TECHNICAL TRAINING

DIAGNOSTIC LEVEL II

HA12CJ(+)/HA32CJ(+)
TRAINING MANUAL DIAGNOSTIC Level 2 HA12CJ-CJ+
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 How to use this document?
MAINTENANCE AND REPAIR OPERATIONS ON YOUR HAULOTTE MACHINE
MUST BE DONE ONLY BY TRAINED ,EXPERIENCED AND AUTHORIZED TECHNICIANS

You have between the hands the summary given during the HAULOTTE technical training
It will enable you to find information necessary for the maintenance and the repair of your
HAULOTTE .machine .
Thanks to the guide below you will reach the required chapter quickly.

Chapter 1: Main features and functions

It is a resume of the information contained in the user manual delivered with the machine:
components, overall dimensions, working zones, commands, etc…

Chapter 2: Study of the electric diagram

You will find there the elements as following:
- A summary of the standardized symbols used by HAULOTTE Group
- The complete wiring diagram of the studied model
- The non exhaustive list of the electric looms and electronic boards
- Localization of the main safety units (tilt , limit switches, sensors,transducers…)
- Logical equations of operation: by function, to diagnose the main dysfunctions

Chapter 3: Study of the hydraulic diagram

You will find there the elements as following:
- a summary of the standardized symbols used by HAULOTTE Group
- the complete hydraulic diagram of the studied model
- the non exhaustive list of the hoses track
- a localization of the main hydraulics manifold (proportional block , on/off movements
b l o c k , …)
Chapter 4: Adjustments
This is the adjustments and calibrations, hydraulics and electric, necessary to the good
maintenance of the material. You will find as well the methods of adjustment with table values.

Chapter 5: Guide of breakdown

Quick summary of the step to be followed for possible sources of breakdown.
In case of any defect or any dysfunction you will be able to identify the elements in question,
whatever they are electric or hydraulic.

Chapter 6: Summary of the versions

This manual treats of the latest version; however this summary table enables you to find the
former versions of the material (electric and hydraulics).

Chapter 7: Special functions

This chapter gathers all the functions and adjustment specific to carry out on the machine. There
does not exist for all the materials and depends on the studied model.
It must be the subject of a special attention of your share because an intervention badly carried
out can deteriorate the good performance of the machine and thus consequently the safety of the
u s e rs .
Only a technician HAULOTTE or approved by HAULOTTE Services is able to carry out this kind
of intervention.
On this chapter, some special adjustment (sensors) are also explained prior to calibration
(depends on the model)
Chapter 8 : List of schematics
This chapter lists all schematics (electric/hydraulic) of all versions and some layout if required

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 REVISION

Revision Edition Subject Created Validated Modified Translated Language

by by by by
00 03- 11 Creation MGD FLH MGD FR/EN
01 09-12 Update parameters MGD MGD FR/EN
+ calibration process
02 07-13 Newest parameters MGD MGD EN
on diagnostic
console
03 12-13 Add Diag Pad info + MGD Central MGD MGD EN
console alarm list R&D
04 02-14 Add chapter MGD EN
schematics
05 07 - 14 Add schematics with MGD EN
ASB (Active Shield
bar) option

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 SUMMARY
1.  MAIN FEATURES AND FUNCTIONS ............................................................................................................. 6 
1.1.  CHARACTERISTICS .......................................................................................................................................... 6 
1.1.1.  ha12 cj-cj+ ............................................................................................................................................ 6 
1.1.2.  LOADING POINTS HA12CJ-CJ+ ........................................................................................................ 8 
1.1.3.  FEATURES HA12CJ-CJ+..................................................................................................................... 9 
1.1.4.  OVERALL DIMENSIONS HA12CJ-CJ+ ............................................................................................ 12 
1.1.5.  WORKING ZONE HA12CJ (HA32CJ)................................................................................................ 13 
1.2.  THE LOWER CONTROLS ........................................................................................................................... 15 
1.3.  THE UPPER CONTROLS ........................................................................................................................... 17 
2.  THE ELECTRICAL PART ............................................................................................................................... 19 
2.1.  SYMBOLS USED ............................................................................................................................................. 19 
2.2.  METHODOLOGY OF CONTROL........................................................................................................................ 23 
2.2.1.  electric continuity control.................................................................................................................... 23 
2.2.2.  Control of an on/off valve .................................................................................................................... 23 
2.2.3.  Control of components ........................................................................................................................ 24 
2.3.  THE ELECTRIC SCHEMA (164P322210) .......................................................................................................... 27 
2.3.1.  looms ................................................................................................................................................... 27 
2.3.2.  module node b2-b3 .............................................................................................................................. 28 
2.4.  LOCALIZATION OF THE MAIN COMPONENTS .................................................................................................. 29 
2.5.  STRUCTURE OF THE SYSTEM .......................................................................................................................... 30 
2.6.  LIST OF COMPONENTS ................................................................................................................................... 31 
2.6.1.  motor ................................................................................................................................................... 31 
2.6.2.  Fuses.................................................................................................................................................... 31 
2.6.3.  inputs ................................................................................................................................................... 32 
2.6.4.  Outputs ................................................................................................................................................ 34 
2.7.  LOGICAL EQUATIONS OF OPERATION............................................................................................................. 37 
2.7.1.  Power .................................................................................................................................................. 37 
2.7.2.  Steering................................................................................................................................................ 37 
2.7.3.  drive ..................................................................................................................................................... 38 
2.7.4.  boom lift............................................................................................................................................... 39 
2.7.5.  Telescoping boom ................................................................................................................................ 40 
2.7.6.  Lifting arm ........................................................................................................................................... 41 
2.7.7.  Turret slewing...................................................................................................................................... 42 
2.7.8.  jib ......................................................................................................................................................... 42 
2.7.9.  Compensation ...................................................................................................................................... 43 
2.7.10.  basket rotation ..................................................................................................................................... 44 
2.7.11.  jib rotation (ha12cj+) .......................................................................................................................... 44 
2.7.12.  version eur ........................................................................................................................................... 45 
2.7.13.  Options usa /cdn/australia ................................................................................................................. 45 
2.8.  ALARMS CODES CONSOLE OPTIMIZER.................................................................................................... 46 
2.9.  ALARMS CODE UPPER CONTROLS ................................................................................................................... 51 
2.10.  DETAILS ON ALARMS SE01 – SE02 - SE03 ....................................................................................................... 51 
2.11.  ALARMS CODES ON VARIABLE SPEED UNIT ZAPI ................................................................................... 54 
3.  THE HYDRAULIC PART................................................................................................................................. 56 
3.1.  SYMBOLS USED ............................................................................................................................................. 56 
3.2.  HYDRAULIC DIAGRAM .................................................................................................................................. 60 
3.3.  MAIN MANIFOLDS .......................................................................................................................................... 60 
3.3.1.  Hydraulic block ................................................................................................................................... 60 
3.3.2.  detail of valves ..................................................................................................................................... 61 
3.4.  THE LOOMS ................................................................................................................................................... 62 
3.4.1.  see spr catalog ..................................................................................................................................... 62 
4.  ADJUSTMENTS ................................................................................................................................................. 63 
4.1.  ADJUSTMENTS WITH CONSOLE OPTIMIZER ................................................................................................. 63 
4.2.  PARAMETERS SETTING .................................................................................................................................. 68 
4.3.  OPTIMIZER MENU .................................................................................................................................... 69 
4.4.  CONSOLE DIAG PAD....................................................................................................................................... 92 
4.5.  ADJUSTMENT OF THE PRESSURES .................................................................................................................. 94 
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 4.5.1.  Procedure ............................................................................................................................................ 94 
5.  BREAKDOWN SERVICE GUIDE ................................................................................................................... 96 
5.1.  NO START...................................................................................................................................................... 96 
5.2.  NO MOVEMENT ............................................................................................................................................. 96 
5.3.  NO ARM LIFT ................................................................................................................................................. 97 
5.4.  NO BOOM LIFT............................................................................................................................................... 97 
5.5.  NO TELESCOPING BOOM ................................................................................................................................ 97 
5.6.  NO TURRET SLEWING .................................................................................................................................... 97 
5.7.  NO JIB ........................................................................................................................................................... 97 
5.8.  NO BASKET ROTATION .................................................................................................................................. 98 
5.9.  NO JIB ROTATION ........................................................................................................................................... 98 
5.10.  NO COMPENSATION ....................................................................................................................................... 98 
5.11.  NO DRIVE ...................................................................................................................................................... 98 
5.12.  NO HIGH SPEED ............................................................................................................................................. 98 
5.13.  NO STEERING ................................................................................................................................................ 98 
5.14.  BATTERY CHARGER ...................................................................................................................................... 99 
6.  SUMMARY OF VERSIONS HA12CJ-HA12CJ+ ......................................................................................... 100 
7.  SPECIAL FUNCTIONS ................................................................................................................................... 101 
7.1.  SYSTEM OF LOAD CONTROL ........................................................................................................................ 101 
7.1.1.  Operation........................................................................................................................................... 101 
7.1.2.  Principle of the load control.............................................................................................................. 101 
7.1.3.  Angle sensors ..................................................................................................................................... 101 
7.1.4.  Management of the nominal load overlap ......................................................................................... 102 
7.1.5.  calibration of the pwm valve ............................................................................................................. 102 
7.1.6.  calibration of load management system ............................................................................................ 103 
7.1.7.  Values of the sensors of weighing...................................................................................................... 107 
7.1.8.  diagnostic .......................................................................................................................................... 108 
7.1.9.  Values of the impedance of the variator unit ..................................................................................... 110 
7.1.10.  brake adjustment on drive motors ..................................................................................................... 111 
8.  LIST OF SCHEMATICS ................................................................................................................................. 112 

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1. MAIN FEATURES AND FUNCTIONS
1.1. CHARACTERISTICS

1 .1 .1 . HA12 CJ-CJ+

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TRAINING MANUAL DIAGNOSTIC Level 2 HA12CJ(+)/HA32CJ(+)
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 1.1.2. LOADING POINTS HA12CJ-CJ+

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 1.1.3. FEATURES HA12CJ-CJ+

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TRAINING MANUAL DIAGNOSTIC Level 2 HA12CJ(+)/HA32CJ(+)
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TRAINING MANUAL DIAGNOSTIC Level 2 HA12CJ(+)/HA32CJ(+)
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 1.1.4. OVERALL DIMENSIONS HA12CJ-CJ+

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 1.1.5. WORKING ZONE HA12CJ (HA32CJ)
 CJ version

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 CJ+ version

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1.2. THE LOWER CONTROLS

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1.3. THE UPPER CONTROLS

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2. THE ELECTRICAL PART
2.1. SYMBOLS USED

Battery with one element

Alternator

Fuse (Here 10 amps)

Coil winding roll

Electric motor

light

Diode

Hourmeter

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 Standard push-button of safety “mushroom-headed
button”

Rotary knob

Push-button

Limit switch

Pressure switch

Key selector with 3 positions (T turret, O neutral, N

platform)

Toggle switch with 2 positions

Electrovalve

relay

horn

Proportional electrovalve

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 Proportional valve PWM type ( Pulse Width
Modulation)

Controller/joysticks

Foot pedal switch

buzzer

“light”

Electrovalve “ON/OFF » ( bang-bang)

Tilt sensor ( ramp detection)

Angle sensor (reach limitation)

Contact « mercury » (angle detection)

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 Resistor (here value 100 ohms, 3 Watts, tolerance
of 5%)

Sensor length (reach limitation)

Pressure sensor (weighing)

Angle sensor (weighing)

Standard light “Led”

Strain gauge

Flexible Blade switch (ILS) detection of the magnets

on the telescopic boom/arm extension

Level detector (diesel tank)

Proximity detector with impulses (detection teeth

slew ring)

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 2.2. METHODOLOGY OF CONTROL

Note: during an intervention on a component or a loom, it is important to remember to switch

OFF the power supply of the machine in order to avoid any risk.

2 .2 .1 . ELECTRIC CONTINUITY CONTROL

The continuity check of a loom or an electric component determines the resistor of this device, in
order to detect a possible interruption of continuity (open circuit, short-circuit…).
This control is carried out with a multimeter commutated in position Ohmmeter (Ω).
First of all, it is necessary to determine the terminals of the component or the cable to control and
insulate them.
Then, connect the multimeter in order to record the value.
It must indicate a value of resistor close to 0 Ω if continuity is good.
In the contrary case (resistor which tends towards the infinite one : ∞), continuity presents a
defect.

Control of insulation
At the contrary of continuity, insulation represents a non electric connectiion between the ground
and the component
The test of insulation consists in obtaining the opposite result of that described for continuity, i.e.
a value of the Ohmmeter which must tend towards the infinite one : ∞

2 .2 .2 . CONTROL OF AN ON/OFF VALVE

Note: These tests are to be carried out when power is ON .
Also control the state of the terminals or any other connectors (oxidation…)
Control supply of the coil
Disconnect the plug socket of supply of the valve in order to connect in derivation the multimeter
on the terminals of the connector (see below).
Select the position to voltmeter (V), then activate the command to the valve which must be
tested.
The voltage indicated by the voltmeter must be close to the tension of battery

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 Control intensity of the coil
Disconnect the plug socket of supply of the valve in order to connect in series the multimeter on
the terminals of the connector (example below).
Select the position Ammeter (A), then activate the command to the valve which must be tested.
The intensity indicated by the voltmeter must be of approximately 2A (to be checked according to
the data manufacturer)

Control resistance of the coil

Disconnect the plug socket of supply of the valve in order to connect the multimeter on the
terminals of the connector industry.
Select the position Ohmmeter (Ω), then compare the value measured with that of the data
manufacturer.
In the event of nonconformity of the coil, to carry out its replacement

2 .2 .3 . CONTROL OF COMPONENTS

 Control of an electric relay

Disconnect the relay,then locate its various terminals.
Control the resistor of the solenoid terminals 85 and 86 (see manufacturer datas)
using a multimeter in Ohmmètre position.
If the resistor is null, change the relay.
If this test is OK, check continuity between terminals 30 and 87a and insulation between
terminals 30 and 87
In the event of dysfunction, replace the relay.

 supply control of the relay

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 Locate the relay without disconnecting it and locating it its various terminals.
Control the continuity of terminal 86 with the ground
.(In the event of defect of continuity, check the concerned loom)
Connect the multimeter in position Voltmeter (V) between terminal 30 and the ground and
thus control the power supply of the component (It must be close to the battery voltage Vbat)
Select the function of this relay and check the output voltage between terminal 87 and
ground.
In the event of dysfunction, replace the relay.

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  Control of a fuse

Color code

Fuse check
Multimeter in Ω position, it must indicate a value near 0

NOK
OK

 Control of a diode
Locate the diode and disconnect it from the loom.
Control must be done with a multimeter in “diode” position.
Connect the multimeter on each terminal of the diode, in one direction then on the
other.
In one direction, the diode should have no continuity,
in the other it must beep
If the diode is beeping in both ways , replace it.

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2.3. THE ELECTRIC SCHEMA (164P322210)
see at the end of the manual

2 .3 .1 . LOOMS

See SPARE PARTS CATALOG

Looms interconnection 164P321860 10A

Low control box 164P321860 8/12A
Door lower control box 164P321860 3A
Upper control box 164P321070 3/5/9/11/12/14/16/17A

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 2 .3 .2 . MODULE NODE B2-B3

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2.4. LOCALIZATION OF THE MAIN COMPONENTS

SQ9

A1

SQ34

A2

SQ1

G1-G2
SQ1 = 1 if machine not in slope
SQ9 =1 if telescopic boom is retracted
SQ34 =1 if arm + boom are in stowed position
A1 Angle detection weighing
(signal ~ 5V in lowest position and 10V if jib is at highest position)
A2 Inclinometer (signal of ~6V if basket is at horizontal position)
G1 Pressure small chamber on jib cylinder (signal from 0.5 to 4V)
G2 Pressure large chamber on jib cylinder (signal from 0.5 to 4V)

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2.5. STRUCTURE OF THE SYSTEM

The ECU module B2 is the master and controls all functions, it communicates with the interfaces
(ECU module B3 and variable speed unit) through can bus network
Each movement is controlled by a command varying from 0 to 100%
In order to guarantee a progressivity and an optimal comfort of use, 2 systems of regulation
speed are used for each movement:
 a variable speed unit speed
 2 proportional PWM valves (PWM : Pulse Width Modulation) for movements
(one for low flow movements such as jib/basket and one for big flow movements such as
boom/arm lift/telescopic boom extension…)

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2.6. LIST OF COMPONENTS
In the following tables, the column n°2 gives the coordinates of the components on different the
sheets from the wiring schematics in order to find their position easily.
The first figure corresponds to the number of page and the second to the column (generally from
1 to 20) of the corresponding page.
The possible options specific to certain countries are not indexed (for more information, it is
appropriate to refer to the wiring schematics corresponding to your machine
The column n°3 indicates the position on the connector of the board or the module if it is
necessary
The state noted “0” corresponds to 0V, opened contact or not activated.
The state noted “1” corresponds to the tension of the circuit, closed or activated contact.

2 .6 .1 . MOTOR

MOTOR
M1 03 - 3 Left traction motor (T-307)
M2 03 - 4 Right traction motor (T 307)
P1 03 - 2 Electric pump (T -306)
L3 03 - 8 Left electric brake (B2- 247)
L4 03 -8 Right electric brake (B13- 248)

2.6.2. FUSES
FUSES

FU1 02 - 3 Main 500A (301)

FU2 03 - 2 Pump 160A (305)
FU3 03 - 8 Variable speed unit 10A (A1- 107)
FU4 02 - 15 Flashing light 3A (905)
FU5 02.-17 Horn 3A (205)
FU6 02.-11 Supply module node B2 10A (203)
FU7 02.-12 Supply module node B3 10A (246)
FU8 02.-14 Supply actuators 3A (242)
FU9 02 - 5 Supply emergency pump 30A (322)
FU10 02 - 6 Supply lower controls 15A (303)
FUxx 02 - 9 2 x 20A on converter I/O not labelled on drawings

Converter 2 x20A fuses (I/O)

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 2 .6 .3 . INPUTS
INPUTS LOWER CONTROLS (node B2)
S1
02 - 5 Battery main switch (309)
SA1
02 - 7 Selection turret - basket (104)
SA140
02 - 6 Emergency stop button (102)
SB2
04 - 2 CN104.11 Option for manual brake release device (174)
SA10a
04 - 4 CN104.17 Enable toggle switch (110)
SA10b
04 - 4 CN104.1 Selection emergency pump (243)
SA20a
04 - 6 CN104.7 arm lifting (120)
SA20b
04 - 6 CN104.8 arm descent (121)
SA22a
04 - 9 CN 104.13 telescopic extension (122)
SA22b
04 - 9 CN104.14 telescopic retraction (123)
SA30a
04 - 8 CN104.3 Boom lift (130)
SA30b
04 - 8 CN104.4 boom descent (131)
SA40a
04 - 12 CN104.9 basket compensation Rise (140)
SA40b
04 - 12 CN104.10 basket compensation Descent (141)
SA50a
04 - 11 CN104.15 jib rise (150)
SA50b
04 - 11 CN104.16 jib descent (151)
SA52a
04 - 10 CN104.19 jib rotation left (152)
SA52b
04 - 10 CN104.20 jib rotation right (153)
SA82a
04 - 5 CN104.5 turret rotation left(182)
SA82b
04 - 5 CN104.6 turret rotation right(183)

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 INPUTS UPPER CONTROLS ( node B3)
SA141 05 - 3 Mushroom-headed button emergency stop (215)
SB6 05 - 3 CN105.12 Foot pedal (B141)
SA141 05 - 3 CN104.1 Horn (B106)
SA21a 05 - 8 CN104.7 Arm lift(B112)
SA21b 05 - 8 CN104.8 Arm descent (B113)
SA35a 05 - 10 CN104.13 Telescope extension (B118)
SA35b 05 - 10 CN104.14 Telescope retraction (B119)
SA43a 05 - 12 CN 104.11 Basket rotation towards left side (B116)
SA43b 05 - 12 CN104.12 Basket rotation towards right side (B117)
SA51a 05 - 7 CN104.15 jib rise (B120)
SA51b 05 - 7 CN104.16 jib descent (B121)
SA53a 05.-11 CN104.19 Jib rotation towards left side(B125)
SA53b 05.-11 CN104.20 Jib rotation towrads right side (B126)
SA67 05 - 13 CN104.17 Selection high speed drive (B122)
SB120 05 - 5 CN104.5 Push-button for speed reduction choice for movements
SB121 05 - 6 CN104.6 Push-button for speed increase choice for movements
SB122 05 - 7 CN105.4 Push-button for emergency pump (option)
SM1 05 - 15 Drive joystick
CN106.10 signal Y 0.5-2.5-4.5VDC (B300)
CN106.26 neutral (B315)
CN104.3 Left steering (B108)
CN104.4 Right steering (B109)
SM2 05 - 17 Movements joystick
CN106.13 signal turret rotation X 0.5-2.5-4.5VDC (B303)
CN106.12 signal boom lift Y 0.5-2.5-4.5VDC (B302)
CN106.27 neutral (B316)

MODULES
V1
03 - 6 Variable speed unit speed
B2
04 ECU Module node B2 (lower controls)
B3
05 ECU Module Node B3 (upper controls)

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 SENSORS
SQ1
04 - 16 CN105.3 Slope sensor (172)
SQ34
04 - 15 CN105.2 Detection arm + boom =1 if presence of metal (171)
SQ9
04 - 14 CN105.4 Detection telescopic IN = 1 if presence of metal (180)
A1
05 - 18 CN106.15 jib angle sensor on jib (weighing) (B304)
A2 Absolute angle sensor on jib or inclinometer (weighing)
03 - 20 CN106.16
G1
03 - 17 CN106.24 Pressure sensor on jib cylinder small chamber
G2
03 - 18 CN106.25 Pressure sensor on jib cylinder large chamber

2.6.4. OUTPUTS
RELAYS
KAB Relay for brakes (for variable speed unit SEVCON only)
04 - 9
KAC
02 - 8 Relay for battery charge (106)
KAF
04 - 6 CN104.21 Relay for flashing lights (271)
KAK
04 - 13 CN104.22 Relay for horn (272)
KAT
02 - 20 Relay for validation supply converter 48/12VDC (106)
KAV
04 - 7 CN104.26 Relay for validation variable speed unit (273)
KMG
03 - 8 Main contactor variable speed unit (176)
KM1
03 - 8 Contactor selection traction/movements (178)
KM2
04.-12 CN105.34 Pump contactor (279)
KMS
04 - 13 CN105.33 Contactor (option emergency pump )
KAM*
04 -8 CN104.24 Relay for keeping power during 3 sec after switching off
the power on machine (202)*

Note : * Relay KAM is installed only on machines with software > V3.01

KAM

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 KMG FU3 FU10 KM2 KM1

VALVES

YV0 04 - 11 CN105.19 Secondary PWM1 movements (low flow) (276)

YV1 04 - 11 CN105.20 Main PWM2 movements (big flow) (277)
YV2a 04 - 13 CN105.29 Left steering (262)
YV2b 04 - 14 CN105.30 Right steering (263)
YV3a 04 - 14 CN105.31 basket compensation rise (240)
YV3b 04 - 15 CN105.32 basket compensation descent (241)
YV4a 04 - 15 CN105.21 Turret slewing towards left (282)
YV4b 04 - 16 CN105.22 Turret slewing towards right (283)
YV5a 04 - 17 CN105.23 Arm lifting (220)
YV5b 04 - 18 CN105.24 Arm descent (221)
YV6a 04 - 18 CN105.25 Boom lift (230)
YV6b 04 - 19 CN105.26 Boom descent (231)
YV7a
05 - 18 CN105.28 telescope IN (B600)
YV7b 05 - 19 CN105.29 telescope OUT (B601)
YV8a 05 - 16 CN105.26 jib rise (B615)
YV8b 05 - 17 CN105.27 jib descent (B607)
YV9a 04 - 19 CN105.27 Basket rotation towards left side (243)
YV9b 04 - 20 CN105.28 Basket rotation towards right side (244)
YV10A 05 - 19 CN105.30 jib rotation to left side (B602)
YV10B 05.-20 CN105.31 jib rotation to right side (B603)

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 LIGHTS -BUZZER
H1
04 - 17 CN104.30 Hour recorder lower controls (173)
BG1
05 - 10 CN106.2 Battery charge state indicator upper controls
BG2
05 - 14 CN106.1 speeds movements indicator upper controls
BG3
04 - 19 CN106.15 Battery charge state indicator lower controls
HA1
02 - 17 Buzzer (207)
HA142
04 - 8 CN104.28 Buzzer lower controls (275)
HL1
02 - 15 Flashing lights (206)
HL2
05 - 3 Work headlight (905)

HL102
05 - 15 CN104.22 Light power supply OK upper controls (B501)
HA141
05 - 8 CN104.29 Buzzer upper controls (B508)
HL142
05 -12 CN104.26 Light overload upper controls (B505)
HL143
05 -7 CN 104.21 Light slope (B500)
HL144
04 - 7 CN104.31 Light overload lower controls (274)

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2.7. LOGICAL EQUATIONS OF OPERATION
For all these conditions, the fuses will have to be checked as a preliminary
The condition of the equations of operation described below refers to the standard EN280,
machines known as Standard
(for other standards USA, CDN, AUS) thank you to refer to HAULOTTE SERVICES of your
sector which will indicate the characteristics of your machine

2.7.1. POWER

CONDITIONS
Function Action Modifying
Prohibiting
Necessary the
the function
function
KAC=0
S1= 1+ SA140=1 + SA1 KAT =0
Power upper (side N) =1 KAV =0
controls Batteries charged + SA141 Module node
KMG = 1
=1 B2 and/or
(Machine
B3 KAM = 0
switched ON
KAC=0
without alarms)
S1 =1 + SA140 + SA1 KAT=0
Power lower
(side T) =1 KAV=0
controls
Batteries charged Module B2
node

2.7.2. STEERING

CONDITIONS
Function Action Prohibiting Modifying
Necessary
the function the function
KM2 = 1+ SQ1 = 0
SA1 (side N) + SB6 = 1 +
Right steering YV1 = 1 (slope )
SM1d=1 + KM1 =0
+ YV2B=1 A movement
A movement
with big flow
already in
already in
progress
progress
before
(boom, arm or
steering
telescoping) or
KM2 =1+ command
SA1 (side N) + SB6 =1 + multiple with
Left steering YV1=1
SM1g=1 + KM1 =0 the drive
+YV2A=1
Defect CAN
bus
Module node
defective B2 or
B3

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 2 .7 .3 . DRIVE

CONDITIONS
Function Action Prohibiting Modifying
Necessary
the function the function
KM1=0
variable
SA1 (side N) + SB6 = 1 +
Low speed speed unit
SA67=0 + SM1 HN =1 +
forward from 0 to
signal between 2.5 and 4.5 V SQ1 = 0
500A
(slope)
brakes A movement
KM1=0
blocked L3/L4already in
variable
SA1 (side N) + SB6 =1 + progress
Low speed speed unit
SA67 = 0 + SM1HN =1 + before the
reverse from 0 to
signal between 2.5 and 0.5 V drive
500A
command
go in
KM1=0
microspeed if
variable
SA1 (side N) + SB6=1 + SQ1 = 0 SQ1 = 0
High speed speed unit
SA67=1+ SM1HN =1 + (slope) (machine in
forward from 0 to
signal between 2.5 and 4.5 V brakes slope) +
500A
blocked L3/L4 SA67 = 0
SQ34=0
KM1=0
SQ9 = 0
variable
SA1 (side N) + SB6=1 + (machine
High speed speed unit
SA67=1+ SM1HN =1 + unfolded)
reverse from 0 to
signal between 2.5 and 0.5 V
500A

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 2 .7 .4 . BOOM LIFT

CONDITIONS
Function Action Modifying
Prohibiting the
Necessary the
function
function

Another
movement with
big flow in
SA1 (side N) + SB6=1 +
progress (YV2-
SM2HN=1 + SM2Y signal
KM1 = 1+ YV5-YV7)
Rise upper between 2.5 and 4.5 V + KM2
YV1 = 1 YV2, YV5 or YV7
controls =1 (if multiple in drive mode) or
YV6A =1 at fault
if not variable speed unit signal
A1, A2, G1, G2
from 0 to 500A)
(overload)
Discharged
batteries 20%
SQ1 =0 (slope)
Another
Slowed
movement with
down
SA1 (side N) + SB6=1 + big flow in
descent
SM2HN=1 + SM2Y signal progress (YV2-
KM1=1 with 50%
Descent upper between 2.5 and 0.5 V+ KM2 =1 YV5-YV7)
+ YV1 = if
controls (if multiple in drive mode) or if YV2, YV5 or YV7
1+ In slope
not variable speed unit signal at fault
YV6B =1
from 0 to 500A) A1, A2, G1, G2
(overload)

Another
movement with
big flow in overload
SA1 (side T) + SA10 = 1 + movement
KM1 = 1+ progress (YV2-
SA30A = 1 + KM2 =1 (if multiple are
Rise lower YV1 = 1 YV5-YV7)
in drive mode) or if not variable slowed
controls + YV6A YV2, YV5 or YV7
speed unit signal from 0 to down
=1 at fault
500A)
Discharged
batteries 20%
SQ1 = 0 (slope)
Another Slowed
movement with down
SA1 (side T) + SA10 =1 + big flow in descent
KM1=1
SA30B =1 + progress (YV2- with 50%
Descent lower + YV1 =
KM2 =1 (if multiple in drive YV5-YV7) if
controls 1+
mode) or if not variable speed YV2, YV5 or YV7 In slope
YV6B =1
unit signal from 0 to 500A) at fault

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 2.7.5. TELESCOPING BOOM
CONDITIONS
Function Action Prohibiting Modifying
Necessary
the function the function
Another
movement
with big flow in
progress
(YV2-YV5-
SA1 (side N) + SB6 =1 + YV6)
SA35A =1 + KM2 =1 (if YV2, YV5 or
Extension KM1 = 1 +
multiple in drive mode) or if YV6 at fault
upper controls YV1= 1+
not variable speed unit signal A1, A2, G1,
YV7A=1
from 0 to 500A) G2
(overload) Modifiable
Discharged speed
batteries 20% movement
SQ1 = 0 by SB120 -
(slopel) SB121)
Another Retraction
movement slowed down
with big flow in with 50% in
progress slope
SA1 (side N) + SB6 =1 +
(YV2-YV5-
KM1 = 1 + SA35A =1 + KM2 =1 (if
Retraction YV6)
YV1 = 1 multiple in drive mode) or if
upper controls YV2, YV5 or
+YV7B=1 not variable speed unit signal
YV6 at fault
from 0 to 500A)
A1, A2, G1,
G2
(overload)

Another
movement overload
with big flow in movement is
progress slowed down
SA1 (side T) + SA10A = 1+
(YV2-YV5- Slowed
KM1 = 1 + SA22A=1 + KM2 =1 (if
extension YV6) down
YV1= 1+ multiple in drive mode) or if
lower controls YV2, YV5 or retraction
YV7A=1 not variable speed unit signal
YV6 at fault with 50% in
from 0 to 500A)
Discharged slope
batteries 20%
SQ1 = 0
(slope)
Another
movement
SA1 (side T) + SA10A =1 +
with big flow in
SA22B=1 + KM2 =1 (if
Retraction KM1 = 1 + progress
multiple in drive mode) or if
lower controls YV1 = 1 (YV2-YV5-
not variable speed unit signal
+YV7B=1 YV6)
from 0 to 500A)
YV2, YV5 or
YV6 at fault

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 2.7.6. LIFTING ARM

CONDITIONS
Function Action Prohibiting the Modifying
Necessary
function the function
Another
movement with
big flow in
progress (YV2-
SA1 (side N) + SB6=1 +
YV6-YV7)
KM1 = 1 + SA21A =1 + KM2 =1 (if
Rise upper YV2, YV6 or
YV1 = 1 multiple in drive mode) or if
controls YV7 at fault
+YV5A=1 not variable speed unit
A1, A2, G1, G2
signal from 0 to 500A)
(overload)
Discharged Modifiable
batteries 20% speed
SQ1 = 0 (slope) movement by
Another (SB120 -
movement with SB121)
big flow in slowed down
progress (YV2- descent with
SA1 (side N) + SB6=1 +
YV6-YV7) 50% if in
KM1 = 1 + SA21B =1 + KM2 =1 (if
Descent upper YV2, YV6 or slope
YV1 = 1 multiple in drive mode) or if
controls YV7 at fault
+YV5B=1 not variable speed unit
A1, A2, G1, G2
signal from 0 to 500A)
(overload)
Discharged
batteries 20%

Another overload
movement with movements
big flow in are slowed
SA1 (side T) + SA10A=1 +
progress (YV2- down
KM1 = 1 + SA20A = 1+ KM2 =1 (if
Rise lower YV6-YV7)
YV1 = 1 multiple in drive mode) or if
controls YV2, YV6 or slowed down
+YV5A=1 not variable speed unit
YV7 at fault descent with
signal from 0 to 500A)
Discharged 50% if in
batteries 20% slope
SQ1 = 0 (slope)
Another
movement with
big flow in
SA1 (side T) + SA10A=1 +
progress (YV2-
KM1 = 1 + SA20B = 1 + KM2 =1 (if
Descent lower YV6-YV7)
YV1 = 1 multiple in drive mode) or if
controls YV2, YV6 or
+YV5B=1 not variable speed unit
YV7 at fault
signal from 0 to 500A)
Discharged
batteries 20%

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 2.7.7. TURRET SLEWING
CONDITIONS
Function Action Prohibiting Modifying
Necessary
the function the function
SA1 (side N) + SB6 =1 + Another
SM2HN=1 + SM2X signal movement
KM1 = 1 +
Right side between 2.5 and 4.5 V + KM2 with low flow
YV0 =1
upper controls =1 (if multiple in drive mode) in progress
+YV4B=1
or if not variable speed unit (YV3-YV8- Movements of
signal from 0 to 500A) YV9- YV10) Drive (position
YV3, YV8, transport)
YV9 or YV10 and/or steering
SA1 (side N) + SB6 =1 + (if this
at fault
SM2HN=1 + SM2X signal movement is
A1, A2, G1, activated in first
Left upper KM1 = 1 + between 2.5 and 0.5 V + KM2
G2 Movements
controls YV0 =1 =1 (if multiple in drive mode)
(overload) slowed down if
+YV4A=1 or if not variable speed unit in slope
Discharged
signal from 0 to 500A)
batteries 20%

SA1 (side T) + SA10A=1 + Another

KM1 = 1 + SA82B = 1 + KM2 =1 (if movement
Right side
YV0 =1 multiple in drive mode) or if with low flow
lower controls
+YV4B=1 not variable speed unit signal in progress
overload
from 0 to 500A) (YV3-YV8-
movements
YV9- YV10)
are slowed
YV3, YV8,
SA1 (side T) + SA10A=1 + down
YV9 or YV10
KM1 = 1 + SA82A = 1 + KM2 =1 (if
Left lower at fault
YV0 =1 multiple in drive mode) or if
controls
+YV4A=1 not variable speed unit signal
Discharged
from 0 to 500A)
batteries 20%

2 .7 .8 . J IB

CONDITIONS
Function Action Prohibiting Modifying
Necessary
the function the function
SA1 (side N) + SB6 =1 + Another
KM1 = 1 + SA51A=1 + KM2 =1 (if movement with Modifiable
Rise upper speed
YV0 = 1 multiple in drive mode) or if low flow in
controls
+YV8A=1 not variable speed unit signal progress (YV3- movement by
from 0 to 500A) YV4-YV9- (SB120 -
SB121
YV10) Office multiple
YV3, YV4, YV9 with the drive
SA1 (side N) + SB6 =1 + or YV10 at fault (position
KM1 = 1 + SA51B=1 + KM2 =1 (if A1, A2, G1, G2 transport)
Descent upper
YV0 = 1 multiple in drive mode) or if (overload) and/or steering
controls
+YV8B=1 not variable speed unit signal Discharged (if this
from 0 to 500A) batteries 20% movement is
SQ1 = 0 activated in
(slope) first)

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 SA1 (side T) + SA10A=1 + Another
KM1 = 1 + SA52A = 1 + KM2 =1 (if movement with overload
Rise lower
YV0 = 1 multiple in drive mode) or if low flow in movements
controls
+YV8A=1 not variable speed unit signal progress (YV3- are slowed
from 0 to 500A) YV8-YV9- down
SA1 (side T) + SA10A=1 + YV10) Descent
KM1 = 1 + SA52B = 1 + KM2 =1 (if YV3, YV4, YV9 slowed down
Descent lower if in slope
YV0 = 1 multiple in drive mode) or if or YV10 at fault
controls
+YV8B=1 not variable speed unit signal Discharged
from 0 to 500A) batteries 20%

2.7.9. COMPENSATION

CONDITIONS
Function Action Prohibiting the Modifying
Necessary
function the function
SA1 (side N) + SB6 = Another
1 + SA41A/B =1 + movement with
KM1 = 1 + KM2 =1 (if multiple in low flow in
Rise/descent
YV0 = 1+ drive mode) or if not progress (YV4-
upper controls
YV3A/B=1 variable speed unit YV8-YV9- YV10) Movement
signal from 0 to 500A) YV4, YV8, YV9 or slowed down
speed unit of 0 to 500A YV10 at fault if in slope

A1, A2, G1, G2

(overload)
Discharged
batteries 20%
emergency mode

Another
movement with
low flow in
SA1 (side T) + progress (YV4-
SA10A=1 + SA40A/B YV8-YV9- YV10)
= 1+ KM2 =1 (if YV4, YV8, YV9 or
KM1 = 1 + YV10 at fault
Rise/descent multiple in drive mode)
YV0 = 1+ A1, A2, G1, G2
lower controls or if not variable speed Prohibited
YV3A/B=1 (overload)
unit signal movement if
from 0 to 500A) Discharged telescope
batteries 20% OUT
Emergency mode

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 2.7.10. BASKET ROTATION

CONDITIONS
Function Action Prohibiting the Modifying the
Necessary
function function
SA1 (side N) + SB6 =1 + Another
Modifiable
SA43A/B = 1+ KM2 =1 (if movement with
(left/right KM1 = 1 + speed
multiple in drive mode) or if low flow in
movement) YV0 = 1 + movement by
not variable speed unit progress (YV3-
YV9A/B=1 (SB120 - SB121
signal from 0 to 500A) YV4-YV8- YV10)
YV3, YV4, YV8 or
YV10 at fault
Movement
slowed down if
A1, A2, G1, G2
in slope
(overload)
Discharged
batteries 20%)
SQ1 = 0 (slope)
emergency mode

2.7.11. JIB ROTATION (HA12CJ+)

CONDITIONS
Function Action Prohibiting the Modifying the
Necessary
function function
SA1 (side N) + SB6 =1 + Modifiable
Another
KM1 = 1 + SA53A/B=1 + KM2 =1 (if speed
upper controls movement with
YV0 = 1 + multiple in drive mode) or if movement by
(left. /right) low flow in
YV10A/B =1 not variable speed unit signal (SB120 - SB121
progress (YV3-
from 0 to 500A)
YV4-YV8- YV9)
YV3, YV4, YV8
or YV9 at fault
SA1 (side N) + SA10A =1 + overload low
A1, A2, G1, G2
KM1 = 1 + SA52A/B = 1+ KM2 =1 (if movements
lower controls (overload)
YV0 = 1 + multiple in drive mode) or if slowing down
(left/right) Discharged
YV10A/B =1 not variable speed unit signal Movement
batteries 20%
from 0 to 500A) slowing down if
Emergency
in slope
mode
SQ1 = 0 (slope)

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 2.7.12. VERSION EUR
in the tables below, the multiple movements are defined independently of the controls
(except for the drive/steering which is made only from upper controls)

Note: in drive, the steering has the priority to the other movements

2.7.13. OPTIONS USA /CDN/AUSTRALIA

USA version:
no cut-off of the movements if the machine is in slope > 3° (alarm sounds only), the
machine is slowed down in drive mode
no movement cut out if machine in overload

CDN version :
same as for USA except for slope ( movements are cut if machine is above 3 meters
workking height ( SQ34 and/or SQ9 = 1)

in drive mode , the steering has the priority from the other movements

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2.8. ALARMS CODES CONSOLE OPTIMIZER
All alarms of the system are shown through the console through various menus
SPEED VARIATOR UNIT ALARMS

CODE DESCRIPTION ACTION

AV01 Problems in stator/rotor Possible faults on ZAPI
current , logic, hardware, (13,18,19,53,57,58,233,234,241,244,247,248,25
current probes, or CAN bus 2,253
network or problems linked to
an over or low voltage
AV02 Problems in main contactor - Possible faults on ZAPI (37,74,75,76,77,242)
KMG or with the contactor for - Check the state of contactors and/or
selection traction/pump KM1 connections
(open circuit, contact stuck
or short-circuit)
AV03 Lack of power or problem in Possible faults on ZAPI (30,31,60,250)
the outputs motors/pump
AV04 Speed variator unit in thermal - Possible fault on ZAPI 62
security - Let’s cool the speed variator unit until the fault
disappears and meanwhile avoid to drive too
much time in rising ramps
AV05 Wrong sequence for starting - Restart the machine in good way
or error on one speed ( battery cut-out , e-stop buttons then key
variator unit input selector for upper/lower control box)
- Check speed variator unit connection
AV06 Problem on batteries or - Possible faults on ZAPI (66,251)
batteries too weak - Reload or replace batteries

CONTACTOR OUTPUTS
CODE DESCRIPTION ACTION
SC01 Output in open or short circuit : Change relay KAV, check wiring and
validation relay KAV is defective (or equipotential (on wires 273 et 0)
missing) or wire is cut
SC02 Output in open or short circuit: Change relay KAF, check wiring and
flashing light relay KAF is defective equipotential (on wires 271 et 0)
(or missing) or wire is cut
SC03 Output in open or short circuit: horn Change relay KAK, check wiring and
relay KAK is defective (or missing) equipotential (on wires 272 et 0)
or wire is cut
SC04 Output in open or short circuit : Change contactor KM2 on speed unit
pump power coil contactor KM2 is plate , check cable 279 between
defective (or missing) or wire is cut chassis loom and turret box or wire
203 on coil (+12V)
SC05 Output in short circuit: brakes Change relay KAB, check cable 275
release relay KAB is defective (or between chassis looms and turret box
missing) or wire is cut (fault only and check the 0 on relay.
with SEVCON speed unit)
SC06 Output in open or short circuit : Change relay KMS, check continuity
emergency pump power coil on wire 208 between turret loom and
contactor KMS is defective (or emergency pump option loom + turret
missing) or wire is cut box, check wire 203 on coil (+12V)
(Fault visible only if the dead man
toggle switch SA10b is activated)

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VALVES OUTPUTS
CODE DESCRIPTION ACTION
EV01 Output in open or short circuit : Change coil YV0, check wire 276
PWM valve for secondary between loom bloc + turret box or wire
movements YV0 is defective (or 203 on coil itself (+12V)
missing) or wire is cut
EV02 Output in open or short circuit : Change coil YV1, check wire 277
PWM valve for main movements between loom bloc + turret box or wire
YV1 is defective (or missing) or wire 203 on coil itself (+12V)
is cut
EV03 - Output in open or short circuit : - Change coil YV2A, check wire 262
ON /OFF valve for left steering between loom bloc + turret box or the
YV2A is defective (or missing) or 203 on coil itself (+12V)
wire is cut - Change coil YV2B, check wire 263
- Output in open or short circuit : between loom bloc + turret box or wire
ON /OFF valve for right steering 203 on coil itself (+12V)
YV2B is defective (or missing) or
wire is cut
EV04 - Output in open or short circuit : - Change coil YV3A, check the wire
ON /OFF valve for basket 240 between loom bloc + turret box or
compensation lifting YV3A is the 203 on coil itself (+12V)
defective (or missing) or wire is cut - Change coil YV3B, check wire 241
- Output in open or short circuit : between loom bloc + turret box or wire
ON /OFF valve for basket 203 on coil itself (+12V)
compensation descent YV3B is
defective (or missing) or wire is cut
EV05 - Output in open or short circuit : - Change coil YV4A, check the wire le
ON /OFF valve: for turntable left 282 between loom bloc + turret box or
rotation YV4A is defective (or the 203 on coil itself (+12V)
missing) or wire is cut - Change coil YV4B, check wire 283
- Output in open or short circuit : between loom bloc + turret box or wire
ON /OFF valve: for turntable right 203 on coil itself (+12V)
rotation YV4B is defective (or
missing) or wire is cut
EV06 - Output in open or short circuit : - Change coil YV5A, check the wire
ON /OFF valve: for arm lift YV5A is 220 between loom bloc + turret box or
defective (or missing) or wire is cut wire 203 on coil itself (+12V)
- Output in open or short circuit : Change coil YV5B, check wire 221
ON /OFF valve: for arm descent between loom bloc + turret box or wire
YV5B is defective (or missing) or 203 on coil itself (+12V)
wire is cut
EV07 - Output in open or short circuit : - Change coil YV6A, check the wire
ON /OFF valve for boom lift YV6A is 230 between loom bloc + turret box or
defective (or missing) or wire is cut wire 203 on coil itself (+12V)
- Output in open or short circuit : - Change coil YV6B, check wire 231
ON /OFF valve: for boom descent between loom bloc + turret box or wire
YV6B is defective (or missing) or 203 on coil itself (+12V)
wire is cut

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EV08 - Output in open or short circuit : - Change coil YV7A, check wire B600
ON /OFF valve for right steering between bloc loom + turret box and
YV7A is defective (or missing) or wire 246 on coil (+12V)
wire is cut - Change coil YV7B, check wire B601
- Output in open or short circuit : between bloc loom + turret box and
ON /OFF valve for left steering wire 246 on coil (+12V)
YV7B is defective (or missing) or
wire is cut :
EV09 - Output in open or short circuit : - Change coil YV8A, check wire B615
ON /OFF valve for jib lifting YV8A is between bloc loom + turret box and
defective (or missing) or wire is cut wire 246 on coil (+12V)
- Output in open or short circuit : - Change coil YV8B, check wire B609
ON /OFF valve for jib descent YV8B between bloc loom + turret box and
is defective (or missing) or wire is wire 246 on coil (+12V)
cut
EV10 - Output in open or short circuit : - Change coil YV9A, check wire 234
ON /OFF valve for basket rotation between bloc loom + turret box and
left side YV9A is defective (or wire 246 on coil (+12V)
missing) or wire is cut - Change coil YV9B, check wire 235
- Output in open or short circuit : between bloc loom + turret box and
ON /OFF valve for basket rotation wire 246 on coil (+12V)
right side YV9B is defective
(or missing) or wire is cut
EV11 - Output in open or short circuit : - Change coil YV10A, check wire B602
ON /OFF valve for jib rotation left between bloc loom + turret box and
side YV10A is defective (or missing) wire 246 on coil (+12V)
or wire is cut - Change coil YV10B, check wire B603
- Output in open or short circuit : between bloc loom + turret box and
ON /OFF valve for jib rotation right wire 246 on coil (+12V)
side YV10B is defective (or missing)
or wire is cut

CAN-BUS ERRORS / EEPROM

CODE DESCRIPTION ACTION

MX01 CAN fault communication check can-bus network
(impedance and connections)
EP01 EEPROM checksum error

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JOYSTICKS(CONTROLLERS) – TOGGLE SWITCHES

CODE DESCRIPTION ACTION

SM1Y Signal out of range or inconsistent Check connection and signal value
neutral value on drive joystick (0.5 -2.5-4.5VDC)
SM2Y Signal out of range or inconsistent Check connection and signal value
neutral value on rotation /lift joystick (0.5 -2.5-4.5VDC)
SM2X Signal out of range or inconsistent Check connection and signal value
neutral value on rotation /lift joystick (0.5 -2.5-4.5VDC)
SW01 Inconsistent value or neutral Check toggle switches from lower
position not OK when power is ON , control box
on one of the toggle switch in lower
control box
SW02 Inconsistent value or neutral Check toggle switches from upper
position not OK when power is ON , control box
on one of the toggle switch in upper
control box

OVERLOAD ALARMS

CODE DESCRIPTION ACTION

OL01 - Adress fault on slave - Problem in checksum parameters validation or
module doing the load overload calibration datas or problem during load
function calibration
- Inconsistant values - Make again the calibration
between EEPROM datas
saved between module
master B2 and slave B3
OL02 Fault in Jib learning Cal 1 Make or redo the Jib learning Cal 1 calibration
process
OL03 - Inconsistent values - Check the jib angle sensor value and the
between jib movement and direction of variation of this value
jib angle measurement (should increase when jib is lifting).
- Fault in A1 relative angle - Jib angle sensor value out of range
sensor - Check sensor and its mounting/connection
OL04 - Inconsistent value - Check the jib inclinometer sensor value and the
between compensation direction of variation of this value
movement and jib angle (should decrease when basket is elevating) –
- Fault in A2 absolute - Jib inclinometer sensor value out of range
angle sensor (inclinometer) - Check sensor and its mounting/connection
OL05 - Fault in G1 pressure - Pressure sensor out of range
sensor in jib cylinder - Check the sensor and its connection
- Pressure variation too - Check if the pressure in the small jib chamber is
important in the jib small varying in good way
chamber - Change the pressure sensor
OL06 - Fault in G2 pressure Pressure sensor out of range
sensor in jib cylinder - Check the sensor and its connection
- Pressure variation too - Check if the pressure in the large jib chamber is
important in the jib large varying in good way
chamber - Change the pressure sensor
OL07 Inconsistent values for the - Too much difference of calculation regarding the
calculation of the pressure pressure datas between modules node B2 and B3
recorded between modules - Restart the machine
node B2 master and slave - change module node B2 and/or node B3
B3

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CODE DESCRIPTION ACTION
OL08 Inconsistent values for the - difference more than 2 seconds between the
calculation of the pressure reference pressure ( calibration value) registered
reference between by module node B3 and the current one registered
modules node B2 master by the master module node B2
and node B3 slave
OL09 Resultant pressure out of Pressure registered in node B2 out of range
range compared to the threshold value ( low and high)
The fault appears if the difference between the
registered value and the recordered value is above
2 seconds

SENSORS ALARMS

CODE DESCRIPTION ACTION

SE01 Check wiring and sensors SQ9 and SQ34 :
Telescopic IN SQ9=1
Incoherent status of
Boom+arm stowed , SQ34 = 1
sensors : no change
Move both movements (telescopic then arm +
during movement
boom) and check if failure has disappeared.

SE02 Check wiring and sensors SQ9 and SQ34 :

Telescopic IN SQ9=1
Anti by-pass safety : Boom+arm stowed , SQ34 = 1
detection of SQ34 Move both movements (telescopic then arm +
from 0 to 1 without any boom) and check if failure has disappeared.
movement) Principle of survey :
1 –failure if without any movement , the sensor
goes from 0 to 1
SE03
E-stop safety :
Check wiring and sensors SQ9 and SQ34 :
detection position
Telescopic IN SQ9=1
before power OFF and
Boom+arm stowed , SQ34 = 1
check position when
Move both movements (telescopic then arm +
power is ON again
boom) and check if failure has disappeared.
(sensor state should
not have changed)

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2.9. ALARMS CODE UPPER CONTROLS
These alarms are the same as the previous table but they are gathered by category and appear
in the form of flash code in upper controls for the operator (visible on power supply light HL102)
The operator could quickly diagnoses the origin of the failure and solves the problem sometimes
without using the OPTIMIZER console

FLASH CODE FAILURES CODE ON OPTIMIZER

1 AV01
2 AV02
3 AV03
4 AV04
5 AV05
6 AV06
7 SC01 - SC02 - SC03 - SC04 - SC05 - SC06
EV01 - EV02 - EV03 - EV04 - EV05 - EV06 - EV07 - EV08 - EV09 -
8
EV10 - EV11
9 EP01
10 SM1Y - SM2Y - SM2X - SW01 - SW02
11 SE01-SE02-SE03

2.10. DETAILS ON ALARMS SE01 – SE02 - SE03

Defect : proximity sensors

0 = no failure
1 = failure
fault SQ34
and SQ9
Function
Fault if shunt after
fault SQ9
SQ34 on power is State of State of
and SQ34
(SE02) swithed sensor slope
(SE01) Number
ON arm/boom sensor Drive Movement
of flashs Reset if defect
(SE03) (SQ34=0 (SQ1=0 authorised authorised
code
Defect unfolded, no tilt,
detected Defect shunt SQ34=1 SQ1=1
Defect if folded) in slope)
when and no
state has
machine movement
changed
starts to detected , no
after
unfold and command
power is
no change and SQ34
ON
on sensors state has
state changed

0 (machine 0 (no All

0 0 0 Micro speed 0 none
unfolded) slope) authorised

EUR mode Machine

0 (machine
1 no drive/ in folded
0 0 0 unfolded) 0 none
(dévers) USA mode position
micro speed authorised

Drive in LS
1 (machine All
0 0 0 0 and HS 0 none
folded) authorised
speed drive

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 Drive in
1 (machine microS and All
0 0 0 1 0 none
folded) HS speed authorised
drive

lower /lift the

boom and
retract and
All
1 0 0 0 0 11 extend the
Micro speed authorised
telescopic
boom
extension

lower /lift the

boom and
EUR mode Machine retract and
no drive/ in folded extend the
1 0 0 0 1 11
USA mode position telescopic
micro speed authorised boom
extension

lower /lift the

boom and
retract and
All
1 0 0 1 0 Micro speed 11 extend
authorised
telescopic
boom
extension

lower /lift the

boom and
EUR mode Machine
retract and
no drive/ in folded
1 0 0 1 1 11 extend
USA mode position
telescopic
micro speed authorised
boom
extension

Defect : proximity sensors

0 = no failure
1 = failure
fault SQ34
Function Fault if
and SQ9
fault SQ9 shunt
after power
and SQ34 SQ34 on State of
is swithed State of
(SE01) (SE02) sensor
ON (SE03) slope
arm/boo Number
sensor Drive Movement Reset if
Defect m of flashs
Defect (SQ1=0 authorised authorised defect
detected (SQ34=0 code
shunt and no tilt,
when unfolded,
no Defect if SQ1=1 in
machine SQ34=1
movement state has slope)
starts to folded)
detected , changed
unfold and
no after power
no change
command is ON
on
and SQ34
sensors
state has
state
changed

Remove
Micro All
0 1 0 0 0 11 shunt on
speed authorised
SQ34

Machine in Remove
0 1 0 0 1 11
EUR mode folded shunt on
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 no drive/ position SQ34
USA mode authorised
micro
speed

Remove
shunt on
Micro All
0 1 0 1 0 11 SQ34
speed authorised
Lower/lift the
boom

EUR mode Remove

no drive/ shunt on
All
0 1 0 1 1 USA mode 11 SQ34
authorised
micro Lower/lift the
speed boom

lower /lift the

boom and
Micro retract and
All
0 0 1 0 0 speed 11 extend
authorised
telescopic
boom
extension

lower /lift the

EUR mode boom and
Machine in
no drive/ retract and
folded
0 0 1 0 1 USA mode 11 extend
position
micro telescopic
authorised
speed boom
extension

lower /lift the

boom and
retract and
Micro extend
0 0 1 1 0 All 11
speed telescopic
authorised
boom
extension

lower /lift the

boom and
EUR mode
retract and
no drive/
All extend
0 0 1 1 1 USA mode 11
authorised telescopic
micro
boom
speed
extension

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2.11. ALARMS CODES ON VARIABLE SPEED UNIT ZAPI
This list of code alarm is shown only on the OPTIMIZER console
(see DIAGNOSTIC/VARIATOR /Internal Variable= xx, CODE ALARM

Code DEFINITION DIAGNOSTIC

OPTIMIZER
The parameters have been altered and the
movements are impossible
If the problem has been solved when power is
13 EEPROM KB
switched OFF then ON (the values are from
now the default values)
If the defect persists: change the variator
Fault in the “hardware “ system of the logic
18 LOGIC FAILURES # 2
board which controls the pump contactor KM2
Problem in the logical circuit of the line
19 LOGIC FAILURES # 1 contactor KMG or in the hardware of the
variator
Problem with the circuit power of the drive
30 VMN LOW
motors or connections,
Problem with the circuit power of the drive
31 VMN HIGH
motors or connections,
The terminals of the power contactor KMG
37 CONTACTOR CLOSED
remain stuck
Failure in the current detection as it didn’t
53 STBY I HIGH drop to 0 when the variator is not activated
Change the variator if the problem persists
Defect in the circuit energizing F1 /F2
57 HIGH FIELD CURRENT check connections
replace the variator if the problem persists
Defect in the field circuit F1 /F2
58 NO FIELD CURRENT Check connections
Replace the variator if the problem persists
The capacitors doesnt charge 0.5 after power
60 CAPACITOR LOAD is ON
Defect in the power circuit
The internal temperature of the variator
exceeds 75°C
62 TH PROTECTION
Defect in the temperature sensor
Let’s cooling the variator before changing it
66 BATTERY LOW batteries discharged more than 80%
74 DRIVER SHORTED The line contactor KMG is in short-circuit
Problem on contactors KM1 or KMG or
75 CONTACTOR DRIVER
brakes L3/L4
Short-circuit or open circuit on contactors or
76 COIL SHORTED
circuit brakes L3/L4
When power is ON, the voltage applied on
77 COIL INTERRUPTED contactor is not correct
Check connections before changing the variator

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 Starting was not carried out correctly, start
again the sequence in the correct order
79 INCORRECT START
(battery cut out, emergency stop, selection
movement then joystick.)
No change of state on input
99 INPUT ERROR # 1 (Problem on modules)
Problem on VMC (Volt Motor Controller),
VMC voltage tries to start without agreement
223 WAITING FOR NODE
of the variator (CAN bus problem or modules)
233 SENSOR I KO Current field sensor NOT OK
234 HW FAULT Problem of inverter, change KM1
Dual command (drive + movements) , release
241 FORW + TOP SPIN
all command
Not used for HAULOTTE, change variator if
242 VALVE COIL SHORTED
alarm appears again
Warning that the maintenance scheduled is
244 CHECK UP NEEDED exceeded (not used by HAULOTTE on this
kind of SEM1 variator )
With power is ON, the variator checks if the
values of the temperature sensor are in the
247 THERMIC SENSOR KB
tolerances
If the problem persists,change the variator
248 KEY-OFF No power on system
No message coming from the CAN-BUS,
249 CAN BUS KO check connections
If the problem persists, change the variator
With power ON, the system checks that the
voltage on field circuit is at 50% Vbat with line
250 VFIELD NOT OK contactor open
Check connections
Mass fault between chassis and variator
251 WRONG SET BATTERY Wrong type of batteries
The system checks the circuit brakes
252 AUX2 OUTPUT KO command, if the received signal does not
correspond, replace the variator
The system checks the commande of KM1
253 AUX1 OUTPUT KO contactor if the received signal does not
correspond, change the contactor

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3. THE HYDRAULIC PART
3.1. SYMBOLS USED

Pump with variable cubic capacity flow

(here maximum 38 cc /rpm)

Pump fixed flow cubic capacity

(here 23 cc/rpm)

Pump with variable flow (used for the hydrostatic

transmission in closed circuits on HAULOTTE big
booms like HA32PX, HA41PX, H28TJ+, H43TPX)

Hydraulic motor with 2 directions of drive

(ex FWD/REV)

Variable cubic capacity drive motor with 2 directions

of drive
15cc for high speed
45 cc for low speed

Filter (normally 10 microns)

check valve

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 calibrated check valve

Priority valve /shuttle valve

piloted check valve

Circuit selector switch/shuttle valve

Position hydraulic valve(used for the HA32/41PX)

Adjustable pressure relief valve

(here set at 145 bars/2104 psi)

Fixed flow restrictor or spray nozzle

(here diameter of 0.75 mm)

Adjustable flow restrictor + check valve

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 Pressure sensor (used for weighing)

Adjustable pressure switch

(here set at 170 bars)

Flow divider

Position valve 4 ways, 3 positions in closed center

Distribuitor/ safety valve

Counter balance valve with piloting line of the

opposite line (here set at 210bars)

Position valve proportional 5/3 with piloting manual

by lever

Rotary cylinder /jack (here range at 180°)

Piloted valve

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 Manual valve with automatic return (used to readjust
the part of compensation on HA32PX/HA41PX)

Position valve proportional 4 ways/3 positions

Pressure balance/flow control valve

Flow regulator

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3.2. HYDRAULIC DIAGRAM
See at the end of this manual

3.3. MAIN MANIFOLDS

3.3.1. HYDRAULIC BLOCK

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 3 .3 .2 . DETAIL OF VALVES

YV6 Boom lift

YV7 Telescoping boom
YV5 Arm lifting
YV2 steering
YV1 (PWM2) Main movements (big flow)
YV0 (PWM1) Secondary movements (low flow)
YV8 jib
YV4 Turret rotation
YV9 Basket rotation
YV3 Basket compensation
YV10 jib rotation (for model HA12CJ+)

 YV10 mounted between compensation block and emergency block with lever if option
HA12CJ+
 Attention 2 types of hydraulic blocks (1 for HA12CJ and 1 for HA12CJ+) with different part
numbers

YV6A

YV7A
YV6B
YV5A
YV7B

YV2A YV5B

YV2B

PWM2 YV1

PWM1 YV0
YV8A
YV4A YV8B

YV9A YV4B

YV9B
YV3A
YV3B

YV10A YV10B*

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 For this machine, the hydraulic block is divided into two parts, each one controlled by a
PWM proportional valve
 Main movements (proportional valve PWM2 YV1): Lifting Arm, boom lift,
Telescoping boom and steering
 Secondary movements (proportional valve PWM1 YV0): Compensation,
Orientation, jib, basket rotation, jib rotation

The hydraulics pressure is obtained by a pump motor unit supplied with a variable speed unit
speed.
When it’s used to control the drive motors, the pump motor unit is supplied in ON/OFF in order to
have the possibilty to multiply the movements in drive mode

3.4. THE LOOMS

3 .4 .1 . SEE SPR CATALOG

for HA12CJ+
164P335310 (2 looms)
for HA12CJ
164P335320 (2 looms)

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4. ADJUSTMENTS
4.1. ADJUSTMENTS WITH CONSOLE OPTIMIZER
The adjustments, parameter settings and lists of alarms of the machine are accessible only
through this console.

Use console OPTIMIZER (ref. 2440320080) with modules node B2/B3

Connection on bottom panel (turret)

On RS232 plug socket located outside the lower turret box

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Description of the console

PARAMETER + or CHANGE
PARAMETER - or CHANGE
PREVIOUS MENU

NEXT MENU

RECORD/ENTER/VALIDATION

BACK TO MAIN MENU

NOTE : on any blue key pads , pressing on left , right or in the center have the same result

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List of menus
Access to main menu

Access to calibration menu (level 2)

Access to the code level 2

Validation by key: , then enter the code

Navigation by this key then enter the code

Level 2 is registered

press following key:

Back to main menu

The console is in level 2 (access to the calibration menu)

once level 2 is set , go to menu :

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2 .PARAMETERS/CALIBRATION/Jib Learning Cal 1

2.PARAMETERS/CALIBRATION
First set the calibration 1

Go in menu OVERLOAD CAL in order to launch the calibration

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List of menus

Access to the main menu

Parameters setting access

Input/output state access

Trouble shooting guide per

function

Machines status

Failures list

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4.2. PARAMETERS SETTING

Speeds settings from lower controls

Movement type Time

Jib rotation full range lock to lock Left 31s +/- 5 sec
(HA12CJ+) right 31s +/- 5 sec
up 22s +/-5 sec
jib
down 26s +/-5 sec
up 24s +/-5s
Arm
down 22s +/-5s
Turret rotation Left 56s +/-5s
(1/2 turn/180°) right 56s +/-5s
up 30s +/-5s
Main boom
down 22s +/-5s
IN 17s +/-5s
Telescopic boom
OUT 17s +/-5s
up 39s +/-2s
Compensation
down 38s +/-2s
speed control from lower control box
Movement type Time
FWD 54s +/-5s on 10 meters
Drive Micro speed
REV 55s +/-5s on 10 meters
FWD 30s +/-5s on 50 meters
Drive High Speed
REV 31s +/-5s on 50 meters
FWD 30s +/-5s on 20 meters
Drive Low Speed
REV 31s +/-5s on 20 meters
up 21s +/-5s
Arm
down 20s +/-5s
Turret rotation Left 43s +/-5s
(1/2 turn/180°) right 43s +/-5s
up 28s +/-5s
Main boom
down 21s +/-5s
Braking distances
Movement type Theoritical distance
Braking distance in High Speed and flat FWD Distance < 1, 5 m
ground REV Distance < 1, 5 m
Speed control from upper controls (hydraulic oil T> 30°C)
Movement type time
Left 3s +/-1s
steering
right 3s +/-1s
IN 16s +/-5s
Telescopic boom
OUT 14s +/-5s
up 20s +/-5s
jib
down 23s +/-5s
Left 20s +/-5s
Basket rotation full range (lock to lock)
right 20s +/-5s
Jib rotation full range lock to lock Left 25s +/-5s
(HA12CJ+) right 25s +/-5s
up 9s +/-5s
Compensation
down 8s +/-5s

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4.3. OPTIMIZER MENU
MOVEMENTS SPEED (%) RAMP
DESIGNATION MIN DEFECT MAX ACC DEC
ACCESS ACCESS
JIB UP AT MINIMAL SPEED CODE CODE
75.2 90 100
(JIB LIFT AT 30% OF ITS SPEED) LEVEL 2 LEVEL 2
OR 3 OR 3
ACCESS ACCESS
JIB UP AT MAXIMAL SPEED CODE CODE
75.2 90 100
(JIB LIFT AT 100% FULL SPEED) LEVEL 2 LEVEL 2
OR 3 OR 3
“JIB DOWN” 0 95.2 100 8 3
“FWD DRIVE” 0 100 100
“REV DRIVE” 0 100 100
“MICRO FWD DRIVE” 0 100 100
“MICRO REV DRIVE” 0 100 100
“PF. UP LEVEL” 0 95.2 100 10 10
“PF. DOWN LEVEL” 0 95.2 100 10 10
“STEERING LEFT” 0 95.2 100 3 3
“STEERING RIGHT 0 95.2 100 3 3
“ARM UP” 0 95.2 100 10 10
“ARM DOWN” 0 95.2 100 10 10
“TURRET LEFT” 0 95.2 100 10 10
“TURRET RIGHT” 0 95.2 100 10 10
“ BOOM UP” 0 95.2 100 10 10
“BOOM DOWN” 0 95.2 100 10 10
“PF. ROT. LEFT” 0 95.2 100 2 3
“PF. ROT. RIGHT” 0 95.2 100 2 3
“JIB ROT. LEFT” 0 95.2 100 12 6
“JIB ROT. RIGHT 0 95.2 100 12 6
“OUT TELESCO” 0 95.2 100 10 10
“TELESCO IN” 0 95.2 100 10 10

Note: the parameters “Turret” are at 80% of the “Platform”value

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MENU OPTIONS

Default
OPTIONS DESCRIPTION Level
value
Choice of the country, between “the
COUNTRY USA 3
USA”, “Australia”, “Europe”
Choice of the type of batteries,
TRACTION BATTERIES No 2
No: Semi-traction, Yes:Traction
Selection of “CANADA” country option
PROHIB IN TILT SIGNAL only valid from US model (slope sensor Inactive 3
active with US country choice)
Activation of the buzzer if machine is in
TRANS BUZZER Inactive 2
drive ( FWD, REV drive)
Activation of the buzzer on movements
MOVEMENT BUZZER Inactive 2
(except steering)
Activation of the flash-light if machine is
TRANS FLASH LIGHT Inactive 2
in drive mode ( FWD, REV drive)
MOVEMENT FLASH Activation of the flash-light on
Inactivate 2
LIGHT movements (except steering)
Activation of the flash-light when power is
FLASH LIGHT ON Inactive 2
ON on the machine
Activation of the limitation of basket
LEVEL LIMIT +10/-10 compensation (slope range for the basket Active 2
+10°/-10°)
Authorize the possibility to release the
electrical brakes on the drive motors
MANUAL UNBRAKING Inactive 2
thanks to the remote control box for
brake release system
Choice of model type
HA12CJ+ version NO 2
(HA12CJ: NO / HA12CJ+ YES)
Correction in current command on PWM
 100 no correction
 <100 movements speed are
PWM YV1 setting 100 2
decreased
 >100 movements speed are
increased

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MENU DIAGNOSTIC

Thanks to this menu , all functions could be tested

 How to understand the logic of DIAGNOSTIC mode


Bit Field: Fields of 6 bits (read from right to left) of value 0bxxxxxx where X can take the value of
0 or 1
Internal Set point : Protected and formatted setpoint command coming from the active control
desk for a given direction (Dir = Neutral or Fwd/Up/Left or Rev/Down/Right).
It could be at zero value in the event of defect of the control device (out of range, inconsistency of
the neutral or the signals) and is formatted between 0 and 1000.
Int. Set Point Limit: Porcentage of application of the internal setpoint protected and formatted
(100% = setpoint not slowed down).
Internal Validation: Current conditions of authorization and cut-off of the movement in each
direction (Fwd/Up/L and Rev/Down/R).
Each of the 7 bits (read from right to left) can take the value of 0 or 1.
The 1st bit on the right is a condition for movement authorisation (1 if it’s authorized, 0 if it’s
prohibited), whereas the 6 other bits represents a particular condition of movement cut-off (1 if
the movement is cut, 0 if it is authorized).

An authorized movement will thus have value of 0000001 for the corresponding direction

Bits reading ( right to left as shown 654321

 1: Condition for the validation of the movement
 2 :Condition for cutting the movement
 3 :Condition for cutting the multiple movement
 4 :Condition fo cutting the movement in overload mode
 5 :Condition for cutting the movement in slope mode
 6 :Condition for cutting the combined movement

Internal Control = internal command validated starting from the setpoint of the function and sent
towards the electrovalves and output relay for a given direction (Dir = Neutral or Fwd/Up/Left
or Rev/Down/Right).
It integrates various logics of operation, and also the dynamic limitations of the instruction and the
slopes of acceleration/deceleration.
It is formatted between a minimal internal speed (bias) and a modifiable maxi speed which could
be modified with the OPTIMZER console
The direction of the command is also indicated

Validation Function

Inputs Outputs
Validation
Securing and Setpoint Control Application of
controls and
formatting of the command Actuator
formatting of
the setpoint [0-100]% [0-100]% on actuators
the command

Setpoint Limit

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 Some useful definitions :

Controls all commands coming from lower/upper controls

Inputs Digitals or analog inputs (ETOR-EANA)
Setpoint (0-100%) In Diagnostic menu ,it’s the parameter Internal setpoint
for the function ( 0-1000pts)
Validation Conditions for cutting the movements
Validation and formatting Conditions for validation of the movement
the command
Setpoint limit /Limitation Condtions for slowing down the movement
Control (0-100%) In Diagnostic menu , it’s the parameter Internal control
for the internal command of the function (0 -1000pts)
Outputs Digitals or Analog outputs ( STOR-SPWM –SANA)
Actuator Any device like valves/cylinders/motors/relays

Some example

Example machine in slope and boom lifting mode :

Binary code : 0010001 ( machine in slope : reading from right to left)

Functions available through DIAGNOSTIC MODE

ELEMENT DESCRIPTION NUMBER

Variables, inputs and outputs relating to
Overload 1
weighing
Variables, inputs and outputs relating to
Machine state 2
the state of the machine.
Variables inputs and outputs relating to the
Drive 3
drive mode
Variables, inputs and outputs relating to
Steering 4
the steering
Variables, inputs and outputs relating to
PF. Level 5
the basket compensation
Variables, inputs and outputs relating to
ARM 6
arm lifting
Variables, inputs and outputs relating to
Turret 7
the orientation of the turret
Variables, inputs and outputs relative to the
Jib 8
jib
Variables, inputs and outputs relating to
Boom- 9
boom raising
Variables, inputs and outputs relating to
PF. Rot. 10
basket rotation
Variables, inputs and outputs relating to jib
Jib rot. 11
rotation
Variables, inputs and outputs relating to
Telescope 12
the telescopic boom
Variables, messages CAN, inputs and
Variator outputs relating to the variable speed 13
transmission
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OVERLOAD - PESAGE

NAME INFORMATION DESCRIPTION VALUES

0:Absent,
1: jib learning(calibration)
Internal Status of the function
ModePesage 2: Normal,
variable weighing
3:Defect,
4:back up
Internal Overload static
Overload 1: static overload
variable machine
Differential pressure
Internal calculated in the
Close Diff B2 (0.1b) Expressed in bar x 0.1
variable module node B2
(turret)
Internal Pressure of
Close ref. (0.1b) Expressed in bar x 0.1
variable calculated reference
Expressed in degree x 0.1
- Near to 0 for the lowest jib
Internal
Jib Angle (0.1 deg) Angle jib/boom position
variable
- Near to 1400 for the upper jib
position
Angle of the
Internal Expressed in degree x 0.1
ABS Angle (0.1 deg) basket/horizontal
variable Around 0 for basket at horizontal
position
Internal Pressure in jib small
Rod Presses (0.1b) Expressed in bar x0.1
variable chamber
Internal Pressure in jib large
Bore Presses (0.1b) Expressed in bar x 0.1
variable chamber
Differential pressure
Internal Must be close to Diff B2 if not
Press Diff B3 (0.1b) calculated in the
variable inconsistency
module node B3 (PF)
Internal
HighStop electric higher limit 1: position reached
variable
Internal
LowStop Electric lowest limit 1: position reached
variable
Value of the sensor of 0V-VbattV
A1 Angle
relative angle If 0V then sensor “in open circuit”
Value of the sensor of 0V-VbattV
A2 Angle
absolute angle If 0V then sensor “in open circuit”
Value of the pressure
0V-5V
G1 Cylinder press sensor jib small
If 0V then sensor “in open circuit”
chamber
Value of the pressure
0V-5V
G2 Cylinder press sensor jib large
If 0V then sensor “in open circuit”
chamber
0: no defect in progress
=0: Detected defect
Similar to OL0x defects
= 1 if defect incremental position
Internal transducer in progress ==>defect
PesAFault Fault in load system
Variable OL03

= 2 if defect absolute position

sensor in progress ==>defect OL04

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 = 4 if defect pressure sensor small
jib chamber in progress ==>defect
OL05

= 8 if defect pressure sensor large

jib chamber in progress ==>defect
OL06

= 16 if defect not of jib learning

==>defect OL01

= 32: none
= 256: none

= 512: inconsistency between

command of the movement and
evolution of the absolute position
sensor ==>defect OL04

=1024: none
= 2048: none

=4096: inconsistency between

calculations of pressures main B2
node/node B3 slave ==> defect
OL07

=8192: inconsistency between

pressures of reference and current
pressure (too much distant) ==>
defect OL08

= 16384: inconsistency calculated

pressure ==> defect OL09

Angular value of
Internal Used to calculate the current
AngAbsZero reference for 0°
variable basket angle
basket level
Angular value of
Internal reference for jib at its Used to calculate the current jib
AngJibLowEnd
variable mechanical lowest angle
position

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MACHINE STATE – ETAT

NAME INFORMATION DESCRIPTION VALUES

ARM/BOOM State of proximity sensor ON: if arm and boom are
SQ34
DOWN:1 UP:0 for arm/boom folded in stowed position
State of proximity sensor
ON: if telescopic is fully
SQ9 TELESCOPE IN:1 OUT:0 for telescopic boom
retracted
position
State of level sensor ON: Not in slope
SQ1 TILT SENSOR, FLAT:1
< X° OFF: Machine in slope
Internal
OVERLOAD YES:1 NO:0 State of weighing 1: Machine in weighing
variable
State principal dead man 1: active and validated
Internal switch or dead man and 0: Inactive or pushed
DEADMAN OK:1 NOK:0
variable emergency pumps switch more than 8s without
(high or low) movement
Value of the bar-graph for
Internal PF SPEED CONTROL 1 to 10
speed variation of the
variable 1-10 (10% to 100% of speed)
upper control box

DRIVE – TRANSLATION

NAME INFORMATION DESCRIPTION VALUES

Set point of the joystick in entry of in mV
SM1 DRIVE JOYSTICK
the module node B3 joystick 0,5-2,5-4,5V
0: joystick in neutral
Internal OUTPUT CENTER position
Information out of neutral position
variable POSIT. 1: joystick out of neutral
position
0: machine with brakes
Internal activated
BRAKE STATUS Information of the brakes status
variable 1: machine with brakes
released
Internal DRIVE SETPOINT From 0 to 1000
Signal of the joystick
Set.Point IN (%) (0% to 100%)
Value of active limitation.
Int. Set 100% if no limitation on the
point LIMITATION movement (also take into account From 0 to 100%
Limit the system of speed regulation :
buttons + and -)
Binary value of the state of the
conditions of activation and
prohibition of the movement
Fwd/Up/L= 000000
Rev/Down/R= 000000
Reading from right to the left
Bits: 654321
Internal 1: Condition of validation of the From 000000 to
CUTTING OUT
Logical movement 111111
2:Condition of cut of the movement
3:Condition of cut in movements in
multiple mode
4:Condition of cut in overload
5:Condition of cut in slope
6:Condition of cut in controlled
movements

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 Set point applied (according to the
Internal DRIVE SETPOINT From 0 to 1000
adjustments and safety measures in
Control OUT(%) (0% to 100%)
process)
0: No drive speed
applied
1: Microspeed applied
Internal Last speed of drive applied. (since at the last step
MicroS:1 LS:2 HS:3
variable power is ON) 2: Low speed applied at
the last step
3: High speed applied
at the last step

STEERING - DIRECTION

NAME INFORMATION DESCRIPTION VALUES

STEERING LEFT OFF: Inactive
SM1G Left steering button activated
BUTTON ON: Active
STEERING RIGHT OFF: Inactive
SM1D right steering button activated
BUTTON ON: active
Set point TOR 0: No signal
Internal
SETPOINT IN (TOR) (either 0% or 100% 1: left setpoint
Set.Point
represent) 2: right setpoint
Value of active limitation.
Int. Set 100% if no limitation on the
point LIMITATION movement (also take into From 0 to 100%
Limit account the system of speed
regulation buttons + and -)
Binary value of the state of
the conditions of activation
and prohibition of the
movement
Fwd/Up/L= 000000
Rev/Down/R= 000000
Reading from right to left
Bits: 654321
Internal 1: Condition of validation of From 000000 to
CUTTING OUT
Logical the movement 111111
2:Condition of cut of the
movement
3:Condition of cut in in
movements in multiple mode
4:Condition of cut in overload
5:Condition of cut in slope
6:Condition of cut in
controlled movements
Set point applied (according
Internal From 0 to 1000
SETPOINT OUT(%) to the adjustments and safety
Control (0% to 100%)
measures in process)
Signal applied to the PWM
YV1 PWM (YV1) 0% to 100%
valve
OFF: Inactive
YV2A Left steering (TOR) ON/OFF valve
ON: Active
OFF: Inactive
YV2B Right steering (TOR) ON/OFF valve
ON: Active

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PF LEVEL – BASKET COMPENSATION

NAME INFORMATION DESCRIPTION VALUES

PF: Button basket OFF: Inactive
SA41A PF:LEVEL BUTTON UP
compensation UP ON: Active
PF:LEVEL BUTTON PF: Button basket OFF: Inactive
SA41B
DOWN compensation down ON: Active
TUR:LEVEL BUTTON Turret: Button basket OFF: Inactive
SA40A
UP compensation UP ON: Active
TUR:LEVEL BUTTON Turret: Button basket OFF: Inactive
SA40B
DWN compensation down ON: Active
Set point ON/OFF 0: No signal
Internal
SETPOINT IN (TOR) (either 0% or 100% 1: signal UP
Set.Point
represented) 2: signal DOWN
Value of active limitation.
Int. Set 100% if not of limitation on the
point LIMITATION movement (also take into From 0 to 100%
Limit account the system of speed
regulation buttons + and -)
Binary value of the state of the
conditions of activation and
prohibition of the movement
Fwd/Up/L= 000000
Rev/Down/R= 000000
Reading from right to left
Bits: 654321
1: Condition of validation of
Internal From 000000 to
CUTTING OUT the movement
Logical 111111
2:Condition of cut of the
movement
3:Condition of cut in in
movements in multiple mode
4:Condition of cut in overload
5:Condition of cut in slope
6:Condition of cut in controlled
movements
Set point applied (according to
Internal From 0 to 1000
SETPOINT OUT(%) the adjustments and safety
Control (0% to 100%)
measures in process)
Signal applied to the PWM
YV0 PWM (YV0) 0% to 100%
valve
OFF: Inactive
YV3A PF.LEVEL UP (TOR) ON/OFF valve
ON: Active
PF.LEVEL DOWN OFF: Inactive
YV3B ON/OFF valve
(TOR) ON: Active

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ARM – (PRIMARY BOOM)

NAME INFORMATION DESCRIPTION VALUES

OFF: Inactive
SA21A PF:ARM BUTTON UP PF: Button for arm lift
ON: Active
OFF: Inactive
SA21B PF:ARM BUTTON DOWN PF: Button for arm descent
ON: Active
OFF: Inactive
SA20A TUR:ARM BUTTON UP Turret: Button for arm lift
ON: Active
TUR:ARM Turret: Button for arm OFF: Inactive
SA20B
BUTTON DOWN descent ON: Active
Set point ON/OFF 0: No signal
Internal
SETPOINT IN (TOR) (either 0% or 100% are 1: signal UP
Set.Point
represented) 2: signal DOWN
Value of active limitation.
100% if not of limitation on
Int. Set
the movement (also take into
point LIMITATION From 0 to 100%
account the system of
Limit
regulation speed: buttons +
and -)
Binary value of the state of
the conditions of activation
and prohibition of the
movement
Fwd/Up/L= 000000
Rev/Down/R= 000000
Reading from right to left
Bits: 654321
Internal 1: Condition of validation of From 000000 to
CUTTING OUT
Logical the movement 111111
2:Condition of cut of the
movement
3:Condition of cut in in
movements in multiple mode
4:Condition of cut in overload
5:Condition of cut in slope
6:Condition of cut in
controlled movements
Set point applied (according
Internal From 0 to 1000
SETPOINT OUT (%) to the adjustments and safety
Control (0% to 100%)
measures in process)
Signal applied to the PWM
YV1 PWM (YV1) 0% to 100%
valve
OFF: Inactive
YV5A ARM UP (TOR) ON/OFF valve
ON: Active
OFF: Inactive
YV5B ARM DOWN (TOR) ON/OFF valve
ON: Active

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TURRET –

NAME INFORMATION DESCRIPTION VALUES

Signal value of the joystick on in mV
SM2X JOYSTICK (mV)
module input Joystick 0,5-2,5-4,5V
0: Joystick in neutral
Internal OUTPUT CENTER position
Information out of neutral
variable POSIT. 1: joystick out of
neutral position
TURRET ROT Turret: Left button turret OFF: Inactive
SA82A
BUTTON L rotation ON: Active
TURRET ROT Turret: right button turret OFF: Inactive
SA82B
BUTTON R rotation ON: Active
PF:
From 0 to 1000
Set point value (0% to 100%)
Internal
SETPOINT IN (%/TOR) (PF: vary from 0 to 100% Turret:
Set.Point
Turret: either 0% or 100%) 0: No signal
1: left setpoint
2: right setpoint
Value of active limitation.
Int. Set 100% if not of limitation on the
point LIMITATION movement (also take into From 0 to 100%
Limit account the system of speed
regulation buttons + and -)
Binary value of the state of
the conditions of activation
and prohibition of the
movement
Fwd/Up/L= 000000
Rev/Down/R= 000000
Reading from right to left
Bits: 654321
Internal 1: Condition of validation of From 000000 to
CUTTING OUT
Logical the movement 111111
2:Condition of cut of the
movement
3:Condition of cut in in
movements in multiple mode
4:Condition of cut in overload
5:Condition of cut in slope
6:Condition of cut in controlled
movements
Set point applied (according
Internal From 0 to 1000
SETPOINT OUT (%) to the adjustments and safety
Control (0% to 100%)
measures in process)
Signal applied to the PWM
YV0 PWM (YV0) 0% to 100%
valve
OFF: Inactive
YV4A TURRET ROT. L (TOR) ON/OFF valve
ON: Active
OFF: Inactive
YV4B TURRET ROT. R (TOR) ON/OFF valve
ON: Active

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JIB -

NAME INFORMATION DESCRIPTION VALUES

OFF: Inactive
SA51A PF:JIB BUTTON UP PF: button Jib UP
ON: Active
OFF: Inactive
SA51B PF:JIB BUTTON DOWN PF: button Jib Descent
ON: Active
OFF: Inactive
SA50A TUR:JIB BUTTON UP Turret: button Jib lift
ON: Active
TUR:JIB BUTTON OFF: Inactive
SA50B Turret: button Jib descent
DOWN ON: Active
0: No signal
Internal Set point TOR
SETPOINT IN (TOR) 1: setpoint UP
Set.Point (either 0% or 100% )
2: setpoint DOWN
Value of active limitation.
100% if not of limitation on the
Int. Set
LIMITATION movement (also take into From 0 to 100%
point Limit
account the system of speed
regulation buttons + and -)
Binary value of the state of
the conditions of activation
and prohibition of the
movement
Fwd/Up/L= 000000
Rev/Down/R= 000000
Reading from right to left
Bits: 654321
Internal 1: Condition of validation of From 000000 to
CUTTING OUT
Logical the movement 111111
2:Condition of cut of the
movement
3:Condition of cut in in
movements in multiple mode
4:Condition of cut in overload
5:Condition of cut in slope
6:Condition of cut in controlled
movements
Set point applied (according
Internal From 0 to 1000
SETPOINT OUT(%) to the adjustments and safety
Control (0% to 100%)
measures in process)
Signal applied to the PWM
YV0 PWM (YV0) 0% to 100%
valve
OFF: Inactive
YV8A JIB UP (TOR) ON/OFF valve
ON: Active
OFF: Inactive
YV8B JIB DOWN (TOR) ON/OFF valve
ON: Active

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BOOM – (SECONDARY OR MAIN BOOM)

NAME INFORMATION DESCRIPTION VALUES

Signal input value of the in mV
SM2Y JOYSTICK (mV)
joystick Joystick 0,5-2,5-4,5V
Internal OUTPUT CENTER Information out of neutral 0: Joystick in neutral
variable POSIT. position 1: joystick out of neutral
TUR:BOOM BUTTON OFF: Inactive
SA30A Turret: Button boom lift
UP ON: Active
TUR:BOOM BUTTON OFF: Inactive
SA30B Turret: Button boom descent
DOWN ON: Active
PF:
From 0 to 1000
Set point (0% to 100%)
Internal
SETPOINT IN (%/TOR) (PF: vary from 0 to 100% Turret:
Set.Point
Turret: either 0% or 100%) 0: No signal
1: setpoint UP
2: setpoint DOWN
Value of active limitation.
100% if not of limitation on
Int. Set
the movement (also take into
point LIMITATION From 0 to 100%
account the system of
Limit
regulation speed: buttons +
and -)
Binary value of the state of
the conditions of activation
and prohibition of the
movement
Fwd/Up/L= 000000
Rev/Down/R= 000000
Reading from right to left
Bits: 654321
Internal 1: Condition of validation of From 000000 to
CUTTING OUT
Logical the movement 111111
2:Condition of cut of the
movement
3:Condition of cut in in
movements in multiple mode
4:Condition of cut in overload
5:Condition of cut in slope
6:Condition of cut in
controlled movements
Set point applied (according
Internal From 0 to 1000
SETPOINT OUT (%) to the adjustments and safety
Control (0% to 100%)
measures in process)
Signal applied to the PWM
YV1 PWM (YV1) 0% to 100%
valve
OFF: Inactive
YV6A BOOM UP (TOR) ON/OFF valve
ON: Active
OFF: Inactive
YV6B BOOM DOWN (TOR) ON/OFF valve
ON: Active

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PF - ROT – BASKET ROTATION

NAME INFORMATION DESCRIPTION VALUES

OFF: Inactive
SA43A PF.ROT. BUTTON LEFT PF: Button left basket rotation
ON: Active
PF.ROT BUTTON OFF: Inactive
SA43B PF: Button right basket rotation
RIGHT ON: Active
0: No signal
Internal Set point TOR
SETPOINT IN (TOR) 1: left setpoint
Set.Point (either 0% or 100% )
2: right setpoint
Value of active limitation.
Int. Set 100% if not of limitation on the
point LIMITATION movement (also take into From 0 to 100%
Limit account the system of speed
regulation buttons + and -)
Binary value of the state of the
conditions of activation and
prohibition of the movement
Fwd/Up/L= 000000
Rev/Down/R= 000000
Reading from right to left
Bits: 654321
1: Condition of validation of the
Internal From 000000 to
CUTTING OUT movement
Logical 111111
2:Condition of cut of the
movement
3:Condition of cut in in
movements in multiple mode
4:Condition of cut in overload
5:Condition of cut in slope
6:Condition of cut in controlled
movements
Set point applied (according to
Internal From 0 to 1000
SETPOINT OUT (%) the adjustments and safety
Control (0% to 100%)
measures in process)
Signal applied to the PWM
YV0 PWM (YV0) 0% to 100%
valve
OFF: Inactive
YV9A PF. ROT. LEFT (TOR) ON/OFF valve
ON: Active
OFF: Inactive
YV9B PF. ROT. RIGHT (TOR) ON/OFF valve
ON: Active

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JIB ROTATION -

NAME INFORMATION DESCRIPTION VALUES

PF:JIB ROT.BUTTON OFF: Inactive
SA53A PF: button for jib left rotation
L ON: Active
PF:JIB ROT.BUTTON PF: Button for jib right OFF: Inactive
SA53B
R rotation ON: Active
TUR:JIB Turret: button for jib left OFF: Inactive
SA52A
ROT.BUTTON L rotation ON: Active
TUR:JIB Turret: button for jib right OFF: Inactive
SA52B
ROT.BUTTON R rotation ON: Active
Set point TOR 0: No signal
Internal
SETPOINT IN (TOR) (either 0% or 100% 1: left setpoint
Set.Point
represent) 2: right setpoint
Value of active limitation.
Int. Set 100% if not of limitation on
point LIMITATION the movement (also take into From 0 to 100%
Limit account the system of speed
regulation buttons + and -)
Binary value of the state of
the conditions of activation
and prohibition of the
movement
Fwd/Up/L= 000000
Rev/Down/R= 000000
Reading from right to left
Bits: 654321
Internal 1: Condition of validation of From 000000 to
CUTTING OUT
Logical the movement 111111
2:Condition of cut of the
movement
3:Condition of cut in in
movements in multiple mode
4:Condition of cut in overload
5:Condition of cut in slope
6:Condition of cut in
controlled movements
Set point applied (according
Internal From 0 to 1000
SETPOINT OUT (%) to the adjustments and safety
Control (0% to 100%)
measures in progress)
Signal applied to the PWM
YV0 PWM (YV0) 0% to 100%
valve
OFF: Inactive
YV10A JIB ROT. LEFT (TOR) ON/OFF valve
ON: Active
JIB ROT. RIGHT OFF: Inactive
YV10B ON/OFF valve
(TOR) ON: Active

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TELESCOPE

NAME INFORMATION DESCRIPTION VALUES

PF:TELES BUTTON PF: Button telescopic boom OFF: Inactive
SA35A
OUT OUT ON: Active
PF: Button telescopic boom OFF: Inactive
SA35B PF: TELES BUTTON IN
IN ON: Active
TUR: TELES BUTTON Turret: Button telescopic OFF: Inactive
SA22A
OUT OUT ON: Active
TUR: TELES BUTTON OFF: Inactive
SA22B Turret: Button telescopic IN
IN ON: Active
Set point TOR 0: No signal
Internal
SETPOINT IN (TOR) (either 0% or 100% 1: setpoint OUT
Set.Point
represent) 2: setpoint IN
Value of active limitation.
100% if not of limitation on
Int. Set
the movement (also take
point LIMITATION From 0 to 100%
into account the system of
Limit
speed regulation buttons +
and -)
Binary value of the state of
the conditions of activation
and prohibition of the
movement
Fwd/Up/L= 000000
Rev/Down/R= 000000
Reading from right to left
Bits 654321
1: Condition of validation of
Internal the movement From 000000 to
CUTTING OUT
Logical 2:Condition of cut of the 111111
movement
3:Condition of cut in in
movements in multiple
mode
4:Condition of cut in
overload
5:Condition of cut in slope
6:Condition of cut in
controlled movements
Set point applied (according
Internal From 0 to 1000
SETPOINT OUT(%) to the adjustments and
Control (0% to 100%)
safety measures in process)
Signal applied to the PWM
YV1 PWM (YV1) 0% to 100%
valve
OFF: Inactive
YV7A JIB ROT. LEFT (TOR) ON/OFF valve
ON: Active
OFF: Inactive
YV7B JIB ROT. RIGHT (TOR) ON/OFF valve
ON: Active

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VARIATOR -

NAME INFORMATION DESCRIPTION VALUES

Internal Value of the batteries
BAT VOLTAGE (mV) Value in mV
variable voltage
Internal General state of main OFF: Inactive
KMG STATUS
variable contactor KMG ON: Active
Internal speed setpoint received on 0 to 255
SETPOINT (MAX:255)
variable the variator (0% to 100%)
current sent by the variator
Internal
OUT POWER AMP (A) on power circuit (pump or xx (A)
variable
drive motors)
Internal Operation of the variator in 0: Inactive
TOP SPIN STATUS
variable mode movements (pump) 1: active
0: Braked machine
Internal Information state of the with brakes ON
BRAKE STATUS
variable brakes 1: machine with
brakes released
Internal Temperature interns
TEMPERATURE (deg. C) Of -40°c with 100°c
variable variator
Internal Alarm code sent by the
CODE ALARM 0 to 255 (see detail)
variable variator

Code DEFINITION DIAGNOSTIC

OPTIMIZER
The parameters have been altered and the
movements are impossible
If the problem has been solved when power is
13 EEPROM KB
switched OFF then ON (the values are from
now the default values)
If the defect persists:change the variator
Fault in the “hardware “ system of the logic
18 LOGIC FAILURES # 2
board which controls the pump contactor KM2
Problem in the logical circuit of the line
19 LOGIC FAILURES # 1 contactor KMG or in the hardware of the
variator (logic board)
Problem with the circuit power of the drive
30 VMN LOW
motors or connections,
Problem with the circuit power of the drive
31 VMN HIGH
motors or connections,
The terminals of the power contactor KMG
37 CONTACTOR CLOSED
remain stuck
Failure in the current detection as it didn’t
53 STBY I HIGH drop to 0 when the variator is not activated
Change the variator if the problem persists
Defect in the circuit energizing F1 /F2
57 HIGH FIELD CURRENT check connections
replace the variator if the problem persists
Defect in the field circuit F1 /F2
58 NO FIELD CURRENT Check connections
Replace the variator if the problem persists
The capacitors doesnt charge 0.5 after power
60 CAPACITOR LOAD is ON
Defect in the power circuit

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 The internal temperature of the variator
exceeds 75°C
62 TH PROTECTION
Defect in the temperature sensor
Let’s cooling the variator before changing it
66 BATTERY LOW batteries discharged more than 80%
Short-circuit or open circuit on contactors
74 DRIVER SHORTED
KMG/KM1 or circuit brakes L3/L4
Problem on contactors KM1 or KMG or
75 CONTACTOR DRIVER
brakes L3/L4
Short-circuit or open circuit on contactors
76 COIL SHORTED
KMG/KM1 or circuit brakes L3/L4
When power is ON, the voltage applied on
contactor is not correct
77 COIL INTERRUPTED
Check connections /open and/or short circuit
on coil before changing the variator
Starting was not carried out correctly, start
again the sequence in the correct order
79 INCORRECT START
(battery cut out, emergency stop, selection
movement then joystick.)
No change of state on input (Problem on
99 INPUT ERROR # 1 modules
Problem on VMC (Volt Motor Controller),
VMC voltage tries to start without agreement
223 WAITING FOR NODE
of the variator (CAN bus problem or modules)
233 SENSOR I KO Current field sensor NOT OK
234 HW FAULT Problem of inverter, change KM1
Dual command (drive + movements) , release
241 FORW + TOP SPIN
all command
Not used for HAULOTTE, change variator if
242 VALVE COIL SHORTED
alarm appears again
Warning that the maintenance scheduled is
244 CHECK UP NEEDED exceeded (not used by HAULOTTE on this
kind of SEM1 variator )
With power is ON, the variator checks if the
values of the temperature sensor are in the
247 THERMIC SENSOR KB
tolerances
If the problem persists,change the variator
248 KEY-OFF No power on system
No message coming from the CAN-BUS,
249 CAN BUS KO check connections
If the problem persists, change the variator
With power ON, the system checks that the
voltage on field circuit is at 50% Vbat with line
250 VFIELD NOT OK contactor open
Check connections
Mass fault between chassis and variator
251 WRONG SET BATTERY Wrong type of batteries
The system checks the circuit brakes
252 AUX2 OUTPUT KO command, if the received signal does not
correspond, replace the variator
The system checks the command of KM1
253 AUX1 OUTPUT KO contactor if the received signal does not
correspond, replace the contactor

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SPEED VARIATOR UNIT ALARMS

CODE DESCRIPTION ACTION

AV01 Problems in stator/rotor Possible faults on ZAPI
current , logic, hardware, (13,18,19,53,57,58,233,234,241,244,247,248,25
current probes, or CAN bus 2,253
network or problems linked to
an over or low voltage
AV02 Problems in main contactor - Possible faults on ZAPI (37,74,75 ,76 ,77,242)
KMG or with the contactor for - Check the state of contactors and/or
selection traction/pump KM1 connections
(open circuit, contact stuck
or short-circuit)
AV03 Lack of power or problem in Possible faults on ZAPI (30,31,60,250)
the motors/pump outputs
AV04 Speed variator unit in thermal - Possible fault on ZAPI 62
security - Let’s cool the speed variator unit until the fault
disappears and meanwhile avoid to drive too
much time in rising ramps
AV05 Wrong sequence for starting - Restart the machine in good way ( battery cut-
or error on one speed out , e-stop buttons then key selector for
variator unit input upper/lower control box)
- Check speed variator unit connection
AV06 Problem on batteries or - Possible faults on ZAPI (66,251)
batteries too weak - Reload or replace batteries

CONTACTOR OUTPUTS

CODE DESCRIPTION ACTION

SC01 Output in open or short circuit : Change relay KAV, check wiring and
validation relay KAV is defective (or equipotential (on wires 273 et 0)
missing) or wire is cut
SC02 Output in open or short circuit: Change relay KAF, check wiring and
flashing light relay KAF is defective equipotential (on wires 271 et 0)
(or missing) or wire is cut
SC03 Output in open or short circuit: horn Change relay KAK, check wiring and
relay KAK is defective (or missing) equipotential (on wires 272 et 0)
or wire is cut
SC04 Output in open or short circuit : Change contactor KM2 on speed unit
pump power coil contactor KM2 is plate , check cable 279 between
defective (or missing) or wire is cut chassis loom and turret box or wire
203 on coil (+12V)
SC05 Output in short circuit: brakes Change relay KAB, check cable 275
release relay KAB is defective (or between chassis looms and turret box
missing) or wire is cut (fault only and check the 0 on relay.
with SEVCON speed unit)
SC06 Output in open or short circuit : Change relay KMS, check continuity
emergency pump power coil on wire 208 between turret loom and
contactor KMS is defective (or emergency pump option loom + turret
missing) or wire is cut box, check wire 203 on coil (+12V)
(Fault visible only if the dead man
toggle switch SA10b is activated)

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VALVES OUTPUTS

CODE DESCRIPTION ACTION

EV01 Output in open or short circuit : Change coil YV0, check wire 276
PWM valve for secondary between loom bloc + turret box or wire
movements YV0 is defective (or 203 on coil itself (+12V)
missing) or wire is cut
EV02 Output in open or short circuit : Change coil YV1, check wire 277
PWM valve for main movements between loom bloc + turret box or wire
YV1 is defective (or missing) or wire 203 on coil itself (+12V)
is cut
EV03 - Output in open or short circuit : - Change coil YV2A, check wire 262
ON/OFF valve for left steering YV2A between loom bloc + turret box or wire
is defective (or missing) or wire is 203 on coil itself (+12V)
cut - Change coil YV2B, check wire 263
- Output in open or short circuit : between loom bloc + turret box or wire
ON /OFF valve for right steering 203 on coil itself (+12V)
YV2B is defective (or missing) or
wire is cut
EV04 - Output in open or short circuit : - Change coil YV3A, check wire 240
ON /OFF valve for basket between loom bloc + turret box or the
compensation lifting YV 3A is 203 on coil itself (+12V)
defective (or missing) or wire is cut - Change coil YV3B, check the wire
- Output in open or short circuit : 241 between loom bloc + turret box or
ON/OFF valve for basket wire 203 on coil itself (+12V)
compensation descent YV 3B is
defective (or missing) or wire is cut
EV05 - Output in open or short circuit : - Change coil YV4A, check wire 282
ON /OFF valve: for turntable left between loom bloc + turret box or wire
rotation YV4A is defective (or 203 on coil itself (+12V)
missing) or wire is cut - Change coil YV4B, check the wire le
- Output in open or short circuit : 283 between loom bloc + turret box or
ON /OFF valve: for turntable right wire 203 on coil itself (+12V)
rotation YV4B is defective (or
missing) or wire is cut
EV06 - Output in open or short circuit : - Change coil YV5A, check wire 220
ON /OFF valve: for arm lift YV5A is between loom bloc + turret box or wire
defective (or missing) or wire is cut 203 on coil itself (+12V)
- Output in open or short circuit : Change coil YV5B, check wire 221
ON /OFF valve: for arm descent between loom bloc + turret box or wire
YV5B is defective (or missing) or 203 on coil itself (+12V)
wire is cut
EV07 - Output in open or short circuit : - Change coil YV6A, check wire 230
ON /OFF valve for boom lift YV6A is between loom bloc + turret box or the
defective (or missing) or wire is cut 203 on coil itself (+12V)
- Output in open or short circuit : - Change coil YV6B, check wire 231
ON /OFF valve: for boom descent between loom bloc + turret box or wire
YV6B is defective (or missing) or 203 on coil itself (+12V)
wire is cut

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EV08 - Output in open or short circuit : - Change coil YV7A, check wire B600
ON /OFF valve for right steering between bloc loom + turret box and
YV7A is defective (or missing) or wire 246 on coil (+12V)
wire is cut - Change coil YV7B, check wire B601
- Output in open or short circuit : between bloc loom + turret box and
ON /OFF valve for left steering wire 246 on coil (+12V)
YV7B is defective (or missing) or
wire is cut :
EV09 - Output in open or short circuit : - Change coil YV8A, check wire B615
ON /OFF valve for jib lifting YV8A is between bloc loom + turret box and
defective (or missing) or wire is cut wire 246 on coil (+12V)
- Output in open or short circuit : - Change coil YV8B, check wire B609
ON /OFF valve for jib descent YV8B between bloc loom + turret box and
is defective (or missing) or wire is wire 246 on coil (+12V)
cut
EV10 - Output in open or short circuit : - Change coil YV9A, check wire 234
ON /OFF valve for basket rotation between bloc loom + turret box and
left side YV9A is defective (or wire 246 on coil (+12V)
missing) or wire is cut - Change coil YV9B, check wire 235
- Output in open or short circuit : between bloc loom + turret box and
ON /OFF valve for basket rotation wire 246 on coil (+12V)
right side YV9B is defective (or
missing) or wire is cut
EV11 - Output in open or short circuit : - Change coil YV10A, check wire B602
ON /OFF valve for jib rotation left between bloc loom + turret box and
side YV10A is defective (or missing) wire 246 on coil (+12V)
or wire is cut - Change coil YV10B, check wire B603
- Output in open or short circuit : between bloc loom + turret box and
ON /OFF valve for jib rotation right wire 246 on coil (+12V)
side YV10B is defective (or missing)
or wire is cut

CAN-BUS ERRORS / EEPROM

CODE DESCRIPTION ACTION

MX01 CAN fault communication check can-bus network
( impedance and connections)
EP01 EEPROM checksum error Chang ECU module

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JOYSTICKS(CONTROLLERS) – TOGGLE SWITCHES

CODE DESCRIPTION ACTION

SM1Y Signal out of range or inconsistent Check connection and signal value
neutral value on drive joystick (0.5 -2.5-4.5VDC)
SM2Y Signal out of range or inconsistent Check connection and signal value
neutral value on rotation /lift joystick (0.5 -2.5-4.5VDC)
SM2X Signal out of range or inconsistent Check connection and signal value
neutral value on rotation /lift joystick (0.5 -2.5-4.5VDC)
SW01 Inconsistent value or neutral Check toggle switches from lower
position not OK when power is ON , control box
on one of the toggle switch in lower
control box
SW02 Inconsistent value or neutral Check toggle switches from upper
position not OK when power is ON , control box
on one of the toggle switch in upper
control box

OVERLOAD ALARMS

CODE DESCRIPTION ACTION

OL01 - Adress fault on slave - Problem in checksum parameters validation or
module doing the load overload calibration datas or problem during load
function calibration
- Inconsistant values - redo the calibration
between EEPROM datas
saved between module
master B2 and slave B3
OL02 Fault in Jib learning Cal 1 Make or make again the Jib learning Cal 1 process
OL03 - Inconsistent values - Check the jib angle sensor value and the
between jib movement and direction of variation of this value (should increase
jib angle measurement when jib is lifting).
- Fault in A1 relative angle - Jib angle sensor value out of range
sensor - Check sensor and its mounting/connection
OL04 - Inconsistent value - Check the jib inclinometer sensor value and the
between compensation direction of variation of this value (should decrease
movement and jib angle when basket is elevating)
- Fault in A2 absolute - Jib inclinometer sensor value out of range
angle sensor (inclinometer) - Check sensor and its mounting/connection
OL05 - Fault in G1 pressure - Pressure sensor out of range
sensor in jib cylinder - Check the sensor and its connection
- Pressure variation too - Check if the pressure in the small chamber is
important in the jib small varying in good way
chamber - Change the pressure sensor
OL06 - Fault in G2 pressure Pressure sensor out of range
sensor in jib cylinder - Check the sensor and its connection
- Pressure variation too - Check if the pressure in the large chamber is
important in the jib large varying in good way
chamber - Change the pressure sensor
OL07 Inconsistent values for the - Too much difference of calculation regarding the
calculation of the pressure pressure datas between modules node B2 and B3
recorded between modules - Restart the machine
node B2 master and slave - change module node B2 and/or node B3
B3

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CODE DESCRIPTION ACTION
OL08 Inconsistent values for the - difference more than 2 seconds between the
calculation of the pressure reference pressure ( calibration value) registered
reference between by module node B3 and the current one registered
modules node B2 master by the master module node B2
and node B3 slave
OL09 Resultant pressure out of Pressure registered in node B2 out of range
range compared to the threshold value (low and high)
The fault appears if the difference between the
registered value and the recordered value is above
2 seconds

SENSORS ALARMS

CODE DESCRIPTION ACTION

SE01 Check wiring and sensors SQ9 and SQ34 :
Telescopic IN SQ9=1
Incoherent status of
Boom+arm stowed , SQ34 = 1
sensors : no change
Move both movements (telescopic then arm +
during movement
boom) and check if failure has disappeared.

SE02 Check wiring and sensors SQ9 and SQ34 :

Telescopic IN SQ9=1
Anti by-pass safety : Boom+arm stowed , SQ34 = 1
detection of SQ34 Move both movemenst (telescopic then arm +
from 0 to 1 without any boom) and check if failure has disappeared.
movement) Principle of survey :
1 –failure if without any movement , the sensor
goes from 0 to 1
SE03
E-stop safety :
Check wiring and sensors SQ9 and SQ34 :
detection position
Telescopic IN SQ9=1
before power OFF and
Boom+arm stowed , SQ34 = 1
check position when
Move both movemenst (telescopic then arm +
power is ON again
boom) and check if failure has disappeared.
(sensor state should
not have changed)

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4.4. CONSOLE DIAG PAD

It’s possible to use the 2nd generation of diagnostic console (also available through laptop)
The presentation of the main menu will depend of the software’s version of the machine

This diagnostic console could be used in WIFI using a VCI adapter (Vehicle Computer Interface)

The full description of how to use that console and their menus is explained in an other technical
note (refer to your nearest HAULOTTE SERVICES of your area)

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Note : With that 2nd generation of console , the name of alarm’s code has been changed ( not the
description and function)

New failure code Original failure code

F01.01 AV01
F01.03 AV02
F01.05 AV03
F01.06 AV04
F01.07 AV05
F01.08 AV06
F02.01 SC04
F02.02 SC06
F03.03 SC01
F03.04 SC05
F03.05 SC02
F03.06 SC03
F04.01 EV03
F04.02 EV04
F04.03 EV05
F04.04 EV06
F04.05 EV07
F04.06 EV08
F04.07 EV09
F04.08 EV10
F04.09 EV11
F04.11 EV02
F04.12 EV01
F05.01 SM1Y
F05.04 SM2Y
F05.06 SM2X
F06.01 OL01-OL02
F06.02 OL07-OL08
F07.01 SE01
F07.20 OL05
F07.21 OL06
F07.22 OL03
F07.23 OL04
F08.07 SW03
F12.01 MX01
F12.02 EP01
F13.01 SW01
F13.02 SW02

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4.5. ADJUSTMENT OF THE PRESSURES

4.5.1. PROCEDURE
Note: the adjustment of the pressures is always done with a hydraulic oil temperature
higher than 20°C
The adjustment of the pressure relief valve is always done in the lift way
(Note: It’s always better to constrain the spring rather than slacken it, the precision is
better)

 Version 1

MP1

MP2

MOVEMENTS Pressures taken on pump exit,

during movement (+/- 2b)
Plug socket MP1
Rise/descent boom 186b
Rise/descent arm 195b/177b
Extension /retraction telescopic boom 188b/175b
Main pressure / steering (D) 210b
Plug socket MP2
jib 172b
Jib rotation 169b
compensation lifting (C) 155b
Compensation descent 168b
Rotation basket 169b
Turret slewing (A left / B right) 100b
Plug M version 2
Main pressure/steering (D) 210b

Connection of the pressure gauge in MP1 (movements big flow) or MP2 (movements low flow)
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Version 2

Note: the pressure plug M on version 2 is fitted directly on main pump

However the settings are the same as for version 1

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5. BREAKDOWN SERVICE GUIDE
This guide does not replace the logical equations described previously in this manual,
it makes it possible to the technician to have a logical step of breakdown service, detailing the
successive stages, while going from main one until the details.
The checking of the electric part is carried out in priority because less sensitive to the external
parameters than the hydraulics part (temperature, pollution, viscosity…).
The denomination of the movements describes below implies the 2 phases (ex not arm lift:
neither raise, nor descent from both controls)
Note: Some options like ASB (Activ Shied Bar) if installed and activated will stop all movements
from upper controls only (except turntable rotation), all movements from lower controls remain
active , refer to Haulotte services for more details

5.1. NO START
 Battery (GB1 48 volts)
 Converter GC1 48VDC /12VDC (+ 2 x20A fuses)
 Emergency stops (S1, SA140 and/or SA141)
 Key selector (SA1)
 contactor KMG
 relays KAT, KAV
 Relay KAC (battery charger)
 Variable speed unit
 Modules node B2 and/or B3
 Fuses FU1, FU2, FU3, FU6, FU7, FU10

5.2. NO MOVEMENT
 No pump (P1)
 No CAN BUS (wires 1001 and 1002)
 contactors KM1 and/or KM2
 machine in slope
 machine in overload
 Components of the system of weighing
 (angle sensors A1 and A2, pressure sensors G1 and G2)
 Calibration of weighing not carried out
 Pedal SB6 upper controls or switch “man dead” SA10 lower controls defective
 joysticks SM1 and/or SM2 (off neutral and/or signals)
 Defective 3.2cc gear pump
 General pressure relief valve190b not adjusted or defective
 Electrovalves YV0 or YV1
 By-pass valve 15b

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5.3. NO ARM LIFT
 Switches SA21, SA20
 Electrovalve YV5
 Incompatibility with the multiple of movements of other functions which are
connected to the same section of the position valve as this one
 No pressure

5.4. NO BOOM LIFT

 Switch low controls SA 30
 Joystick SM2 (off neutral and/or signal)
 Electrovalve YV6
 Incompatibility with the multiple of movements of other functions which are
connected to the same section of this valve
 No pressure

5.5. NO TELESCOPING BOOM

 toggle switch SA22 lower controls or SA35 upper controls
 Electrovalve YV7
 Incompatibility with the multiple of movements of other functions which are
connected to the same section of this valve
 No pressure

5.6. NO TURRET SLEWING

 Switch posts SA82 low
 Joystick SM2 (off neutral and/or signal)
 Electrovalve YV4
 Incompatibility with the multiple movements of other functions which are
connected to the same section of this valve
 Not adjusted or defective pressure relief 100b valve
 No pressure

5.7. NO JIB
 Switch SA50 lower controls or SA51 upper controls
 Electrovalve YV8
 Incompatibility with the multiple of movements of other functions which are
connected to the same section of this valve
 No pressure

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5.8. NO BASKET ROTATION
 Switch upper controls SA43
 Electrovalve YV9
 Incompatibility with the multiple of movements of other functions which are
connected to the same section of this valve
 Not adjusted or defective counterbalance 140b valves
 No pressure

5.9. NO JIB ROTATION

- Switch SA52 lower controls or SA53 upper controls
- Electrovalve YV10
- Incompatibility with the multiple of movements of other functions which are
connected to the same section of this valve
- Not adjusted or defective counterbalance valves 210 B
- No pressure

5.10. NO COMPENSATION
- Toggle switchs SA40 lower controls or SA41 upper controls
- Electrovalve YV3
Incompatibility with the multiple of movements of other functions which are connected
to the same section of this valve
- Not adjusted or defective counterbalance valves 210b

5.11. NO DRIVE
- Joystick SM1 (off neutral and/or consigns)
- Contactor KM1
- Electromagnets of brake system L3/L4
- Defective motor (M1, m2)
- Another movement in progress

5.12. NO HIGH SPEED

- Proximity detectors SQ 34, SQ 9
- Selection High speed SA67 upper controls

5.13. NO STEERING
- Rocker on joystick SM1
- Electrovalve YV2
- Incompatibility with the multiple of movements of other functions if they’ve
started before the steering
- Contactor KM1 or KM2
- No pressure

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5.14. BATTERY CHARGER

STATE LED
Fixed RED In initial load phase
binkling red Duration of too long load
FIXED YELLOW Phase of stabilization
blinkling green In phase of equalization
Fixed green Finished load

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 ZIVAN 110vac

6. SUMMARY OF VERSIONS HA12CJ-HA12CJ+

Wiring Hydraulic
HA 12 CJ - HA12CJ+
diagram diagram
EC - CDN - USA -
164P322210 164P316940
All models from 01-2010 AUS

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7. SPECIAL FUNCTIONS
7.1. SYSTEM OF LOAD CONTROL
The load management system has as a function to detect an overlap of nominal load, to inform
the user and to prohibit certain movements.
For that, the jib of the machine equipped with a cylinder for double purpose, must be
instrumented by 2 angular sensors and 2 pressure sensors (1 in each chamber of the jib cylinder)

7.1.1. OPERATION
The system uses four sensors:
 A pressure sensor who measures the pressure in the large chamber of the jib
cylinder (G2)
 A pressure sensor who measures the pressure in the small chamber of the jib
cylinder (G1)
 A relative angle sensor who measures the angle between the link piece and jib
(A1)
 An absolute angle sensor (or inclinometer) who measures the angle of the link
piece compared to gravity (A2)
 A module B3 node located in upper control box specific to the model

7.1.2. PRINCIPLE OF THE LOAD CONTROL

The module node B3 compares the current resulting pressure with the maximum pressure
authorized in the position given by the relative angle sensor. In the event of overload, it informs
the module node A via can bus network
According to this information, the main module node A controls the actuators and forbidden some
movements.
The authorized maximum pressure is determined by a calibration carried out in factory, or within
the maintenance routine check
A jib cycle with nominal load controls the system by several automatic stops, during which the
module records at each step, the angle and the static pressure.
The software limits the clearance of jib to its two positions also called electric stops so that the
cylinder is never at full mechanical stroke

7.1.3. ANGLE SENSORS

Relative angle sensor (A1)
This potentiometric sensor measures the relative angle of a moving part compared to the
structure on which it is fixed,
The pin of output of the potentiometer makes it possible to follow the movement of jib and thus
delivers signals according to the position of this one.

Absolute angle sensor (A2)

Another geometrical parameter has an impact raised on the pressure: the absolute angle
(compensation) of jib, therefore the slope of the basket
The sensor delivers angular information of position between the part holder and an “absolute”
reference
This sensor consists of a beam in an oil bath whose position is imposed by gravity, oil has as a
function to deaden the movements of the pendulum.
A mathematical formula corrects the pressure according to the measured angles, bring back it to
a value corresponding to the horizontal basket.
The correction of the absolute angle is limited to a range from - 10° to +10°.

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 7.1.4. MANAGEMENT OF THE NOMINAL LOAD OVERLAP
An overlap of nominal load involves:
 The activation of the sound buzzer,
 The activation of lights for overload (HL 13) and for defect (HL 1)
 The forbidden of all the movements from platform.
 The deceleration of all the movements from turret.

7 .1 .5 . CALIBRATION OF THE PWM VALVE

PWM valve: Pulse Width Modulation Valve
Note: due to the coil hysterisis on PWM valve YV0 and the sensitivity of the overload
sensors , the overload detection could be affected even if the basket is empty , that’s why
if this valve is changed , it’s strongly recommended to calibrate it
Attention this procedure will erase the overload calibration
 Prerequisites
 Main switch SA1 on turret position (T)
 Machine under power
 Tilt sensor SQ1 not activated
 Oil temperature > 10°C
 Machine in stowed position : (proximity switchs arm + boom SQ34 = 1 + telescopic boom
extension SQ9 = 1)
 Jib in the axis and basket at horizontal position (no checkings are done by the system)
 Jib cylinder purge done ( proceed to lift/down the jib 5 times)
 Batteries must be charged (≥ 40% load)

 PWM setting
o Setting of jib lowering speed at minimun speed
If not already done : Menu PARAMETERS -> CODE ACCESS level 2 -> Code->2031
Menu : PARAMETERS -> SPEEDS -> jib up Minimum speed (remain in this menu
during all this adjustment)
• As long as the console displays this menu, the speed of the jib is set up automatically on
minimum speed.
The default setting is 90.0%.
The electrical stops are no longer present.
• Change the setting, use the "+" and "-" in the console. It is imperative to confirm the setting
by pressing the * key, otherwise the value is not taken into account.

Procedure
Set the jib min speed
Lift the jib from full height and record the time , it must be 68 +/- 2 sec
( if not in the range , adjust the jib up minimum speed parameters

Set the jib max speed

Menu : PARAMETERS -> SPEEDS -> jib up Maximum speed and stay in this menu
during this adjustment
Lift the jib from full height and record the time , it must be 21 +/- 2 sec
( if not in the range , adjust the jib up maximum speed parameters)
END of PWM settting

• IMPORTANT : even if the overload calibration has already been done , the fact to
calibrate the PWM valve will automatically cancel the overload calibration

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 7 .1 .6 . CALIBRATION OF LOAD MANAGEMENT SYSTEM
 Prerequisites
 Main key selector toggle switch SA1 on turret position (T)
 Machine always switched ON
 Tilt sensor SQ1 not activated
 PWM adjustment done
(if not see PWM adjustment process)
 Machine in stowed position : (proximity switches arm + boom SQ34 = 1 + telescopic
boom extension SQ9 = 1)
 Jib in the axis and basket on horizontal position (no checks are done by the system)
(the basket compensation is possible with the dead man button in the calibration menu)
 No failures OL01 to OL09 Weighing (failures erase only in code level 3)
Lift the jib UP and DOWN lock to lock (without load) before starting the procedure (oil
temperature > 10°)
 Basket at horizontal position ( When the load is in the basket , check basket level 0° +/-
0.5°)
 Put load on basket (see below)

ATTENTION : the load in the basket must correspond to the required load for each model:
(HA12CJ + = 240kg (529lbs) et HA12CJ = 260kg (573lbs) ,
(no control are made by the system).

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 Procedure

Menu PARAMETRES ->CODE ACCES -> code->2031

Menu PARAMETRES -> CALIBRATION -> Jib learning: Cal. 1

Select
Active

Press

The setting or
checking the PWM
must be made
before the
calibration load.
If this is not the
case see the
procedure for
adjusting the PWM

These 5
Drain jib cylinder . If not OK start again
mouvements
5 Movements from low
purge the jib Stop to high stop.
cylinder. Press (*) when done

If not OK Display

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 Lowest jib
position
detection

Maintain the toggle switch (jib down) until pump stops

running and the following message appears

NOTE: It happens
several seconds
between the end of
the movement and
the pump stop, so
wait until the end of
both conditions

Activate and hold the toggle switch (jib UP)

(Full duration is around 10 minutes and it’s necessary to stabilize pressure
at each level (stop at least 10 seconds at each level) to:

In highest position with jib at full stroke and pump Note: If you release
stops running the button too early,
the calibration must
be restart from the
beginning
Jib lifts from step of 5°

Jib descent phase

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 Activate and hold the toggle switch (down jib)
The jib must be down until its lowest position (full stroke)

+
Pump stops running

If not OK Display

If OK

Note: A message may appear OL05 or

OL06, do not take care about this and
End
make a movement to swing out from
calibration
the mechanical stop

END OF CALIBRATION (JIB LEARNING)

Remove the load.
Raise the jib from the lower control box of about 20 ° and down it until the lowest
electric stop
Check that the jib stops before the full mechanical stroke (the rod cylinder must be
visible at about 10 mm)
Switch OFF and ON again the power on the machine and check that the load
failures is present in the menu FAILURES
If necessary, remove the errors in OL01 OL09 stored in EEPROM (menu access by
level 3).

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 7.1.7. VALUES OF THE SENSORS OF WEIGHING

The normal range of operation of the relative sensor A1 is of approximately of

5V (+-0.5V) out of jib lowest stop and with 10V (+-0.5V) out of jib high stop
The signal of the absolute sensor (or inclinometer) A2 with basket at flat level must be
around 6V (+-0.5V)
The normal operating range of the pressure sensors G1 (small chamber of the jib
cylinder) and G2 (large chamber of the jib cylinder) is between 500mV and 4000mV.
These sensors work into opposite during the jib movement
Indicative values:

SENSORS A1 A2 G1 G2
(mV) (mV) (mV) (mV)

JIB MINI POSITION 5000 5940 1290 1290

JIB HORIZONTAL 7495 5960 530 985

JIB MAXI POSITION 9980 5980 1175 1365

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 7 .1 .8 . DIAGNOSTIC
It’s a summary of the main faults noted during the load management control, with the actions to
be done for erase the problem:

DEFECT ACTION DIAGNOSTIC

Alarm during more decrease the charge the machine with 240kg (HA12CJ+)
10sec after the stop adjustment “Jib Up or 260kg (HA12CJ).
of the movement at minimum Speed” enter the code level 3.
100% of load (thus speed is slower In menu “ PARAMETERS SPEEDS”
following a between low stop select “Jip Up minimum speed”.
movement of rise and high stop) take 3 measurements of jib lifting from low
(step 2 and/or 3) calibrate again. stop to high stop:
- lower the jib to lowest position
More generally control the load - wait for a few seconds
presence of alarm system. - lift the jib
at 100% of load note the - when jib starts to move launch the
whatever the modifications in the stop watch, and stop it when the machine
position machine’s file arrives at full position

If the measured times are stable (less than

3 seconds between maximum value and
measured value minimum), decrease
speed “Jip Up minimum speed”
Put 70 sec.

take at least two new measurements.

check that the time is slower.

If the time is slower, calibrate again then

control the load system

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 No alarm at 120% increase the charge the machine with 240kg (HA12CJ+)
of nominal load at adjustment “Jib Up or 260kg (HA12CJ).
highest position minimum Speed” enter the code level 3.
(step 3) (thus speed is faster In menu “PARAMETERS SPEEDS”
between low stop select “Jip Up minimum speed”.
More generally no and high stop). take 3 measurements of jib lifting from low
alarm at 120% of Calibrate again stop to high stop:
load whatever the - lower the jib to lowest position
position is control the load - wait for a few seconds
system. - lift the jib
note the - when jib starts to move launch the
modifications in the stop watch, and stop it when the machine
file machine’s file. arrives at full position

If the measured times are stable (less than

3 seconds between maximum value and
measured value minimum), decrease
speed “Jip Up minimum speed”
”.  put 66 sec

To take at least two new measurements.

To check that time is faster.

If time is faster, calibrate again and control

the load system.
Before calibration , possibility of checking
that the jib makes a light reverse movement
after a movement of lift near the highest
position with 100% of load + 10kg.

Summary cases where some actions must be done according to the symptom
HA12CJ/+
Elements PWM
drain calibration
adjustment
calibration badly made X X X
change of hydraulic block X X X
change of PWM valve X X X
leak on the hydraulics circuit of jib cylinder X
Element of the ON/OFF jib block X
The jib cylinder X X X
modification of the version of machine (having an
X X
impact on the permitted load )
loss of parameters X X
Replacement of hose on jib cylinder X X X
replacement of the absolute angle sensor X
replacement of the relative angle sensor X
replacement of the pressure sensor X
machines machines
replacement of the platform controls box
CAN CAN
replacement of the lower control box X X
replacement node B2 X X
replacement node B3 X X

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 7.1.9. VALUES OF THE IMPEDANCE OF THE VARIATOR UNIT
Before any check, disconnect all wires from the variable speed unit

TERMINALS TERMINALS IMPEDANCE VALUE

B- T (VMNT) 128.6 KΩ
B- F2 128.9 KΩ
B+ Connector A1 64 KΩ
F1 F2 132.7 KΩ

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 7.1.10. BRAKE ADJUSTMENT ON DRIVE MOTORS
In case the engine and/or brake is changed, the procedure described below explains how to
readjust or check the brakes gap
Photo A: with a Allen key of 4mm, check the 3 screws (tightening torque of these screws 5,6 - 6,8
Nm).
These 3 screws are assembled to with loctite 242.
Photo B: checking of the gap between brake and flask

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8. LIST OF SCHEMATICS

See below all schematics (electric/hydraulic) of all versions

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 TRAINING MANUAL DIAGNOSTIC Level 2 HA12CJ-CJ+
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TRAINING MANUAL DIAGNOSTIC Level 2 HA12CJ(+)/HA32CJ(+)
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TRAINING MANUAL DIAGNOSTIC Level 2 HA12CJ(+)/HA32CJ(+)
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TRAINING MANUAL DIAGNOSTIC Level 2 HA12CJ(+)/HA32CJ(+)
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TRAINING MANUAL DIAGNOSTIC Level 2 HA12CJ(+)/HA32CJ(+)
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With ASB (Activ Shield Bar) option

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TRAINING MANUAL DIAGNOSTIC Level 2 HA12CJ(+)/HA32CJ(+)
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TRAINING MANUAL DIAGNOSTIC Level 2 HA12CJ(+)/HA32CJ(+)
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TRAINING MANUAL DIAGNOSTIC Level 2 HA12CJ(+)/HA32CJ(+)
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TRAINING MANUAL DIAGNOSTIC Level 2 HA12CJ(+)/HA32CJ(+)
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TRAINING MANUAL DIAGNOSTIC Level 2 HA12CJ(+)/HA32CJ(+)
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