9 AC 79 163
F 257
1 5 2 6 10 S20 m bc vt J g
1 0 1 10
Ep5 G M
S19 20
O 112 204 O
46 27 101 Ep:6 167 Ep1 241 232
240
AB AB AB AB AB AB AB AB Ep15 cab N 48
236
99 94 95 78 96 103 104
2
29
U U U U U U AC
S Ep2 cab
G AC
Ep1 mot
59
T T T T S6 H11 S27 H14 226
47 188 264A
S E19 30 25 26
71 28 30
M8 4 M4 M10 r g J v bl n H H H
Q 4 2 S 4 2
vit 1
2
vit 1
4 2
vit 1
T Ep:2
Q
raz +perm
vit 1 raz +perm
AR
M
raz +perm
M TOIT raz
+perm 2
M LAT Ep:7 AD 86
2 M 3 3 3
3 -
1 Ep11 cab
- -
K10 Y10
- 1 1 Ep12 cab S35 Y1 M9
M3 M2 AV 1
Ep5 cab K7 Ep:7 264B 85
T Ep14 cab 131 32 K4
43 S S 130 205
31 K8 K3
18 19 258
56 132
93 200 205
199 Y4

S S

27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

(25/06/2009) 80-02-M153EN
 A8
Electrical schematic diagrams MLT 630 T Series D-E3/MLT 731 T Series D-E3
MLT 742 T Series 4-E3/MLT 731 T Series E-E3
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

J
J
A 41 A
G 207
206
K18 S26 F10 P F29 F12 F13 F16 F14 F15
B4 B2 S13c
39
K m o D 196
B5
B1 A
227 AA
B3
49 197
B 84 137
132 133 P P G L
57 Q
C 259 252 C
B7 B6 S11 S21
203 60 254
3 S25 S16 o m g n K0
K2 44 G
S7 S36 06 S9
5
4 n Q G G Q
139
AA 218 D D
240 K1 g
146 + + D
R Ep15
F25 F26 A 153 165 190 191 154
266
E 3 3 L 105 98 100 E
G G -
116 117 235
K4 K3 S14 A2 g
AA n S Tempo
5 5 R R L L R
193 192 S40
G G C C C C Allume
170 5 AC 251 E21 267 Q L cigare
213 212 Ep10 I O
Ep20 AC K K 253 115 108 3 51
Ep22 123 122 239 247
268B 269B E20 E22 K9 AC R8
40 E 248 Ep11 250 Ep14 r 164 149
G 150 O AC G
M7 G 06
jvt ro 121 120
G
124 125 237 E1 E2 O E3
Y2 Y3 O AA E4
268A 269A Ep12 2 Z 216 M6
2
Ep21 23 Ep19 V11
38 jvt Ep12 125 111 124 N Q 101
K2 1 54 H10
Ep2
258 M5 E5 E6 Z 2 Ep13 cab 83
K0
jvt

I I

43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65

+ perm
}
+ apc
K K
F20
P
F17 F22 F19 F11 F18 F2 o
S13a S13b F30 AE
A B A A
A A B
135 162 86 88 198
S S
80

S Ep1 cab SWF 521 008 S P P P

+
SWF 521 054 Ep4 cab
M SWF 596 390 Ep6 cab S41
+
SWF 596 151 M
159 160 158 156 5 9 S28 5 6 9 3 4 9 S15 bl j bc
G
211 1 0 1 7 2 8 10 201 1 7 2 8 10 A
1 0 1 10 SWF 521 110 TV X82
143
+ Ep7 cab
SWF 596 473 V2 K6
M M S V2 Ep5 cab 77
AC M M 208 S29
S
263 Ep14 cab F23 F24 F27 F28 G G
O O
Ep2 cab Ep8 cab
S39
194 195
102
C C C C C C C F
Ep4 cab Ep9 cab 130 144
89 bl Ep3 114 1
AE AE
Ep13 136 Ep9
256
C C F AE
Dégivrage 265 127 126 219
vitre ar E17 E18 E15 E16 119 249 Ep8
E25 E26 Ep3 cab O
Ep10 cab F Q O
M
107 118 50 52 109 255 145 147
Q av ga av dr H20 H16 H15 a H15b 245 244 246 Z 53 110 Q
Ep11 cab Ep1 cab
Ep5 cab 267 ZO E13 E14 Z
M11 H17 E7 E27 H19 E8 O E9 E10 E11 E12 V13 E23 E24 V14 G
262 S S S S S S N 141 220 V12 124 125
125 238 243 124 111
70
Ep2 83 111 Ep12 54 111
258 199 200 106 201 199 200 9 72 140 Ep12 Ep12 54
91 Z 2 2 Z 2 Z K6

S S

66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91

80-02-M153EN (25/06/2009)
 B1
MLT 634 T LSU Series D-E3 Electrical schematic diagrams
MLT 731 T LSU Series D-E3
MLT 634 T LSU Series E-E3
MLT 735 T LSU Series 5-E3

– Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2
– Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B7

80

(25/06/2009) 80-02-M153EN
 B2
Electrical schematic diagrams MLT 634 T LSU Series D-E3
MLT 731 T LSU Series D-E3
MLT 634 T LSU Series E-E3
MLT 735 T LSU Series 5-E3

Components
Item Type Designation Position on diagram
A1 A Car radio C40
A2 A Electro proportional manipulator C14
A3 A Module ECU RC2-2 C8
E1 E Rear right hand indicator light B23
E2 E Front right-hand indicator light B24
E3 E Rear left-hand indicator light B22
E4 E Front left-hand indicator light B22
E5 E Left hand brake light B33
E6 E Right hand brake light B34
E7 E Rear right hand side light B34
E8 E Front right hand side light B34
E9 E Rear left hand side light B34
E10 E Front left hand side light B34
E11 E Front left-hand dipped light B35
E12 E Front right-hand dipped light B36
E13 E Front left-hand headlight B31
E14 E Front right-hand headlight B31
E15 E Rear right-hand working light (option) B31
E16 E Rear left-hand working light (option) B31
E17 E Front left-hand working light (option) B39
E18 E Front right-hand working light (option) B17
E19 E Rotating beacon light C25
E20 E Left-hand reverse light (option) B17
E21 E Roof light B35
E22 E Right-hand reverse light (option) B35
E23 E Rear left-hand fog light (option) B30
E24 E Rear right-hand fog light (option) B33
E25 E Head jib left work light E8
80

E26 E Head jib right work light D31

E27 E License Plate light (option) D37
F1 Fuse Free (10A Max) E8
F2 Fuse Rear working light (option) (15A) D31
F3 Fuse Rear windscreen/roof wiper (7,5A) D37
F4 Fuse Engine stop electrovalve (10A) E12
F5 Fuse Rotating beacon light (7,5A) D39
F6 Fuse Wheel alignment (5A) E12
F7 Fuse Overload safety (10A) D20
F8 Fuse Forward/reverse/neutral Transmission (15A) E13
F9 Fuse Fault alarm/light (5A) E3
F10 Fuse Alarm/brake (15A) D22
F11 Fuse Boom working light (15A) D31
F12 Fuse Flashing lights (10A) D25
F13 Fuse Fan (30A) D26
F14 Fuse Cigarette lighter socket (10A) D28
F15 Fuse Free (25A Max) D29
F16 Fuse Air conditioning (option) (10A Max) D26

80-02-M153EN (25/06/2009)
 B3
MLT 634 T LSU Series D-E3 Electrical schematic diagrams
MLT 731 T LSU Series D-E3
MLT 634 T LSU Series E-E3
MLT 735 T LSU Series 5-E3

Components
Item Type Designation Position on diagram
F17 Fuse Free (15A Max) D29
F18 Fuse Front working lights (option) (15A) D31
F19 Fuse Rear window defrosting (option) (15A Max) D30
F20 Fuse Pneumatic seat (10A) D29
F21 Fuse Front windscreen wiper/windscreen-washer (10A) D37
F22 Fuse Free (15A Max) E13
F23 Fuse Right hand side lights/dashboard (7,5A) C33
F24 Fuse Left-hand side lights (7,5A) C34
F25 Fuse Right-hand indicator light (7,5A) C23
F26 Fuse Left-hand indicator light (7,5A) C24
F27 Fuse Dipped lights (15A) C34
F28 Fuse Headlights (15A) C36
F29 Fuse Warning/ceiling light (15A) D25
F30 Fuse Stalk switch (25A) D34
F31 Fuse Starter (20A) D2
F32 Fuse Electro proportional modules (3A) E15
F33 Fuse Module ECU RC2-2 (1A) D9
F40 Fuse Equipment (40A) C1
F41 Fuse Equipment (40A) C2
F42 Fuse Pre-heating (80A) C1
F43 Fuse Alternator (80A) C2
G1 G Battery B3
G2 G Alternator B4
H10 Indicator Warning lamp B25
H11 Indicator Front wheel alignment light C12
H14 Indicator Rear wheel alignment light C13
H15 Indicator counter/rotations Light B32
H16 Indicator Cooland temperature light B32

80
H17 Indicator Diesel gauge light B32
H19 Indicator Fan light B32
H20 Indicator Clock light B32
K0 Relay Air conditioning relay (option) B26/D26
K1 Relay Joystick transmission cut-off reverse relay B15/C18
K2 Relay Transmission cut-off relay D16/B18
K3 Relay Reverse gear relay B13/C16
K4 Relay Forward gear relay B13/C16/C8
K5 Relay Machine fault alarm D5
K6 Relay Free B36/C36
K7 Relay Movement cut-off (option) B20/D20
K8 Relay Starter safety relay B13/C2
K9 Relay Flashing/Warning unit B23
K10 Relay Overload safety module B19
K15 Relay Proportional joystick power supply cut-off relay B3/D15
K16 Relay Preheater relay B1/B2
K17 Relay Module relay lights B5
K18 Relay Transmission cut-off module D15

(25/06/2009) 80-02-M153EN
 B4
Electrical schematic diagrams MLT 634 T LSU Series D-E3
MLT 731 T LSU Series D-E3
MLT 634 T LSU Series E-E3
MLT 735 T LSU Series 5-E3

Components
Item Type Designation Position on diagram
M1 M Starter C2
M2 M Front screenwiper B37
M3 M Windscreen washer B36
M4 M Roof wiper (option) B38
M5 M Alarm B22
M6 M Fan B26
M7 M Reverse gear alarm (option) B17
M8 M Rear cab screen wiper B37
M9 M Diesel pump B12
M10 M Side windscreen wiper B39
M11 M Pneumatic seat compressor B29
P1 P Hour meter/Rotation counter B5
P2 P Fuel gauge B4
P3 P Engine coolant temperature B3
R1 R Preheating plugs B2
R2 R Fuel sensor C3
R3 R Sensor and thermo-switch for engine coolant temperature C3
R5 R Pump control module resistance B10
R6 R Attachment proportional module resistance D14
R7 R Telescoping proportional module resistance D14
R8 R Cigarette lighter resistance B28
S1 S Key switch E2
S2 S Reverse/forward gear shift D13
S3 S Engine oil pressure switch B5
S4 S Brake fluid B6
S5 S Air filter clogging B6
S6 S Front wheel alignment detector B12
S7 S Brake switch C15/B8
80

S8 S Front windscreen wiper and windscreen-washer switch C37

S9 S Alarm control D22
S10 S Wheel alignment switch D12
S11 S Warning light switch D24
S12 S Transmission oil pressure B8
S13a S Side light switch D32
S13b S Dipped light switch/headlight D33
S13c S Flashing switch D23
S14 S Gear lever transmission cut-off switch C18
S15 S Front/rear working light switch (option) D31
S16 S Stop switch D22
S17 S Transmission oil temperature B7
S18 S Working lights on boom switch (option) D31
S19 S Rotating beacon switch C39
S20 S Rear windscreen wiper/roof switch C39
S21 S Fan switch D26
S22 S Overload stress gauge D19

80-02-M153EN (25/06/2009)
 B5
MLT 634 T LSU Series D-E3 Electrical schematic diagrams
MLT 731 T LSU Series D-E3
MLT 634 T LSU Series E-E3
MLT 735 T LSU Series 5-E3

Components
Item Type Designation Position on diagram
S23 S Clogging hydraulic filter B7
S25 S Pedal transmission cut-off switch D18
S26 S Transmission cut-off switch E18
S27 S Rear wheel alignment detector B13
S28 S Rear window defrost switch (option) D30
S29 S Rear fog light switch (option) C35
S30 S Steering pressure B4
S32 S Transmission cut-off switch on mono-lever C15
S36 S Cold start switch B12
S39 S Pneumatic seat switch B29
S40 S Cigarette lighter time delay switch B28
S41 S Seat switch C15
S42 S Movement neutralization switch (option) C21
V1 V Diode C6
V2 V Diode (only for TUV) C31/C32
V3 V Diode (LED) battery charge lamp D5
V4 V Diode (LED) engine oil pressure lamp D5
V5 V Diode (LED) engine coolant temperature lamp D7
V6 V Diode (LED) air/oil clogging lamp D6
V7 V Diode (LED) transmission oil pressure lamp D8
V8 V Diode (LED) transmission oil temperature lamp D7
V9 V Diode (LED) brake fluid lamp D6
V10 V Diode (LED) brake lamp D8
V11 V Diode (LED) flashing/warning light lamp B23
V12 V Diode (LED) side lights lamp B33
V13 V Diode (LED) dipped lights light B35
V14 V Diode (LED) headlights light B36
V15 V Diode (LED) steering fault light C4
Y1 Electrovalve Engine stop electrovalve B12

80
Y2 Electrovalve Forward gear electrovalve B16
Y3 Electrovalve Reverse gear electrovalve B16
Y4 Electrovalve Cold start electrovalve B11
Y5 Electrovalve Pump electrovalve B9
Y6 Electrovalve Telescope proportional electrovalve B14
Y7 Electrovalve Électrovalve proportionnelle accessoire B14
Y14 Electrovalve Movement neutralization electrovalve B21
A Connector Fuse/relay panel (13 contact plug) X41
B Connector Fuse/relay panel (13 contact plug) X40
Change the Connector Fuse/relay panel (13 contact plug) X39
seals
D Connector Fuse/relay panel (6 contact plug) X37
E Connector Fuse/relay panel (8 contact plug)
F Connector Fuse/relay panel (8 contact plug)
G Connector Fuse/relay panel (21 contact plug) X44
H Connector Fuse/relay panel (5 contact plug) X42
I Connector Fuse/relay panel (7 contact plug) X38
J Connector Relay/fuse panel (8 contact plug + 2 contact plug) X45

(25/06/2009) 80-02-M153EN
 B6
Electrical schematic diagrams MLT 634 T LSU Series D-E3
MLT 731 T LSU Series D-E3
MLT 634 T LSU Series E-E3
MLT 735 T LSU Series 5-E3

Components
Item Type Designation Position on diagram
K Connector K1 X6 relay option provision
L Connector K0 X5 relay option provision
M Connector Provision option (8 contact plug + 1 contact plug) X4
N Connector Engine box X24
O Connector Rear plug option provision (8 contact plug) X19
P Connector Switch
Q Connector Fan heating X30
R Connector Option air conditioning X31
S Connector Cab X26
T Connector Front windscreen wiper X77
U Connector Strain gauge
V Connector JSM adaptation harness
W Connector Diagnostic connector
X Connector Adaptation TUV X2
Z Connector 16 way plug (PCB dashboard)
AA Connector Car radio X27
AB Connector Windscreen wiper switch connector (9 ways + 2 ways) X79 X80
AC Connector Digicode connector X78
AD Connector K6 Relay Option Provision
80

80-02-M153EN (25/06/2009)
 B7
634 T LSU Series D-E3/MLT 731 T LSU Series D-E3 Electrical schematic diagrams
MLT 634 T LSU Series E-E3/MLT 735 T LSU Series 5-E3

E E
J

S1 F9 Fus.Therm. 2A E Z F1
r
J J J J
B B B E Z
155

30 30 17 17 50 19 19 54 15 58 I I I OP K5 G F33
D 64 63 65 66 67 68 Z Z V3 V4 V9 V6 V5 V8 V7 V10 D
92
Z Z Z Z Z Z Z r r W
82 M W
16 12 13 7 6 F E F E E F E E W
N N N N
F31 W
8 6 3 11
N bl g o n vt v W
15
V1 V1 V1 V1 V1 V1 V1 V1 m W
B I B I I I I I
C F40 F41 K8
r r r r/n n vt o vi
C
152 62 19 55 17 8 21 33 202 45 A3
V1 V1 V1 V1 V1 V1 41 42 33 17 51 50 52
B n N N N 3,5s
F42 F43 14 12 M1 R3 R2 ep18
N 17 V15 B K4
29 20 G1 24 81 7 142 Z 18 223 224 13 23 g 16 1 27 31 32 28 47 46 49 2
K16 K16 N N N 221 90
25
bc P r r m jvt jvt vt r j jvt jvt
B
28 26
1 K17 P P P T P S7 B
P N S3 S4 S5 S23 S17 S12
27 22 P3 P2 10 24 184 113
19 18 5 14 15 4 21
K15 S30 G2
9
P1 K17222
72 73 ep7 ep2
N N N N 140 141 56 R5
R1 R1 R1 R1 138 91 91 74 205 258
10 11 22 225
jvt jvt Y5
69 F
J

A A

1 2 3 4 5 6 7 8 9 10

+ perm
E + apc E
151 41 207

F4 F6 F22 F8 G S26
F32

80
A B B B H 206
58 161 156 166 189

M ep4 K18
259
B4 B2 AC AC 132 49 133

D
76
S10 M 242
39 40
D
B1 K
214 157
B5 K2 S25
S2 R7 R6 B3 197
K15
B7 B6
G
AC 257
R F
139

AC ep5
PCB j 203 60
K1
K4 K3
20
A2 S7 S41 S14
C 32 G G C
N M 130 71 240 241
170 5 G
o
G
131 168 171 217 146 213 212
2 ep1 169 173 ep10 192 193
ep22 ep20
ep1 H11 H14 236 172 ep16 X S32
AC 260 269B 268B 123 122 239 247
K K
46 48 29 27 233 231
30 25 26 232 AC 167
K
H 226 H H 148
T S6 S27 G Y2 Y3 E20 E22 M7 O
S36 H Y6 Y7 G
B 47 28 210
112
209
ep17
228 227 269A 268A 124 125 237 B
ep2 ep7 ep21 23 ep19
101 ep12
38 2
Y4 Y1 M9 258 205
K3 K8 K4 129
K1 K2
jvt

A A
MLT 6/7 T LSU 1 / 2

Ä3
11 12 13 14 15 16 17 18
(25/06/2009) 80-02-M153EN
 B8
Electrical schematic diagrams 634 T LSU Series D-E3/MLT 731 T LSU Series D-E3
MLT 634 T LSU Series E-E3/MLT 735 T LSU Series 5-E3

MLT 6/7 T LSU 2 / 2

E J E
J
Ä3

F7 F10 P F29 F12 F13 F16

S13c
m o J r D 196 v
S22 G G P B 84
D 163 vt 57 P P LG 137 A D
K7 Q
S11 S21
S16 o m g n K0
G M D
S9 n G
m bc vt J g 128 vt 4 218
Q G Q
g
75 P A 153 165 190 191 154

C S42 F25 F26 C

AC
g n 105 456

E21 AC R R L L R
U U U U U U 204 C C C C L Q
G ep6
I ep15
115 3
ep11 ep14
K9 E
79 30 264A 112 150 235 117 116 248 121 108 250 120 51 149 164
r g J v bl n jvt ro r
101
B O O O B
188 Z 457 G
Y14 M5 E5 E6 E1 E2 E3 E4 H10 M6
K10 V11 K0
S N
31 K7 264B 125 ep12 124
Z 125 124
ep7 ep12 ep12
132 111 54 9 216 83
205 2 2 2

jvt
A A

19 20 21 22 23 24 25 26 27

E E

P F30
F14 F15 F17 F20 F19 F11 F18 F2 o F3 F21 F5
S13a S13b AD
A AC A A B A A A B A
80

D 135 162 86 88 198 J AA D

S SWF 521 008 S SWF 521 110 S S SWF 521 054
P P P
+ + + 85 80 87
SWF 596 390 SWF 596 473 SWF 596 151
160 159 211 158 S28 S18 S15 bl J bc
G AB AB S 252 254
5 9 5 6 9 3 4 9

EG Lateral
1 72 8 10 1 7 2 8 10
K6 AA

EG Toitl
1 0 1 10 1 0 201 SWF 521 243 SWF 521 005
D D D M M M V2 143
S8 +
SWF 596 307
+
SWF 596 628
AA
77
S
208
V2 S29 0 1 0 1 0 2 3 7 4 8 9 5 9 + +
V2 97
R
C F23 F24 F27 F28 G G 10 C
F 1 5 2 6 10 1 0 1 L
263 194 195 S20 S19 -
S C C C C C C C F C C F A1 AA
98 100 102 114 144
S39 ep3 AD AD AB AB AB AB AB
AD AB 59 AB AB
vitre arrière
Dégivrage

89 119 136 1
Tempo bl ep13 ep8 99 94 95 78 96 103 104 251 253
S40 455 127 126 219 ep9
S
F j bc
B T T T T E19 AA B
E26 E25 E17 E18 E15 E16 H20 H17 H16 H15a H15b
245 244 246 107 249 118 50 52 109 130 255 256 145 53 110 147
M8 S M4 M10 AA
Allume
R8 M Z O Q O Z O Z G raz
4
+per.
2 M
2
vit 1 S raz
4
+perm
2 vit 1
raz
4
+perm
2
vit 1
raz
4 +perm 2
2 M
vit 1
cigare 457 141 72 220 70 O 3 - AV 3
M AR
- 3
M
-
TOIT
3
1-
LAT
J
1
M11 S S S S S S N V12 M3 M2 1 1
262 140 E7 E27 H19 E8 E9 E10 E11 E12 V13 E23 E24 E13 E14 V14 K6
S S
101 ep2 199 200 106 201 9 91
Z 125 ep12 238 124 Z 124 243 125
54 111
Z 43 T
258 83 111 ep12 111 56 93 199 200
2 2 54 2 ep12

A A

28 29 30 31 32 33 34 35 36 37 38 39 40

80-02-M153EN (25/06/2009)
 C1
MT 1030 S Series 4-E3 Electrical schematic diagrams
MT 1030 ST Series 4-E3

– Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C2
– Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C7

80

(25/06/2009) 80-02-M153EN
 C2
Electrical schematic diagrams MT 1030 S Series 4-E3
MT 1030 ST Series 4-E3

Components
Item Type Designation Position on diagram
E1 E Rear right hand indicator light B32
E2 E Front right-hand indicator light B32
E3 E Rear left-hand indicator light B33
E4 E Front left-hand indicator light B33
E5 E Left hand brake light B30
E6 E Right hand brake light B30
E7 E Rear right hand side light B52
E8 E Front right hand side light B53
E9 E Rear left hand side light B54
E10 E Front left hand side light B54
E11 E Front left-hand dipped light B54
E12 E Front right-hand dipped light B55
E13 E Front left-hand headlight B56
E14 E Front right-hand headlight B56
E15 E Rear right-hand working light (option) B50
E16 E Rear left-hand working light (option) B50
E17 E Front left-hand working light (option) B49
E18 E Front right-hand working light (option) B49
E19 E Rotating beacon light C45
E20 E Left-hand reverse light (option) B26
E21 E Roof light C34
E22 E Right-hand reverse light (option) B27
E23 E Rear left-hand fog light (option) B55
E24 E Rear right-hand fog light (option) B56
E25 E Head jib left work light B49
E26 E Head jib right work light B48
E27 E License Plate light (option)
F1 Fuse Stabilizer safety (7,5A) F19
80

F2 Fuse Rear working light (option) (15A) F50

F3 Fuse Rear windscreen/roof wiper (7,5A) F41
F4 Fuse Engine stop electrovalve (10A) F12
F5 Fuse Rotating beacon light (7,5A) F45
F6 Fuse Wheel alignment (5A) F13
F7 Fuse Overload safety (10A) F16
F8 Fuse Forward/rear/reverse transmission (15A) F24
F9 Fuse Fault alarm/light (5A) F4
F10 Fuse Alarm/brake (15A) F29
F11 Fuse Working lights on boom (15A) F49
F12 Fuse Flashing lights (10A) F34
F13 Fuse Fan (30A) F36
F14 Fuse Free (25A Max) F38
F15 Fuse Free (25A Max) F39
F16 Fuse Air conditioning (option) (10A Max) F37
F17 Fuse Free (15A Max) F39
F18 Fuse Front working lights (option) (15A) F50
F19 Fuse Rear window defrosting (option) (15A Max) F48

80-02-M153EN (25/06/2009)
 C3
MT 1030 S Series 4-E3 Electrical schematic diagrams
MT 1030 ST Series 4-E3

Components
Item Type Designation Position on diagram
F20 Fuse Pneumatic seat (10A) F40
F21 Fuse Front windscreen wiper/windscreen-washer (10A) F42
F22 Fuse Free (15A Max) F41
F23 Fuse Right-hand side lights/dashboard (7,5A) C52
F24 Fuse Left-hand side lights (7,5A) C54
F25 Fuse Right-hand indicator light (7,5A) C32
F26 Fuse Left-hand indicator light (7,5A) C33
F27 Fuse Dipped lights (15A) C54
F28 Fuse Headlights (15A) C56
F29 Fuse Warning/ceiling light (15A) F54
F30 Fuse Stalk switch (25A) F34
F31 Fuse Starter (20A) D2
F40 Fuse Equipment (40A) C1
F41 Fuse Equipment (40A) C1
F42 Fuse Pre-heating (80A) C1
F43 Fuse Alternator (80A) C1
G1 G Battery B3
G2 G Alternator B5
H10 Indicator Warning lamp A34
H11 Indicator Front wheel alignment light B14
H14 Indicator Rear wheel alignment light C14
H15 Indicator counter/rotations Light
H16 Indicator Cooland temperature light B51
H17 Indicator Diesel gauge light B51
H19 Indicator Fan light B53
H20 Indicator Clock light B51
K0 Relay Air conditioning relay (option) D37/A37
K1 Relay Free D21/A21

80
K2 Relay Transmission cut-off relay D25/A28
K3 Relay Reverse gear relay C25/B24
K4 Relay Forward gear relay C11/C25/B23
K5 Relay Machine fault alarm E6
K6 Relay Free D21/A21
K7 Relay Movement cut-off relay/(option) A16/D16
K8 Relay Starter safety relay C2/B24
K9 Relay Flashing/Warning unit C31
K10 Relay Overload safety module B15
K16 Relay Preheater relay B2/B1
K17 Relay Module relay lights B6/B7
K18 Relay Transmission cut-off on seat module D27
M1 M Starter C3
M2 M Front screenwiper B42
M3 M Windscreen washer B41
M4 M Roof wiper (option) B44
M5 M Alarm A29
M6 M Fan C36

(25/06/2009) 80-02-M153EN
 C4
Electrical schematic diagrams MT 1030 S Series 4-E3
MT 1030 ST Series 4-E3

Components
Item Type Designation Position on diagram
M7 M Reverse gear alarm B26
M8 M Rear cab screen wiper B43
M9 M Diesel pump A12
M10 M Side windscreen wiper B45
M11 M Pneumatic seat compressor A40
P1 P Hour meter B6
P2 P Fuel gauge C5
P3 P Engine coolant temperature C4
R1 R Preheating plugs A1
R2 R Fuel sensor D4
R3 R Sensor and thermo-switch for engine coolant temperature D4
S1 S Key switch F3
S2 S VL and VI valve lever forward/reverse gear reverser E24
S3 S Engine oil pressure switch B7
S4 S Brake fluid B8
S5 S Air filter clogging B9
S6 S Front wheel alignment detector C13
S7 S Brake switch B11/D26
S8 S Front windscreen wiper and windscreen-washer switch D43
S9 S Alarm control D30
S10 S Wheel alignment switch D14
S11 S Warning light switch E33
S12 S Transmission oil pressure B11
S13a S Side light stalk switch E52
S13b S Headlight/dipped light stalk switch E53
S13c S Indicator light stalk switch E32
S14 S Gear lever transmission cut-off switch C28
S15 S Front/rear working light switch (option) D50
80

S16 S Stop switch E30

S17 S Transmission oil temperature B10
S18 S Working lights on boom switch (option) D49
S19 S Rotating beacon switch C46
S20 S Rear windscreen wiper/roof switch C44
S21 S Fan switch D37
S22 S Overload stress gauge E15
S23 S Clogging hydraulic filter B9
S24 S VL and VI valve lever transmission cut-off switch D28
S25 S Pedal transmission cut-off switch D28
S26 S Transmission cut-off switch F28
S27 S Rear wheel alignment detector C14
S28 S Rear window defrost switch (option) D48
S29 S Rear fog light switch (option) D56
S30 S Steering pressure B5
S31 S Cold start switch B12
S33 S Telescope retraction switch D19

80-02-M153EN (25/06/2009)
 C5
MT 1030 S Series 4-E3 Electrical schematic diagrams
MT 1030 ST Series 4-E3

Components
Item Type Designation Position on diagram
S36 S Switch on seat D27
S39 S Pneumatic seat switch C40
S42 S Movement cut-off deletion switch (option) D17
S44 S Telescope retraction switch (option) D18
S45 S Deflation/dump switch (option) D18
S46 S Boom lowering switch (option) C18
S47 S Attachment switch C18
V1 V Diode C8
V2 V Diode (only for TUV) D52
V3 V Diode (LED) battery charge lamp E7
V4 V Diode (LED) engine oil pressure lamp E7
V5 V Diode (LED) engine coolant temperature lamp E9
V6 V Diode (LED) air/oil clogging lamp E9
V7 V Diode (LED) transmission oil pressure lamp E11
V8 V Diode (LED) transmission oil temperature lamp E10
V9 V Diode (LED) brake fluid lamp E8
V10 V Diode (LED) brake lamp E11
V11 V Diode (LED) flashing/warning light lamp B31
V12 V Diode (LED) side lights lamp B52
V13 V Diode (LED) dipped lights light B55
V14 V Diode (LED) headlights light B57
V15 V Diode (LED) steering fault light D5
Y1 Electrovalve Engine stop electrovalve A12
Y2 Electrovalve Forward gear electrovalve B25
Y3 Electrovalve Reverse gear electrovalve B25
Y4 Electrovalve Cold start electrovalve A12
Y5 Electrovalve R.H. stabilizer electrovalve B19
Y6 Electrovalve L.H. stabilizer electrovalve B20
Y7 Electrovalve Movement cut-off electrovalve (option) A17

80
Y8 Electrovalve Discharge electrovalve C20
A Connector Fuse/relay panel (13 contact plug)
B Connector Fuse/relay panel (13 contact plug)
Change the Connector Fuse/relay panel (13 contact plug)
seals
D Connector Fuse/relay panel (6 contact plug)
E Connector Fuse/relay panel (8 contact plug)
F Connector Fuse/relay panel (8 contact plug)
G Connector Fuse/relay panel (21 contact plug)
H Connector Fuse/relay panel (5 contact plug)
I Connector Fuse/relay panel (7 contact plug)
J Connector Fuse/relay panel (8 contact plug + 2 contact plug)
K Connector K1 predisposition relay option
L Connector K0 predisposition relay option
M Connector Provision option (8 contact plug + 1 contact plug)
N Connector Engine box
O Connector Rear plug provision option (8 contact plug)
P Connector Stalk switch

(25/06/2009) 80-02-M153EN
 C6
Electrical schematic diagrams MT 1030 S Series 4-E3
MT 1030 ST Series 4-E3

Components
Item Type Designation Position on diagram
Q Connector Ventilation heating
R Connector Option air conditioning
S Connector Cab
T Connector Front screenwiper
U Connector Strain gauge
W Connector Movement cut-off provision
Z Connector 16 way plug (PCB Dashboard)
AA Connector Car radio
AB Connector Windscreen stalk switch connector (9 ways + 2 ways)
AC Connector Digicode connector
80

80-02-M153EN (25/06/2009)
 C7
MT 1030 S Series 4-E3 Electrical schematic diagrams
MT 1030 ST Series 4-E3
J
F F

S1 F9 Fus.Therm. 2A E Z F4
r
J J J J
B B B 321
E Z
E E
118 118 I I I OP K5
30 30 17 17 50 19 19 54 15 58
Z V3 V4 V9 V6 V5 V8 V7 V10
141 119 119 119 119 129 204 Z
AD F Z Z Z Z Z Z Z A A
130
12 21 12 21 11 bl E F E E F E E 338 229

N N N N F31 N AC
D
8 3 11 6 23 12
g o n vt v D

R3 R2 V15 V1 V1 V1 V1 V1 V1 V1 V1 V1 m n
AC
B Z 27
I B I I I I I
F40 F41 K8 24 7

N N 26 95 28 47 85 75
C
M 24 13
N M C
32 31
B n 25 263 139 3,5s
F42 F43 22 M1 N V1 V1 N V1 N V1 V1
N AD AD
N P3 P2 2
121 1 30 116 323 B K4
29 20 G1 203 P 13 23 16

K16 121 10 N
K16 S30 G2
30 25 26
B 202 P1 324
P P B
AD P P P T S7
27
28 121 121
S3 S4 S5 S23 S17 S12 T
19 18 22 4 5 14 15 21 K17 K17 S31
140 121 14
R1 R1 R1 R1 N N N N 54
325 15 15 20 322 96 55 173
jvt
Y4 Y1 M9
jvt
A 120 F A
J

1 2 3 4 5 6 7 8 9 10 11 12

F F

F6 F7 F1
J K

80
B B S22 G G G
E 287 286 E
98 233 127 235
227 156
122 M AC M
S10
K7 M W AC G G
S44 340
239
D r K6 K1 D
m bc vt J g G S42 S45
S33 G GG G
r vt
S46 V1
82 84 36 34 283 284 281 282
o
C 14 13 C
H14 258

U U U U U U S47 J JK K
G 3 7 Y8 J K
S6 H11 S27 258
121 W g n n
29 217 218
105 r g J v bl n
B B
196 83 35 37 o
Y5 Y6
195
260 G G
K10
261
41 MT1030S T 1
197
K7 Y7 K6 K1
A A
1/3

13 14 15 16 17 18 19 20 21 22
(25/06/2009) 80-02-M153EN
 C8
Electrical schematic diagrams MT 1030 S Series 4-E3
MT 1030 ST Series 4-E3
J J
F F
65 122
G S26 P
F8 339
F10 S13c F29 F12
B4 B2
m o j r
H B1 J AA P B
E B5 E
vt
B3
191 192 97 P P
S2 B7 B6 365 364 S11
K2 K18 S25 S16 o m g n
246 265
AA D
F R
D S24 S9 16 D
PCB 329 S7 S36 193 AA n
++
vt
g AC
R
A3 A 359
245 66
L
P F25 F26
262 333
- 158
331 337 249 A2 AA g n
K4 K3 AC S
C AC AA C
176 E21
AC G G 315 315 AC C C C C
S14 358
H 330 H 56 57 O 194 366 367 I K9 175 3
O 183

267
H 4 177 E 181 163 180 87
ro n
5 153 155 182
264 197 74 220 O jvt ro O O r
B J AA B
O Z
Y2 Y3 E20 M7 G E5 O E6 V11 E1 E2 O E3 E4 S N
K4 K8 K3 54 E22 184 184 90
184
55 154 185 M5 185 185 166 348 9
2 2 Z 2 H10
K2
jvt
A A

23 24 25 26 27 28 29 30 31 32 33 34 35

F F

F13 F16 F14 F15 F17 F20 F22 F3 F21 F5

v
80

D A B A B A
E E
132 133 128 135
A 201 G
Q A A AB AB S
S21 K0 232 231 230 228

EG Lateral
SWF 521 243 SWF 521 005

EG Toitl
+ +
S8 SWF 596 307 SWF 596 628
D 1
0 2 3 7 4 8 9 5 9 D
0
Q G G Q 0 1

F 1 5 2 6 10 1 0 1 10
225 226 341
239
S20 S19
D D D D M M M
M AC
R R R 350
C M6 AB AB AB AB AB C
AB AB AB
Q S39 343 351 353 346
Q 99 349 352 345 E19
S
238 T T T T S
B 4 M2 2 1 vit S 4 M8 2 1 vit 4 M4 2
1 vit
4 M10 2 1 vit B
raz +perm raz +perm raz +perm raz +perm2
2 M M AR M TOIT M LAT
131 G AC 3 - AV
3
-
3 - 3 -
M M3 1 1 1 1

342
73 T
96 S S
K0 M11 146 344 347

A A
MT1030S T 1
2/3
36 37 38 39 40 41 42 43 44 45 46
80-02-M153EN (25/06/2009)
 C9
MT 1030 S Series 4-E3 Electrical schematic diagrams
MT 1030 ST Series 4-E3

F F

P F30
F19 F11 F18 F2 o
S13a S13b
A B A A
E 199 234 134 136 E

S S S S P P P
SWF 521 008 SWF 521 110 SWF 521 054
+ + +
SWF 596 390 SWF 596 473 SWF 596 151
S28 S18 S15 bl j
A
5 9 9 3 4 9
5 6

1 7 2 8 10 205 bc
D 1 0 1 10 1 0 1 7 2 8 10 2 0 1 D
V2
122
S
313
V2 S29
V2
F23 F24 F27 F28

C
369 S C C C C C C C F C C F C
138 bl 174 162 1 86 88 164 195 206 207 89 165
357 187 186 320 179 200
O Q 178
Dégivrage O
vitre arrière j bc
E26 E25 E17 E18 E16 E15 H20 H17 H16 H16B H15A F E7 H19 E8 E9 E10 E11 E12 E23 E24 E13 E14
B Q B
203
121
121
121
Z Z Z
185 131 166 184 90 166 184 185 90 166
S 202
V12 V13 V14
S O O
368 AD
S S S S S 9 140
Z 2
Z 2
Z

80
A A

47 48 49 50 51 52 53 54 55 56 57

MT1030S T 1
3/3

(25/06/2009) 80-02-M153EN
 C10
Electrical schematic diagrams MT 1030 S Series 4-E3
MT 1030 ST Series 4-E3
80

80-02-M153EN (25/06/2009)
 D1
MLT 1035 LT LSU Series 4-E3 Electrical schematic diagrams
MLT 1035 LT LSU Series 5-E3

– Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D2
– Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D7

80

(25/06/2009) 80-02-M153EN
 D2
Electrical schematic diagrams MLT 1035 LT LSU Series 4-E3
MLT 1035 LT LSU Series 5-E3

Components
Item Type Designation Position on diagram
E1 E Rear right hand indicator light B40
E2 E Front right-hand indicator light B40
E3 E Rear left-hand indicator light B41
E4 E Front left-hand indicator light B41
E5 E Left hand brake light B39
E6 E Right hand brake light B39
E7 E Rear right hand side light B54
E8 E Front right hand side light B55
E9 E Rear left hand side light B55
E10 E Front left hand side light B55
E11 E Front left hand side light B56
E12 E Front right hand side light B56
E13 E Front left-hand headlight B58
E14 E Front right-hand headlight B58
E15 E Rear right-hand working light (option) B49
E16 E Rear left-hand working light (option) B50
E17 E Front left-hand working light (option) B49
E18 E Front right-hand working light (option) B49
E19 E Rotating beacon light B23
E20 E Left-hand reverse light (option) B16
E21 E Roof light C43
E22 E Right-hand reverse light (option) B16
E23 E Rear left-hand fog light (option) B57
E24 E Rear right-hand fog light (option) B57
E25 E Head jib left work light C47
E26 E Head jib right work light C48
E27 E License Plate light (option) B54
F2 Fuse Rear working light (option) (15A) F49
80

F3 Fuse Rear windscreen / roof wiper (7,5A) F20

F4 Fuse Engine stop electrovalve (10A) F51
F5 Fuse Rotating beacon light (7,5A) F24
F6 Fuse Wheel alignment (5A) F36
F7 Fuse Slope + overcharge safety (10A) F26
F8 Fuse Forward/rear/neutral transmission (15A) F12
F9 Fuse Fault alarm/light (5A) F4
F10 Fuse Alarm / brake (15A) F38
F11 Fuse Working lights on boom (15A) F48
F12 Fuse Flashing lights (10A) F43
F13 Fuse Fan (30A) F44
F14 Fuse Cigarette lighter socket (10A) F45
F15 Fuse Free (25A Max) F46
F16 Fuse Air conditioning (option) (10A Max) F44
F17 Fuse Rear hydraulic (option) (15A Max) F34
F18 Fuse Front working lights (option) (15A) F49
F19 Fuse rear window defrosting (option) (15A Max) F47
F20 Fuse Pneumatic seat (10A) F46

80-02-M153EN (25/06/2009)
 D3
MLT 1035 LT LSU Series 4-E3 Electrical schematic diagrams
MLT 1035 LT LSU Series 5-E3

Components
Item Type Designation Position on diagram
F21 Fuse Front windscreen wiper / windscreen-washer (10A) F20
F22 Fuse Boom suspension (option) (15A Max) F29
F23 Fuse Right-hand side lights / dashboard (7,5A) C53
F24 Fuse Left-hand side lights (7,5A) C55
F25 Fuse Right-hand indicator light (7,5A) D40
F26 Fuse Left-hand indicator light (7,5A) D41
F27 Fuse Dipped lights (15A) C56
F28 Fuse Headlights (15A) C58
F29 Fuse Warning / ceiling light (15A) F43
F30 Fuse Stalk switch (25A) F55
F31 Fuse Starter (20A) D2
F32 Fuse Electro proportional modules (3A) F14
F33 Fuse Module ECU RC2-2 (1A) D10
F40 Fuse Equipment (40A) C1
F41 Fuse Equipment (40A) C2
F42 Fuse Pre-heating (80A) C1
F43 Fuse Alternator (80A) C2
G1 G Battery B3
G2 G Alternator B5
H10 Indicator Warning lamp A42
H11 Indicator Front wheel alignment light B36
H14 Indicator Rear wheel alignment light B37
H15 Indicator Counter/rotations light B53
H16 Indicator Cooland temperature light B52
H17 Indicator Diesel gauge light B53
H19 Indicator Fan light B54
H20 Indicator Clock light B52
K0 Relay Air conditioning relay (option) B44/D44

80
K1 Relay Valve lever transmission cut-off relay D59/A59
K2 Relay Transmission cut-off relay D15/A18
K3 Relay Reverse gear relay A12/D16
K4 Relay Forward gear relay C9/A13
K5 Relay Machine fault alarm E5
K6 Relay Free D58/A58
K7 Relay Movement cut-off (option) A27/D27
K8 Relay Starter safety relay C2/A12
K9 Relay Flashing / Warning unit B39
K10 Relay Overload safety module B26
K15 Relay Proportional joystick power supply cut-off relay B3/D14
K16 Relay Preheater relay B2/B1
K17 Relay Module relay lights B6
K18 Relay Transmission cut-off on seat module D17
K19 Relay Module tempo 2 seconds E34
K20 Relay Aggravating movement cut-off relay (option) A29/C29
K21 Relay Boom suspension cut-off relay (option) A30
K22 Relay Boom suspension power supply relay (option) A30/D31

(25/06/2009) 80-02-M153EN
 D4
Electrical schematic diagrams MLT 1035 LT LSU Series 4-E3
MLT 1035 LT LSU Series 5-E3

Components
Item Type Designation Position on diagram
K23 Relay Boom suspension angular relay (option) B30/A32
M1 M Starter C2
M2 M Front screenwiper B20
M3 M Windscreen washer B20
M4 M Roof wiper (option) B22
M5 M Alarm A38
M6 M Fan B44
M7 M Reverse gear alarm (option) B17
M8 M Rear cab screen wiper B21
M9 M Diesel pump A52
M10 M Side windscreen wiper B23
M11 M Pneumatic seat compressor B46
P1 P Hour meter / Rotation counter A5
P2 P Fuel gauge B4
P3 P Engine coolant temperature B3
R1 R Preheating plugs A2/(D13)
R2 R Fuel sensor C4/(D14)
R3 R Sensor and thermo-switch for engine coolant temperature C3
R5 R Pump control module resistance B11
R6 R Attachment proportional module resistance
R7 R Telescope proportional module resistance
R8 R Cigarette lighter resistance B45
S1 S Key switch F2
S2 S Forward/reverse gear reverser D12
S3 S Engine oil pressure switch B6
S4 S Brake fluid B7
S5 S Air filter clogging B7
S6 S Front wheel alignment detector B36
80

S7 S Hand brake switch (hand brake on) B9/D17

S8 S Windscreen wiper/ front windscreen washer switch D21
S9 S Alarm control D38
S10 S Wheel alignment switch E36
S11 S Warning switch E41
S12 S Transmission oil pressure B9
S13a S Side light stalk switch E53
S13b S Dipped light/headlight stalk switch E54
S13c S Indicator light stalk switch E40
S14 S Gear lever transmission cut-off switch C18
S15 S Rear/front working light switch (option) D49
S16 S Stop switch D39
S17 S Transmission oil temperature B8
S18 S Boom working light switch (option) D48
S19 S Rotative beacon switch D24
S20 S Rear/roof windscreen wiper switch D23
S21 S Fan switch E44

80-02-M153EN (25/06/2009)
 D5
MLT 1035 LT LSU Series 4-E3 Electrical schematic diagrams
MLT 1035 LT LSU Series 5-E3

Components
Item Type Designation Position on diagram
S22 S Overload stress gauge E26
S23 S Clogging hydraulic filter B8
S25 S Transmission/pedal cut-off switch E18
S26 S Transmission/pedal cut-off selection switch F19
S27 S Rear wheel alignment detector B36
S28 S Rear window de-frost switch (option) D47
S29 S Rear fog light switch (option) D57
S30 S Steering pressure B4
S35 S Cold start switch B51
S36 S Switch on seat D17
S37 S Slope switch D33
S38 S Boom angular switch D33
S39 S Pneumatic seat switch C46
S40 S Cigarette lighter B45
S41 S Rear hydraulic control switch (option) D34
S42 S Movement cut-off neutralization switch (option) C27
S43 S Retracted telescope position detection switch (option) C29
S44 S Attachment pressure switch (option) D29
S45 S Attachment pressure switch (option) C29
S46 S Telescope extension pressure switch (option) C29
S47 S Tilt switch (option) C29
S48 S Boom lowering switch (option) B29
S49 S Boom position pressure switch, on VL valve (option) D30
S50 S Boom suspension switch (option) D30
V1 V Diode C7
V2 V Diode (only for TUV) D53
V3 V Diode (LED) battery charge lamp E6
V4 V Diode (LED) engine oil pressure lamp E6

80
V5 V Diode (LED) engine coolant temperature lamp E8
V6 V Diode (LED) air/oil clogging lamp E7
V7 V Diode (LED) transmission oil pressure lamp E9
V8 V Diode (LED) transmission oil temperature lamp E8
V9 V Diode (LED) brake fluid lamp E7
V10 V Diode (LED) brake lamp E9
V11 V Diode (LED) flashing/warning light lamp B40
V12 V Diode (LED) side lights lamp B54
V13 V Diode (LED) dipped lights light B56
V14 V Diode (LED) headlights light B58
V15 V Diode (LED) steering fault light C4
Y1 Electrovalve Engine stop electrovalve A52
Y2 Electrovalve Forward gear electrovalve B15
Y3 Electrovalve Reverse gear electrovalve B15
Y4 Electrovalve Cold start electrovalve A51
Y5 Electrovalve Pump electrovalve A10
Y6 Electrovalve Électrovalve proportionnelle accessoire B13
Y7 Electrovalve Telescope proportional electrovalve B14

(25/06/2009) 80-02-M153EN
 D6
Electrical schematic diagrams MLT 1035 LT LSU Series 4-E3
MLT 1035 LT LSU Series 5-E3

Components
Item Type Designation Position on diagram
Y10 Electrovalve Slope electrovalve on the right B32
Y11 Electrovalve Slope electrovalve on the left B33
Y12 Electrovalve Rear hydraulic control selector electrovalve A35
Y14 Electrovalve Movement cut-off electrovalve B28
Y15 Electrovalve Boom 1 suspension electrovalve (option) A31
Y16 Electrovalve Boom 2 suspension electrovalve (option) A31
A Connector Fuse / relay panel (13 contact plug) X41
B Connector Fuse / relay panel (13 contact plug) X40
Change the Connector Fuse / relay panel (13 contact plug) X39
seals
D Connector Fuse / relay panel (6 contact plug) X37
E Connector Fuse / relay panel (8 contact plug)
F Connector Fuse / relay panel (8 contact plug)
G Connector Fuse/relay panel (21 contact plug + 1 contact plug) X44
H Connector Fuse / relay panel (5 contact plug) X42
I Connector Fuse / relay panel (7 contact plug) X38
J Connector Fuse / relay panel (8 contact plug) X45
K Connector K1 X6 relay option provision
L Connector K0 X7 relay option provision
M Connector Provision option (8 contact plug + 1 contact plug) X4
N Connector Engine box X24
O Connector Rear plug option provision (8 contact plug) X19
P Connector Stalk switch
Q Connector Fan heating X30
R Connector Option air conditioning X31
S Connector Cab (X26)
T Connector Front windscreen wiper X77
U Connector Strain gauge
V Connector Diagnostic connector
W Connector Movement cut-off provision
80

X Connector Adaptation TUV X2

Z Connector 16 way plug (PCB Dashboard)
AA Connector Car radio X27; X53
AB Connector Windscreen wiper stalk switch connector (9 ways + 2 ways) X79;
X80
AC Connector Digicode connector X78
AD Connector Movement cut-off provision (1 contact plug) X43
AE Connector K6 X7 option provision

80-02-M153EN (25/06/2009)
 D7
MLT 1035 LT LSU Series 4-E3 Electrical schematic diagrams
MLT 1035 LT LSU Series 5-E3
J MLT1035L T LSU
F F Ä3 1/3

S1 F1
F9 Fus.Therm. 2A E Z
J J J J 155

E E Z E
I I I OP
30 30 17 17 50 19 19 54 15 58 K5
64 63
92
Z V3 V4 V9 V6 V5 V8 V7 V10
65
82 6 66 Z Z Z Z Z Z Z G F33
B B B F
16 12 13 7 67 E F E E F E E M r r V
N N N N F31 N 68 151 V
D 8 6 3 11 n g o n vt v V D
15 12 Z V1 V1 V1 V1 V1 V1 V1 V1 m n V
B
142 V
r r r r/n n vt o vi V
F40 F41 I B I I I I
K8 62
A3
221 3,5s
C V1 19 55 17 8 21 33 41 42 33 17 51 50 52 C
B n I 45
R3 R2 V15 N
F42 F43 14
M1 ep:18 N V1 V1 V1 N V1 V1 K4
N Z
17
B
29 20 16
202 S7 1 27 31 32 28 47 46 49 2
18 23
K16 G1 13
K16 N 81
N N 90 223 224
P
B 152
26 P3 25 bc
G P P P T P 113 r r m jvt jvt vt r j jvt jvt B
28
P2 1
184
K17 S3 S4 S5 S23 S17 S12
27 9 ep:7
22 4 5 15 14 141 73 P 10 24

N K15
72 S30 G2 N K17 56 21 ep:2
R5
R1 R1 R1 R1
N N N 140 P1 74
205 258
138 91
225 10 22 11 91 222
jvt
Y5
jvt
A 69 J F A

1 2 3 4 5 6 7 8 9 10 11

+ permanent
F + apc F
41
G 207
F8 F32 206 S26 F3 F21 F5
B4 B2
K A B

80
H 189 B1 A
E B5 o 85 80 E
ep:4 166 87
B3
259 133 49 AB AB
242 S

EG Lateral
B7 B6
K2

EG Toitl
S2 R1 R2 K15 K18 S25 G S8 SWF 521 243
+
SWF 521 005
+
203 60 SWF 596 307 SWF 596 628
97
0 1 0 1 0 2 3 7 4 8 9 S19
D 5 9 D
R F S7 S36 F
1 5 2 6 10
139
PCB 217 S20 1 0 1 10
K4 K3 146
A2
ep:10
G V1 G G AB AB AB AB AB
ep:1 241
S14 AB AB
C
213
G 215 5 AB C
240 ep:22 o o o 59 99 94 95 78 96 103 104
212
236
X ep:20 S
232 167 210 171 173 168 169 ep:16
AC 39 K K
112 172 260 182 B 183 B AC T T T T E19
AC 101 231 123 122 239 247
226 E20 E22 M7 227 132 AC M8 2 1 vit S M4 2 1 vit M10 2 1
B
233
4 2 S raz
4
+perm
4
+perm
4
+perm vit B
H H H 40
M3 raz +perm
2M
1 vit
3
M AR raz
3
M TOIT raz
3
2 M LAT

n J ro Y2 Y3 124 125 237 G 3 -

-
1 Ep11 cab 1
- -
1
Y6 228 Y7 209
ep:21 182 A 183 A ep:19 43 M2 AV 1
Ep5 cab
23
ep:12 O 56 T S S
ep:17 2
129 38 93
K3 K8 K4 K2 199 200

A jvt A

12 13 14 15 16 17 18 19 20 21 22 23 24
(25/06/2009) 80-02-M153EN
 D8
Electrical schematic diagrams MLT 1035 LT LSU Series 4-E3
MLT 1035 LT LSU Series 5-E3

+ permanent
F + apc F

F7 F22 F17 F6
161

S22 G G B G A B B
E r r r E
1 8 2 3 9 10 11 4 5 12 6 13 14 7 58
156 61
34
K19 76
163 M 211
159 160
ro j j j r S10
K7
S50 S38
bl r m AC M M
D P r D
m bc vt J g 79 G M W S44 P 257
vi K22 35
ep:5
128 75 P S49 9 3
S37 S41
S42 S45 j

S43 K20 P 46 27

C 1 0 S46 V1 10 7 1
ro ro
48 29 C
K21 185
U U U U U U vi S47
G 204 m ep:25
170
37 ep:23
W 36
30 188 S48 134 S6 H11 S27 H14
r g J v bl n ep:6 71 jvt 47 ep:2 71 28 ep:7
264 A V1 32
175 A 174 A
B 131 B
AD 112
jvt
K10 101 K23 jvt m
130
Y10 Y11 j 258 205
bl ro v or or
Y14 175 B 174 B ep:24
264 B ep:26 42 131 32
31 ep:7 44 ep:7 130
132
K7 205
K20 K21 K22 Y15 Y16 K23 205 Y12
A A

25 26 27 28 29 30 31 32 33 34 35 36 37

J J
+ permanent
F + apc F

F10 P F29 F12 F13 F16 F14 F15 F20 F19 F11 F18 F2
S13c
m o J r D A A A B A A
P B
80

E 158 135 162 86 88 E

84
57
P P S11 137 S S S S
Q SWF 521 008 SWF 521 110
+
SWF 521 054
+
D S21 G
+
SWF 596 390 SWF 596 473 SWF 596 151
S16 o m g n S28 S18 S15
n 218 K0 5 9 5 6 9 3 4 9

D S9 4 g 1 01 7 2 8 10 201
1 7 2 8 10 D
1 0 1 10
vt Q G G Q D D D M
A 187 AC
F25 F26
P ep:15 S V2
105 AC 153 165 154
235 g Dégivrage
n
vitre arrière
S
C O C C C C R L L R 263
102
S C
E21 98 100
116 117
ep:11
115 108
ep:14
3 51 Q S39
I Tempo
E26
248 250 229 216 E25 E18 E15 E16
K9 S40 E17
E O 121 O 120 164
Allume
150 jvt ro r cigare
B M6 R8 M B
E5 E6 Z E1 E2 E3 E4 Ep5 cab G
124 125 V11 125 111 124 S S N Q M11
ep:12
54 ep:2 262 S S S S S S
ep:12 199 200 9 83
K0 101 199 200 106 201 199 200
M5 2 Z 2
H10
258

jvt
A A
MLT1035L T LSU
Ä3 2/3
38 39 40 41 42 43 44 45 46 47 48 49 50

80-02-M153EN (25/06/2009)
 D9
MLT 1035 LT LSU Series 4-E3 Electrical schematic diagrams
MLT 1035 LT LSU Series 5-E3

+ permanent
F + apc F

P F30
F4 o
S13a S13b AE K
AA
A J
E 198 197 E
P P P 252
254
214 bl bc
j
A G G
AA
AC
D
143 AA D
AC V2 K6 K1 + +
157
77 R
V2 S29
G G L
G G -
20
F23 F24 F27 F28
A2 AA
208
O 194 195 192 193
C C C C O C C C C F C
ep:3
144
ep:8
256 C C F AE K
N M 89
ep:13
114 1
AE K 253
107
2 186 127 126 219
136 249
ep:9 AE K 251
119
bl 130
30 25 26 246
Q AA AA
H16 H15a F 245 244
E27
118 50 52 109
Z
255 145 53 110 147 148
B T B
S35 Z O Z
H20 H17 H15b O E7 H19 E8 E9 E10 E11 E12 E23 E24 E13 E14 V14 G G J
141 220 238 V13 124 125
229 V12 125 83 111 243 124
ep:12 111 54 111

80
Y4 Y1 M9 72 140
70
ep:12
54
18 19 N 91 Z ep:12 2 2 Z 2 Z K6 K1
A A
MLT1035L T LSU
Ä3 2/3
51 52 53 54 55 56 57 58 59 60

(25/06/2009) 80-02-M153EN
 D10
Electrical schematic diagrams MLT 1035 LT LSU Series 4-E3
MLT 1035 LT LSU Series 5-E3
80

80-02-M153EN (25/06/2009)
MLT 634 120 LSU PS Series D-E3 E1
Electrical schematic diagrams
MLT 735 120 LSU PS Series 4-E3
MLT 741 120 LSU PS Series 4-E3
MLT 634 120 LSU PS Series E-E3
MLT 735 120 LSU PS Series 5-E3
MLT 741 120 LSU PS Series 5-E3

– Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E2
– Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E3

80

(25/06/2009) 80-02-M153EN
 E2 MLT 634 120 LSU PS Series D-E3
Electrical schematic diagrams
MLT 735 120 LSU PS Series 4-E3
MLT 741 120 LSU PS Series 4-E3
MLT 634 120 LSU PS Series E-E3
MLT 735 120 LSU PS Series 5-E3
MLT 741 120 LSU PS Series 5-E3
Components
Item Type Designation Position on diagram
A1 Electronic control unit power supply ECU RC2 H7
A2 Electro proportional manipulator L68
A3 Car radio (option) H38
A4 ECM Engine C5
A5 Module MCS (potentiometer) B9
A6 Clock R78
A8 Electrical control unit ECU M59
A9 Module Murphy B28
A10 Module Fuel level D25
A11 Engine coolant temperature module C28
A12 Hour meter / rev counter D29
B1 Time delays 3,5 sec ± 0,5 H5
B2 Gear display L53
B3 Front wheel alignment sensor H26
B4 Rear wheel alignment sensor H27
B5 Left loudspeaker G39
B6 Right loudspeaker I39
B7 Air intake pressure sensor C14
B8 Fuel pressure sensor C15
B9 Primary speed sensor D16
B10 Secondary speed sensor D17
B11 Engine oil pressure sensor C16
E1 E Rear right hand indicator light S72
E2 E Front right-hand indicator light S73
E3 E Rear left-hand indicator light S74
E4 E Front left-hand indicator light S75
E5 E Left hand brake light S80
E6 E Right hand brake light S80
80

E7 E Rear right hand side light S59

E8 E Front right hand side light S61
E9 E Rear left hand side light S63
E10 E Front left hand side light S63
E11 E Front left-hand dipped light S66
E12 E Front right-hand dipped light S67
E13 E Front left-hand headlight S64
E14 E Front right-hand headlight S65
E15 E Right-hand working tail light S56
E16 E Left-hand working tail light S56
E17 E Left front work light S52
E18 E Right front work light S53
E19 E Rotating beacon light H23
E20 E Left hand reverse light N46
E21 E Roof light R77
E22 E Right hand reverse light N47
E23 E Left rear fog light S69
E24 E Right rear fog light S70

80-02-M153EN (25/06/2009)
MLT 634 120 LSU PS Series D-E3 E3
Electrical schematic diagrams
MLT 735 120 LSU PS Series 4-E3
MLT 741 120 LSU PS Series 4-E3
MLT 634 120 LSU PS Series E-E3
MLT 735 120 LSU PS Series 5-E3
MLT 741 120 LSU PS Series 5-E3
Components
Item Type Designation Position on diagram
E25 E Left working light on boom (option) S49
E26 E Right working light on boom (option) S50
E27 E Rear plate lighting (option) S60
F1 Fuse Power supply ECU RC2 (7,5A) G7
F2 Fuse Rear working lights (15A) Q56
F3 Fuse Rear, roof and side windscreen wiper (10A) G14
F4 Fuse Murphy / preheating relay / diesel water presence sensor (10A) B24
F5 Fuse Rotating beacon light (7,5A) G25
F6 Fuse Wheel alignment (5A) G27
F7 Fuse Safety system (10A) G33
F8 Fuse Reverser + transmission cut-off switch (15A) L45
F9 Fuse Lights / fault alarm / modules (5A) B25
F10 Fuse Alarm / brake (15A) Q80
F11 Fuse Working lights on boom (option) (15A) Q52
F12 Fuse Flashing lights (10A) Q73
F13 Fuse Fan (30A) L73
F14 Fuse Cigarette lighter plug (25A) L77
F15 Fuse Free (25A Max) L78
F16 Fuse Air conditioning (option) (10A Max) L76
F17 Fuse Free (15A Max) L79
F18 Fuse Front working lights (15A) Q57
F19 Fuse Rear window defrosting (option) (15A Max) Q49
F20 Fuse Pneumatic seat (option) (10A) L80
F21 Fuse Front windscreen wiper and windscreen-washer (10A) G15
F22 Fuse Free (15A Max) Q43
F23 Fuse Right hand side light / dashboard lighting (7,5A) R61
F24 Fuse Left-hand side lights (7,5A) R63
F25 Fuse Right indicator lights (7,5A) R73

80
F26 Fuse Left indicator lights (7,5A) R75
F27 Fuse Dipped lights / Dipped light signal light / rear fog light option (15A) R66
F28 Fuse Headlight / headlight signal light (15A) R64
F29 Fuse Warning / ceiling light / option (15A) Q77
F30 Fuse Lighting switch (25A) Q60
F31 Fuse Starter / manipulator power cut-off (20A) C2
F32 Fuse Electro proportional module (3A) L72
F33 Fuse Diagnostic connector (1A) G8
F34 Fuse ECM engine (30A) C4
F35 Fuse Diagnostic connector fuse (5A) G8
F40 Fuse Power (40A) C1
F41 Fuse Power (40A) C2
F42 Fuse Pre-heating (80A) C1
F43 Fuse Alternator (80A) C2
G1 G Battery 12V D5
G2 G Alternator 75A D28
H11 Indicator Front wheel alignment light I27

(25/06/2009) 80-02-M153EN
 E4 MLT 634 120 LSU PS Series D-E3
Electrical schematic diagrams
MLT 735 120 LSU PS Series 4-E3
MLT 741 120 LSU PS Series 4-E3
MLT 634 120 LSU PS Series E-E3
MLT 735 120 LSU PS Series 5-E3
MLT 741 120 LSU PS Series 5-E3
Components
Item Type Designation Position on diagram
H14 Indicator Rear wheel alignment light I29
H15a Indicator Rev counter/hour meter module lighting D29
H15b Indicator Rev counter/hour meter module lighting D31
H16 Indicator Engine coolant temperature module lighting C28
H17 Indicator Fuel level module lighting D24
H19 Indicator Fan switch lighting S61
H20 Indicator Clock lighting R78
H21 Indicator Cigarette lighter lighting N78
K0 Relay Air conditioning relay (option) M76/N75
K1 Relay Free Q44/S49
K2 Relay Transmission cut-off relay N49/L46
K3 Relay Free N50/L46
K4 Relay Free S42/L47
K5 Relay Machine fault alarm B30/G34
K6 Relay Free Q45/S44
K7 Relay Overload safety I33
K8 Relay Start safety N57/C2
K9 Relay Flashing / warning light unit. R70
K10 Relay Overload safety module I32
K15 Relay Manipulator power cut-off L7/D2
K16 Relay Preheating D1/D8
K17 Relay Module signal lights D32/D36
K19 Relay Transmission cut-off module L42
M1 M Starter C3
M2 M Front screenwiper I15
M3 M Windscreen washer I14
M4 M Roof windscreen wiper I20
M5 M Horn S79
80

M6 M Fan N73
M7 M Reverse gear alarm (option) N48
M8 M Rear windscreen wiper I17
M10 M Side windscreen wiper I22
M11 M Pneumatic seat compressor (option) N81
P1 P Hour meter / Rotation counter D30
P2 P Fuel gauge D25
P3 P Engine coolant temperature C29
R1 R Preheating resistances D1
R2 R Fuel gauge C25
R4 R Rear window defroster R46
R6 R Attachment proportional control module L69
R7 R Telescope proportional control module L70
R8 R Cigarette lighter resistance N77
R9 R Diesel water presence sensor D9
R10 R Resistance 120 ohms B13
S1 S Switchr ‡ key B4

80-02-M153EN (25/06/2009)
MLT 634 120 LSU PS Series D-E3 E5
Electrical schematic diagrams
MLT 735 120 LSU PS Series 4-E3
MLT 741 120 LSU PS Series 4-E3
MLT 634 120 LSU PS Series E-E3
MLT 735 120 LSU PS Series 5-E3
MLT 741 120 LSU PS Series 5-E3
Components
Item Type Designation Position on diagram
S2 S Reverse/forward gear shift L66
S4 S Brake fluid D38
S5 S Air filter clogging D11
S7 S Hand brake switch I6/N43
S8 S Rear and front wiper switch + windscreen washer G17
S9 S Alarm Q64
S10 S Wheel alignment switch G27
S11 S Warning light switch Q72
S12 S Transmission oil pressure I5
S13 S Lighting switch/indicator lights/horn Q61
S13a S Side lights Q61
S13b S Dipped lights / headlights Q62
S13c S Indicator lights Q63
S14 S Trailer speed limitation switch M60
S15 S Interrupteur phares de travail Q53
S16 S Stop switch Q80
S17 S Transmission oil temperature I4
S18 S Boom working lights switch (option) Q49
S19 S Rotative beacon switch G23
S20 S Rear/roof windscreen wiper switch G19
S21 S Fan switch L73
S22 S Strain gauge G31
S23 S Clogging hydraulic filter D40
S24 S Air intake temperature sensor D15
S25 S Pedal transmission cut-off switch N63
S26 S Transmission cut-off switch M64
S28 S Rear window de-frost switch (option) Q47
S29 S Rear fog light switch (option) Q66

80
S30 S Steering pressure D34
S32 S Coolant liquid temperature sensor D14
S38 S Speed sensor L55
S39 S Pneumatic seat switch (option) M81
S40 S Cigarette lighter N77
S41 S Seat switch N44
S42 S Movement neutralization switch H34
V1 V Diode C37
V2 V Diode (only for TUV) R61
V3 V Diode (LED) battery charge lamp B35
V4 V Diode (LED) engine oil pressure lamp B37
V5 V Diode (LED) engine coolant temperature lamp G2
V6 V Diode (LED) air/oil filter clogging light B39
V7 V Diode (LED) transmission oil pressure lamp G5
V8 V Diode (LED) transmission oil temperature lamp G4
V9 V Diode (LED) brake fluid lamp B38
V10 V Diode (LED) hand brake light G6
V11 V Diode (LED) flashing/warning light lamp S71

(25/06/2009) 80-02-M153EN
 E6 MLT 634 120 LSU PS Series D-E3
Electrical schematic diagrams
MLT 735 120 LSU PS Series 4-E3
MLT 741 120 LSU PS Series 4-E3
MLT 634 120 LSU PS Series E-E3
MLT 735 120 LSU PS Series 5-E3
MLT 741 120 LSU PS Series 5-E3
Components
Item Type Designation Position on diagram
V12 V Diode (LED) side lights lamp S58
V13 V Diode (LED) dipped lights light S68
V14 V Diode (LED) headlights light S65
V15 V Diode (LED) steering fault light B34
V16 V Diode (LED) red engine fault light D11
V17 V Diode (LED) orange engine fault light D12
V18 V Diode (LED) orange engine preheating light D13
Y2 Electrovalve Gearbox forward gear electrovalve (low) N53
Y3 Electrovalve Gearbox reverse gear electrovalve N52
Y5 Electrovalve Hydraulic pump proportional electrovalve I8
Y6 Electrovalve Électrovalve proportionnelle accessoire M69
Y7 Electrovalve Telescope proportional electrovalve M70
Y11 Electrovalve Gearbox forward gear electrovalve (high) N54
Y12 Electrovalve Gearbox Electrovalve 3 N55
Y13 Electrovalve Gearbox Electrovalve 2 N56
Y14 Electrovalve Gearbox Electrovalve 1 N57
Y15 Electrovalve Movement neutralization electrovalve I35
Y16 Electrovalve Electronic injector 1 C17
Y17 Electrovalve Electronic injector 2 C18
Y18 Electrovalve Electronic injector 3 C19
Y19 Electrovalve Electronic injector 4 C20
Y20 Electrovalve Injection pump solenoid D19
Y21 Electrovalve Discharge electronic valve C21
A Connector Fuse / relay panel (13 contact plug) X41
B Connector Fuse / relay panel (13 contact plug) X40
Change the Connector Fuse / relay panel (13 contact plug) X39
seals
D Connector Fuse / relay panel (6 contact plug) X37
E Connector Fuse / relay panel (8 contact plug)
80

F Connector Fuse / relay panel (8 contact plug)

G Connector Fuse/relay panel (21 contact plug + 1 contact plugt) X44+X43
H Connector Fuse / relay panel (5 contact plug) X42
I Connector Fuse / relay panel (7 contact plug) X38
J Connector Relay/fuse panel (8 contact plug + 2 contact plug) X45
K Connector K1 X6 relay option provision
L Connector K0 X5 relay option provision
M Connector Provision option (8 contact plug + 1 contact plug) X4
N Connector Engine box X24
O Connector Rear plug provision (8 contact plug) X19
P Connector Lighting switch
Q Connector Fan heating X30
R Connector Option air conditioning X31
S Connector Cab X26
T Connector Front windscreen wiper X77
U Connector Strain gauge
V Connector BB3 diagnostic connector
W Connector ECM connector diagnostic connector

80-02-M153EN (25/06/2009)
MLT 634 120 LSU PS Series D-E3 E7
Electrical schematic diagrams
MLT 735 120 LSU PS Series 4-E3
MLT 741 120 LSU PS Series 4-E3
MLT 634 120 LSU PS Series E-E3
MLT 735 120 LSU PS Series 5-E3
MLT 741 120 LSU PS Series 5-E3
Components
Item Type Designation Position on diagram
X Adaptation CE
Z Light module
AA Car radio X27, X53 (option)
AB Windscreen wiper switch (9 ways + 2 ways) X79;X80
AC Digicode connector X78
AD Movement cut-off provision (1 contact plug) X43
AE K6 X7 Relay option provision
AG Connector RC2/2 X24A

80

(25/06/2009) 80-02-M153EN
 E8 MLT 634 120 LSU PS Series D-E3
Electrical schematic diagrams
MLT 735 120 LSU PS Series 4-E3
MLT 741 120 LSU PS Series 4-E3
MLT 634 120 LSU PS Series E-E3
MLT 735 120 LSU PS Series 5-E3
MLT 741 120 LSU PS Series 5-E3
80

80-02-M153EN (25/06/2009)
 E9
MLT 735 120 LSU PS Series 4-E3/MLT 741 120 LSU PS Series 4-E3 MLT 634 120 LSU PS Series D-E3 Electrical schematic diagrams
MLT 735 120 LSU PS Series 5-E3/MLT 741 120 LSU PS Series 5-E3 MLT 634 120 LSU PS Series E-E3
0 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

A A
J
J 35

F4 F9
S1 Fus.Therm. E Z
R10 (2A) 29

33
J J J J A5 A A
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I I IOP
+
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N ep:21 458B 157
30 30 17 17 50 19 19 54 15 58
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8 17 A9 V15 V3 V4 V9 V6
64 63
1K 4
N ep:19
K5
92 65 19 11 457B 5 8 2
B B Z Z Z Z Z
82 66 - 2
9
N 457M
ep:20
27
38 26 34 23
67 canale IVS 6 ep:4 3 1 9 6 7 4
16 7 13 12
F31 68 151
- N 11
8
5
N N N N 214
452 X F E F E
10 13 3 6 15 ep:2 + 3
B7 B8 B11 B
31 g o n
22 23 21 24 20 20 bl
B 127 V1 V1 V1 V1
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A11 26 81 B
C F40 F41 K8 I B I C
460 126
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F42 F43 14 M1 1 2 3 9 10 40 57 44 35 38 60 59 63 43 37 42 52 10 53 25 26 24 23 20 21 45 18 219 V1 V1 V1
N AC N 72
ep:18
19
37 38 41 39 40 26 52 50 35 43 18 14 12 W AG B
53 G1 T T W A 25 18 270
N N N C C A10 N A12 90
223
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P 21 6 24 S32 S24 B9 B10 Y20 W
20 8 5 4
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36
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C 1 140
P P P
Z Z Z W D P1
D 25 49
S5 K17 S30 K17 S4 S23 D
46
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N N N 2
W F
K15 N 73
220
3 74
44
138 225 10 22 11 N 48 141 222 56 205
ep:6
42 70
R1 R1 R1 R1 69

J 57

E 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 E

F F
151

F1 F3 F21 F5 F6 F7
B5

80
G A B
G F35 V 85 80
A B B S22 G G G
155
18 1
87 161
58 AA
V5 V8 V7 V10 17 F33 V 16 99
AB S 3 M
163

Z Z Z Z M V 5 AB 76
K7 252
5
S20 S19 S10
V 13
S8lgav 1 3 7 4 8 9 1 9
254
15/54

25 22 24 28 2 0 1 0 1 9 1 0 128
lgar int 1Ë 2Ë
4 V 12 76 108

V 15
m
0 1 0 3 G 9 M 75 AA
E F E E 97
AA AA
V 3
ep:2
egar
1 5 2 6 10 5 10 5 10
m bc vt j g jvt 79 S420 + vt nvt
vt v m n V 11
+egav
1 1 7 2 8 9
B7
V1 V1 V1 8 54 14 53 44 43 42 45 V 4
+lgav F SWF 525 243
+
SWF 586 373 S8
SWF 525 005
+
SWF 525 005
+
SWF 586 373 S14
A7 A4
L B8
H SWF 586 373 S9 257 H
I I I ep:5 B2

B1 A1 5 6 10 R B1

3,5s 1 27 41 42 24 50 51 52 AB AB AB A8
-
269 33 45
AB AB AB AB
46
+
27
+
SWF 525 110
+
SWF 586 374 S3
A3 vi nvi

31 30 59 94 95 78 96 103 104 B3 _ B4 _
U U U U U U AA AA
V1 V1 ZA V1 I S E19
S7 31 2 28 40 39
T T T T S 48
G 204
202 29
253
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1 +perm 2
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1 +perm 2 1 +perm 2
vit
1 +perm 2
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30 188
ep:6 251

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raz
M2 S raz
M8
vit raz
M4 raz
M10 264 A

T P M M M M H11 H14
3 3 3 3 AD AA
I S17 S12 - - - -
258 71 205 K10 I
ep:3 M3 4 4 4 Ep11 cab 4
Y15
Y5 32 264 B
35
21 22
T Ep5 cab
S S ep:7
43 131
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B6
258 AG AG 56
93 199 200
130
134 205
112
101
132
K7

J J
35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57

(25/06/2009) 80-02-M153EN
 E10
Electrical schematic diagrams MLT 634 120 LSU PS Series D-E3 MLT 735 120 LSU PS Series 4-E3/MLT 741 120 LSU PS Series 4-E3
MLT 634 120 LSU PS Series E-E3 MLT 735 120 LSU PS Series 5-E3/MLT 741 120 LSU PS Series 5-E3
41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81

K K
151 151

F8 A2 F32 F13 F16 F14 F15 F17 F20

Up Dw R6 R7
230
S2 vi
G 41
D A
L A L
H R
1
F
189
84
242
K2 PCB Q
137 158
166
B2
S21 G
S38 K15
K19 AC 61 4 2 3 5 1 2 1 3 2 4
K3 K4 K0
B4 B2 AC 187
4 1 3 2
bl o
217
232
B1
44 ZE ZE F E
B5 B3
ZA ZA 167
170
173 171
172
168 169 260
Q Q G G D DD DA AM
240 263
34 35 36 37 176 177 40 39 234 4 2 3 8
215
ep:0 23 175 153 154 165 190 191 196 159 160
M A8 AF AF 42 207 ep:16 S39 M
B7 B6
206 R L 211
M
G G 26 21 36 17 16 9 10 7 19 18 8 24 1 2 23 6 231
R RL L AC M
203 261 ep:1 229 5
op pre Trans D +12V Dis DatDis 5VDis Clk Dis 0V SS SS TX RX dir R dir F G up G dw Enabl
S14 S26 210
233
A B C 87 87a 30 2 1 2
R alarm sol R sol L sol H sol 3 sol 2 sol 1 eng start com 0V handb Enabl 1 0 1 7 9 133 1 0 1 7 2 8 9 98 100
112
15 30 28 29 33 32 31 35 12 13 20 22 101
60 D 86
ep:4 5
S25 Y6 Y7 Q L Tempo M
S7 S41 259 ep:10 174 183 182 181 180 179 178 212 5 10 5 6 10
M6 S40 H21
228 209

247 123 122 239 G H ZA ZA ZA ZA ZA ZA AC SWF 525 024

+
SWF 525 110
+
49
164 149
M11
146
M7 r g j ro bc vt AC SWF 586 374 S7 SWF 586 372 S3

O 213
241 134 ep:17
R8
262

N 8
E20 E22 H Q G ep:2
N
124 125 237
Y3 Y2 Y11 Y12 Y13 Y14
n n n n n n
139
ep:12
226 227 2 ZA ZA ZA ZA ZA ZA 185 186 43 132 129 83 101 258

K2 K3 K8 56
K0

O 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 O

P P

P
F30
o P
F22 F19 F11 F2 F18 P F12 F29 F10
S13 1 7 5
80

30 L 49
S13a
A B A A 9
Q B 30 30 S13c
S11 B Q
K AE 135 162 88 86 S9 2 8 5 10
0 1 2 S13b L R 1 0
0
57
156 197 198
S S S S 57/58 56a 56b 54s 54d 31
2 4 3 9 8 4 S29
9 M G G S18 S15 0 1 9
S28 V2 P P P P
1
6 3 1 7
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1 0 1 9 1 0 1 7 2 8 9 1 0 2 1 7 2 8 9 89
g n S16
K1 K6 bl bc J
P
77
SWF 525 192 218 236
+
C V2 5 10 SWF 586 371 S2 n 4

G GG G 5 10 5 6 10 3 4 10 SWF 525 005

AC ep:15
g 1
+
SWF 525 005 SWF 525 110 SWF 525 053
S
SWF 586 374 S6
A 453

R
192 193 194 195 + + +
SWF 586 372 S4 V2 F23 F24 F28 F27
143
F25 F26 P 235
R
SWF 586 374 S2 SWF 586 373 S2
208 105 H20
AE A 2 O
K K AE S 5 O
o m S A6
6
87 87a 87 87a 116 117
R4 C C O C C C C F C C F 144 ep:8 256 C C C C E21
102 bl ep:3
86 86
114 249 1 K9 ep:11 115 108 ep:14 3 51
+ C
K AE ep:13
119
136
107 ep:9 50 53 110 52 109 - 248 250 I
R
F E O O
454
Q 255 145 121 120
245 244 246 118 4 1 E5 E6
148 147
E25 E26 E17 E18 E15 E16 3 12
150

Z O O Z Z Z AC 124 125
S 3 7 V11 E1 E2 E3 E4 S
H G G S S S S S V12 E7 E27 H19 E8 243
ep:12
E9 E10 E13 E14 E11 E12 E23 E24 S S N
125 238 124 124 125 125 124 ep:12
ep:12
V14 V13 M5
ep:12
200 199 106 201 199 200 Z 2 83 111 2 54 54 111 Z 54 111 Z 130 2
ep:12 Z 2 111 54 199 200 216 2

K4 K1 K6

T 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120
T

80-02-M153EN (25/06/2009)
MLT 634 -120 LSU Series D-E3 F1
Electrical schematic diagrams
MLT 735 120 LSU Series 4-E3
MLT 741 120 LSU Series 4-E3
MLT 634 120 LSU Series E-E3
MLT 735 120 LSU Series 5-E3
MLT 741 120 LSU Series 5-E3

– Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F2
– Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F7

80

(25/06/2009) 80-02-M153EN
 F2 MLT 634 -120 LSU Series D-E3
Electrical schematic diagrams
MLT 735 120 LSU Series 4-E3
MLT 741 120 LSU Series 4-E3
MLT 634 120 LSU Series E-E3
MLT 735 120 LSU Series 5-E3
MLT 741 120 LSU Series 5-E3
Components
Item Type Designation Position on diagram
A1 A Electronic control unit ECU RC2 H11
A2 A Electro proportional manipulator L26
A3 A Car radio (option) M3
A4 A ECM Engine C6
A5 A Module MCS (potentiometer) B10
A6 A Clock R38
A9 A Module Murphy B30
A10 A Module Fuel level D26
A11 A Engine coolant temperature module C30
A12 A Hour meter / rev counter D32
B1 B Time delays 3,5 sec ± 0,5 H8
B3 B Front wheel alignment sensor H30
B4 B Rear wheel alignment sensor H31
B5 B Left loudspeaker L4
B6 B Right loudspeaker N4
B7 B Air intake pressure sensor C15
B8 B Fuel pressure sensor C16
B9 B Primary speed sensor D17
B10 B Secondary speed sensor D18
B11 B Engine oil pressure sensor C17
E1 E Rear right hand indicator light S32
E2 E Front right-hand indicator light S33
E3 E Rear left-hand indicator light S34
E4 E Front left-hand indicator light S35
E5 E Left hand brake light S40
E6 E Right hand brake light S40
E7 E Rear right hand side light S9
E8 E Front right hand side light S21
80

E9 E Rear left hand side light S23

E10 E Front left hand side light S23
E11 E Front left-hand dipped light S26
E12 E Front right-hand dipped light S27
E13 E Front left-hand headlight S24
E14 E Front right-hand headlight S25
E15 E Right-hand working tail light S16
E16 E Left-hand working tail light S16
E17 E Left front work light S12
E18 E Right front work light S13
E19 E Rotating beacon light H27
E20 E Left hand reverse light N17
E21 E Roof light R37
E22 E Right hand reverse light N18
E23 E Left rear fog light S29
E24 E Right rear fog light S30
E25 E Left working light on boom (option) S9
E26 E Right working light on boom (option) S10

80-02-M153EN (25/06/2009)
MLT 634 -120 LSU Series D-E3 F3
Electrical schematic diagrams
MLT 735 120 LSU Series 4-E3
MLT 741 120 LSU Series 4-E3
MLT 634 120 LSU Series E-E3
MLT 735 120 LSU Series 5-E3
MLT 741 120 LSU Series 5-E3
Components
Item Type Designation Position on diagram
E27 E Rear plate lighting (option) S20
F1 Fuse Power supply ECU RC2 (7,5A) G11
F2 Fuse Rear working lights (15A) Q16
F3 Fuse Rear, roof and side windscreen wiper (10A) G18
F4 Fuse Murphy / preheating relay / diesel water presence sensor (10A) B25
F5 Fuse Rotating beacon light (7,5A) G29
F6 Fuse Wheel alignment (5A) G31
F7 Fuse Safety system (10A) G36
F8 Fuse Reverser + transmission cut-off switch (15A) L16
F9 Fuse Lights / fault alarm / modules (5A) B26
F10 Fuse Alarm / brake (15A) Q41
F11 Fuse Working lights on boom (option) (15A) Q12
F12 Fuse Flashing lights (10A) Q33
F13 Fuse Fan (30A) L31
F14 Fuse Cigarette lighter plug (25A) L36
F15 Fuse Free (25A Max) L38
F16 Fuse Air conditioning (option) (10A Max) L34
F17 Fuse Free (15A Max) L39
F18 Fuse Front working lights (15A) Q17
F19 Fuse Rear window defrosting (option) (15A Max) Q9
F20 Fuse Pneumatic seat (option) (10A) L40
F21 Fuse Front windscreen wiper and windscreen-washer (10A) G18
F22 Fuse Free (15A Max) Q3
F23 Fuse Right hand side light / dashboard lighting (7,5A) R21
F24 Fuse Left-hand side lights (7,5A) R23
F25 Fuse Right indicator lights (7,5A) R32
F26 Fuse Left indicator lights (7,5A) R34
F27 Fuse Dipped lights / dipped light signal light (15A) R26

80
F28 Fuse Headlight / headlight signal light (15A) R24
F29 Fuse Warning lights / ceiling light / option (15A) Q37
F30 Fuse Lighting switch (25A) P20
F31 Fuse Starter / manipulator power cut-off (20A) C3
F32 Fuse Electro proportional module (3A) RELAY L30
F33 Fuse Diagnostic connector (1A) G12
F34 Fuse ECM engine (30A) C5
F35 Fuse Diagnostic connector fuse (5A) G12
F40 Fuse Power (40A) C2
F41 Fuse Power (40A) C3
F42 Fuse Pre-heating (80A) D2
F43 Fuse Alternator (80A) D3
G1 G Battery 12V D6
G2 G Alternator 75A D30
H11 Indicator Front wheel alignment light I31
H14 Indicator Rear wheel alignment light I32
H15a Indicator Rev counter/hour meter module lighting D32
H15b Indicator Rev counter/hour meter module lighting D33

(25/06/2009) 80-02-M153EN
 F4 MLT 634 -120 LSU Series D-E3
Electrical schematic diagrams
MLT 735 120 LSU Series 4-E3
MLT 741 120 LSU Series 4-E3
MLT 634 120 LSU Series E-E3
MLT 735 120 LSU Series 5-E3
MLT 741 120 LSU Series 5-E3
Components
Item Type Designation Position on diagram
H16 Indicator Engine coolant temperature module lighting C30
H17 Indicator Fuel level module lighting D26
H19 Indicator Fan switch lighting S20
H20 Indicator Clock lighting R38
H21 Indicator Cigarette lighter lighting N37
K0 Relay Air conditioning relay (option) M34/O34
K1 Relay Free R3/S3
K2 Relay Transmission cut-off relay O14/L20
K3 Relay Reverse gear relay M20/O23
K4 Relay Forward gear relay M21/O25
K5 Relay Machine fault alarm B32
K6 Relay Free R4/S4
K7 Relay Overload safety I37/G37
K8 Relay Start safety C3/O24
K9 Relay Flashing / warning light unit. S30
K10 Relay Overload safety module I35
K15 Relay Manipulator power cut-off D3/M30
K16 Relay Preheating D2/D9
K17 Relay Module signal lights D34/D39
K19 Relay Transmission cut-off module M12
M1 M Starter D4
M2 M Front screenwiper I18
M3 M Windscreen washer I17
M4 M Roof windscreen wiper I23
M5 M Horn S39
M6 M Fan N31
M7 M Reverse gear alarm (option) N18
M8 M Rear windscreen wiper I21
80

M10 M Side windscreen wiper I25

M11 M Pneumatic seat compressor (option) N40
P1 P Hour meter / Rev counter D33
P2 P Fuel gauge D26
P3 P Engine coolant temperature C31
R1 R Preheating resistances D3
R2 R Fuel gauge C26
R4 R rear window defroster R6
R6 R Attachment proportional control module L27
R7 R Telescope proportional control module L28
R8 R Cigarette lighter resistance N37
R9 R Diesel water presence sensor D10
R10 R Resistance 120 ohms B14
S1 S Key switch B5
S2 S Reverse/forward gear shift L24
S4 S Brake fluid D41
S5 S Air filter clogging D12

80-02-M153EN (25/06/2009)
MLT 634 -120 LSU Series D-E3 F5
Electrical schematic diagrams
MLT 735 120 LSU Series 4-E3
MLT 741 120 LSU Series 4-E3
MLT 634 120 LSU Series E-E3
MLT 735 120 LSU Series 5-E3
MLT 741 120 LSU Series 5-E3
Components
Item Type Designation Position on diagram
S7 S Hand brake switch H9/N12
S8 S Rear and front wiper switch + windscreen washer G20
S9 S Alarm Q24
S10 S Wheel alignment switch G31
S11 S Warning light switch Q32
S12 S Transmission oil pressure I8
S13 S Lighting/indicator lights/horn switch Q21
S13a S Side lights Q21
S13b S Dipped lights / headlights Q22
S13c S Indicator lights Q23
S15 S Interrupteur phares de travail Q13
S16 S Stop switch Q40
S17 S Transmission oil temperature I7
S18 S Boom working lights switch (option) Q9
S19 S Rotative beacon switch G27
S20 S Rear/roof windscreen wiper switch G23
S21 S Fan switch L31
S22 S Strain gauge G35
S23 S Clogging hydraulic filter I4
S24 S Air intake temperature sensor D16
S25 S Pedal transmission cut-off switch M8
S26 S Transmission cut-off switch M7
S28 S Rear window de-frost switch (option) Q6
S29 S Rear fog light switch (option) Q26
S30 S Steering pressure D37
S32 S Coolant liquid temperature sensor D15
S34 S Gear lever transmission cut-off switch L10
S39 S Pneumatic seat switch (option) M41

80
S40 S Cigarette lighter N37
S41 S Seat switch N13
S42 S Movement neutralization switch H37
V1 V Diode C40
V2 V Diode (only for TUV) R21
V3 V Diode (LED) battery charge lamp B38
V4 V Diode (LED) engine oil pressure lamp B40
V5 V Diode (LED) engine coolant temperature lamp G6
V6 V Diode (LED) air/oil filter clogging light G3
V7 V Diode (LED) transmission oil pressure lamp G8
V8 V Diode (LED) transmission oil temperature lamp G7
V9 V Diode (LED) brake fluid lamp B41
V10 V Diode (LED) hand brake signal light G9
V11 V Diode (LED) flashing/warning light lamp S31
V12 V Diode (LED) side lights lamp S18
V13 V Diode (LED) dipped lights light S28
V14 V Diode (LED) headlights light S25
V15 V Diode (LED) steering fault light B37

(25/06/2009) 80-02-M153EN
 F6 MLT 634 -120 LSU Series D-E3
Electrical schematic diagrams
MLT 735 120 LSU Series 4-E3
MLT 741 120 LSU Series 4-E3
MLT 634 120 LSU Series E-E3
MLT 735 120 LSU Series 5-E3
MLT 741 120 LSU Series 5-E3
Components
Item Type Designation Position on diagram
V16 V Diode (LED) red engine fault light D12
V17 V Diode (LED) orange engine fault light D13
V18 V Diode (LED) orange engine preheating light D14
Y2 Electrovalve Forward gear electrovalve N21
Y3 Electrovalve Reverse gear electrovalve N20
Y5 Electrovalve Hydraulic pump proportional electrovalve I11
Y6 Electrovalve Électrovalve proportionnelle accessoire N27
Y7 Electrovalve Telescope proportional electrovalve N28
Y15 Electrovalve Movement neutralization electrovalve I38
Y16 Electrovalve Electronic injector 1 C18
Y17 Electrovalve Electronic injector 2 C19
Y18 Electrovalve Electronic injector 3 C20
Y19 Electrovalve Electronic injector 4 C21
Y20 Electrovalve Injection pump solenoid D20
Y21 Electrovalve Discharge electronic valve C23
A Connector Fuse / relay panel (13 contact plug) X41
B Connector Fuse / relay panel (13 contact plug) X40
Change the Connector Fuse / relay panel (13 contact plug) X39
seals
D Connector Fuse / relay panel (6 contact plug) X37
E Connector Fuse / relay panel (8 contact plug)
F Connector Fuse / relay panel (8 contact plug)
G Connector Fuse/relay panel (21 contact plug + 1 contact plugt) X44+X43
H Connector Fuse / relay panel (5 contact plug) X42
I Connector Fuse / relay panel (7 contact plug) X38
J Connector Relay/fuse panel (8 contact plug + 2 contact plug) X45
K Connector K1 X6 relay option provision
L Connector K0 X5 relay option provision
M Connector Provision option (8 contact plug + 1 contact plug) X4
80

N Connector Engine box X24

O Connector Rear plug provision (8 contact plug) X19
P Connector Lighting switch
Q Connector Fan heating X30
R Connector Option air conditioning X31
S Connector Cab X26
T Connector Front windscreen wiper X77
U Connector Strain gauge
V Connector BB3 diagnostic connector
W Connector ECM connector diagnostic connector
X Connector Adaptation CE
Z Connector Light module
AA Connector Car radio X27, X53 (option)
AC Connector Digicode connector X78
AB Connector Windscreen wiper switch (9 ways + 2 ways) X79;X80
AD Connector Movement cut-off provision (1 contact plug) X43
AE Connector K6 X7 Relay option provision
AG Connector Connector RC2/2 X24A

80-02-M153EN (25/06/2009)
 F7
MLT 735 120 LSU Series 4-E3/MLT 741 120 LSU Serie 4-E3 MLT 634 -120 LSU Series D-E3 Electrical schematic diagrams
MLT 735 120 LSU Series 5-E3/MLT 741 120 LSU Serie 5-E3 MLT 634 120 LSU Series E-E3
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

J
J 35

S1 F4 F9
Fus.Therm. E Z
B R10 (2A) 29
B
A5 A A
33

J J J J canale analogique 28 27
458M
E Z
I I I OP
+
1 N ep:21 458B 157
K5
30 30 17 17 50 19 19 54 15 58
1K ep:5 8 17 A9 V15 V3 V4 V9
64 63 4 N ep:19
92 65 19 11 457B 5 8 2
B B Z Z Z Z
82 66 - 2
9
N 457M
ep:20
27
canale IVS 38 26 34
67 6 ep:4 3 1 9 6 7 4
16 7 13 12
F31 68 151
- N 11
5
N N N N 214
452 X 8 F E F
+ 3
B
10 13 3 6 15 31
ep:2 B7 B8 B11 bl g o
C B
22 23 21 24 20 20
127 V1 V1 V1 C
F34 A4 32 33 34 35 30 29 Y16 Y17 Y18 Y19 Y21 461 466 A11 26 81 B I
F40 F41 B
K8 460 126
51
7 8 15 16 43 45 33 54 41 62 22 20 21 46 55 38 48 51 40 47 56 39 35 57 7 63 8 64 34 58 19 17
R2 265
Bat+ Bat+ Bat+ Bat+ +8V val 0V sig +5V phm CAN S CAN H CAN L 5V p air m 5V p comb m 5V p hui m m inj 1 m inj 2 m inj 3 m inj 4 m dech
221 V1 V1 19 55

B J1 J2 91 184 62
n Bat- Bat- Bat- Bat- Bat- + ap cont prech ent sort ent stop war prech t° eau alim t° air v mot 8V vit pompe inj sol m J1939+ J1939- cdl- cdl+ batt- batt+
AC 7 142
H16 P3
F42 F43 14 M1 1 2 3 9 10 40 57 44 35 38 60 59 63 43 37 42 52 10 53 25 26 24 23 20 21 45 18 219 89 V1
N AC N AG ep:18
19
37 38 41 39 40 26 52 50 35 43 18 14 12 W 72

53 G1 T T A 25 18
N N N C C
A10 A12 90
W B N 223

45
ep:3
P 21 6 24 S32 S24 B9 B10 Y20 W
20 8 5 4
B
D K16 152
36
K16
C 1 140
P P D
Z Z Z W D P1 224
25 49
S5 P2 K17 S30 S4
46
4 5 17 16
ep:1
R9 V16 V17 V18 W E H17 G2 H15a 3 H15b
N N N 2
W F K17
K15 N 73
220
44 74
R1 R1 R1 R1 138 225 10 22 11 N 48
ep:6
141 56

42 70 222

69

J 57

E E
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

F F
151

F1 F3 F21 F5 F6 F7

80
G A B
G F35 V 85 80
A B B S22 G G G
155 87 161
18 1
AB 58
V6 V5 V8 V7 V10 17 F33 V 16 99 AB S 3 M
163

Z Z Z Z Z M 5 V 5 76
K7
S20 S190 S100
V 13 1 3 7 4 8 9
23 25 22 24 28
S8 1 9 1 9
15/54

2 0 1 1 128
m lgar 1è 2è
4 V 12

V 15 0 1
int lgav
3 G 9 M 75
E E F E E 97 0

ep:2 V 3 1 5 2 6 10 5 10 5 10 79 S420
egar +egav +lgav F m bc vt j g jvt
n vt v m n V 11 1 1 7 2 8 9

V1 V1 V1 V1 8 54 14 53 44 43 42 45 V 4
SWF 525 243
+
SWF 586 373 S8
SWF 525 005
+
SWF 525 005
+
SWF 586 373 S9 257 SWF 586 373 S14
H I I I I ep:5
H
B1 A1 5 6 10

240 8 269 33 3,5s 1 27 41 42 24 50 51 52 AB AB AB AB SWF 525 110

45
AB AB AB 46
+
27
+
+
SWF 586 374 S3

V1 V1 V1 V1 V1 31 30 59 94 95 78 96 103 104 E19 B3 _ B4 _

U U U U U U
I S
S7 31 2 28 40 39
T T T T S 48
G 204
29
241
202
1 +perm 2 1 +perm 2 1 +perm 2 1 +perm 2 30 188 ep:6
113 ep:1 48 47 vit vit vit vit 47 28 r g j vt bl n
ep:2
36 7 11 3
raz
M2 S raz M8 raz
M4 raz
M10
ep:2 ep:7
264 A

P M M M M H11 H14
P T 3 3 3 3 AD
S23 S17 S12 - - - 4-
258 71 205 K10
I 9 ep:7 ep:3 M3 4 4 4 Ep11 cab Y15 I
Y5 21 22
T Ep5 cab 32 264 B
35 S S 31
ep:7

205 258 AG AG 43
56
93 199 200
131
130
132 205
112
101
K7

J 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 J

(25/06/2009) 80-02-M153EN
 F8
Electrical schematic diagrams MLT 634 -120 LSU Series D-E3 MLT 735 120 LSU Series 4-E3/MLT 741 120 LSU Serie 4-E3
MLT 634 120 LSU Series E-E3 MLT 735 120 LSU Series 5-E3/MLT 741 120 LSU Serie 5-E3
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

K K

151 151

F8 A2 F32 F13 F16 F14 F15 F17 F20

B5 R6 R7
L S2 L
G D
vi

41 189 A
AA H
R F 84 A
1

139 S34 166 K2 242

PCB Q
137 158

252 ep:4
S21 G
254 4 2 3 5 1 3 2 4 K15
207
K19
76 108
S25 B4
K0
AA 226
B2
B1
44 217
AA AA 49
260
F E

+ vt nvt B5 B3 K3 K4 230
173 171
172
168 169
Q Q G G D DD DA AM 263
M A7 A4 B7 S26 1 7 2 8 9
4 2 3 8 M
L B8
1 0 ep:1
153 154 165 190 191 196 159 160
B2 236 ep:16
98 S39
R B1 B7 B6
AC 212 R L 211
M
A8
5 6 10
AC V1 G G 231
R RL L AC M
A3 - vi nvi 203 60 233
A B C 87 87a 30 2 1 2
470 100
AA
SWF 525 110
+ AC
AA SWF 586 372 S3
AC D 86
259
215
ep:24
473
ep:26
471
Y6 Y7 Q L Tempo M
253
132
S7 S41 ep:10 5
210 M6 S40
46
232 213 167 112
228 209
H21
251
247 123 122 239
474B 475B
101 164 149
M11
N 146 N
AA M7 ep:17 262
8
Y3 Y2 R8 ep:2
G O E20 E22 474A 475A H H H Q G
124 125 237 ep:23

B6 ep:12 472
ep:25
227 2 129 83 101 258

K2 38 K3 K8 K4 K0

O O

57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80

P P

F30 P
o P P
F22 F19 F11 F2 F18 F12 F29 F10
S13 1 7 5
80

30 L 49

A B A A S13a 9 452

Q B 30 30
S13c B Q
K AE 135 162 88 86 S13b
S9 S11 2 8 5 10
0 1 2 L 0 R 1 0
57
156 197 198
S S S S 57/58 56a 56b 54s 54d 31
2 4 3 9 8 4 S290
M G G S15
1 1 9
9 S280 1 9
S180 1 7 2 8 9 V2 10 2 1 7 2 8 9 89
P P P P g n
6 3 1 7
D M S16
K1 K6 1 1
bl bc J
P
77
SWF 525 192
+ 218 234
C SWF 586 371 S2 n
V2 5 10
A AC
4

G GG G 5 10 5 6 10 3 4 10 SWF 525 005

+ g 1
ep:15

SWF 586 374 S6

SWF 525 005 SWF 525 110 SWF 525 053 453
192 193 194 195 + + +
S V2 143
P
R SWF 586 374 S2 SWF 586 373 S2 SWF 586 372 S4
208 F23 F24 F28 F27 F25 F26 105 H20
235
R
AE A 2 O
K K AE S 5 O
o m S A6
6
87 87a 87 87a 116 117
R4 C C O C C C C F C C F 144 ep:8 256 C C C C E21
102 bl ep:3
114 249 1 ep:11 115 108 ep:14 3 51
86 86
+ C
K AE ep:13
119
136
107 ep:9 50 53 110 52 109 - 248 250 I
R
F K9 E O O
454
Q 255 145 4 121 1 120
245 244 246 118 E5 E6
148 147
E25 E26 E17 E18 E15 E16 12 150

Z O 3 O Z Z Z AC 124 125
7
S G G S S S E7 E27 H19 E8 E9 E10 E13 E14 V14 E11 E12 V13 E23 E24 V11 E1 E2 E3 E4 S S N S
S S V12 125 238
243
ep:12 124 125 ep:12
124 125 ep:12 124

ep:12
M5
200 199 106 201 199 200 Z 2 83 111 2 54 54 111 Z 54 111 Z 130 2
ep:12 Z 2 111 54 199 200 216 2

K1 K6

T 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 T

80-02-M153EN (25/06/2009)
 G1
MT 732 Series D-E3 Electrical schematic diagrams
MT 932 Series D-E3

– Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G2
– Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G7

80

(25/06/2009) 80-02-M153EN
 G2
Electrical schematic diagrams MT 732 Series D-E3
MT 932 Series D-E3

Components
Item Type Designation Position on diagram
E1 E Rear right hand indicator light B35
E2 E Front right-hand indicator light B35
E3 E Rear left-hand indicator light B36
E4 E Front left-hand indicator light B36
E5 E Left hand brake light B33
E6 E Right hand brake light B33
E7 E Rear right hand side light B44
E8 E Front right hand side light B45
E9 E Rear left hand side light B46
E10 E Front left hand side light B46
E11 E Front left-hand dipped light B46
E12 E Front right-hand dipped light B47
E13 E Front left-hand headlight B48
E14 E Front right-hand headlight B48
E15 E Rear right-hand working light (option) B42
E16 E Rear left-hand working light (option) B42
E17 E Front left-hand working light (option) B41
E18 E Front right-hand working light (option) B41
E19 E Rotating beacon light B17
E20 E Left-hand reverse light (option) B29
E21 E Roof light C37
E22 E Right-hand reverse light (option) B29
E23 E Rear left-hand fog light (option) B47
E24 E Rear right-hand fog light (option) B48
E25 E Head jib left work light B40
E26 E Head jib right work light B41
E27 E License Plate light (option)
F1 Fuse Free (10A Max) F11
80

F2 Fuse Rear working light (option) (15A) F42

F3 Fuse Rear windscreen / roof wiper (7,5A) F14
F4 Fuse Engine stop electrovalve (10A) F18
F5 Fuse Rotating beacon light (7,5A) F18
F6 Fuse Wheel alignment (5A) F20
F7 Fuse Overload safety (10A) F23
F8 Fuse Forward/reverse/neutral Transmission (15A) F27
F9 Fuse Fault alarm/light (5A) F4
F10 Fuse Alarm / brake (15A) F33
F11 Fuse Working light on boom (15A Max) F40
F12 Fuse Flashing lights (10A) F38
F13 Fuse Fan (30A) F52
F14 Fuse Free (10A) F54
F15 Fuse Free (25A Max) F54
F16 Fuse Air conditioning (option) (10A Max) F52
F17 Fuse Free (15A Max) F55
F18 Fuse Front working lights (option) (15A) F41
F19 Fuse Rear window defrosting (option) (15A Max) F40

80-02-M153EN (25/06/2009)
 G3
MT 732 Series D-E3 Electrical schematic diagrams
MT 932 Series D-E3

Components
Item Type Designation Position on diagram
F20 Fuse Pneumatic seat (10A Max) F56
F21 Fuse Front windscreen wiper / windscreen-washer (10A) F14
F22 Fuse Free (15A Max) F57
F23 Fuse Right hand side lights / dashboard (7,5A) C44
F24 Fuse Left-hand side lights (7,5A) C46
F25 Fuse Right-hand indicator light (7,5A) D35
F26 Fuse Left-hand indicator light (7,5A) C36
F27 Fuse Dipped lights (15A) C46
F28 Fuse Headlights (15A) C48
F29 Fuse Warning / ceiling light (15A) F37
F30 Fuse Stalk switch (25A) E46
F31 Fuse Starter (20A) D2
F40 Fuse Equipment (40A) C1
F41 Fuse Equipment (40A) C2
F42 Fuse Pre-heating (80A) C1
F43 Fuse Alternator (80A) C2
G1 G Battery B3
G2 G Alternator B5
H10 Indicator Warning lamp A37
H11 Indicator Front wheel alignment light B20
H14 Indicator Rear wheel alignment light B21
H15 Indicator Counter/rotations light B44
H16 Indicator Cooland temperature light B43
H17 Indicator Diesel gauge light B43
H19 Indicator Fan light B45
H20 Indicator Clock light B43
K0 Relay Air conditioning relay (option) A54/D53
K1 Relay Free A58/D58

80
K2 Relay Transmission cut-off relay E28/B31
K3 Relay Reverse gear relay B27/D28
K4 Relay Forward gear relay C10/B26/D28
K5 Relay Machine fault alarm E6
K6 Relay Free A57/D57
K7 Relay Movement cut-off control relay D24/A23
K7a Relay Forced movement switch relay D24/C24
K8 Relay Starter safety relay C2/B27
K9 Relay Flashing/Warning unit B34
K10 Relay Overload safety module B22
K16 Relay Preheater relay B1/A2
K17 Relay Module relay lights B6/B7
K18 Relay Transmission cut-off module F29
M1 M Starter C2
M2 M Front screenwiper B14
M3 M Windscreen washer B13
M4 M Roof wiper (option) B16
M5 M Alarm B33

(25/06/2009) 80-02-M153EN
 G4
Electrical schematic diagrams MT 732 Series D-E3
MT 932 Series D-E3

Components
Item Type Designation Position on diagram
M6 M Fan B52
M7 M Reverse gear alarm B29
M8 M Rear cab screen wiper B15
M9 M Diesel pump B19
M10 M Side windscreen wiper B17
M11 M Pneumatic compressor A56
P1 P Hour meter B6
P2 P Fuel gauge C5
P3 P Engine coolant temperature C4
R1 R Preheating plugs A1
R2 R Fuel sensor D4
R3 R Sensor and thermo-switch for engine coolant temperature D4
S1 S Key switch F3
S2 S VL VI valve lever forward / reverse gear reverser E27
S3 S Engine oil pressure switch B7
S4 S Brake fluid B8
S5 S Air filter clogging B8
S6 S Front wheel alignment detector B20
S7 S Brake switch B11/D29
S8 S Front windscreen wiper and windscreen-washer switch D15
S9 S Alarm control D33
S10 S Wheel alignment switch E20
S11 S Warning light switch E36
S12 S Transmission oil pressure B10
S13a S Side light stalk switch E44
S13b S Dipped light/headlight stalk switch E44
S13c S Indicator light stalk switch E35
S14 S Gear lever transmission cut-off switch C31
80

S15 S Front/rear working light switch (option) D42

S16 S Stop switch D33
S17 S Transmission oil temperature B10
S18 S Working lights on boom switch (option) D41
S19 S Rotating beacon switch D18
S20 S Rear windscreen wiper / roof switch D17
S21 S Fan switch E52
S22 S Overload stress gauge E22
S23 S Clogging hydraulic filter B9
S24 S VL and VI valve lever transmission cut-off switch E31
S25 S Pedal transmission cut-off switch D30
S26 S Transmission cut-off switch F31
S27 S Rear wheel alignment detector B21
S28 S Rear window defrost switch (option) D40
S29 S Rear fog light switch (option) D48
S30 S Steering pressure B5
S31 S Cold start switch B18

80-02-M153EN (25/06/2009)
 G5
MT 732 Series D-E3 Electrical schematic diagrams
MT 932 Series D-E3

Components
Item Type Designation Position on diagram
S32 S Seat switch D29
S39 S Pneumatic seat switch C56
S42 S Movement cut-off deletion switch B23
S43 S Retracted telescope switch D22
S44 S Telescope retraction switch D23
S45 S Deflation/dump switch D23
S46 S Boom lowering switch C23
S47 S Attachment switch C23
V1 V Diode D7
V2 V Diode (only for TUV) D44
V3 V Diode (LED) battery charge lamp E7
V4 V Diode (LED) engine oil pressure lamp E7
V5 V Diode (LED) engine coolant temperature lamp E9
V6 V Diode (LED) air/oil clogging lamp E8
V7 V Diode (LED) transmission oil pressure lamp E10
V8 V Diode (LED) transmission oil temperature lamp E10
V9 V Diode (LED) brake fluid lamp E8
V10 V Diode (LED) brake lamp E11
V11 V Diode (LED) flashing/warning light lamp B34
V12 V Diode (LED) side lights lamp B44
V13 V Diode (LED) dipped lights light B47
V14 V Diode (LED) headlights light B49
V15 V Diode (LED) steering fault light D5
Y1 Electrovalve Engine stop electrovalve B19
Y2 Electrovalve Forward gear electrovalve B28
Y3 Electrovalve Reverse gear electrovalve B28
Y4 Electrovalve Cold start electrovalve B18
Y7 Electrovalve Movement cut-off electrovalve C24
Y8 Electrovalve Discharge valve electrovalve C12

80
A Connector Fuse / relay panel (13 contact plug)
B Connector Fuse / relay panel (13 contact plug)
Change the Connector Fuse / relay panel (13 contact plug)
seals
D Connector Fuse / relay panel (6 contact plug)
E Connector Fuse / relay panel (8 contact plug)
F Connector Fuse / relay panel (8 contact plug)
G Connector Fuse / relay panel (21 contact plug)
H Connector Fuse / relay panel (5 contact plug)
I Connector Fuse / relay panel (7 contact plug)
J Connector Fuse / relay panel (8 contact plug + 2 contact plug)
K Connector K1 provision relay option
L Connector K0 provision relay option
M Connector provision option (8 contact plug + 1 contact plug)
N Connector Engine box
O Connector Rear plug provision option (8 contact plug)
P Connector Stalk switch
Q Connector Ventilation heating

(25/06/2009) 80-02-M153EN
 G6
Electrical schematic diagrams MT 732 Series D-E3
MT 932 Series D-E3

Components
Item Type Designation Position on diagram
R Connector Option air conditioning
S Connector Cab
T Connector Front screenwiper
U Connector Strain gauge
V Connector Anti-theft connection
W Connector Aggravating movement cut-off connection
X Connector Aggravating movement cut-off diode connection
Z Connector 16 way plug (PCB Dashboard)
AA Connector Car radio
AB Connector Windscreen stalk switch connector (9 ways + 2 ways)
AC Connector K6 relay option provision
AD Connector Hour meter / rev counter
80

80-02-M153EN (25/06/2009)
 G7
MT 732 Series D-E3 Electrical schematic diagrams
MT 932 Series D-E3
MT732 1/3
J
) + Perm MT932 1/3
F + Apc F
Euro 3
S1 F9 Fus.Therm. 2A E Z F1
r
J J J J G
B B B 321
E Z
E E
I I I OP
118 118 30 30 17 17 50 19 19 54 15 58 K5 227 156
119 119 119 119 Z V3 V4 V9 V6 V5 V8 V7 V10
141 129 204 Z AD
F Z Z Z Z Z Z Z
130
M
12 21 21 12
11 bl E F E E F E E
F31 AB
D N N N N N g o n vt v D
8 6 3 11 23
R3 R2 V15 V1 V1 V1 V1 V1 V1 V1 V1 V1 m n
B 12 Z r vt

F40 24 7 I B I I I I
F41 K8
N N 3,5s 14 13
C
M 26 95 24 13 28 47
C
32 31
B n 25 263 139 75
Y8
F42 F43 M1 V1 V1 N V1 V1 V1
3 7
22
N AD AD N N K4
N 17 P3 121
P2 1 30 116 323 B
29 20
G1 203 I g n n
K16 121 P 10 N S7
S30 324 P 85

B 202 G2 P1 324
P P P B
27
AD 121 121 P S4 S5 S23 T 173
15 15 20 325
K17 S3 14 S17 S12
N N N N 21 140 121 K17 54

R1 K16
55
R1 R1 R1 96
28 15 5 14 4 322
jvt jvt
A J F A

1 2 3 4 5 6 7 8 9 10 11 12

) + Perm
F + Apc F

F3 F21 F5 F4 F6 F7 (10A)
G
A B

80
A B B S22 G
E 133 128 E
135 98 233 235
AB AB A A 122
S S10 M M
EG Lateral

79 341
229
EG Toitl

S8 SWF 521 243

+
SWF 596 307 Ep3 cab SWF 521 005
+ V
0 1 0
1 0 2 3 7 4 8 9
SWF 596 628
S43 S44 K7
D
157
V D
5 9
K7a
G
F
1 5 2 6 10 27
105
S20 1 0 1 10
121 m bc vt j g 127 342 S45
S19 N M 167 WW 337 335 339
315
2 S46 v X
AB AB AB AB 82 34 X
C AB AB AB AB WW 336 C
Ep15 cab 344 338
151 150 149 148 147 152 153 30 S47 K7a Y7
S Ep2 cab 26 U U U U U U
334 332
99
T T T T T 25
84 36
331
S E19 S31
S 4 M8 2 4 M4 2 4 M10 2
r g j v bl n 340 315
B 4 2 +perm 1 vit +perm 1 vit +perm 1 vit B
raz +perm 1 vit
raz
M AR
raz
M TOIT
raz 2 M
LAT G 121
2 M
AV 3
-
3
-
3
- Y4 Y1 M9 S6 H11 S27 H14
M3 3
- 1 Ep11 cab 1 1 121
37 I 0 II 1 7 2 8 10

M2 1
Ep5 cab
Ep14 cab S42
73 T S S Ep12 cab 18 19 83 167 35
K10 3 6 9
96 146 289 289 41
K7 333

A A

13 14 15 16 17 18 19 20 21 22 23 24 25
(25/06/2009) 80-02-M153EN
 G8
Electrical schematic diagrams MT 732 Series D-E3
MT 932 Series D-E3

J
) + Perm
J
F + Apc F
65

F8 G 122
K18 S26 F10 P F29 F12
B4 B2
S13c
H 29
m o J r
250
B5
B1 P B
E 192 E
262 B3 vt 97
P P
K2 191 D
S2 B7 B6 S11
S24 330

246 264 261

S16 o m g n
V
F R
D S9 D
PCB
K4 K3 S7 S32 PCB
176
n V
vt
G G S25 4 g
265
A3 57 P A 155
254
193 F25 F26 158
66
248 266 249
O g n S
C 315
O C
V S14 I E21
V 5 C C C C
H 247 H 315
194 O 175 O 3
V V 220 177 154

267
H 56 O 256 K9 E
183 182
ro n
103 181 163 180 87
123 jvt ro r
B 378 G B
M5 E5 E6 Z
M7
184
O V11 N
K4 K8 K3 Y2 Y3 E20 E22
54 184 185 159
257 197
K2
185 E1 E2 E3 E4
9
55
2
2
Z 185 166 184 90
H10
A A

26 27 28 29 30 31 32 33 34 35 36 37 38

) + Perm
F + Apc F

F19 F11 F18 F2 P o

S13a S13b F30
A B A A AA
J
80

E 199 234 134 136 E

S S S S P P P
SWF 521 008 SWF 521 110 SWF 521 054
+ + + 381
SWF 596 390 SWF 596 473 SWF 596 151
S15 bl j bc 382
S28 S18 A
5 9 5 6 9 3 4 9 AA
D 1 0 1 7 2 8 10 2 0 1 1 7 2 8 10 205 AA D
+ +
1 0 1 10
V2 122
R
S V2
313
V2 S29 L
-
F23 F24 F27 F28 A2 AA
C S C
385
C C C C C C C F C C F
Dégivrage bl
vitre arrière 138 174 162 1 86 88 164 196
380

O O 105 383
E25 E26 E17 E18 156 187 186 320 200 121 206 207 89 165 bc
167
H17 H15a Q Z AA AA
F 179
178
E10 E12 J
B V14 B
E15 E16 Z E8 Z
203 E11 E23 E24 E13 E14 J
H20 H16 H15b V13
S S S S S S 154 121
121
121
V12 E7 H19 166 E9 166
Z
289 289 384 289 289 289
N 202
184 90
184 185 90 166

9 Z MT732 2/3
140
Z
jvt MT932 2/3
A A
Euro 3

39 40 41 42 43 44 45 46 47 48 49 50

80-02-M153EN (25/06/2009)
 G9
MT 732 Series D-E3 Electrical schematic diagrams
MT 932 Series D-E3

MT732 3/3
) + Perm MT932 3/3
F + Apc F
MT1033HL T 3/3
Euro 3
F13 F16 F14 F15 F17 F20 F22
AC K
D v
A
E 132
A E
287 286
201 G
Q
S21
K0
232 231
A B G G

D K6 K1 D
329 230 228
Q G G Q
225 239 226
D D D D M M V M M G G G G
R R R 283 284 281 282
C C

S39 AC AC K K
Q L AC K

238 217 218

m
B B
M6 G G G
Q M

80
131
K0 M11 K6 K1
A A

51 52 53 54 55 56 57 58

(25/06/2009) 80-02-M153EN
 G10
Electrical schematic diagrams MT 732 Series D-E3
MT 932 Series D-E3
80

80-02-M153EN (25/06/2009)
 H1
MLT 742H T LSU Series 4-E3 Electrical schematic diagrams

– Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H2
– Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H7

80

(25/06/2009) 80-02-M153EN
 H2
Electrical schematic diagrams MLT 742H T LSU Series 4-E3

Components
Item Type Designation Position on diagram
A1 A Electronic control unit C9
A2 A Electro proportional manipulator C20
A3 A Car radio C47
E1 E Right-hand rear indicator light B26
E2 E Front right-hand indicator light B26
E3 E Left-hand rear indicator light B26
E4 E Front left-hand indicator light B27
E5 E Left hand brake light B24
E6 E Right hand brake light B25
E7 E Right-hand rear sidelight B36
E8 E Front right hand side light B36
E9 E Left-hand rear sidelight B37
E10 E Front left hand side light B37
E11 E Front left hand dipped headlight B37
E12 E Front right hand dipped headlight B38
E13 E Front left-hand headlight B39
E14 E Front right-hand headlight B39
E15 E Right-hand rear work light (optional) B34
E16 E Left-hand rear work light (optional) B34
E17 E Front left-hand working light (option) B33
E18 E Front right-hand working light (option) B33
E19 E Rotating beacon light C43
E20 E Left-hand reverse light (option) B13
E21 E Roof light C28
E22 E Right-hand reverse light (option) B14
E23 E Left-hand rear fog light B38
E24 E Right-hand rear fog light B38
E25 E Left-hand boom work light B33
80

E26 E Right-hand boom work light B33

E27 E License Plate light (option) B36
F1 Fuse ECU supply (7,5A) E9
F2 Fuse Rear work light (optional) (15A) E34
F3 Fuse Rear/roof screen wipers (7,5A) E40
F4 Fuse Solenoid engine stop valve (10A) E44
F5 Fuse Rotating beacon light (7,5A) E43
F6 Fuse Wheel alignment (5A) E45
F7 Fuse Overload safety (10A) E22
F8 Fuse Reverser + transmission cut-off switch (15A) E18
F9 Fuse Fault alarm/light (5A) E3
F10 Fuse Alarm/brake (15A) E24
F11 Fuse Boom work light (15A) E33
F12 Fuse Flashing lights (10A) E28
F13 Fuse Fan (30A) E28
F14 Fuse Cigarette lighter (10A) E30/E47
F15 Fuse Free (25A Max) E30
F16 Fuse Air conditioning (option) (10A Max) E29

80-02-M153EN (25/06/2009)
 H3
MLT 742H T LSU Series 4-E3 Electrical schematic diagrams

Components
Item Type Designation Position on diagram
F17 Fuse Free (15A Max) E31
F18 Fuse Front work lights (optional) (15A) E33
F19 Fuse Rear screen defrosting (optional) (15A max) E32
F20 Fuse Air suspension seat (option) (10A) E31
F21 Fuse Front windscreen wipers/washers (10A) E41
F22 Fuse Free (15A Max) E40
F23 Fuse Right hand side light/instrument panel (7,5A) C35
F24 Fuse Left hand side light (7,5A) C37
F25 Fuse Right-hand indicator light (7,5A) D26
F26 Fuse Left-hand indicator light (7,5A) D26
F27 Fuse Codes (15A) C37
F28 Fuse Headlights (15A) C39
F29 Fuse Warning/ceiling light (15A) E28
F30 Fuse Stalk switch (25A) E37
F31 Fuse Starter (20A) D2
F32 Fuse Electro proportional modules (3A) E20
F33 Fuse Diagnostic connector (1A) D10
F40 Fuse Equipment (40A) C1
F41 Fuse Equipment (40A) C2
F42 Fuse Pre-heating (80A) C1
F43 Fuse Alternator (80A) C2
G1 G Battery B3
G2 G Alternator B4
H10 Indicator Warning lamp B27
H11 Indicator Front wheel alignment light C45
H14 Indicator Rear wheel alignment C45
H15 Indicator Counter/rotations light B35
H16 Indicator Cooland temperature light B35

80
H17 Indicator Diesel gauge light B34
H19 Indicator Fan light B36
H20 Indicator Slow speed indicator lamp (tortoise) B15
H21 Indicator High speed indicator lamp (hare) B15
H22 Indicator Clock light B34
K0 Relay Air conditioning relay (option) A29/D29
K1 Relay Joystick transmission cut-off reverse relay D46/A46
K2 Relay Transmission cut-off relay D14/A18
K3 Relay Reverse gear relay C15/A19
K4 Relay Forward gear relay C14/A19
K5 Relay Machine fault alarm D5
K6 Relay Free (optional EVTdF) D46/A46
K7 Relay Movement cut-off relay/(option) B22/D23
K8 Relay Starter safety relay A17/C2
K9 Relay Flashing/Warning unit B25
K10 Relay Overload safety module C22
K11 Relay Reversing light and buzzer/engine rotation direction Q13/A18
K13 Relay Slow speed relay B16/D15

(25/06/2009) 80-02-M153EN
 H4
Electrical schematic diagrams MLT 742H T LSU Series 4-E3

Components
Item Type Designation Position on diagram
K14 Relay High speed relay D15/B16
K15 Relay Proportional joystick supply cut-off relay B3/D20
K16 Relay Preheater relay B1/B2
K17 Relay Module relay lights B5
K18 Relay Transmission cut-off module D17
M1 M Starter C2
M2 M Front screenwiper B41
M3 M Windscreen washer B40
M4 M Roof wiper (option) B42
M5 M Alarm B24
M6 M Fan B28
M7 M Reversing warning (optional) B14
M8 M Cab rear screen wiper B41
M9 M Diesel pump B45
M10 M Side windscreen wiper B43
M11 M Air seat compressor B31
P1 P Hour meter/tachometer B4
P2 P Module Fuel level B4
P3 P Water temperature engine FUSES module B3
R1 R Preheating plugs A1
R2 R Fuel sensor C3
R3 R Sensor and thermo-switch for engine coolant temperature C3
R5 R Accelerator potentiometer (injection pump) B11
R6 R Attachment proportional module resistance D20
R7 R Telescoping proportional module resistance D19
S1 S Key switch E2
S2 S Forward/reverse shuttle control D19
S3 S Engine oil pressure switch B6
80

S4 S Brake fluid B6
S5 S Air filter clogging B7
S6 S Front wheel alignment detector B45
S7 S Hand brake switch B17/B9
S8 S Front windscreen wiper and windscreen-washer switch D41
S9 S Alarm control D24
S10 S Wheel alignment switch D45
S11 S Warning light switch E27
S13a S Sidelight stalk E35
S13b S Dip/main beam stalk E36
S13c S Indicator light stalk switch E26
S15 S Front/rear work light switch (option) D34
S16 S Stop switch D24
S18 S Boom work light switch (option) D33
S19 S Rotating beacon switch C44
S20 S Roof/rear screen wiper switch C43
S21 S Fan switch D29

80-02-M153EN (25/06/2009)
 H5
MLT 742H T LSU Series 4-E3 Electrical schematic diagrams

Components
Item Type Designation Position on diagram
S22 S Overload stress gauge E21
S23 S Clogging hydraulic filter B7
S24 S Tortoise/hare speed selector switch D16
S25 S Accelerator switch (put into neutral) D18
S26 S Maximum speed limiter switch (snail) C13
S27 S Rear wheel alignment detector B46
S28 S Rear windscreen de-froster switch (option) D32
S29 S Front fog light switch (optional) C38
S30 S Switch on brake pedal B4/D16
S31 S Cold start switch B44
S39 S Air seat switch C32
S41 S Seat switch B18
S42 S Movement cut-off deletion switch (option) D23
V1 V Diode C6
V2 V Diode (only for TUV) C33/D35
V3 V Diode (LED) battery charge lamp D5
V4 V Diode (LED) engine oil pressure lamp D6
V5 V Diode (LED) engine coolant temperature lamp D7
V6 V Diode (LED) air/oil clogging lamp D7
V7 V Diode (LED) transmission oil pressure lamp D8
V8 V Diode (LED) transmission oil temperature lamp D8
V9 V Diode (LED) brake fluid lamp D6
V10 V Diode (LED) brake lamp D9
V11 V Diode (LED) flashing/warning light lamp B25
V12 V Sidelight indicator LED B35
V13 V Diode (LED) dipped lights light B38
V14 V Diode (LED) headlights light B39
V15 V Diode (LED) steering fault light C4
Y1 Electrovalve Solenoid engine stop valve B44

80
Y2 Electrovalve Forward gear solenoid valve B14
Y3 Electrovalve Reverse gear solenoid valve B15
Y4 Electrovalve Cold start solenoid valve B44
Y6 Electrovalve High speed solenoid valve B16
Y7 Electrovalve Maximum speed limiter solenoid valve (snail) B13
Y8 Electrovalve Hydraulic motor rotation direction solenoid valve B13
Y9 Electrovalve Hydraulic pump proportional electrovalve A10
Y10 Electrovalve Telescope proportional electrovalve B19
Y11 Electrovalve Attachment proportional electrovalve B20
Y14 Electrovalve Movement cut-off solenoid valve C23
A Connector Fuse/relay panel (13 contact plug) X41
B Connector Fuse/relay panel (13 contact plug) X40
Change the Connector Fuse/relay panel (13 contact plug) X39
seals
D Connector Fuse/relay panel (6 contact plug) X37
E Connector Fuse/relay panel (8 contact plug)
F1 Connector ECU supply (7,5A)
G Connector Fuse/relay panel (21 contact plug) X44

(25/06/2009) 80-02-M153EN
 H6
Electrical schematic diagrams MLT 742H T LSU Series 4-E3

Components
Item Type Designation Position on diagram
H Connector Fuse/relay panel (5 contact plug) X42
I Connector Fuse/relay panel (7 contact plug) X38
J Connector Relay/fuse panel (8 contact plug + 2 contact plug) X45
K Connector K1 X6 relay option provision
L Connector K0 X5 relay option provision
M Connector Provision option (8 contact plug + 1 contact plug) X4
N Connector Engine box X24
O Connector Rear plug option pre-wiring (8 contact plug) X19
P Connector Stalk switch
Q Connector Heating ventilation X15B
R Connector Option air conditioning X15
S Connector Cab X26
T Connector Front windscreen wiper X77
U Connector Strain gauge
V Connector Fault finding plug
X Connector Adaptation TUV X2
Z Connector 16 way plug (PCB Dashboard)
AA Connector Car radio X53-X27
AB Connector Windscreen wiper stalk switch connector (9 ways + 2 ways) X79-
X80
AC Connector Digicode connector X78
AD Connector K6 relay option pre-wiring X7
80

80-02-M153EN (25/06/2009)
 H7
Electrical schematic diagrams
MLT 742H T LSU Series 4-E3

E F1 E
S1 F9 Fus.Therm. 2A E Z
r
G
J J J J K5
I I I OP
E Z 155
F33
64 63
30 30 17 17 50 19 19 54 15 58
65 66 67 68 Z M r r V
92 V3 V4 V9 V6 V5 V8 V7 V10 V
D Z Z Z Z Z Z Z V D
82
B B B V
16 12 13 7 F31 6 F E F E E F E E
N N N N V
8 6 3 11 bl g o n vt v V
15 N 81 142 Z V1 V1 V1 V1 V1 V1 V1 V1 m n
B 62 r r r r/n n vt o vi
F40 F41 K8 I B I I I I I A1
C 21 41 42 33 17 51 50 52 C
19
R3 R2 V15 V1
17 8

B n Z ep18
N o N N 3,5s 45

F42 F43 14
12
M1 21 152
V1 V1 V1 16 V1 V1
N 17
24 7
90 223
B S7 1 27 31 47 46 49 2
29 20
G1 G N N 18 24 13 55 23 g

K16 26 25
N
184
P1 P r r jvt jvt
B K16 P N P
113 m vt r j B
P3 P2 N K17
224 ep2

27
28 22 P
1
265
S3 S4 S5 9 S23 258
5 14 15 4
K15 73
10 91
266 K17
NNNN 265
141
S30 G2 56 ep7
R5
R1 R1 R1 R1 10 11 22 225
256
140
91
72
r/n
205

Y9
69 J bc F jvt
jvt
A A

1 2 3 4 5 6 7 8 9 10 11

+ perm
+ apc

E E
G F8
151

36 41 42 F32
H
259
35 189
S30 S25

80
166

D
K11 K2 K14 139 268 269 ep4
R7 R6 K15 D
S2
H H 187 202
S24 241 242
215 212 K13 K18 R F j
S26 61
PCB
K4 K3 L R B4 B2

ep10 G G
177
186 234
B5 B1 A2
ep1
C 170 133 ep21 229 5 ep25
185 37
236
B3
39
C
213
174
230 ep23 ep26 ep29
134
132
183B 182B 123 122 239 247 207B 222B 206B
jvt
AC B7 B6 AC 210
171 173
172
O AC 203 60
AC 232 175 167 112
101
168 169
ep16 217
Y7 Y8 E20 E22 M7 Y2 Y3 H20 H21 Y6 K14 K13 226 260
183A 182A 207A 222A 206A S7 S41 40
X
ep20 ep27 240 ep28
230
134
ep24
34 265 H H H 233 231

B 44 124 125 237 261

132 ep26 266 B
ep22 ep12 ep7
240
146 227 ro n
ep2
38 2 205
ep28 Y10209 ep17
Y11228
258 261
ep7
205
K8 K2 K11 K3 K4 129

A A

12 13 14 15 16 17 18 19 20 21

(25/06/2009) 80-02-M153EN
 H8
Electrical schematic diagrams
MLT 742H T LSU Series 4-E3

J
j J
j
r
E F7 F10 P S13c o E
S11 m F29 F12 F13 F16 F14 F15 F17
AC
S22 G G P B J r D v 196 A
84
163 57 P P Q A 137 G L
m bc vt j g g n S21 160 159 211
D K7 M S16 o m n K0 D
128 75 g
S42 S9 G
UUUUUU
vt 4
ep15
F25 F26 Q G Q D D D D M M
G G P D
g n
218
A 179
153 165 190 191 154
204
r g J v bl n C C C AC
C 79 30 188 ep16 235 116 117 C 105 R C
264A
3 AC r RR L L
115
ep9 ep14
E21
I O Q L
K10 Y14 121 108 120 51 216 180
264B
E5 E6 K9 E E1 E2 E3
ep19 E4 H10
31
170 181 150 124 125
jvt ro 51 M6 164 149
248 125 111 250 124
B 230 ep12
Z ep12 ep2 ep12 B
134
ep2
112 O O S N G
132 258 101 2 V11 2 258 2 83

Z K0
K7 M5 jvt
jvt
jvt
A A

21 22 23 24 25 26 27 28 29 30 31

E P F30 E
F20 F19 F11 F18 F2 o F22
S13a S13b
A A B A A
135 162 86 88

S S S S P P P
80

SWF 521 008 SWF 521 054

158 + SWF 521 110 +
SWF 596 390 + bl j A bc B
D SWF 596 473 SWF 596 151
D
S28 5 6
S18 3 4 9
S15 156
5 9 9
201
V2 143 M
M 1 0
10
1 0
1 7 2 8 10 1 7 2 8 10 208
1
V2
77
S29
163 S V2
S39 F23 F24 F27 F28
Dégivrage
C vitre arrière 102
S C C C C C C C F C C F
C
89 114
178 127 126 219
bl j
ep3
119 136 1 144
M ep13
ep9
ep8

E25 E26 E17 E18 E16 E15 H20 H17 H16 H15a H15b
245 244 246 Q 107 249 118 50 52 109 130 255 256 145 53 110 bc
262 M11 180 141 72 220 70 Z
B Z O Z Z B
ep2
S S S S S S N E7 E27 H19 E8 O E9 E10 E11 E12 E23 E24 E13 111E14
258 140
V12 125 ep12 238 Q 111ep2 124 111 V13 124 ep12 125 V14
199 200 106 201 9 91 ep12 ep2 ep2
Z 2 83 258 2 54 258 Z 2 54 258 Z

A A

31 32 33 34 35 36 37 38 39 40

80-02-M153EN (25/06/2009)
 H9
Electrical schematic diagrams
MLT 742H T LSU Series 4-E3

E F3 F21 F5 F4 F6 F14 E
K AD
A B A AA
A B B
85 80 87 198 197
58
251
AB AB S 214 76
S10
G G
252
D

EG Latéral
D AA D

EG Toit
SWF 521 243 SWF 521 005
S8 +
SWF 596 307
+
SWF 596 628
AA
97 01 0 1 0 2 3 74 8 9 AC 257
ep5 K1 K6 + +
157 R
F 1 5 2 6 10
1 0
5 9 AC 32
G L
S20 -
1 10 S19 131 46 71 29 G G G 98 100

130
H14 A3 AA
H11 194 195 193 192 Tempo
C AB AB AB AB AB 20 C
AB AB AB AD 253 S40
N M 48 27
K K AD
59 99 94 95 78 96 103 104 E19
S 2
ep1 mot
K AD 254
R8
Allume
T TTT AA cigare
M8 2 Svit 1 M4 M10 2 30 25 26
147 148
AA
4 2
S 4 4 2 4 vit

S27
B
raz
+perm vit 1
2 M raz +perm raz +perm vit 1
raz +perm
2
1
LAT S6 B
T
M M TOIT M
3 - AV 3 -
AR
3 - 3 - 47 28 G G
M3 M2
1 1 1 1
S31 ep2 ep7

43 T S S 258 205 101

56 93 199 200
Y4 Y1 M9 K1 K6

80
A 18 19 A

40 41 42 43 44 45 46 47 48

(25/06/2009) 80-02-M153EN
 H10
Electrical schematic diagrams
MLT 742H T LSU Series 4-E3
80

80-02-M153EN (25/06/2009)
 I1
MT 1033H L Electrical schematic diagrams

– Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I2
– Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I7

80

(17/11/2008) 80-02-M153EN
 I2
Electrical schematic diagrams MT 1033H L

Components
Item Type Designation Position on diagram
E1 E Rear right hand indicator light B35
E2 E Front right-hand indicator light B35
E3 E Rear left-hand indicator light B36
E4 E Front left-hand indicator light B36
E5 E Left hand brake light B34
E6 E Right hand brake light B34
E7 E Rear right hand side light B44
E8 E Front right hand side light B44
E9 E Rear left hand side light B45
E10 E Front left hand side light B45
E11 E Front left hand dipped headlight B45
E12 E Front right hand dipped headlight B46
E13 E Front left-hand headlight B47
E14 E Front right-hand headlight B47
E15 E Rear right-hand working light (option) B42
E16 E Rear left-hand working light (option) B41
E17 E Front left-hand working light (option) B41
E18 E Front right-hand working light (option) B41
E19 E Rotating beacon light B13
E20 E Left-hand reverse light (option) B22
E21 E Roof light C37
E22 E Right-hand reverse light (option) B22
E23 E Rear left-hand fog light (option) B46
E24 E Rear right-hand fog light (option) B46
E25 E Head jib left work light B40
E26 E Head jib right work light B40
E27 E License Plate light (option)
F1 Fuse Tilt safety (7,5A) E49
80

F2 Fuse Rear work light (optional) (15A) E42

F3 Fuse Rear/roof screen wipers (7,5A) E10
F4 Fuse Solenoid engine stop valve (10A) E14
F5 Fuse Rotating beacon light (7,5A) E14
F6 Fuse Wheel alignment (5A) E16
F7 Fuse Overload safety (10A) E32
F8 Fuse Forward/reverse/neutral transmission (15A) E25
F9 Fuse Fault alarm/light (5A) E4
F10 Fuse Alarm/brake (15A) E33
F11 Fuse Boom work lights (15A max) E40
F12 Fuse Flashing lights (10A) E37
F13 Fuse Fan (30A) E38
F14 Fuse Free (25A Max) E17
F15 Fuse Free (25A Max) E17
F16 Fuse Air conditioning (option) (10A Max) E39
F17 Fuse Free (15A Max) E18
F18 Fuse Front work lights (optional) (15A) E41
F19 Fuse Rear screen defrosting (optional) (15A max) E40

80-02-M153EN (17/11/2008)
 I3
MT 1033H L Electrical schematic diagrams

Components
Item Type Designation Position on diagram
F20 Fuse Pneumatic seat (10A Max) E18
F21 Fuse Front windscreen wipers/washers (10A) E11
F22 Fuse Boom suspension (option) (15A Max) E19
F23 Fuse Right side light/instrument panel (7,5A) C43
F24 Fuse Left hand side light (7,5A) C45
F25 Fuse Right-hand indicator light (7,5A) C47
F26 Fuse Left-hand indicator light (7,5A) E37
F27 Fuse Codes (15A) C45
F28 Fuse Headlights (15A) C47
F29 Fuse Warning/ceiling light (15A) E37
F30 Fuse Stalk switch (25A) E45
F31 Fuse Starter (20A) D2
F40 Fuse Equipment (40A) C1
F41 Fuse Equipment (40A) C2
F42 Fuse Pre-heating (80A) C1
F43 Fuse Alternator (80A) C2
G1 G Battery C3
G2 G Alternator B5
H10 Indicator Warning lamp B37
H11 Indicator Front wheel alignment light C16
H14 Indicator Rear wheel alignment light C16
H15 Indicator Counter/rotations light B43
H16 Indicator Cooland temperature light B43
H17 Indicator Diesel gauge indicator light FUSES B42
H19 Indicator Fan light B44
H20 Indicator Slow speed indicator lamp (tortoise) B23
H21 Indicator High speed indicator lamp (hare) B23
H22 Indicator Clock light B42

80
K0 Relay Air conditioning relay (option) D39/B39
K1 Relay Free (option) D48/A48
K2 Relay Transmission cut-off relay D23/B26
K3 Relay Reverse gear relay C23/B26
K4 Relay Forward gear relay C23/B25
K5 Relay Machine fault alarm D5
K6 Relay Free (option) D48/A48
K7 Relay Movement cut-off relay/(option) B32/D33
K7a Relay Forced movement switch relay C32/D32
K8 Relay Starter safety relay C2/B25
K9 Relay Flashing/Warning unit C34
K10 Relay Overload safety module A31
K11 Relay Reversing lights relay and buzzer/motor direction D21/B26
K12 Relay K3 - K11 power supply D26/B26
K13 Relay Slow speed relay C23/B25
K14 Relay Fast speed relay D23/B24
K16 Relay Preheater relay B1/B2
K17 Relay Module relay lights B6

(17/11/2008) 80-02-M153EN
 I4
Electrical schematic diagrams MT 1033H L

Components
Item Type Designation Position on diagram
K18 Relay Transmission cut-off module D27
M1 M Starter C2
M2 M Front screenwiper B11
M3 M Windscreen washer B10
M4 M Roof wiper (option) B12
M5 M Alarm B33
M6 M Fan C38
M7 M Reverse gear alarm B22
M8 M Rear cab screen wiper B12
M9 M Diesel pump B15
M10 M Side windscreen wiper B13
M11 M Pneumatic seat compressor B18
P1 P Hour meter module B6
P2 P Module Fuel level B4
P3 P Engine coolant temperature module B4
R1 R Preheating plugs A1
R2 R Fuel sensor C4
R3 R Sensor and thermo-switch for engine coolant temperature C4
S1 S Key switch E3
S2 S Reverse/forward gear shift D25
S3 S Engine oil pressure switch B7
S4 S Brake fluid B7
S5 S Air filter clogging B8
S6 S Front wheel alignment detector B16
S7 S Hand brake switch B9/C27
S8 S Front windscreen wiper and windscreen-washer switch D11
S9 S Alarm control D33
S10 S Wheel alignment switch D16
80

S11 S Warning light switch D36

S12 S Transmission oil pressure
S13a S Sidelight stalk E43
S13b S Dip/main beam stalk E44
S13c S Indicator light stalk switch E35
S14 S Free
S15 S Front/rear working light switch (option) D42
S16 S Stop switch D34
S17 S Free
S18 S Working lights on boom switch (option) D41
S19 S Rotating beacon switch C14
S20 S Rear windscreen wiper/roof switch C13
S21 S Fan switch D38
S22 S Overload stress gauge E31
S23 S Clogging hydraulic filter B8
S24 S Tortoise/hare speed selector switch C24
S25 S Accelerator switch (put into neutral) D28

80-02-M153EN (17/11/2008)
 I5
MT 1033H L Electrical schematic diagrams

Components
Item Type Designation Position on diagram
S26 S Maximum speed limiter switch (snail) C21
S27 S Rear wheel alignment detector B16
S28 S Rear windscreen de-froster switch (option) D40
S29 S Front fog light switch (optional) C46
S30 S Steering pressure B5
S31 S Cold start switch B14
S32 S Boom angular position switch D48
S33 S Switch on brake pedal D24
S35 S Transmission cut-off relay D29
S36 S Switch on seat C28
S39 S Pneumatic seat switch C18
S42 S Movement cut-off override switch B32
S43 S Retracted telescope switch D31
S44 S Telescope retraction switch D32
S45 S Deflation/dump switch C32
S46 S Boom lowering switch C32
S47 S Attachment switch C32
V1 V Diode D6
V2 V Diode (only for TUV) C43
V3 V Diode (LED) battery charge lamp D6
V4 V Diode (LED) engine oil pressure lamp D7
V5 V engine coolant temperature LED D8
V6 V Diode (LED) air/oil clogging lamp D8
V7 V Diode (LED) transmission oil pressure lamp D9
V8 V Diode (LED) transmission oil temperature lamp D9
V9 V Diode (LED) brake fluid lamp D7
V10 V Diode (LED) brake lamp D10
V11 V Diode (LED) flashing/warning light lamp B34
V12 V Sidelight indicator LED B43

80
V13 V Diode (LED) dipped lights light B46
V14 V Diode (LED) headlights light B47
V15 V Diode (LED) steering fault light C5
Y1 Electrovalve Engine stop electrovalve B15
Y2 Electrovalve Forward gear solenoid valve B23
Y3 Electrovalve Reverse gear solenoid valve B23
Y4 Electrovalve Cold start solenoid valve B14
Y5 Electrovalve Movement safety solenoid valve B48
Y6 Electrovalve High speed solenoid valve B24
Y7 Electrovalve Maximum speed limiter solenoid valve (snail) B21
Y8 Electrovalve Hydraulic motor rotation direction solenoid valve B21
Y9 Electrovalve Movement cut-off electrovalve (option) C33
A Connector Fuse/relay panel (13 contact plug)
B Connector Fuse/relay panel (13 contact plug)
Change the Connector Fuse/relay panel (13 contact plug)
seals
D Connector Fuse/relay panel (6 contact plug)
E Connector Fuse/relay panel (8 contact plug)

(17/11/2008) 80-02-M153EN
 I6
Electrical schematic diagrams MT 1033H L

Components
Item Type Designation Position on diagram
F Connector Fuse/relay panel (8 contact plug)
G Connector Fuse/relay panel (21 contact plug)
H Connector Fuse/relay panel (5 contact plug)
I Connector Fuse/relay panel (7 contact plug)
J Connector Fuse/relay panel (8 contact plug + 2 contact plug)
K Connector K1 predisposition relay option
L Connector K0 predisposition relay option
M Connector Option provisions (8 contact plug + 1 contact plug)
N Connector Engine box
O Connector Rear plug provision option (8 contact plug)
P Connector Stalk switch
Q Connector Ventilation heating
R Connector Option air conditioning
S Connector Cab
T Connector Front screenwiper
U Connector Strain gauge
Z Connector 16 way plug (PCB Dashboard)
AA Connector Car radio
AB Connector Windscreen stalk switch connector (9 ways + 2 ways)
AC Connector Digicode connector
80

80-02-M153EN (17/11/2008)
 I7
Electrical schematic diagrams
MT 1033H L

J
S1 F9 Fus.Therm. 2A E Z
E E
J J J J
B B B E Z
30 30 17 17 50 19 19 54 15 58 I I I OP 254
118 118 119 119 119 119 Z K5
141 Z V3 V4 V9 V6 V5 V8 V7 V10
130 129 204 AD Z Z Z Z Z Z Z
D 12 21 12 21 F31 11 F E F E E F E E D
N N N N
8 6 11 3 N bl g o n vt v
23
V1 V1 V1 V1 V1 V1 V1 V1 m n
B
R3 R2 V15
F40 F41 K8 Z I B I I I I I
C n 24 7 N N N C
B N N V1 3,5s
75

F42 F43 22 12 M1 n M 26 95 24 13 28 AB
N 17
32 31
25 263 139 V1 V1 V1 V1 V1
29
20 G1 N AD AD B
K16 P3 121
P2 30
1 116
203 13 23
21 121 P 10 N P1 338 339
P P P P
B 27
K16 22
202
S30 G2 S7 B
28 5 14 15 4 S3 S4 S5 S23
N N N N AD 121 121
21 K17 K17 14
R1 R1 R1 R1 15 20 15 340 140 192 192
jvt
173

120
18
F jvt
J 19
A A

1 2 3 4 5 6 7 8 9 10

) + Perm
+ Apc

E E
F3 F21 F5 F4 F6 F14 F15 F17 F20 F22

A B A B B A B J AA
133 128 135 98 233

AB AB S M

80
122
S10 A A
D
A A 383 382
D
232 231 230 228
EG Lateral

362 229
SWF 521 243 SWF 521 005
EG Toitl

S8
+
SWF 596 307
+
SWF 596 628 AC AA
0 1 0 1 0 2 3 7 4 8 9 5 9 AA
AC ++
F 1 5 2 6 10 R
S20
1 0
27 M 365
M
1 10 S19 M - L
C D D D D AC M A2 AA C
82 84 36 34
AB AB AB AB AB
157
N M AA
AB AB H11
150 149 148 153 2
S39
385 384
99 152 147 152
S E19 S6 H14 S27
121

T M8 S M10 30 25 26
T T T M4
B 4
+perm vit
2
1 S 4
+perm
2
vit 1
4
+perm
2
vit 1
4 vit 2
+perm 2 1
105
J AA B
raz 2 raz
AR raz
TOIT raz
LAT
3
M
-
AV
3
M
-
3
M
- 3
M
- T 196
195
83 35
AC
M3 M2
1 1 1 1
S31 M
73
96
T S 367
146 289 Y4 Y1 M9 M11

A A

10 11 12 13 14 15 16 17 18 19 20

(17/11/2008) 80-02-M153EN
 I8
Electrical schematic diagrams
MT 1033H L

E F8 E

65 330
103
G 306 359 K18 AC AC
305
248
B4 B2 363 S35
B1
B5
D K11 K2 B3 D
S33 S2 PCB
H H B7 B6 S25
66 K14 108
223
R F K12
333 256 216 271
S26 S24 PCB
57
S7 S36
C K4 K3 K13 L R
260
AC 345
C
361
O AC 257 255
245
194
183 182 G G 224 253 307 360 252

123
251
H H H 344 343
378 197 249 191
B 198 74 85
E20 E22 56 5 247 250
G B
M7
Y7 264 Y8 184 185 159 Y2 54 Y3 H20 H21 Y6 K2
262 261 198
55 K14
192
K13
192
K4 K8 K3 192
K12 192
K11

A A

20 21 22 23 24 25 26 27 28 29 30

J J
) + Perm
+ Apc

E F7 F10 P F29 F12 F13 F16 E

S13c
m o j r v
S22 G P B D
235 vt 132
r 97 P P A 201 G
r S11 Q
S43
80

D M S16 o m g n S21 K0 D
D
K7a K7 S9 n 366
S44 vt AC Q G G Q
m bc vt j g
127
G g
P A 155
S45 o v F25 F26 225 239 226

158
C v g R R R C
n
S46 K7a Y9 S M6
176 E21
C C C C Q
UUUUUU o 154 Q
S47 j/v I K9 175 3

n 4 177 E 181 163 180 87

r 238

O jvt ro O O
B r g j v bl n G j/v j/v
220
G B
o E6 Z
37
r
I 0 II 1 7 2 8 10 E5 O V11 E1 E2 O E3 E4 S N 131
184 184 90
K7 S42 M5 185 185 166 H10 348 9 K0
K10 41
3 6 9
2 Z 2
jvt

A A

30 31 32 33 34 35 36 37 38 39 40

80-02-M153EN (17/11/2008)
 I9
Electrical schematic diagrams
MT 1033H L

) + Perm
+ Apc

E P E
F19 F11 F18 F2 o F1
S13a S13b F30 J K
A B A A
287 286
A
199 234 134 136

S S S S P P P
SWF 521 008 SWF 521 054
+ SWF 521 110
D + + bl j 259
D
9
SWF 596 390
SWF 596 473 SWF 596 151 A G G
5
S28 5 6 9 S18 3 4 9 S15 205 bc
1 0
1 0 1 7 201 1 7 10 V2 K6 K1 S32
1 10 2 8 10 2 8
313
122
S29
S V2 G
V2 F23 F24 F27 F28 G G G
C C
283 284 281 282
387 S C C C C C C C F C C F
138 bl 174 162 1 86 88 164 195 206 207 89 165 K
156 187 186 336 179 200 J J K
Q 178 J K
Dégivrage O O
vitre arrière j bc
E26 E25 E17 E18 E16 E15 H22 H17 H16 H16B H15 F E7 H19 E8 E9 E10 E11 E12 E23 E24 E13 E14 217 218 258
B Q B
203 121
Z Z Z
S
121 121
V12 185 131 166 184 90 166
V13 184 185 90 166
V14 G G
202
386 AD O O Y5
S S S S S S 140
Z 2
Z 2
Z K6 K1
265

80
A A

39 40 41 42 43 44 45 46 47 48 49

(17/11/2008) 80-02-M153EN
 I10
Electrical schematic diagrams
MT 1033H L
80

80-02-M153EN (17/11/2008)
 ELECTRICAL COMPONENTS LOCATION

pages

120 LSU wiring layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3

– 120 PS engine wiring harness key. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2
– 120 PS engine wiring layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3
– ECM components harness key (120 LSU) . . . . . . . . . . . . . . . . . . . . . . . . . . . A4
– ECM wiring harness components diagram (120 LSU) . . . . . . . . . . . . . . . . . . . A4

LOCATIONS: 2D AND 3D VIEW

– MT 1030 ST Series 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1
– Series 4 and series D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C1
– Series 5 et series E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D1

80

(11/05/2011) 80-03-M153EN
 A2
Electrical components location

120 LSU engine wiring harness key

Components
Item Type Designation
X1 Connector Main harness connections
X2 Connector Accelerator (MCS module)
X3 Connector Resistance
X4 Connector ECM Engine
X5 Connector Fuel gauge
X6 Connector Air filter clogging
X7 Connector Preheat
X8 Connector Weight
X9 Connector Water in diesel indicator
X10 Connector ECM fuse
X11 Connector Preheating relay
X12 Connector Grey power fuse (80A)
X13 Connector Blue Power fuse (40A)
X14 Connector Clock earth
X15 Connector CAN
B+ Connector Alternator
D+ Connector Alternator
M Connector Starter
80

80-03-M153EN (11/05/2011)
 A3
Electrical components location

120 LSU wiring layout

180°

X4
X5
X3

X6

X2 (MCS)

B+ D+
X7
X15 (CAN)
X1
M

X8 80

X10
X11
X12 (80A) X14 X9
X13 (40A)

(11/05/2011) 80-03-M153EN
 A4
Electrical components location

ECM components harness key (120 LSU)

Components
Item Type Designation Assembly
B7 B Air intake pressure sensor i.c. engine
B8 B Fuel pressure sensor i.c. engine
B9 B Primary speed sensor i.c. engine
B10 B Secondary speed sensor i.c. engine
B11 B Oil pressure sensor i.c. engine
S24 S Air intake temperature sensor i.c. engine
S32 S Coolant liquid temperature sensor i.c. engine
Y16 Electrovalve Electronic injector 1 i.c. engine
Y17 Electrovalve Electronic injector 2 i.c. engine
Y18 Electrovalve Electronic injector 3 i.c. engine
Y19 Electrovalve Electronic injector 4 i.c. engine
Y20 Electrovalve Solenoid of the injection pump i.c. engine
Y21 Electrovalve Discharge electronic valve i.c. engine
W Connector ECM connector diagnostic connector i.c. engine

ECM wiring harness components diagram (120 LSU)

Y21

Y16 Y17 Y18 Y19

Y20

B10
80

B9

B7

B8
J2
B11

S24

Connecteur W S32

80-03-M153EN (11/05/2011)
 B1
Electrical components location

COMPONENT LOCATIONS 2D AND 3D VIEWS

Pages

– MT 1030 ST Series 4
2D locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2
3D locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4

80

(23/05/2011) 80-03-M153EN
 B2
Electrical components location

WIRING DIAGRAM KEY

MT 1030 ST S.4--E.3
Item Designation Item Designation
1 Relay and fuse holder plate 36 Strain gauge
10 Complete left front headlight 37 Complete right rear light
11 Complete left front headlight 38 Diode
12 Complete right front headlight 39 Harness
13 Complete right front headlight 40 Hand brake switch
14 Alarm 41 Complete left rear light
15 Hazard warning light switch 42 De-mister switch
16 Rotating beacon switch 43 Indicator lamp
17 Rear work lamp switch 44 Main harness
18 Rear work lamp switch 45 M8 C05 ZN.C nut
19 Fog light switch 46 M8 ZN nut
20 Wheel alignment switch 47 Clogged oil filter indicator
21 Transmission cut-off switch 48 Transmission oil pressure switch
22 Roof screenwiper switch 49 Oil temperature sensor
23 Clock 50 Electrical control valve
24 Key switch 51 Relay
25 Switch 52 Safety switch
26 Fuel gauge 53 Buzzer
27 Water temperature indicator 54 Safety valve block
28 Hour meter 55 Safety valve block
29 Brake fluid tank 56 Transmission cut-off module
30 Stop switch 58 Shunt
31 Transmission cut-off switch 59 Windscreen wiper motor
32 Windscreen washer reservoir 60 Sensor
33 Safety panel 61 Sensor
34 Boom pre-wiring switch 62 Windscreen wiper switch
35 Forced operation switch
80

80-03-M153EN (23/05/2011)
 B3
Electrical components location
ELECTRIC CIRCUIT

MT 1030 ST S.4-E3

nC
48 jvt32
jvtM
oB
jvt
blC
jvtM
4 5
6

bcC 3 2 1

jC
29
jvtM roG 2

jvt50
32 31 bl/nB 1
4
5 3
51 23
BP 203 50 49 7 1
blB
jvtM jvtL
blP

-
41 Ep 1
mI viG r41

+
rA
mP - +
rK
nV vtB r26
roV
oK
r/nI
ro62
g58
m40
4 8
jvt29 o21 mT 30 bl/s27

56
vtP 3 n62 mJ r23
jvtM
rP
oV
A gG
jH
nN
2
1 5
jvt27
jvt26

9
rB

+
gV

12
o41

6
oP
26 10

3
o53 jvt26

-
g58
bl/s27
(U.K)11
jP mL

S
vt23
jvt50 jvt47 13
r19 6 r/nL
oK jvt54 jvt56 jvt28 jvt37 jvt40 jvt29 jvt12 jvt19 jvtR jvtL jvt21 jvtQ jvtP jvtL jvtP
bl27

8
4 3 jvt61 jvtL jvt51 jvt50 jvt53 jvtK jvt10 jvt59 jvtO jvtS jvtJ jvtP jvtP jvt60 jvtL g58
bl blB
5 1 2
7 1 r/nV

8
jvtM

7
6 7
oEp1 r20 jvtM

5
11 CA 93 1 28

10
ro62 oK1 jvt27

00000000
r30 jvtK blK

RPM x 100
blV

15
rK1
nK r/n19 oEp1
53 45 bl

6
vtV

5
bck1
M

20
10 21

30
F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 28 F29

F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12

25
7.5A
viS

K7
nk1

46
A

5
viL vtk0
40 B
7.5A
bl/n51 7.5A
jS
mk0

K5
K8
7.5A rB
mR

+
r26 10A 5A
bl/sC
10A rR
27
B
vt30 7.5A 15A

-
gG

-
j39

13 7.5A 5A
r27

K9
jvt28

K2 K3 K4
rok0

K6
m39

7.5A 15A

+
14 bl28 roL

S
mP 7.5A g58

52

K0 K1
C 15A 10A jvt26
o29
47
oV

F13 F14 F15

G
15A 30A
bl28 13 6 15A r21 bl/s28
39 E G

F30
4 1
blL 25A viA

1
bl/s26
60 bl51 jK6
3

21
8
D F

7
59

1
7 1 H I ro50 jvt27
j52 jvtM m56

5
n33

1
8
6
m52 n/sI rN blK jvtM 1
bl10 nK 4
gI
D r33 jS bl62

6
gK

1
1 2 3 jS
I
jvt50 jV 2
rO g12 n62
g58 rR blk6 jL 5
r40 j12
N
7 jL
rH j10 vik6 bl62 6 3
n56 n10
bc10
C H vtL r/n49 gL g47
vt14 n/s40 m48 nL
1 rK6

vt50 jL
bc
bc62

nK 1 5
n jL
bl55 m20 n43 bc12
rS
g58 jvtM bl/bcK j56 g58 roO nO rN
oL
bl/bc12
rS
bl/s28
viS viG jG nG oG nA roA vtB jG oA

44 rS
rS
24
blG

2
rG bcG rG

2
gA g58 oG blB r/n28

1 1 1 2 3
3 4 3 4
4 5 6

V
7 8 9

K6 K1

80
g58 j24 viB j24 ro27 nI j24 gI vtI jvt23 10 DA 330
g58
6 BB 184 16
34
rN roH jvtM jvtM
blB jvtM jvtM m26 j24 r/n28 o24 jvtM jvtM g58 nH m21 m31
r/n41
m31 r24 j24 j28 r24
vi24 r/n37

19

9
61

1
viB r24 j24 jvtM r24 rA

2
10
9

1
1 r

2
10
19 8 9 1
jvtM

9
17
18 7 2

1
10

35

2
1
jvt20
14

10
17 6 1 3 11
16 5 4
15 14
12

O J T
25
13

1
6 2

7 3
5 1

8 4

2
10
mG jvtM

2
S

10
rG rD bl/bcK

1
oK r/n19 gK

2
10
bl/bcK jvtM rK

43 18
8
5

E
n/s61
2

3
1

F
7 6

1
m20 n/s43
R jvt20 m61

2
B A

10
2 1 5 D A vtI
20
3 4
jvt m60 jvtM
vt/nY r/nY rA jvtM jvtM oA mA j62 vtQ vtP jvtM C B r
C rB
11 AA 1279
42
vtY viY jA m62 jvtM vtA bl10 mB vt62 o
37
n60

9
vi

1
jvt43

2
10
Q jvt19
12

9
1 2

11 AA 1279

1
8

2
10
1 2
1 9
o31

15 (U.K)13
3 4

10 17 viX vtX
rG

mJ
r 21 22
X P gG

9
r/nX

9
9
vt/nX

1
7

1
jvtM

2
8

10

10
10
gV jvt33
1

gD Y OPTION
8

12 1 1 12

36 gM
g39
11 2
10 3
2 11
blC n41 gC bl/bcR o37 jvt41 o50 r37
bl41 nC g37 bl/bcC oEp1 nG r30 jvtM o jvtM
2
OPCION
58
3 10

33
bl/bc37 jvt55 3
bl59 mP roB bl59 n59 g56 9 4 4 9 bl55
1 OPZIONALE
bc59 roA vtP n32 jP gA
gO
8
7
5
6
5
6
8
7
1

7
2

8
3

9
o
38 3 4
54
2 5
jvt54
TEST

1 2 3
gH 1 6 rG 2
4 5 6 o C bl54 3
gC
A nG 1
gL bl39
K
B

62
8 9
7
jvt21 bl/bcC
gT
10 AG 222 55 jvtM

6
5
3

1
2
bcC
jC
(10/09/2010) 80-03-M153EN
 B4
Electrical components location
ELECTRICITY (ENGINE - TRANSMISSION)

MT 1030 ST S.4-E3

6 8

3
80

KEY: WIRING DIAGRAM (ENGINE - TRANSMISSION)

MT 1030 ST S.4-E.3
Item Designation
1 Glow plug
2 Engine oil pressure switch
4 3 Electrovalve
5 4 Water temperature sensor
5 Water temperature sensor
6 Oil temperature sensor
7 O-ring
8 Transmission oil pressure switch
9 Solenoid valve (Delphi)
80-03-M153EN (10/09/2010)
 C1
Electrical components location

COMPONENT LOCATIONS 2D AND 3D VIEWS

Pages

– Series 4 et Series D (120 CV)

Location 2D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C2
Location 3D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C10

80

(10/09/2010) 80-03-M153EN
 C2
Electrical components location

WIRING DIAGRAM KEY

MLT 630/731 T S.D-E.3 - MLT 742 T S.4-E.3
Item Designation Item Designation
1 Relay and fuse holder plate 36 Strain gauge
10 Complete left front headlight 37 Complete right rear light
11 Complete left front headlight 40 Hand brake switch
12 Complete right front headlight 41 Complete left rear light
13 Complete right front headlight 42 De-mister switch
14 Alarm 43 Indicator lamp
15 Hazard warning light switch 44 Main harness
16 Rotating beacon switch 45 M8 C05 ZN.C nut
17 Rear work lamp switch 46 M8 ZN nut
18 Rear work lamp switch 47 Clogged oil filter indicator
19 Fog light switch 48 Transmission oil pressure switch
20 Wheel alignment switch 49 Oil temperature sensor
21 Transmission cut-off switch 50 Electrical control valve
22 Roof screenwiper switch 51 Relay
23 Clock 52 Relay
24 Key switch 53 Electrical socket
25 Switch 54 Forward/reverse lever
26 Fuel gauge 55 Cigarette lighter
27 Water temperature indicator 56 Transmission cut-off module
28 Hour meter 57 Switch
29 Brake fluid tank 58 Shunt
30 Stop switch 59 Windscreen wiper motor
31 Transmission cut-off switch 60 Wheel alignment switch
32 Windscreen washer reservoir 61 Sensor
33 Safety panel 62 Windscreen wiper switch
34 Boom pre-wiring switch 63 Switch
35 Forced operation switch 64 Diode
80

80-03-M153EN (10/09/2010)
 C3
Electrical components location
ELECTRIC CIRCUIT

MLT 630 Turbo S.D-E3

MLT 731 Turbo S.D-E3
MLT 742 Turbo S.4-E3
(U.K)11
vtX39
48 n32
nM vtX39 4 5 6

31
vtX40 nM
gEp22
n
vtX39 3 2 1

10

Ep 22 - 21
vtX39
29
2
gEp21

BP 203 50 2 1 32 vtX40 1
4
5 3
51 23
49 7 1
54
vtEp18
nM nX24
vtX26

-
vtX38 jX44 vt40 vtEp15
X75

+
vtX1 4 8 vtX41
jX26
jX4
jX4
vt58
vtEp1
nM
vt57
3

2
1 5
56 - +

vtX40 vt26

vtX38
j62
jX26
5 4

Ep1 n 29 vt21 vtX2

vt62 vtX1
30 vt27
vt23

53 jX26
jX4
A vtEp4 vtX42 n27
n26

9
X41
vtEp1 vtX42 vtX40

+
jX4

12
Ep 19 - 20

6
vtX26
26

3
n26

-
1 2 vt58
vtX26 vt27
vtX24

S
gEp19 vt23 nEp7 n12 nX25 nX26 n55 n21 n59 nX26 n51 n56 nX24 nX24

X20 gEp20 vt19 13 6

nEp12 nEp2 n10 nX26 n52 nX30 n58 n19 nX24 n29 n28 nX24

64 vtX4

41 X18

8
8 1 VtEp18 vtEp18
7 1 vtEp10 vtX24

8
7 2

7
vt20
11 CA 92 1 nM n

5
45 28
6 3
vt

10
4 3 1 2
j62 n27

00000000
1

M
5 1 2 5 4 2

RPM x 100
vtX4

15
6 7
10 21
vtX6
vt n

6
jX4
46

F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 28 F29

5
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12
7.5A
vtX6

K7

20
vtEp10

30
vtEp15

vtEp13
vtEp14
vtEp13
vtEp10
nEp12

vtEp11

25
nEp12

nEp12

bcX47
vtEp9

A
vtEp8

vtX6
Ep 18
vtEp15

vtEp10
vtEp14

nEp12

7.5A
vtEp9
vtEp8

5
bcX24 7.5A

K5
vtX45

K8
vt51 7.5A
vtX30
10A 5A
vtX40
vtX6

+
X40
vt26 B 10A
vtX39

X44
7.5A 15A vt58
vt30 7.5A 5A
27

-
vtX31

K9
G

K2 K3 K4
K6
7.5A 15A

47 40 vt27 7.5A vtx4 n28

K0 K1
vtX24

S
jX26 C 15A 10A
jX41

F13 F14 F15

15A 30A
vt29 vt26
15A vt21
13 6 E G

F30
25A vt28

60

1
X23 vtX7

21
n26

8
D F

7
vtEp22

1
H I
vt33 n27
59

5
7 1

1
8
6
vtEp9 vtEp20 nM 1
vtX38 vt33 4
vt10
D 3

6
4 1

1
nEp7 bcX45
1 2

vtX4
3 vtEp11
vt12 vt58 j55 jX30 7
I jX4
vtX7 bcX45
j62
vt62 2
bcX24
X11 nEp2 vt56 vt12
H
vtX7 5
gEp7
gEp6

nEp2 vtX38 vt57 vtX24 vt49 vtX24 vt47 1 vtX7 bcX24 j62
vt10 6 3

vtEp4
vt10
vt10
C 1 5 X37 vt14 vt40 vt48 vtX24
j
j62
X39

bcX24
vt40 vtEp14
vtEp5 vt43
nEp7
Ep 7 - 6 57 vt56
vt12
VtEp3
vt58 vt54 vt54 vtEp4
X38 vtX44
X43 bcX24
bcX45
vtX24
vt12
vt28 X42 bcX45
bcX47 vtX44 vtX44 vtX44 vtX44 jX41 jX41 jX41 jX40 vt63 jX41 vt52

Ep 15-14-13-12-11-10- 9- 8 Ep 5 Ep 4 Ep 3 44 bcX45
bcX45
24
VtX44 vtX44 vtX44 vtX44 vtX11 vt58 vtX44vtX40 jX44 vt28

Ep 2 1 2 1 2
1 2 3

34
3 4 3 4
4 5 6

X4
7 8 9

X7 X6

80
8

2
10
vt58 bc24 bcX40bc24 vt27 vtX38 bc24 vtX38 vtX38 n23 vt21 vt56
35
nM
n20 16
vtEp18 nM nM vt26 bc24 vt28 vt24 nM nM vt31 vt31
bc24 vtX4 bc24 bc24 vt28 n52 bc24 vtX41
j 19 61

1
vtX45 bcX40 nX45 bc24 vtX48 bc24 nM bc24

2
10
9

1
1 2 1 2

9
10

1
8

2
vtEp8
14

10
19 8 9

17
18 7 2
6 1
10
3 11
X1 X2
vt
vt61 43 17
16 5 4 12 n20
n 25

9
vtEp15
vtEp13
vtEp10

vtEp11

15 14

1
nEp12
vtEp8

6 2

7 3
5 1

8 4
13

2
10
vt

1
8

2
10
vt60

X48 X47 52 X45 18

X24
7 6
2 1 5 vtEp5 vt43
vtEp5 vtX38

9
3 4
nEp2

1
20

2
10
8
5

j
6

vtX40
2

3
1

37

9
42

1
n43

2
10
vtX53 vtX53 jX41 nM nM vtX41 jX41 vt62 jX25 nM
vtX27 vtX27 11 AA 1265 n19
vtX53 vtX53 vtX41 j62 nM jX41 vtX75 jX40 j62 jX26
11 AA 1265

1
VtX27 vtX27
15

2
10
vtX4 vtX44 nM
vt31
1

n55 vtEp6 vtX44 jX37 vtEp3

1 2
1 9
vtX44
vt 21 22

9
1 2

1
8

2
10
vtX2
X53
3 4
10 9

9
X25

1
j

9
vtX4 nM

1
8

2
10
10 17

2
10
8 7
E
6 5
F
vtX37 n33

X27 X26 4

2
3

1
B

C
A
D

C
A

B
vt55 jX37 n63
vt55 nM nM
vtX44
12 1
11 2
1 12
2 11 OPTION
10 3

58
3 10
j59 jX26 jX40 j59 vt59 vt
vt
vtX41 9 4 4 9
33 OPCION
OPZIONALE
_

j59 jX41 jX26 vt32 vtX26

+

vtEp1 8 5 5 8

36 X31 X30 vtX42

7 6 6 7
3 4

63 55 2 5

TEST
1 2 3
vtX24 1 6 vtX44
4 5 6
A C
vtX44 vtX39
vt56 B

62 12
9
7 8
n21 vtX39
nM

6
5
3

1
2
(U.K)13
vtX39
vtX39

(10/09/2010) 80-03-M153EN
 C4
Electrical components location

WIRING DIAGRAM KEY

MLT Turbo LSU
Item Designation Item Designation
1 Relay and fuse holder plate 36 Strain gauge
10 Complete left front headlight 37 Complete right rear light
11 Complete left front headlight 40 Hand brake switch
12 Complete right front headlight 41 Complete left rear light
13 Complete right front headlight 42 De-mister switch
14 Alarm 43 Indicator lamp
15 Hazard warning light switch 44 Main harness
16 Rotating beacon switch 45 M8 C05 ZN.C nut
17 Rear work lamp switch 46 M8 ZN nut
18 Rear work lamp switch 47 Clogged oil filter indicator
19 Fog light switch 48 Transmission oil pressure switch
20 Wheel alignment switch 49 Oil temperature sensor
21 Transmission cut-off switch 50 Electrical control valve
22 Roof screenwiper switch 51 Relay
23 Clock 52 Relay
24 Key switch 53 Electrical socket
25 Switch 55 Cigarette lighter
26 Fuel gauge 56 Transmission cut-off module
27 Water temperature indicator 57 Switch
28 Hour meter 58 Shunt
29 Brake fluid tank 59 Windscreen wiper motor
30 Stop switch 60 Wheel alignment switch
31 Transmission cut-off switch 61 Sensor
32 Windscreen washer reservoir 62 Windscreen wiper switch
33 Safety panel 63 Switch
34 Boom pre-wiring switch 64 Diode
35 Forced operation switch
80

80-03-M153EN (10/09/2010)
 C5
Electrical components location
ELECTRIC CIRCUIT

MLT Turbo LSU

(U.K)11
vtX39
48 n32
nM vtX39 4 5 6

31
vtX40 n nM
vtX39 3 2 1

10

Ep 22 - 21
gEp22
23
2

gEp21

32 29 vtX40
4
1
5 3
51 vtX39

BP 203 50 2 1

49
vtEp18 nX24

-
nM vtX26
7 1

+
vtX41
vtX38 jX44
jX26
jX4
vtX1
vt58
vt40
nM
4
3

2
8

56 - +
vtEp15

vtX40
vt26 X75
vt57
jX4 vtEp1 1 5
vt27

vtX38
j62
jX26 Ep1 n 29 vt21 vt21
vt62 vtX1
30 n27
vt23
n26

53 jX26 A

9
vtX40

+
jX4

12
6
X41
jX4

Ep 19 - 20
26

3
n26

-
vtX26
vt58 vt27
1 2
vtX24

S
vtX26
gEp19 vt23 nEp17 nEp7 n12 nX25 nX26 n55 n21 n59 nX26 n51 n56 nX24 nX24 vtX4
X20 gEp20 vt19 13 6
nEp12 nEp2 n10 nX26 nX45 nX30 n58 n19 nX24 n29 n28 nX24

64

8
vtEp18
41 X18 vtX24

8
8 1

7
VtEp18 vtEp10 n
1
nM

7
11 CA 92

5
7 2

28

10
7 1 n27

00000000
45
6 3
vt

RPM x 100
4 3 1 2
vt20

15
M
5 1 2 5 4 1 2
vt n

6
j62

5
vtX6

F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 28 F29
6 7

F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12

7.5A

20
10

K7
21

30

25
vtX4 A
46 vtX6
vtEp10

vtEp15

vtEp14
vtEp13

vtEp13
vtEp10

vtEp11

5
nEp12

7.5A
nEp12

nEp12

jX4
vtEp9

vtEp8

vtX6
Ep 18
vtEp15

vtEp10
vtEp14

nEp12

7.5A vtX45
vtEp9
vtEp8

K5
bcX47

K8
7.5A
bcX24 10A 5A
vtX30 vtX40

+
vt51
B B 10A vtX39

27
vtX6

X40
7.5A 15A

X44

-
7.5A 5A vt58
vt26

K9

K2 K3 K4
K6
7.5A 15A
vtX31 n28

40
7.5A
G vtX24

S
vt30

K0 K1
C 15A 10A vtx4

47 vt27 vt26

F13 F14 F15

15A 30A
15A
jX41
jX26 G vt21
E vt28

F30
25A
vt29
59

1
n26

60
13 6

21
8
X23
D F vtX7

7
1

1
H n27
I vtEp22

1
8
6
7 1 vt33
vtEp9 vtEp20 nM 1
vtX38 vt33 4
vt10
D 3

6
4 1

1
nEp7 bcX45
1 2

vtX4
3 vtEp11
vt12 vt58 j55 jX30 7
I jX4
vtX7 bcX45
j62
vt62 2
bcX24
X11 nEp2 vt56 vt12
H
vtX7 5
gEp7
gEp6

nEp2 vtX38 vt57 vtX24 vt49 vtX24 vt47 1 vtX7 bcX24 j62
vt10 6 3

vtEp4
vt10
vt10
C 1 5 X37 vt14 vt40 vt48 vtX24
j
j62
X39

bcX24
vt40 vtEp14
vtEp5 vt43
nEp7
Ep 7 - 6 57 vt56
vt12
VtEp3
vt58 vtX36 vtX36vtEp4
X38 vtX44
X43 bcX24
bcX45
vtX24
vt12
vt28 X42 bcX45
bcX47 vtX44 vtX44 vtX44 vtX44 jX41 jX41 jX41 jX40 vt63 jX41

Ep 15-14-13-12-11-10- 9- 8 Ep 5 Ep 4 Ep 3 44 bcX45
bcX45
24
VtX44 vtX44 vtX44 vtX44 vtX11 vt58 vtX44vtX40 jX44 vt28

Ep 2 1 2 1 2
1 2 3

34
3 4 3 4
4 5 6

X4
7 8 9

X7 X6

80
8

2
10
vt58 bc24 bcX40bc24 vt27 vtX38 bc24 vtX38 vtX38 n23
35
nM
n20 16
vtEp18 nM nM vt26 bc24 vt28 vt24 nM nM vtX35
vtX29 vt52
vtEp16
X36 vtX41
j 19 61

1
vt56

2
10
bc24 vtX2 bc24 bc24 vt28 n52 bc24

9
vt31 n63

1
8

9
10
vtX45 bcX40 nX45 bc24 vtX48 bc24 nM bc24

1
vtX42

2
vtEp8
14

10
19 8 9 4 5 6

17
18 7 2
6 1
10
3 11 X3 X2 X1 vtEp4
vtX42 3 2 1
vt vt61 43 17
16 5 4 12 vtEp1 n20
n 25

9
vtEp15
vtEp13
vtEp10

vtEp11

15 14

1
nEp12
vtEp8

13

2
10
9

1
6 2

7 3
5 1

8 4

2
10
vtX28 vt vt60
vtX29
X48
X47
4

18
3

vtX28
52 X45
2

X24
7 6
br vtX3
2 1 5
bl vtEp5
vtEp5 vt43
vtX38

9
3 4
nEp2

1
20

2
10
X35 vtX40
j

8
5

37
6

7 vtX27 vtX27
2

3
1

9
42

1
n43

2
10
vtX53 vtX53 jX41 nM nM vtX41 jX41 vt62 jX25 nM VtX27 vtX27 n19
vtX53 vtX53 vtX41 j62 nM jX41 vtX75 jX40 j62 jX26

1
X53

9
Ep 17-16

1
8

2
11 AA 1265

10
vt31

8
vtX36 vtX4 vtX44 nM
1

3
2

4
1 9 1 2
X25 n55 vtEp6 vtX44 jX37 vtEp3

15
vtX44

vt31
vt 21 22

9
nM

1
11 AA 1265

2
10 9

10
10 17

9
j

2
7

10
vtX4

2
n33

10
X27 X26
8 7
E
vtEp16 6

4
5

3
F
vtX37
vt55 jX37 n63 12 1

X28 nEp17 B A
1 12
OPTION
2 1
1

D
2

A
vt55 nM nM
vtX35 11 2 2 11
3
4

C B

36 j59 jX26 jX40 j59 vt59

j59 jX41 jX26 vt32 vtX26
vtX35
vt
vt
C vtX44
vtX41
10 3
9 4
3 10
4 9 58 33 OPCION
OPZIONALE
_
+
X31
X30

vtEp1 8 5 5 8
vtEp16
3 4

7 6

X29 nEp17 vtX42 6 7 2 5

55

TEST
1

63
1 2 3
vtX3 1 6 vtX44
3
4

4 5 6 vtX24 A C
vtX44 vtX39
vtX35 B
7 8 9

62 vt56 n21 vtX39

nM 12

6
5
3

1
2
(U.K)13
vtX39
vtX39

(10/09/2010) 80-03-M153EN
 C6
Electrical components location

WIRING DIAGRAM KEY

MLT 634 120 LSU S.D-E.3 - MLT 735/741 120 LSU S.4-E.3
Item Designation Item Designation
1 Complete left front headlight 28 Switch
2 Complete left front headlight 29 Windscreen wiper switch
3 Indicator light panel 30 Electronic box
4 Alarm 31 Fuse carrier
5 Complete right front headlight 32 Module
6 Complete right front headlight 33 Complete pump
7 Wheel alignment switch 34 Cigarette lighter
8 Oil temperature sensor 35 Complete electrovalve
9 Transmission oil pressure switch 36 Strain gauge
10 Electrical control valve 37 Clogged oil filter indicator
11 Hand brake switch 38 Wheel alignment switch
12 Shunt 39 Electrical socket
13 Transmission cut-off module 40 Complete left rear light
14 Safety panel 41 Complete right rear light
15 Diode 42 Clock
16 Indicator lamp 43 Fuel gauge
17 Stop switch 44 Hour meter
18 Brake fluid tank 45 Water temperature indicator
19 Windscreen washer reservoir 46 Windscreen wiper motor
20 Transmission cut-off switch 47 Harness
21 Relay 48 Main harness
22 Fog light switch 49 M8 ZN nut
23 Wheel alignment switch 50 M8 C05 ZN.C nut
24 Diode 51 M8 ZN nut
25 Key switch 52 M8 ZN nut
26 Harness 53 Complete seat
27 Relay and fuse holder plate 54 Transmission cut-off switch
80

80-03-M153EN (10/09/2010)
 C7
Electrical components location
ELECTRIC CIRCUIT

MLT 634 120 LSU S.D-E3

MLT 735 120 LSU S.4-E3
MLT 741 120 LSU S.4-E3

(U.K)2
nM
3 2

39 27 X42 bc25
1
vtEp18
20
4 7 1
vtEp9
7 1

vtEp4 vtX36
bc25
vtX48 vtEp8
21 3 5 4
2
vtX40
1
22
5 1

F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 28 F29
vt1 bl

F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12

7.5A
vt12 vtX41

K7
vtX36 j n

X39
5 6
vtEp11 A 15A
6 2 bc25 _ m

X45
15A 7.5A
5 1
vt5 7.5A bc25 nM

9
K5

1
7 3
n23

K8
7.5A +

2
vt5

10
n ro r 10A 5A vt44
vt1
g bl bl/bc n
19
10A 8 4
B nM
vt1 7.5A 15A

vt1
7.5A 5A nX46

K9

K2 K3 K4
K6
7.5A 15A
bc25 vt29 vt54 vt54
vtEp14 7.5A
bc25 n18 vtX1

K0 K1
23
15A 10A
vt5 C vtEp5
47 38 j

F13 F14 F15

15A 30A
vtEp3
vt5
15A 15A
E G
vtX48 vtX40

18
vtX40
X75

F30
25A
vtX47
16

1
1

1
vt44 vtX2 n16 vt7 n19

2
10
85 87D 81
vtX26
37 X46

21
8
13 6 D F n22 n16 nM

7
1

87
86
H I
nX45

5
7 1

1
n16

8
6
1 8 vtX39
vt23 vt20 vtEp15
2 7
j29
X43 bcX40 vtX44
54
n23
17 vtX39 4 5

X40
3 vt vt38 nM
6

X38

6
1
3 6
vtX4 vtX46 vtX40
40 4 5
jX4 vt12 j34 jX30
X47 bc25 vt20 vtX39
vtX39
3 2 1

1
7 nM

2
bcX47

10
4 3 vtX44 n14
X37

vtX10A
bcX10A

vt32

vt11

vt37
vt24
X20
5 1 2

42

vt8
vt9
vt4
6 7 vt21 vtX46

X18 8 1
vtEp18
X48 vtX45 3 4
X62
vtX38
nEp7

vt43 nX10A
vtEp10

vtEp15
vtEp14

nEp12

-
vtEp8

vtX10A
vtEp9

7 2 2 5
vt17 vt
vtX41

+
1 6
6 3
vt45 vtX10A

1
1 2

TEST
vtX41
3
Ep 18
1 2 5 4
jX26

2
vt43
vt18 1
vtX10A
10
13 6
15 vt45
vtEp10

21
vtEp15
vtEp13

vtEp14
vtEp13

nEp12
vtEp10

vtEp11
nEp12

nEp12
vtEp9

vtEp5
vtEp8

vt42
nEp7
vt16

7 1 n54
vtX44
B
n45
jX44
14 n43
43
A
C
vtX44

vtEp24

vtEp26
jX26

vtX31

vtX30

vtX5

vtX6
vtX6
vtX5
vt14
X41

vtX6
vt14
vtX7

vtX7

vtX6
vtX7
vtX7

vtX5
vtX5
vt54

vt12
vtX4
jX41

9
jX4
jX4 vtX40

+
Ep 1

12
vtEp10

6
jX4

3
n43

-
j29 vt45

Ep 15 - 14 - 13 - 12 - 11 - 10 - 9 - 8 jX26
X44 13
5 1
vtEp1
vt53 vt
n vtX10A
25
2

S
jX26 vt12
3 nM
vtX1
jX4
44
8
4
vt11 vt32
Ep 7 - 6 j32

8
vtX62
vtEp18
vt12
X31 X30 34 28

8
49 50

7
j n45
gEp7
gEp6

vtX26

10
vt22 vt n32

00000000
_

RPM x 100
+
vt
vtEp10

6
vtEp15

vtX26

15
vtEp11
vtEp13
nEp12
vtEp8

n1 nEp25 n34

6
2 1
vt42 vt n34

5
n
E

20
F
nX26

30
n18

25
n28 nX36 nX25

36
B A

35 jX37 nM nX45 nX10A n22

D

5
A

10
2

8
6
C
B
nX30 n13 n54

bcX10A
7

bcX10A
vtX45

bcX10A
9

bcX10A
C

bcX47
bcX45

bcX45
bcX45
bcX45

bcX45
bcX45
2 1 5
vtX4 j n46 n21 nX26 vtX40
vt32 n

+
3 4
vtEp6 n5 n12 nX26 vt
Ep 5 nEp17 nEp7 n32
M

-
41 2
1
g30
nP
vtX44 nM
nEp2 nX10A
nX10A
nEp12
nX10A
vtX39
n44
vt32

S
vtX44 jX37 vtEp3
vtX38 24 vt44
45
32 vt43
n43
vt45
vt24 n

33

80
mEp21 12 11 10 10 11 12
vt44 9 8 7 7 8 9
vtX38
bcEp21
6
3
5
2
4
1
4
1
5
2
6
3 X36 vtX26
vt46 nM 1
46 vtX4
vtX37
nM 4

X11
12 1 1 12
n28 j46 j29 nM
jX41
n44
vtX42
vtEp4
4 5 6
29 jX41
jX26
vt29
5
2
vtX4
vtX44
11 2
10 3
2 11
3 10
12
vtX42 3 2 1
j46 vtX41 9 4 4 9
j29 nEp2
X24A X103
4
vtEp1 7 1
vt29 6 3
vtX42 8 5 5 8
j29
8 5 2 jX26 7 6 6 7
vtEp1
Ep 21 - 19 - 20 mEp20 gEp29 vtX28
9 6 3 vt29
jX40 vt13 vtX10A
nEp21 vtX29
X53 53
4

vt19 vtEp4
3

bcEp19 gEp27 vt13

X25 vtX28
2

j46
1

vt11
vtX3
Ep 2 vtX27
Ep27-28-29

nM
26
vtX27 nEp2
7 4
Ep 17-16

48
2

X35
2 1
gEp27 3 4

vtX38
jX26
X101
gEp29 4 3

vt13 11
1

g30 6 5 2 1 vtX38

X28 jX25
j29
g30
g30
vtEp28
vtX27
vtX27
8 7
vt53
17

n30
vtX40
vtX11

vtX44
9

vt29 g31
jX41

jX40
jX41

jX44
vt28
jX41
vt12

vtEp16 jX40 g30 n30

g31
nEp17 n30
Ep25-26
jX41
51
1

vtX35 gX101 n33 Ep 22 Ep24-23

3

vtX75
4

vtX35 n30 1 2 3

vtX41
jX41 31 g30
gX4 P 4 5 6 vtX35
vtX29
vtEp16
vtX46
vt13
vt20

gAEp25
B

gBEp26
gAEp23

gBEp24
7 8 9

vtEp16 nM C A
bcX40

vtX62

vtEp18
vtX62

vtX38

vtX62
bc25

bc25

nEp22
bc25

bc25
vt43

vt12
10

n42
nM
nM

nM
nM

nEp17 nM
X26 52 X4
1

vtX3 nM
X3 X2

bcEp22
nX101

vtEp5 vt16
3
4

mEp22
2 1
nP

j29
1 2
n30

vtX35
vtEp28

vtX38
vtEp28
gX101
gX101

nEp2
gEp29
gEp27
gX101
gX101

jX41
g33
n31
g31

n30
nP

19
9
8

vtX41
X1
vtX44

vtX44
vtX44

vtX44
vtX44

vtX44

vtX44

vtX38
vtX44
vtX44
vtX44

vtX44

vtX44

X29
18
10

7
2
10

17
1

11

1
6
16
12

5
4
14
13

15

vtX53 2 2 2
vtX39
1 1 1
vtX53

X27 30 3 4 3 4 3 4
br
vtX39
nM
4 5
6
5
2

vtX53 bl
vtX39
X10A X10B 8 (U.K)6
1

9
3 2

vtX53
X5 X6 X7 vtX39
1

(10/09/2010) 80-03-M153EN
 C8
Electrical components location

WIRING DIAGRAM KEY

MLT 634 120 LSU PS S.D-E.3 - MLT 735/741 120 LSU PS S.4-E.3
Item Designation Item Designation
1 Complete left front headlight 30 Module
2 Complete left front headlight 31 Complete electrovalve
3 Indicator light panel 32 Strain gauge
4 Alarm 33 Clogged oil filter indicator
5 Complete right front headlight 34 Wheel alignment switch
6 Complete right front headlight 35 Electrical socket
7 Wheel alignment switch 36 Complete left rear light
8 Hand brake switch 37 Complete right rear light
9 Complete seat 38 Electronic box
10 Shunt 39 M8 ZN nut
11 Transmission cut-off module 40 M8 ZN nut
12 Safety panel 41 Harness (Gear box)
13 Windscreen washer reservoir 42 Valve
14 Brake fluid tank 43 Sensor
15 Stop switch 44 Transmission oil pressure switch
16 Fog light switch 45 Oil temperature sensor
17 Wheel alignment switch 46 Diode
18 Shunt 47 Main harness
19 Transmission cut-off switch 48 M8 ZN nut
20 Switch 49 M8 C05 ZN.C nut
21 Gear indicator 50 Harness
22 Key switch 52 Fuse carrier
23 Electronic box 53 Harness
24 Windscreen wiper switch 54 Transmission cut-off switch
25 Indicator lamp 55 Clock
26 Relay and fuse holder plate 56 Fuel gauge
27 Cigarette lighter 57 Hour meter
28 Switch 58 Water temperature indicator
29 Complete pump
80

80-03-M153EN (10/09/2010)
 C9
Electrical components location
ELECTRIC CIRCUIT

MLT 634 120 LSU PS S.D-E3

MLT 735 120 LSU PS S.4-E3
MLT 741 120 LSU PS S.4-E3
nM
3 2

35 26 X42 bc22 1
n vtEp18
54 (U.K)2
4 7 1
7 1 bc22
X57 3 5 4 vtX40

1
13
2
vtEp9 vtX48 n
vt10 5 1

F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 28 F29

F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12

7.5A
vt1 bl

K7
vt23 vt10

X39
5 6
A 15A
bc22 vtEp8

16
vtEp11 6 2 _ m

X45
15A 7.5A vtX41
5 1 j
vt5 7.5A bc22

K5
7 3

K8
7.5A +
vt5
25
n ro r vt57 nM

9
10A 5A

1
g bl bl/bc n vt1 vt7

2
8 4
n17

10
B 10A
7.5A 15A
nM
vt1 n25
vt1
7.5A 5A nX46

K9

K2 K3 K4
K6
17
7.5A 15A
bc22 vtEp5 n17 n54 n13
vtEp14 7.5A j
bc22 n25 vt24 n14 vt19

K0 K1
C 15A 10A vtX40

34
vt5
53 vt34

F13 F14 F15

15A 30A

X75

9
vtEp3

1
15A 15A vtX48 n16

2
vtX40

10
vt5 E G
14

F30
25A
vtX47 n25

1
vt57 n13

85 87D 81
vtX2
X46
vtX26
33

21
8
13 6 D F

7
nM

87
86
H I
nX45

5
4
7 1 3

1
8
6
1 8 vtX39
vt17 2 5 vtEp15
2 7
j24
X43 bcX40 1 6

15 vtX39 4 5

X40

TEST
6
3 nM
X38

6
1
3 6
vtX46
36 vtX4 vtX40
X47 vtX39 3 2 1
4 5
jX4 vt10 j27 jX30 bc22
vtX39
12
7
bcX47
4 3 vtX44
X37

vtX10A
vtX10
vtX10
bcX10A n20

vt30

vt33
vt46
X20

vt8
5 1 2

vt4
B

Ep 1
6 7 vtX57 vtX44 A

X48 vtX46 C

X62
vtEp18 vtX44 vtX36 nX10A

X18

-
1 vtX45 5 1
vt23
11
8
vtX38

55
nEp7

+
2
vt56
vtEp10

vtX41
vtEp15
vtEp14

vtEp1
nEp12

vtEp8

nM
vtEp9

7 2
vt15 3 vtX10A
8
4 nM
6 3
vt58 vtX10A vt56

1
1 2 vt8
Ep 18
1 2 5 4 vt30

2
jX26
vtX10A vt55

18
vt14 1 10 vt58
13 6 vt vt23
vtEp10

21 n58
vtEp15
vtEp13

vtEp14

nEp12
vtEp13
vtEp10
nEp12

nEp12
vtEp11

3
vtEp9

56
vtEp5
vtEp8

nEp7

vt20 n56
vt25

7 1
vt54

9
jX44 vt23 vtX40

+
vtEp10

12
6
jX26

vtX31
22

vtX30

vtX5

vtX6
vtX6
vt20

vtX5
vt12
X41

vtX6
vtX7

vtX7

vtX6
vt12

vtX7
vtX7

vtX5
vtX5

jX41
vtX4
vt19
jX4

3
jX4 nM n56

2
10

-
vt58
jX4 n20
j24 vtX44
vt
19 vt57
n57 vtX10A

S
Ep 15 - 14 - 13 - 12 - 11 - 10 - 9 - 8 jX26
jX26
X44 vt23
vt18
vt 20 vt30
57

8
jX4
vt19
Ep 7 - 6 j30

9
j

1
n19 vtEp18

8
8

2
10

7
n12 n30

5
vt10
X31 X30 27 21

10
n58

00000000
gEp6 gEp7
28

RPM x 100
vtX26 vt23

15
vt16 vt vt23

6
_

4
+

5
n
n27

20
vtEp10
vtEp15

vt
vtEp13

vtEp11

vtX26
nEp12

30
2 1
n23

25
2

1
vtEp8

E nX36
vt55 vt vt23

5
bcX10A
F

bcX10A
bcX10A
bcX10A

bcX47
bcX45

bcX45
bcX45

bcX45
10

bcX45
bcX45
n28

8
32 31
B A

7
vtX45
49
D

9
A
jX37 nM nEp12 nX10A
vt30 C
vtX4 j vtX40
n27

+
B
7 6 nX10A nX10A n57
2 1 5 Ep 5 C
vtEp6
nX25 nX10 vt57
47
n1
3 4

46 48

-
n16 nX26 n14 vtX39
nX10A n57

37 2 g38 vtX44 nM
Ep 4 - 3 n19 nX45
vt30

S
n11
58
vtX44 jX37 vtEp3 n23 n30
1 nP vt57
vtX38 n23 n11 nX77
vt58
vt46
30 nX26
nX26
nX57
n10
n5
nEp17 M
vt56
n56
n
mEp21
vt57
12
9
11
8
10
7
10
7
11
8
12
vtX26 X9 vt23
vt23
X77 n30 nEp7 nEp2

9
29 vtX38
6 5 4
vtX77 nM 1

80
4 5 6 vt18 4
bcEp21 jX77 vt19 vtX4

24
3 2 1 j24
nM 1 2 3 jX41 vt11
2
vtX37
jX41 jX26 vt20 vt24 12 1 1 12
5 nM
vtX62
n57
7

8
4

5
1

2
jX77
vt24
jX26
vtX34
vtX36
vtX36
j24
j24
6 3
vtX4
nEp2 X11 vtX1
11 2
10 3
2 11
3 10
10
X24A X103 9 6 3 vt24 --
vtX41 9 4 4 9
25 26
1

8 5 5 8
jX40
23 vtEp1 vtX42
24 23 22 21 20 19 18 17 16 15

Ep 21-19-20 9
vtEp1
2

vt13 vtEp4 7 6 6 7
vtX34 vt23
mEp20
nEp21
gEp25
jX77 vtX10 vtX27
X53 vt8
vtX10A

X34
28 29 30 31 32 33

bcEp19 gEp23 vtX10 vtX27 2 1

vtX10 nEp2 vtX42
3
vtX10 4 3 4

8
6

50
vtX38
X25
vt23 vtX10 Ep 1 6 5
vt11
7 8

vt23 vtX10 vtX27 8

2 1
7
vt9
E vt21
Ep23-24-25

nM vtX27
9
2

vtX10

X36 7 4
Ep 17-16

10

jX26 gEp23 C vt21

1

35 36

--
gEp25 Ep 2
X101

n28
U vt10
X10B X10 41 45
12

vtX38
X26 g38
13

vtEp24 vt23
X28
4 5 6 vtX1
jX25 g38 g52 vtEp4 nM
j24 g38
vt23 3 2 1
nM bcEp22 Ep 22

vtX38
vtX38
n38 n38
17

vt23
vt23
vt23
vt23
vt23
vt23

vt23
vt23
nM
vt11 vtX42 nEp22
9

vtEp16 vt24 g38 n38

nEp17 n29 n21 mEp22
jX40 g52
1

vt21

P
vtX35 gX101
3

jX41
4

vtX28 vtX9
vtX35 vtX75 n38

52
vtX29 vtX9
4
3

g38

10
8
7

11

12
40
vtX41 vtX28 vtX10
2

B
gX4

1
2
5

3
6

4
vtEp16 jX41 vtX3 C A
bcX40

vtX62
vtX62

vtX38

vtEp18
vtX62
bc22

bc22

bc22

bc22
vt56
nM

vt10
nEp17
42

n55
nM
nM

nM
nM
1

vtX3 nM
39 X35
3

vtEp5 vt25
4

nX101

vtX35 nM
nP

nEp2
n38

j24
vtEp24
gX101
gX101

vtEp24
gEp25
gEp23
gX101
gX101

g29
n52
g52

n38
nP

19
9

jX41 jX41

X29
8
vtX44

vtX44
vtX44

vtX44
vtX44

vtX44

vtX44

vtX44
vtX44
vtX44

vtX44

vtX44

vtX11
18
10

7
2

vtX35 vtEp16 vt23

17

vtX41 jX41
10

11

vtX29 vtX46 vt10 vtEp4

3

1
6
1

16

4
7
vt10
12

12 1
5
4

11
10
14

jX41

8
7

9
8 2 vtX39
13

15

5
vtX53 2 2 2

38
1 1 1
vtX44
vtX53 9 6 3
vtX40
3 4 3 4 3 4

X3 X2 X1
vtX39
nM
4 5
6
5
2

vtX53 jX40

(U.K)6
vtX39 3 2 1

vtX53
X27 X4 vt28
X5 X6 X7 X10A 43 44 vtX39
1

jX44

(10/09/2010) 80-03-M153EN
 C10
Electrical components location

KEY: WIRING DIAGRAM (ENGINE - TRANSMISSION)

MLT 634 120 LSU (PS) S.D-E3 - MLT 735/741 120 LSU (PS) S.4-E3
Item Designation
1 Air pressure sensor
2 O-ring
3 Glow plug
4 Air temperature sensor
5 Seal
6 Fuel pressure sensor
7 Seal
8 Speed sensor
9 O-ring
10 Bolt
11 Speed sensor
12 O-ring
13 Bolt
14 Oil pressure sensor
15 JO-ring
16 Water temperature sensor
17 O-ring
18 Oil temperature sensor
19 O-ring
20 Transmission oil pressure switch
21 Oil temperature sensor
22 O-ring
23 Sensor
24 Seal
25 Transmission oil pressure switch
26 O-ring
80

80-03-M153EN (10/09/2010)
 C11
Electrical components location
ELECTRICITY (ENGINE - TRANSMISSION)

MLT 634 120 LSU S.D-E3

MLT 634 120 LSU PS S.D-E3
MLT 735 120 LSU S.4-E3
MLT 735 120 LSU PS S.4-E3
MLT 741 120 LSU S.4-E3
MLT 741 120 LSU PS S.4-E3

18 20
3
26
4 19
1 5
2

6 7

9
10
8 25 23
21

80
26 24
22

13

16 11
12
17 14

15

(10/09/2010) 80-03-M153EN
 C12
Electrical components location
80

80-03-M153EN (10/09/2010)
 D1
Electrical components location

COMPONENT LOCATIONS 2D AND 3D VIEWS

Pages

– Series 5 et Series E
Location 2D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D2
Location 3D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D14

80

(10/09/2010) 80-03-M153EN
 D2
Electrical components location

WIRING DIAGRAM KEY

MLT 634 LSU T S.E-E3 - MLT 735 LSU T S.5-E3
Item Designation Item Designation
1 Relay and fuse holder plate 40 Hand brake switch
10 Complete left front headlight 41 Complete left rear light
11 Complete left front headlight 43 Indicator lamp
12 Complete right front headlight 44 Main harness
13 Complete right front headlight 45 M8 C05 ZN.C nut
14 Alarm 46 M8 ZN nut
17 Complete electrovalve 47 Clogged oil filter indicator
19 Fog light switch 48 Transmission oil pressure switch
20 Wheel alignment switch 49 Oil temperature sensor
21 Transmission cut-off switch 50 Electrical control valve
23 Clock 51 Relay
24 Key switch 55 Cigarette lighter
26 Fuel gauge 56 Transmission cut-off module
27 Water temperature indicator 57 Switch
28 Hour meter 58 Shunt
29 Brake fluid tank 60 Sensor
30 Stop switch 61 Sensor
31 Transmission cut-off switch 62 Windscreen wiper switch
33 Safety panel 63 Switch
36 Strain gauge 64 Diode
37 Complete right rear light
80

80-03-M153EN (10/09/2010)
 D3
Electrical components location
ELECTRIC CIRCUIT

MLT 634-LSU Turbo S.E-E3

MLT 735-LSU Turbo S.5-E3

(U.K)11
vtX39
48 nX70
nM vtX39 4 5 6

31
vtX40 n nM
vtX39 3 2 1

10

Ep 22 - 21
gEp22
23
2

gEp21
29 vtX40
4
1
5 3
51 vtX39

50 2 1

49
vtEp18 nX24

-
nM vtX26
7 1

+
vtX41

56 X70 X75
vtX38 jX44 vt40
vtX1 4 8
vtEp15
jX26 nM 3
- +
vt26
jX4 vt58 2
vtX40
vt57

30
jX4 vtEp1 1 5
vt27
j62 vt23
n 29 vt21 vt21
vtX38 n26
jX26 vt62 vtX1 n27
jX26 A

9
vtX40
Ep1

+
jX4

12
6
X41
jX4

Ep 19 - 20
26

3
n26

-
vtX26
vt58 vt27

X19
1 2
vtX24

S
vtX26
gEp19 vt23 nEp17 nEp7 n12 nX25 nX26 n55 n21 nX77 nX26 n51 n56 nX24 nX24 vtX4
X20 gEp20 vt19 13 6
nEp12 nEp2 n10 nX26 nX45 nX30 n58 n19 nX24 n29 n28 nX24 nEp21

64

8
vtEp18
41 X18 vtX24

8
8 1

7
VtEp18 11 AA 1360 vtEp10 n
1
nM

5
7 2

28

10
7 1 n27

00000000
45
6 3
vt

RPM x 100
4 3 1 2
vt20

15
M
5 1 2 5 4 1 2
vt n

6
j62

5
vtX6

F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 28 F29
6 7

F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12

7.5A

20
10

K7
21

30

25
vtX4 A
46 vtX6
vtEp10

vtEp15

vtEp14
vtEp13

vtEp13
vtEp10

vtEp11

5
nEp12

7.5A
nEp12

nEp12

jX4
vtEp9

vtEp8

vtX6
Ep 18
vtEp15

vtEp10
vtEp14

nEp12

7.5A vtX45
vtEp9
vtEp8

K5
bcX47

K8
7.5A
bcX24 10A 5A
vtX30 vtX40

+
vt51
B B 10A vtX39

27
vtX6

X40
7.5A 15A

X44

-
7.5A 5A vt58
vt26

K9

K2 K3 K4
K6
7.5A 15A
vtX31 n28

40
7.5A
G vtX24

S
vt30

K0 K1
C 15A 10A vtx4

47 vt27 vt26

F13 F14 F15

15A 30A
15A
jX41
jX26
17 E G vt21 vt28

F30
25A
vt29

1
n26

60
13 6

21
8
D F vtX7
X77

7
1

1
H n27
I vtEp22

1
8
6
7 1 vt33
vtEp9 vtEp20 nM 1
vtX38 vt33 4
vt10
D 3

6
4 1

1
nEp7 bcX45
1 2

vtX4
3 vtEp11
vt12 vt58 j55 jX30 7
I jX4
vtX7 bcX45
j62
vt62 2
bcX24
X11 nEp2 vt56 vt12
H
vtX7 5
gEp7
gEp6

nEp2 vtX38 vt57 vtX24 vt49 vtX24 vt47 1 vtX7 bcX24 j62
vt10 6 3

vtEp4
vt10
vt10
C 1 5 X37 vt14 vt40 vt48 vtX24
j
j62
X39

bcX24
vt40 vtEp14
vtEp5 vt43
nEp7
Ep 7 - 6 57 vt56
vt12
VtEp3
vt58 vtX36 vtX36vtEp4
X38 vtX44
X43 bcX24
bcX45
vtX24
vt12
vt28 X42 bcX45
bcX47 vtX44 vtX44 vtX44 vtX44 jX41 jX41 jX41 jX40 vt63 jX41

Ep 15-14-13-12-11-10- 9- 8 Ep 5 Ep 4 Ep 3 44 bcX45
bcX45
24
vtX44 vtX44 vtX44 vtX44 vtX11 vt58 vtX44 vtX40 jX44 vt28

Ep 2 1

3
2

4
1

3
2

4
1

4
2

5
3

X4
7 8 9

X7 X6

80
nM
vt58 bc24 bcX40bc24 vt27 vtX38 bc24 vtX38 vtX38 n23 n20
vtEp18 nM nM vt26 bc24 vt28 vt24 nM nM vtX35
vtX29
vtEp16
vtX46
vt56
vt31 n63
X36 bc24 vtX2 bc24 bc24 vt28 nX46 bc24
vtX41
j 19 61

9
vtX45 bcX40 nX45 bc24 vtX48 bc24 nM bc24

1
vtX42

2
vtEp8
14

10
19 9 4 5 6

X3 X2
8

17
18 7 2 10
6 1 3 11
16 5 4 12
X1 vtEp4
vtX42
vtEp1
3 2 1
vt vt61 43
n
vtEp15
vtEp13
vtEp10

vtEp11

15 14 13
nEp12
vtEp8

n20

6 2

7 3
5 1

8 4
vtX28 vt vt60
vtX29
X48
X47
X46
4
3

vtX28
X45
2

X24
7 6
br vtX3
2 1 5
bl vtEp5
vtEp5 vt43
3 4 vtX38 nEp2

X35 jX77
jX77
vtX40
j
20
37 62 jX41 vtX27 vtX27

1
n43

2
10
vtX53 vtX53 jX41 nM nM vtX41 jX41 vt62 jX25 nM jX26
7

VtX27 vtX27 n19

jX26
8

vtX53 vtX53 vtX41 j62 nM jX41 vtX75 jX40 j62 jX26

1
X53
jX40
Ep 17-16

vtX70 vt31

8
nX36 vtX4 vtX44 nM
1

3
2

4
1 9 1 2
X25 n55 vtEp6 vtX44 jX37 vtEp3 jX77
vtX26
vtX77
vtX44

vt31
vt 21

1
vtX4 nM

2
10 9

10
10 17 j
n33
X27 X26
vtX37
8 7
E
vtEp16 6 5
F 12 1
4 3

vt55 jX37 n63 nM 1 12

X28 nEp17 B A
2 1
11 2
1

D
2

A
vtX35 vt55 nM vtX44
2 11
10 3
3
4

C B

36 33
3 10
vtX35
C
vtX41 9 4 4 9
vt
vt vtEp1 8 5 5 8
_
+
X31
X30

6 7
vtEp16
4
7 6 3
vtX42

X29 nEp17
55 58 2 5

TEST
1

vtX3
63 vtX24 1 6 vtX44
3
4

A C
vtX44 vtX39
vtX35 vt56 B
n21 vtX39
nM 12

6
5
3

1
2
(U.K)13
vtX39
vtX39

(10/09/2010) 80-03-M153EN
 D4
Electrical components location

WIRING DIAGRAM KEY

MLT 1035L LSU Turbo S.5-E3
Item Designation Item Designation
1 Relay and fuse holder plate 37 Complete right rear light
10 Complete left front headlight 40 Hand brake switch
11 Complete left front headlight 41 Complete left rear light
12 Complete right front headlight 43 Indicator lamp
13 Complete right front headlight 44 Main harness
14 Alarm 45 M8 C05 ZN.C nut
16 Electrovalve 46 M8 ZN nut
17 Complete electrovalve 47 Clogged oil filter indicator
19 Fog light switch 48 Transmission oil pressure switch
20 Wheel alignment switch 49 Oil temperature sensor
21 Transmission cut-off switch 50 Electrical control valve
23 Clock 51 Relay
24 Key switch 55 Cigarette lighter
26 Fuel gauge 56 Transmission cut-off module
27 Water temperature indicator 57 Switch
28 Hour meter 58 Shunt
29 Brake fluid tank 60 Sensor
30 Stop switch 61 Sensor
31 Transmission cut-off switch 62 Windscreen wiper switch
33 Safety panel 64 Roll corrector switch
36 Strain gauge
80

80-03-M153EN (10/09/2010)
 D5
Electrical components location
ELECTRIC CIRCUIT

MLT 1035L-LSU Turbo S.5-E3

(U.K)11
7 1 vtX39
48 jX44
jX26
nX70
nM vtX39 4 5 6

31
vtX40 n nM
66 jX4 vtX39 3 2 1

10

Ep 22 - 21
gEp22
23
2
jX4 vt40
gEp21
j62
A
vtX1
nM
4
3
8

56 29 vtX40
4
1
5 3
51 vtX39

50 2 1

49
jX26 vt58 2
vtEp18 nX24

-
vt57 nM vtX26
jX26 vtEp1 1 5

+
vtX41
vtX38 jX4
X70 X75

X41
jX4 Ep1 - + vtEp15
vtX40
vt26
vtX26

vtX38
vt58
vtX26 n 29 vt21 vt21
30 vt27
vt23
n26
vt23 vt62 vtX1 n27
vt19 13 6

26

9
vtX40

12
nEp17 nEp7 n12 nX25 nX26 n55 n21 nX77 nX26 n51 n56 nX24 nX24

6
nEp12 nEp2 n10 nX26 nX45 nX30 n58 n19 nX24 n29 n28 nX24 nEp21

Ep 19 - 20

3
7 n26

-
1
m vt20 vt27
bl
1 2
vtX24

S
j62
vtX4
X19 gEp19
gEp20
Ep 18
jX4 VtEp18
45 65
vtX4
28

8
11 AA 1360
41 X20 bcX47
bcX24 B
M vtEp10
vtEp18

46
vtX24

8
3

7
X40
vt51 nM n
X16A vt

7
X18

5
8 1

10
vt26 n27

00000000

RPM x 100
4 3 7 2
vtX6

15
5 1 2 10 21
vt30 vt n

6
6 3
vtX6
16 1

5
6 7 1 2

20
F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 28 F29

F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12

7.5A
vt27

K7

30

25
5 4 1 2 vtX6
1 2
jX26 A

5
7.5A
vtEp15

vtEp10
vtEp14

nEp12

vtX45
27
vt29 7.5A
vtEp9
vtEp8

vtX30

K5
vtEp10

vtEp15

vtEp13
vtEp14
vtEp13
vtEp10
nEp12

K8
vtEp11
nEp12

nEp12

13 7.5A
vtX44

vtEp9

6
vtEp8
vt64

10A 5A vtX6 vtX40

+
X44
7 1 B 10A
vt58 vtX39
vtEp9 7.5A 15A
vtX31
G

-
7.5A 5A
vt10

K9

K2 K3 K4
X39
vtx4

K6
7.5A 15A n28
vtEp11 7.5A
jX41 vtX24

S
K0 K1
C 15A 10A
vt12 vt26
17
vt21

F13 F14 F15

15A 30A

40 vt12
vt10 C 15A
E G vt28

F30
25A
vtX7

1
vt10 n26

60 47
vtEp22
X77

21
8
vt10 D F bcX45 n27

7
1

1
H I vt33
vtEp14 bcX45

1
vtEp20

8
6
vt12 bcX24
2 1 1 2 vt33 nM 1
VtEp3 bcX24 4
jX4 j62
gEp24 gEp25 vt12
D 3

6
1
vtX7
1 2
4 1
gEp23 gEp26 vt28
vt58 j55 jX30 7
I vtX7
bcX24
j
vt62
5
2

3 1 vtX7
bcX24 j62
vtX38
nEp7 vtX4 H vtX24 vt49 vtX24 vt47 vtX16A
bcX45 j62
6 3

X11
gEp7
gEp6

nEp2 vt56
X37 vt14 vt40 vt48 vtX24 vtX24
24
Ep 25 - 26
Ep 23 - 24

1 5
nEp2 vtX38 vt57
vtX44
X43 bcX45
bcX47
vtEp5 vt43
nEp7
Ep 7 - 6
vtEp4
vt40
vt58 vtX36 vtX36vtEp4
X38 44
bcX45
bcX45
57 vt56
X42 vtX44 vtX44 vtX44 vtX44 jX41 jX41 jX41 jX40 vtX33 jX41
vtX44 vtX44 vtX44 vtX44 vtX11 vt58 vtX44vtX40 jX44 vt28

Ep15-14-13-12-11-10-9-8 Ep 5 Ep 4 Ep 3 1

3
2

4
1

3
2

4
1

4
2

5
3

Ep 2
X4
7 8 9

vtX27 vtX27 X7 X6
X53 vtX27 vtX27

80
61

1
vt58 bc24 bcX40bc24 vt27 vtX38 bc24 vtX38 vtX38 n23
vtEp18 nM nM vt26 bc24 vt28 vt24 nM nM vtX35 vtEp16
X36

8
vtX29 vtX46
vt56 nX33 nM

19 9
vt31
vtX42
vtEp4
4 5 6
bc24
vtX45 bcX40 nX45
vtX2 bc24 bc24 vt28 nX46 bc24
bc24 vtX48 bc24 nM bc24 n20
vtX41
19 14
X3 X2
8
18 7 2 10
17 6 1 3 11 X1 vtX42
vtEp1
3 2 1

vt
j

1
16 5 4 12

2
vtEp8

10
vtEp15
vtEp13
vtEp10

vtEp11

15 14 13
nEp12
vtEp8

vtX28 6 2

7 3
vtEp5
20
5 1

8 4
vt j
vtX29
4
3

vtX40
X46
X48
X47

vtX28 vt31 vtEp5 vt43

2

vt64
6

X24 vtX3
X45 21 vtX38

9
7 vtX44
br

1
n43 nEp2

2
10
2 1 5
bl vt
3 4 n19
vt31
X35 jX77

1
43
nM

2
10
jX77
vt61
37 62 jX41
n33
n64
jX26
7

vtX53 vtX53 jX41 nM nM vtX41 jX41 vt62 jX25 nM n

jX26 n20
8

vtX53 vtX53 vtX41 j62 nM jX41 vtX75 jX40 j62 jX26 jX40 vt60
Ep 17-16

vtX70
nX36 vtX4 vtX44 nM jX77

vtEp25
vtX16A
X25
vtEp23
n55 vtEp6 vtX44 jX37 vtEp3

vt20
vtX26
n43
1 2
1 9 1 2

3 4
vtX77
vtX4
10 9

10 17

X27 X26 vtEp16

8

4
7

3
j
E
F

vt55 jX37 nX33

vtX37
nM
12 1
11 2
1 12
2 11
10 9

X49B
X28 nEp17
8 7
B A
vtX44
2
2 1
1

D
vt
2

A 10 3 6 5

vtX35 vt55 nM 3 10
1
4 3
vt
3
4

C B
vtX41
33
9 4 4
X33

36
2 1

vtX35
C
5 8
vt vtEp1 8 5

64
vt 6 7
7 6
_
+

vtX42
58
X31
X30

vtEp16
3 4

vtX24
X29 nEp17 2 5

55

TEST
1

vtX3 vt56 1 6 vtX44

3
4

A C
vtX44 vtX39
vtX35 B
n21 vtX39
nM 12

6
5
3

1
2
(U.K)13
vtX39
vtX39

(10/09/2010) 80-03-M153EN
 D6
Electrical components location

WIRING DIAGRAM KEY (ECU CIRCUIT)

MLT 634 LSU Turbo S.E-E3
MLT 735/1035L LSU T S.5-E3
Item Designation
1 Harness
2 Electronic box
3 Multi-plug
4 Fuse carrier
5 Complete pump
6 Potentiometer harness
80

80-03-M153EN (10/09/2010)
 D7
Electrical components location
WIRING DIAGRAM (ECU CIRCUIT)

MLT 634-LSU Turbo S.E-E3

MLT 735-LSU Turbo S.5-E3
MLT 1035L-LSU Turbo S.5-E3

EP1 11AA 1361 - 1363

rX112
X4
1 2 3

4 5 6

7 8 9

r2 r2
X112 X111
r4 r/n2 jvt5
rEP1 jvtX107
jvt2 X106

6
r2
j2
vt2

2 jvtX106
1 m2

5 1

80
ep1
r2
r2
rX112
r3
4 n2
r4
A G
vi2

3
B F
H

C jvtX107 m5
E
D
r6 n3 jvtX106
o2
vt2 r/nX111 rEP1
vt3 j6 r4
vi3 o3 vt6 r4 rEP1

14
3
2 1
26 15
40 29
28 27

52 41

jvt3 jvt2

2 jvt2 jvtX106

X107
(10/09/2010) 80-03-M153EN
 D8
Electrical components location

WIRING DIAGRAM KEY

MLT 731 Turbo S.E-E3
Item Designation Item Designation
1 Relay and fuse holder plate 40 Hand brake switch
10 Complete left front headlight 41 Complete left rear light
11 Complete left front headlight 43 Indicator lamp
12 Complete right front headlight 44 Main harness
13 Complete right front headlight 45 M8 C05 ZN.C nut
14 Alarm 46 M8 ZN nut
19 Fog light switch 47 Clogged oil filter indicator
20 Wheel alignment switch 48 Transmission oil pressure switch
21 Transmission cut-off switch 49 Oil temperature sensor
23 Clock 50 Electrical control valve
24 Key switch 51 Relay
26 Fuel gauge 54 Forward/reverse lever
27 Water temperature indicator 55 Cigarette lighter
28 Hour meter 56 Transmission cut-off module
29 Brake fluid tank 57 Switch
30 Stop switch 58 Shunt
31 Transmission cut-off switch 60 Sensor
33 Safety panel 61 Sensor
36 Strain gauge 62 Windscreen wiper switch
37 Complete right rear light 64 Diode
80

80-03-M153EN (10/09/2010)
 D9
Electrical components location
ELECTRIC CIRCUIT

MLT 731 Turbo S.E-E3

7 1 X42 64 vtEp8 31 vtX26

X75 (U.K)11
jX44
jX26 vtEp10 vtX41
j 19 X70 10
1
vtX39
jX4 vt n20 vtX39
vt58 vt54 vt54 vtEp4

1
4 5 6
jX4 nM

2
10
_ nM
j62 1 5 vtX6
43
10 21 vtX39 3 2 1

F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 28 F29
+

F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12

7.5A
jX26 vtX6

K7
54
vt61 vtX39
jX26
jX4
A A
7.5A
7.5A
H vtX6 n20
n

X41

K5
vt40

K8
7.5A
jX4 vtX30
vtX1 4 8

56
10A 5A
vtX26 10A vtX6 vt60 n29 vtX1 nM 3
B

X44
7.5A 15A vt62 vt21 vtX2 vt58
vt58 vt58 5 4
vt57
2

vtX26
7.5A 5A
vtX31 vtEp5 vtEp1 1 5

K9
G

K2 K3 K4
20

K6
7.5A 15A
vtEp4 vtX42 vtX40
vt23 7.5A vtx4
vtX40 j
29 23

K0 K1
C 15A 10A
vt19 13 6 jX41 nX70
vtEp1 vtX42

F13 F14 F15

15A 30A

9
vt21

1
15A n43 nM nX24

2
10
VtEp18

-
E G

F30
25A n19

+
1

1
7 1 vtX7 vtX41
vtEp15

21
8
D F
vt20
30

7
vtEp22

1
H I vt26
j62 vt31
vt33
Ep1

5
vtX40
21

1
8
6
vtX4 vtX44
vtEp20 vt vt27
41 Ep 18 jX4
bcX47
3
I
vt33
vtX2 vt23
n26

9
jX4

1
nM n27

2
10
bcX24 vtX7
7 n33
B D

9
vt51

6
vtX40
X40

4 3 vtX7
1

12
6
5 1 2 vtX24 vt49 vtX24 vt47
vt26 1 vtX7

26
6 7

3
vt58 j55 jX30 vt14 vt40 vt48 vtX24 n26

-
vt30 vt27
33
vtEp15

vtEp10
vtEp14

vtX24
nEp12

vt27

S
n21
vtEp9
vtEp8

jX26
vt29 X37 X38 vtX44
X43 vtX44
vtX44
C
B
A
vtX4

8
13 6
nM vtEp18
7 1 vtX24

8
vtEp18

7
vtEp9 3 4
n
51 vtX40 nM

7
1

5
5

28
3
vt10

TEST

10
2 5 4
n27

00000000

RPM x 100
vtEp11 1 6 2

15
vt12 vt n

6
n

20
vt12

30

25
vt10

5
vt10
vt10
C vtX45
X39

vtX40

+
vtEp14 bcX45 vtX39
vt12 bcX45
n10
45 27

-
VtEp3 bcX24 n51 n12
n28
vt12 vtX48
bcX24
n19 n56 n28
46 vtX24

S
13 6 vtX47 n21 n58 n29
55
vt28 vt26
X46

85 87D 86
vtX4 n55 nX24 nX77
j

87
30
nX25 nX24 nX24 vt28
bcX24

X19 60 47 X31 X30 X33

nX45
bcX24
bcX45
nX26
nX26
nX26
nEp7
nX24
nX30 M n26
n27
vtX46 nEp12 nX45

X20 vt n55
X48 vtX45
vtX24
nEp2
_
+

vt bcX45
vtX4

X18 10
bcX47
2

8
E
vt vtX37
1

7
8 1 F

9
bcX40 bcX45 12 1
B A nX33 vtX4 j 1 12
7 2 D A vtX46 bcX45 nM
jX37 nM
X47
vtEp6 11 2 2 11
6 3 C
B bc24 vtX44
1 2 C 10 3

58
3 10

24
5 4 1 2
bc24 vtX41 9 4

40
4 9
vtEp1 8 5 5 8
bc24
vtEp10

vtEp15

vtX44 nM
vtEp13
vtEp14
vtEp13
vtEp10
nEp12

vtEp11
nEp12

nEp12

7 6
vtEp9

6 7
vtEp8

vtX48 vtX42
vtX44 jX37 vtEp3 5 1
vtEp5 vt43 vtX38 vtX24

80
nEp7 nEp7 6 2 bc24

X45 7 3
bc24
vt56

61
vt28
8 4

Ep 15-14-13-12-11-10- 9- 8
nM
nX46
bc24
4

3
1
X77
vtX4
Ep 5 Ep 4 Ep 3 bc24 nM 1

44 X53 X11 nEp2

nEp2 vt56
vtX38 vt57 j62
4

- 6 vtX27
vtEp4
vt62
5
2

p7
8

vtX77 vtX27
vt40
14
vtEp15

j62
vtEp13
vtEp10

vtEp11

vtEp5 vt43
57
nEp12

E 6 3
vtEp8

vtX26 j62 nEp2

jX77 vt56

2
7
1
6
5
62 jX41
jX26
jX77 Ep 2
vtX27
VtX27
1

7 4 1
3 4 vt62 vtX38
8 5 2 jX26

37 36 9 6 3 vt62
jX40
vtX39
vtX39
vtX70
50 nM

6
5
3

1
2
48
jX77

Ep 22 - 21
vtX39
vtX39
vt21 vt56 gEp22
vt31 vt31 gEp21

1 2
2 1 vt58 bc24 bcX40 bc24 vt27 vtX38 bc24 vtX38 vtX38 n23
1 2
vtEp18 nM nM vt26 bc24 vt28 vt24 nM nM

X23 49 vtX38
1 2 X2 X1 vtX44 vtX44 vtX44 vtX44
vtX44 vtX44 vtX44 vtX44
jX41 jX41 jX41 jX40 vtX33 jX41 vtX46
vtX11 vt58 vtX44vtX40 jX44 vt28
vtX53 vtX53
vtX53 vtX53 vtX41
jX41 nM nM vtX41 jX41 vt62
j62 nM jX41 vtX75 jX40 j62
jX25
jX26
nM
19 8
18 7 2
9
10
17 6 1 3 11

Ep 19 - 20
2 2
2
gEp7

1 3
gEp6

1 1
1 2 16 5 4 12
3 4 3 4
4 5 6 1 2
1 9 vtX38 15 14 13
gEp19
X4
7 8 9

X7 X6
1 2
3 4
gEp20
10 17
12
X27 X26 X25 X24 (U.K)13
(10/09/2010) 80-03-M153EN
 D10
Electrical components location

WIRING DIAGRAM KEY (CONTROL UNIT AND HYDRAULICS)

MLT 731 Turbo S.E-E3
Item Designation
1 Manipulator
2 Harness
3 Valve
4 Control unit
5 M8 ZN nut
6 M8 ZN nut
7 Discharge valve module
8 Discharge valve
80

80-03-M153EN (10/09/2010)
 D11
Electrical components location
WIRING DIAGRAM (CONTROL UNIT AND HYDRAULICS)

MLT 731 Turbo S.E-E3

11AA 1366

X4
X4 1

3
2

4
1

3
2

4
X6 1

4
2

5
3

X2
7 8 9
X202
X204
3

1
4

2
X201 g7
n7
6
X205 rX205 oX205
oX210
rX206
rX210
nX208
nEP1 X203 5
oX204
rX204

X206 X207
rX201 roX207 roX206 roX210
r7 rX210

4 8
vtX208
rX206 7
nX203 7 14
6 13
5 12
gX202 4 11

2 3 10
2
1
9
8

X208
nX203
vt7

jvt

80
roX211 bc ro
jX214 bc j
nX213 8 1 8 1 bc n 8 1

blX212 7 2 7 2 bc bl 7 2

roX207 6 3 6 3 bc ro 6 3

rX201 5 4 5 4
bc r 5 4

oX204 bc or
rX206 bc r
EP 1

X212 X211 X210

blX210 roX210
nEP1 nEP1
2 1
2 1

EP1
nX203

3 2 1
2 1
nX211 nX212

jX210
nX210 nX213 nX214
nEP1
nEP1

X214 X213
(10/09/2010) 80-03-M153EN
 D12
Electrical components location

WIRING DIAGRAM KEY

MLT 634 120 LSU S.E-E3 - MLT 735/741 120 LSU S.5-E3
Item Designation Item Designation
1 Complete left front headlight 22 Fog light switch
2 Complete left front headlight 23 Wheel alignment switch
3 Instrument panel 24 Diode
4 Alarm 25 Key switch
5 Complete right front headlight 26 Harness
6 Complete right front headlight 27 Relay and fuse holder plate
7 Sensor 28 Switch
8 Oil temperature sensor 29 Windscreen wiper switch
9 Transmission oil pressure switch 30 Electronic box
10 Electrical control valve 31 Fuse carrier
11 Hand brake switch 32 Module
12 Shunt 33 Hydraulic pump
13 Transmission cut-off module 34 Cigarette lighter
14 Safety panel 35 Complete electrovalve
15 Diode 36 Strain gauge
16 Indicator lamp 37 Clogged oil filter indicator
17 Stop switch 38 Sensor
18 Brake fluid tank 40 Complete left rear light
20 Transmission cut-off switch 41 Complete right rear light
21 Relay 42 Clock
43 Fuel gauge
80

80-03-M153EN (10/09/2010)
 D13
Electrical components location
ELECTRIC CIRCUIT

MLT 634-120LSU S.E-E3

MLT 735-120LSU S.5-E3
MLT 741-120LSU S.5-E3

(U.K)2
nM

27 X42 bc25
1
vtEp18
20
vtEp9
7 1

vtEp4 vtX36
bc25
vtX48 vtEp8
21 3 5 4
2
vtX40
1
22
5 1

F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 28 F29
vt1 bl

F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12

7.5A
vt12 vtX41

K7
vtX36 j n

X39
vtEp11 A 15A
6 2 bc25 _ m

X45
15A 7.5A
5 1
vt5 7.5A bc25 nM

9
K5

1
7 3
n23

K8
7.5A +

2
vt5

10
10A 5A vt44
vt1
vt1
vt1
B
7.5A
7.5A
10A
15A
5A
8 4
nM
nX46
X70

K9

K2 K3 K4
K6
7.5A 15A
bc25 vt29 vt54 vt54
vtEp14 7.5A
bc25 n18 vtX1

K0 K1
23
15A 10A
vt5 C vtEp5
38 j

F13 F14 F15

15A 30A
vtEp3
vt5
15A 15A
E G
vtX48 vtX40

18
vtX40
X75

F30
25A
vtX47
16

1
1

1
vt44 vtX2 n16 vt7 nX70

2
10
85 87D 81
vtX26
37 X46

21
8
13 6 D F n22 n16 nM

7
1

87
86
H I
nX45

5
7 1

1
n16

8
6
vtX39
vt23 vt20 vtEp15
j29
X43 bcX40 vtX44
54
n23
17 vtX39 4 5

X40
3 vt vt38 nM
6

X38

6
1
vtX4 vtX46 vtX40
40 X19 jX4 vt12 j34 jX30
X47 bc25 vt20 vtX39
vtX39
3 2 1

1
7 nM

2
bcX47

10
4 3 vtX44 n14
X37

vtX10A
bcX10A

vt32

vt11

vt37
vt24
X20
5 1 2

42

vt8
vt9
vt4
6 7 vt21 vtX46

X18 8 1
vtEp18
X48 vtX45 3 4
X62
vtX38
nEp7

vt43 nX10A
vtEp10

vtEp15
vtEp14

nEp12

-
vtEp8

vtX10A
vtEp9

7 2 2 5
vt17 vt vtX41

+
1 6
6 3
vt45 vtX10A vtX4

1
1 2

TEST
vtX41
3
Ep 18
1 2 5 4
jX26

2
vt43
vt18 1
vtX10A
10
13 6
15 vt45
vtEp10

21
vtEp15
vtEp13

vtEp14
vtEp13

nEp12
vtEp10

vtEp11
nEp12

nEp12
vtEp9

vtEp5
vtEp8

vt42
nEp7
vt16

7 1 n54
vtX44
B
n45
jX44
14 n43
43
A
C
vtX44

vtEp24

vtEp26
jX26

vtX31

vtX30

vtX5

vtX6
vtX6
vtX5
vt14
X41

vtX6
vt14
vtX7

vtX7

vtX6
vtX7
vtX7

vtX5
vtX5
vt54

vt12
vtX4
jX41

9
jX4
jX4 vtX40

+
Ep 1

12
vtEp10

6
jX4

3
n43

-
j29 vt45

Ep 15 - 14 - 13 - 12 - 11 - 10 - 9 - 8 jX26
X44 13
5 1
vtEp1
vt53 vt
n vtX10A
25
2

S
jX26 vt12
3 nM
vtX1
jX4
44
8
4
vt11 vt32
Ep 7 - 6 j32

8
vtX62
vtEp18
vt12
X31 X30 34 28

8
49 50

7
j n45
gEp7
gEp6

vtX26

10
vt22 vt n32

00000000
_

RPM x 100
+
vt
vtEp10

6
vtEp15

vtX26

15
vtEp11
vtEp13
nEp12
vtEp8

n1 nEp25 n34

6
2 1
vt42 vt n34

5
n
E

20
F
nX26

30
n18

25
n28 nX36 nX25

36
B A

35 jX37 nM nX45 nX10A n22

D

5
A

10
2

8
6
C
B
nX30 n13 n54

bcX10A
7

bcX10A
vtX45

bcX10A
9

bcX10A
C

bcX47
bcX45

bcX45
bcX45

bcX45

bcX45
bcX45
2 1 5
vtX4 j nX77 n21 nX26 vtX40
vt32 n

+
3 4
vtEp6 n5 n12 nX26 vt
Ep 5 nEp17 nEp7 n32
M

-
41 2
1
g30
nP
vtX44 nM
nEp2 nX10A
nX10A
nEp12
nX10A
vtX39
n44
vt32

S
vtX44 jX37 vtEp3
vtX38 24 vt44
45
32 vt43
n43
vt45
vt24 n

33

80
mEp21 12 11 10 10 11 12
vt44
vtX38
9 8 7 7 8
5
9 X77 vtX4
bcEp21
nM
6
3
5
2
4
1
4
1 2
6
3 X36 vtX26
vtX77 nM
4
1
vtX37

X11
12 1 1 12
n28 jX77 j29 nM
jX41
n44
vtX42
vtEp4
4 5 6
29 jX41
jX26
vt29
5
2
vtX4
vtX44
11 2
10 3
2 11
3 10
12
vtX42 3 2 1
jX77 vtX41 9 4 4 9

X24A
Ep 21 - 19 - 20 mEp20
X103
gEp29
vtEp1 7

8
4

5
1

2
vt29
jX26
j29
j29
6 3 nEp2
vtX42
vtEp1
8
7
5
6
5
6
8
7
9 6 3 vt29
nEp21 vtX28 vtX10A
jX40 vt13
bcEp19 gEp27 vtX29
X53 53
4

vtX70 vtEp4
3

vt13

X25 vtX28
2

jX77
1

vt11
g31 vtX3
Ep 2 vtX27
48
Ep27-28-29

nM
55 5A
26
vtX27 nEp2
7 4
Ep 17-16

X35
2 1
3 4

vtX38
jX26 gX101
4 3

vt13 11
1

6 5 2 1 vtX38

X28 jX25 g55

gX101
vtX27 8 7
vt53
vtX44
vtX40
vtX11

j29 gEp27
jX41

jX40
jX41

jX44
vt28
vt12
jX41
vt42

vtX27
gEp29 vtEp28

X101
9

vt29 g30 g31

vtEp16 jX40 n30
g30
nEp17 n30
Ep25-26
51
1 2
jX41 3
1

g30
vtX35 n33 Ep 22 Ep24-23
17
3

vtX75 5
4

4 6
n30
vtX35
vtX41 vtEp16
P vtX35 vt13
9
g30
7 8

jX41 gX4 vtX29 vtX46 vt20

gAEp25
B

gBEp26
gAEp23

gBEp24
vtEp16 nM n30
X4 C A
bcX40

vtX62

vtEp18
vtX62

vtX38

vtX62
bc25

bc25

nEp22
bc25

bc25
31
vt43

vt12
10

n42
nM
nM

nM
nM

nEp17 nM g30

52
1

vtX3 nM gX4
X3 X2

bcEp22
vtEp5 vt16
3
4

mEp22
2 1
j29
1 2
vtX35 g55 vtX38 nEp2
jX41
19
9

n30
X26 nP
8

vtX41 nX101
X1
vtX44

vtX44
vtX44

vtX44
vtX44

vtX44

vtX44

vtX38
vtX44
vtX44
vtX44

vtX44

vtX44

X29
18
10

7
2
10

17
vtEp28
vtEp28
gX101
1

gX101
gEp29
gEp27
gX101
gX101

11

1
6
g33
n31
g31

n30
nP

16
12

5
4
14
13

15

vtX53 2 2 2
vtX39
1 1 1
vtX53

X27 30 3 4 3 4 3 4
br
vtX39
nM
4 5
6
5
2

vtX53 bl
vtX39
X10A X10B 8 (U.K)6
1

9
3 2

vtX53
X5 X6 X7 vtX39
1

(10/09/2010) 80-03-M153EN
 D14
Electrical components location

KEY: WIRING DIAGRAM (ENGINE - TRANSMISSION)

MLT 634/731 (LSU) T S.E-E3
MLT 735/1035L LSU T S.5-E3
Item Designation
1 Glow plug
2 Engine oil pressure switch
3 Electrovalve
4 Water temperature sensor
5 Water temperature sensor
6 Oil temperature sensor
7 O-ring
8 Transmission oil pressure switch
9 Solenoid valve (Delphi)
10 O-ring
80

80-03-M153EN (10/09/2010)
 D15
Electrical components location
ELECTRICITY (ENGINE - TRANSMISSION)

MLT 634-LSU Turbo S.E-E3

MLT 731 Turbo S.E-E3
MLT 735-LSU Turbo S.5-E3
MLT 1035L-LSU Turbo S.5-E3

6 8
2 10
7

3
9

80
4
5

(10/09/2010) 80-03-M153EN
 D16
Electrical components location

KEY: WIRING DIAGRAM (ENGINE - TRANSMISSION)

MLT 634 120 LSU (PS) S.E-E3
MLT 735/741 120 LSU (PS) S.5-E3
Item Designation
1 Air pressure sensor
2 O-ring
3 Glow plug
4 Air temperature sensor
5 Seal
6 Fuel pressure sensor
7 Seal
8 Speed sensor
9 O-ring
10 Bolt
11 Speed sensor
12 O-ring
13 Bolt
14 Oil pressure sensor
15 O-ring
16 Water temperature sensor
17 O-ring
18 Oil temperature sensor
19 O-ring
20 Transmission oil pressure switch
21 Oil temperature sensor
22 O-ring
23 Sensor
24 Seal
25 Transmission oil pressure switch
26 O-ring
80

80-03-M153EN (10/09/2010)
 D17
Electrical components location
ELECTRICITY (ENGINE - TRANSMISSION)

MLT 634-120LSU S.E-E3

MLT 634-120LSU PS S.E-E3
MLT 735-120LSU S.5-E3
MLT 735-120LSU PS S.5-E3
MLT 741-120LSU S.5-E3
MLT 741-120LSU PS S.5-E3

18 20
3
26
4 19
1 5
2

6 7

9
10
8 25 23
21

80
26 24
22

13

16 11
12
17 14

15

(10/09/2010) 80-03-M153EN
 D18
Electrical components location
80

80-03-M153EN (10/09/2010)
 ELECTRICAL CONTROL AND ADJUSTMENT

Pages

4TH5 HYDRAULIC PILOT CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3

CANDRIVE MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1
ELECTRONIC CONTROL OF THE A10VO EK1 PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . C1
PGV MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D1
OPERATION AND ADJUSTMENT OF THE LONGITUDINAL STABILITY
WARNING DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E1

80

(16/05/2011) 80-04-M153EN
 A2
Electrical control and adjustment
80

80-04-M153EN (16/05/2011)
 A3
Electrical control and adjustment

4TH5 HYDRAULIC PILOT CONTROL UNIT

Pages

4TH5 HYDRAULIC PILOT CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5

– Component locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5
– Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6
– Mechanical characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7
– Precautions for fitting and use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10
– Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10
– Recommendations for the removal of the hydraulic pilot control unit . . . . . . . . A11
– Hydraulic pilot control unit repair procedures . . . . . . . . . . . . . . . . . . . . . . . . . A12
MULTIFUNCTION JOYSTICK (JSM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A16
– Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A16

80
– JSM Joystick schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A17

(16/05/2011) 80-04-M153EN
 A4
Electrical control and adjustment
80

80-04-M153EN (16/05/2011)
 A5
Electrical control and adjustment

4TH5 HYDRAULIC PILOT CONTROL UNIT

Component locations

Multifunction joystick JSM

4TH5 hydraulic
pilot control
unit

80

(16/05/2011) 80-04-M153EN
 A6
Electrical control and adjustment

Functioning

Design

4TH5 pilot control units basically comprise a control lever (5), four pressure adjustment valves and
a body (10).
Each pressure adjustment valve comprises a control spool (6), a control spring (7), a return
spring (8) and a plunger (9).

Connection ports

P Supply
T Reservoir
1, 2, 3, 4 Control ports
80

Functioning

When not actuated the control lever is held in zero position by the four return springs (8). The control
ports (1, 2, 3, 4) are connected to the tank port T via the drilling (11).
When the lever (5) is deflected, the plunger (9) compresses the return spring (8) and the control
spring (7) and moves the control spool (6). Firstly, the connection between the relevant control port
and the tank port T closes, then, as the plunger (9) continues in its movement the control phase
begins when, supplied by P through the drilling (11) the control spool (6) finds its balance between
the force of the control spring (7) and the force resulting from the hydraulic pressure in the relevant
port (port 1, 2, 3 or 4).
Through the interaction of the control spool (6) and the control spring (7) the pressure in the control
ports is proportional to the stroke of the plunger (9) and thus the position of the control lever (5).
The boot (12) protects the mechanical components of the hydraulic control unit against external
contamination.

80-04-M153EN (16/05/2011)
 A7
Electrical control and adjustment

Mechanical characteristics

4Th5
Inlet pressure (bar) Up to 35
Back pressure at Port T (bar) Up to 3
Pilot oil flow (P to 1-2-3-4) (liters/minute) Up to 13
Max. permissible operating torque at lever (Nm) 10 during operation
80 exceptional one time loading
Weight (kg) 1,9

Hydraulic symbol

Joystick designation/deflection

Fixing bolts
1. Lever deflection when simultaneously
actuating two actuators.

2. Lever deflection when actuating one

80
actuator.

(16/05/2011) 80-04-M153EN
 A8
Electrical control and adjustment

Bird’s eye view of layout of joystick in cab

Front machine

4 T
P
3 1
2

Telehandler rear

Control curve 106

Pilot pressure, bar
80

Joystick deflection ° (for one port - for two ports)

4TH5
Number of ports controlled 1 2
Operating torque in N.m A 0,9 1,4
B 1,7 2,9
C 2,5 4,3

The operating torques indicate take into account the hydraulic force applied to the plunger, the force
arising from the standard return spring and the resistance arising from the boot.

80-04-M153EN (16/05/2011)
 A9
Electrical control and adjustment

Precautions for fitting and use

Essential precautions

- Do not direct the jet of a pressure washing device directly at the unit.

- Ensure the electrical cable is under no mechanical stress.

- During the operation protection via the rubber boot must be ensured.

- Do not use anything other than the original grip and lever.

4TH5 fitting precaution

- Mounting flange flatness = 0,5 mm

- Bolt head dimensions = Ø 10 mm

- Tightening torque for flange fixing bolts = 10 N.m max

- Hydraulic connections tightening torque = 30 N.m max

Installation 4TH5

80
Nominal diameter/fixing with 4 bolts
Fixing bolts D = 92 to 108 mm

(16/05/2011) 80-04-M153EN
 A10
Electrical control and adjustment

MAINTENANCE
Troubleshooting

Precautions
Before carrying out any troubleshooting procedure to identify the cause of breakdown or dismantling
the hydraulic control unit, it is essential to first carry out an investigation into the hydraulic circuit
to check for any possible cause of the breakdown external to the hydraulic control unit.

Faults related to abnormal operation of equipment attached to the hydraulic control unit.

Malfunction observed Probable cause Additional checks Solutions

No movement: lifting, 1. Leak See “Faults observable
lowering, crowd, tilt through visual
inspection”
2. Control spool seized Replace the hydraulic
or blocked control unit
Lack of movement 1. Poor pressure signal Replace the hydraulic
speed: lifting, lowering, control unit
crowd, tilt 2. Leak See “Faults observable
through visual
inspection”
No accessory or boom 1. See chapter “EMS” Checking connection See chapter “EMS”
extension movement

Faults observed through abnormal operation of the hydraulic control unit

Malfunction observed Probable cause Additional checks Solutions

Joystick does not return 1. Defective universal Replace the universal
80

automatically to neutral joint joint

position:
1. Returns manually with
obvious resistance
Joystick does not return 1. Lipped seal too hard Change guides and
automatically to neutral inside guide plungers
position: 2. Control unit setting Remove the control unit Replace the hydraulic
2. Returns manually with spring broken for visual inspection control unit
no resistance
3. Control unit cup
broken
The handgrip turns 1. Control components Re-tighten all controller
have loosened components

80-04-M153EN (16/05/2011)
 A11
Electrical control and adjustment

Visually observable defects

Malfunction observed Probable cause Additional checks Solutions

Damaged boot Replace boot
Oil on armrest coming Leak between guide and Lift the boot to visually Change guides and
from base of boot plunger inspect plungers
Seepage on body Porous body Replace the hydraulic
control unit

Recommendations for removal of hydraulic pilot control unit

- When removing the control unit, plug all openings immediately in order to prevent any contamination
of the hydraulic circuit.
- When re-fitting the control unit, remove plastic plugs from openings and pipes just before making
connections.
- Do not tighten connectors to a torque greater than that specified in the assembly instructions.
- Always check the quality of the hydraulic oil whenever maintenance/repair work is done.
- The use of PTFE tape, hemp and jointing compound is forbidden.
- Hydraulic lines and connections must be under not strain of any kind.

General recommendations

Precautions:
- BEFORE REMOVING THE HYDRAULIC CONTROL UNIT FROM THE TELEHANDLER IT IS ESSENTIAL
TO THOROUGHLY CLEAN THE CONTROL UNIT AND ITS SURROUNDINGS. DO NOT DIRECT THE JET
FROM A PRESSURE WASHER DIRECTLY AT THE CONTROL UNIT.
- THE HYDRAULIC CIRCUIT MUST BE KEPT PERFECTLY CLEAN OF ALL CONTAMINANTS. FIT PLASTIC
PLUGS ON PIPES AND OPENINGS AS SOON AS THEY ARE EXPOSED.

Wear protective clothing and use suitable equipment to avoid any accident, particularly

80
with hydraulic fluid.
Place all the actuators on the telehandler connected to the joystick control in their rest
position (on the ground, as low as they will go etc.) to avoid any accident arising from
uncontrolled movements when the hydraulic circuit is disconnected.
With the machine switched off, release any stored pressures, by moving all the joystick
control spools, moving the lever in every direction.

Removal of the hydraulic joystick control

- Fit plugs as soon as pipework has been disconnected from the control. Be sure to catch any
leaked oil in an appropriate recipient.
- Unscrew the fixing bolts and remove the joystick control.

(16/05/2011) 80-04-M153EN
 A12
Electrical control and adjustment

Re-fitting the joystick control

- Ensure all mating faces are perfectly clean.

- Check the mounting flange on the telehandler for flatness (tolerance 0,5 mm).
- Check the condition of all seals on line connectors.
- Clean the joystick control if it has been in prolonged storage.
- Offer the controller up to the flange and fix it to the telehandler using the bolts, torqueing them
to a maximum of 10 N.m.
- Attach the pipework to the controller as per the connections diagram, applying a maximum torque
of 30 N.m.
- Ensure that flexible hoses are correctly arranged, avoiding twists or rubbing.
- When the above steps have been correctly carried out the device can be put into service.

Repair procedures for the hydraulic control unit

Replacement of boot or hand-grip

Preliminary operations:
- Remove the controller from the armrest on the telehandler,
or create space by unscrewing the 4 fixing bolts from the
mounting flange in order to gain access to the electrical
cable.
- Secure the controller either in a vice or using a self-locking
wrench (jaws around the body, 65 mm).

NOTE: - It is not necessary to completely remove the

controller in order to unclip the electrical
connection.
- It is not necessary to remove or disconnect devices
which do not have an electrical connection.
80

Telehandler switched off:

- place all telehandler devices attached to the
joystick controller in their rest position.
- release stored pressures by moving the joystick’s
control spools, moving the joystick in all
directions.

Removing the hand-grip:

- Lift and fold back the boot.
- Take the wiring grommet from its housing to free the cable.
- Unscrew the fixing nut from the hand-grip (open-ended
19 mm spanner).

Re-fitting:
- Tightening torque: 40 ± 10% N.m.
- Unscrew and remove the hand-grip.

80-04-M153EN (16/05/2011)
 A13
Electrical control and adjustment

Universal joint removal

Preliminary operations:
- Remove the joystick controller from the telehandler
armrest.
- Secure the controller in a vice.
- Remove the hand-grip.

NOTE: It is recommended to remove the controller from the

telehandler. It is possible to carry out this operation
without removing the controller from the telehandler,
taking care to immobilize the body with regard to the
armrest using a self-locking wrench (jaws around the
body, opening 65 mm).

Universal joint removal:

- Insert an 8 mm Allen key into the universal joint and
unscrew it.

Re-fitting:
- Put a drop of Loctite 262 on the end of the universal joint
thread.
- Tightening torque: 50 ± 10% N.m

Remove: - the universal joint,

- the adjustment shim(s).

Refitting:
- Adjust the static sag of the universal joint by selecting the shims necessary to obtain a play-
free contact between the universal joint cam and the plungers. At its rest position the plungers
should not be depressed more than 0,2 mm. To check this value, inspect the displacement of
the plunger opposite one which is depressed.

80
NOTE: It can be hard to measure the static sag in situ. It is sometimes necessary to re-adjust after
re-fitting and checking the controller for correct operation.

When swapping out a universal joint for an identical replacement, start with shims of the thickness
already used on the controller.

(16/05/2011) 80-04-M153EN
 A14
Electrical control and adjustment

Removal of guides/plungers and control units

Preliminary operations:
- Remove the joystick controller from the telehandler
armrest.
- Remove the hand-grip.
- Remove the universal joint.

NOTE: It is recommended to remove the controller from the

telehandler. It is possible to carry out this operation
without removing the controller from the telehandler,
taking care to immobilize the body with regard to the
armrest using a self-locking wrench (jaws around the
body, opening 65 mm).

Dis-assembly:
- Place the controller body on a workbench.
- Remove the retention plate.

Re-fitting:
- Line up the cut-outs on the plate and the body for the
wiring grommets.

- Insert the end of a small screwdriver between the guide

and body, then carefully lift the guide to disengage it from
the body.

NOTE: Hold the guide with the other hand while removing it to limit the effect of the return spring.

- Remove the guide/plunger assembly.

- Repeat for the other 3 sub-assemblies.
80

Re-fitting:
- Use the retention plate to simultaneously engage the 4 guides with the body, ensuring they all
enter at 90°.

Re-assembly is the reverse of dis-assembly.

80-04-M153EN (16/05/2011)
 A15
Electrical control and adjustment

Checking the control units:

- Remove the control units from the body (plain long-nosed

pliers).
- Visually inspect the condition of the guides/plungers.
If any defect is observed replace the 4 sub-assemblies.
- Inspect the control units, paying particular attention to their
spring. If any defect is observed, replace the 4 units.

Old version New version

Guide/plunger Guide/plunger

Ring

Control unit Control unit

1st Guide/plunger A defective Replace with guide/plunger A’

scenario NOTE: on the control unit replace the half-moon
washers C with the C washer C’ and the cup D by D’
(included in the guide/plunger replacement kit).

80
2nd Control unit B defective Replace it with control unit B’
scenario NOTE: it is essential to replace the guide/plunger A
with A’ (do not use the C washer C’ or the cup D’
included in the guide/plunger replacement kit).
3rd Defective guide/plunger A’ Replace with guide/plunger A’
scenario or or
Control unit B’ defective Control unit B’

Re-assembly is the reverse of dis-assembly.

(16/05/2011) 80-04-M153EN
 A16
Electrical control and adjustment

MULTI-FUNCTION JOYSTICK (JSM)

Overview

JSM controller

Boom head
electrovalve (ON5) Accessory (R1)
Boom extension (R2)
Printed circuit board
Gear selector
DOWN
UP R
+ N
F
Forward/reverse shuttle control

J1 to J4: Replaces proportional thumbwheels

J5: Boom head accessory button

80

J10 J11 J6: Free

J4 J5 J6 J10: Forward/reverse gear switch

J1 J2 J3
J11: “+” et “-” press-button unit and PS unit

J12 J12: Boom extension (R2)

J13 J13: Accessory (R1)

J14

80-04-M153EN (16/05/2011)
 A17
Electrical control and adjustment

JSM Joystick wiring diagram

BoomEVhead Forward/reverse gear Accessoires

Attachments Boom extension
Télescope
tête de flèche Power Shift
Boutons Buttons
Power Shift Inverseur marche
electrovalve (optional) (optional)
(option) (option) shift Avant/Arrière
R1 R2
ON 5 UP/DOWN F/N/R

+ +

J5 J11 J10 J13 1 6 J12 1 6

Circuit
Printed
J14 17 6 7 2 4 3 5 1 9 11 10 12 imprimé
circuit

turquoise
Turquoise
Orange
yellow
Marron

Rouge
orange

Jaune

black

Blanc
white
Rose
Noir
brown

Bleu
Violet

pink

blue
red
purple

Gris
green
Vert
grey

1 1 2 1 2 3 4 5 1 2 3 4

1_12V Power supply

1_Alimentation (12 V) 1_Signal vers
to EMS
EMSAccessory
Accessoire
1_Option
boom 2_Immobilizer signal (12V)
2_S.Anti Démarage(12V) 2_Signal vers EMSBoom
to EMS Télescope
extension
head 1_S.PS
1_S.PS+(12V)
+(12V) 3_S.Marchesignal
3_Forward AV.(12V)
(12V) 3_Alimentation
3_5V 5V de
supply from EMSl'EMS
Accessory
1_S.Option EV Tête de flèche Accessoire
solenoid 2_S.PS-(12V)
2_S.PS -(12V) 4_S.Marchesignal
4_Reverse AR.(12V)
(12V) 4_5V supply from EMS Boom
5_0V 4_Alimentation 5V de l'EMS
valve 4 3
5_0V 2 3
extension Télescope
1 2 2 1 1 4
signal 5 2
6 1

80

(16/05/2011) 80-04-M153EN
 A18
Electrical control and adjustment
80

80-04-M153EN (16/05/2011)
 B1
Electrical control and adjustment

CANDRIVE MODULE

Pages

– THE CANDRIVE MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3

– INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4
– OPERATION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6

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Electrical control and adjustment
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Electrical control and adjustment

THE CANDRIVE MODULE

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Electrical control and adjustment

INSTRUCTIONS

Functioning

The Murphy unit converts digital data from the Can Bus into analogue data which can be displayed
on the instrument panel.

ECM LSU ECU

PAD tool
Can Bus J1939
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Rev counter

Engine coolant temperature gauge

Engine coolant temperature indicator

Clogged air/oil filter indicator

Murphy unit Instrument panel

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Electrical control and adjustment

Pin out

PIN FUNCTION Voltage

1 Negative DC, power supply (Earth) 0V
2 Positive DC, supply (+ignition switch controlled) 12 V
3 Negative DC, return current from gauge 0V
4 Engine coolant temperature gauge output 9V
5 CAN Hi 2,5 V

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6 Engine temperature indicator output 12,7 V
7 Clogged air filter indicator output 14,1 V
8 CAN Lo 2,5 V
9 Tachometer output
Pin 7 gives a square wave output (0V to battery positive DC)
with a frequency proportional to engine speed. At 1500 RPM
engine speed, the output frequency is 121 Hz approx.
10 Factory use
11 Factory use
12 Factory use

NB. All the values shown are indicative only.

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Electrical control and adjustment

OPERATION AND MAINTENANCE

Indicator LED

All standard models have a green CAN LED. A flashing CAN LED indicates that CANdrive is powered,
but is not receiving any J1939 data. A constantly lit CAN LED indicates power on with good CANbus
connection and J1939 activity. (Note: J1939 activity can originate from any device on the CANbus
network, and may not necessarily be valid data from the engine ECU).

Maintenance

CANdrive has no user serviceable parts.

Maintenance is therefore limited to the following preventative checks:
Check that electrical connections are secure.

Check the CANdrive is correctly installed and protected against liquids and an excessive
build-up of dust or dirt.
The front label and casing can be wiped with a clean, damp cloth. Do not use cleaning
solvents.
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Electrical control and adjustment

ELECTRONIC CONTROL OF THE A10VO EK 1 PUMP

Pages

ELECTRONIC CONTROL OF THE A10VO EK 1 PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C2

– 1 - Hydraulic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C2
– 2 - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C3
– 3 - Component description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C3
– 4 - Operating principles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C4
– 5 - Control threshold according to engine revolutions . . . . . . . . . . . . . . . . . . . . . . . .C4
– 6 - Error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C5
– 7 - Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C6
– 8 - Recording . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C6
– 9 - Configuring RC2-2 microcontroller: menu F1 (parametrage and configuration). . . . .C8
– 10 - Electrical diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C10

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Electrical control and adjustment

ELECTRONIC CONTROL OF THE A10VO EK 1 PUMP

1 - Hydraulic diagram
Valve FR 19B

Valve DR 290B

Solenoid valve EK1

A10V63
PUMP

Pump swash plate

angle control

Valve FR 19B Solenoid valve EK1

Valve DR 290B
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Pump swash plate angle control

S - Aspiration min.: -1 bar* (max. flow)
Max. 0 bar (zero flow)

B - Pressure min. 19 bar (pump stand-by pressure)

Max. 270 bar (main pressure relief valve pressure at control block)

X - LS min. 0 bar (Δp = 19 bar)

Load signal Max. 251 bar (270 - 19 bar)

L1 min. 0.0001 bar (19 bar)

Max. 0,1 bar (270 bar) * in general - 0,2 bar
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2 - General

The A10VO EK1 pump is an axial piston variable pump controlled by an RC2 microcontroller which
controls the pump’s output, thereby avoiding all engine overloads.

3 - Component description

100 PS

1 - EK1 proportional solenoid valve

4

2 - Accelerator position sensor (on injection

2 pump)

3 - Engine revolutions sensor (terminal W

3
on alternator)

4 - RC2 control unit (behind driver’s seat in

cab)
1

120 PS

1 - EK1 proportional solenoid valve

3

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2
2 - ECM (engine computer)

3 - RC2 control unit (behind driver’s seat in

cab)

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Electrical control and adjustment

4 - Operating principle

The electronic unit receives two pieces of information which permit it to authorize either full pump
output or 60% of its capacity.
One signal comes from the pedal position sensor (theoretical information about the engine revolutions)
and the other comes from terminal W on the alternator (real information about the engine revolutions).
The control unit compares the real and theoretical revolutions and deduces from this if the engine is
overloaded or not.
For example, if the engine is losing more than 50 rpm at idle the RC2 stops the pump exceeding 60%
output flow through the bias of the EK1 proportional solenoid valve, reducing its power supply.

5 - Control threshold according to engine revolutions

3000

Control threshold
Real diesel engine revolutions at terminal W on alternator

300
300tr/min
rpm

2500

2000 200
200tr/min
rpm
Q=100%

1500

50
50tr/min
rpm
1050
1000 Q=60%

500
80

x
0
Pedal position
0% 50% 100%
Q = pump flow Loss of revolutions tolerance range

The curve above indicates the control threshold according to engine revolutions. For example, at
1500 rpm the system accepts a difference of 200 rpm (y) between the real and theoretical rpm.
If the difference exceeds this value the electronics send out a command to reduce the capacity of
the pump.

When the real engine revolutions are below 1050 rpm (configurable value: F1, 4, 6 Switch rpm) the
pump capacity is automatically reduced to the minimum authorized value of 60% (configurable value:
F1, 4, 1GLR mini).

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Electrical control and adjustment

6 - Error codes

BB3 ⇒ F2
PAD ⇒ Fault reading

1- Actual Faults
2- Saved Faults
3- Delete Faults

The red LED on the RC2-2 flashes at different frequencies to indicate different faults.

DIAGNOSTIC MENU F2 Red LED flash

Error code Likely cause Effect Solution frequency
Pump proportional Hydraulic pump As a consequence of Check cable, connector 1000 ms
solenoid valve proportional solenoid the positive safety on and solenoid. (1 second)
valve cable cut or short the solenoid valve, the
circuited. pump keeps 100% flow.
The telehandler engine
may stall as there is
no electronic power
control.

Diesel potentiometer Diesel set point Maximum pump output Adjust diesel set-point 2000 ms
potentiometer on reduced to 30% flow. potentiometer. Check (2 seconds)
injection pump cable and connector.
(theoretical rpm) not
adjusted, wire cut or
short-circuited.
Diesel sensor * Cable to alternator Diesel engine load Check cable and 500 ms
(real rpm) cut or short- exceeds tolerance. connector. (1/2 second)
circuited. Active control of flow =
60%

* Caution: if the telehandler engine stalls in use the diesel sensor error code is displayed and the

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pump is locked into 100%. In this event it is necessary to switch off the ignition and re-start.

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7 - Measurement

BB3 ⇒ PROC
PAD ⇒ Parameter reading

When the PROC menu is selected you have a choice of 8 parameters. You must then select two of
them by pressing the number that corresponds to the required parameter. The two lines selected will
then show the values measured.

Menu PROC - Reading dynamic values

VALUE UNIT DESCRIPTION
1- Engine speed RPM Diesel engine set point (real engine revolutions)
2- Pump % Maximum authorized pump output
3- Nominal potentiometer % Not used
4- Diesel potentiometer % Gross value engine revolutions potentiometer
5- Diesel characteristic RPM Diesel learning curve (theoretical engine revolutions

6- D nominal value RPM Revolutions set point (learning curve - overwriting)

7- Swi output Not used
8- Prop current mA Supply current to pump solenoid valve

8 - Recording

BB3 ⇒ TEACH

When the TEACH menu is selected you can choose from 4 parameters. You must choose one of the
first two parameters. Parameters 3 and 4 are not used.

Menu available Function

1- Save Params The purpose of this function is to record and save in the RC2-2 memory all
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modifications made by the BB3 calibration tool.

2- Default Params The purpose of this function is to automatically re-establish all the factory settings
for menu F1. It is also called RESET.
Caution: After carrying out a factory reset, a minimum of two parameters must still
be set manually (blue highlights for setting theoretical engine revolutions).
1- Setting the “diesel potentiometer” F1, 1, 2 + setting procedure
6- “Diesel charac” learning curve, F1, 2, 1 and curve setting

3- Get EEPROM Not used

4- Send EEPROM Not used

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9 - Configuring RC2-2 microcontroller: menu F1 (parametrage and configuration)

1 - Gen settings 2 - GLR settings 3 - Param 1 GLR

1 - nominal potentiometer 1 - diesel charac 1 - P1 (nA > nN)

min. position / Adjustment range min. 0 Adjustment range min. 1

max. position / max. 1 max. 2000
step +/- 1 step +/- 10
0 400
Not used
Creation of learning curve

2 - diesel potentiometer 2 - GLR on/off 2 - P2 (nA < nN)

idle speed value 1 GLR off Adjustment range min. 1

min. position > 0,6 value 2 GLR on max. 2000
max. revolutions GLR on step +/- 10
max. position < 4,4 400

Potentiometer set point, diesel Example

Power regulation activation
engine revolutions
3 - Iiters/min pump 3- 3 - I1 (nA>nN n’>0)
(mA)
Adjustment range min. 200 0,8 V Adjustment range min. 0
max. 600 4,3 V max. 1000
step +/- 10 step +/- 10
400 mA 100
Minimum current proportional
solenoid valve
4 - max pump liters 4 - teeth diesel 4 - I2 (nA>nN n’<0)
(mA)
Adjustment range min. 1000 Adjustment range min. 1 Adjustment range min. 0
max. 1600 max. 300 max. 1000
step +/- 10 step +/- 1 step +/- 10
1200 mA MLA17 100
MLTB17
Maximum current to proportional Number of teeth on engine flywheel
solenoid valve or engine revolutions reading
coefficient
5 - Dither - freq 5 - fixed eng spd 5 - I3 (nA<nN n’<0)
(rpm)
value 1 100 Hz Adjustment range min. 0 Adjustment range min. 0
value 2 200 Hz max. 3000 max. 1000
100 Hz step +/- 10 step +/- 10
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Dither frequency adjustment 0 rpm 400

6 - CAN-service 6 - diesel-up 6 - I4 (nA<nN n’>0)

(ms)
value 1 on Adjustment range min. 500 Adjustment range min. 0
value 2 off max. 3000 max. 1000
off step +/- 22 step +/- 10
3000 240
Injector pump acceleration inertia
Not used ms
ramp
7 - displacem swi 7 - diesel-down 7 - D factor
(ms)
value 1 setting poti Adjustment range min. 500 Adjustment range min. 0
value 2 setting BB3 max. 3000 max. 1000
BB3 step +/- 22 step +/- 10
setting 500 ms 50
Max. pump output: controlled by
Injector pump deceleration inertia
potentiometer or BB3
ramp

8 - nom displacem 8- 8 - D call rate

Adjustment range min 0% Adjustment range min. 3

max 100% max. 6
+/- 1% step +/- 3
100 % 3
Max. permitted pump output in %

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4 - Param 2 GLR 5 - Ramps 6 - Calibration

1 - GLR min R pump out 1-
MLT B-E2 (ms)
adjustment range min 0% 60% Adjustment range min. 22
max 80% max. 10000 22 ms
step +/- 1% MLA Euro2 step +/- 22
60%
Min. permitted pump output Ramp between potentiometer set
in %. point and tilt towards maximum
NOTE: Do not set to less than output
40%.
2 - measure time R pump in 2 - Error Current
(ms) (ms)
adjustment range min 50 Adjustment range min. 22 22 ms Adjustment range min. 0%
max 1000 max. 10000 max. 100% 30%
step +/- 10 step +/- 22 step +/- 1%
150 ms
Ramp between potentiometer set
point and tilt towards minimum
output
3 - dump idle spee 3-
(rpm)
adjustment range min 50
max 300
step +/- 5
50 rpm
Engine load tolerance at idle
4 - dump half spee 4-
(rpm)
adjustment range min 50
max 500
step +/- 5
200 rpm
Engine load tolerance at half
revolutions
5 - dump full spee 5 - Min Cur SP
(rpm) (µA)
adjustment range min 50 Adjustment range min. 0
max 500 max. 5000 1000
step +/- 5 step +/- 100 µA

80
300 rpm
Engine load tolerance at
maximum revolutions
6 - Switch rpm 6 - Max Cur SP
(rpm) (µA)
adjustment range min 800 Adjustment range min. 1000
max 2500 max. 15000 7000
step +/- step +/- 100 µA
1050 rpm
Revolutions, output locked
at minimum
7 - Const ramp 7 - Min Cur DP
(ms) (µA)
adjustment range min 0 Adjustment range min. 0 Euro 2
max 2000 max. 5000 5000
step +/- step +/- 100 µA
1000 ms
Ramp GLR min → GLR max
8- 8 - Max Cur DP
(µA)
Adjustment range min. 1000 Euro 2
max. 15000 12000
step +/- 100 µA

Setting theoretical revolutions sensor User-adjustable settings

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10 - Electrical diagrams

100 PS

ignition switcht
electronics power
emergency supply
stop button
Movement outputs
Supply for proportional
and on/off outputs

earth

frequency inputs
proportional

proportional
rotational speed 1 2,3 A

outputs
sensors (W) sources 5V, 2x15 mA
solenoid valves
stabilized voltage

outputs
On/off
Voltage inputs
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potentiometers

TxD RS
232RxD
current inputs

BB-3
diagnostics
port
reserved

CAN H
CAN L
On/off inputs

RC2-2 earth

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Electrical control and adjustment

7,5A
G
vi
1A A
r r
M B
C
D
H
E

r r r r/n n vt o vi
A1
41 42 33 17 51 50 52

1 27 28 31 32 47 46 49 2

r r jvt m jvt r j vt jvt jvt

potentiometers

proportional
solenoid valves

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Electrical control and adjustment

120 PS

ignition switcht
electronics power
emergency supply
stop button
Movement outputs
Supply for proportional
and on/off outputs

earth

frequency inputs
proportional

proportional
2,3 A

outputs
sources 5V, 2x15 mA
solenoid valves
stabilized voltage

outputs
On/off
Voltage inputs
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TxD RS
current inputs

232 RxD BB-3

diagnostics
port
reserved

CAN H ECM Bus

CAN L Can
On/off inputs

RC2-2 earth

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Electrical control and adjustment

F1

G
155
F35 V
18 1
V10 17 F33 V 16

M 5 V 5

V 13

4 V 12

V 15

ep:2 V 3

V 11

8 54 14 53 44 43 42 45 V 4

A1
1 27 41 42 24 50 51 52

31 30

S7 31 2 28 40 39

ep:1 48 47
36 7 11 3

ep:3
Y5 21 22
35

AG AG

39 40 41

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Electrical control and adjustment
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Electrical control and adjustment

PGV MODULE

Pages

PGV module operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3

– Operating principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3
– Location of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D4
– Description of electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D5
– Description of hydraulic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D5
– Electricity (function of wires) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6
– Electricity (internal wiring connections in joystick) . . . . . . . . . . . . . . . . . . . . . . D7
– Wiring diagram (cabling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D8
– Wiring diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D9
– Hydraulics (component diagram) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10
– Hydraulics (schematic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11

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Input testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12
– Testing «extend boom» command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12
– Verification of «retract boom command» . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D13
– Testing «Accessory direction 1» command . . . . . . . . . . . . . . . . . . . . . . . . . . . D14
– Testing «Accessory direction 2» command . . . . . . . . . . . . . . . . . . . . . . . . . . . D15
Testing outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D16
– Installation of equipment for testing proportional solenoid valve . . . . . . . . . . . D16
– Installation of multi-meter for testing outputs . . . . . . . . . . . . . . . . . . . . . . . . . D17

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PGV MODULE
Operation of PGV module

Operating principle

The PGV module is an electronic interface that feeds an on/off signal to the boom extension and
accessory solenoid control valves.

The module also controls a PWM proportional solenoid valve, which modulates the increase and
decrease in pilot pressure.

Ref. unit
100 %
f = 150 Hz
I MAX = 45 % Parameters 233504
X = (1,2) * 1-1* 60
1-2 75
1-3 1900
I MAX 1-4 1250
2-1 55
X-2
2-2 75
X-1
2-3 1350
2-4 1250

t * The 1 corresponds to boom retraction

X-3 X-4 movement parameters.
The 2 corresponds to boom extension
movement parameters.

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Component locations

16 4
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19 10 1

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Description of electrical components

1 2 16
1 Solenoid valve (assembly)
2 Solenoid valve (proportional)
5 3 ON/OFF solenoid valve
4 Manipulator
6 9 4 5 Proportional solenoid valve connector
6 ON/OFF solenoid valve connector
3
7 Telehandler harness
8 Joystick wiring harness
9 Electronic control unit wiring harness
7 8
16 233 504 electronic unit (PGV module)

Description of hydraulic components

1
3

80

19 10

1 Solenoid valve (assembly)

2 Solenoid valve (proportional)
3 ON/OFF solenoid valve
10 Feed block + accumulator
19 Control Valve

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Electricity (function of cables)

Function of cables

1 - Green accessory button signal

2 - Yellow boom extension button signal
3 - Supply (+) boom extension buttons
4 - Transmission cut-off button
5 - Supply (+) transmission cut-off button
6 - Supply (+) accessory buttons
7 - Green boom extension button signal
7 - Yellow accessory button signal

Male connector: Female connector:

telehandler joystick

8 1 1 8 8 1 1 8
Harness 7 2 7 7 2 7 Harness
2 2
machine 6 3 3 6 6 3 3 6 manipulator
5 4 4 5 5 4 4 5
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PGV module

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Electrical control and adjustment

Electricity (internal wiring connections, joystick)

Joystick
connector
Yellow accessory
Boom Accessory Green accessory button signal
extension buttons button signal
buttons Yellow boom Green boom
extension button 1 8 extension
Transmission 7 button signal
signal 2
cut-off button
+12 machines 3 6 +12 machines
(boom extension 4 5 (accessory
button supply) button supply)
Transmission +12 machines
cut-off signal (transmission
cut-off button
supply)

3 + 6 + 5 +

5 joystick
buttons green button green button grey button

Boom Accessory Transmission

extension button cut-off button
button

80
yellow button yellow button

7 2 1 8 4 (K2 relay)

Boom Boom Accessory Accessory Transmission

retraction extension retraction extension cut-off signal
signal signal signal signal

PGV module

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Electrical control and adjustment

Wiring diagram (cabling)

2
Telehandler PGV module
harness Electronic box

4 1

n4

n11 n6 bc7
ro n2 n3 bc3
j n1 n9 bc4
n 8 1 1 8 n8 n5 8 1 1 8 bc6
bl 7 2 2 7 n7 n10 7 2 2 7 bc8
ro 6 3 3 6 n n 6 3 3 6 bc5
r 5 4 4 5
n n 5 4 4 5

o n n bc9
r bc11
bc12
bc10

jvt bl jvt ro
jvt jvt

1- Manipulator
3
80

2- Electronic box

3- Electrovalve

4- Telehandler wiring harness

jvt n
j
jvt
jvt

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Schematic diagram

+ 12 V PGV module
Attachment
Electronic card B C pos
A direction 1
Telescope extension
Transmission
7,5 A F.1 D E cut-off relay
Telescope retraction
Proportional bl Attachment
solenoid valve m
pos
direction 2
Wire No. Wire No.

Accessory 1 E
solenoid valve 1 9 10 Attachment 2
r jvt j 1 1
2 3 4 3
Pre-wiring for jvt ro 2 2
TUV option Boom extension B Telescope
solenoid valve 11 6 extension
r r 3 3 A Transmission
5 Cable colors 5 12 cut-off
ro or 4 n 4
Transmission cut-off
7 7 11 9
relay
r 5 n 5
Pre-wiring 7
9 9
for optional
accessory auto- Boom retraction
ro 6 n 6 D Telescope
solenoid valve 7 10 8 retraction
locking jvt bl 7 7
8 5 6 5
jvt
Accessory 2
n 8 8 C Attachment 1
solenoid valve

Joystick buttons
8 1 1 8 8 1 1 8
7 2 2 7 7 2 2 7
6 3 3 6 6 3 3 6
5 4 4 5 5 4 4 5

jvt

0V

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Hydraulics (component diagram)

Hydraulic circuit MLT 630/731 Series B - E2

16

7 1
3

Lay-out in cabin to the right 8

of operator

19
10
1 - Electrovalve
2 - Electrovalve
3 - Electrovalve
5 5 - Control block control hoses
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6 - Control block control hoses

7 - Supply hose
8 - Return (to tank) hoses
10 - Feed block

6 16 - Module
19 - Control Valve

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Hydraulics schematic diagram

Min. pressure ≈ 10 bar

Max. pressure ≈ 140 bar 0,7 L. 10 - Feed block + accumulator
13 b
P1 1 - Solenoid valve (controlled by the electronic
35 b 10 module)
U
19 - Control Valve
45 ±5 b EA - Accessory element
ET - Boom extension element
P2 T
R - Hydraulic tank
P - Equipment pump
T P M - I.C. engine
M4
M2
Telescoping

CA - Suction strainer
ELECTRICAL
B1
COMMANDS
A1
Telescope M2 M1
extension Attachment
M3
Telescope M4 M3 M1
Attachments

retraction Attachment
B2

A2
1

X1 X2

LS CF EF 80
M3 M4
700 μ

P
43,77 cm3/tr M
M1 M2

CA

Y1 Y2
R 19

(10/09/2010) 80-04-M153EN
 D12
Electrical control and adjustment

Input verification

Testing “extend boom” command

Connect the multi-meter between the joystick connector and the input connector on the electronic
module.

Without pressing
the joystick
0V button
0 20 V

8 1 1 8 8 1 1 8
7 2 2 7 7 2 2 7

6 3 3 6 6 3 3 6
5 4 4 5 5 4 4 5

Joystick
Electronic module connector
input connector

Multi-meter

When pressing
the joystick
80

12 V button

0 20 V

8 1 1 8 8 1 1 8
7 2 2 7 7 2 2 7

6 3 3 6 6 3 3 6
5 4 4 5 5 4 4 5

Joystick
Electronic module
connector
input connector

Multi-meter
80-04-M153EN (10/09/2010)
 D13
Electrical control and adjustment

Testing the “retract boom” command

Connect the multi-meter between the joystick connector and the input connector on the electronic
module.

Without pressing
0V the joystick
button
0 20 V

8 1 1 8 8 1 1 8
7 2 7
7 7 2 7
2 2
6 3 3 6 6 3 3 6
5 4 4 5 5 4 4 5

Joystick
Electronic module connector
input connector

Multi-meter

When pressing
the joystick

80
12 V button
0 20 V

8 1 1 8 8 1 1 8
7 2 7
7 7 2 7
2 2
6 3 3 6 6 3 3 6
5 4 4 5 5 4 4 5

Joystick
Electronic module connector
input connector

Multi-meter
(10/09/2010) 80-04-M153EN
 D14
Electrical control and adjustment

Testing the “Accessory direction 1” command

Connect the multi-meter between the joystick connector and the input connector on the electronic
module.

Without pressing
0V the joystick
button
0 20 V

8 1 8
8 1 1 8 8 1
7 2 2 7 7 2 2 7

6 3 3 6 6 3 3 6
5 4 4 5 5 4 4 5

Joystick
Electronic module
connector
input connector

Multi-meter

When pressing
the joystick
12 V button
80

0 20 V

8 1 8
8 1 1 8 8 1
7 2 2 7 7 2 2 7

6 3 3 6 6 3 3 6
5 4 4 5 5 4 4 5

Joystick
Electronic module connector
input connector

Multi-meter
80-04-M153EN (10/09/2010)
 D15
Electrical control and adjustment

Testing the “Accessory direction 2” command

Connect the multi-meter between the joystick connector and the input connector on the electronic
module.

Without pressing
the joystick
0V button
0 20 V

8 1 1 8 8 1 1 8
7 2 2 7 7 2 2 7

6 3 3 6 6 3 3 6
5 4 4 5 5 4 4 5

Joystick
Electronic module connector
input connector

Multi-meter

When pressing
the joystick
12 V button

80
0 20 V

8 1 1 8 8 1 1 8
7 2 2 7 7 2 2 7

6 3 3 6 6 3 3 6
5 4 4 5 5 4 4 5

Joystick
Electronic module connector
input connector

Multi-meter
(10/09/2010) 80-04-M153EN
 D16
Electrical control and adjustment

Testing outputs

Installation of equipment for testing proportional solenoid valve

Using a measurement adapter (Ref. 662196), it is possible

to check the proportional solenoid valve supply. After
approximately 3 seconds, the voltage measured at the
solenoid valve should correspond to 45% of the voltage at
the battery.

(see table on following page)

Adapter 662196

f = 150 Hz
100 %
IMAX = 45 %
X = (1,2)

I MAX

X-2
X-1

t
X-3 X-4
80

80-04-M153EN (10/09/2010)
 D17
Electrical control and adjustment

Connecting multi-meter to test outputs

Connect the multi-meter between the PGV module output connector and the telehandler connector.
Carry out the operations described in the table below.

V
0 20 V

PGV module

Male connector:
telehandler
2
1
8 1 8
8 8 1 8
1 1
7 7
7 7 2 7
Telehandler 2 2 2

harness 6 3 3 6 6 3 3 6
5 4 4 5 5 4 4 5

Output connector
on electronic unit

Brown wire
Multi-meter
Blue wire

Adapter
Ref. 662196

80
V
0 20 V

Proportional
solenoid valve

Joystick

(10/09/2010) 80-04-M153EN
 D18
Electrical control and adjustment

8 1 2 7 Proportional Proportional
Connector terminal → solenoid valve solenoid valve
Brown wire Blue wire
Joystick button
None 0V 0V 0V 0V 0V 0V

Start of press Battery voltage 0 V 0V 0V 0V 0V

Yellow Held for 3 seconds Battery voltage 0 V 0V 0V 45% U battery 0V
accessory
Release start Battery voltage 0 V 0V 0V 45% U battery 0V
Released 3 seconds 0V 0V 0V 0V 0V 0V
Start of press 0V Battery voltage 0V 0V 0V 0V
Green Held for 3 seconds 0V Battery voltage 0V 0V 45% U battery 0V
accessory
Release start 0V Battery voltage 0V 0V 45% U battery 0V
Released 3 seconds 0V 0V 0V 0V 0V 0V
Start of press 0V 0V Battery voltage 0V 0V 0V
Yellow Held for 3 seconds 0V 0V Battery voltage 0V 45% U battery 0V
boom
Release start 0V 0V Battery voltage 0V 45% U battery 0V
extension
Released 3 seconds 0V 0V 0V 0V 0V 0V
Start of press 0V 0V 0V Battery voltage 0V 0V
Green Held for 3 seconds 0V 0V 0V Battery voltage 45% U battery 0V
boom
Release start 0V 0V 0V Battery voltage 45% U battery 0V
extension
Released 3 seconds 0V 0V 0V 0V 0V 0V
80

80-04-M153EN (10/09/2010)
 E1
Electrical control and adjustment

OPERATION AND ADJUSTMENT OF THE LONGITUDINAL

STABILITY WARNING DEVICE

Pages
Operation and adjustment of the longitudinal stability warning device . . . . . . . . . . . . E2
Safety system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3
Procedure for checking the strain gauge on the longitudinal stability
warning device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E4
– Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E4
– Electric checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E4

80

(16/05/2011) 80-04-M153EN
 E2
Electrical control and adjustment

Operation and adjustment of the longitudinal stability warning device

This adjustment must be made with a stable rear axle temperature. Do not carry out this
adjustment after carrying out brake tests as the difference in temperature between the
axle and the gauge will adversely affect the adjustment.

Before adjusting the unit move the machine in order to ensure the strain gauge is
positioned.
A last check of this setting must be made before the machine is delivered.

Diagram 1 Diagram 2
Affix the adhesive label after
carrying out adjustments and
1 Red LED checking compliance. (A new
label to be affixed whenever
adjustment is carried out)

2 Red LEDs SE
2 Yellow LEDs SA
LY
4 Green LEDs 224
777

Adjustment control access

hole. (Tool diameter 2 mm;
length 40 mm minimum)
80

80-04-M153EN (16/05/2011)
 E3
Electrical control and adjustment

Safety system

2 Red LEDs

Test button

Audible warning disabled

indicator light

2 Yellow LEDs Disable audible

warning button

4 Green LEDs
DEUTSCH
IPD - USA
DT04-3P

80
Power connector and signal out
from aggravating movement
cut-off

Connection to strain gauge

Adjustment micro-contact
(accessible with 6 mm
Allen key)

(16/05/2011) 80-04-M153EN
 E4
Electrical control and adjustment

Procedure for checking the longitudinal stability warning device strain gauge

Connections

Supply + red wire/contact No1

Supply - and PT 100 brown wire/contact No2
Measurement + yellow wire/contact No3
Measurement - green wire/contact No4
PT 100 blue wire/contact No5
Shielding white wire/contact No6

Description of strain gauge connectors

Shielding 6 1 Supply A+

PT 100 5 2 Supply A-

Measurement - M 4 3 Measurement M+

Before carrying out any electrical test, visually inspect the gauge and its connections.
80

Electrical check

Disconnect the gauge from the electrical circuit.

Using a multi-meter, take the following measurements.

350 Ω
off 500Ω
5 KΩ
Fig. A
Measure the resistance between A+ and A- = Z supply
(supply resistance)
Values: 300Ω ≤ Z supply ≤ 400Ω

Fig. A

80-04-M153EN (16/05/2011)
 E5
Electrical control and adjustment

Fig. B
Measure the resistance M+ and M- = Z supply
350 Ω (measurement system resistance)
off 500Ω Values: 300Ω ≤ Z supply ≤ 400Ω
5 KΩ

Fig. B

Fig. C
Measure the resistance between A- and PT100
109 Ω = Z PT100
off 500Ω Values: 101Ω + 0,39xT (gauge temperature)
5 KΩ
Example:
T = 20°C so Z PT100 = 101Ω + 7,8Ω = 109Ω

Fig. C

Fig. D
Measure the resistance between A+ and the shielding:
l Zbl
off 500Ω
Zbl > 30MΩ (infinite resistance or open circuit)
5 KΩ

Fig. D
80

Fig. E
l Measure the resistance between A+ and the telehandler
earth: Z earth
off 500Ω
5 KΩ Z earth > 30MΩ (infinite resistance or open circuit)

Fig. E

(16/05/2011) 80-04-M153EN
 E6
Electrical control and adjustment
80

80-04-M153EN (16/05/2011)
 ELECTRICAL SPECIFIC TOOLING

pages

DIAGNOSTIC CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DOCKING STATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
WORKSHOP AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
BREAK OUT BOX KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SOLENOID ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

80

(11/05/2011) 80-09-M153EN
 2
Electrical specific tooling

DIAGNOSTIC CASE
80

80-09-M153EN (11/05/2011)
 3
Electrical specific tooling

12
11

10

5
9
13

6 8

7
1

3 4

80
Diagnostic toolkit .......................................................................................746120

Consisting of:

1. 1 Cigar lighter socket supply cable ............................................745240

2. 1 Red battery crocodile clip and cable .......................................745241
3. 1 Black battery crocodile clip and cable .....................................745242
4. 1 Supply cable ........................................................................745243
5. 1 Portable VCI cable ................................................................745244
6. 1 Manitou OBD Diag cable .......................................................745245
7. 1 Manitou RC2/RC4 Diag cable ................................................745246
8. 1 CE L standard Mains cable: 3m .............................................745247
9. 1 Diag power supply unit 3G 60W .............................................745251
10. 1 Battery LI-ION 7.4V/9.6AH ....................................................745367
11. 1 PAD (rugged PC and case kit) ................................................745438
12. 1 VCI (Vehicle Communication Interface/PAD)............................745439
13. Styli (batch of 3) ......................................................................745368
(11/05/2011) 80-09-M153EN
 4
Electrical specific tooling

DOCKING STATION

Docking station (battery charging)..............................................................745236

WORKSHOP AREA
80

Workshop area (area + station)...................................................................745235

80-09-M153EN (11/05/2011)
 5
Electrical specific tooling

BREAK OUT BOX KIT

Break out box (DT type connectors)

Break out box (DTM type connectors)

Break out box kit .......................................................................................785503

Consisting of:

1. 1 break out box (DT type connectors) ........................................785504

2. 1 Break out box (DTM type connectors) .....................................785505

SOLENOID ADAPTER
80

Solenoid adapter ........................................................................................662196

(11/05/2011) 80-09-M153EN
 6
Electrical specific tooling
80

80-09-M153EN (11/05/2011)