Manitou Telehandler MT625 HA 75K ST3B S1 MINING Repair Manual 647766 - PDF DOWNLOAD

647766EN (22/04/2019)

MT 625 HA 75K ST3B S1 MINING

Repair manual additional to standard repair manual Ref: 647469

647766EN

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DATE OF ISSUE 22/04/2019

OBSERVATION - 1st ISSUE

This ADDITIONAL REPAIR MANUAL 647766 is a specific supplement.

For assemblies of parts not included in this document consult the repair manual reference 647469.

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

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

Transmission

6repair manual 647469

Axle

6repair manual 647469

6repair manual 647469

- Bodywork

Options

- Attachments

6repair manual 647469

6repair manual 647469

90

cab

6repair manual 647469

110

Driver’s

80

Electricity

Frame

00 70

Hydraulic

85

Boom

50

40

Brake

10

6repair manual 647469

20

Engine

30

General characteristics and safety

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Interactive repair manual

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Abbreviations list °

Angle degree

Ω

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

a

Ampere: unit of measurement for electrical current intensity. It is one of the basic International System (SI) units.

aoc

Ammonia Oxidation Catalysts: elimination of the excess ammonia (NH3) by oxidation from combustion gases having undergone selective catalytic reduction (SCR) of nitrogen oxides (NOx), by injection of DEF.

apc

After Power Contact: positive power supply after switching on the ignition.

Bmep

Bloc Manipulateur ÉlectroProportionnel - Electro-proportional joystick unit: controls the hydraulic movements of lowering, lifting, tilting and digging by electronic sensors.

can

Controller Area Network: control communication network for inter-system communication (J1939, Open, etc.).

co

Carbon Monoxide: colourless, odourless and highly toxic gas.

cRc

Comfort Ride Control: Boom suspension.

cVt

Continuous Variable Transmission.

def

Diesel Exhaust Fluid: aqueous solution consisting of 32.5% urea and 67.5% demineralised water, used to transform 85% of pollutants (NOx) into water vapour (H2O) and harmless nitrogen (N2).

doc

Diesel Oxide Catalyst: part of the exhaust gas filter or a post-treatment device used to reduce polluting emissions (HC and CO).

dpf

Diesel Particulate Filter : o FAP.

dsB

Double Switch Board: smart double switch board connected to a LIN network via a wiring harness.

dtc

Diagnostic Trouble Code: fault codes

ecm/ecu

Electronic or Engine Control Module/Unit : ECU making it possible to control the machine or the engine.

eGR

Exhaust Gaz Recirculation : Exhaust gas recirculation circuit to intake to reduce oxygen supply and reduce NOx.

fap

Filtre À Particule (= Diesel Particulate Filter): filtration system used to trap fine particles, carcinogenic for humans, contained in combustion gases, particular from wood fires and Diesel engines.

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fmi

Failure Mode Identifier: identifies the type of fault: 0 – The data is valid but the data is above the normal operational range.

1 – The data is valid but the data is below the normal operational range.

2 – The data is erratic, intermittent, or incorrect.

3 – The voltage is above normal or the voltage is shorted high.

4 – The voltage is below normal or the voltage is shorted low.

5 – The current is below normal or the circuit is open.

6 – The current is above normal or the circuit is grounded.

7 – The mechanical system is not responding properly.

8 – There is an abnormal frequency, an abnormal pulse width, or an abnormal time period.

9 – There has been an abnormal update.

10 – There is an abnormal rate of change.

11 – The failure mode is not identifiable.

12 – The device or the component is damaged.

13 – The device requires calibration.

14 – There is a special instruction for the device.

15 – The signal from the device is high (least severe).

16 – The signal from the device is high (moderate severity).

17 – The signal from the device is low (least severe).

18 – The signal from the device is low (moderate severity).

19 – There is an error in the data from the device.

20 – There is an error in the data from the device (high).

21 – There is an error in the data from the device (low).

31 – The device has failed and the engine has shut down.

gr.

Greek: signifies a word of Greek origin.

h

hours: unit of measurement for time derived from the second (1 h = 3600 s).

hc

Hydrocarbon: organic compound consisting exclusively of carbon (C) and hydrogen (H) atoms.

hz

Hertz: One hertz is equivalent to one event per second (s-1 or 1⁄ s).

hs

High Side: power side power supply.

hVac

Heating, Ventilation and Air-Conditioning: in-cab heating, ventilation and air-conditioning block.

hmi

Human-Machine Interface: dashboard screens.

i.V.

Interactive View: 2nd generation MANITOU machine diagnostics software.

Jsm

Joystick Switch & Move: Control handle serving to perform all telescope movements, as well as to control machine forward and reverse movements with one hand.

lat.

Latin: signifies a word of Latin origin.

lin

Local Interconnect Network.

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llmi

Longitudinal Load Moment Indicator: displaying machine stability.

ls

Low Side: ground side power supply.

lsu

Load Sensing Ultra: hydraulic load detection.

m

Metre: unit of measurement for length. It is one of the basic International System (SI) units.

min.

minute : unit of measurement for time derived from the second (1 min = 60 s).

nc

o NF.

nf = nc

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

no

Normally Open: normally open contact.

nox

Nitrogen Oxide: regulated air pollutants.

pad

Plug And Diag: MANITOU machine diagnostics software.

ps/ps+

Power Shift: semi-automatic gear box.

Power Shift +: automatic gear box from 3rd gear and higher.

pwm

Pulse Width Modulation: modulation of the pulse width (MLI) of a fixed-frequency digital electronic signal synthesising intermediate analogue signals over a certain duration.

s

Second: unit of measurement for time. It is one of the basic International System (SI) units.

sahR

Spring Applied Hydraulically Released: method of blocking the parking brake (negative brake).

scR

Selective Catalytic Reduction: reduction of nitrogen oxides (NOx) emitted by internal combustion engines.

spn

Suspect Parameter Number: identifies the component concerned by the fault.

spu

Safety Power Unit: machine controller.

usB

Universal Serial Bus.

V

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

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Contents 00.1 Work during the Warranty Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 00.2

00.3

GENERAL INSTRUCTIONS AND SAFETY NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 00.2.1

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

00.2.2

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

00.2.3

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

00.2.4

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

GENERAL CHARACTERISTICS AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 00.3.1

CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

00.3.2

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

00.3.3

Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

00.3.4

DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 MT 625 HA 75K ST3B S1 - Standard with floating forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 MT 625 HA 75K ST3B S1 - Standard with FIXED PLATFORM 1.2 M 200 kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

00.4

GENERAL CONTROL AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 00.4.1

STANDARD TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

00.4.2

METRIC - IMPERIAL UNIT CONVERSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

00

GENERAL, CHARACTERISTICS AND SAFETY

GENERAL, CHARACTERISTICS AND SAFETY

00

10

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GENERAL, CHARACTERISTICS AND SAFETY 00.1 Work during the Warranty Period Veuillez vérifier la période de garantie de votre matériel avant toutes opérations.

La garantie ne serait plus couverte si l’intervention effectuée pendant cette période n’était pas conforme aux recommandations.

00.2 GENERAL INSTRUCTIONS AND SAFETY NOTICE 00.2.1 FOREWORD This chapter deals with the general instructions and safety notice during inspection and maintenance work.

Other instructions and warnings are indicated in each chapter concerned.

In order to reduce accident risks, make sure to: – Follow the instructions in the truck operating and maintenance manual. ⇒ This manual should be found in all trucks.

– Please follow all safety instructions.

– Use the appropriate tools for any work to be performed.

– Use original Manitou spare parts.

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

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

00.2.2 SERVICING POSITION Before any intervention: 1 2 3 4

-

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

Turn off the engine and remove the ignition key.

Let the machine cool down.

Take all the pressure out of the circuits concerned.

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00.2.3 EXPLANATION OF SYMBOLS The symbols shown below are used to warn of potential hazards as well as to provide useful information concerning a procedure.

sYMBoLe

oBseRVAtIon

danGeR

Indicates an imminent hazardous situation which, if not avoided will result in death or serious injury.

waRninG

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

caution

Indicates a potentially hazardous situation which, if not avoided, may result in minor injury or damage to property. It is also used to warn users of unsafe practices.

tip pRotect the enViRonment specific toolinG

11

00

GENERAL, CHARACTERISTICS AND SAFETY

Indicates a tip to facilitate the performance of a procedure.

Indicates a message to draw attention to important information regarding environmental protection.

Indicates special tools for performing a task.

4

"see": Indicates a cross-reference to a manual.

5

“see”: Indicates a cross-reference to a page.

0

“see”: Indicates a cross-reference to a picture.

3

"WeIGHt": Indicates the weight of an item.

(E.g.: it helps to anticipate an action linked to a person's health or the choice of lifting equipment)

2

"tIGHtenInG toRQue": Indicates the value of tightening torque to be applied.

1

"oPtIon": Indicates the presence of an option.

The manufacturer cannot predict all possible risky situations. Consequently, the safety instructions given in the manual are not exhaustive.

At any time, as an operator, you must consider, within reason, the possible risk to yourself, to others or to the lift truck itself when you repair, service or drive it.

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

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GENERAL, CHARACTERISTICS AND SAFETY

00

12

00.2.4 SERVICING RULES

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

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

pRÉcaution 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.

aVeRtissement Before carrying out any operation on an electrically powered component, activate the battery cut-off.

1 2

pRÉcaution Press the battery switch at least 30 seconds after disconnecting the electrical contact with the ignition key.

aVeRtissement If the telehandler does not have a battery isolating switch, disconnect the battery terminals then gather them.

pRÉcaution ECU

Before carrying out any welding operations, think of disconnecting computers.

pRÉcaution A machine operating in a contaminated environment should be specifically equipped. Moreover, local safety notices deal with maintenance and repair work on such machines.

GENERAL, CHARACTERISTICS AND SAFETY

13

00

647766EN 00 (22/04/2019)

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

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

Always wear protection glasses, gloves, safety shoes as well as any other protection required for the work to be carried out.

danGeR when carrying out maintenance operations near a mobile object, make sure it is securitized.

pRotÉGeR l’enViRonnement when changing, or draining oils or fuel, or any other operation with liquids, solids, gases that are harmful to the environment, make sure the necessary precautions are taken to avoid contaminating the environment.

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GENERAL, CHARACTERISTICS AND SAFETY

00

14

danGeR when lifting or shoring a component of the machine, make sure the equipment used is suitable for at least the load for which it is subjected by the component and that it meets the national standards for lifting devices. when using a jack, make sure it is used on a flat, uniform surface, is sturdy enough to support the load, that its lifting capacity is sufficient and that it is correctly placed and positioned under the machine.

pRÉcaution Make sure no object or tool which could cause an accident is left in the machine.

aVeRtissement Never control any leaks using a hand.

max. min.

MAX MIN

pRÉcaution Never adjust a component to over the maximum capacity indicated by the manufacturer.

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GENERAL, CHARACTERISTICS AND SAFETY

00

15

00.3 GENERAL CHARACTERISTICS AND SPECIFICATIONS 00.3.1 CHARACTERISTICS Designation

MT 625 HA 75K ST3B S1 MINING

Weight of truck with standard attachment (fixed platform 1.2 m)

unladen

11309.60 lb (5130 kg)

laden

12114.28 lb (5495 kg)

Unladen weight distribution per axle with standard attachments

FR

5930.37 lb (2690 kg)

RR

5379.22 lb (2440 kg)

Traction force (unladen)

7261.04 lbf (3230 daN)

00.3.2 LUBRICANTS AND FUEL Designation Fuel tank Engine oil Cooling system Hydraulic tank Brake system Air-conditioning system Front/rear axle differential Front/rear wheel reduction gear Lubrication of pins and pivots Boom pad lubrication

Type GNR HP (High-Performance Non-Road Diesel): EN590 / ASTM D975 MANITOU EVOLOGY OIL 10W40 API CJ4 Cooling liquid (protection -35°) MANITOU ISO VG 46 Hydraulic oil MANITOU Mineral brake fluid R134a gas Special MANITOU oil for immersed brakes MANITOU SAE 80W90 Mechanical transmission oil MANITOU blue multi-purpose lubricant MANITOU black multi-purpose lubricant

Quantity 16.64 gal US (63 ℓ) 2.95 gal US (11.2 ℓ) 3.17 gal US (12 ℓ) 22.45 gal US (85 ℓ) 0.26 gal US (1 ℓ) 25.59 oz av (725 ±25 g) 1.05 gal US / 1.00 gal US (4 ℓ / 3.8 ℓ) 0.21 gal US / 0.23 gal US (0.8 ℓ / 0.9 ℓ)

1823

1994

1956

00.3.3 Size

3779

GENERAL, CHARACTERISTICS AND SAFETY

00

16

00.3.4 DIMENSIONS MT 625 HA 75K ST3B S1 - Standard with floating forks A B C C1 D D1 D2 E F F1 G G1 G2 G3 H H1 I J K L N O P2 P3 R S T U1 U2 V V1 V2 W W1 W2 W3 Y Z

in (mm) 47.24 (1200) in (mm) 90.55 (2300) in (mm) 39.01 (991) in (mm) 36.53 (928) in (mm) 153.30 (3894) in (mm) 150.82 (3831) in (mm) 128.93 (3275) in (mm) 200.55 (5094) in (mm) 58.74 (1492) in (mm) 58.74 (1492) in (mm) 9.44 (240) in (mm) 12.99 (330) in (mm) 9.96 (253) in (mm) ° ° in (mm) 23.74 (603) in (mm) 31.37 (797) in (mm) 39.96 (1015) in (mm) 1.77 (45) in (mm) 51.73 (1314) in (mm) 4.92 (125) ° 37 ° 52 in (mm) 124.01 (3150) in (mm) 261.86 (6651.5) in (mm) 154.92 (3935) in (mm) 78.508 (1994) in (mm) 80.86 (2054) in (mm) 185.03 (4700) in (mm) 30.11 (765) in (mm) 130.33 (3310.5) in (mm) 71.37 (1813) in (mm) in (mm) in (mm) ° 12 117 °

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MT 625 HA 75K ST3B S1 - Standard with FIXED PLATFORM 1.2 M 200 kg

D1

C1

G2

G1

P2

P3

N

U1 U2

C2

G

59.05 (1500) 90.55 (2300) 96.06 (2440) 36.53 (928) 11.81 (300) 150.82 (3831) 128.93 (3275) 210.35 (5343) 58.74 (1492) 58.74 (1492) 9.44 (240) 12.99 (330) 9.96 (253) 23.74 (603) 31.37 (797) 47.24 (1200) 50.86 (1292) 51.73 (1314) 37 52 124.01 (3150) 271.65 (6900) 160.43 (4075) 75.59 (1920) 80.86 (2054) 190.55 (4840) 30.11 (765) 130.31 (3310) 71.37 (1813) -

L

in (mm) in (mm) in (mm) in (mm) in (mm) in (mm) in (mm) in (mm) in (mm) in (mm) in (mm) in (mm) in (mm) in (mm) in (mm) ° ° in (mm) in (mm) in (mm) in (mm) in (mm) in (mm) ° ° in (mm) in (mm) in (mm) in (mm) in (mm) in (mm) in (mm) in (mm) in (mm) in (mm) in (mm) in (mm) ° °

D2

A

B

C

I

E

J

F1

F W

V

K

A B C C1 C2 D D1 D2 E F F1 G G1 G2 G3 H H1 I J K L N O P2 P3 R S T U1 U2 V V1 V2 W W1 W2 W3 Y Z

R

V1

S

V2

17

00

GENERAL, CHARACTERISTICS AND SAFETY

T

00

18

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GENERAL, CHARACTERISTICS AND SAFETY

00.4 GENERAL CONTROL AND ADJUSTMENT 00.4.1 STANDARD TIGHTENING TORQUES

b

standard tightening torques To be used. unless otherwise indicated in the removal or refit operations. sCReW / nut AsseMBLY - with hexagon head screws without flanges ou cylinder head hexagon socket screws.

- for dry-fitted zinc-plated fasteners and for torque tools having a ± 20 % class C tightening torque accuracy (equivalent to pneumatic screwdrivers).

1 - nF e 25-030-1 : Ø x “coarse” pitch

Grade 8.8 n.m lb-in 8.2 72.57 20 177 40 354 69 611 111 982 175 1549 240 2124 341 3018 470 4160 588 5204 874 7735 1181 10453 1614 14285 2068 18303

M6 x 1 M8 x 1.25 M10 x 1.5 M12 x 1.75 M14 x 2 M16 x 2 M18 x 2.5 M20 x 2.5 M22 x 2.5 M24 x 3 M27 x 3 M30 x 3.5 M33 x 3.5 M36 x 4

b b

Grade 10.9 n.m lb-in 12.1 107 30 265 59 522 102 903 163 1443 256 2266 352 3115 501 4434 691 6116 864 7647 1284 11364 1735 15356 2371 20985 3037 26880

Ø x “fine” pitch

Grade 8.8 n.m lb-in 22 195 43 (46) 380 (407) 74 (78) 655 (690) 123 1088 190 168 279 2469 391 3460 531 4700 659 5833 965 8541 1351 11957 1821 16117 -

M8 x 1 M10 x 1.25 (x 1) M12 x 1.5 (x 1.25) M14 x 1.5 M16 x 1.5 M18 x 1.5 M20 x 1.5 M22 x 1.5 M24 x 2 M27 x 2 M30 x 2 M33 x 2 -

Grade 10.9 n.m lb-in 32 283 63 (68) 558 (602) 108 (115) 956 181 1602 279 2470 410 3629 574 5080 780 6903 967 8559 1418 12550 1984 17560 2674 23667 -

For hexagon screws with flanges (nF e 25-030-1) : Apply an increased torque of +10%.

Where washers are used. the following coefficient is to be applied (FD e 25-502) : -

Plate : +0%

-

smooth tapered washer (CL): +5% -

-

spring (or Grower) washer without jaws (W) : +10% Conical. internal teeth (CDJ-JZC) : +15%.

2 - With marking :

4

6

5

4t ------------

6t ------------

8t ------------

M6 x 1 M8 x 1.25 M10 x 1.25 M12 x 1.25 M14 x 1.5

b

M16 x 1.5

(flange : 4.8T) n.m lb-in

n.m

lb-in

6.5

57.5

16

142

32

283

59

522

5.4 (5.5) 13 (13) 25 (27) 47 (50)

48 (49) 115 (115) 221 (239) 416 (443)

75 (78)

664 (690)

91

113 (120)

1000 (1062)

137

11

7t (n.m)

5t (n.m)

Ø x Pitch

8

7

(flange : 6.8T) n.m lb-in

n.m

lb-in

11

97

25

221

52

460

95

841

7.8 (7.5) 19 (19) 39 (39) 72 (71)

69 (66) 168 (168) 345 (345) 637 (628)

805

108 (110)

956 (974)

147

1213

172 (170)

1522 (1504)

226

(flange : 8.8T) n.m lb-in

(flange : 10.9T) n.m lb-in

(flange : 11.9T) n.m lb-in

(15.5)

(137.2)

(17.5)

(155)

(38)

(336)

(42)

(372)

(80)

(708)

(89)

(788)

(145)

(1283)

(160)

(1416)

12 (12) 29 (29) 61 (61) 108 (110)

106 (106) 257 (257) 540 (540) 956 (974)

1301

172 (175)

1522 (1549)

(230)

(2036)

(260)

(2301)

2000

265 (270)

2345 (2390)

(360)

(3186)

(400)

(3540)

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

GENERAL, CHARACTERISTICS AND SAFETY

00.4.2 METRIC - IMPERIAL UNIT CONVERSION ConVeRsIon CoeFFICIents: Metric unit (s.I) Coefficient °C (Celsius degree) x 1.8 + 32 3 cm (centimeter cube) x 0.06102 cv (cheval vapeur) x 0.9859 bar (bar) x 14.51 g (gram) x 0.0353 kg (kilogram) x 2.2046 km/h (kilometer per hour) x 0.6214 kW (kilowatt) x 1.34048 ℓ (liter) x 0.2642 ℓ (liter) x 1.0567 m (meter) x 3.2808 m (meter) x 39.37 mℓ (milliliter) x 0.0338 mm (millimeter) x 0.03937 µm (micrometer) x 0.03937 N (Newton) x 0.2248 N.m (Newton meter) x 0.7376 rad/s (radian/second) x 9.5493 t (metric ton) x 2204.62 tr/min (tour per minute) x 1

= = = = = = = = = = = = = = = = = = = =

Imperial unit us °F (Fahrenheit degree) cu.in. (cubic inches) hp (horsepower) psi (pound-force/square inch) oz av (ounce avoirdupois) (oz : lat. onza) lb (pound) (lat . libra) mph (miles per hour) hp (horsepower) gal US (US gallon) qt US (quart US gallon) ft (foot) in (inch) fl oz (fluid ounce) (fl : fluid, oz : lat. onza) in (inch) mil (thousands of an inch) lbf (pound-force) (lb : lat. libra, f : force) ft-lb (pound-force-foot) (ft : foot, lb : lat. libra) rpm (revolution per minute) lb (pound) (lat. libra) rpm (revolution per minute)

= = = = = =

unit in (inch) (pouce) oz av (once avoirdupois) mm (millimeter) µm (micrometer) kg (kilogram) ° (angle degree)

otHeR unIt ConVeRsIons: unit ft (foot) lb (pound) (lat. libra) m (meter) mm (millimeter ) t (metric ton) rad (radian)

Coefficient x 12 x 16 x 1000 x 1000 x 1000 x 57.2958

19

00

647766EN 00 (22/04/2019)

00

20

GENERAL, CHARACTERISTICS AND SAFETY

647766EN 00 (22/04/2019)

BRAKE

Contents 40.1

BRAKE CONTROL AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 40.1.1

Bleeding procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

40.1.2

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

40.1.3

Bleed the master cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

40.1.4

Bleed front and rear axle service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

40.1.5

Bleed front and rear axle parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

40.2 Specific brake tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 BRAKE FLUID BLEEDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

40

40.2.1

40

22

BRAKE

647766EN 40 (22/02/2019)

647766EN 40 (22/02/2019)

BRAKE

23

BRAKE 40.1 BRAKE CONTROL AND ADJUSTMENT 40.1.1 Bleeding procedure 40.1.2 Location 5

6 1

40

2

3

4

7

1 2 3 4 5 6 7

-

Front brake master cylinder Rear brake master cylinder Service brake pedal Accumulator block Brake fluid tank Front axle Rear axle

24

647766EN 40 (22/02/2019)

BRAKE

40.1.3 Bleed the master cylinders 1

2

1 12 2

3

4

13

8

40

7

X31

X30

8

2

X31

3

X31

4

X31

5

X29

X30 4

X31

9

X30

2

1

11

6

5

647766EN 40 (22/02/2019)

25

Unclip the 2 heating outlets (1).

Remove the 2 screws (2) located behind the 2 outlets (1).

Unclip the set of 3 switches (3).

Remove the screw (4) located behind the set of 3 switches (3).

Remove the 2 screws (5) and take off the steering column casing (6).

Unclip the temperature button (7).

Remove the 2 screws from the heating valve (8) located behind the temperature button (7).

–– –– ––

10

––

isconnect the 4-position ventilation switch (9).

D Disconnect the air conditioning on/off connector (10).

Remove the air hose (11) which connects to the dashboard (12).

Disconnect the set of switches (3 + 13) so that the dashboard can be removed.

9

40

–– –– –– –– –– –– ––

BRAKE

–– 15

––

emove the brake fluid tank plug and fit the adapter (14) R of the bleeder (15).

Operate the bleeder.

–– ––

Bleed the master cylinders by undoing the screws (16).

Wait until oil comes out then do up the screws.

14

16 16

647766EN 40 (22/02/2019)

BRAKE

26 40 - 1

40.1.4

Bleed front and rear axle service brake

5 1 2

––

6

Bleed the brake fluid in the order of the screws (1) to (4).

40.1.5 –– 40 - 2

7 3

40

4 8

Bleed front and rear axle parking brake

Bleed the brake fluid in the order of the screws (5) to (8).

647766EN 40 (22/02/2019)

BRAKE

27

40.2 Specific brake tooling 40.2.1 BRAKE FLUID BLEEDER

40

Bleed valve supplied with all the components required for bleeding the brake circuits of Manitou products.

Operating instructions included.

MANITOU Reference BRake Bleed kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .554019 spaRe paRts: – TOP MANOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 719980 – BOTTOM MANOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 719981

– Membrane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 661913 – HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 661914 – FLEXIBLE BRAKE (ORANGE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 720693 – VALVE RETRACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 744747 – SET OF 6 CAPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 787147

40

28

BRAKE

647766EN 40 (22/02/2019)

HYDRAULICS

Contents

70.1.1

Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

70.1.2

Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

70

70.1 Hydraulic schematic diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

30

647766EN 70 (25/03/2019)

HYDRAULICS

HYDRAULICS 70.1 Hydraulic schematic diagrams

70

70.1.1 Key Item BA BP BCMA BMHP CA CAR D EA EI EL ET EVP EVS D3 EVTF (O) FDAR FDAV FPar FPav FR GEP M MC1 MC2 MH P / PV PAAV PAAV (O) PDD PH PP PRES PRF (O) R R1 RDU RF RLF VAI(O) VC VE VDAR VDAV VI VIC VL VT VVT (O)

Designation Feed Block + Accumulator (AC) 8 EV control block Aggravating movement cut-off block Hydraulic proportional manipulator block Suction strainer Check valve Valve bank Attachment element Tilting element Lifting element Telescope element Dynamic flow priority valve element Safety valve element 3-position steering distributor Boom head electrovalve Rear disc brake Front disc brake Rear negative brake Front negative brake Return filter Electrically driven pump KUBOTA V3307 CR-TE4 (Turbo) engine Front brake master cylinder Rear brake master cylinder Hydrostatic motor Hydraulic pump / Fan control pump Front attachment connector Front attachment connector Dynamic steering pump Hydrostatic pump Pressure test port Pressure switch Leak return plug Main hydraulic tank Secondary hydraulic tank Unidirectional flow reducer Cooler Brake fluid tank Isolation valve Compensating cylinder Counterbalance valve Rear steering cylinder Front steering cylinder Tilting cylinder Compensation Isolation Cylinder Lifting cylinder Telescopic boom cylinder Carriage locking cylinder

Position on diagram M15 Q20 O25 O22 S11 I24/M20/M21/S11 K36 K34 K32 K29 K35 K26 K28 C13 C40 C18 C4 G7 G7 Q15 O20 O3 A7 A9 A10 O5 C37 A34/A41 G16 O12 A31/B31/E9/K24/M15 G2 G40 S15 Q19 G5 Q13 A8 A34 A30 A27/E27/E37 C16 C6 A25 A32 E24 E35 A37

647766EN 70 (25/03/2019)

HYDRAULICS

31

70.1.2 Diagram 2

3

4

5

6

7

8

RLF

RLF1

10

MC2

FRONT AXLE

14

L2

A

VDAV

FDAV

min

2

max

L1

16

17

18

19

20

21

22

23

24

A B

T

2

1

RDU

PRES 8 ±1 b

RDU

30

31

32

33

34

35

36

37

38

39

40

41

42

VI

VE

V2

VIC

PP

PAAV(O)

V2

V2

3917.7 psi (270 bar)

V1

PAAV

PP

B1 B2 P2

Y7 P2

C1

V1

B

VL 2902 psi 2902 psi (200 b) (200 b)

A1 A2

C2

C4

C3 Y17

C1

P2

V1

VT

VE

R

A

VAI(O) C2

3047.1 psi (210 bar) V2

V1

P1

PAAV(O)

EVTF(O)

C

3047.1 psi (210 bar) V2

E

VE

FPav Without any pressure the spring brakes the machine

Ø1

FRONT AXLE P1

29

V1

P

L

G

28

VC

PP

P1

27

VVT(O)

FDAR

M5 M4

26

1

VDAR

E

25

3 2 1

D3

Y6

15

AR

AV

3

6.71 cu.in/rev (110 cm3/tr)

P2

13

B1

MH

C

12

3 B2

MC1

P2

11

RLF2

B1

B2

A

9

REAR AXLE

1

PDD

Without any pressure the spring brakes the machine

G

2031.4 psi (140 b)

REAR AXLE

Ø1

PRF(O)

9.76 cu.in/rev (160 cm3/tr)

FPar

NF O 8b

P

F

T LS

5b

I

CAR

LS

1b 1A 1B

P

T

2b 2A 2B

3554.95 psi (245 b)

3 3b A 3B

I

4b 4A 4B

2611.8 psi (180 b)

3554.95 psi (245 b)

3554.95 psi (245 b)

70

3554.95 psi (245 b) 3003.57 psi (207 bar)

K

P

PP

LP

Pin Y3

Y4 r=1.16

M

1.89 cu.in/rev (31 cm3/tr)

P

M5

F00B

M3

F00A

3.23 cu.in/rev (53 cm3/tr)

0.73 cu.in/rev (12 cm3/tr)

PPLS

5078.5 psi (350 bar)

CAR

EVP

EVS

1a

EL

2a

EI

3a

EA

ET 4a

D

M

Y13

EPS

Psahr SAHR

1741.2 psi (120 bar)

IN

L2 MA

CAR

T

Y39 O

A

0.12 cu.in/rev (2 cm3/tr)

P

GEP M

362.75 psi (25 bar)

M4 Q

Y12

362.75 psi (25 bar)

0.05 gal US 217.65 psi (0.32 ℓ 15 bar) AC

M

0.05 gal US 2611.8 psi (0.32 ℓ 180 bar)

LS

BA

O

K

AC

PH 5078.5 psi

S

MB (350 bar)

S

A+

BP

A-

B+

B-

Y31

Y32

Y33

Y34

Y35

Y36

Y37

Y38

IN

B

Q

T

RF VA

58.04 psi (4 bar)

C+

C-

D+

D-

FR CAR S

CA

43.53 psi (3 bar)

29.02 psi (2 bar)

65.29 psi (4.5 bar)

23.778 gal US/min 0,39 mil (10 µm) (90 ℓ/min) 4.92 mil (125 µm)

R1 R

S

70

32

HYDRAULICS

647766EN 70 (25/03/2019)

ELECTRICITY

Contents 80.1 WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 80.1.1

POSITIONS BY DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Diagram - A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Diagram - B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Diagram - C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

80

80.2 Electricity locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

80

34

ELECTRICITY

647766EN 80 (26/03/2019)

647766EN 80 (26/03/2019)

ELECTRICITY

80.1 WIRING DIAGRAMS 80.1.1 POSITIONS BY DIAGRAM Item

Component

X1 X2 X4 X7 X8 X41 X42 X43 X44 X45 X47 X48 X49 X51 X52 X53 X54 X67 X92

S2 S2 M1 K15 B8 E21 E22 E23 E24 E25 E26 E27 E28 E29 E30 E30 E31 A4 Y13

X106A X106B X106C X106D X108 X109 X10A X10B X110 X111 X112 X118A X118A X118B X118B X118D X118E X138 X138A X138B X139A X139B X156 X157 X158 X159 X160 X161 X162 X163 X164 X165 X167 X268

A17 A18 A22 A22 A19 A20 A21

A23 A23 S50 A23 A23

F65 F65 S1a M1 K23

M12

A16

Designation Ignition switch Ignition switch Starter excitation Pre-start alarm timer relay Pre-start alarm buzzer Orange flash Orange flash Orange flash Orange flash Front right red flash Front left red flash Rear right green flash Rear left green flash Front right green flash Front left green flash Rear right red flash Rear left red flash JSM Negative brake electrovalve Main harness / Boom bottom electrical predisposition harness interconnection Boom head electrical plug harness Camera kit harness Boom head electrical connector harness predisposition Colour camera 1 (front) Colour camera 2 (rear right) CAN info for Guardian Angel CAN info for Guardian Angel Colour camera 3 (rear left) Colour camera 3 (front to rear) Reversing information (displayed on JSM) for camera kit Digicode predisposition Digicode predisposition Anti-theft shunt Anti-theft shunt Engine cut-off for Guardian Angel Engine cut-off for Guardian Angel Emergency stop button RECM info for Guardian Angel RECM info for Guardian Angel Brake pedal potentiometer info for brake test function Brake pedal potentiometer info for brake test function Backup pump power supply cable / battery cut-off Backup pump power supply cable / 250A fuse holder Backup pump power supply cable / 250A fuse holder Starter (+ bat) / fuse box Starter (+ bat) / battery cut-off Backup pump relay power supply Backup pump relay control Backup pump relay ground (harness supplied with pump) Terminal - backup pump Backup pump ground cable terminal SPU 40-26 battery direct ground Camera kit quad monitor

Diag. position wA B6 B8 H4 A4 A6 G6 G7 G7 G7

Diag. position B

Diag. position C

Standard component X X X

G9 G9 G10 G10 I9 I10 I10 I10 B11 E11

X X

G10

X

H10 G10 G10

X

C12 A14 I4 J4 C13 C14 C10 D1

X C6

D1

X C5 C6 C5

B3

X E6 F6 C6 D6

E5 F3 F2 E5 H4 F2 F1 G2 G3 J14 H5

X X X X X X X X X X X B12

Item

Component

X271 X272 X273 X278 X279 X284 X285 X289 X290 X291 X292 X294 X301 X302 X303B X303C X304B X304C

S1a/S1b

M5 S15 M1 M1 M2 M2

Battery cut-off S1a/battery cut-off S1b connecting cable Battery cut-off S1a/starter connecting cable Start-up plug Battery cut-off S1a/M5 chassis connecting cable Battery cut-off S1a/battery (-) terminal connecting cable Battery cut-off S1a/battery cut-off S1b connecting cable Battery cut-off S1a/battery (+) terminal connecting cable Alternator IG / L Alternator B+ Start-up plug X273/battery (+) terminal connecting cable CC2 C6 transmission ECU Start-up plug S1a/battery (+) terminal connecting cable Cable x278/Frame ground Park brake switch Front cab ground Front cab ground Cab rear ground Cab rear ground

X304D

M2

Rear cab ground

X304D X309 X310A X310B X313

M2

S19

X314

S20

Rear cab ground Battery cut-off S1a/battery (-) terminal connecting cable Main harness / main harness interconnection Main harness / engine harness interconnection Revolving light switch Front and rear cab working light switch + telescope light option Start-up plug X273/battery (-) terminal connecting cable Main harness / Boom electrical predisposition harness interconnection Boom bottom electrical predisposition switch Terminal + BAUSER module permanent External emergency stop 1 External emergency stop 1 External emergency stop 2 External emergency stop 2 Camera kit quad monitor power supply Camera kit electronic box power supply Orange light on active brake (parking or service brake) Red/green light on transmission engaged 4 orange flashes Camera electronic box power supply Door sensor Transmission cut-off on door Emergency steering switch Emergency steering EV Speed sensor Electronic level Ignition switch for Guardian Angel display Inclinometer for Guardian Angel Translation cut-off (brake test function) Parking brake cut-off (brake test function) Brake test switch Buzzer (brake test function) Brake test module connection Brake test module connection Brake test module connection Pressure switch (brake test function) Pressure switch (brake test function) Pressure switch fault light (brake test function) Guardian Angel / Camera kit harness connection Brake pedal relay module

G2 G2 A2

X321 X360 X362 X373 X400A X400B X401A X401B X407 X408 X409 X410 X411 X412 X413 X414 X415 X416 X502 X505 X511 X514 X515 X516 X517 X518 X519 X520 X521 X522 X523 X524 X525 X526

S32 G1 S59 S59 S60 S60 A16 A21 H54 E35 E21/E22/E23/E24 A16 S61 K28/K29 S62 Y23 B41 B40 S63 B40

S500 B45 A24 A24 A24 B44 B43 H501 A23

Designation

Diag. position wA E4 F4 I5 E5 F5 E5 F5 E6 E7 G5 D12 G5 I14 H12 I14 A14 G14/J14 I14

Diag. position B

Diag. position C

Standard component

X X X X X X X J7/J8/J9/ J12/J13/J14 A14

H5 D11 D11 H7

X X X X

H9

X

H5 H12

X

H11 G5

X X H6 H6 H4 H4 C10 C10

D9

80

ELECTRICITY

35

H13 G6 E12 D8 F9 B9 C8 C3 / D3 D3 / E3 B3 I1 A8 C8 B6 I10 H7 J7 I10 G5 F5 F4 A7 D4

36

647766EN 80 (26/03/2019)

ELECTRICITY

Fuses and relays

Splices Diag. position C

Item

H13 G13 A8 B8 B5 C7 C7 C7 E7 E5 D4 E3 G7

C2

Diag. position A

Diag. position B

Diag. position C

Standard component

10A

SAUER ECU + JSM + EV FN + Handling Mode

B9

X

F7 F10 F11 F12 F19 F20 F65 F70

10A 2A 15A 15A 30A 20A 250 A 15A

B9 B10 B10 B10 B10 B10 F3 B11

X X X X X X X

F73

20A

C7

X

F74 F80 K3 K15

5A 2A 20/35A

Hydraulic system ECU Front + rear wheel alignment sensors + indicator lights Flashing light unit (power + APC) Rear fog lights power supply BUS-BAR C Power supply (F27/F28/F29/F30) Heating power supply Access backup pump Door sensor relay and backup pump relay power supply K16 and K17 relay power supply (management of red and green flashing lights) Pre-start alarm timer relay power supply Camera electronic box power supply Stop light relay Pre-start alarm timer relay 3/5/7/9 seconds

C7

X C11

E10 A4

X

K16

Red and green flashing light in forward gear control relay

G11

K17

Red and green flashing light in reverse gear control relay

G12

K18

Lighting stalk switch power supply relay on +APC Rear working light power supply relay on reverse gear control Backup pump relay Emergency steering relay Stop light/active parking brake power supply relay Red/green light on transmission engaged power supply relay Transmission cut-off relay on door Transmission cut-off relay on door Camera power supply timer relay Engine cut-off relay (Guardian Angel function) Brake activation relay (Guardian Angel function) Brake pedal relay (brake test function) Translation cut-off relay (brake test function)

H14

K23 K25 K26 K27 K28 K29 K30 K120 K121 K122 K123

B12 F10 D12 D12 H9

Designation

F4

K19

F10 F10 F12 F12

G13 G2

X C9

D10 G13 E8 E9 E14 A5 A6 D3 A7

Composition of MINING diagrams A, B and C. X19A-12 K2-3 Sch.6 Sch.6 36

F10 / G10 G9 / G9 H11 H9 / I9 G5/G7 G5/G7

Intensity

1

BF2/M5

180

Diag. position B B1 E2 C1 B2/B3 D1 F2 J3 J3 H2 H2 E2 E2 E5

3

K3

- Grey component and black wires = Exiting component in standard repair manual: 647469 Diag.6 => 6diagram 1 to 8 in standard repair manual: 647469

5

2

188

189

EP500 EP501 EP503 EP504 EP505 EP507 EP509 EP510 EP511 EP512 EP513 EP514 EP515 EP517 EP518 EP520 EP521 EP522 EP523 EP524 EP525 EP526 EP527 EP528 EP529 EP530 EP54 EP55 EP83 EP84 EP85 EP87 EP88 EP89 EP90 EP91 EP92 EP93 EP94 EP95 EP96 EP99

Diag. position A

37

80

Item

rose

86 1

K29

30 3

2

5

85

87

4 87a

X40-6 Sch.6

X67-12 Sch.A

- Green component and wires = Adaptation for MINING assembly Diag.A => 6diagram A to B in this MINING repair manual: 647766

647766EN 80 (26/03/2019)

ELECTRICITY

37

Diagram - A 5

6

7

S2

B

B

B

B

X67

X66-B X65-B Diag.3

green

red

A2

2

1

yellow 5

87

black

2

85

black

4

X310B

87a

blue

X409 1

BF1/M1 X201 Diag.1

S1b

X2902

G2

X40-6 Diag.6

2

U

X19A-11 Diag.6

brown

X411 2

blue

brown

blue

2

1

2

1

2

1

2

1

X41

X42

M1

X309

X321

-

70 mm2 black

727

B+

E22

X313

X57-34 Diag.2

BF2/M1-F14 Diag.6

226

EP90

S19

6

221

S20

0

X314 223

226

X276A Diag.6

10

210

X314-10 Diag.7

0

228

225

2

6

229

3

H20 X312-10 Diag.6

224

9

10

211 210

209

1

1

227

H19

BF2/M3 K9-4 Diag.7

Diag.7

1

1

5

9

X273

I

J

1

1

2

X106D

1

2

X106B

1

2

X516-2 Diag.C

X516-1 Diag.C

K121-87a(4) Diag.B

90

EP518

E24

Diag.6

43

X106C X525-2 Diag.B

K19-30 / K30-30 Diag.B

X44

E23

2

X525-1 Diag.B

ORANGE FLASH

BX167

X160

X43

X304B M2

312 1

66

brown

G1

blue

186 BF2/M3 Diag.2

X373 B+

brown

X294

blue

X291

black

BF1/M3-K22 Diag.1

X4

1

X106A

E21 +

Y13

BF2/M2 F27 Diag.7

blue

brown

X164

70 mm2 black

M12

70 mm2 black

35 mm2 black

70 mm2 black

70 mm2 black

87

X40-6 Diag.6

90

30

35 mm2 black

85

188

313

X157

K23 X163

5

465

F65

X161

1

1

X515-1 Diag.C

X285

red

86

X158

2

X279

2

X92

X515-2 Diag.C

27

EP87

X31-5 Diag.6

70 mm2 black

35 mm2 black

X162

4

2

X272

180

36 188

3~

S1a

BF2/M5 3

K3

27

5

222

4

H

B+

1

BF1/M1-F43 Diag.1

1

K25 Diag.B

F

L

3

K3

X514-2 Diag.B

EP88

EP89

X19A-12 K2-3 Diag.6 Diag.6

EP3 Diag.6 X276A-33 Diag.7

X315-10 Diag.7

1 463

464

X162

G

IG

X289

1

H54

189

3

1

710

black

37

3

X159

2

BF2/M5

189

X278

46

37

X271

53 9

BF1/M2 -F55 Diag.1

12

70 mm2 black

711

X156 X284

35 mm2 black

E

1

180

36

X19A-12 K2-3 Diag.6 Diag.6

Diag.8

C3

X310A

X118B

X57-25 Diag.8

C2

X292

80

3

10

S32 X276A-7 Diag.7

X362 465

K19-87 Diag.B

466

5

0

90

1

2

X360

461

7

462

B

463

C

10

1

5

80

464

A

+ -

8

160

10

EP.13 Diag.3

EP517

7

1

H32 9

Diag.3

S15

X302

0

X13-14 Diag.6

80

4

9

90

5

3

159

6

1

27

7

271

8

K26

30

86

12

K27-30 K29-30 Diag.B Diag.B K28-30 Diag.B

X413-2 Diag.B

PWM +/ D OUT +

K25-30 Diag.B

K17-30 Diag.B

11

white

X308(8) Diag.6

28

9

265

10

692

11

268

12

131

274

X118A

269

X333-2 Diag.2 BF2/M1-F1 Diag.1 BF2/M2-F33 Diag.1

8

28

692

10

brown

green green

265

EP99

BF2/M1-F2 Diag.1

X303C M1

EP85

K2-3 Diag.6

blue

X401B-2 Diag. B

268

X303C M1

black

PWM -/ D OUT -

EP76-Diag. 2 X310A-B8 Diag. 1 X310A-B1 Diag. 1

black

pink

B

grey

A

27

7

280 A

B

81

EP13 Diag.3

A

28

B

A

27

Grey

B

A

273

82

278

A

7

19

8

45

Blue

A

grey

Yellow

14

BF2/M1

X415-5 Diag.B X401B-5 Diag. B

271

D

82 19 45

13

B

F70

Grey

A

280

F74 20A F73 5A

S59-A2 Diag. B

6

A

X2

3

Blue

1

4

S59-B1 Diag. B

Purple

Purple

5

10

5 33

C

S59-C2 Diag. B

2

58

6

X401B-3 Diag.B

X138 4

15

5

EP75 Diag.8

K30-86 SchB

3

54

9

brown

X310A-Diag.1

B

19

8

7

F20

50a 19

F19

4

278

17

3

F12

17

2

F11

30

1

277

30

51

X1

217

OP

F10

2

F9

SPU

EVM

1

green

Diag.2

DEM

S50

12

-

+

164

X8

Yellow

8

F7

5

6

179

4

279

2

279

1

11

2 mm2

277

9

black

7

black

3

B8

10

s

T

X7

9

as Ch 5 M 4 ab M 2C 3 M 1M M

K15

A

8

F4

4

273

3

730

2

52

1

6

H15 9

79 78

78

65

K121-30 (3) Diag.B

3

X517-6 Diag.C

X306-9 Diag.5

159 X306-3 Diag.5 160

X303B M1

brown

X304C M2

2

Starting connector

X313-10 Diag.6

black

X301

M5

black

X165

M3

274

X304B M2

647766EN 80 (26/03/2019)

ELECTRICITY

38

Diagram - B 6

7 red

1

19

87a

MENU

8

37

3

X502

SWITCH CAM 2 SWITCH CAM 3

WHITE

SWITCH CAM 4

1

1

X162 Diag.A 1

X505

20

2

X505

55

3

X505

54

4

X505

B40

1

3

F70 Diag.A

X108 4

1

2

3

grey

X67-11 Diag.A pink

red

X138A

86 1

52 X138 Diag.1

EP515

K28

30 3

2

5

85

87

A20 CAM 4

87a

5 87

86

87a

1

X519-14 Diag.C

2

31

brown

BF2/M5-K2-1 Diag.6

EP91

X45

X47

X48

1

2

X49

1

X138-3 Diag. A

blue

X138-2 Diag. A

265 7

5

X400A X400B

1 6

1

2

3

4

5

grey 1

2

1

2

5

85

87

4 87a

3

E25 red AV DR

E26 red AV GA

2

1

E27 green AR DR

2

5

85

87

BF2/M3-F74-4 Diag.A

K17

30

86

V6 V6

4 87a

blue

86

E28 green AR GA white

EP93 EP93

EP94 green yellow/black

brown

X51

yellow

2

3

2

5

85

87

2

5

85

87

4 87a

X314-1 Diag.A

4 87a

white

blue

86 A

blue

EP94

3

BF2/M1-F14 Diag.6 BF2/M2-F31 Diag.6

144

blue brown

K27

30

1

X138-6 Diag. A

1 6

EP85 Diag.A

K19

30

1

B

C

1

X410

blue

K18

30 3

2

5

85

87

4 87a

blue

X118A-6 Diag. A BF2/M1-F7 Diag.A

4

86

blue purple

87a

EP90 Diag.A

X52 1

2

X53 1

2

blue

brown

X289-L Diag. 1

3

3

yellow

K16

black

brown

266

2

yellow

X333-3 Diag.2

1

30

white

EP84

blue brown

2

86

brown

brown

brown

white/black

yellow

purple

blue

yellow/black

grey

green

white

green

red

orange

EP96

C2

X54 1

2

X14-1 Diag.6

E35 1

11

10

9

7

6

5

4

3

2

1

X10B

M2

M2 M2

M2

M2

black

black

X304D

X304D

E32 green AR GA

black

E31 green AR DR

X304D

brown

M2

E30 red AV GA

black

6 8

EP99 Diag. A

red AV DR

X304D

X10 Diag. 2

X304D

7

black

brown

X10A

brown

8

1

X304D

4 12

9

2

X304D

J

10

3

black

5

4

brown

3

5

black

6

X304D

7

X304D

11

8

black

12

9

black

10

EP510

13

11

EP509

12

E29

white/black

50696443-indice

black

brown/black

X514

X304D

MODULE E5/S5 N

8

1

C1

brown

M1/E4n

CAN low

B2

4

1

PROGRAMME

************

M1/E2

I

B1

blue

X401A X401B

M1/E5

2

A2

EP91

V5

EP83

1

R12

M1/S1

CAN high

white/black

black

EP516

53

A1

grey

M1/E3n

M1/E1

yellow/black

EP512

pink 67

4,7K 6

26

M1/S2

EP96

A2

blue

EP92

EP92

E33

R11

4,7K 6

EP511

14

M1/S3 M1/S4 n

yellow

68 16

27

M1/S5 n

H

15

31 14 7

16

A1

brown

EP95

DEM

RECM

SPU

SPU

RECM

DEM

80

S59

87

pink

69

EP95

5

red

green

EP54 EP55

blue

brown/black

black

red

2 85

green

X310A-C5 Diag.3

white

E33 B2

K30

3

green

X138B

white

6

green

1

69

B1

EP90 Diag.A

30

1

white

X414

C2

X7-4 Diag.A

4

44

C1

1

brown

5

2 85

4

38

S60

-Batt

NC

A19 CAM 3

K29

3

blue

+Batt

4

black

black

A22

X111

3

X412

black

EP507

2

1

30

brown/black

G

2

A18

blue

4

86

blue

3

17

EP508

1

green

48

6

pink

46

1

red

49

5

black

2

green

51

45

V9

F

X110 4

white

red

50

4

47

43

3

CAM 2

18

3

V8

2

A17

X67-12 Diag.A

31

EP513 EP514

E

1

CAM 1

2

V7

X109 4

red

ELECTRONIC LEVEL

red

EP501

1

1

2

2

A21

red

29

EP505 31

30

1

X413

2A

1

X162 Diag.A

D

F80

X112

S61

SPEED SENSOR

SWITCH CAM 1

GREEN BLUE

black

X502

BROWN

red

X502

2

Diag.A

red

1

22

B41

87a

black

EP503

EP502

28

32

Diag.A

green

black

Y23 X118D X118A

X118B X118E

black

C

X407 X408

4

87

Audio

5

85

Yellow Video

2

K25

3

GND

10

30

White

64

1

+12DC

10

86

Black

9

2

Red

63

1

NC

9

X416

Audio

8

Yellow Video

62

F70 Diag.A

GND

7

8

X268 13

4

White

61

10

+12DC

6

7

9

Black

6

green

7

Red

BUZZER

5

1

NC

N

4

60

2

Audio

EP506

3

59

5

5

Yellow Video

N

58

4

11

GND

23

3

12

White

R

6

+12DC

EP504

8

Black

BL

3

Red

B42

36

brown

F70 Diag.A

SC

X415

0V CAM 1 0 4

X511

57

10

+12V

23

56

S62 6

5

SOS

Vid9o CAM 3

J

S63

EP518 Diag.A EP517 Diag.A

Vid9o CAM 4

X511

65

Audio

R

24

66

65

Yellow Video

X511

White

13

30

44

MODE

Vid9o CAM 2

V

86

30

38

CH2

Red

X511

DC12-24V

14

CH1

9

black GND

24

55

EP506

54

45

42

68

2

black

EP504 41

27

40

37

36

25

26

35

39

R

green

EP500

43 34

15

7

C8

C7

C3

C6

C2

B8

B5

C1

B3

B2

A4

A8

A5

A3

A1

86

33

B

1

0

1

Vid9o CAM 1

87

GND

85

87a

14

A16

+12DC

87

13

MONITOR

66

Black

85

K121

12

Audio CAM 1

K120

11

X106C-1 Diag.A X106C-2 Diag.A

black

2

GUARDIAN ANGEL

10

green

A

18

9

GND

17

A23

8

s as Ch 5 M 4 ab M 2C 3 M 1M M

X525

Info CAM 4

5

Info CAM 3

4

Info CAM 1

3

Info CAM 2

2

black

1

M2

M2

M2

M2

X304D M2

647766EN 80 (26/03/2019)

ELECTRICITY

39

Diagram - C 1

2

3

4

5

6

7

8

9

K123

6 85

11

EP517 Diag.A

4/5

EP520

A

10

12

13

14 s as Ch 5 M 4 ab M 2C 3 M 1M M

3

24 87

86

87a

X304D M2 X515

30

12

13

14

EP521

1

27

2

27

X92-1 Diag.A X310A-C3 (EP88) Diag.A

EP522

B

1

S500

0

X517

1 5

3

6

23

7 2

EP523

19

V10

8

2

C

3

4

2

5

1

7

10

9

X516 1

90

2

90

X13-14 (EP518) Diag.A X301-1 Diag.A

EP525

TEST

X139A

6

22

EP524

H15 1

28

21

27

K122 X139 Diag.3

D

3

4

2

5

1

6

X139B

EP528 5

6

20

4

10

3

25

29

2

30

1

X526 EP527

EP529

8

EP526

26

1

9

2

E

X524

H501

X523

2

B43 F 16

1

2

X522

4

1

15

13

21

19

CAN high

17

CAN low

- Batt

+ Batt

- Batt

+ Batt

- Batt

M1/E15n

+ Batt-P

M1/E16

M1/E12

M1/E17

M1/E13a

M1/E18a

M1/E14a

M1/E7a

PROGRAMME

grey 1

X519

- Batt

1

grey 2

+7,27Vdc 1

MODULE E18/S7

+7,27Vdc +7,27Vdc

6

+7,27Vdc FUS 1

M1/S1a

30 +7,27Vdc

5

M1/S3a

11 5 10

M1/S12

M1/E6

M1/S11

M1/E5

M1/S10

M1/E4

M1/S9

M1/E3

M1/E10

M1/E2

M1/E9

M1/E1

-Batt

J4 J1

8 9

J

M1/E8 +Batt-P

MEM

1

M1/E11

-Batt

I

16

X520

X518

29 +Batt -P

A24

X521

5

M1/S2a

BUZZER

2

H

J2

8 7

+ Batt

14

grey 3

18

EP530 grey 4

G

1

80

B44 EP54 Diag.B

B45

647766EN 80 (26/03/2019)

ELECTRICITY

40

80.2 Electricity locations 2

Specific MINING component

3 2

7

8

6

15

3

9

1

7 30

6

27 25 3

29

14

28

11

26

16

80

18

20

4 5

23

15

24 21

22

19 13

10 12

5 4

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

-

Front working lights Rear working lights Orange LED indicator lights on cab (sidelights) Red LED headlights driving direction Green LED headlights driving direction Red LED rear lights driving direction Green LED rear lights driving direction Rear electric socket Rear left emergency stop button Front right emergency stop button LCD screen Front right camera Rear right side camera Rear right camera Rear left camera Preheat rod Engine block heater connecting cable Main isolator Starter isolator Jump start Diesel decongealant Proximity sensor Pre-start alarm Battery On-board electronic system control (speed, machine’s inclination sensor, engine and transmission) Inclinometer Door open transmission cut-off Brake test switch Absence of steering and hydraulic braking switch Platform control console