HT21RT HT23RTJ

TECHNICAL TRAINING
DIAGNOSTIC LEVEL II
HT21RT–HT23RTJ
HT61RT–HT67RTJ
TRAINING MANUAL DIAGNOSTIC Level 2 HT21RT-HT23RTJ
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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: like
components, overall dimensions, working zones, commands, etc…
Chapter 2: Study of the wiring schematics
You will find there the elements following:
- A summary of the standardized symbols used by HAULOTTE Group
- The complete wiring diagram of the model studied
- 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 schematics
You will find there the elements following:
- a summary of the standardized symbols used by HAULOTTE Group
- the complete hydraulic diagram of the model studied
- the non exhaustive list of the hoses track
- a localization of the main hydraulics manifold (proportional,on/off movements,drive block,…)
Chapter 4: Adjustments
This is the all 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
It’s a quick summary of the steps 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 same model of the machine (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 machines and depends on the model studied.
It must be the subject of a special attention from your part as 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)

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SUMMARY
1. MAIN FEATURES AND FUNCTIONS .................................................................................................................. 5
1.1. THE CHARACTERISTICS ........................................................................................................................................ 5
1.1.1. main components........................................................................................................................................ 5
1.1.2. Overall dimensions .................................................................................................................................... 7
1.1.3. main datas .................................................................................................................................................. 9
1.1.4. working zones........................................................................................................................................... 11
1.1.5. precautions for transport mode ................................................................................................................ 13
1.2. THE COMMANDS ................................................................................................................................................ 14
1.2.1. upper controls .......................................................................................................................................... 14
1.2.2. lower controls .......................................................................................................................................... 20
1.3. THE MULTIPLE MOVEMENTS............................................................................................................................... 26
1.3.1. standard version ....................................................................................................................................... 26
1.3.2. australia version ...................................................................................................................................... 27
1.3.3. us-cdn version .......................................................................................................................................... 28
1.4. STRUCTURE OF THE SYSTEM .............................................................................................................................. 29
1.4.1. Locations of ecu modules ......................................................................................................................... 30
2. THE ELECTRICAL PART ................................................................................................................................... 31
2.1. SYMBOLS USED .................................................................................................................................................. 31
2.2. METHODOLOGY OF CONTROL ............................................................................................................................ 37
2.2.1. electric continuity control ........................................................................................................................ 37
2.2.2. Control of an on/off valve ........................................................................................................................ 37
2.2.3. Control of components ............................................................................................................................. 38
2.3. THE ECU MODULES ........................................................................................................................................... 41
2.3.1. the ecu module spu ................................................................................................................................... 41
2.3.2. the display indicator................................................................................................................................. 42
2.3.3. The ecu module node b2........................................................................................................................... 43
2.3.4. The pcb in lower control box ................................................................................................................... 45
2.3.5. egv kubota module ................................................................................................................................... 48
2.4. LOCALIZATION OF THE MAIN COMPONENTS ....................................................................................................... 51
2.5. DESIGNATION OF ELECTRICAL ITEMS ................................................................................................................. 57
2.5.1. Definition of the prefixes and suffixes ...................................................................................................... 57
2.5.2. Definition of the families of items ............................................................................................................ 58
2.6. LIST OF ITEMS ON SCHEMATICS.......................................................................................................................... 59
2.6.1. engine ....................................................................................................................................................... 59
2.6.2. Fuses ........................................................................................................................................................ 59
2.6.3. inputs ........................................................................................................................................................ 60
2.6.4. Outputs ..................................................................................................................................................... 62
2.7. THE WORKING ZONE CONTROL .......................................................................................................................... 65
2.7.1. How the system works .............................................................................................................................. 65
2.7.2. State of the limit switchs in the zone ........................................................................................................ 67
2.8. LOGICAL FUNCTIONS ......................................................................................................................................... 70
2.8.1. ecu power managgement .......................................................................................................................... 70
2.8.2. engine start version fixed rpm .................................................................................................................. 71
2.8.3. engine start version variable rpm ............................................................................................................ 74
2.8.4. brake release ............................................................................................................................................ 79
2.8.5. drive ......................................................................................................................................................... 79
2.8.6. oscillating axle ......................................................................................................................................... 81
2.8.7. tilt function ............................................................................................................................................... 82
2.8.8. steering ..................................................................................................................................................... 82
2.8.9. load selection/measurement ..................................................................................................................... 84
2.8.10. all movements........................................................................................................................................... 87
2.8.11. boom......................................................................................................................................................... 87
2.8.12. telescopic boom ........................................................................................................................................ 90
2.8.13. turret rotation ........................................................................................................................................... 93
2.8.14. jib ............................................................................................................................................................. 95
2.8.15. basket rotation.......................................................................................................................................... 97
2.8.16. basket compensation ................................................................................................................................ 98
2.8.17. emergency mode..................................................................................................................................... 100
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2.8.18. generator option..................................................................................................................................... 100
3. THE HYDRAULIC PART ................................................................................................................................... 101
3.1. SYMBOLS USED ................................................................................................................................................ 101
3.2. THE HYDRAULIC SCHEMATICS ......................................................................................................................... 105
3.3. MAIN HYDRAULIC MANIFOLDS ......................................................................................................................... 105
3.3.1. Drive block ............................................................................................................................................. 106
3.3.2. steering block ......................................................................................................................................... 109
3.3.3. block on/off............................................................................................................................................. 111
3.3.4. proportional block pvg ........................................................................................................................... 113
3.3.5. Safety valves ........................................................................................................................................... 114
3.3.6. The hydraulic pumps .............................................................................................................................. 115
3.4. HELP GUIDE FOR HYDRAULIC LEAKS ................................................................................................................ 115
4. ADJUSTMENTS ................................................................................................................................................... 119

4.1. ADJUSTMENTS USING THE CONSOLES .............................................................................................................. 119
4.1.1. failures menu .......................................................................................................................................... 124
4.1.2. access code............................................................................................................................................. 136
4.1.3. Settings menu ......................................................................................................................................... 137
4.1.4. movements times .................................................................................................................................... 138
4.1.5. diagnostic menu ..................................................................................................................................... 148
4.1.6. Menus inputs /outputs ............................................................................................................................ 155
4.1.7. Menu informations ................................................................................................................................. 161
4.2. LOAD MANAGEMENT SYSTEM .......................................................................................................................... 163
4.2.1. principle ................................................................................................................................................. 163
4.2.2. sensors values ........................................................................................................................................ 163
4.2.3. how to check the sensors ........................................................................................................................ 164
4.3. ADJUSTMENT OF THE PRESSURES ..................................................................................................................... 165
4.3.1. Table of pressures .................................................................................................................................. 165
4.3.2. Plug port for pressures check ................................................................................................................ 166
4.3.3. pressures adjustment on pumps.............................................................................................................. 167
5. SIMPLE USER GUIDE FOR BREAKDOWN ................................................................................................... 169
5.1. QUICK CHECKING ON MOVEMENTS .................................................................................................................. 169
5.2. QUICK CHECKING ON DRIVE MODE .................................................................................................................. 169
5.3. QUICK CHECKING ON STEERING MODE ............................................................................................................. 170
5.4. QUICK CHECKING ON ENGINE ........................................................................................................................... 171
5.5. NO START ..................................................................................................................................................... 176
5.6. NO MOVEMENT ........................................................................................................................................... 176
5.7. NO BOOM FUNCTION ONLY ............................................................................................................................... 176
5.8. NO TELESCOPING ONLY .................................................................................................................................... 176
5.9. NO TURRET ROTATION ONLY ................................................................................................................... 177
5.10. NO JIB ONLY .................................................................................................................................................. 177
5.11. NO BASKET ROTATION ONLY....................................................................................................................... 177
5.12. NO COMPENSATION ONLY ......................................................................................................................... 177
5.13. NO DRIVE ONLY ............................................................................................................................................ 177
5.14. LOW SPEED ONLY ...................................................................................................................................... 177
5.15. NO STEERING ONLY ..................................................................................................................................... 178
5.16. NO OSCILLATING AXLE ONLY .......................................................................................................................... 178
6. SUMMARY OF VERSIONS HT21RT- HT23RTJ ............................................................................................ 179
7. SPECIAL FUNCTIONS ....................................................................................................................................... 179
7.1. CANBUS SYSTEM ........................................................................................................................................... 179
7.2. ADJUSTMENT PROCEDURE OF SPECIFIC DEVICES .............................................................................................. 180
7.2.1. any ils sensor.......................................................................................................................................... 180
7.2.2. angle sensor ........................................................................................................................................... 181
7.2.3. tilt sensors .............................................................................................................................................. 182
7.2.4. cables on telescopic boom...................................................................................................................... 183
7.2.5. kubota accelerator coil .......................................................................................................................... 186
7.2.6. Kubota fuel coil and sensors .................................................................................................................. 187

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1. MAIN FEATURES AND FUNCTIONS
1.1. THE CHARACTERISTICS
1.1.1.MAIN COMPONENTS

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1.1.2.OVERALL DIMENSIONS
HT21RT
HT23RTJ

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1.1.3. MAIN DATAS

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1.1.4.WORKING ZONES

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1.1.5.PRECAUTIONS FOR TRANSPORT MODE
Anchor points
Lock pin on turret

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1.2. THE COMMANDS
1.2.1.UPPER CONTROLS

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DISPLAY on UPPER CONTROLS

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Detail on symbols
Symbol Name Output Control Description

ON Light test at machine’s start up
ON Selected Command console is upper
BLINK Safety valves maintenance tool is active (safety
Power On HL102 valves ON or OFF)
BLINK Machine powered on and command console is
not upper command console
OFF Other cases
ON Enable pedal is valid (movement is enable)
Enable
HL103 BLINK Safety valves maintenance tool is active (safety
Pedal
valves ON or OFF)
OFF Other cases
ON Gas oil low level is detected (SQ189 sensor open
for 10seconds)
Fuel low HL164
level valves ON or OFF)
OFF Other cases
BLINK Failure has been detected or is active
Failure / HL140 BLINK Safety valves maintenance tool is active (safety
Danger valves ON or OFF)
OFF Other cases
ON Tilt is detected (even with folded machine)
Tilt HL148 BLINK Safety valves maintenance tool is active (safety
valves ON or OFF)
OFF Other cases
ON Overload is active
ON Underload is active
Overload HL142 BLINK Overload system is failing
valves ON or OFF)
OFF Other cases

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ON Reach limitation is active
BLINK Reach limitation sensors failure is active or
detected
Reach BLINK for CE & AU, if position is P5, applied load is
HL147
limitation 500lb validated and load selector is on 1000lb
position
valves ON or OFF)
OFF Other cases
ON Applied load is 230kg / 500lb
230kg BLINK Machine position is P5 (230kg/500lb zone),
applied load is 450kg/1000lb and telescope
/ HL158
extension or boom descent set points are active
500lb BLINK Safety valves maintenance tool is active (safety
valves ON or OFF)
OFF Other cases
450kg ON Applied load is 450kg / 1000lb
/ HL159 BLINK Safety valves maintenance tool is active (safety
1000lb valves ON or OFF)
OFF Other cases
ON Engine is preheating before starting
Engine
HL150 BLINK Safety valves maintenance tool is active (safety
Preheat valves ON or OFF)
OFF
DPF HL165
valves ON or OFF)
OFF Other cases
HEST HL166 valves ON or OFF)
OFF Other cases

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DPF BLINK Safety valves maintenance tool is active (safety
HL167 valves ON or OFF)
Disabled
OFF Other cases
Inverted
HL880 OFF Unplugged light
Turret
ON Tilt 10° is active and basket level raise set po int
is active
ON Tilt -10° is active and basket level descent set
Basket Tilt HL561 point is active
valves ON or OFF)
OFF Other cases
ON Engine failure has been detected (F09.xx)
ON Engine immobilizing timer running (1s if start
Engine stop HL169 phase failed, 3s if engine was stopped normally)
valves ON or OFF)
OFF Other cases
ON Engine warning has been detected (TIII semi-
electronic and TIV only)
BLINK
Engine (5 times at Service counter is lower than 20h
HL168 power-on)
warning
valves ON or OFF)
ON Service counter is detected to null value
OFF Other cases

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1.2.2.LOWER CONTROLS

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• DISPLAY INDICATOR on LOWER CONTROLS
LED Function Color

1 Safety command control Orange
2 Failure Red
3 Outreach limit Orange
4 Overload Red
5 Wait to start Orange
6 Engine Warning Orange
7 Engine Stop Red
8 DPF Orange
9 DPF disable Orange
10 HEST Red

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• Detail on indicators

ON Selected Command console is overriding
command console
Power On LED1
valves ON or OFF)
OFF Other cases
ON Tilt active and machine not in P1 position
BLINK Active or detected failure
Warning LED2 BLINK Service counter null valued
valves ON or OFF)
OFF Other cases
ON Reach limit is reached or overran
BLINK Reach limit system failure is active or detected
Reach BLINK For STD and AUS countries, blinking if load

LED3 selector is on “1000lb” position and applied load is
limitation
500lb (machine in P5 position)
valves ON or OFF)
OFF Other cases
ON Overload alarm is active
BLINK Overload system failure is active/detected
Overload LED4
valves ON or OFF)
OFF Other cases
ON Engine’s preheat is running before starting
Engine’s
LED5 BLINK Safety valves maintenance tool is active (safety
preheat
valves ON or OFF)
OFF Other cases

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ON Engine’s warning is active
BLINK
(5 times at Service counter is lower than 20h
Engine’s power on)
LED6
warning BLINK Service counter is null valued (time to next
(permanent) maintenance)
valves ON or OFF)
OFF Other cases
ON (3s) Engine’s immobilizing time is running
ON (1s) Engine’s start failed (time out on start phase)
Engine’s ON
LED7 Engine failure (coolant, pressure, alternator…)
stop (permanent)
valves ON or OFF)
OFF Other cases
DPF BLINK Safety valves maintenance tool is active (safety
LED8 valves ON or OFF)
Disabled
OFF Other cases (unused for now)
DPF LED9
valves ON or OFF)
HEST LED10
valves ON or OFF)

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Note : the display is showing 2 informations
When power is switched ON during the checking , the display is showing how many hours are
remaining before the next service on KUBOTA engine
This service hours counter is resetted at 500hours if
• The new program is installed in the SPU
• By connecting the diagnostic console OPTIMIZER (with daily code) in menu 3.7
Service Counter
After checking the final display is showing the running hours (all lights OFF if no alarm in progress)
(this counter could also be resetted by connecting the diagnostic console OPTIMIZER (daily code) ,
in menu 3.8 Hourmeter )
For more details regarding how to connect./use the console , refer chapter 4

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1.3. THE MULTIPLE MOVEMENTS
1.3.1.STANDARD VERSION

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1.3.2.AUSTRALIA VERSION

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1.3.3.US-CDN VERSION

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1.4. STRUCTURE OF THE SYSTEM
The sytems has 3 ECU modules (SPU is the master and 2 slave ECU node B2 located one in lower
controls and one in upper controls
DIGITAL /ANALOG U104 ECU DIGITAL /ANALOG

INPUTS (SLAVE) OUTPUTS
NODE B2
BASKET
CAN 2.0 A CAN 2.0 B TURRET

HAULOTTE J1939
DIGITAL /ANALOG
INPUTS
U100 ECU U106 ECU U101 ECU Semi

(SLAVE) (MASTER) DISPLAy Electronic
DIGITAL /ANALOG NODE B2 NODE SPU (SLAVE) KUBOTA
DIGITAL /ANALOG
BAUSER 808
DIGITAL /ANALOG
OUTPUTS Engine
type V2403
OUTPUTS
INPUTS
(@2 CAN) NODE EGV

type @2 CAN)

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1.4.1.LOCATIONS OF ECU MODULES
Lower box
U100 ECU
(SLAVE)
NODE B2
U101 ECU
DISPLAY
(SLAVE)
U106 ECU
(MASTER)
NODE SPU
Upper box
U104 ECU
(SLAVE)
NODE B2

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2. THE ELECTRICAL PART
2.1. SYMBOLS USED
Battery with 2 elements (normally each of them

represents 6VDC)
Alternator
Fuse (Here 5 amps)
winding dual coil (start/stop engine coil)
Electric motor
Diode (A anode/K kathode)
Hourmeter

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Standard push-button of safety “mushroom-headed
button”/emergency stop button
Rotary knob
Push-button
Limit switch
Pressure switch
Key selector with 3 positions

(T turret, O neutral, N platform)
Key selector with 2 postions
Toggle switch with 2 positions

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Electrovalve
relay
Horn
Proportional electrovalve
Proportional valve PWM type ( Pulse Width Modulation)
Controller/joysticks

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Pedals or “foot dead man” switch
buzzer
“indicator”
Electrovalve “ON/OFF » ( bang-bang)
Tilt sensor ( ramp detection)
Angle sensor (reach limitation)

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Position switch « mercury style » (angle detection)
Resistor (here value 120 ohms, 1/4 Watts)
Sensor length (reach limitation)
Pressure sensor (weighing)
Angle sensor (weighing)
Standard indicator “Led”
Strain gauge

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Load cell /strain gauge (F force /I intensity )
Flexible Blade Switch (ILS) detection of the magnets on

boom/arm extension
Level detector (diesel tank)
Proximity detector with impulses

(detection teeth slew ring)
Temperature sensor

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2.2. METHODOLOGY OF CONTROL
Note: During an intervention on a component or a loom, it is important to switch OFF the power
supply of the machine in order to avoid any risk.
2.2.1.ELECTRIC CONTINUITY CONTROL

The continuity check of a loom or an electric component determines the resistor of this device, in
order to detect a possible interruption of continuity (open circuit, short-circuit…).
This control is carried out with a multimeter commutated in position Ohmmeter (Ω).
First of all, it is necessary to determine the terminals of the component or the cable to control and
insulate them.
Then, connect the multimeter in order to record the value.
It must indicate a value of resistor close to 0 Ω if continuity is good.
In the contrary case (resistor which tends towards the infinite one: ∞), continuity presents a defect.
Control of insulation
At the contrary of continuity, insulation represents a non electric connection between the ground
and the component
The test of insulation consists in obtaining the opposite result of that described for continuity, i.e. a
value of the Ohmmeter which must tend towards the infinite one: ∞
2.2.2.CONTROL OF AN ON/OFF VALVE

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

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

Disconnect the plug socket of supply of the valve in order to connect the multimeter on the
terminals of the connector industry.
Select the position Ohmmeter (Ω), then compare the value measured with that of the data
manufacturer.
In the event of nonconformity of the coil, replace it
2.2.3.CONTROL OF COMPONENTS
• Control of an electric relay

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

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

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• Control of a fuse
Color code
• Fuse check
Multimeter in Ω position, it must indicate a value near 0
NOK
OK
• Control of a diode
locate the diode and disconnect it from the loom.
Control must be done with a multimeter in “diode” position.
connect the multimeter on each terminal of the diode, in one direction then on the
other.
In one direction, the diode should have no continuity,
in the other it must beep
If the diode is beeping in both ways, replace it.

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2.3. THE ECU MODULES
This chapter shows the different modules installed in the machine
2.3.1.THE ECU MODULE SPU

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2.3.2.THE DISPLAY INDICATOR

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2.3.3.THE ECU MODULE NODE B2

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Note: on all modules, there is 2 types of digital outputs :
LS (Low Side) and HS: (High Side)
Exception : safety valves where HS and LS outputs are combined as follow :

For all these outputs , at OFF state , the module detects an open circuit but the software ignore this
information and drives the outputs

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2.3.4.THE PCB IN LOWER CONTROL BOX
See below a picture and the location of fuses and relays

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2.3.5.EGV KUBOTA MODULE
This module EGV (Electronic Governor) controls electronically the speed of the engine (no more
accelerator coil)
It does not require any calibration
• Layout detail on EGV module
SV162
ST161
YA166

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• Detail of pins

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• Quick trouble shooting guide
The alarm details in SPN could be checked by connecting the OPTIMIZER console and go in
diagnostic menu /4.2 functions/ engine elec /Failure SPN 1 (more details see chapter 4 of this
document)

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2.4. LOCALIZATION OF THE MAIN COMPONENTS
SR400 Tilt sensor + 10°

SR420 Tilt sensor – 10°
SP480/SP481 Load cells (2 in one block)
YV401 Platform compensation down

YV421 Platform compensation up
YV500 Jib lift
YV510 Jib down
YV440 Platform rotation right
YV460 Platform riotation left
SQ380 ** ILS sensor boom length

SQ381 ** Boom length sensor
SQ320 Boom in/down sensor
(=1 if in machine is stowed)
SQ321 Boom in/down ILS sensor
(=1 if in machine is stowed)
SQ991 Chain break sensor
SR380 ** ILS boom angle sensor

SR381 ** Boom angle sensor (=1 if > 50°)
SQ990 Chain break sensor
ST160 Engine overheating sensor

SP162 Engine oil pressure sensor
ST161 Engine water temperature
sensor
YV600 FWD drive valve
YV620 REV drive valve
YV390 Boom safety valve

YV101 Load sensing valve
( by-pass valve)
YV102 PVG valve movements and
steering
YV381 PVG valve boom lift
YV382 PVG valve telescopic boom
YV391 Safety valve boom down
YV392 Safety valve telescopic boom
YV890 Safety valve turret rotation
SQ142 Tilt/slope sensor
SQ189 Low fuel tank detection
ST125 Hydraulic oil overheating sensor
YV686 High speed valve for drive
YV782 Brake release valve
YV780 Oscillating axle valve
YV781 Oscillating axle valve
SP692 High speed detection
YV622 Synchro mode steering valve
YV621 Crab mode steering valve
YV602 Front right steering
YV601 Front left steering
ILS : Interrupteur Lame Souple / Flexible blade proximity sensor

(ON if in front of the magnet only)
** dual load option only
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• Photos in detail SR420
SR400
SQ320
SQ321
SQ381
SQ380
SR380
SR381

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ST161
SP162
R160
ST160

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Version 1 : Engine equipped with 2 fixed rpm (idle/accelerator speed )
YA166 YA164
Fuel pump
Version 2 : Engine equipped with variable speed engine: idle / speed controlled electronically by an
EGV (Electronic Governor ) KUBOTA module
YA166
SV162

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SQ991 SQ990
SQ141
SQ189

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SP480/SP481
Note : the strain gauges is protected by a fuse (FU34 = 1A) located inside the upper control box

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2.5. DESIGNATION OF ELECTRICAL ITEMS
The electrical components are identified by a system of letters and figures.
Designation in order to designate each component: per function /family
its nature (relay, contactor,…)
its family (movements boom, movements drive,…)
its sub family (lift, descent, forward,…)
Example:
Y V 7 2 1
valves Family: 700 Sub-family: 720 to 739:

Movements and descent
outriggers
Here : valve for outriggers descent
2.5.1.DEFINITION OF THE PREFIXES AND SUFFIXES
Prefixes Identification of the component Suffix

CE Electrical colelctor
CNB Basket connector
C Capacitor
D Diode
E Heating H
E Lamp /light L
E Fan V
F Fuse U
G Alternator
G Battery B
H Sound buzzer A
H Light L
K Contactor M
K Auxiliary relay A
K Preheating relay T
M Motor or pump
P Indicator, display
Q Circuit breaker F
Q Cut out switch S
R Resistor
R Potentiometer P
S Switch A
S Push button B
S Joystick J
S Controller M
S Pressure sensor P
S Position sensor Q
S Angle sensor R
S Temperature sensor T
S Speed sensor V
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T Transformer
U Converter/electronic module/box
X Plug socket P
Y Electrovalve V
Y Coil of command A
Y Electric brake B
2.5.2. DEFINITION OF THE FAMILIES OF ITEMS
FAMILY SUB-FAMILY DESCRIPTION

100 to 119 supply
120 to 139 movements
100 General 140 to 159 Safety
160 to 179 engine
180 to 199 Accessories
200 to 219 Lift
220 to 239 descent
240 to 259 extension telescope
200 Movements arm
260 to 279 Retraction telescope
280 to 289 General
290 to 299 Safety
300 to 319 lift
320 to 339 descent
340 to 359 extension telescope
300 Movements boom
360 to 379 Retraction telescope
380 to 389 General
390 to 399 Safety
400 to 419 Lift
420 to 439 descent
440 to 459 Left
400 Movements PF/bucket
460 to 479 Right
480 to 489 General
490 to 499 safety
500 to 509 lift
510 to 519 Descent
520 to 529 Left
530 to 539 Right
500 Movements jib
540 to 549 extension telescopic boom
550 to 559 Retraction telescopic boom
560 to 569 General
570 to 579 Safety
600 to 619 Front
620 to 639 Back
640 to 659 Left
600 Movements drive
660 to 679 Right
680 to 689 General
690 to 699 safety
700 to 719 Lift
720 to 739 Descent
740 to 759 Left
700 Movements outriggers
760 to 779 Right
780 to 789 Main
790 to 799 safety
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840 to 859 Left
800 Movements rotation 860 to 879 Right
880 to 889 Main
890 to 899 safety
900 to 919 Lift
900 Movements scissors/mats 920 to 939 Descent
980 to 989 Main
990 to 999 Safety
2.6. LIST OF ITEMS ON SCHEMATICS

In the following tables:
the column n°2 gives the coordinates of the compone nts 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 column n°3 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.ENGINE
ENGINE ELEMENTS
M101 02 - 9 Starter(163)
YA164 02 - 14 Start/stop engine coil (165) version with fixed rpm only
YA166 03 - 15 Electronic fuel coil
ALT 02 - 11 Alternator (Ignition 183 = 12V if alternator is powered )
2.6.2.FUSES
FUSES
FU1 04 - 03 Hold coil engine 10A (172)
FU2 04 - 04 Pull coil engine 10A (165)
FU4 04 - 02 Option relay generator 25A (193)
FU5 04 - 8 + main KMG line 30A (101)
FU7 04 - 15 V ECU modules B2 line 15A (both controls + display) (109)
FU8 04 -0 8 Lights line 20A (180)

FU9 04 - 12 + accessories line 20A (183)
FU11 04 - 9 Accelerator line 7.5A (Vbat permanent (105)
FU13 04 -11 V power line KMP + SPU 20A (103)
FU19 04 - 14 Selection turret/basjet 5A (119)
FU34 09- 09 Protection strain gauge 1A (B401)

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FU122 03 - 03 Emergency pump line 250A (141)
FU161 03 - 06 Preheating line 100A (160)
FU180 03 - 02 Option cooler line 30A (190)
Note the other fuses are not used
2.6.3.INPUTS
INPUTS
SA100
04 - 06 Main power selection ON/OFF (100)
SA110
05 - 12 A.12:B.22 Start/stop engine + dead man switch lower controls
SA145
04 -17 Safety descent switch lower controls (144)
SA146
08 - 09 CN105.14 Load selection 230/450kg (B143=1 if 230kg)
SA162
06 - 12 CN104.3 Accelerator toggle switch (164)
SA185
04 - 11 Turret rotation light selection (185)
SA187
04 -17 Selection turret/basket (115)
SA189
08- 08 CN104.11 Option generator (B116)
SA191
04 – 09 Turret lights selection (182)
SA300
06 - 08 CN104.12/13 Boom descent/lift lower controls (320/300)
SA301
06 - 06 CN104.15/16 Telescopic boom IN/OUT lower controls (360/340)
SA400
06 - 09 CN104.10/11 Basket compensation Up/Down lower controls
(481/480)
SA480
08 - 15 CN105.35/36 Basket rotation upper controls left/right (B124/B123)
SA481
08 - 17 CN104.10/9 Basket compensation (Down B115/Up B114)
SA500
06 - 11 CN104.8/7 Jib lift/descent lower controls
SA501
08 - 14 CN104.13/14 Jib lift/descent upper controls
SA680
08 - 07 CN104.6 Low/high spped ( B111 = 1 in HS mode)
SA681
08 - 13 CN104.13/14 Steering mode (B104 = crab / B105 = synchro)
SA880
06 - 04 CN104.16/17 Turret rotation left/right lower controls (840/860)
SB105
08 - 06 CN104.1 Horn (B106)
SB106
08 - 12 CN105.12 Foot switch upper controls (B141)
SB120
08 - 05 CN105.4 Emergency pump (B129)

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SB143
04 - 14 Main E-stop on turret (143)
SB144
08 - 03 Main E-stop on basket (143)
SB161
08 - 04 CN105.3 Start/stop engine upper controls (B128)
SM120
09 – 7 Turret/boom lift joystick
CN105.9 Off neutral (B103)
CN106.12 Y signal lift/descent (B302)
CN106.13 X signal orientation (B303)
SM121
06 – 4 Telescopic boom joystick
CN105.8 off neutral (B102)
CN106.11 Y signal from 0.5 to 4.5V (B301)
SM122
09 – 7 Drive joystick
CN104.3 SM4d right steering (B108)
CN104.4 SM4g left steering (B109)
CN105.6/7 Off neutral (B100/B101)
CN105.10 Y signal drive (B300)
FWD from 2.5 to 0.5 V
Reverse from 4.5 to 2.5 V
MODULES
U100
ECU module node B2 turret (slave)
U101
Display CAN (lower controls)
U104
ECU module node B2 basket (slave)
U106
SPU CAN gateway (master)
EGV
03- 14 Electronic Governor module for engine rpm control
SENSORS
SQ142
05 – 14 B.16 Tilt sensor (150 = 0 if in slope)
SQ189
06 – 17 CN104.1 Fuel level ( 189 =1 if on reserve)
SQ320
05 – 11 B.15 Boom stowed (381 = 0 if boom < > 15°)
SQ321
05 -12 B.23 Boom stowed (387 = 1 if front of magnet)
SQ380
05 – 08 B.21 Boom length detection (380 =1 if in front of magnet)
SQ381
05 – 10 A.17 Boom length (382 = 0 if boom extended)
SQ990 06 - 14 CN104.3 Boom chain (990=0 engine stops)
SQ991
06– 15 CN104.2 Boom chain (991=0 engine stops)
SR380
05 – 09 B.19 Boom angle detection (384 = 1 if in front of magnet)

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SR381
05– 10 A.11 Boom angle detection (383= 1 if angle > 50°)
SR400
09 – 10 CN105.16 Basket compensation (tilt +10°)
SR420
09 – 12 CN105.17 Basket compensation (tilt -10°)
SP162
03- 16 Engine oil pressure ( 173 = 0 if P < 3b)
SP480
09 – 15 CN106.4/5 Strain gauges for basket overload
SP692
06 – 16 CN104.1 High speed detection (692 = 0 if HS mode)
ST125
06 – 19 CN105.3 Hydraulic oil overheating (125 =0 if T> 85°c)
ST126
03 – 02 Engine oil cooler detection
ST160
03 – 17 Engine oil overheating (174 =1 if T high)
ST161
03 -13 Engine cooilg circuit (175 =1 if T>120°c)
SV162
03-14 Engine speed sensor
2.6.4.OUTPUTS
RELAYS
KA1
06 – 12 CN104-26 Engine start/stop (170)
KA2
06 – 17 CN104-31 Starter (176)
KA3
04 – 17 Power line (103)
KA4
06 – 16 CN104-23 Generator command (192)
KA5
06 – 14 CN104-24 Accelerator (169)
KA9
06 -13 CN104-30 Horn (187)
KMG
04- 06 General (100)
KMP
04 – 14 Main (hold power a few seconds after KMG is OFF (142)
KM8
04 – 09 Option turret lightning (front/rear) (182)
KM120
03 – 04 Emergency pump (145)
KM160
03 – 07 Preheating (162)
VALVES
YV101 05 – 11 B.7 Load Sensing (120)
Movement and steering

YV102 07 – 12 CN106.15
signal from 25 % to 75% of Vbat

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Boom lift/descent (302)
YV381 07 – 17 CN106.16
Telescoping boom extension/retraction (342)

YV382 07 -15 CN106.1
07 -19 CN106.2 Turret slewing (883)

YV880
Signal from 25% to 75% of Vbat
YV390 05 – 09 B.17 Safety boom lift (390)
YV391 05 – 08 B.30 Safety boom descent (391)

YV392 05 – 07 B.6 Safety telescopic boom extension (392)
YV401 09 – 13 CN105.28 Basket compensation down (B600)
YV421 09 – 14 CN105.27 Basket compensation up (B607)
YV440 09 – 12 CN105.33 Basket rotation left (B605)
YV460 09 – 11 CN105.34 Basket rotation right (B606)
YV500 09 – 07 CN105.31 Jib lifting (B603)
YV510 09 – 06 CN105.32 Jib descent (B604)
YV600 05 – 12 A.2 PWM valve FWD drive (B600)
YV601 07 – 07 CN105.31 Front left steering (601)
YV602 07 – 08 CN105.32 Front right steering (601)
YV620 05 – 13 B.25 PWM valve REV drive (B620)
YV621 07 – 09 CN105.33 Crab steering mode option (621)
YV622 07 – 08 CN105.34 Synchroneous steering mode option (622)
YV686 07 – 03 CN105.27 High speed drive (686)
YV780 07 – 05 CN105.29 Oscillating axle unlocking (780)
YV781 07 – 06 CN105.30 Oscillating axle unlocking (781)
YV782 07 – 04 CN105.28 Brake release function (782)
BUZZER AND INDICATORS

HA105
04 – 13 Horn (184)
HA141
08 -09 CN105.16 buzzer upper control box (B508)
HA142
05 – 8 CN104.22 Buzzer lower control box (186)
EL181
06 – 20 CN105.21 Flashing light option (188)

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EL185
04 – 11 Rotation light option on turret (185)
EL191
04 - 07 Turret light front/rear option
EL192 Turret light front/rear option
04 - 07
04 - 08
04 - 08
EL195
09 - 16 Working light option on basket (183)
HL102
08 - 15 CN104.22 Power on upper controls (B501)
HL103
08 - 14 CN104.21 Foot switch pedal (B500)
HL140
08 - 16 CN104.24 Danger (B503)
HL142
08 - 17 CN104.26 Overload (B505)
HL147
08 - 17 CN104.27 Outreach (B506)
HL148
08 -16 CN104.25 Tilt (B504)
HL149
08- 18 CN104.28 Load selection (230/450kg) (B507)
HL150
08 - 18 CN104.30 Preheating (B509)
HL164
08 - 15 CN104.23 Fuel level (B502)
HL165
08 - 11 CN104.34 DPF engine (B522)
HL166
08 - 11 CN104.35 HEST gas regeneration (B522)
HL167
08 -12 CN104.36 Gas regeneration inhibited (B521)
HL168
08 -13 CN104.32 Engine warning (B523)
HL169
08 - 13 CN104.33 Engine stop (B524)
HL561
08 - 12 CN104.31 Basket compensation (B511)
HL880
08 -12 CN104.29 Turret at 180° (B510)

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2.7. THE WORKING ZONE CONTROL
2.7.1. HOW THE SYSTEM WORKS

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If machine is single load option (250kg/500lbs), there is only 2 zones P1 and P2
All limit switchs for P5 zone have been removed from telescopic boom (only SQ320/SQ321 are
remaining on telescopic boom section)

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2.7.2. STATE OF THE LIMIT SWITCHS IN THE ZONE

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• Detail of the limit switchs state according to the zone

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2.8. LOGICAL FUNCTIONS
This chapter describes function per function the necessary conditions in order to authorize or
prohibits the movement
It’s more detailed than in the chapter 5 so the service technician will have the choice , to go first to
the main topics in chap 5 to follow or consulting this chapter in order to have more details of the
function who needs to be checked .
• Glossary
U Up ANA IN Analogic Input

D Down DIG IN Digital Input
L Left DIG OUT Digital output
R Right ANA OUT Analog output
F FWD PWM Pulse Width Modulation
(Proportionnal valve in current)
B REV VAR Internal variable in the Module (not
accessible with the console)
I/O Inputs/outputs
2.8.1.ECU POWER MANAGGEMENT

The “ECU power management” describes the requirements relative to the power on and self power
off of the master ECU module.
• REQUIREMENTS
REQUIREMENTS DEFINITION
The ECU is supplied by a permanent 12V: 12VP. The ECU requests its own
F PM_V_001
shutdown.
The ECU stops when the following conditions are set:
WakeUpInput value set to 0 or 12VC and 12VD < 5000mV
F PM_V_002 and No EEPROM request pending
and stop request not suspended: (engine immobilizing time)
WUI=0 & VAR[SuspendCoreShutdown]=0 requested shutdown
F PM_V_003 Shutdown is timed out protected: shutdown is forced after 10 seconds

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2.8.2.ENGINE START VERSION FIXED RPM
The “Engine management: TierIII fixed RPM” function describes the requirements relative to Kubota
TIII engine running at two fixed speeds (idle speed, accelerated speed): start /stop sequence and
preheating sequence, safeties.
• I/O FUNCTIONS
• REQUIREMENTS
The engine start and stop function happens at the specified set point (start request or
stop request) depending on the activated panel:
EN_V_001
VAR[CmdConsole]=UCC & SB161= SETPOINT[EngineStartStop]=
VAR[CmdConsole]=LCC & SA110S= SETPOINT[EngineStartStop]=
The engine start and stop control happens at the specified control (start or stop
request) depending on the machine status (EMSTOP=1 means no emergency
EN_V_002 stopper pushed)
SETPOINT[EngineStartStop]= & EMSTOP & VAR[EngineStatus]=preheat | ready
to start CONTROL[EngineStartStop]=1
(SETPOINT[EngineStartStop]= | \EMSTOP | VAR[PowerOn]=0 &
EN_V_003
VAR[EngineStatus]=running) CONTROL[EngineStartStop]=0
Preheating time is calculated according to the analogue coolant temperature sensor
ST161. This sensor measures a resistance, giving a time as following:
- 15s if temperature is lower than -10°C: ST161>9700Ω
VAR[CoolantTemp]<-10 VAR[PreheatTime_ms]=15000
- 10s if temperature is lower than 0°C: 9700 Ω ≥ST161> 5900Ω
10≤VAR[CoolantTemp]<0
EN_V_004
VAR[PreheatTime_ms]=10000- 5s if temperature is lower than 5°C:
5900Ω≥ST161>5000Ω 0≤VAR[CoolantTemp]<+5
VAR[PreheatTime_ms]=5000
- no preheat if temperature is higher than 5°C: 50 00Ω≥ST161
5≤VAR[CoolantTemp]

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Preheating time is calculated according to the analogue coolant
temperature sensor ST161. This sensor measures a resistance,
giving a time as following:
- 15s if temperature is lower than -10°C: T161>9700Ω
VAR[CoolantTemp]<-10
VAR[PreheatTime_ms]=15000- 10s if temperature is lower
than 0°C: and 9700 Ω ≥ST161> 5900Ω
EN_V_004 10≤VAR[CoolantTemp]<0
VAR[PreheatTime_ms]=10000- 5s if temperature is lower than
5°C: and 5900 Ω≥ST161>5000Ω
0≤VAR[CoolantTemp]<+5
- no preheat if temperature is higher than 5°C: 500 0Ω≥
ST161 5≤VAR[CoolantTemp]
VAR[EngineStatus]:
0 engine init (initialization, or formerly running)
1 engine preheat
2 engine ready to start
EN_V_005 3 engine starting
4post heating : no post heating
5engine running
6engine stop: immobilizing time, no allowed restart during 3 s:
the engine stop light is ON during this time
Cooling temperature failure is activated 1 if:
VAR[CoolantTempFailure]=1, VAR[EngineStop]=1
EN_V_006 Liquid cooling sensor active (=OFF) when engine running and
15s after cranking
sensor filtering: 2s
Oil pressure failure is activated if: VAR[OilPressureFailure]=1,
VAR[EngineStop]=1
EN_V_007
Oil pressure sensor active (=1) when engine running
sensor filtering: 6s
impossible with On/Off control (“engine is running”
EN_V_008
“Dplus=1”)
Engine failures are activated if :
EN_V_009 [cooling temperature failure] or [oil pressure failure] or [D+
failure]

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Init
RequestHeating
BreakHeating
PreHeatin
PreheatTime_ms
BreakHeating
ReadyTo
WaitToStartAgainTime_ms
RequestStart
BreakStart
Stop | Start
TimeOutStart_ms
EngineRunning
EngineRunning
Stop Running
Conditions Kubota Mechanical

EN_V_010 RequestHeating Rising edge on start/stop switch SETPOINT[EngineStartStop]=
PreHeatingTime Function of the engine temperature PreheatTime_ms=F(CoolantTemp)
RequestStart 1 (always true) 1
EngineRunning Alternator ON (D+) DPLUS=1
Stop Rising edge on start/stop switch SETPOINT[EngineStartStop]=
or Power OFF (wake-up or | VAR[PowerOn]=0 | \EMSTOP
emergency) | T6s(DPLUS=0)
or Alternator OFF for more than 6s | VAR[CoolantTempFailure]=1
(stalling) | VAR[OilPressureFailure]=1
or Engine overheating failure active
(F09.01)
or Engine oil pressure low failure
active (F09.02)
WaitToStartAgain 1s if start has failed (break or VAR[WaitToStartAgain_ms]=1000ms
timeout)
or 3s if engine was running or
VAR[WaitToStartAgain_ms]=3000ms
BreakHeating Power OFF (wake-up or emergency) VAR[PowerOn]=0 | \EMSTOP
or Rising edge on start/stop switch | SETPOINT[EngineStartStop]=
BreakStart Power OFF (wake-up or emergency) VAR[PowerOn]=0 | \EMSTOP
or Rising edge on start/stop switch | SETPOINT[EngineStartStop]=
TimeoutStart 8s VAR[TimeOutStart_ms]=8000ms
EN_V_011 While emergency pump is running, engine starting is inhibited.

• CONDITIONS

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2.8.3.ENGINE START VERSION VARIABLE RPM
The “Engine management: TierIII variable RPM” function describes the requirements relative to
Kubota TIII engine running with variable speeds (idle speed, speed set according to movement’s
need): start sequence, stop sequence, preheating sequence, safeties.
The speed is controlled by a EGV (Electronic Governor ) Kubota module , there is no more
accelerator coil
• I/O FUNCTIONS
• REQUIREMENTS
Communication between engine ECU and SPU uses the CAN link #2 with extended
F EE_V_001
identifiers, according to the J1939 norm (extended identifiers, speed 250kbs)
Engine ECU sends data on the CAN link if it is supplied via the KA1 relay: time out is
F EE_V_002 activated on the engine speed frame to detect reception failures; the failure is timed at KA1
relay activation (2s).
The engine ECU sends periodically (1000ms) the coolant temperature to the SPU in the
F EE_V_003
standard J1939 frame “ET1”
The engine ECU sends periodically (200ms) the engine speed to the SPU in the proprietary
F EE_V_004
J1939 frame “TSCK” (
The engine ECU sends periodically (1000ms) the engine ECU battery potential to the SPU
F EE_V_005
in the standard J1939 frame “VEP”
When a failure or a warning is detected, the engine ECU sends the standard failure frame
F EE_V_006 DM1 the frame signals sensors failures (speed sensor, temperature sensor), actuator
failures, or battery over voltage: VAR[EngineStop], VAR[EngineWarning]
The SPU commands automatically preheat at engine’s start up demand, controls the
F EE_V_007
preheat time and at the end of preheat time starts automatically the engine.

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Total preheat time will be (based on data received through ET1 frame)
- 15s if temperature is lower than -10°C : VAR[CoolantTemp]<-10
- 10s if temperature is lower than 0°C : -10 ≤VAR[CoolantTemp]<0
F EE_V_008 VAR[PreheatTime_ms]=10000
- 5s if temperature is lower than +5°C : 0 ≤VAR[CoolantTemp]<+5
- no preheat if temperature is higher than 5°C : 5 ≤VAR[CoolantTemp]
The engine preheat, start and stop function happens at the specified set point (start request
or stop request) depending on the activated panel:
F EE_V_009 VAR[CmdConsole]=UCC & SB161= SETPOINT[EngineStartStop]=
VAR[CmdConsole]=LCC & SA110S= SETPOINT[EngineStartStop]=
VAR[EngineStatus]:
0 engine init (initialization, or formerly running)
1 engine preheat
2 engine ready to start
F EE_V_010 3 engine starting
4post heating : no post heating
5engine running
6engine stop: immobilizing time, no allowed restart during 3 s: the engine stop light is ON
during this time
Engine is considered as running if engine speed is higher than 800RPM
F EE_V_011 VAR[EngineSpeed]≥800RPM VAR[EngineRunning]=1
Cooling temperature failure is activated 1 if: VAR[CoolantTempFailure]=1,

VAR[EngineStop]=1
F EE_V_012 Liquid cooling sensor active ( =OFF ) when engine running and 15s after cranking
sensor filtering: 2s filtering 30s after engine start up
Oil pressure failure is activated if: VAR[OilPressureFailure]=1, VAR[EngineStop]=1
F EE_V_013 Oil pressure sensor active ( =OFF) when engine running and 15s after cranking
sensor filtering: 6s filtering
D+ failure is activated 1 if: VAR[DplusFailure]=1, VAR[EngineStop]=1
F EE_V_014 D+ input = OFF when engine running
input filtering: 2s
The starter relay KA2 is activated during a maximum of 8s: if the engine is not seen as
F EE_V_015 running, the “starting” stage ends, the new stage is “init”.

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Init
RequestHeating
BreakHeating
PreHeatin
PreheatTime_ms
BreakHeating
ReadyToS
WaitToStartAgainTime_ms
RequestStart
BreakStart
Stop | Start
TimeOutStart_ms
EngineRunning
EngineRunning
Stop
Running
Conditions Kubota Electronical
F EN_V_010 RequestHeating Rising edge on start/stop switch SETPOINT[EngineStartStop]=

PreHeatingTime Function of the engine PreheatTime_ms=F(CoolantTemp)
temperature
RequestStart 1 (always true) 1
EngineRunning Engine speed above 800RPM VAR[EngineSpeed]>800RPM
Stop Rising edge on start/stop switch SETPOINT[EngineStartStop]=
or Power OFF (wake-up or | VAR[PowerOn]=0 | \EMSTOP
emergency) | T6s(DPLUS=0)
or Alternator OFF for more than | VAR[CoolantTempFailure]=1
6s (stalling) | VAR[OilPressureFailure]=1
or Engine overheating failure
active (F09.01)
or Engine oil pressure low failure
active (F09.02)
WaitToStartAgain 1s if start has failed (break or VAR[WaitToStartAgain_ms]=1000ms
timeout)
or 3s if engine was running or VAR[WaitToStartAgain_ms]=3000ms
BreakHeating Power OFF (wake-up or VAR[PowerOn]=0 | \EMSTOP
emergency) | SETPOINT[EngineStartStop]=
or Rising edge on start/stop
switch
BreakStart Power OFF (wake-up or VAR[PowerOn]=0 | \EMSTOP
emergency) | SETPOINT[EngineStartStop]=
or Rising edge on start/stop
switch
TimeoutStart 8s VAR[TimeOutStart_ms]=8000ms
F EE_V_016 Idle speed of the engine is set to 1100RPM.
F EE_V_017 Minimum engine speed with one movement running (at least) is set to 1200RPM
F EE_V_018 Maximum speed of the engine is set to 2700RPM.

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The engine speed is set according to the controlled movement, with an offset of 5%, with a
minimum equals to 1200RPM, a maximum equals to 2400RPM (2 requested movements)
or 2700RPM (3 requested movements). :
- Drive High Speed or Drive High Speed : 2400 RPM + 5% 2400 RPM
- Drive Micro Speed : 2400 RPM + 5% 2400 RPM
- Telescope Extend : 2410 RPM + 5% 2400 RPM
- Telescoping Retract : 1600 RPM + 5% 1600 RPM + 5%
F EE_V_019 - Boom Raise : 1400 RPM + 5% 1400 RPM + 5%
- Boom Descent : 1400 RPM + 5% 1400 RPM + 5%
- Turret Rotation (Left and Right) : 490 RPM + 5% 1200 RPM + 5%
- Jib Raise : 165 RPM + 5% 1200 RPM + 5%
- Jib Descent : 130 RPM + 5% 1200 RPM + 5%
- Platform Rotation (Left or Right) : 25 RPM + 5% 1200 RPM + 5%
- Platform Level Up : 300 RPM + 5% 1200 RPM + 5%
- Platform Level Down : 225 RPM + 5% 1200 RPM + 5%
If simultaneous movements are requested, the each movement engine speeds are added
and the engine speed is set according to the result, with a minimum equals to 1200RPM
EE_V_020
(minimum speed with one movement), a maximum equals to 2400RPM (2 requested
movements) or 2700RPM (3 requested movements).
With two simultaneous movements, the engine speed is set :
- Telescoping Extend + Boom Raise : 2400 RPM + 5%: Engine Max
speed for two movements
- Telescoping Extend + Turret Rotation : 2400 RPM + 5%: Engine Max
- Telescoping Extend + Jib Lifting : 2400 RPM + 5%: Engine Max
- Telescoping Extend + Jib Lowering : 2400 RPM + 5%: Engine Max
- Telescoping Extend + Platform Rotation : 2400 RPM + 5%: Engine Max
- Telescoping Retract + Boom Descent : 2400 RPM + 5%: Engine Max
- Telescoping Retract + Turret Rotation : 2090 RPM + 5%
- Telescoping Retract + Jib Lifting : 1765 RPM + 5%
F EE_V_021 - Telescoping Retract + Jib Lowering : 1730 RPM + 5%
- Telescoping Retract + Platform Rotation : 1625 RPM + 5%
- Boom Raise + Turret Rotation : 1890 RPM + 5%
- Boom Raise + Jib Raise : 1565 RPM + 5%
- Boom Raise + Jib Descent : 1530 RPM + 5%
- Boom Raise + Platform Rotation : 1425 RPM + 5%
- Boom Descent + Turret Rotation : 1890 RPM + 5%
- Boom Descent + Jib Raise : 1565 RPM + 5%
- Boom Descent + Jib Descent : 1530 RPM + 5%
- Boom Descent + Platform Rotation : 1425 RPM + 5%
- Turret Rotation + Jib Raise : 1200 RPM + 5% Engine min speed when
movements running
- Turret Rotation + Jib Descent : 1200 RPM + 5% Engine min speed when
movements running
- Turret Rotation + Platform Rotation : 1200 RPM + 5% Engine min speed when
movements running

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With three simultaneous movements, the engine speed is set :
- Telescoping Extend + Boom Raise + Turret Rotation :
2700 RPM: Engine Max speed for three movements
- Telescoping Extend + Boom Raise + Jib Raise
: 2700 RPM: Engine Max speed for three movements
- Telescoping Extend + Boom Raise + Jib Descent :
- Telescoping Extend + Boom Raise + Platform Rotation
- Telescoping Retract + Boom Descent + Turret Rotation
F EE_V_022 - Telescoping Retract + Boom Descent + Jib Raise
- Telescoping Retract + Boom Descent + Jib Descent :
- Telescoping Retract + Boom Descent + Platform Rotation
- Boom Raise + Turret Rotation + Jib Raise : 2055 RPM
- Boom Raise + Turret Rotation + Jib Descent : 2020 RPM
- Boom Raise + Turret Rotation + Platform Rotation : 1915 RPM
- Boom Descent + Turret Rotation + Jib Raise : 2055 RPM
- Boom Descent + Turret Rotation + Jib Descent : 2020 RPM
- Boom Descent + Turret Rotation + Platform Rotation : 1915 RPM
F EE_V_023 With generator running, the engine speed is set to 2400RPM.
• CONDITIONS

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2.8.4.BRAKE RELEASE
The “Brake releasing” function defines the requirements relative to the brake releasing : activation
and inhibition of brake in case of driving or steering, depending on the machine state and position.
• I/O FUNCTIONS
2.8.5. DRIVE
The “Drive” function describes the requirements relative to the drive movement in terms of speed
selection, validation of the drive conditions. This movement is available only from upper controls.
• I/O FUNCTIONS

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• CONDITIONS
Following conditions inhibit the drive movements (F & R: Forward and Reverse):
Cut Off F&R Cut Off Condition

General 1 Generator is running CONTROL[Generator]=1
Simultaneous 1 Requirements
Movements VAR[AuthorizedMvt]=0
Overload 1 Overload alarm active VAR[Overload]=1

1 Underload alarm active with machine VAR[Underload]=1 &
not in P1 position VAR[MachinePosition]≠P1
Tilt 1 For STD or AUS countries or for USA VAR[Tilt]=1 &
country version with “Prohib In Tilt” VAR[MachinePosition]≠P1 &
option activated, drive is inhibited (OPT[Country]=STD |
when machine is unfolded and tilt OPT[Country]=AUS |
active OPT[ProhibInTilt]=Active)
Reach limit
Failure 1 Failure F02.04 active F02.04(A)
1 Failure F10.01 active F10.01(A)
1 Failure F10.02 detected when F10.02(D) &
machine is unfolded VAR[MachinePosition]≠P1
1 Failure F06.01 active and machine F06.01(A) &
1 Failure F12.01 is active F12.01(A)
Specific 1 Micro speed applied and engine VAR[DriveSpeed]=micro &
speed greater than 2450RPM VAR[EngineSpeed]>2450RPM
1 : this condition inhibits the movement
The micro speed (speed of drive out of P1 position) is a slow down of low speed drive: limitation of the control
current done with the “µS Drive Fwd” and “µS Drive Rev” sets.
With “Prohib Unfolded Drv” Option activated, drive function is allowed with machine position P1 only: other
position inhibits the drive function (no micro speed).

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• REQUIREMENTS
The drive speed is controlled by the “Drive Speed” set point coming from the upper command
console :
VAR[CmdConsole]=(UCC) SETPOINT[DriveSpeedSelection]=0|1
F DS_V_001
SETPOINT[DriveSpeedSelection]=0 means low speed selection.
SETPOINT[DriveSpeedSelection]=1 means high speed selection.
Micro speed selection is forced if machine is detected out of P1 zone (including error cases):
F DS_V_002 VAR[MachinePosition]≠P1 | FO7.04(D)=1 | FO7.11(D)=1 | FO7.17(D)=1
CONTROL[DriveSpeed] =Micro
In P1 machine position, shifting from low speed to high speed is applied statically or
dynamically with speed selector on high speed selection and steering mode not on
synchronized since the beginning of the drive movement :
F DS_V_003 SETPOINT[SteeringMode]=S VAR[HighSpeedInhib]=1
CONTROL[Drive]=N:0 VAR[HighSpeedInhib]=0
SETPOINT[DriveSpeedSelection]=1 & SETPOINT[SteeringMode]≠S &
VAR[HighSpeedInhib]=0 CONTROL[DriveSpeed] =High
In P1 machine position, shifting from high speed to low speed is statically or dynamically with
speed selector out of high speed selection or steering mode on synchronized mode :
F DS_V_004
SETPOINT[DriveSpeedSelection]=0 | SETPOINT[SteeringMode]= S
CONTROL[DriveSpeed]=Low
Due to the shifting from 4WS synchronized mode to 4WS crab mode or 2WS mode while
driving, the shifting from low speed to high speed is considered when no drive movement is
F DS_V_007 running:
SETPOINT[DriveSpeedSelection]=1 & VAR[HighSpeedInhib]=1 & CONTROL[Drive]≠N:0
CONTROL[DriveSpeed]=Low
While driving in low speed, for USA and AUS versions, leaving the P1 zone causes the
F DS_V_005 shifting from low speed to micro speed without drive stopping, and without stopping the
movement causing the leave of P1 zone.
While driving in low speed, for STD versions, leaving the P1 zone causes the shifting from low
F DS_V_006 speed to micro speed without drive stopping (the lifiting movement causing the leave of P1
zone is stopped).
2.8.6.OSCILLATING AXLE
The “Oscillating axle” function defines the requirements relative to the release the oscillating axle:
activation and inhibition of the oscillating axle electro valve depending on machine position.
• I/O FUNCTIONS

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2.8.7.TILT FUNCTION
The function “Tilt” defines the requirements for setting tilt alarm and flag for other functions
• I/O FUNCTIONS
The tilt sensor give an information for a excessive machine tilt position
F TT_*_001 • SQ142 = 0: excessive tilt position or unwired tilt sensor
• SQ142 = 1: allowed tilt position
The excessive tilt position is considered to inhibit movements for STD and AUS versions and for
F TT_*_002 USA version when “Prohib In Tilt” option is active: see each movement section for movements’
cuttings.
Note : the option “Prohib in Tilt” must be validated in order to cut movements when machine is tilted
Refre Menu
2.8.8.STEERING
The “wheels steering” function defines the requirements relative to the steering movement:
basically, steering wheels are the front wheels.
Optionally, machines are equipped with 4 wheels steering system which enables the following
functions:
2WS : front wheels steering
Synchro : front and back axles steering in opposite directions
Crab : front and back axles steering in same direction
• I/O FUNCTIONS

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• CONDITIONS
Following conditions inhibit the steering movements (Left and Right):
Cut Off L&R Cut Off Condition

Simultaneous 1 Requirement SM_*_001
VAR[AuthorizedMvt]=0
Movements
Overload 1 Overload alarm active VAR[Overload]=1
1 Underload alarm active and machine VAR[Underload]=1 &
out of P1 position VAR[MachinePosition]≠P1
Tilt 1 For STD and AUS version, and for USA VAR[Tilt]=1 &
version with “Prohib In Tilt” option VAR[MachinePosition]≠P1 &
activated, drive is inhibited when (OPT[Country]=STD |
machine is unfolded and tilt activated OPT[Country]=AUS |
OPT[ProhibInTilt]=Active)
Reach limit
1 Failure F06.01 active and machine not F06.01(A) &
in P1 position and overriding console is VAR[CmdConsole]≠OCC &
not active VAR[MachinePosition]≠P1
Specific
• 1 : this condition inhibits the movement
There is not limitation of drive movement set point.

With “Prohib Unfolded Drv” Option activated, steering function is allowed with machine position P1 only: other
position inhibits the steering function.

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2.8.9.LOAD SELECTION/MEASUREMENT
The function “Load selection” defines the selecting for the load to be applied at current time
depending on machine configuration.
The function “Load measurement” defines the requirements to measure the load in the basket.
• I/O FUNCTIONS
Version Std and Australia
The value of SA146 switch (used to select the current load) is considered from lower and
F LS_CE_001
upper command console.
The SA146 switch is a permanent two positions switch, the load selector value is considered
when all movements are stopped (including drive and steering). Its value is 0 if SA146 is on
F LS_CE_002 1000lb/450kg position, 1 if SA146 is on 500lb/230kg position.
SA146=0 VAR[CurLoadSelector]=1000lb
SA146=1 VAR[CurLoadSelector]=500lb
Once at machine’s power off, the current applied load is saved to EEPROM:
F LS_CE_003
VAR[PowerOn]= VAR[EepAppliedLoad]=VAR[EepAppliedLoad]
Once at machine’s power on, the applied load at previous machine’s power off is reloaded
F LS_CE_004 from EEPROM:
VAR[PowerOn]= VAR[AppliedLoad]=VAR[EepAppliedLoad]
From P1 position to P4 position, to change the applied load from which the overload threshold
is computed, the load selector value is considered when all movements are stopped (including
drive and steering):
F LS_CE_005 VAR[MachinePosition]=P1..P4 & VAR[CurLoadSelector]=1000lb & VAR[MvtRunning]=0 &
VAR[DriveRunning]=0 VAR[AppliedLoad]=1000lb
VAR[MachinePosition]=P1..P4 & VAR[CurLoadSelector]=500lb & VAR[MvtRunning]=0 &
VAR[DriveRunning]=0 VAR[AppliedLoad]=500lb
In P5 position, when current applied load is 1000lb (typical case: coming from P4 position with
boom lowering movement or from P2 position with boom telescoping out movement), the
F LS_CE_006 applied load can be changed to 500lb.
VAR[MachinePosition]=P5 & VAR[AppliedLoad]=1000lb & VAR[CurLoadSelector]=500lb &
VAR[MvtRunning]=0 & VAR[DriveRunning]=0 VAR[AppliedLoad]=500lb

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In P5 position, when current applied load is 500lb and overload is inactive, the applied load
is automatically changed to 500lb_P5:
F LS_CE_007 VAR[MachinePosition]=P5 & VAR[AppliedLoad]=500lb & VAR[Overload]=0
VAR[AppliedLoad]=500lb_P5
In P5 position, when current applied load is 500lb, the applied load can be changed to
1000lb (typical case: previously not in P5 position with 1000lb selected, next in P5 position,
stopped by reach limitation, load selection to 500lb and overload activated, operator should
F LS_CE_008 select again its previous 1000lb load to move the machine out of P5 position):
VAR[MachinePosition]=P5 & VAR[AppliedLoad]=500lb & VAR[CurLoadSelector]=1000lb
VAR[AppliedLoad]=1000lb
In P5 position, when applied load is 500lb_P5, the load selector is not considered:
VAR[MachinePosition]=P5 & VAR[AppliedLoad]=500lb_P5 &
F LS_CE_009
VAR[CurLoadSelector]=500lb|1000lb VAR[AppliedLoad]=500lb_P5
In case of position error, the load selector value is not considered (no change of applied
load):
VAR[MachinePosition]>P5 & VAR[AppliedLoad]=500lb_P5
F LS_CE_010 VAR[AppliedLoad]=500lb_P5
VAR[MachinePosition]>P5 & VAR[AppliedLoad]=500lb VAR[AppliedLoad]=500lb
VAR[MachinePosition]>P5 & VAR[AppliedLoad]=1000lb VAR[AppliedLoad]=1000lb
The operator is warned about the current load selection via the LED devices (upper
F LS_CE_011 command control):
Overload function is available in Europe or Australia countries version or in USA country
version with activation of weighing system option: it is based on strain gauges system
LM_*_001
providing a 4mA..20mA signals depending linearly on the load.
Each strain gauge measures a load between 0kg (4mA) and 1000kg (20mA).
The system manages 2 different load 500lb (230kg) and 1000lb (450 kg) to produce
LM_*_002
overload alarm flag.
The overload threshold for 240kg load (500lb) is 250kg(550lb) (normal load + 10%), if the
computed load overruns the overload threshold during 1 second, the overload alarm is
LM_*_003
activated :
VAR[AppliedLoad]=230kg & 1s(VAR[WeightValue_kg]>250kg) VAR[Overload]=1
The overload threshold for 450kg load (1000lb) is 495kg (1100lb) (normal load + 10%), if
the computed load overruns the overload threshold during 1 second, the overload alarm is
LM_*_004
activated :

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For ANSI/CSA
From lower command console, the applied load is always 1000lb
LS_ANSI_001 (SA146 switch state is not considered)
VAR[CmdConsole]=UCC|OCC VAR[AppliedLoad]=1000lb
At power on, the applied load is by default 1000lb (whichever the command console may be):
LS_ANSI_002
VAR[PowerOn]= VAR[AppliedLoad]=1000lb
The 500lb selection is considered only in case of reached limit (P5 zone): while machine is
stopped due to reach of limit, the operator gives a pulse on the load selector to validate the
500lb selection.
When the machine goes of the P5 zone, the load selection goes back automatically to 1000lb
selection
0 VAR[AppliedLoad]=10
VAR[MachinePosition]=
LS_ANSI_003
VAR [MachinePosition] 1 Light (reach limitation)
VAR[CurLoadSelector]=
3 VAR[AppliedLoad]=500lb_
Remark: The hour and date of rising edge on load selector switch is EEPROM saved at P5
position passing. The last date is readable via the diagnostic tool in the EVENT LOG menu
Overload function is available in Europe or Australia countries version or in USA country
version with activation of weighing system option: it is based on strain gauges system
F LM_*_001
providing a 4mA..20mA signals depending linearly on the load. Each strain gauge measures
a load between 0kg (4mA) and 1000kg (20mA).
The system manages 2 different load 500lb (230kg) and 1000lb (450 kg) to produce overload
F LM_*_002
alarm flag.
The overload threshold for 240kg load (500lb) is 250kg(550lb) (normal load + 10%), if the
F LM_*_003
activated :
The overload threshold for 450kg load (1000lb) is 495kg (1100lb) (normal load + 10%), if the
F LM_*_004
activated :

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2.8.10. ALL MOVEMENTS
The function “LS Valve” defines the requirements regarding the control of the LS valve:
The Load Sensing valve provides hydraulic pressure to the system in order to enable every
movement.
• I/O FUNCTIONS
2.8.11. BOOM
The “Boom Lifting” function describes the requirements relative to boom lifting to enable upwards or
downwards boom movements.
• I/O FUNCTIONS

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• CONDITIONS
Following conditions
inhibit the boom raise movement (U:Up) and/or boom descent movement (D:down):
Cut Off U D Cut Off Condition
General 1 1 Generator is running CONTROL[Generator]=1
Simultaneous 1 1 Requirement
Movements
Overload 1 Overload alarm active and overriding VAR[Overload]=1 &
console is not active VAR[CmdConsole]≠OCC
1 Overload alarm active and (overriding VAR[Overload]=1 &
console is not active or machine in P5 (VAR[CmdConsole]≠OCC |
position) VAR[MachinePosition]=P5)
1 From upper command console, VAR[Underload]=1 &
underload alarm active VAR[CmdConsole]=UCC
Tilt 1 1 Tilt is detected and machine position is VAR[Tilt]=1 &
P4 or P5 according to “Prohib In Tilt” VAR[MachinePosition]=P4|P5 &
option OPT[ProhibInTilt]=Active
1 1 Tilt is detected and error is detected on VAR[Tilt]=1 &
LoweringKO
telescope’s length (less than 10s VAR[MachinePosition]=P &
telescope in movement), according to OPT[ProhibInTilt]=Active
“Prohib In Tilt” option
Reach limit 1 Machine in P5 position and 1000lb load VAR[MachinePosition]=P5 &
selection VAR[AppliedLoad]=1000lb
Failure 1 1 Failure F02.04 active F02.04(A)
1 1 Failure F04.05 active and emergency F04.05(A) & CTRL[EmergencyPump]=0
pump not running
pump not running
1 1 Failure F12.01 active with active code 1 F12.01(A,IC=1)
(CAN failure with turret slave node)
1 Failure F04.34 active with active codes F04.34(A,IC=3) &
1 and 2 and machine not in P1 position VAR[MachinePosition]≠P1
1 Failure F06.01 active and machine not F06.01(A) & VAR[CmdConsole]≠OCC &
in P1 position and overriding console is VAR[MachinePosition]≠P1
not active
not active
not active
not active
in P1, P2 or P3 position and overriding VAR[MachinePosition]>P3
console is not active

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1 Under conditions Failure F07.04 active See §26 Machine Position
Specific 1 Estimated weight is under -40kg and (VAR[WeightValue_SP480_kg]<-40kg |
upper panel is activated (to prevent VAR[WeightValue_SP481_kg]<-40kg)
damages on basket) & VAR[CmdConsole]=UCC
Empty : this condition does not inhibit the movement
Following conditions limits the set point of boom lifting up movement and/or boom lowering
movement (100%=full speed movement)
Direction Value Slow Down Condition

Down | Up 60 Machine position is failing VAR[MachinePosition]>P5
Down | Up 60 Command console is overriding VAR[CmdConsole]=OCC
command console
Down | Up 60 Tilt is active VAR[Tilt]=1
Down | Up 60 Failure F06.01 is active F06.01(A)
Down 60 Boom lowering movement is CTRL[BoomLifting]=D &
running and applied load is 1000lb VAR[AppliedLoad]=1000lb &
and machine position is P4 and VAR[MachinePosition]=P4 &
boom limit is reached VAR[AngleReachLimit]=1
Up 75 Boom lifting is running with CTRL[BoomLifting]=U &
machine’s position P4 or P5 VAR[MachinePosition]=P4|P5
Down 60 Boom lowering is running with CTRL[BoomLifting]=D &
machine’s position P4 or P5 VAR[MachinePosition]=P4|P5
Down | Up 80 Command console is lower VAR[CmdConsole]=LCC
command console
In case several slowdown conditions are active, the lowest value is applied limits.
With emergency pump running, all slow down values are reset to value “100” (no slow
down).

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2.8.12. TELESCOPIC BOOM
The “Boom Telescoping” function describes the requirements relative to boom telescoping to
enable retraction/extension telescopic movements.
• I/O FUNCTIONS
The boom telescoping function is enabled while engine is running or while emergency pump
is activated, and when the maintenance tool “Safety valves ON” is inactive

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CONDITIONS
Following conditions
inhibit the boom extension movement (O: out) and/or boom retraction movement (I: in):
Cut Off O I Cut Off Condition
Simultaneous 1 1 Requirements
Movements
Overload 1 1 Overload alarm active and overriding VAR[Overload]= 1 &
1 1 From upper command console, out of VAR[Underload]=1 &
P1 position, underload alarm active VAR[CmdConsole]=UCC &
and overriding console is not active VAR[MachinePosition]≠P1
1 Overload alarm active machine in P5 VAR[Overload]= 1 &
position VAR[MachinePosition]=P5
Tilt 1 Tilt is detected and machine is out of VAR[Tilt]=1 &
position P1, according to “Prohib In VAR[MachinePosition]≠P1 &
Tilt” option OPT[ProhibInTilt]=Active
Reach limit 1 Machine in P5 position and 1000lb VAR[MachinePosition]=P5 &
load selection VAR[AppliedLoad]=1000lb
Failure 1 1 Failure F02.04 active F02.04(A)
1 1 Failure F04.06 active and emergency F04.06(A) &
pump not running CTRL[EmergencyPump]=0
1 1 Failure F12.01 active with active code F12.01(A,IC=1)
1 (CAN failure with turret slave node)
1 Failure F04.34 active with active F04.34(A,IC=3) &
codes 1 and 2 (the two valves are VAR[MachinePosition]≠P1
failing) and machine not in P1 position
1 Failure F06.01 active and machine not F06.01(A) & VAR[CmdConsole]≠OCC
in P1 position and overriding console & VAR[MachinePosition]≠P1
is not active
is not active
is not active
is not active
1 Under conditions Failure F07.04 active See Machine Position
Specific cut

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Following conditions limits the set point of boom telescoping out movement and/or boom
telescoping in movement (100%=full speed movement)

Out | In 80 Command console is overriding VAR[CmdConsole]=OCC
command console
Out | In 80 Tilt is active VAR[Tilt]=1
Out | In 80 Failure F06.01 is active F06.01(A)
Out 55 Lifting up and turret rotation are VAR[BoomLifting]=U &
running simultaneously with VAR[TurretRotation]≠N
telescoping out
In 70 Boom lowering is running VAR[BoomLifting]=D
simultaneously with telescoping in
In 80 Machine position is failing VAR[MachinePosition]>P5
Out | In 80 Command console is lower VAR[CmdConsole]=LCC
command console
Out 80 Lifting up is running simultaneously VAR[BoomLifting]=U
with telescoping out
In case several slowdown conditions are active, the lowest value is applied at the limit.
With emergency pump running, all slow down values are reset to value “100” (no slow down).
No need to detect neutral set point position to reset the slow down due to simultaneous
movements

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2.8.13. TURRET ROTATION
The “Turret Rotation” function describes the requirements relative to turret rotation to enable left or
right turret orientation.
• I/O CONDITIONS
• CONDITIONS
Following conditions inhibit the turret rotation movements (L& R : Left and Right):
Simultaneous 1 Requirement
Movements
Overload 1 Overload alarm active and VAR[Overload]= 1&
overriding console is not active VAR[CmdConsole]≠OCC
out of P1 position, underload VAR[CmdConsole]=UCC &
alarm active and overriding VAR[MachinePosition]≠P1
Tilt
Reach limit
1 Failure F04.03 active and F04.03(A) &
emergency pump not running CTRL[EmergencyPump]=0
1 Failure F04.11 active and F04.11(A) &
emergency pump not running CTRL[EmergencyPump]=0
1 Failure F12.01 active with active F12.01(A,IC=1)
code 1 (CAN failure with turret
slave node)
Specific

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Following conditions limits the set point of turret rotation movement (100%=full speed movement)

Left | Right 60 Machine position is failing VAR[MachinePosition]>P5
Left | Right 60 Command console is overriding VAR[CmdConsole]=OCC
command console
Left | Right 60 Tilt is active while machine is VAR[Tilt]=1 &
unfolded VAR[MachinePosition]≠P1
Left | Right 60 Calibration not done: failure F06.01(A)
F06.01
Left | Right 60 Gauges out of range: failure F06.03(A)
F06.03
Left | Right 60 Incoherent gauges F06.04(A)
Left | Right 60 Gauges low power F06.05(A)
Left | Right 60 Failure F04.34 is active F04.34(A)
Left | Right 80 Command console is lower VAR[CmdConsole]=LCC
command console
Left | Right 70 Boom telescoping out and boom CTRL[BoomTelescoping]=O &
lifting up are running CTRL[BoomLifting]=U
simultaneously with turret rotation
(slow down forced until neutral
detection of orientation movement
set point), mechanical engine
• Boom lifting safety valves can be activated during factory’s tests using the diagnostic tool
“SafetyValvesON” (see also requirement BL_V_102, BT_V_102):
MAINT[SafetyValvesON]=1 YV880=1, LSD1.x=1
• Boom lifting safety valves can be inactivated during factory’s tests using the diagnostic tool
“SafetyValvesOFF” (see also requirement BL_V_103, BT_V_103):
MAINT[SafetyValvesOFF]=1 YV880=0

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2.8.14. JIB
The “Jib Lifting” function describes the requirements relative to jib lifting to enable up/down jib
movements.
Please note that this section is useful only for HT23RTJ(HT67RTJ) machines
Remark: the ON/OFF valves driving the jib lifting movement (YV500/YV510) are physically
connected to the slave node B2 present in the upper panel box.
• I/O FUNCTIONS

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• CONDITIONS
Following conditions inhibits the jib raise movement (U: up) and/or jib descent movement (D: down):

1 1 Machine version is not HT67 OPT[Model Version]≠HT67
Movements
Overload cut 1 1 Overload alarm active and overriding VAR[Overload]=1 &
underload alarm active VAR[CmdConsole]=UCC
Tilt cut
Reach limit cut
Failure cut 1 1 Failure F02.04 active F02.04(A)
pump not running
pump not running
1 1 Failure F12.01 active F12.01(A)
Specific cut 1 Estimated weight is under -40kg and (VAR[WeightValue_SP480_kg]<-40kg |
upper panel is activated (to prevent VAR[WeightValue_SP481_kg]<-40kg)
damages on basket) & VAR[CmdConsole]=UCC
Following conditions limits the set point of jib lifting movement and/or jib lowering movement
(100%=full speed movement)

Up | Down 60 Command console is overriding VAR[CmdConsole]=OCC
command console
Up | Down 60 Tilt is active while machine is VAR[Tilt]=1 &
Up | Down 60 Failure F06.01 is active F06.01(A)
Up | Down 80 Command console is lower VAR[CmdConsole]=LCC
command console
With emergency pump running, all slow down values are reset to value “100” (no slow
down).

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2.8.15. BASKET ROTATION
The “Basket Rotation” function describes the requirements relative to the rotation of basket in terms
of validation, slowdowns and actuators.
This movement is available only from upper controls.
Remark: the ON/OFF valves driving the platform rotation movement (YV440/YV460) are physically
connected to the slave node B2 present in the upper control box.
• I/O FUNCTIONS
• CONDITIONS
Following conditions inhibit the platform rotation movements (L & R: Left and Right):

Simultaneous 1 Requirement
Movements
Overload 1 Overload alarm active VAR[Overload]= 1
1 From upper command console, out of VAR[Underload]=1 &
P1 position, underload alarm active VAR[MachinePosition]≠P1
Tilt
Reach limit
1 Failure F04.08 active and emergency F04.08(A) &
1 Failure F04.11 active and emergency F04.11(A) &
Specific

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Following conditions limits the set point of platform rotation movement (100%=full speed movement)

Left | Right 60 Tilt is active while machine is VAR[Tilt]=1 &
In case several slowdown conditions are active, the lowest value is applied limits. With
emergency pump running, all slow down values are reset to value “100” (no slow down).
2.8.16. BASKET COMPENSATION

The “Compensation” function describes the requirements relative to the compensation of basket in
terms of validation, slowdowns and actuators.
Remark: the ON/OFF valves driving the basket compensation movement (YV421/YV401) are
physically connected to the slave node B2 present in the upper control box.
• I/O FUNCTIONS

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• CONDITIONS
Following conditions inhibit the platform level raise movement (U: up) and/or the platform level
descent movement (D: down):

1 With upper command console VAR[CmdConsole]=UCC &
activated, positive basket tilt (+10°) is SR400=ON
reached
1 With upper command console VAR[CmdConsole]=UCC &
activated, negative basket tilt (-10°) is SR420=ON
reached
Movements
Overload 1 1 Overload alarm active and overriding VAR[Overload]= 1 &
1 1 Underload alarm active with upper VAR[Underload]=1 &
command console activated, and VAR[CmdConsole]=UCC &
machine not in P1 position VAR[MachinePosition]≠P1
Tilt cut
Reach limit cut
Failure cut 1 1 Failure F02.04 active F02.04(A)
1 1 Failure F07.15 is active F07.15(A)
1 1 Failure F12.01 active F12.01(A)
Specific cut

Following conditions limits the set point of jib lifting movement and/or jib lowering movement
(100%=full speed movement)

Up | Down 60 Command console is overriding VAR[CmdConsole]=OCC
command console
Up | Down 60 Tilt is active while machine is VAR[Tilt]=1 &
No movement’s slow down from lower command console.

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2.8.17. EMERGENCY MODE
The “Emergency Pump” function defines the requirements relative to the emergency pump start and
stop.
• I/O FUNCTIONS
• REQUIREMENTS
From lower command console and overriding command console, the emergency pump function is
EP_V_001
inactive while engine is running.
From lower command console, the emergency pump switch is served as an enable switch (the 8s
EP_V_002
safety timer is activated).
EP_V_003 From upper command console, the emergency pump function is inactive while engine is running
2.8.18. GENERATOR OPTION
The “Generator” function defines the requirements relative to the movements .
• I/O FUNCTIONS
From upper command console, the generator is activated if no movement or drive is running and if
GEN_V_001 engine is running and if generator relay is not failing (the 200ms time out is used to check the
generator relay is OK) :

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3. THE HYDRAULIC PART
3.1. SYMBOLS USED
Pump with variable flow

(here maximum 38 cc/rpm)
Pump with fixed cubic capacity flow

(here 23 cc/rpm)
Pump with variable flow (used for the hydrostatic

transmission in closed circuits on HAULOTTE big
booms like HT23RTJ,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)

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check valve
check calibrated valve
Priority valve /shuttle valve
piloted check valve
Circuit selector switch/shuttle valve
Position hydraulic valve

(used on HA32PX/HA41PX)
Adjustable pressure relief valve

(here set at 145 bars/2104 psi)
Fixed flow restrictor or spray nozzle

(here diameter of 0.75 mm)

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Adjustable flow restrictor
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 pilot 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°)

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Piloted valve
Manual valve with automatic return (used to

readjust the part of compensation on HA32/41PX)
proportional valve 4 ways/3 positions
Pressure balance/flow control valve
Flow regulator

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3.2. THE HYDRAULIC SCHEMATICS
See at the of this manual
3.3. MAIN HYDRAULIC MANIFOLDS

All blocks are in the turret part (no electrical valves in chassis)
Safety valves block
Steering valves block (2WS)
Drive valves block
PVG valves block

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3.3.1. DRIVE BLOCK
YV780
YV782
YV686
YV781 SP692
• Détail of the block
Valves Function
YV686 High speed drive
YV780 Brake release
YV781 Oscillating axle unlocking
YV782 Oscillating axle unlocking
SP692 Pressure switch (high speed drive cut if YV686 spool
remains stuck with machine in elevated mode)

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• Detail drive block in chassis
Distribuitor Function
FD1 to FD3 Flow dividers for divide the oil fow on driving motors
BV1 Valve for unlocking oscillating axle
PD1 and PD2 Valve for locking oscillating axle
CV1 to CV6 Calibrated check valves
ORF1 to ORF3 Flow restrictor

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FD2 FD1 ORF3 FD3
PD1
CV1
CV6
BV1
PD2
CV2 CV4

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FD1 FD3 ORF1
FD3
ORF2
PD1
CV3 CV5
3.3.2.STEERING BLOCK
• 4WS (4 Wheels steering) model
YV601/YV602 YV621/YV622
YV622 YV621
YV602 YV601

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• 2WS (4 Wheels steering) model
YV602 YV601
VALVE FUNCTION
YV601 Front Left steering
YV602 Front right steering
YV621 Crab mode (option 4WS)
YV622 Synchro mode (option 4WS)

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3.3.3.BLOCK ON/OFF
• HT21RT/HT61RT model
YV440
YV460
YV421
YV401

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• HT23RTJ/HT67RTJ model
YV510
YV460
YV421
YV440
YV401
YV500
CB1
CB2
VALVE FUNCTION
YV401 Basket compensation descent
YV421 Basket compensation lifting
YV440 Basket rotation left
YV460 Basket rotation right
YV500 Jib lifting (only HT23RTJ/HT67RTJ)
YV510 Jib descent (only HT23RTJ/HT67RTJ)
CB1 – CB2 Counterbalance valves 210b/3045psi

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3.3.4. PROPORTIONAL BLOCK PVG
YV101
Y Y Y Y
V V V V
3 3 1 8
8 8 0 8
1 2 2 0
Y
V
1
0
1
VALVE DESCRIPTION
YV101 By-pass valve (Load Sensing)
YV102 Steering + ON/OFF movements (jib-basket)
YV381 Boom lifting
YV382 Telescopic boom extension
YV880 Turret rotation

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3.3.5.SAFETY VALVES
• Turret rotation
YV890
• Boom and telescopic boom
YV391
YV392
YV390
• Drive valves (FWD/REV)
YV620
YV600

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3.3.6.THE HYDRAULIC PUMPS
There is 3 pumps coupled at the exit of the main engine
1. 1 hydrostatic pump with cancellation of flow used for FWD/REV drive (around
350b/5000psi
2. 1 charge pump used for brake/oscillating circuits (around 25b/362psi)
3. 1 equipement variable cubic capacity pump used for all movements (around
240b/3400psi)
350b High Pressure valves
2 3
YV600 FWD drive valve
Port plug for pressure adj (minimess)
350b High Pressure valve YV620 REV drive valve
3.4. HELP GUIDE FOR HYDRAULIC LEAKS

The next diagram will help the technician to search for hydraulic leaks on hoses
In order to detect the leak, it’s necessary to activate the command at full stroke

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CHASSIS 4WS

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CHASSIS 2WS

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TURRET

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4. ADJUSTMENTS
4.1. ADJUSTMENTS USING THE CONSOLES
The adjustments, parameters setting and list of alarms of the machine are accessible with 2 kinds of
console.
Note : in order to connect the OPTIMIZER console a special adapter is required
(either on lower or upper control box) ,
(part number 4000001090)
• Connection console OPTIMIZER on panels (turret/basket)
connect the adapter to the plug socket located at the right side of the lower controls or in front of the
upper controls (as shown below) then the console through AMP connector

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• Connection console DIAG PADon panels (turret/basket)
The 2nd type of console called DIAG PAD could work in WIFI using a VCI device as shown below :
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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• Description of the OPTIMIZER 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 the main menu
Parameters setting access
List of Failures
Access code level >1
Adjustment /calibration
Trouble shooting guide per

function
Input/output state access
Machines status

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• Access to the code level 2
Validation by the key: , then enter the code
Navigation by this key to 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)

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4.1.1.FAILURES MENU
• How to get acces to the menus
1. FAILURES
1.1 DETECTED FAILS

Detected: xx / 53
Active: xx / 53
1.2 ALL FAILS

Detected: xx / 53
Active: xx / 53
1.3 FAILURES LOG
[+] & [–] to erase all failures (access level 2 or 3): [DETECTED FAILS] ou [ALL FAILS]
[+] et [–] to erase failure log (access level 2 or 3): menu [FAILURE LOGS]
[*] to acknowledge the current failure (access level 2 or 3)
<cat> : failure category
<num> : failure identification
<status> : NO FAILURE
(A) ACTIVE (currently active failure) |
(D) DETECTED (active once and no more activated)
<code> : internal failure code providing information about the cause (case: several conditions to
activate the failure)
Times : occurrence counter since last reset
<nbr> : failures total number
Note :
• For any failure code type A (ACTIVE), it will appear on display in lower control and the warning
light will flicker on upper controls(see photos below)
In order to reset the current failure, it will be necessary to check the faulty component
• For any failure code type D (DETECTED), it will also appear on display in lower control and the
warning light will flicker on upper controls.
In order to reset the failure which has been detected and no more active, it will be necessary to fold the
machine until full stowed position, then switch OFF then ON again the main power

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MENU DESCRIPTION LEVEL
1.1 DETECTED FAILS Counters and state of detected and active failures 2*
F<cat>.<num> F<cat>.<num> : <status> <code>
<description>
<detail>
Times: xxxxx <index>/<nbr>
1.2 ALL FAILS Counters and state of all failures (56 in total) 2*
F03: RELAY
F04: ELECTRO-VALVES
F05: JOYSTICKS
F07: SENSORS
F08: ELECTRIC CIRC.
F09: ENGINE
F10: FUNCTIONS
F11: SECURITIES
F12: INTERNAL FAULTS
F13: SWITCHES
1.3 FAILURE LOGS Last failures detected log 3*
F<cat>.<num>.<code>
* Note: when the menu is accessible with level 3, it will not appear if the console is in level 2
(example menu 1.3 FAILURE LOGS which is accessible only with daily code)
• LIST OF FAILURES BY FUNCTION
FAILURES CODE DESCRIPTION

F02 : CONTACTOR
F02.02 (D) Safety pump relay failure while safety pump on (open circuit or short circuit)
Emergency Pump KM120
Chk KM120 Check relay, Check connection to ground, connection to U100 ECU.
Check connections on PCB.
F02.04 (D) Incoherence between the emergency stopper status and the presence of
Power Contactor voltage on power line
Chk KMP EMSTOP=0 & (VC>5V | VD>5V)
Check emergency stoppers, KMP relay, check fuses, wiring.
F02.05 (D) Preheating relay Failure (open circuit or short circuit)
Heating Relay KM160
Chk KM160 Check relay, Check connection to ground, connection to U100 ECU.
F03 : RELAY
F03.06 (D) Horn relay Failure (open circuit or short circuit)
Horn Relay KA9
Chk KA9 Check relay, Check connection to ground, connection to U100 ECU

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F03.08 (D) Start relay Failure (open circuit or short circuit)
Start Relay KA2
Chk KA2 Check relay, Check connection to ground, connection to U100 ECU
F03.09 (D) Engine supply relay Failure (open circuit or short circuit)
Supply/KeySwitch KA1
Rel Check relay, Check connection to ground, connection to U100 ECU
Chk KA1 Check connections on PCB.
F03.10 (D) Accelerator pull relay / accelerator hold output Failure (open circuit or short
Accelerator Relay circuit)
Check KA5 001 KA5
002 AccHold
Check relay and output, Check connection to ground, connection to U100 ECU
F03.11 (D) Generator relay Failure while generator on (open circuit or short circuit)
Generator Relay KA4
Chk KA4 Check relay, connection to ground and to U100 ECU.
F04 : ELECTRO-VALVES
F04.01 (D) Steering valves failure (steering mode function failures handled by F04.33)
Steering 001 YV102: steering proportional electro valve failure while steering (open circuit
Chk YV102/601/602 or short circuit on YV102)
002 YV602: steering on/off electro valve failure (open circuit or short circuit)
004 YV601: steering on/off electro valve failure (open circuit or short circuit)
YV102 : Check connection to ground (pin3), check connection to 12V supply
(YV102_S/pin2), check connection to U100 ECU analogue output (pin1)
YV602/YV601: check connection to ground, connection to U100 ECU
Note that YV102_S output is always seen as “Failure”, do not consider this
information.
F04.02 (D) Basket compensation valves failure
Compensation 001 YV102: compensation proportional electro valve failure while basket rotation
Chk movement (open circuit or short circuit on YV102)
YV102/401/YV421 002 YV401: compensation on/off electro valve failure (open circuit or short circuit)
while basket compensation movement
004 YV421: compensation on/off electro valve failure (open circuit or short circuit)
while basket compensation movement
(YV102_S/pin2), check connection to U100 ECU analog output (pin1)
YV401/YV421: check connection to ground, check connection to U104 ECU
information.
F04.03 (D) Turret rotation valves failure
Turret rotation 001 YV880: turret rotation proportional electro valve failure while turret rotation
Chk YV880/890 movement (open circuit or short circuit on YV880)
002 YV890: turret rotation safety valve failure (open circuit or short circuit) while
turret rotation movement
YV890: check connection to ground (via LSD1.x U100 digital output), check
connection to U106 ECU
information.

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F04.05 (D) Boom lifting valves failure :
Boom 001 YV381: boom lifting proportional electro valve failure (open circuit or short
Chk YV381/390/391 circuit on YV381) while boom lifting movement
002 YV390: boom lifting safety valve failure (open circuit or short circuit) while
boom lifting movement
004 YV391: boom lifting safety valve failure (open circuit or short circuit) while
boom lifting down movement
YV390/YV391: check connection to ground (YV390: via LSD2.x U106 digital
output, YV391: via LSD1.x U106 digital output), check connection to U106 ECU
information.
F04.06 (D) Boom telescoping valves failure
Telescope 001 YV382: boom telescoping proportional electro valve failure (open circuit or
Chk YV382/392 short circuit on YV382) while boom telescoping movement
002 YV392: boom telescoping safety valve failure (open circuit or short circuit)
while boom telescoping out movement
YV392: check connection to ground (YV392: via LSD1.x U106 digital output),
check connection to U100 ECU
information.
F04.07 (D) Jib lifting valves failure with jib option:
Jib 001 YV102: jib lifting proportional electro valve failure while jib lifting movement
Chk YV102/500/510 (open circuit or short circuit on YV102)
002 YV510: jib descent on/off electro valve failure (open circuit or short circuit)
while jib lifting movement
004 YV500: jib lifting on/off electro valve failure (open circuit or short circuit)
while jib lifting movement
information.
F04.08 (D) Basket rotation valves failure
Cage Rotation 001 YV102: compensation proportional electro valve failure while basket rotation
Chk YV102/460/440 movement (open circuit or short circuit on YV102)
002 YV460: basket rotation on/off electro valve failure (open circuit or short
circuit) while basket rotation movement
004 YV440: basket rotation on/off electro valve failure (open circuit or short
circuit) while basket rotation movement
information.
F04.10 (D) Failure is detected on proportional electro valve (YV600 and/or YV620) : open
Drive circuit or short circuit (driving or not driving)
Chk YV600/YV620 001 YV600
002 YV620
Check YV600 and YV620 electro valves (connection to ground, to U106 ECU)

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F04.11(D) LS valve failure detected : short circuit or open circuit
Principal Check connection to LSD1.x output
movements
Chk YV101
F04.20 (D) Drive speed valves failure:
Drive Speed YV686: drive speed electro valve failure (open circuit or short circuit on
Chk YV686 YV686)
YV686: Check connection to ground, check connection to U100 ECU digital
output
F04.33 (D) Steering mode valves failure with 4 wheels steering option activated
Steering mode 001 YV621: steering mode on/off electro valve failure (open circuit or short
Chk YV621/YV622 circuit)
002 YV622: steering mode on/off electro valve failure (open circuit or short
circuit)
YV621/YV622: Check connection to ground, check connection to U100 ECU
digital output
F04.34 (D) Oscillating axle unlocking valves failure:
Front Axle 001 YV780: oscillating axle unlocking electro valve failure (open circuit or short
Unlocking circuit)
Chk YV780/YV781 002 YV781: oscillating axle unlocking electro valve failure (open circuit or short
circuit)
YV780/YV781: Check connection to ground, check connection to U100 ECU
digital outputs
F04.35 (D) Brake releasing valves failure:

Brake Releasing YV782: brake releasing valve failure (open circuit or short circuit)
Chk YV782 YV782: Check connection to ground, check connection to U100 ECU digital
output
F05 : JOYSTICKS
F05.01 (D) Drive joystick failure: out of range [0.2..4.8] V or out of neutral incoherence
Drive Joystick 001 SM122Y analog value out of range
Check SM122Y 002 SM122Y analog value and SM122RrON or SM122FtON digital values are
incoherent
SM122Y: check 5V supply, check connection to ground, check joystick
F05.03 (D) Boom telescoping joystick failure: out of range [0.2..4.8] V
Telescope 001 SM121Y analog value out of range
Joystick 002 SM121Y analog value and SM121YON digital value are incoherent
Check SM121Y SM121Y: check 5V supply, check connection to ground, check joystick
F05.04 (D) Boom lifting joystick failure:
Boom Joystick 001 SM120Y analog value out of range
Check SM120Y 002 SM120Y analog value and SM120XYON digital value are incoherent
SM120Y: check 5V supply, check connection to ground, check joystick
F05.05 (D) Turret rotation joystick failure:
Turret Joystick 001 SM120X analog value out of range
Check SM120X 002 SM120X analog value and SM122XYON digital value are incoherent
SM120X: check 5V supply, check connection to ground, check joystick
F05.11 (A) No detection of joystick’s neutral position at machine start up.
Joystick neutral SM122Y: check SM122FtON / SM122RrON, check joystick, check 5V supply,
Check SM122Y
Joystick neutral 2 SM121Y: check SM121YON, check joystick, check 5V supply,
Check SM121Y

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Joystick neutral 3 SM121Y: check SM120XYON, check joystick, check 5V supply,
Check SM120X/Y
F06 : OVERLOAD
F06.01(A) No overload calibration, do/redo overload calibration with country option STD or
No Loading Cal AUS, or country option USA and Load Measurement option Active
Calibrate VAR[LoadGaugesNotCalibrated]=1
Make the calibration
F06.03 (D) Gauges out of range with country option STD or AUS, or country option USA
Gauges out of and Load Measurement option Active and basket tilt in the range (-10°/+10°)
Range 001 SP480 not in 1500µA 19500µA
Check 002 SP481 not in 1500µA 19500µA
SP480/SP481 VAR[LoadGaugesOutOfRange]=1
Check SP480 and SP481 connections to ground, to U104 ECU analog inputs
F06.04(D) SP480 measured weight and SP481 measured weight are more than 50kg
Incoh Gauges (and gauges are not out of range) with country option STD or AUS, or country
Check SP480/481 option USA and Load Measurement option Active
VAR[LoadGaugesIncoherent]=1
Check SP480 and SP481 connections to ground, to U104 ECU analog inputs
Redo calibration
F06.05(D) Low power for strain gauges is detected low :
Low Power VbattB2 basket is under 8500mV
Check gauges
supply
F07 : SENSORS
F07.02 (D) Cable alarm : break detected, check cable sensors SQ990/SQ991
Chain Alarm 001 sensor SQ990
Chk 002 sensor SQ991
cable/SQ990/991 Check connection to ground, to supply, check also SQ990 and SQ991 sensor
F07.04 (A) Incoherence between boom position sensors: SR380/SR381/SQ320
Boom Angle 001 SR381: detection of front descending while SR380=0 (with or without boom
position movement)
Chk SR380- 002 SR381: detection of front raising while SR380=0 (with or without boom
381/SQ320 movement)
004 SR380: detection of front raising when boom lowering and SR381=0
008 SR380: detection of front descending when boom lowering and SR381=1
016 SR381: detection of active state while SQ320=1 & SQ321=1
(redundancy of P1 position OK)
Check position sensors in low state (telescope in, boom < 10°):
SQ320=ON & SQ321=ON & SR381=OFF & SR380=OFF
Check position sensors while boom lifting, from telescope in and boom=0° to
boom fully elevated (telescope still in)
st
1 position : SQ320=ON & SQ321=ON & SR381=OFF & SR380=OFF
Then:(SQ320=ON & SQ321=OFF)|( SQ320=OFF & SQ321=ON) &
SR381=OFF & SR380=OFF
Then: SQ320=OFF & SQ321=OFF & SR381=OFF & SR380=OFF (20° boom
elevation)
Then: SQ320=OFF & SQ321=OFF & SR381=OFF & SR380=ON (near 52°)
Then: SQ320=OFF & SQ321=OFF & SR381=ON & SR380=ON (52°)
Then: SQ320=OFF & SQ321=OFF & SR381=ON & SR380=OFF (above 55°)
To erase the failure: fold down the machine, check the position sensors (repair
if one is broken), switch off the machine and then switch ON again the power.

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F07.11(A) Incoherence between telescope position sensors: SQ380/SQ381/SQ320
Teles. Lenght 001 SQ381: detection of front descending while SQ380=0 (with or without boom
posit. movement)
Chk SQ380- 002 SQ381: detection of front raising while SQ380=0 (with or without boom
381/SQ320 movement)
004 SQ380: detection of front raising when boom lifting or telescope extension
and SQ381=0
008 SQ380: detection of front descending when boom lifting or telescope
extension and SQ381=1
016 SQ381: detection of active state while SQ320=1 & SQ321=1 (redundancy of
P1 position OK)
Check position sensors in low state (telescope in, boom < 10°):
SQ320=ON & SQ321=ON & SQ381=ON & SQ380=OFF
Check position sensors while boom telescoping, from telescope in and
boom=0° to telescope fully out and boom=0°:
st
1 position : SQ320=ON & SQ321=ON & SQ381=ON & SQ380=OFF
Then:(SQ320=OFF & SQ321=ON)|(SQ320=ON & SQ321=OFF) & SQ381=ON
& SQ380=OFF
Then: SQ320=OFF & SQ321=OFF & SQ381=ON & SQ380=OFF (2m
telescope length)
Then: SQ320=OFF & SQ321=OFF & SQ381=ON & SQ380=ON (near reach
limit)
Then: SQ320=OFF & SQ321=OFF & SQ381=OFF & SQ380=ON (reach limit)
Then: SQ320=OFF & SQ321=OFF & SQ381=OFF & SQ380=OFF (reach limit)
To erase the failure: fold down the machine, check the position sensors (repair
if one is broken), switch off the machine and then switch ON again the power.
F07.15 (D) Incoherence between basket tilt sensors: SR400/SR420

Compensation Check position sensors with basket tilt = 0°
pos. SR400=OFF & SR420=0FF
Chk SR400/SR420 Check position sensors with basket tilt > 10°
SR400=ON & SR420=OFF
Check position sensors with basket tilt < -10°
SR400=OFF & SR420=ON

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F07.17(A) Problem detected between SQ320/SQ381
Incoh Position 2 001 SQ320=ON + SQ381 =ON + SR381=ON
Chk SQ320- 002 SQ320=ON + SQ381 =OFF + SR381=ON
381/SR381 004 SQ320=ON + SQ381 =OFF + SR381=OFF
008 SQ320=ON + SQ321 =OFF + SQ380=ON + SR380=OFF
016 SQ320=OFF + SQ321 =ON + SQ380=ON + SR380=OFF
032 SQ320=ON + SQ321 =OFF + SQ380=OFF + SR380=ON
064 SQ320=OFF + SQ321 =ON + SQ380=OFF + SR380=ON
128 SQ320=ON + SQ321 =OFF + SQ380=ON + SR380=ON
256 SQ320=OFF + SQ321 =ON + SQ380=ON + SR380=ON
Check position sensors in low state (telescope in, boom = -15°):
SQ320=ON & SQ321=ON & SQ381=ON & SR381=OFF
Check position sensors with Telescope=2m, boom=0°:
SQ320=OFF & SQ321=OFF & SQ381=ON & SR381=OFF
Check position sensors with Telescope>10m, boom=0°:
SQ320=OFF & SQ321=OFF & SQ381=OFF & SR381=OFF
Check position sensors with Telescope>10m, boom>52°:
SQ320=OFF & SQ321=OFF & SQ381=OFF & SR381=ON
To erase the failure: fold down the machine, check SQ320 and SQ321 sensors
(possible short circuit) SQ381 sensor (possible open circuit) and SR381
(possible short circuit), repair if needed, switch on, (raise the boom until
SQ320=OFF & SQ321=OFF, SQ381=ON, SR381=OFF), switch off. The
purpose is to check the unfolded position.
F07-30 (D) Engine is not running and engine oil pressure is detected
Engine oil
pressure
Check D+/SP162
F07.31(D) Incoherence between DPLUS signal and engine state : engine is not running
D+ Signal and DPLUS in ON position
Chk D+ and
IG/speed sensor
F08 : ELECTRIC CIRC.
F08.04 (D) Detected ECU voltage difference
Calc. Input Supply 001 Difference between U106 (SPU) and U100 (turret B2)
Chk 002 Difference between U106 (SPU) and U104 (basket B2)
U100/U104/U106 Check U100, U104 and U106 supply voltage
Check supply voltage coherence between all ECU (more than 2000mV far
during the first 4 seconds after start up)
F08.05 (D) Detected failure on regulated 5V output of U104 ECU (basket slave node)
Calc. Input Supply supplying the joysticks.(If F08.05 active then F05.01, F05.03, F05.04 and
Chk U106 5V regul F05.05 are hidden)
F09 : ENGINE
F09.01 (D) Engine overheat :
Water temperature T2s(ST160 & T15s(VAR[EngineStatus]=RUNNING)
Engine overheat
F09.02 (D) Engine oil pressure :
Oil pressure T6s(SP162 & T15s(VAR[EngineStatus]=RUNNING)
Engine pressure

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F09.07 (D) Available with semi electronic engine, warning lamp received from engine ECU:
Amber warning J1939 , for more details and explanation of failures , see Diagnostic menu 4.2
lamp functions / engine elec failure SPN 1 to 5 for SPN codes
Check engine or 110/158/190/3509/523774/523771/523772
speed sensor
SV162
F09.08 (D) Available with semi electronic engine, stop lamp code received from engine
Red stop lamp ECU: J1939 , for more details and explanation of failures , see Diagnostic menu
Check engine or 4.2 functions/ engine elec failure SPN 1 to 5 for codes
speed sensor 158/190/3509/523771/523772
SV162
F09.10 (D) Alternator failure : only for future TIV versions/semi electronic engines
D+ T2s(DPLUS=OFF & VAR[EngineStatus]=RUNNING)
Engine alternator
F10 : FUNCTIONS
F10.01 (D) While driving in micro speed, measured current for YV600 or YV620
Drive proportional electro valves is too high :
RPM current too VAR[MachinePosition]≠P1 & (YV600[current]> xxx µA | YV600[current]> xxx
high µA)
F10.02 (D) While driving in micro speed, pressure is detected in the hydraulic high speed
Drive 2 circuit :
SP692+Unfolded 001 VAR[MachinePosition]≠P1 & SP692=OFF
(speed selected) 002 VAR[MachinePosition]=P1 & CONTROL[DriveSpeed]=High &
CONTROL[Drive]≠N & SP692=ON
Check high speed circuit (YV686), check SP692 sensor (15b) :
case 001 = probably hydraulic failure, or SP692 disconnected
case 002 = probably SP692 failure (shunt, wrong calibration adjusting pressure)
F12 : INTERNAL FAULTS
F12.01 (A) CAN network failure
CAN Fault 001 CAN failure detected with turret B2 ECU (U100)
Check wires 002 CAN failure detected with basket B2 ECU (U104)
Machine not supplied, with multimeter, check the resistance between 1001
(CAN high) and 1002 (CAN low) is nearly 60 ohms (if 0ohm or 120ohm: failure,
check “res term” connection for all ECUs)
Check ECU supplies line
Check address connections for each B2 ECU (CN106.18/CN106.19/CN106.20)
F12.02 (A) Internal failure of SPU: access to EEPROM (read or write).
E2P Read/Write Restart machine.
Error
Change U106 ECU
F12.04 (A) Detected change in software machine identification : all the settings forced to
E2P Param Reset default values (ramps, speeds, options, machine configuration and erase of
Check SETTINGS calibration).
F13 : SWITCHES
F13.01(A) Detected failure on lower console switches: two directions active at the same
Lower box time
switches 001 turret rotation switch
SC to UBATT 002 boom telescoping switch
004 boom lifting switch
008 jib lifting switch
016 basket compensation switch
Check turret rotation, boom telescoping, boom lifting, jib lifting and
compensation switches.

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F13.02 (A) Detected failure on upper console switches: two directions active at the same
Platform switches time
SC to UBATT 001 jib lifting switch
002 basket rotation switch
008 steering rocker switch
016 steering mode switch
Check basket rotation, jib lifting, compensation, steering and steering mode
switches.
F13.10 (A) Neutral detection failure at start up for lower console switches
Switches neutral 001 turret rotation switch
- 002 boom telescoping switch
004 boom lifting switch
008 jib lifting switch
032 engine start/stop switch
Check turret rotation, boom telescoping, boom lifting, jib lifting and
compensation switches.
Check engine start-stop.
F13.11 Neutral detection failure at start up for upper console switches
Switches neutral 2 001 jib lifting switch
- 002 basket rotation switch
008 steering rocker switch
016 engine start/stop switch
032 emergency pump switch
064 horn switch
128 generator switch
Check basket rotation, jib lifting, compensation, steering switches.
Check generator, engine start-stop, horn and emergency pump switches.
F15 : J1939
F15.06 Problem detected in J1939 CAN
Check CAN2 Machine not supplied, with multimeter, check the resistance between 2001
- (CAN high) and 2002 (CAN low) is nearly 60 ohms (if 0ohm or 120ohm: failure,
check “res term” connection for all ECUs)
Check ECU supplies line
Check CAN connection for Display and/or engine.

1.3 Failures Log Detailed list of failures code 3*
Example as shown on display : 32 alarms
have been activated then detected and
registered in memory
By pushing enter, the detail of all alarms are

shown in order of appearance (example 1st
alarm is F04.01 code 002 :fault on valve
YV602) and so on
Note if for example both valves for jib YV102 and YV510 are faulty, then the failure code F04-07-
displayed will be at code 003 (001+002).

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• Explanation of the specific failures F07.04 angle sensors (for dual load only)
• Explanation of the specific failure F07.11 length sensors (for dual load)

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• Explanation of the specific failure F07.17 incoherence between sensors state
(for dual load only

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4.1.2.ACCESS CODE
• How to get access in the console
2. ACCESS CODE
2.1 ENTER CODE
2.2 MODIFY CODE
[+] or [–] to change the value

[*] to save the value
Menu Description Level

2.1 Enter Code
2.2 Modify Code 3

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4.1.3.SETTINGS MENU
3. SETTINGS
3.1 SPEEDS
3.2 RAMPS
3.3 OPTIONS
3.4 CALIBRATION
3.5 MACHINE CONFIG
3.6 MAINTENANCE
3.7 SERVICE COUNTER
3.8 HOURMETER
3.9 DATE & HOUR
3.10 SERIAL NUMBER
[+] or [–] to change the value

[+] and [–] to restore default value
[*] to save the value
Note : some menus might not be accessible (depending of the model)

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4.1.4.MOVEMENTS TIMES
Default Execution
Movement Value (%) time (s)
Configuration
Lifting Up 76.0% 42s Upper panel control
Lifting Down 96.0% 42s Upper panel control
Telescoping Out 75.6% 27s Upper panel control
Telescoping In 90.0% 27s Upper panel control
Orientation 96.0% 64s Upper panel control, 180° rotation
Upper panel control, full steering range
Steering 96.0% 4s
from left to right/right to left
Jib lifting Up 77.6% 29s Upper panel control
Jib lifting Down 67.6% 28s Upper panel control
Upper panel control, 15s for 20° stroke.
Basket Compensation Up 66.4% 15s
To be adjusted related to basket stroke.
Upper panel control, 15s for 20° stroke.
Basket Compensation Down 52.0% 15s
To be adjusted related to basket stroke.
Basket Rotation left or right 75.6% 15s Upper panel control
Upper panel control/High speed selected,
HS/LS Drive Forward 68.0% 27s
measured on 50m length
Upper panel control/High speed selected,
HS/LS Drive Reverse 68.0% 27s
Upper panel control/Unfolded machine,
Micro speed Drive Forward 35.6% 72s
Upper panel control/Unfolded machine,
Micro speed Drive Reverse 35.6% 72s

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• The menus in detail

3.1 SPEEDS Movement Maximum and Minimum Speeds
HS/LS Drive Fwd Max High speed and Low Speed drive forward maximum speed 2*
HS/LS Drive Rev Max High speed and Low Speed drive reverse maximum speed 2*
µS Drive Fwd Max Micro speed drive forward maximum speed 2*
µS Drive Rev Max Micro speed drive reverse maximum speed 2*
Steering Max Steering speed (same for left and right directions) maximum speed 2*
Lifting Up Max Boom lifting up maximum speed 2*
Lifting Dn Max Boom lifting down maximum speed 2*
Turret Rotation Max Turret rotation maximum speed 2*
Telescoping Out Max Boom telescoping out maximum speed 2*
Telescoping In Max Boom telescoping in maximum speed 2*
Jib lifting up Max Jib lifting up maximum speed 2*
Jib lifting Dn Max Jib lifting down maximum speed 2*
Compensation up Max Basket compensation up maximum speed 2*
Compensation Dn Max Basket compensation down maximum speed 2*
Basket Rotation Max Basket rotation (same for left and right directions) maximum speed 2*
Drive Fwd Min All speeds drive forward minimum speed (threshold) 2*
Drive Rev Min All speeds drive reverse minimum speed (threshold) 2*
Lifting Up Min Boom lifting up minimum speed (threshold) 2*
Lifting Dn Min Boom lifting down minimum speed (threshold) 2*
Turret Rotation Min Turret rotation minimum speed (threshold) 2*
Telescoping Out Min Boom telescoping out minimum speed (threshold) 2*
Telescoping In Min Boom telescoping in minimum speed (threshold) 2*
3.2 RAMPS
Drive Fwd Acc All speeds drive forward acceleration duration 2*
Drive Fwd Dec All speeds drive forward deceleration duration 2*
Drive Rev Acc All speeds drive reverse acceleration duration 2*
Drive Rev Dec All speeds drive reverse deceleration duration 2*
Steering Acc Steering acceleration duration 2*
Steering Dec Steering deceleration duration 2*
Lifting Up Acc Boom lifting up acceleration duration 2*
Lifting Up Dec Boom lifting up deceleration duration 2*
Lifting Down Acc Boom lifting down acceleration duration 2*
Lifting Down Acc Boom lifting down deceleration duration 2*
Telescoping Out Acc Boom telescoping out acceleration duration 2*
Telescoping Out Dec Boom telescoping out deceleration duration 2*
Telescoping In Acc Boom telescoping in acceleration duration 2*
Telescoping In Dec Boom telescoping in deceleration duration 2*
Orientation Acc Turret Orientation acceleration duration 2*
Orientation Dec Turret Orientation deceleration duration 2*
Jib Lifting Up Acc Jib Lifting up acceleration duration 2*
Jib Lifting Up Dec Jib Lifting up deceleration duration 2*
Jib Lifting Down Acc Jib Lifting down acceleration duration 2*
Jib Lifting Down Dec Jib Lifting down deceleration duration 2*

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Compensation Up Acc Basket compensation up acceleration duration 2*
Compensation Up Dec Basket compensation up deceleration duration 2*
Compensation Dn Acc Basket compensation down acceleration duration 2*
Compensation Dn Dec Basket compensation down deceleration duration 2*
Basket Rotation Acc Basket rotation acceleration duration 2*
Basket Rotation Dec Basket rotation deceleration duration 2*
3.3 OPTIONS
Country Country choice: 3*
0 [STD] Standard version conforming to Europe EN280 norm
1 [AUS] Australia version conforming to AS norm
2 [USA] USA version conforming to ANSI norm
Buzzer Buzzer special activations:
0 [Off] no special activation
1 [Mvts] activation while boom lifting, boom telescoping,
No code
turret orientation, jib lifting, basketrotation, basket compensation
2 [Drive] activation while drive, steering
3 [Drive+Mvts] activation under conditions (1) or (2)
Flashing light Flashing light special activations:
0 [Off] no special activation
1 [Mvts] activation while boom lifting, boom telescoping,
No code
turret orientation, jib lifting, basket rotation, basket compensation
2 [Drive] activation while drive, steering
3 [Drive+Mvts] activation under conditions (1) or (2)
Fleet management Activation of the fleet management system: transmission over CAN
(GPS tracking for R&D) bus of data to generate activity report
No code
0 [Inactive] no transmission
1 [Active] transmission over CAN bus activated (see §38)
Prohib in Tilt Used to prohibit up movements with active tilt position 2*
0 [Inactive] all movements are authorized with tilt detected
1 [Active] up movements/drive (if unfolded) are inhibited
Prohib Unfolded drive Used from STD version only, to prohibit drive while machine is 2*
unfolded (Russia option only)
0 [Inactive] drive function allowed if machine is unfolded
(under defined requirements)
1 [Active] drive function inhibited if machine is unfolded
(machine position not in P1)
Load Measurement Used for USA version only, to activate the load measurement 2*
system according to US regulations
0 [Inactive] load measurement system (failures + safeties)
disabled
1 [Active] load measurement system (failures + safeties)
activated
3.4 CALIBRATION 2*
The menus
3.4 CALIBRATION
RESET 0kg
RESET 250kg RESET 50 to 300kg

or

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• STEP 1 Calibration of the offset (reset 0kg?)
Reset 0kg?
[OK] Calibrate
[+]
[OK] [+]
[OK]
Reset 0kg Reset 0kg
Not calibrated Calibrated
Calibrate? [-] Erase?
[-]YES [+]NO [-]YES [+]NO
[-]
Reset 0kg
EMPTY BASKET
[OK]Calibrate
[OK]
Reset 0kg
Checking
....................
Reset 0kg
[+] Range=[5200-8200]
SP480:Failure|Success SP480=xxxx:OK|NOK
[+]Infos [OK]Exit [OK]Next
[OK] [OK]
Reset 0kg
Failure|Success
[OK]To End
Note for gain adjustment

As 250 kg might be difficult to find on site , there is a possibility to choose any weight between 50 and
300kg (using daily code ), this will permit to the technician to calibrate the machine with a wider choice of
weights
In both cases the accuracy of the load installed in basket is very important ( tolérance ± 5kg maxi)

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• 1st POSSIBILITY : Calibration of the gain with fixed weight of 250kg (550lbs)
Reset 250kg?
[OK] Calibrate
[+]
[OK] [+]
[OK]
Reset 250kg Reset 250kg
[-]
Reset 250kg
LOAD BASKET WITH
250kg
[OK]When ready
[OK]
Reset 250kg
LOAD BASKET WITH
250kg
[OK]When ready
[OK]
Reset 250kg
[OK] Calibrate
[OK]
Reset 250kg
Checking
....................
Reset 250kg
[+] Range=[550-700]
[OK] [OK]
Reset 250kg
Failure|Success
[OK]To End

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• 2nd POSSIBILITY Calibration of the gain with adjustable weight ( 50 to 300kg)
Reset 50kg to 300kg?
[OK] Calibrate
[+]
[OK] [+]
[OK]
Reset 50kg to 300kg Reset 50kg to 300kg
[-]
Reset 50kg to 300kg

LOAD BASKET WITH
50kg to 300kg
[OK]When ready
[+] 1 time Reset 50kg to 300kg Push [+] button =
[OK] SET LOADED WEIGHT +5kg
[-] 255kg [+] on calibration
[OK]When ready weight
Reset 50kg to 300kg
SET LOADED WEIGHT [+] 2 times [-] 2 times
[-] 250kg [+]
[OK]When ready
Reset 50kg to 300kg Push [-] button =
SET LOADED WEIGHT -5kg
[-] 245kg [+] on calibration
[-] 1 time [OK]When ready weight
Push [-]/[+] button

To set the Calibration weight with 5kg step
Reset 50kg to 300kg

SET LOADED WEIGHT
[-] xxxkg [+] xxx : calibration weight from 50kg to 300kg set by the user
[OK]When ready
[OK]
Reset 50kg to 300kg
[OK] Calibrate
[OK]
Reset 50kg to 300kg

Checking
....................
Reset 50kg to 300kg

[+] Range=[550-700]
[OK]
[OK]
Reset 50kg to 300kg

Failure|Success
[OK]To End

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• Message of possible errors during overload calibration
Reset xxxxx Fold the machine in P1 zone, restart calibration.

Unfolded Machine
Detected
Press Any Key
Reset xxxxx Correct the basket level (out of -10°/+10°), restar t
Basket Tilt calibration.
Detected
Press Any Key
Reset xxxxx Tilt is active, move the machine to a flat surface
Machine Tilt and restart calibration.
Detected
Press Any Key
Reset xxxxx Out of range detected for SP480 and/or SP481
Gauges out of Range (failure F06.03): repair and restart calibration
Check SP480/SP481
Press Any Key
Reset xxxxx For USA version only, activate the Load
Activate Load Meas. Measurement option in
->SETTINGS->OPTIONS 3.SETTINGS => 3.1 OPTIONS
Press Any Key
Reset xxxxx To set the gain, the offset must be calibrated first
Do Reset 0kg first
Press Any Key
• Weight control
In the menu of the console display, the function “Weight control “? permits to see the current weight
measured in the platform, the current alarm’s state and the current applied load
Control Weight ?
Press OK to start
[OK] [+] or [-]
Weight=xxxxkg/xxxxlb
Overload=YES|NO
Selected=230kg|450kg
[+]/[-]Return
To control the weight embedded in the platform. With empty basket, the measured weight should be
0±10kg.
In case it is out of this range, he offset (0kg) calibration should be done again

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3.5 MACHINE CONFIGS LEV
Engine Engine choice (not used yet, only TIERIII machines): 3*
0 [TIERIII fixed . speed TIERIII engine with fixed RPM
1 [TIER III variable speed TIER III engine with variable RPM
2 (TIERS IV)
Model version Machine type choice: (to validate the jib presence) 2*
0 [HT61RT/HT21RT] no jib
1 [HT67RTJ/HT23RTJ] with standard jib, the activation of this option
is checked with the state of jib control electro valves (YV500/YV510)
Wheels steering Wheel steering abilities: 2*
0 [2WS] front axle steering only
1 [4WS] front and rear axles steering ability
(see Steering Mode),
the activation of this option is checked with the state of 4WS steering
control electro valves (YV621/YV622)
Drive Pump Type of the drive pump. Caution, these settings sets the PWM electro 3*
valves threshold and maximum currents for driving (for all the available
drive speeds).
SERIE42 SAUER drive pump
A10VG REXROTH drive pump
Dual capacity load Dual load system activation/deactivation, if deactivated only 230kg/503lbs 3*
is enabled
0 : inactive : dual load system inactivated
1 : active : dual load system activated

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3.6 MAINTENANCE 3
Safety Valves ON 3
Safety valves ON Normal mode, no control of safety
To activate the safety Inactive Valves with this procedure
valves when no Press +/- to change
movement is
running.
When activated, all
Safety valves ON Normal mode, no control of safety
movements are SA110E detected Active Valves with this procedure
inhibited. Inactive for 10s Waiting for enable switch SA110E
Press +/- to change
This tool can be

activated only from
lower command Safety valves ON Activation of YV390, YV391, YV392,
SA110E released Active YV890, GND1 and GND2
console with a level 3 Before 10s timer All movements are inhibited
access code. Press +/- to change
Switch OFF the

machine in order to Safety valves ON All LEDs are blinking.
get out of this mode. Active Activation of YV390, YV391, YV392,
YV890, GND1 and GND2
Press +/- to change All movements are inhibited
After pushing the [+]
button (check
“Active” state of
Safety valves ON), Related actions:
operator must keep - Activation of this item from lower command console only
the SA110E enable - Inhibition of all movements when activated
switch on lower - When activated:
command console YV390=1
for 10s before the YV391=1
activation of safety
YV392=1
valve is fully
operational. YV890=1
In case the operator

releases the switch
before the 10s
deadline, the
procedure interrupts.
When the “Safety

Valves ON” function
is validated, all LEDs
blink permanently
(upper and lower
panel).

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Safety Valves OFF Safety valves OFF Normal mode, no control of safety 3
Inactive Valves with this procedure
To inhibit the safety
valves when Press +/- to change
one/several [+] pushed
movement is & lower panel selected
running. & SafetyValves ON inactive
Safety valves OFF All LEDs are blinking.
This tool can be Active Deactivation of YV390, YV391, YV392,
activated only from YV890, GND1 and GND2
lower command Press +/- to change
console with a level 3
access code.
Related actions:
Switch OFF the - Activation of this item from lower command console only
machine in orderto - When activated:
get out from this YV390=0
mode. YV391=0
YV392=0
When the “Safety YV890=0
Valves ON” function
is validated, all LEDs
blink permanently
(upper and lower
panel).
Menu 3.7 SERVICE COUNTER Level 2

Edit service counter Reset the hours for engine maintenance
( up to 500hours)
MENU 3.8 HOURMETER Level 3
Edit hourmeter Reset the running hours on display
MENU 3.9 DATE AND HOUR Level 3
Edit hour and date Change hour and date
MENU 3.10 SERIAL NUMBER Level 3
Edit serial number Change the serial number

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4.1.5.DIAGNOSTIC MENU
The diagnostic menu is very important on that model as it will permit to the technician to focuse only on
the dysfunction encountered and then save time to repair the machine
The explanation done below is built on the same basis for all movements including drive mode.
Commands all commands coming from lower/upper controls

Inputs Digitals or analogic inputs (ETOR-EANA)
Setpoint (0-100%) In Diagnostic menu ,it’s the parameter Internal setpoint
for the function described Neutral to Fwd/up:left or
Rev/down/Right ) ( 0-1000pts)
This setpoint is null when no movement is performed or
there is failire on the josytick
Cuttings Conditions for cutting the movements
-- null movement is authorized
-- 1 movement is inhibited
Validation and formatting Conditions for validation of the movement
the command
Slow down Condtions for slowing down the movement
( from 0 to 100%)
Control (0-100%) In Diagnostic menu , it’s the parameter Internal control
for the internal command of the function (0 -1000pts)
Outputs Digitals or Analogic outputs ( STOR-SPWM –SANA)
Actuator Any device like valves/cylinders/motors/relays
• Explanation of the cinematic grafcet
Cuttings
Function
DIG IN DIG OUT
ANA IN ANA OUT
Secured and Setpoint Secured and Control Actuators
Commands formatted formatted Actuators
soles set point [0-100]% control [0-100]%
Slowdown
• Explanation of the Cuttings function
Bit Field : 8 bits bits field (to be read from right to left), value 0bxxxxxxxx where x is 0 or 1 valued
all bits to null value =movement is authorized
1 : movement is inhibited / 0 : condition OK (movement is authorized)
This is valid for every movement.
Bit 0 (D for Disable) : movement general deactivation (1=movement not selected)

Bit 1 (G for General) : general inhibition
Bit 2 (M for Multiple Movements) inhibition due to simultaneous movement cutting
Bit 3 (O for Overload) : inhibition due to machine in overload
Bit 4 (T for Tilt) inhibition due to machine tilted (in slope)
Bit 5 (R for Reach Limit) inhibition due to machine in reach limit
Bit 6 (F for Failure) : inhibition due to failures
Bit 7 (S for Specific) : inhibition due to specific conditions
Fwd/Up/L : Forward drive / Up for lifting /L for left
Rev /Down/R : Reverse drive / Down for descent / R for right

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See some examples
Drive cuttings
Fwd/Up/L : 00000000 Drive movement is authorized
Rev/Down/R: 00000000
SFRTOMGD
Drive cuttings
Fwd/Up/L : 00010000 Drive movement is forbidden due to “T” safety (Tilt) which is at 1
Rev/Down/R: 00010000 (machine is unfolded and Tilt sensor is activated)
SFRTOMGD
Lifting cuttings
Fwd/Up/L : 00000000 Boom raise is authorized, but boom descent is forbidden due to
Rev/Down/R: 00100000 “R” safety (Reach limit) which is at 1
SFRTOMGD (machine is in P5 zone with 1000lb load toggle switch selected
Lifting cuttings
Boom raise and descent are forbidden due to “D” safety (Disable)
Fwd/Up/L : 00000001
Rev/Down/R: 00000001 Which is at 1
SFRTOMGD (engine or back up not running or safety valves maintenance tool
Note : the joystick values are inverted compared to some other models
Position Front /right Neutral Rear /left

Values 0.5VDC (~100pts) 2.5VDC (~500 pts) 4.5VDC(~900pts)

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Menus in detail per function
4.1 MOVEMENTS DESCRIPTION
Drive (1/8)
SM122 Value of the drive joystick : 0.5mV ( front) – 2.5mV(neutral) – 4.5mV (rear)
SM122ONFt Out of neutral front (ON=joystick out of neutral)
SM122ONRr Out of neutral rear (ON=joystick out of neutral)
SB106 Enable pedal (ON=enable pedal pushed)
SA680 High speed selector : ON if selector = high speed (rabbit)
SA681C Crab steering mode selector : ON if selector = crab
SA681S Synchro steering mode selector : ON if selector = synchro
Drive Setpoint Computed set point for drive : 0(no movement) .. 1000 (max)
Applied Speed Low speed (00) / High speed (01) /micro speed (10) : based on SA680 and SA81S
selectors value
Drive cuttings Drive cuttings conditions
Drive slowdown Drive slow down value (≠100 if micro speed, 100 for low speed and high speed)
Drive control Computed control for drive
YV600 Analogue output – front drive
YV620 Analogue output – rear drive
YV686 Digital output – high speed drive (ON=high speed drive running)
YV782 Digital output – axle unbraking (ON=unbraking)
YV780 Digital output – oscillating axle unlocking (ON=oscillant axle)
YV781 Digital output – oscillating axle unlocking (ON=oscillant axle)
Steering (2/8)
SM122L Joystick rocker : Steering left button
SM122R Joystick rocker : Steering right button
Steering Setpoint Computed set point for steering: 0(no movement) - 1000 (max)
Steering cuttings Drive cuttings conditions
Steering control Computed control for steering
Steering mode Current steering mode : 0=2 wheels steering, 1=Crab steering, 2=Synchro steering
YV102 Analogue output – basket and jib movements (for U<Ubatt/2) and steering (for U>Ubatt)
YV102_S Digital output – supply for YV102 PVG
YV601 Digital output – front left steering
YV602 Digital output – front right steering
YV621 Digital output – optional (4WS) : crab left rear steering / Synchro right rear steering
YV622 Digital output – optional (4WS) : synchro left rear steering / crab right rear steering
YV101 Digital output – LS valve control
LSD02 Digital output – LS valve connection to ground (OK if 0.000mV)
Boom (4/8)
SA300U Lower panel – boom lifting up button
SA300D Lower panel – boom lifting down button
SA110E Lower panel – enable switch
SM120Y Value of the lifting joystick : 0.5mV (up) – 2.5mV(neutral) – 4.5mV (down)
SM120ON Out of neutral for SM120X and SM120Y axis of S120 joystick
Lifting Setpoint Computed set point for lifting: 0(no movement). 1000 (max)
Lifting Slowdown Lifting slow down value
Lifting cuttings Lifting cuttings conditions
Lifting control Computed control for Lifting
YV381 Analogue output – lifting movements (0..Ubatt/2 = down, Ubatt/2..Ubatt = up)
YV390 Digital output – control for lifting safety valve (up and down)
YV391 Digital output – control for lifting down safety valve (down movement only)
LSD01 Digital output – connection to ground for YV391

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LSD02 Digital output – connection to ground for YV390 and YV101
Jib (6/8)
SA500U Lower panel – jib lifting up button
SA500D Lower panel – jib lifting down button
SA501U Upper panel – jib lifting up button
SA501D Upper panel – jib lifting down button
Jib Lift. Setpoint Computed set point for jib lifting : 0(no movement) .. 1000 (max)
Jib Lift. Slowdown Jib lifting slow down value
Jib Lift. cuttings Jib lifting cuttings conditions
Jib Lift. control Computed control for jib lifting
YV500 Digital output – jib lifting up control
YV510 Digital output – jib lifting down control
Telescope (5/8)
SA301O Lower panel – boom telescoping out button
SA301I Lower panel – boom telescoping in button
SM121Y Value of the telescoping joystick : 0.5mV (OUT) – 2.5mV(neutral) – 4.5mV (IN)
SM121ON Out of neutral for SM121 joystick
Telescoping Setpoint Computed set point for telescoping : 0(no movement) .. 1000 (max)
Telescoping Slowdown Lifting slow down value
Telescoping cuttings Lifting cuttings conditions
Telescoping control Computed control for Lifting
YV382 Analogue output – telescoping movements (0..Ubatt/2 = in, Ubatt/2..Ubatt = out)
YV392 Digital output – control for lifting down safety valve (down movement only)
Platform Level (8/8)
SA400U Lower panel – compensation up button
SA400D Lower panel – compensation down button
SA481U Upper panel – compensation up button
SA481D Upper panel – compensation down button
Compens. Setpoint Computed set point for Compensation : 0(no movement) .. 1000 (max)
Compens. Slowdown Compensation slow down value
Compens. cuttings Compensation cuttings conditions
Compens. control Computed control for Compensation
YV421 Digital output – Compensation up control
YV401 Digital output – Compensation down control
Basket Rotation (7/8)
SA480L Upper panel – basket rotation left button
SA480R Upper panel – basket rotation right button

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Bsk. Rot. Setpoint Computed set point for Basket rotation : 0(no movement) .. 1000 (max)
Bsk. Rot. Slowdown Basket rotation slow down value
Bsk. Rot. cuttings Basket rotation cuttings conditions
Bsk. Rot. control Computed control for Basket rotation
YV440 Digital output – Compensation up control
YV460 Digital output – Compensation down control
Turret Rotation (3/8)
SA880L Lower panel – turret rotation left button
SA880R Lower panel – turret rotation right button
SM120X Value of the turret rotation joystick : 0.5mV (right) – 2.5mV(neutral) – 4.5mV (left)
SM120ON Out of neutral for SM120X and SM120Y axis of S120 joystick
Tur. Rotat. Setpoint Computed set point for turret rotation: 0(no movement) 1000 (max)
Tur. Rotat. Slowdown Turret rotation slow down value
Tur. Rotat. cuttings Turret rotation cuttings conditions
Tur. Rotat. control Computed control for jib lifting
YV880 Analogue output – telescoping movements (0..Ubatt/2 = left, Ubatt/2..Ubatt = right)
YV890 Digital output – safety control for turret rotation
4.2 FUNCTIONS DESCRIPTION

Engine (Mech) (1/3) Engine stage 3
Power On Machine powered on : key on ON position
Active Console Currently Active panel, 1=lower command console, 2=upper command console,
3=overriding command console
Start setpoint Engine start set point
Start control Engine control : 0=init step, 1=preheat step, 2=ready to start step, 3=start step, 4=post
heat step, 5=running step, 6=immobilizing step
12VP Battery potential (permanent 12V)
ST161 Coolant proportional temperature (0..Vbatt), 0mV=harness malfunction, Vbatt= coolant
hot temperature
R. ST161 Computed resistance in ohms for ST161 sensor
Preheating time Computed preheating time (in ms) according to R.ST161
Temperature Fail Engine coolant Temperature failure, check ST160, check harness
Pressure Fail Engine pressure failure, check SP162, check harness
Dplus Failure Engine alternator failure, check harness
DPLUS DPLUS signal, should be >12V when engine is running, near 0V when engine is
stopped
SP162 Engine Pressure
ST160 Engine digital coolant temperature
SA162 Accelerator button on lower panel
KA1 Stop engine relay (ON=engine supplied)
KA2 Start engine relay (ON=start request)
KM160 Preheat relay (ON=preheat request)
KA5 Accelerator pull relay (ON=accelerator pull activated, during the first 100ms of
acceleration only)
AccelHold Accelerator hold output (ON=accelerator hold activated, during all the acceleration)

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Engine (Elec) (2/3) Engine stage 4
Active Console Currently Active panel,
1=lower command console,
2=upper command console,
Start setpoint Engine start set point
Start control Engine control : 0=init step, 1=preheat step, 2=ready to start step, 3=start step, 4=post
heat step, 5=running step, 6=immobilizing step
Engine Stop Lamp Engine stop request coming from ECU engine (CAN)
Temperature (CAN) Coolant temperature (in °C) comin g from ECU engine (CAN)
Engine Speed rqst Engine speed request (in RPM) from U104 ECU (master HAULOTTE Group ECU)
Engine Speed ackn Measured engine speed (in RPM) coming from ECU engine (CAN)
Engine Ubatt (CAN) Measured battery potential (in mV) coming from ECU engine (CAN)
12VP Measured battery potential (permanent 12V) coming from U104 ECU (12VP)
Preheating time Computed preheating time (in ms) according to R.ST161
Temperature Fail Engine coolant Temperature failure, check ST160, check harness
Pressure Fail Engine pressure failure, check SP162, check harness
Dplus Failure Engine alternator failure, check harness
DPLUS DPLUS signal, should be >12V when engine is running, near 0V when engine is
stopped
SP162 Engine Pressure
ST160 Engine digital coolant temperature
SA162 Accelerator button on lower panel
KA1 Stop engine relay (ON=engine supplied)
KA2 Start engine relay (ON=start request)
KM160 Preheat relay (ON=preheat request)
KA5 Accelerator pull relay (ON=accelerator pull activated, during the first 200ms of
acceleration only)
AccelHold Accelerator hold output (ON=accelerator hold activated, during all the acceleration)
DM1[0] Status 11111111 : OK, no detected problem
Engine lamp status, 2 bits for each flag:
Malfunction Stop Lamp Warning Lamp Protect Lamp Result
Lamp
11 11 11 11 No failure
xx 01 xx xx Stop lamp
activated
(engine stop)
xx 11 01 xx Warning lamp
activated
(engine
warning)
DM1[1] Flash 11111111 : OK, no detected problem
Flash code for engine lamp, 2 bits for each flag
00 Slow, useful if the lamp status is 01
01 Fast, useful if the lamp status is 01
11 Fix, useful if the lamp status is 01
DM1 Failure Count Should be 0, if non zero detected failure by engine ECU
Number of activated failures in the DM1 frame
DM1 Length Should be 0, if non zero detected failure by engine ECU
Length of the DM1 frame

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Failure SPN 1 SPN Cause Repair:
110 Engine overheat Overheat of engine water temperature (ST161)
Water temperature sensor
110 low Ground short circuit of sensor /harness
Water temperature sensor
110 high Open circuit of sensor / harness, =+VB short circuit
Open /short circuit or damage of harness.
158 Battery voltage: High Failure of battery
190 Engine overrun Engine speed exceeds threshold speed
Sensor supply voltage 1:
3509 Low Sensor supply voltage 1
CAN Communication
523774 Abnormal CAN Bus (2000/2001)
Open circuit, short circuit, or damage of harness
523771 Actuator Abnormal (YA166).
Engine Speed Sensor Open circuit, short circuit, or damage of harness
523772 Abnormal (SV162).
Failure Mode 1 First detected failure mod in the DM1 frame coming from engine ECU.
Failure Count 1 First detected failure counter in the DM1 frame coming from engine ECU
Failure SPN 2 See Failure SPN 1
Failure Mode 2 Second detected failure mod in the DM1 frame coming from engine ECU.
Failure Count 2 Second detected failure counter in the DM1 frame coming from engine ECU
Failure Mode 3 Third detected failure mod in the DM1 frame coming from engine ECU.
Failure Count 3 Third detected failure counter in the DM1 frame coming from engine ECU
Failure Mode 4 Fourth detected failure mod in the DM1 frame coming from engine ECU.
Failure Count 4 Fourth detected failure counter in the DM1 frame coming from engine ECU
Failure Mode 5 Fifth detected failure mod in the DM1 frame coming from engine ECU.
Failure Count 5 Fifth detected failure counter in the DM1 frame coming from engine ECU
Reach Limit (3/3)
Machine Position Machine position Px : 0=init, 1/2/3/4/5 : current position, >5 :position failure
Applied load Current applied load : 0 for 1000 pounds (454kg) load, not 0 (01 or 10) for 500 pounds
(227kg) applied load
SQ320 Mechanical switch for boom down (<15°) + tele scope in, ON=Boom<15° + Telescope In
SQ381 Mechanical switch for boom length : ON=Telescope<xm
SQ380 ILS sensor for boom length : ON=in front of a magnet
SR381 Mechanical switch for boom angle : ON=Boom>50°
SR380 ILS sensor for boom angle : ON=in front of a magnet
Telescope Zone Computed boom length zone
Angle Zone Computed boom angle zone
Function status 0 if reach limit function is OK, non 0 if failure
4.3 STATE DESCRIPTION

Overload (1/5)
Estimated Load (kg) Estimated load in kilograms computed via SP480 and SP481 gauges signal value and
offset+gain calibration values
Estimated Load (lb) Estimated load in pounds computed via SP480 and SP481 gauges signal value and
SP480 Signal value for SP480 strain gauge in micro ampere : 4000µA to 20000µA
SP481 Signal value for SP481 strain gauge in micro ampere : 4000µA to 20000µA
Applied load Current applied load : 0 for 1000 pounds (454kg) load, not 0 (01 or 10) for 500 pounds
(227kg) applied load
Overload Alarm Overload flag alarm, 1=overload currently detected
Underload Alarm Underload flag alarm, 1=underload currently detected
No calibration Calibration flag, 1=weighing system not calibrated

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Gauges Incoherence Incoherence flag, 1=estimated load from SP480 and SP481 gauges are more than 80kg
SP480 Out of Range Out of range flag for SP480 gauge, valid range is between 3500µA--20000µA
SP481 Out of Range Out of range flag for SP481 gauge, valid range is between 3500µA--.20000µA
Gg1 estim. load (kg) Estimated load in kilograms computed via SP480 gauge and offset+gain calibration
values
Gg2 estim. load (kg) Estimated load in kilograms computed via SP481 gauge and offset+gain calibration
values
Gauge 1 Offset Calibrated offset for SP480 gauge
Gauge 1 Gain Calibrated gain for SP480 gauge
Gauge 2 Offset Calibrated offset for SP481 gauge
Gauge 2 Gain Calibrated gain for SP481 gauge
Overload thres (kg) Overload threshold corresponding to the current applied load
Hysteresis (kg) Hysteresis to acknowledge the overload alarm flag
(acknowledge= Overload thres-Hysteresis)
Undeload thres (kg) Underload threshold
Machine State (2/5)
Active Console Currently Active panel, 1=lower command console, 2=upper command console,
Telescope In Telescope in flag, i.e. telescope zone lower than 4.
Tilt Tilt detected with unfolded machine (unfolded=not in P1 zone)
Overload Alarm Machine currently overloaded
Machine Position Machine position Px : 0=init, 1/2/3/4/5 : current position, >5 :position failure
Boom Down Inhibited 1 : inhibition of boom down movement (position error), telescope in for more than 10
seconds to liberate the boom down movement.
Telesc Out Inhibited 1 : inhibition of telescope out movement (position error), fold the machine and repair.
Mode State (3/5)
U100 Mode Estimated load in kilograms computed via SP480 and SP481 gauges signal value and
U104 Mode Estimated load in pounds computed via SP480 and SP481 gauges signal value and
EEPROM State (4/5)
Max EEPROM stack Maximum number of simultaneous read or write EEPROM requests (since power on)
Curr. EEPROM stack Current number of simultaneous read or write EEPROM requests
Curr. EEPROM status Current EEPROM driver status
EEPROM stack error More than 32 simultaneous read or write EEPROM requests detection, restart machine
if non zero
EEPROM status error EEPROM driver status (0=non error) , restart machine if non zero
EEPROM State (5/5)
Execution time T10ms Duration of fast task (in µs)
Execution time T40ms Duration of slow task (in µs)
4.1.6. MENUS INPUTS /OUTPUTS
ECU Nb ITEM DESCRIPTION

5.1 DIGITAL INPUTS
Turret master 1 SQ320 Mechanical switch for boom down + telescope in, ON(Ubatt V)= boom
Node (U106) angle< 15° & boom length< xm
SPU can gateway 2 SR381 Mechanical switch for boom angle, ON(Ubatt V)=boom angle >50°
3 SR380 ILS boom angle, ON(0V)= in front of on of the 2 magnets
4 SQ381 Mechanical switch for boom length, ON(Ubatt V)=boom length <10
meters
5 SQ380 ILS boom length, ON(0V)=in front of one of the 5 magnets

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6 EMSTOP Status of emergency stopper push button (lower & upper, series
connected), if ON the all emergency stoppers are inactivated, if OFF one
at least of the emergency stopper is pushed.
7 SA187T Selection key on turret position, ON=Ubatt V
8 SA187B Selection key on basket position, ON=Ubatt V
9 SA110S Start/stop engine switch, ON=Ubatt V
10 SA110ES Enable switch or emergency pump switch depending on engine state,
ON=Ubatt V
11 SA145 Safety command switch, ON=Ubatt V=switch activated
12 SQ142 Tilt, ON (Ubatt V)=tilt<5°
13 DPLUS DPLUS signal : Alternator ON (Ubatt V) when running engine
14 SP162 Oil pressure sensor, OFF while engine running =problem
15 ST162 Coolant temperature sensor, OFF while engine running=problem
Turret slave 1 SA880R Turret rotation right switch (turret rotation right = orientation right seen
Node (U100) from the basket)
2 SA880L Turret rotation left switch (turret rotation left = orientation left seen from
the basket)
3 SA301O Boom telescoping out switch
4 SA301I Boom telescoping in switch
5 SA300U Boom lifting up switch
6 SA300D Boom lifting down switch
7 SA400U Basket compensation up switch
8 SA400D Basket compensation down switch
9 SA162 Accelerator switch
10 SQ189 Fuel low level if ON
11 SA500U Jib Lifting up switch
12 SA500D Jib Lifting down switch
13 SQ990 Cable break if OFF
14 SQ991 Cable break if OFF
14 SP692 Pressure detected in the high speed hydraulic circuit if OFF
15 ST125 Overheat detected for hydraulic oil if ON
Basket slave 1 SB161 Start/Stop engine switch
Node (U104) 2 SB120 Emergency pump switch
3 SB105 Horn switch
4 SA680 High speed/Low speed selector switch: OFF=low speed
5 SA146 500lb/1000lb load selector switch: OFF=500lb selection
6 SB106 Enable pedal: ON=pressed pedal
7 SA480L Basket rotation left switch
8 SA480R Basket rotation left right switch
9 SA481U Basket compensation up switch
10 SA481D Basket compensation down switch
11 SA501U Jib lifting up switch
12 SA501D Jib lifting down switch
13 SM122L Steering left switch
14 SM122R Steering right switch
15 SR400 Tilt +10° sensor optional, ON=Basket Tilt>10°
(tilt limit range=[-10°,+10°])

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16 SR420 Tilt +10° sensor optional, ON=Basket Tilt<-10°
(tilt limit range=[-10°,+10°])
17 SM122FtON Off neutral forward direction position for SM122 joystick
(ON if joystick pushed)
18 SM122RrON Off neutral reverse direction position for SM122 joystick
(ON if joystick pulled)
19 SM120ON Off neutral position for SM120 joystick (ON if turret rotation OR lifting
pushed or pulled)
20 SM121ON Off neutral position for SM121 joystick
(ON if telescoping joystick pushed or pulled)
21 SA189 Generator
22 SA681C Steering mode : crab mode wheels (4WS option)
23 SA681S Steering mode : synchronized wheels (4WS option)
5.2 DIGITAL OUTPUTS
Turret master 1 YV101 Load Sensing valve, ON=movement running
Node (U106) 2 YV390 Lifting safety valve, ON=lifting up or down running
SPU can gateway
3 YV391 Lifting down safety valve, ON=lifting down running
4 YV392 Telescoping out safety valve; ON=telescoping out running
5 YV890 Turret Rotation safety valve, ON=orientation left or right running
6 AccelHold Hold accelerator output, ON=accelerator hold available only for
mechanical engine
7 LSD1.x Connection to ground for YV890 and YV392 and YV391 safety valves
8 LSD2.x Connection to ground for YV101 and YV390 safety valves
Turret slave 1 YV686 High speed drive valve, ON=High speed running or timed
Node (U100) 2 YV782 Brake releasing valve
3 YV780 Oscillating axle unlocking valve
4 YV781 Oscillating axle unlocking valve
5 YV601 Front left steering valve
6 YV602 Front right steering valve
7 YV621 Crab/Synchro wheels steering valve:
8 YV622 Crab/Synchro wheels steering valve:
9 KM160 Engine preheat relay
10 KA5 Engine start relay
11 KA1 Engine supply relay
12 KA2 Pull accelerator relay available only for mechanical engine
13 KM120 Emergency pump relay
14 KA9 Horn relay
15 HA142 Buzzer
16 EL181 Flashing light relay
17 KA4 Generator relay
18 YV382_S Connection to Ubatt for YV382 proportional valve
Basket slave 1 YV460 Basket rotation right on/off valve
Node (U104) 2 YV440 Basket rotation left on/off valve
3 YV401 Basket compensation up on/off valve
4 YV421 Basket compensation down on/off valve

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5 YV510 Jib lifting up on/off valve
6 YV500 Jib lifting down on/off valve
7 HL150 PreHeat Light
8 HL168 Warning Light
9 HL169 Stop Light
10 HL103 Enable pedal light (ON=enable pedal validated)
11 HL102 Ignition light
12 HL164 Fuel low level light
13 HL140 Danger light
14 HL148 Tilt light
15 HL142 Overload light
16 HL147 Reach limitation light
17 HL149 Load selection light
18 HL561 Out of +10/-10° light
5.3 ANALOG INPUTS
Turret master 1 ST161 Coolant proportional temperature (0..Ubatt: the lowest the temperature,
Node (U106) the lowest the voltage value)
SPU can gateway 2 WUI SPU wake-up input
3 12VP Permanent 12V supply
4 12VB Sensors 12V supply
5 12VD HSD01 to HSD06 outputs 12V supply
6 12VC HSD07 to HSD12 outputs 12V supply
Turret slave 1 VBAT U100 U100 node supply voltage (nearly 12V)
Node (U100)
Basket slave 1 SM120X Orientation joystick : SM120 X axis, 0.5V..4.5V (neutral=2.5V+/-0.2V)
Node (U104) 2 SM120Y Lifting joystick: SM120 Y axis, 0.5V..4.5V (neutral=2.5V+/-0.2V)
3 SM121 Telescoping joystick: SM121 Y axis, 0.5V..4.5V (neutral=2.5V+/-0.2V)
4 SM122 Driving joystick: SM122 Y axis, 0.5V..4.5V (neutral=2.5V+/-0.2V)
5 SP480 Redundant strain gauge for load measurement, 4mA..20mA
6 SP481 Redundant strain gauge for load measurement, 4mA..20mA
7 VBAT U104 U104 node supply voltage
8 5V U104 U104 node 5V supply for joysticks
5.3 ANALOG OUTPUTS
Turret master 1 YV600 Forward drive proportional valve (PWM type, current control)
Node (U106) 2 YV620 Reverse drive proportional valve (PWM type, current control)
SPU can gateway
Turret slave 1 YV381 Boom lifting proportional valve (PVG type, voltage control): 0 to Ubatt/2
Node (U100) down direction, Ubatt/2 to Ubatt up direction
2 YV382 Boom telescoping proportional valve (PVG type, voltage control) : 0 to
Ubatt/2 in direction, Ubatt/2 to Ubatt out direction
3 YV880 Turret orientation proportional valve (PVG type, voltage control) : 0 to
Ubatt/2 right direction, Ubatt/2 to Ubatt left direction
4 YV102 Basket movements (jib lifting, basket compensation and rotation) and
steering proportional valve (PVG type, voltage control) : 0 to Ubatt/2
basket movements, Ubatt/2 to Ubatt steering
Basket slave 1 HA141 Upper panel Buzzer : connected on PVG output, the control of the
Node (U100) buzzer is done switching the internal relay of the B node with PVG
control to VBATT.

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• DETAIL ON MENUS
Below it’s an explanation of the different informations written on the screen of the OPTIMIZER console
• DIGITAL INPUTS
• DIGITAL OUTPUTS

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• ANALOG INPUTS
• ANALOG OUTPUTS
Reminder CO ( open circuit ) and CC ( short circuit)

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4.1.7.MENU INFORMATIONS
PARAMETER DESCRIPTION LEVEL

6.1 VERSIONS
HT21RT-HT23RTJ Soft revision : <model version>.<release>.<diag>.< machine id >
SPU BSP ACTIA SPU Drivers revision
SPU Bootloader SPU boot loader revision
Net Server Lib Master/slave network communication library revision
Specific SOC Lib Serial on CAN library revision
Slave Node B2 Soft revision for B2 type slave nodes
6.2 EVENT LOG SPY MENU (reserved for R&D) 3
!!FACTORY USE ONLY!!
+ and – to erase log
Override. Activation 8 last dates of overriding control command activation and contexts 3
associated with each date
Context: aaa aaa bbb ccc
aaa aaa : measured weight when activating the overriding
system (kg)
bbb : applied load (0:1000lb / !=0:500lb)
ccc : 1=overload, 2=underload
Enter P5 zone 8 last dates of P5 zone entering 3
Context: aaa bbb ccc ddd
aaa : country option (0:USA / 1:STD / 2:AUS)
bbb : previous position (2:P2 / 3:P3 / 4:P4)
ccc : telescope movement (00=no movement, 01=out, 10=in)
ddd : boom movement (00=no movement, 01=up, 10=down)
Country change 8 last dates of “country” option’s modification 3
aaa : country option old value (0:USA / 1:STD / 2:AUS)
bbb : country option new value (0:USA / 1:STD / 2:AUS)
ccc & ddd : always 000
Zone Error 8 last dates of position error detection (F07.17) 3
aaa : zone error identifier
bbb : previous position (1:P1 / 2:P2 / 3:P3 / 4:P4 / 5:P5)
ccc : telescope movement (00=no movement, 01=out, 10=in) at
error raise
ddd : boom movement (00=no movement, 01=up, 10=down) at
error raise
Angle Error 8 last dates of boom angle error (F07.04) 3
error raise
error raise
Length Error 8 last dates of boom length error (F07.11) 3
Context : aaa bbb ccc ddd
error raise
error raise

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Soft Rev .change 8 Last Dates of software uploading (vXX.YY.WW.ZZ) 3
Context : aaa bbb ccc ddd
aaa : software identifier (XX)
bbb : software identifier (YY)
ccc : software identifier (WW)
ddd : software identifier (ZZ)
6.3 DATA LOG Not used
6.4 DATE & HOUR Not used
* No Level access code to read / Level access code needed to erase event log

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4.2. LOAD MANAGEMENT SYSTEM
4.2.1.PRINCIPLE
The function of the Load Management System is to detect a overlap of the nominal load, then to
inform the user and prohibit certain movements.
For that, a load cell is fixed between the platform and the extensible structure,
This gauge measures the weight of the basket with the persons on it (F) and generates a signal
proportional to the weight which it supports (I),
This information is transmitted to the module Node B2 which carries out the digital analogical
conversion of the signal
The ECU SPU master module linked by CANBUS will send all processing datas
The coherence between the 2 load cells are checked periodically, if the measured load is more than
50kg during 1 second, the load cells are considered incoherent
4.2.2.SENSORS VALUES
2 strain gauges (SP480/SP481) are located inside the structure of the sensor, one on the upper
side and the other on the lower side, each gauge is connected to an amplifier (non visible from
outside)
each cell has 3 wires (+ Alim, GND and signal),

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4.2.3.HOW TO CHECK THE SENSORS
The sensors could be checked using the console via the diagnostic menu overload or also
setttings/calibration menu
The values shown below are theoretical and depends of the calibration of the load cells
(gain), the weight of the basket if equipped with its optional acessories
Load Cell Basket empty Basket with Basket with

230kg/550lbs 450kg/100lbs
SP480/SP481 ~ 6700 µA ~10700 µA ~ 14700 µA
(between 5.2mA and 8.2mA)

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4.3. ADJUSTMENT OF THE PRESSURES
4.3.1. TABLE OF PRESSURES

Trhe tolerance of prresure is ± 5 bars/72 psi except for main pressure where the tolerance
is 2 bars /29 psi
DESIGNATION Bars-Psi
Main 240-3480
Load Sensing 30-435
Standby unit 130-1885
Boom lift full stroke 240-3480
Boom descent 100-1450
Telescoping extension 100-1450
Telescoping extraction 240-3480
Turret slewing 120-1740
Jib lifting 210-3046
Jib descent 240-3480
Basket rotation 140-2031
Charge pressure in drive circuit 25-362
Drive FWD/REV 320-4641
Cubic capacity change on driving motor 50 - 725

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4.3.2.PLUG PORT FOR PRESSURES CHECK
• Drive circuit
• Equipement circuit

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4.3.3.PRESSURES ADJUSTMENT ON PUMPS
• Load sensing (LS)
• Flow
• Cubic capacity pump
LS adjustment
Main pressure
adjustment
Cubic capacity
adjustment
HS drive
adjustment
• The pump is preset with a stand-by pressure LS of 30b/435psi

• The pump is preset with a main pressure of 240b /3480psi
LS adjustment
Main pressure
adjustment
Note :for adjustment,remove the cap then turn HEX screw CW or CCW for pressure adjustment

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CC adjustment
Note : if no pressure , check

coupling between pump and engine

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5. SIMPLE USER GUIDE FOR BREAKDOWN
This guide does not replace the logical equations described previously in this manual,
it allows the technician to have a logical step of breakdown service, detailing the successive steps
to be followed starting from general tips 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 lifting : neither
raise, nor descent from both controls (up and down)
For a quicker diagnostic :
• Do check the failures code on Cluster display and refer to the alarms list before scrolling this
breakdown guide
• Do check all fuses
5.1. QUICK CHECKING ON MOVEMENTS

Thanks to this quick table, you could check for each movement , which valve must be activated
(example for jib lifting = YV101 +YV102 +YV500 = 1)
5.2. QUICK CHECKING ON DRIVE MODE

Same as above
(example for FWD drive in High speed mode YV600+YV782+YV686+YV780+YV781 = 1)

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5.3. QUICK CHECKING ON STEERING MODE
(example for FR steering YV101+YV102+YV602 = 1)
YV xxx 101 102 601 602 621 622

FL 2WS steering x x x
FR 2WS steering x x x
4WS steering crab mode (L) x x
4WS steering crab mode (R) x x x x
4WS steering synchro mode (L) x x
4WS steering synchro mode (R) x x x x

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5.4. QUICK CHECKING ON ENGINE

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5.5. NO START
• Battery GB1
• Emergency stops (SA100/SB143/SB144)
• engine start push buttons (SA110/SB161)
• Key selection turret/basket SA187
• Fuel level SQ141
• Temperature water engine (ST161)
• Pressure oil engine (SP162)
• Engine overheating (ST160)
• Relays KA1/KA2/KA3/KMG/KMP
• Load alternator (D+ OFF)
• Relay for power line KA3
• drive joystick SM122 off neutral
• Start/stop engine coil YA164 (with engine equipped with fixed rpm)
• Electronic accelerator coil YA166 with engine equipped with variable rpm control
• Sensors SV162 /ST161 (for engine equipped with variable rpm control)
• Preheating conditions (KM160)
• ECU modules (SPU/Node B2 turret – basket)
• EGV module (engine equipped with electronic accelerator)
5.6. NO MOVEMENT
• Machine in overload above 3 meters (load cells SP480/SP481 ) or wrong calibration
• Toggle swith for load selection SA146
• Platform in slope/tilt above 3 meters(SQ142 : not for US)
• Load sensing valve YV101
• Switch dead man low control box SA110
• Pedal switch SB106 (upper controls only)
• Drive joystick SM122 off neutral and/or signal out of range
• No pressure LS (25/30bars) or equipement pump (240bars)
5.7. NO BOOM FUNCTION ONLY

• Switch SA300 (lower control box)
• joystick SM120 off neutral and/or signal out of range
• Valves YV380/YV390/YV391
• Machine in outreach limitation (SQ321/SR380/SR381)
• No pressure
5.8. NO TELESCOPING ONLY

• Switch SA301 (lower control box)
• Joystick SM121 off neutral and/or signal out of range
• Valves YV382/YV392
• Machine in outreach limitation (SQ320/SQ380/SQ381)
• No pressure

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5.9. NO TURRET ROTATION ONLY
• Switch S880 (lower control box)
• joystick SM120 off neutral and/or signal out of range
• No pressure
5.10. NO JIB ONLY

• Switch SA500 or SA510
• No pressure
5.11. NO BASKET ROTATION ONLY

• Switch SA480
• No pressure
5.12. NO COMPENSATION ONLY

• Switch SA400 or SA481
• Other movement running
• Tilt switchs SR400/SR420
• No pressure
5.13. NO DRIVE ONLY

• Machine in slope SQ142 (not in US mode)
• Joystick SM122 off neutral and/or signal out of range
• Valve YV782 (brake release)
• Valves YV101/YV600/YV620/YV686
• No pressure on pump output
• Circuit brake release circuit (pressure/hoses)
5.14. LOW SPEED ONLY

• Switch SA680
• Limit switchs SQ320/SQ321/SQ381(machine unfolded)
• Valve YV686
• Pressure switch SP692
• ECU modules (SPU/Nodes B2 turret – basket)

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5.15. NO STEERING ONLY
• Rocker of joystick SM122
• Toggle switch SA681for crab/synchroneous 4WS steering mode
• Valves YV102/YV601/YV602 (for 2WS)
• Valves YV102/YV621/YV622 (for 4WS)
• Circuit of brake release circuit (YV782)
• Machine in overload
• ECU modules (SPU/Nodes B2 turret – basket)
5.16. NO OSCILLATING AXLE ONLY

• Machine not in drive mode and not in stowed position
• Piloted valves BV1/PD1/PD2

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6. SUMMARY OF VERSIONS HT21RT- HT23RTJ
HT21RT –HT23RTJ Electric Hydraulic

HT61RT – HT67RTJ schematics shematics
Version with fixed engine rpm
166P325080
(YA164 start/stop engine coil) All countries 166P328300J
Version with variable engine rpm with
166P325080
EGV Kubota module All countries 166P328300K
Version with Tiers 4 engine and e-stop
166P325080
circuit modified All countries 166P328300L
7. SPECIAL FUNCTIONS
7.1. CANBUS SYSTEM
CAN = Controller Area Network
BUS = network (2 wires CAN H (High) and CAN L (Low) for datas transmission between ECU)
ECU = Electronic Control Unit (called “module” in HAULOTTE Group)
• PRINCIPLE
The CAN is a serial communication system, this clever system permits a safe and quick
transmission between different units (or peripherals) connected on the bus (like sensors, valves,
joysticks and so on.)
The CAN bus is a network on which the electronic units (called nodes) are connected and is able
to communicate each other on the network thanks to the defined protocol.
The Bus is a network on which are connected electronic units (called node) able to communicate
between them by the network thanks to a preset protocol.
All the connected peripherals have the possibility simultaneously of sending messages on the
bus.
Each message receives a set of priorities, which makes it possible the other peripherals to
recognize the message which interests it and to be unaware of the others.
(ex the values standard signal movements will be treated in priority because they must be
transmitted very frequently due to their value )
• CAN BUS LINE CHECK

From any controls in parallel on the line (shunt between wires 1001 and 1002) = reading 60 Ω
Note
One shunt removed = 120 Ω.

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Two shunts removed = 240 Ω
7.2. ADJUSTMENT PROCEDURE OF SPECIFIC DEVICES

This chapter explains how to adjust the different devices located in the machine
7.2.1.ANY ILS SENSOR

As shown below, the best adjustment is between 6 and 15 mm and in the center of the
magnet
- Fit the sensor so as the distance between magnets and

sensor will be ideally between 6 and 15mm
Example for SR380
Loosen mounting
screws to adjust

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7.2.2.ANGLE SENSOR
Example for SR381 (it must be adjusted when boom angle reaches 52 ± 2°)
Note:This angle has been calcukated in order to stop the telescopic function when this boom
angle is reached and then always keep the machine in ist safe working zone (P2/P5)
Before starting with the switch adjustment, ensure the switch is positioned so that the roller is
centrally located on the cam
• Procedure
Connect the console (OPTIMIZER)

Scroll in the menu INPUTS/OUTPUTS in order to find SR381
SR381 U106/02/15
State ON (12.034V)
Mech. Boom angle
Lift the boom at 52° (check with electronic level)

Loosen the mounting bolts for the SR381 switch support and lower the boom and check that the
switch will change to ON to OFF state when it’s approach the center of the magnet

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7.2.3. TILT SENSORS
The tilts sensors SR400/SR420 must be adjusted in order to limit the inclination of the
basket compensation at +/- 10° (as shown below)

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7.2.4.CABLES ON TELESCOPIC BOOM
This following procedure must be carried out after replacing the telescopic boom and during
maintenance routine check
• Procedure
Step 1 Be sure that the boom section is horizontal, with the telescope retracted and insert an
axle in order to lock all the telescopic elements between them.
Step 2 : Check that the head screws of the clevis axle are oriented towards the external of the
boom section (as indicated below) and well in place around pulleys and guides

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Step 3 : Check that the rope is well oriented (see indication “TOP”) , then check to fi the
Belleville washers as shown below
Step 4 : for the exit cables ate the rear part of the boom , start to tight the HEX nut by
alterning left and right nut until getting the distance
(D-4) ± 0.2mm (by default, the difference between the washers when the nuts are tensioned
and not tensioned is 4mm)
In this position, check the setting in order to center the limit switch SQ990 then lock the whole
assembly with the counternut.

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SQ990
Step 5 :Do the same process for the front part of the boom with the retraction cables (limit
switch SQ991)

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7.2.5.KUBOTA ACCELERATOR COIL
Note: This procedure is applied only for engine version 1 equipped with fixed rpm
This adjustment must be done when the accelerator coil has been replaced
• Accelerator at idle speed (the cam should flush the screw without strength
• At full rpm, push the rod the right distance of the bellows is 38.6 mm , if not adjust the
threadened rod

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7.2.6.KUBOTA FUEL COIL AND SENSORS
Note : this procedure is valid only for engine version 2 equipped with EGV module for
speed control

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• Sensor replacement

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• Solenoide replacement
15mm

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Version 1 with fixed engine speed
(start/stop coil YA164)

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Version 2 with variable engine rpm (module EGV)

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TECHNICAL TRAINING

Chapter 1: Main features and functions

TRAINING MANUAL DIAGNOSTIC Level 2 HT21RT-HT23RTJ

4. ADJUSTMENTS ................................................................................................................................................... 119

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Lock pin on turret

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Symbol Name Output Control Description

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LED Function Color

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Symbol Name Output Control Description

Reach BLINK For STD and AUS countries, blinking if load

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DIGITAL /ANALOG U104 ECU DIGITAL /ANALOG

CAN 2.0 A CAN 2.0 B TURRET

U100 ECU U106 ECU U101 ECU Semi

(@2 CAN) NODE EGV

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TRAINING MANUAL DIAGNOSTIC Level 2 HT21RT-HT23RTJ

Battery with 2 elements (normally each of them

Fuse (Here 5 amps)

winding dual coil (start/stop engine coil)

Diode (A anode/K kathode)

TRAINING MANUAL DIAGNOSTIC Level 2 HT21RT-HT23RTJ

Key selector with 3 positions

Key selector with 2 postions

Toggle switch with 2 positions

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Proportional valve PWM type ( Pulse Width Modulation)

TRAINING MANUAL DIAGNOSTIC Level 2 HT21RT-HT23RTJ

Electrovalve “ON/OFF » ( bang-bang)

Tilt sensor ( ramp detection)

Angle sensor (reach limitation)

TRAINING MANUAL DIAGNOSTIC Level 2 HT21RT-HT23RTJ

Resistor (here value 120 ohms, 1/4 Watts)

Sensor length (reach limitation)

Pressure sensor (weighing)

Angle sensor (weighing)

Standard indicator “Led”

TRAINING MANUAL DIAGNOSTIC Level 2 HT21RT-HT23RTJ

Flexible Blade Switch (ILS) detection of the magnets on

Level detector (diesel tank)

Proximity detector with impulses