Technical Training Level II HA12CJ - EN - E02-14

TECHNICAL TRAINING
DIAGNOSTIC LEVEL II
HA12CJ(+)/HA32CJ(+)
TRAINING MANUAL DIAGNOSTIC Level 2
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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
block,)
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
users.
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
00
01
03- 11
09-12
02
07-13
03
12-13
04
02-14
Creation
Update parameters
+ calibration process
Newest parameters
on diagnostic
console
Add Diag Pad info +
console alarm list
Add chapter
schematics
Created Validated
by
by
MGD
FLH
MGD

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Central
R&D
Modified
by
MGD
Translated Language
by
MGD
FR/EN
MGD
FR/EN
MGD
MGD
EN
MGD
MGD
EN
MGD
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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.
4.2.
4.3.
4.4.
4.5.
ADJUSTMENTS WITH CONSOLE OPTIMIZER ................................................................................................. 63

PARAMETERS SETTING .................................................................................................................................. 68
OPTIMIZER MENU .................................................................................................................................... 69
CONSOLE DIAG PAD....................................................................................................................................... 92
ADJUSTMENT OF THE PRESSURES .................................................................................................................. 94

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4.5.1.
5.
Procedure ............................................................................................................................................ 94
BREAKDOWN SERVICE GUIDE ................................................................................................................... 96

5.1.
5.2.
5.3.
5.4.
5.5.
5.6.
5.7.
5.8.
5.9.
5.10.
5.11.
5.12.
5.13.
5.14.
NO START...................................................................................................................................................... 96
NO MOVEMENT ............................................................................................................................................. 96
NO ARM LIFT ................................................................................................................................................. 97
NO BOOM LIFT............................................................................................................................................... 97
NO TELESCOPING BOOM ................................................................................................................................ 97
NO TURRET SLEWING .................................................................................................................................... 97
NO JIB ........................................................................................................................................................... 97
NO BASKET ROTATION .................................................................................................................................. 98
NO JIB ROTATION ........................................................................................................................................... 98
NO COMPENSATION ....................................................................................................................................... 98
NO DRIVE ...................................................................................................................................................... 98
NO HIGH SPEED ............................................................................................................................................. 98
NO STEERING ................................................................................................................................................ 98
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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1.1.2. LOADING POINTS HA12CJ-CJ+

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1.1.3. FEATURES HA12CJ-CJ+

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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 ().
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 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 (), 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 Ohmmtre 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 position, it must indicate a value near 0
OK
NOK
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
Low control box
Door lower control box
Upper control box
164P321860 10A
164P321860 8/12A
164P321860 3A
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
SQ9
SQ34
A1
A2
G1
G2
= 1 if machine not in slope

=1 if telescopic boom is retracted
=1 if arm + boom are in stowed position
Angle detection weighing
(signal ~ 5V in lowest position and 10V if jib is at highest position)
Inclinometer (signal of ~6V if basket is at horizontal position)
Pressure small chamber on jib cylinder (signal from 0.5 to 4V)
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 n2 gives the c oordinates 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 n3 indicates the position on the connec tor 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
SA1
SA140
SB2
SA10a
SA10b
SA20a
SA20b
SA22a
SA22b
SA30a
SA30b
SA40a
SA40b
SA50a
SA50b
SA52a
SA52b
SA82a
SA82b
02 - 5
Battery main switch (309)
02 - 7
Selection turret - basket (104)
02 - 6
Emergency stop button (102)
04 - 2
CN104.11
Option for manual brake release device (174)
04 - 4
CN104.17
Enable toggle switch (110)
04 - 4
CN104.1
Selection emergency pump (243)
04 - 6
CN104.7
arm lifting (120)
04 - 6
CN104.8
arm descent (121)
04 - 9
CN 104.13
telescopic extension (122)
04 - 9
CN104.14
telescopic retraction (123)
04 - 8
CN104.3
Boom lift (130)
04 - 8
CN104.4
boom descent (131)
04 - 12
CN104.9
basket compensation Rise (140)
04 - 12
CN104.10
basket compensation Descent (141)
04 - 11
CN104.15
jib rise (150)
04 - 11
CN104.16
jib descent (151)
04 - 10
CN104.19
jib rotation left (152)
04 - 10
CN104.20
jib rotation right (153)
04 - 5
CN104.5
turret rotation left(182)
04 - 5
CN104.6
turret rotation right(183)

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INPUTS UPPER CONTROLS ( node B3)

SA141 05 - 3
SB6
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
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 - 3
Mushroom-headed button emergency stop (215)
05 - 13
05 - 15
CN106.10
CN106.26
CN104.3
CN104.4
SM2
05 - 17
CN106.13
CN106.12
CN106.27
Drive joystick
signal Y 0.5-2.5-4.5VDC (B300)
neutral (B315)
Left steering (B108)
Right steering (B109)
Movements joystick
signal turret rotation X 0.5-2.5-4.5VDC (B303)
signal boom lift Y 0.5-2.5-4.5VDC (B302)
neutral (B316)
MODULES
V1
B2
B3
03 - 6
Variable speed unit speed
04
ECU Module node B2 (lower controls)
05
ECU Module Node B3 (upper controls)

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

(B305)
03 - 18
CN106.25
Pressure sensor on jib cylinder small chamber

Pressure sensor on jib cylinder large chamber
2.6.4. OUTPUTS
RELAYS
KAB
KAC
KAF
KAK
KAT
KAV
KMG
KM1
KM2
KMS
KAM*
04 - 9
Relay for brakes (for variable speed unit SEVCON only)
02 - 8
(285)
Relay for battery charge (106)
04 - 6
CN104.21 Relay for flashing lights (271)
04 - 13
CN104.22 Relay for horn (272)
02 - 20
04 - 7
Relay for validation supply converter 48/12VDC (106)

CN104.26 Relay for validation variable speed unit (273)
03 - 8
Main contactor variable speed unit (176)
03 - 8
Contactor selection traction/movements (178)
04.-12
CN105.34 Pump contactor (279)
04 - 13
CN105.33 Contactor (option emergency pump )
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)
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)
YV7a

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LIGHTS -BUZZER
H1
BG1
BG2
BG3
HA1
HA142
HL1
HL2
HL102
HA141
HL142
HL143
HL144
04 - 17
CN104.30
Hour recorder lower controls (173)
05 - 10
CN106.2
Battery charge state indicator upper controls
05 - 14
CN106.1
speeds movements indicator upper controls
04 - 19
CN106.15
Battery charge state indicator lower controls
02 - 17
04 - 8
Buzzer (207)
CN104.28
Buzzer lower controls (275)
02 - 15
Flashing lights (206)
05 - 3
Work headlight (905)
05 - 15
CN104.22
Light power supply OK upper controls (B501)
05 - 8
CN104.29
Buzzer upper controls (B508)
05 -12
CN104.26
Light overload upper controls (B505)
05 -7
CN 104.21
Light slope (B500)
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
Power upper
controls
Action
KMG = 1
(Machine
switched ON
without alarms)
Power lower
controls
Necessary
Prohibiting
the function
KAC=0
S1= 1+ SA140=1 + SA1
KAT =0
(side N) =1
KAV =0
Batteries charged + SA141 Module node
=1
B2 and/or
B3
KAC=0
S1 =1 + SA140 + SA1
KAT=0
(side T) =1
KAV=0
Batteries charged
Module B2
node
Modifying
the
function
KAM = 0
2.7.2. STEERING
Function
Action
Right steering
KM2 = 1+
YV1 = 1
+ YV2B=1
Left steering
KM2 =1+
YV1=1
+YV2A=1
CONDITIONS
Prohibiting
Modifying
Necessary
the function the function
SQ1 = 0
SA1 (side N) + SB6 = 1 +
(slope )
SM1d=1 + KM1 =0
A movement
A movement
with big flow
already in
already in
progress
progress
before
(boom, arm or
steering
telescoping) or
command
SA1 (side N) + SB6 =1 + multiple with
the drive
SM1g=1 + KM1 =0
Defect CAN
bus
Module node
defective B2 or
B3

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2.7.3.
DRIVE
Function
Low speed
forward
Low speed
reverse
High speed
forward
High speed
reverse
Action
KM1=0
variable
speed unit
from 0 to
500A
KM1=0
variable
speed unit
from 0 to
500A
KM1=0
variable
speed unit
from 0 to
500A
KM1=0
variable
speed unit
from 0 to
500A
Necessary
CONDITIONS
Prohibiting
the function
SA1 (side N) + SB6 = 1 +

SA67=0 + SM1 HN =1 +
signal between 2.5 and 4.5 V
Modifying
the function
SQ1 = 0
(slope)
brakes
blocked L3/L4
A movement
already in
SA1 (side N) + SB6 =1 +
progress
SA67 = 0 + SM1HN =1 +
before the
drive
command
go in
microspeed if
SQ1 = 0
SA1 (side N) + SB6=1 +
SQ1 = 0
(machine
in
SA67=1+ SM1HN =1 +
(slope)
slope) +
brakes
SA67 = 0
blocked L3/L4
SQ34=0
SQ9 = 0
(machine
unfolded)
SA67=1+ SM1HN =1 +

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2.7.4.
BOOM LIFT
CONDITIONS
Function
Rise upper
controls
Descent upper
controls
Rise lower
controls
Descent lower
controls
Action
KM1 = 1+
YV1 = 1
+ YV6A =1
KM1=1
+ YV1 =
1+
YV6B =1
KM1 = 1+
YV1 = 1
+ YV6A
=1
KM1=1
+ YV1 =
1+
YV6B =1
Necessary
Prohibiting the
function
Another
movement with
big flow in
progress (YV2SM2HN=1 + SM2Y signal
YV5-YV7)
between 2.5 and 4.5 V + KM2
YV2, YV5 or YV7
=1 (if multiple in drive mode) or
at fault
if not variable speed unit signal
A1, A2, G1, G2
from 0 to 500A)
(overload)
Discharged
batteries 20%
SQ1 =0 (slope)
Another
movement with
big flow in
SM2HN=1 + SM2Y signal
progress (YV2between 2.5 and 0.5 V+ KM2 =1
YV5-YV7)
(if multiple in drive mode) or if YV2, YV5 or YV7
not variable speed unit signal
at fault
A1, A2, G1, G2
from 0 to 500A)
(overload)
Modifying
the
function
Slowed
down
descent
with 50%
if
In slope
Another
movement with
overload
big flow in
SA1 (side T) + SA10 = 1 +
movement
progress (YV2SA30A = 1 + KM2 =1 (if multiple
are
YV5-YV7)
in drive mode) or if not variable
slowed
YV2, YV5 or YV7
speed unit signal from 0 to
down
at fault
500A)
Discharged
batteries 20%
SQ1 = 0 (slope)
Another
Slowed
movement with
down
SA1 (side T) + SA10 =1 +
big flow in
descent
SA30B =1 +
progress (YV2with 50%
KM2 =1 (if multiple in drive
YV5-YV7)
if
mode) or if not variable speed YV2, YV5 or YV7 In slope
unit signal from 0 to 500A)
at fault

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2.7.5. TELESCOPING BOOM

Function
Action
Extension
upper controls
KM1 = 1 +
YV1= 1+
YV7A=1
Retraction
upper controls
extension
lower controls
Retraction
lower controls
KM1 = 1 +
YV1 = 1
+YV7B=1
KM1 = 1 +
YV1= 1+
YV7A=1
KM1 = 1 +
YV1 = 1
+YV7B=1
CONDITIONS
Prohibiting
Modifying
Necessary
Another
movement
with big flow in
progress
(YV2-YV5SA1 (side N) + SB6 =1 +
YV6)
SA35A =1 + KM2 =1 (if
YV2, YV5 or
multiple in drive mode) or if
YV6 at fault
A1, A2, G1,
from 0 to 500A)
G2
Modifiable
(overload)
speed
Discharged
movement
batteries 20%
by SB120 SQ1 = 0
SB121)
(slopel)
Retraction
Another
slowed down
movement
with big flow in with 50% in
slope
progress
SA1 (side N) + SB6 =1 +
(YV2-YV5SA35A =1 + KM2 =1 (if
YV6)
YV2, YV5 or
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-YV5Slowed
SA22A=1 + KM2 =1 (if
YV6)
down
YV2, YV5 or
retraction
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
progress
(YV2-YV5not variable speed unit signal
YV6)
from 0 to 500A)
YV2, YV5 or
YV6 at fault

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2.7.6. LIFTING ARM
Function
Action
Rise upper
controls
KM1 = 1 +
YV1 = 1
+YV5A=1
Descent upper
controls
KM1 = 1 +
YV1 = 1
+YV5B=1
Rise lower
controls
Descent lower
controls
CONDITIONS
Prohibiting the
Modifying
Necessary
function
the function
Another
movement with
big flow in
progress (YV2SA1 (side N) + SB6=1 +
YV6-YV7)
SA21A =1 + KM2 =1 (if
YV2, YV6 or
YV7 at fault
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
YV6-YV7)
50% if in
SA21B =1 + KM2 =1 (if
YV2, YV6 or
slope
YV7 at fault
A1, A2, G1, G2
(overload)
Discharged
batteries 20%
KM1 = 1 +
YV1 = 1
+YV5A=1
SA1 (side T) + SA10A=1 +

SA20A = 1+ KM2 =1 (if
KM1 = 1 +
YV1 = 1
+YV5B=1

SA20B = 1 + KM2 =1 (if

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Another
movement with
big flow in
progress (YV2YV6-YV7)
YV2, YV6 or
YV7 at fault
Discharged
batteries 20%
SQ1 = 0 (slope)
Another
movement with
big flow in
progress (YV2YV6-YV7)
YV2, YV6 or
YV7 at fault
Discharged
batteries 20%
overload
movements
are slowed
down
slowed down
descent with
50% if in
slope
HA12CJ(+)/HA32CJ(+)
41/118
2.7.7. TURRET SLEWING

Function
Action
Right side
upper controls
KM1 = 1 +
YV0 =1
+YV4B=1
Left upper
controls
KM1 = 1 +
YV0 =1
+YV4A=1
Right side
lower controls
Left lower
controls
2.7.8.
CONDITIONS
Prohibiting
Modifying
Necessary
SA1 (side N) + SB6 =1 +
Another
SM2HN=1 + SM2X signal
movement
between 2.5 and 4.5 V + KM2 with low flow
=1 (if multiple in drive mode)
in progress
or if not variable speed unit
(YV3-YV8Movements of
YV9- YV10)
Drive (position
transport)
YV3, YV8,
YV9 or YV10 and/or steering
SA1 (side N) + SB6 =1 +
(if this
at fault
movement is
SM2HN=1 + SM2X signal
A1, A2, G1, activated in first
between 2.5 and 0.5 V + KM2
G2
Movements
=1 (if multiple in drive mode)
slowed down if
(overload)
or if not variable speed unit
in slope
Discharged
batteries 20%
KM1 = 1 +
YV0 =1
+YV4B=1

SA82B = 1 + KM2 =1 (if
from 0 to 500A)
KM1 = 1 +
YV0 =1
+YV4A=1

SA82A = 1 + KM2 =1 (if
from 0 to 500A)
Another
movement
with low flow
in progress
(YV3-YV8YV9- YV10)
YV3, YV8,
YV9 or YV10
at fault
overload
movements
are slowed
down
Discharged
batteries 20%
JIB
Function
Action
Rise upper
controls
KM1 = 1 +
YV0 = 1
+YV8A=1
Descent upper
controls
KM1 = 1 +
YV0 = 1
+YV8B=1
CONDITIONS
Prohibiting
Modifying
Necessary
SA1 (side N) + SB6 =1 +
Another
Modifiable
SA51A=1 + KM2 =1 (if
movement with
speed
low flow in
not variable speed unit signal progress (YV3- movement by
(SB120 from 0 to 500A)
YV4-YV9SB121
YV10)
Office multiple
YV3, YV4, YV9 with the drive
or YV10 at fault
SA1 (side N) + SB6 =1 +
(position
A1, A2, G1, G2
SA51B=1 + KM2 =1 (if
transport)
(overload)
and/or steering
(if this
Discharged
movement
is
batteries 20%
from 0 to 500A)
activated
in
SQ1 = 0
first)
(slope)

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Rise lower
controls
KM1 = 1 +
YV0 = 1
+YV8A=1
Descent lower
controls
KM1 = 1 +
YV0 = 1
+YV8B=1

SA52A = 1 + KM2 =1 (if
from 0 to 500A)
SA52B = 1 + KM2 =1 (if
from 0 to 500A)
Another
overload
movement with
movements
low flow in
progress (YV3- are slowed
down
YV8-YV9Descent
YV10)
YV3, YV4, YV9 slowed down
if in slope
or YV10 at fault
Discharged
batteries 20%
2.7.9. COMPENSATION
Function
Rise/descent
upper controls
Action
KM1 = 1 +
YV0 = 1+
YV3A/B=1
CONDITIONS
Prohibiting the
Necessary
function
SA1 (side N) + SB6 =
Another
1 + SA41A/B =1 +
movement with
KM2 =1 (if multiple in
low flow in
drive mode) or if not
progress (YV4variable speed unit
YV8-YV9- YV10)
signal from 0 to 500A) YV4, YV8, YV9 or
speed unit of 0 to 500A
YV10 at fault
Modifying
the function
Movement
slowed down
if in slope
A1, A2, G1, G2

(overload)
Discharged
batteries 20%
emergency mode
Rise/descent
lower controls
KM1 = 1 +
YV0 = 1+
YV3A/B=1
Another
movement with
low flow in
progress
(YV4SA1 (side T) +
YV8-YV9YV10)
SA10A=1 + SA40A/B
YV4,
YV8,
YV9
or
= 1+ KM2 =1 (if
YV10 at fault
multiple in drive mode)
A1, A2, G1, G2
or if not variable speed
(overload)
unit signal
Discharged
from 0 to 500A)
batteries 20%
Emergency mode

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Prohibited
movement if
telescope
OUT
HA12CJ(+)/HA32CJ(+)
43/118
2.7.10. BASKET ROTATION
Function
(left/right
movement)
Action
KM1 = 1 +
YV0 = 1 +
YV9A/B=1
CONDITIONS
Prohibiting the
Modifying the
Necessary
function
function
SA1 (side N) + SB6 =1 +
Another
Modifiable
SA43A/B = 1+ KM2 =1 (if
movement with
speed
low flow in
movement by
progress (YV3(SB120 - SB121
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+)

Function
Action
upper controls
(left. /right)
KM1 = 1 +
YV0 = 1 +
YV10A/B =1
lower controls
(left/right)
KM1 = 1 +
YV0 = 1 +
YV10A/B =1
CONDITIONS
Prohibiting the Modifying the
Necessary
function
function
Modifiable
SA1 (side N) + SB6 =1 +
Another
SA53A/B=1 + KM2 =1 (if
speed
movement with
movement by
low flow in
(SB120 - SB121
progress (YV3from 0 to 500A)
YV4-YV8- YV9)
YV3, YV4, YV8
or YV9 at fault
SA1 (side N) + SA10A =1 +
A1, A2, G1, G2
SA52A/B = 1+ KM2 =1 (if
(overload)
Discharged
batteries 20%
from 0 to 500A)
Emergency
mode
SQ1 = 0 (slope)

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overload low
movements
slowing down
Movement
slowing down if
in slope
HA12CJ(+)/HA32CJ(+)
44/118
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
current , logic, hardware,
current probes, or CAN bus
network or problems linked to
an over or low voltage
Problems in main contactor
KMG or with the contactor for
selection traction/pump KM1
(open circuit, contact stuck
or short-circuit)
Lack of power or problem in
the outputs motors/pump
Speed variator unit in thermal
security
Possible faults on ZAPI

(13,18,19,53,57,58,233,234,241,244,247,248,25
2,253
AV02
AV03
AV04
AV05
Wrong sequence for starting

or error on one speed
variator unit input
AV06
Problem on batteries or
batteries too weak
- Possible faults on ZAPI (37,74,75,76,77,242)

- Check the state of contactors and/or
connections
Possible faults on ZAPI (30,31,60,250)

- Possible fault on ZAPI 62
- Lets cool the speed variator unit until the fault
disappears and meanwhile avoid to drive too
much time in rising ramps
- Restart the machine in good way
( battery cut-out , e-stop buttons then key
selector for upper/lower control box)
- Check speed variator unit connection
- Possible faults on ZAPI (66,251)
- Reload or replace batteries
CONTACTOR OUTPUTS
CODE
DESCRIPTION
ACTION
SC01
Output in open or short circuit :

validation relay KAV is defective (or
missing) or wire is cut
Output in open or short circuit:
flashing light relay KAF is defective
(or missing) or wire is cut
Output in open or short circuit: horn
relay KAK is defective (or missing)
or wire is cut
pump power coil contactor KM2 is
defective (or missing) or wire is cut
Change relay KAV, check wiring and

equipotential (on wires 273 et 0)
SC02
SC03
SC04
SC05
SC06
Output in short circuit: brakes

release relay KAB is defective (or
missing) or wire is cut (fault only
with SEVCON speed unit)
emergency pump power coil
contactor KMS is defective (or
(Fault visible only if the dead man
toggle switch SA10b is activated)

2420344390
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Change relay KAF, check wiring and

Change relay KAK, check wiring and
Change contactor KM2 on speed unit
plate , check cable 279 between
chassis loom and turret box or wire
203 on coil (+12V)
Change relay KAB, check cable 275
between chassis looms and turret box
and check the 0 on relay.
Change relay KMS, check continuity
on wire 208 between turret loom and
emergency pump option loom + turret
box, check wire 203 on coil (+12V)
HA12CJ(+)/HA32CJ(+)
46/118
VALVES OUTPUTS
CODE
DESCRIPTION
ACTION
EV01

PWM valve for secondary
movements YV0 is defective (or
PWM valve for main movements
YV1 is defective (or missing) or wire
is cut
- Output in open or short circuit :
ON /OFF valve for left steering
YV2A is defective (or missing) or
wire is cut
ON /OFF valve for right steering
YV2B is defective (or missing) or
wire is cut
ON /OFF valve for basket
compensation lifting YV3A is
compensation descent YV3B is
ON /OFF valve: for turntable left
rotation YV4A is defective (or
ON /OFF valve: for turntable right
rotation YV4B is defective (or
ON /OFF valve: for arm lift YV5A is
ON /OFF valve: for arm descent
wire is cut
ON /OFF valve for boom lift YV6A is
ON /OFF valve: for boom descent
wire is cut
Change coil YV0, check wire 276

between loom bloc + turret box or wire
203 on coil itself (+12V)
EV02
EV03
EV04
EV05
EV06
EV07

2420344390
E02-14

- Change coil YV2A, check wire 262
between loom bloc + turret box or the
- Change coil YV2B, check wire 263
- Change coil YV3A, check the wire

240 between loom bloc + turret box or
the 203 on coil itself (+12V)
- Change coil YV4A, check the wire le

the 203 on coil itself (+12V)

wire 203 on coil itself (+12V)
Change coil YV5B, check wire 221
HA12CJ(+)/HA32CJ(+)
47/118
EV08
EV09
EV10
EV11

wire is cut
wire is cut :
ON /OFF valve for jib lifting YV8A is
ON /OFF valve for jib descent YV8B
is defective (or missing) or wire is
cut
ON /OFF valve for basket rotation
left side YV9A is defective (or
right side YV9B is defective
ON /OFF valve for jib rotation left
side YV10A is defective (or missing)
or wire is cut
ON /OFF valve for jib rotation right
side YV10B is defective (or missing)
or wire is cut
- Change coil YV7A, check wire B600

between bloc loom + turret box and
wire 246 on coil (+12V)
- Change coil YV7B, check wire B601


CAN-BUS ERRORS / EEPROM

CODE
DESCRIPTION
MX01
CAN fault communication
EP01
EEPROM checksum error

2420344390
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ACTION
check can-bus network

(impedance and connections)
HA12CJ(+)/HA32CJ(+)
48/118
JOYSTICKS(CONTROLLERS) TOGGLE SWITCHES

CODE
DESCRIPTION
ACTION
SM1Y
Signal out of range or inconsistent

neutral value on drive joystick
neutral value on rotation /lift joystick
Inconsistent value or neutral
position not OK when power is ON ,
on one of the toggle switch in lower
control box
on one of the toggle switch in upper
control box
Check connection and signal value

(0.5 -2.5-4.5VDC)
(0.5 -2.5-4.5VDC)
(0.5 -2.5-4.5VDC)
Check toggle switches from lower
control box
SM2Y
SM2X
SW01
SW02
Check toggle switches from upper

control box
OVERLOAD ALARMS
CODE
DESCRIPTION
ACTION
OL01
- Adress fault on slave

module doing the load
function
- Inconsistant values
between EEPROM datas
saved between module
master B2 and slave B3
Fault in Jib learning Cal 1
- Problem in checksum parameters validation or

overload calibration datas or problem during load
calibration
- Make again the calibration
OL02
OL03
OL04
OL05
OL06
OL07
Make or redo the Jib learning Cal 1 calibration

process
- 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
- 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
- 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
Pressure sensor out of range
- Check if the pressure in the large jib chamber is
important in the jib large
varying in good way
chamber
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

calculation of the pressure
reference between
modules node B2 master
and node B3 slave
Resultant pressure out of
range
- difference more than 2 seconds between the

reference pressure ( calibration value) registered
by module node B3 and the current one registered
by the master module node B2
OL09
Pressure registered in node B2 out of 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
SE01
Incoherent status of
sensors : no change
during movement
SE02
Anti by-pass safety :
detection of SQ34
from 0 to 1 without any
movement)
ACTION
Check wiring and sensors SQ9 and SQ34 :

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

Telescopic IN SQ9=1

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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
AV01
AV02
AV03
AV04
AV05
AV06
SC01 - SC02 - SC03 - SC04 - SC05 - SC06

EV01 - EV02 - EV03 - EV04 - EV05 - EV06 - EV07 - EV08 - EV09 EV10 - EV11
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
after
Fault if shunt
fault SQ9
power is
SQ34 on
and SQ34
swithed
(SE02)
(SE01)
ON
(SE03)
Defect
detected
Defect shunt
Defect if
when
and no
state has
machine
movement
changed
starts to
detected , no
after
unfold and
command
power is
and SQ34
no change
ON
on sensors
state has
state
changed
0
State of
sensor
arm/boom
(SQ34=0
unfolded,
SQ34=1
folded)
State of
slope
sensor
(SQ1=0
no tilt,
SQ1=1
in slope)
0 (machine
unfolded)
0 (machine
unfolded)
1 (machine
folded)

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Drive
authorised
Movement
authorised
Number
of flashs
code
Reset if defect
0 (no
slope)
Micro speed
All
authorised
none
1
(dvers)
EUR mode
no drive/
USA mode
micro speed
Machine
in folded
position
authorised
none
Drive in LS
and HS
speed drive
All
authorised
none
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Defect
detected
when
machine
starts to
unfold and
no change
on
sensors
state
Defect
shunt and
no
movement
detected ,
no
command
and SQ34
state has
changed
Defect if
state has
changed
after power
is ON
Drive in
microS and
HS speed
drive
All
authorised
Micro speed
EUR mode
no drive/
USA mode
micro speed
All
authorised
Machine
in folded
position
authorised
Micro speed
All
authorised
EUR mode
no drive/
USA mode
micro speed
Machine
in folded
position
authorised
State of
sensor
arm/boo
m
(SQ34=0
unfolded,
SQ34=1
folded)
State of
slope
sensor
(SQ1=0
no tilt,
SQ1=1 in
slope)
Defect : proximity sensors

0 = no failure
1 = failure
fault SQ34
Function
Fault if
and SQ9
fault SQ9
shunt
after power
and SQ34
SQ34 on
is swithed
(SE01)
(SE02)
ON (SE03)
1 (machine
folded)

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none
11
lower /lift the

boom and
retract and
extend the
telescopic
boom
extension
11
lower /lift the

boom and
retract and
extend the
telescopic
boom
extension
11
lower /lift the

boom and
retract and
extend
telescopic
boom
extension
11
lower /lift the

boom and
retract and
extend
telescopic
boom
extension
Drive
authorised
Movement
authorised
Number
of flashs
code
Reset if
defect
Micro
speed
All
authorised
11
Remove
shunt on
SQ34
EUR mode
Machine in
folded
11
Remove
shunt on
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no drive/
USA mode
micro
speed
position
authorised
Micro
speed
All
authorised
EUR mode
no drive/
USA mode
micro
speed
Micro
speed
EUR mode
no drive/
USA mode
micro
speed
Micro
speed
EUR mode
no drive/
USA mode
micro
speed
All
authorised
All
authorised
Machine in
folded
position
authorised
All
authorised
All
authorised
SQ34
11
Remove
shunt on
SQ34
Lower/lift the
boom
11
Remove
shunt on
SQ34
Lower/lift the
boom
11
lower /lift the

boom and
retract and
extend
telescopic
boom
extension
11
lower /lift the

boom and
retract and
extend
telescopic
boom
extension
11
11
lower /lift the

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

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79
INCORRECT START
99
INPUT ERROR # 1
223
WAITING FOR NODE
233
234
SENSOR I KO
HW FAULT
241
FORW + TOP SPIN
242
VALVE COIL SHORTED
244
CHECK UP NEEDED
247
THERMIC SENSOR KB
248
KEY-OFF
249
CAN BUS KO
250
VFIELD NOT OK
251
WRONG SET BATTERY
252
AUX2 OUTPUT KO
253
AUX1 OUTPUT KO
Starting was not carried out correctly, start

again the sequence in the correct order
(battery cut out, emergency stop, selection
movement then joystick.)
No change of state on input
(Problem on modules)
Problem on VMC (Volt Motor Controller),
VMC voltage tries to start without agreement
of the variator (CAN bus problem or modules)
Current field sensor NOT OK
Problem of inverter, change KM1
Dual command (drive + movements) , release
all command
Not used for HAULOTTE, change variator if
alarm appears again
Warning that the maintenance scheduled is
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
tolerances
If the problem persists,change the variator
No power on system
No message coming from the CAN-BUS,
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
contactor open
Check connections
Mass fault between chassis and variator
Wrong type of batteries
The system checks the circuit brakes
command, if the received signal does not
correspond, replace the variator
The system checks the commande of KM1
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
YV7
YV5
YV2
YV1 (PWM2)
YV0 (PWM1)
YV8
YV4
YV9
YV3
YV10
Boom lift
Telescoping boom
Arm lifting
steering
Main movements (big flow)
Secondary movements (low flow)
jib
Turret rotation
Basket rotation
Basket compensation
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
YV3A
YV9B
YV3B
YV10A

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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 its 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
Jib rotation full range lock to lock
(HA12CJ+)
type
Time
Left
31s +/- 5 sec
right
31s +/- 5 sec
up
22s +/-5 sec
jib
down
26s +/-5 sec
up
24s +/-5s
Arm
down
22s +/-5s
Left
56s +/-5s
Turret rotation
(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
FWD
Drive High Speed
REV
FWD
Drive Low Speed
REV
up
21s +/-5s
Arm
down
20s +/-5s
Left
43s +/-5s
Turret rotation
(1/2 turn/180)
right
43s +/-5s
up
28s +/-5s
Main boom
down
21s +/-5s
Braking distances
Movement
type
Theoritical distance
FWD
Distance < 1, 5 m
Braking distance in High Speed and flat
ground
REV
Distance < 1, 5 m
Speed control from upper controls (hydraulic oil T> 30C)
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
Left
25s +/-5s
Jib rotation full range lock to lock
(HA12CJ+)
right
25s +/-5s
up
9s +/-5s
Compensation
down
8s +/-5s

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4.3. OPTIMIZER MENU

SPEED (%)
MOVEMENTS
DESIGNATION
MIN
DEFECT
RAMP
MAX
ACC
DEC
ACCESS
CODE
LEVEL 2
OR 3
ACCESS
CODE
LEVEL 2
OR 3
ACCESS
CODE
LEVEL 2
OR 3
ACCESS
CODE
LEVEL 2
OR 3
JIB UP AT MINIMAL SPEED

(JIB LIFT AT 30% OF ITS SPEED)
75.2
90
100
JIB UP AT MAXIMAL SPEED

(JIB LIFT AT 100% FULL SPEED)
75.2
90
100
JIB DOWN
95.2
100
FWD DRIVE
100
100
REV DRIVE
100
100
MICRO FWD DRIVE
100
100
MICRO REV DRIVE
100
100
PF. UP LEVEL
95.2
100
10
10
PF. DOWN LEVEL
95.2
100
10
10
STEERING LEFT
95.2
100
STEERING RIGHT
95.2
100
ARM UP
95.2
100
10
10
ARM DOWN
95.2
100
10
10
TURRET LEFT
95.2
100
10
10
TURRET RIGHT
95.2
100
10
10
BOOM UP
95.2
100
10
10
BOOM DOWN
95.2
100
10
10
PF. ROT. LEFT
95.2
100
PF. ROT. RIGHT
95.2
100
JIB ROT. LEFT
95.2
100
12
JIB ROT. RIGHT
95.2
100
12
OUT TELESCO
95.2
100
10
10
TELESCO IN
95.2
100
10
10
Note: the parameters Turret are at 80% of the Platformvalue

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MENU OPTIONS
OPTIONS
DESCRIPTION
COUNTRY
Choice of the country, between the

USA, Australia, Europe
TRACTION BATTERIES
PROHIB IN TILT SIGNAL
TRANS BUZZER
MOVEMENT BUZZER
TRANS FLASH LIGHT
MOVEMENT FLASH
LIGHT
FLASH LIGHT ON
LEVEL LIMIT +10/-10
MANUAL UNBRAKING
HA12CJ+ version
PWM YV1 setting
Default
value
Choice of the type of batteries,

No: Semi-traction, Yes:Traction
Selection of CANADA country option
only valid from US model (slope sensor
active with US country choice)
Activation of the buzzer if machine is in
drive ( FWD, REV drive)
Activation of the buzzer on movements
(except steering)
Activation of the flash-light if machine is
in drive mode ( FWD, REV drive)
Activation of the flash-light on
movements (except steering)
Activation of the flash-light when power is
ON on the machine
Activation of the limitation of basket
compensation (slope range for the basket
+10/-10)
Authorize the possibility to release the
electrical brakes on the drive motors
thanks to the remote control box for
brake release system
Choice of model type
(HA12CJ: NO / HA12CJ+ YES)
Correction in current command on PWM
100 no correction
<100 movements speed are
decreased
>100 movements speed are
increased

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Level
USA
No
Inactive
Inactive
Inactive
Inactive
Inactivate
Inactive
Active
Inactive
NO
100
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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 its authorized, 0 if its
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
controls
Validation
Control Application of
Securing and Setpoint
and
formatting of
the command
formatting of
the setpoint [0-100]%
[0-100]% on actuators
the command
Outputs
Actuator
Setpoint Limit

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Some useful definitions :

Controls
Inputs
Setpoint (0-100%)
Validation
Validation and formatting
the command
Setpoint limit /Limitation
Control (0-100%)
Outputs
Actuator
all commands coming from lower/upper controls

Digitals or analog inputs (ETOR-EANA)
In Diagnostic menu ,its the parameter Internal setpoint
for the function ( 0-1000pts)
Conditions for cutting the movements
Conditions for validation of the movement
Condtions for slowing down the movement
In Diagnostic menu , its the parameter Internal control
for the internal command of the function (0 -1000pts)
Digitals or Analog outputs ( STOR-SPWM SANA)
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
Overload
Machine state
Drive
Steering
PF. Level
ARM
Turret
Jib
BoomPF. Rot.
Jib rot.
Telescope
Variator
DESCRIPTION
Variables, inputs and outputs relating to
weighing
the state of the machine.
Variables inputs and outputs relating to the
drive mode
the steering
the basket compensation
arm lifting
the orientation of the turret
Variables, inputs and outputs relative to the
jib
boom raising
basket rotation
Variables, inputs and outputs relating to jib
rotation
the telescopic boom
Variables, messages CAN, inputs and
outputs relating to the variable speed
transmission

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NUMBER
1
2
3
4
5
6
7
8
9
10
11
12
13
HA12CJ(+)/HA32CJ(+)
72/118
OVERLOAD - PESAGE
NAME
INFORMATION
Internal
variable
ModePesage
Internal
variable
Overload
Internal
variable
Close Diff B2 (0.1b)
Internal
variable
Close ref. (0.1b)
Internal
variable
Internal
variable
Internal
variable
Internal
variable
Internal
variable
Internal
variable
Internal
variable
Jib Angle (0.1 deg)
ABS Angle (0.1 deg)

Rod Presses (0.1b)
Bore Presses (0.1b)
Press Diff B3 (0.1b)
Status of the function

weighing
Overload static
machine
Differential pressure
calculated in the
module node B2
(turret)
Pressure of
calculated reference
Angle jib/boom
Angle of the
basket/horizontal
position
Pressure in jib small
chamber
Pressure in jib large
chamber
Differential pressure
calculated in the
module node B3 (PF)
VALUES
0:Absent,
1: jib learning(calibration)
2: Normal,
3:Defect,
4:back up
1: static overload
Expressed in bar x 0.1

Expressed in degree x 0.1
- Near to 0 for the lowest jib
position
- Near to 1400 for the upper jib
position
Expressed in degree x 0.1
Around 0 for basket at horizontal
Expressed in bar x0.1
Must be close to Diff B2 if not
inconsistency
HighStop
electric higher limit
1: position reached
LowStop
Electric lowest limit
1: position reached
Value of the sensor of

relative angle
Value of the sensor of
absolute angle
Value of the pressure
sensor jib small
chamber
Value of the pressure
sensor jib large
chamber
0V-VbattV
If 0V then sensor in open circuit
0V-VbattV
A1
Angle
A2
Angle
G1
Cylinder press
G2
Cylinder press
Internal
Variable
DESCRIPTION
PesAFault
Fault in load system
0V-5V
0V-5V
0: no defect in progress
=0: Detected defect
Similar to OL0x defects
= 1 if defect incremental position
transducer in progress ==>defect
OL03
= 2 if defect absolute position
sensor in progress ==>defect OL04

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HA12CJ(+)/HA32CJ(+)
73/118
= 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
Internal
variable
AngAbsZero
Internal
variable
AngJibLowEnd
Angular value of
reference for 0
basket level
Angular value of
reference for jib at its
mechanical lowest
position

2420344390
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Used to calculate the current

basket angle
Used to calculate the current jib
angle
HA12CJ(+)/HA32CJ(+)
74/118
MACHINE STATE ETAT
NAME
SQ34
INFORMATION
ARM/BOOM
DOWN:1 UP:0
SQ9
TELESCOPE IN:1 OUT:0
SQ1
TILT SENSOR, FLAT:1
Internal
variable
OVERLOAD YES:1 NO:0
Internal
variable
DEADMAN OK:1 NOK:0
Internal
variable
PF SPEED CONTROL
1-10
DESCRIPTION
State of proximity sensor
for arm/boom folded
State of proximity sensor
for telescopic boom
position
State of level sensor
< X
VALUES
ON: if arm and boom are
in stowed position
State of weighing
1: Machine in weighing
State principal dead man

switch or dead man and
emergency pumps switch
(high or low)
Value of the bar-graph for
speed variation of the
upper control box
1: active and validated

0: Inactive or pushed
more than 8s without
movement
ON: if telescopic is fully

retracted
ON: Not in slope
OFF: Machine in slope
1 to 10
(10% to 100% of speed)
DRIVE TRANSLATION
NAME
INFORMATION
DESCRIPTION
Set point of the joystick in entry of
the module node B3
SM1
DRIVE JOYSTICK
Internal
variable
OUTPUT CENTER
POSIT.
Information out of neutral position
Internal
variable
BRAKE STATUS
Information of the brakes status
Internal DRIVE SETPOINT

Set.Point IN (%)
Int. Set
point
Limit
LIMITATION
Internal
Logical
CUTTING OUT
VALUES
in mV
joystick 0,5-2,5-4,5V
0: joystick in neutral
position
1: joystick out of neutral
position
0: machine with brakes
activated
1: machine with brakes
released
From 0 to 1000
(0% to 100%)
Signal of the joystick

Value of active limitation.
100% if no limitation on the
movement (also take into 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 the left
Bits:
654321
1: Condition of validation of the
movement
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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From 0 to 100%
From 000000 to
111111
HA12CJ(+)/HA32CJ(+)
75/118
Internal
Control
Internal
variable
DRIVE SETPOINT
OUT(%)
MicroS:1 LS:2 HS:3
Set point applied (according to the

adjustments and safety measures in
process)
From 0 to 1000
(0% to 100%)
Last speed of drive applied. (since

power is ON)
0: No drive speed
applied
1: Microspeed applied
at the last step
2: Low speed applied at
the last step
3: High speed applied
at the last step
STEERING - DIRECTION
NAME
SM1G
SM1D
INFORMATION
STEERING LEFT
BUTTON
STEERING RIGHT
BUTTON
Internal
SETPOINT IN (TOR)
Set.Point
Int. Set
point
Limit
LIMITATION
Internal
Logical
CUTTING OUT
Internal
Control
YV1
SETPOINT OUT(%)
PWM (YV1)
DESCRIPTION
Left steering button activated
right steering button activated
Set point TOR
(either 0% or 100%
represent)
100% if no limitation on the
movement (also take into
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 movement
2:Condition of cut of the
movement
3:Condition of cut in in
movements in multiple mode
6:Condition of cut in
controlled movements
Set point applied (according
to the adjustments and safety
measures in process)
Signal applied to the PWM
valve
YV2A
Left steering (TOR)
ON/OFF valve
YV2B
Right steering (TOR)
ON/OFF valve

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VALUES
OFF: Inactive
ON: Active
OFF: Inactive
ON: active
0: No signal
1: left setpoint
2: right setpoint
From 0 to 100%
From 000000 to
111111
From 0 to 1000
(0% to 100%)
0% to 100%
OFF: Inactive
ON: Active
OFF: Inactive
ON: Active
HA12CJ(+)/HA32CJ(+)
76/118
PF LEVEL BASKET COMPENSATION

NAME
INFORMATION
SA41A
PF:LEVEL BUTTON UP
SA41B
SA40A
SA40B
PF:LEVEL BUTTON
DOWN
TUR:LEVEL BUTTON
UP
TUR:LEVEL BUTTON
DWN
Internal
Set.Point
SETPOINT IN (TOR)
Int. Set
point
Limit
LIMITATION
Internal
Logical
CUTTING OUT
Internal
Control
SETPOINT OUT(%)
YV0
PWM (YV0)
DESCRIPTION
PF: Button basket
compensation UP
PF: Button basket
compensation down
Turret: Button basket
compensation UP
Turret: Button basket
compensation down
Set point ON/OFF
(either 0% or 100%
represented)
100% if not of limitation on the
Fwd/Up/L= 000000
Rev/Down/R= 000000
Bits: 654321
the movement
movement
movements
Set point applied (according to
the adjustments and safety
valve
YV3A
PF.LEVEL UP (TOR)
ON/OFF valve
YV3B
PF.LEVEL DOWN
(TOR)
ON/OFF valve

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VALUES
OFF: Inactive
ON: Active
OFF: Inactive
ON: Active
OFF: Inactive
ON: Active
OFF: Inactive
ON: Active
0: No signal
1: signal UP
2: signal DOWN
From 0 to 100%
From 000000 to
111111
From 0 to 1000
(0% to 100%)
0% to 100%
OFF: Inactive
ON: Active
OFF: Inactive
ON: Active
HA12CJ(+)/HA32CJ(+)
77/118
ARM (PRIMARY BOOM)

NAME
INFORMATION
DESCRIPTION
SA21A
PF:ARM BUTTON UP
PF: Button for arm lift
SA21B
PF:ARM BUTTON DOWN
PF: Button for arm descent
SA20A
TUR:ARM BUTTON UP
Turret: Button for arm lift
SA20B
TUR:ARM
BUTTON DOWN
Turret: Button for arm

descent
Set point ON/OFF
(either 0% or 100% are
represented)
100% if not of limitation on
the movement (also take into
account the system of
regulation speed: buttons +
and -)
movement
Fwd/Up/L= 000000
Rev/Down/R= 000000
Bits: 654321
the movement
movement
valve
Internal
SETPOINT IN (TOR)
Set.Point
Int. Set
point
Limit
LIMITATION
Internal
Logical
CUTTING OUT
Internal
Control
SETPOINT OUT (%)
YV1
PWM (YV1)
YV5A
ARM UP (TOR)
ON/OFF valve
YV5B
ARM DOWN (TOR)
ON/OFF valve

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VALUES
OFF: Inactive
ON: Active
OFF: Inactive
ON: Active
OFF: Inactive
ON: Active
OFF: Inactive
ON: Active
0: No signal
1: signal UP
2: signal DOWN
From 0 to 100%
From 000000 to
111111
From 0 to 1000
(0% to 100%)
0% to 100%
OFF: Inactive
ON: Active
OFF: Inactive
ON: Active
HA12CJ(+)/HA32CJ(+)
78/118
TURRET
NAME
INFORMATION
SM2X
JOYSTICK (mV)
Internal
variable
SA82A
SA82B
OUTPUT CENTER
POSIT.
Information out of neutral
TURRET ROT
BUTTON L
TURRET ROT
BUTTON R
Turret: Left button turret

rotation
Turret: right button turret
rotation
Internal
SETPOINT IN (%/TOR)
Set.Point
Int. Set
point
Limit
LIMITATION
Internal
Logical
CUTTING OUT
Internal
Control
SETPOINT OUT (%)
YV0
DESCRIPTION
Signal value of the joystick on
module input
PWM (YV0)
Set point value

(PF: vary from 0 to 100%
Turret: either 0% or 100%)

movement
Fwd/Up/L= 000000
Rev/Down/R= 000000
Bits: 654321
the movement
movement
movements
valve
YV4A
TURRET ROT. L (TOR)
ON/OFF valve
YV4B
TURRET ROT. R (TOR)
ON/OFF valve

2420344390
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VALUES
in mV
Joystick 0,5-2,5-4,5V
0: Joystick in neutral
position
1: joystick out of
neutral position
OFF: Inactive
ON: Active
OFF: Inactive
ON: Active
PF:
From 0 to 1000
(0% to 100%)
Turret:
0: No signal
1: left setpoint
2: right setpoint
From 0 to 100%
From 000000 to
111111
From 0 to 1000
(0% to 100%)
0% to 100%
OFF: Inactive
ON: Active
OFF: Inactive
ON: Active
HA12CJ(+)/HA32CJ(+)
79/118
JIB -
NAME
INFORMATION
DESCRIPTION
SA51A
PF:JIB BUTTON UP
PF: button Jib UP
SA51B
PF:JIB BUTTON DOWN
PF: button Jib Descent
SA50A
TUR:JIB BUTTON UP
Turret: button Jib lift
SA50B
TUR:JIB BUTTON
DOWN
Turret: button Jib descent
SETPOINT IN (TOR)
Set point TOR

(either 0% or 100% )
Internal
Set.Point
Int. Set
point Limit
LIMITATION
Internal
Logical
CUTTING OUT
Internal
Control
SETPOINT OUT(%)
YV0
PWM (YV0)
YV8A
JIB UP (TOR)
YV8B
JIB DOWN (TOR)
VALUES
OFF: Inactive
ON: Active
OFF: Inactive
ON: Active
OFF: Inactive
ON: Active
OFF: Inactive
ON: Active
0: No signal
1: setpoint UP
2: setpoint DOWN

From 0 to 100%
movement
Fwd/Up/L= 000000
Rev/Down/R= 000000
Bits: 654321
From 000000 to
the movement
111111
movement
movements
From 0 to 1000
(0% to 100%)
0% to 100%
valve
OFF: Inactive
ON/OFF valve
ON: Active
OFF: Inactive
ON/OFF valve
ON: Active

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HA12CJ(+)/HA32CJ(+)
80/118
BOOM (SECONDARY OR MAIN BOOM)
NAME
INFORMATION
SM2Y
JOYSTICK (mV)
Internal
variable
SA30A
SA30B
OUTPUT CENTER
POSIT.
TUR:BOOM BUTTON
UP
TUR:BOOM BUTTON
DOWN
Internal
SETPOINT IN (%/TOR)
Set.Point
Int. Set
point
Limit
LIMITATION
Internal
Logical
CUTTING OUT
Internal
Control
SETPOINT OUT (%)
YV1
PWM (YV1)
YV6A
BOOM UP (TOR)
YV6B
BOOM DOWN (TOR)
DESCRIPTION
Signal input value of the
joystick
Information out of neutral
position
Turret: Button boom lift
Turret: Button boom descent
Set point
(PF: vary from 0 to 100%
Turret: either 0% or 100%)
VALUES
in mV
Joystick 0,5-2,5-4,5V
0: Joystick in neutral
1: joystick out of neutral
OFF: Inactive
ON: Active
OFF: Inactive
ON: Active
PF:
From 0 to 1000
(0% to 100%)
Turret:
0: No signal
1: setpoint UP
2: setpoint DOWN

From 0 to 100%
account the system of
regulation speed: buttons +
and -)
movement
Fwd/Up/L= 000000
Rev/Down/R= 000000
Bits: 654321
From 000000 to
the movement
111111
movement
From 0 to 1000
(0% to 100%)
0% to 100%
valve
OFF: Inactive
ON/OFF valve
ON: Active
OFF: Inactive
ON/OFF valve
ON: Active

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HA12CJ(+)/HA32CJ(+)
81/118
PF - ROT BASKET ROTATION
NAME
INFORMATION
DESCRIPTION
SA43A
PF.ROT. BUTTON LEFT
PF: Button left basket rotation
SA43B
PF.ROT BUTTON
RIGHT
PF: Button right basket rotation
Internal
SETPOINT IN (TOR)
Set.Point
Int. Set
point
Limit
LIMITATION
Internal
Logical
CUTTING OUT
Internal
Control
SETPOINT OUT (%)
YV0
PWM (YV0)
YV9A
PF. ROT. LEFT (TOR)
YV9B
PF. ROT. RIGHT (TOR)
Set point TOR

(either 0% or 100% )
VALUES
OFF: Inactive
ON: Active
OFF: Inactive
ON: Active
0: No signal
1: left setpoint
2: right setpoint

From 0 to 100%
Fwd/Up/L= 000000
Rev/Down/R= 000000
Bits: 654321
1: Condition of validation of the
From 000000 to
movement
111111
movement
movements
Set point applied (according to
From 0 to 1000
the adjustments and safety
(0% to 100%)
0% to 100%
valve
OFF: Inactive
ON/OFF valve
ON: Active
OFF: Inactive
ON/OFF valve
ON: Active

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HA12CJ(+)/HA32CJ(+)
82/118
JIB ROTATION -
NAME
SA53A
SA53B
SA52A
SA52B
INFORMATION
PF:JIB ROT.BUTTON
L
PF:JIB ROT.BUTTON
R
TUR:JIB
ROT.BUTTON L
TUR:JIB
ROT.BUTTON R
Internal
SETPOINT IN (TOR)
Set.Point
Int. Set
point
Limit
LIMITATION
Internal
Logical
CUTTING OUT
Internal
Control
SETPOINT OUT (%)
YV0
PWM (YV0)
YV10A
JIB ROT. LEFT (TOR)
YV10B
JIB ROT. RIGHT

(TOR)
DESCRIPTION
PF: button for jib left rotation
VALUES
OFF: Inactive
ON: Active
OFF: Inactive
ON: Active
OFF: Inactive
ON: Active
OFF: Inactive
ON: Active
0: No signal
1: left setpoint
2: right setpoint
PF: Button for jib right

rotation
Turret: button for jib left
rotation
Turret: button for jib right
rotation
Set point TOR
(either 0% or 100%
represent)
From 0 to 100%
movement
Fwd/Up/L= 000000
Rev/Down/R= 000000
Bits: 654321
From 000000 to
the movement
111111
movement
From 0 to 1000
(0% to 100%)
measures in progress)
0% to 100%
valve
OFF: Inactive
ON/OFF valve
ON: Active
OFF: Inactive
ON/OFF valve
ON: Active

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HA12CJ(+)/HA32CJ(+)
83/118
TELESCOPE
NAME
SA35A
SA35B
SA22A
SA22B
INFORMATION
PF:TELES BUTTON
OUT
PF: TELES BUTTON IN
TUR: TELES BUTTON
OUT
TUR: TELES BUTTON
IN
Internal
SETPOINT IN (TOR)
Set.Point
Int. Set
point
Limit
LIMITATION
Internal
Logical
CUTTING OUT
Internal
Control
SETPOINT OUT(%)
YV1
PWM (YV1)
YV7A
JIB ROT. LEFT (TOR)
YV7B
JIB ROT. RIGHT (TOR)
DESCRIPTION
PF: Button telescopic boom
OUT
PF: Button telescopic boom
IN
Turret: Button telescopic
OUT
Turret: Button telescopic IN
VALUES
OFF: Inactive
ON: Active
OFF: Inactive
ON: Active
OFF: Inactive
ON: Active
OFF: Inactive
ON: Active
0: No signal
1: setpoint OUT
2: setpoint IN
Set point TOR

(either 0% or 100%
represent)
the movement (also take
From 0 to 100%
into account the system of
speed regulation buttons +
and -)
movement
Fwd/Up/L= 000000
Rev/Down/R= 000000
Bits 654321
From 000000 to
the movement
111111
movement
movements in multiple
mode
overload
From 0 to 1000
to the adjustments and
(0% to 100%)
safety measures in process)
0% to 100%
valve
OFF: Inactive
ON/OFF valve
ON: Active
OFF: Inactive
ON/OFF valve
ON: Active

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HA12CJ(+)/HA32CJ(+)
84/118
VARIATOR -
NAME
Internal
variable
Internal
variable
Internal
variable
INFORMATION
BAT VOLTAGE (mV)
KMG STATUS
SETPOINT (MAX:255)
Internal
variable
OUT POWER AMP (A)
Internal
variable
TOP SPIN STATUS
Internal
variable
BRAKE STATUS
Internal
variable
Internal
variable
TEMPERATURE (deg. C)
CODE ALARM
Code
OPTIMIZER
DESCRIPTION
Value of the batteries
voltage
General state of main
contactor KMG
speed setpoint received on
the variator
current sent by the variator
on power circuit (pump or
drive motors)
Operation of the variator in
mode movements (pump)
Information state of the
brakes
Temperature interns
variator
Alarm code sent by the
variator
DEFINITION
13
EEPROM KB
18
LOGIC FAILURES # 2
19
LOGIC FAILURES # 1
30
VMN LOW
31
VMN HIGH
37
CONTACTOR CLOSED
53
STBY I HIGH
57
HIGH FIELD CURRENT
58
NO FIELD CURRENT
60
CAPACITOR LOAD
VALUES
Value in mV
OFF: Inactive
ON: Active
0 to 255
(0% to 100%)
xx (A)
0: Inactive
1: active
0: Braked machine
with brakes ON
1: machine with
brakes released
Of -40c with 100c
0 to 255 (see detail)
DIAGNOSTIC
The parameters have been altered and the
movements are impossible
If the problem has been solved when power is
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
board which controls the pump contactor KM2
Problem in the logical circuit of the line
contactor KMG or in the hardware of the
variator (logic board)
The terminals of the power contactor KMG
remain stuck
Failure in the current detection as it didnt
drop to 0 when the variator is not activated
Change the variator if the problem persists
Defect in the circuit energizing F1 /F2
check connections
replace the variator if the problem persists
Defect in the field circuit F1 /F2
Check connections
Replace the variator if the problem persists
The capacitors doesnt charge 0.5 after power
is ON
Defect in the power circuit

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HA12CJ(+)/HA32CJ(+)
85/118
62
TH PROTECTION
66
BATTERY LOW
74
DRIVER SHORTED
75
CONTACTOR DRIVER
76
COIL SHORTED
77
COIL INTERRUPTED
79
INCORRECT START
99
INPUT ERROR # 1
223
WAITING FOR NODE
233
234
SENSOR I KO
HW FAULT
241
FORW + TOP SPIN
242
VALVE COIL SHORTED
244
CHECK UP NEEDED
247
THERMIC SENSOR KB
248
KEY-OFF
249
CAN BUS KO
250
VFIELD NOT OK
251
WRONG SET BATTERY
252
AUX2 OUTPUT KO
253
AUX1 OUTPUT KO
The internal temperature of the variator

exceeds 75C
Defect in the temperature sensor
Lets cooling the variator before changing it
batteries discharged more than 80%
Short-circuit or open circuit on contactors
KMG/KM1 or circuit brakes L3/L4
Problem on contactors KM1 or KMG or
brakes L3/L4
Short-circuit or open circuit on contactors
KMG/KM1 or circuit brakes L3/L4
When power is ON, the voltage applied on
contactor is not correct
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
(battery cut out, emergency stop, selection
movement then joystick.)
No change of state on input (Problem on
modules
Problem on VMC (Volt Motor Controller),
VMC voltage tries to start without agreement
of the variator (CAN bus problem or modules)
Current field sensor NOT OK
Problem of inverter, change KM1
Dual command (drive + movements) , release
all command
Not used for HAULOTTE, change variator if
alarm appears again
Warning that the maintenance scheduled is
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
tolerances
If the problem persists,change the variator
No power on system
No message coming from the CAN-BUS,
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
contactor open
Check connections
Mass fault between chassis and variator
Wrong type of batteries
The system checks the circuit brakes
command, if the received signal does not
correspond, replace the variator
The system checks the command of KM1
contactor if the received signal does not
correspond, replace the contactor

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HA12CJ(+)/HA32CJ(+)
86/118
SPEED VARIATOR UNIT ALARMS

CODE
DESCRIPTION
ACTION
AV01
Problems in stator/rotor
current , logic, hardware,
current probes, or CAN bus
network or problems linked to
an over or low voltage
Problems in main contactor
KMG or with the contactor for
selection traction/pump KM1
(open circuit, contact stuck
or short-circuit)
Lack of power or problem in
the motors/pump outputs
Speed variator unit in thermal
security
Possible faults on ZAPI

(13,18,19,53,57,58,233,234,241,244,247,248,25
2,253
AV02
AV03
AV04
AV05
Wrong sequence for starting

or error on one speed
variator unit input
AV06
Problem on batteries or
batteries too weak
- Possible faults on ZAPI (37,74,75 ,76 ,77,242)

- Check the state of contactors and/or
connections
Possible faults on ZAPI (30,31,60,250)

- Possible fault on ZAPI 62
- Lets cool the speed variator unit until the fault
disappears and meanwhile avoid to drive too
much time in rising ramps
- Restart the machine in good way ( battery cutout , e-stop buttons then key selector for
upper/lower control box)
- Check speed variator unit connection
- Possible faults on ZAPI (66,251)
- Reload or replace batteries
CONTACTOR OUTPUTS
CODE
DESCRIPTION
ACTION
SC01

validation relay KAV is defective (or
Output in open or short circuit:
flashing light relay KAF is defective
Output in open or short circuit: horn
relay KAK is defective (or missing)
or wire is cut
pump power coil contactor KM2 is
Change relay KAV, check wiring and

SC02
SC03
SC04
SC05
SC06
Output in short circuit: brakes

release relay KAB is defective (or
missing) or wire is cut (fault only
with SEVCON speed unit)
emergency pump power coil
contactor KMS is defective (or
(Fault visible only if the dead man
toggle switch SA10b is activated)

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Change relay KAF, check wiring and

Change relay KAK, check wiring and
Change contactor KM2 on speed unit
plate , check cable 279 between
chassis loom and turret box or wire
203 on coil (+12V)
Change relay KAB, check cable 275
between chassis looms and turret box
and check the 0 on relay.
Change relay KMS, check continuity
on wire 208 between turret loom and
emergency pump option loom + turret
box, check wire 203 on coil (+12V)
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VALVES OUTPUTS
CODE
DESCRIPTION
ACTION
EV01

PWM valve for secondary
movements YV0 is defective (or
PWM valve for main movements
YV1 is defective (or missing) or wire
is cut
ON/OFF valve for left steering YV2A
cut
wire is cut
compensation lifting YV 3A is
ON/OFF valve for basket
compensation descent YV 3B is
ON /OFF valve: for turntable left
rotation YV4A is defective (or
ON /OFF valve: for turntable right
rotation YV4B is defective (or
ON /OFF valve: for arm lift YV5A is
ON /OFF valve: for arm descent
wire is cut
ON /OFF valve for boom lift YV6A is
ON /OFF valve: for boom descent
wire is cut

EV02
EV03
EV04
EV05
EV06
EV07

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- Change coil YV3B, check the wire

- Change coil YV4B, check the wire le

Change coil YV5B, check wire 221
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EV08
EV09
EV10
EV11

wire is cut
wire is cut :
ON /OFF valve for jib lifting YV8A is
ON /OFF valve for jib descent YV8B
cut
left side YV9A is defective (or
right side YV9B is defective (or
ON /OFF valve for jib rotation left
side YV10A is defective (or missing)
or wire is cut
ON /OFF valve for jib rotation right
side YV10B is defective (or missing)
or wire is cut



CAN-BUS ERRORS / EEPROM

CODE
DESCRIPTION
MX01
CAN fault communication
EP01
EEPROM checksum error

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ACTION
check can-bus network

( impedance and connections)
Chang ECU module
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JOYSTICKS(CONTROLLERS) TOGGLE SWITCHES

CODE
DESCRIPTION
ACTION
SM1Y

neutral value on drive joystick
on one of the toggle switch in lower
control box
on one of the toggle switch in upper
control box

(0.5 -2.5-4.5VDC)
(0.5 -2.5-4.5VDC)
(0.5 -2.5-4.5VDC)
Check toggle switches from lower
control box
SM2Y
SM2X
SW01
SW02
Check toggle switches from upper

control box
OVERLOAD ALARMS
CODE
DESCRIPTION
ACTION
OL01
- Adress fault on slave

module doing the load
function
- Inconsistant values
between EEPROM datas
saved between module
master B2 and slave B3
Fault in Jib learning Cal 1
- Inconsistent values
between jib movement and
jib angle measurement
- Fault in A1 relative angle
sensor
- Inconsistent value
between compensation
movement and jib angle
- Fault in A2 absolute
angle sensor (inclinometer)
important in the jib small
chamber
important in the jib large
chamber
recorded between modules
node B2 master and slave
B3
- Problem in checksum parameters validation or

overload calibration datas or problem during load
calibration
- redo the calibration
OL02
OL03
OL04
OL05
OL06
OL07
Make or make again the Jib learning Cal 1 process

- Check the jib angle sensor value and the
direction of variation of this value (should increase
when jib is lifting).
- Jib angle sensor value out of range
- Check the jib inclinometer sensor value and the
direction of variation of this value (should decrease
when basket is elevating)
- Jib inclinometer sensor value out of range
- Pressure sensor out of range
- Check if the pressure in the small chamber is
varying in good way
Pressure sensor out of range
- Check if the pressure in the large chamber is
varying in good way
- Too much difference of calculation regarding the
pressure datas between modules node B2 and B3
- Restart the machine
- change module node B2 and/or node B3

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CODE
DESCRIPTION
ACTION
OL08

reference between
modules node B2 master
and node B3 slave
Resultant pressure out of
range
- difference more than 2 seconds between the

reference pressure ( calibration value) registered
by module node B3 and the current one registered
by the master module node B2
OL09
Pressure registered in node B2 out of 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
SE01
Incoherent status of
sensors : no change
during movement
SE02
Anti by-pass safety :
detection of SQ34
from 0 to 1 without any
movement)
ACTION

Telescopic IN SQ9=1
Telescopic IN SQ9=1
Move both movemenst (telescopic then arm +
Principle of survey :
1 failure if without any movement , the sensor
goes from 0 to 1
SE03
E-stop safety :
detection position
before power OFF and
check position when
power is ON again
(sensor state should
not have changed)

Telescopic IN SQ9=1
Move both movemenst (telescopic then arm +

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4.4. CONSOLE DIAG PAD

Its possible to use the 2nd generation of diagnostic console (also available through laptop)
The presentation of the main menu will depend of the softwares version of the machine
This diagnostic console could be used in WIFI using a VCI adapter
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 alarms code has been changed ( not the
description and function)
Original failure code
AV01
AV02
AV03
AV04
AV05
AV06
SC04
SC06
SC01
SC05
SC02
SC03
EV03
EV04
EV05
EV06
EV07
EV08
EV09
EV10
EV11
EV02
EV01
SM1Y
SM2Y
SM2X
OL01-OL02
OL07-OL08
SE01
OL05
OL06
OL03
OL04
SW3
MX01
EP01
SW01
SW02
New failure code

F01.01
F01.03
F01.05
F01.06
F01.07
F01.08
F02.01
F02.02
F03.03
F03.04
F03.05
F03.06
F04.01
F04.02
F04.03
F04.04
F04.05
F04.06
F04.07
F04.08
F04.09
F04.11
F04.12
F05.01
F05.04
F05.06
F06.01
F06.02
F07.01
F07.20
F07.21
F07.22
F07.23
F08.07
F12.01
F12.02
F13.01
F13.02

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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 20C
The adjustment of the pressure relief valve is always done in the lift way
(Note: Its always better to constrain the spring rather than slacken it, the precision is
better)
Version 1
MP1
MP2
MOVEMENTS
Plug socket MP1
Rise/descent boom
Rise/descent arm
Extension /retraction telescopic boom
Main pressure / steering (D)
Plug socket MP2
jib
Jib rotation
compensation lifting (C)
Compensation descent
Rotation basket
Turret slewing (A left / B right)
Plug M version 2
Main pressure/steering (D)
Pressures taken on pump exit,

during movement (+/- 2b)
186b
195b/177b
188b/175b
210b
172b
169b
155b
168b
169b
100b
210b
Connection of the pressure gauge in MP1 (movements big flow) or MP2 (movements low flow)
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Version 2
B
A
C
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)
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

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

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

Not adjusted or defective pressure relief 100b valve
No pressure
5.7. NO JIB
Switch SA50 lower controls or SA51 upper controls
Electrovalve YV8
No pressure

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5.8. NO BASKET ROTATION
Switch upper controls SA43
Electrovalve YV9

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
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 theyve

started before the steering
Contactor KM1 or KM2
No pressure

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

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ZIVAN 110vac
6. SUMMARY OF VERSIONS HA12CJ-HA12CJ+
HA 12 CJ - HA12CJ+
EC - CDN - USA All models from 01-2010 AUS

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Wiring
diagram
Hydraulic
diagram
164P322210
164P316940
HA12CJ(+)/HA32CJ(+)
100/118
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 , thats why
if this valve is changed , its 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 > 10C
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
mouvements
purge the jib
cylinder.
Drain jib cylinder .

5 Movements from low
Stop to high stop.
Press (*) when done
If not OK start again
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 its 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
stops running
Note: If you release

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
Display
End
calibration
Note: A message may appear OL05 or

OL06, do not take care about this and
make a movement to swing out from
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
(mV)
A2
(mV)
G1
(mV)
G2
(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
Its 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

10sec after the stop
of the movement at
100% of load
following a
movement of rise
(step 2 and/or 3)
decrease the
adjustment Jib Up
minimum Speed
(thus speed is slower
between low stop
and high stop)
calibrate again.
More generally
presence of alarm
at 100% of load
whatever the
position
control the load

system.
note the
modifications in the
machines file
charge the machine with 240kg (HA12CJ+)

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

or 260kg (HA12CJ).
enter the code level 3.
In menu PARAMETERS SPEEDS
select Jip Up minimum speed.
take 3 measurements of jib lifting from low
stop to high stop:
- lower the jib to lowest position
- wait for a few seconds
- lift the jib
- when jib starts to move launch the
stop watch, and stop it when the machine
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
calibration badly made
change of hydraulic block
change of PWM valve
leak on the hydraulics circuit of jib cylinder
Element of the ON/OFF jib block
The jib cylinder
modification of the version of machine (having an
impact on the permitted load )
loss of parameters
Replacement of hose on jib cylinder
replacement of the absolute angle sensor
replacement of the relative angle sensor
replacement of the pressure sensor
replacement of the platform controls box
replacement of the lower control box
replacement node B2
replacement node B3

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PWM
adjustment
X
X
X
drain
calibration
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
machines
CAN
X
X
X
machines
CAN
X
X
X
HA12CJ(+)/HA32CJ(+)
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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
BBB+
F1
TERMINALS
T (VMNT)
F2
Connector A1
F2

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IMPEDANCE VALUE
128.6 K
128.9 K
64 K
132.7 K
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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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Technical Training Level II HA12CJ - EN - E02-14

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TECHNICAL TRAINING

How to use this document?

TRAINING MANUAL DIAGNOSTIC Level 2

MAIN FEATURES AND FUNCTIONS ............................................................................................................. 6

THE ELECTRICAL PART ............................................................................................................................... 19

THE HYDRAULIC PART ................................................................................................................................. 56

ADJUSTMENTS WITH CONSOLE OPTIMIZER ................................................................................................. 63

TRAINING MANUAL DIAGNOSTIC Level 2

BREAKDOWN SERVICE GUIDE ................................................................................................................... 96

SUMMARY OF VERSIONS HA12CJ-HA12CJ+ ......................................................................................... 100

SPECIAL FUNCTIONS ................................................................................................................................... 101

LIST OF SCHEMATICS ................................................................................................................................. 112

TRAINING MANUAL DIAGNOSTIC Level 2

1. MAIN FEATURES AND FUNCTIONS

TRAINING MANUAL DIAGNOSTIC Level 2

TRAINING MANUAL DIAGNOSTIC Level 2

1.1.2. LOADING POINTS HA12CJ-CJ+

TRAINING MANUAL DIAGNOSTIC Level 2

1.1.3. FEATURES HA12CJ-CJ+

TRAINING MANUAL DIAGNOSTIC Level 2

TRAINING MANUAL DIAGNOSTIC Level 2

TRAINING MANUAL DIAGNOSTIC Level 2

1.1.4. OVERALL DIMENSIONS HA12CJ-CJ+

TRAINING MANUAL DIAGNOSTIC Level 2

1.1.5. WORKING ZONE HA12CJ (HA32CJ)

TRAINING MANUAL DIAGNOSTIC Level 2

TRAINING MANUAL DIAGNOSTIC Level 2

1.2. THE LOWER CONTROLS

TRAINING MANUAL DIAGNOSTIC Level 2

TRAINING MANUAL DIAGNOSTIC Level 2

1.3. THE UPPER CONTROLS

TRAINING MANUAL DIAGNOSTIC Level 2

TRAINING MANUAL DIAGNOSTIC Level 2

2. THE ELECTRICAL PART

Battery with one element

Fuse (Here 10 amps)

Coil winding roll

TRAINING MANUAL DIAGNOSTIC Level 2

Standard push-button of safety mushroom-headed

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

Toggle switch with 2 positions

TRAINING MANUAL DIAGNOSTIC Level 2

Proportional valve PWM type ( Pulse Width

Foot pedal switch

Electrovalve ON/OFF ( bang-bang)

Tilt sensor ( ramp detection)

Angle sensor (reach limitation)

Contact mercury (angle detection)

TRAINING MANUAL DIAGNOSTIC Level 2

Resistor (here value 100 ohms, 3 Watts, tolerance

Sensor length (reach limitation)

Pressure sensor (weighing)

Angle sensor (weighing)

Standard light Led

Flexible Blade switch (ILS) detection of the magnets

Level detector (diesel tank)

Proximity detector with impulses (detection teeth

TRAINING MANUAL DIAGNOSTIC Level 2

2.2. METHODOLOGY OF CONTROL

ELECTRIC CONTINUITY CONTROL

CONTROL OF AN ON/OFF VALVE

Note: These tests are to be carried out when power is ON .

TRAINING MANUAL DIAGNOSTIC Level 2