MF - HA20-260 PX - EN - E02-14

TECHNICAL TRAINING
DIAGNOSTIC LEVEL II
HA20PX–HA260PX
HA61JRT–HA80JRT
TRAINING MANUAL DIAGNOSTIC Level 2 HA20PX-HA260 PX
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How to use this document?
MAINTENANCE AND REPAIR OPERATIONS ON YOUR HAULOTTE MACHINE
MUST BE DONE ONLY BY TRAINED ,EXPERIENCED AND AUTHORIZED TECHNICIANS
You have between the hands the summary given during the HAULOTTE technical training
It will enable you to find information necessary for the maintenance and the repair of your
HAULOTTE machine .
Thanks to the guide below you will reach the required chapter quickly.
Chapter 1: Main features and functions

It is a resume of the information contained in the user manual delivered with the machine:
components, overall dimensions, working zones, commands, etc…
Chapter 2: Study of the electric diagram
You will find there the elements as following:
- A summary of the standardized symbols used by HAULOTTE Group
- The complete wiring diagram of the studied model
- The non exhaustive list of the electric looms and electronic boards
- Localization of the main safety units (tilt , limit switches, sensors,transducers…)
- Logical equations of operation: by function, to diagnose the main dysfunctions
Chapter 3: Study of the hydraulic diagram
You will find there the elements as following:
- a summary of the standardized symbols used by HAULOTTE Group
- the complete hydraulic diagram of the studied model
- the non exhaustive list of the hoses track
- a localization of the main hydraulics manifold (proportional blockk , on/off movements
block,…)
Chapter 4: Adjustments
This is the adjustments and calibrations, hydraulics and electric, necessary to the good maintenance
of the material. You will find as well the methods of adjustment with table values.
Chapter 5: Guide of breakdown
Quick summary of the step to be followed for possible sources of breakdown.
In case of any defect or any dysfunction you will be able to identify the elements in question,
whatever they are electric or hydraulic.
Chapter 6: Summary of the versions
This manual treats of the latest version, however this summary table enables you to find the former
versions of the material (electric and hydraulics).
Chapter 7: Special functions
This chapter gathers all the functions and adjustment specific to carry out on the machine. There
does not exist for all the materials and depends on the studied model.
It must be the subject of a special attention of your share because an intervention badly carried out
can deteriorate the good performance of the machine and thus consequently the safety of the users.
Only a technician HAULOTTE or approved by HAULOTTE Services is able to carry out this kind of
intervention.
On this chapter, some special adjustment ( sensors) are also explained prior to calibration (depends
on the model)
Chapter 8: HA260PXNB
This chapter is dedicated to the latest model of HA20PX-HA260PX .
The main modifications are on the upper control box with new josyticks and a new ECU module
node B1 located in upper controls which communicates with HEAD module node A through CAN
BUS connection
All hydraulics and operations remains identical for the operator
Chapter 9: List of Schematics
In that chapter, all schematics in A3 size are listed (electric/hydraulic) and if required some extras
lay out
TRAINING MANUAL DIAGNOSTIC Level 2 HA20PX-HA260PX

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REVISION
Revision Edition Subject Created Validated Modified Translated Language

by by by by
00 03-12 Creation with MGD FLC MGD FR/EN/SP/
version Mil4 POR
01 07-13 Add sensors adj MGD FLC MGD MGD EN
+ newest
schematics with
power line 246
on sensors
03 12-13 Add Diag Pad MGD Central MGD MGD EN
info + console R&D
alarm list
04 02-14 Add chapter MGD EN
schematics

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SUMMARY
1. MAIN FEATURES AND FUNCTIONS .................................................................................................................. 6
1.1. CHARACTERISTICS ............................................................................................................................................... 6
1.1.1. main components........................................................................................................................................ 6
1.1.2. Overall dimensions..................................................................................................................................... 8
1.1.3. working zones ............................................................................................................................................. 9
1.2. COMMANDS (UP AND DOWN) .......................................................................................................................... 12
2. THE ELECTRICAL PART.................................................................................................................................... 16

2.1. SYMBOLS USED .................................................................................................................................................. 16
2.2. METHODOLOGY OF CONTROL ............................................................................................................................ 20
2.2.1. electric continuity control ........................................................................................................................ 20
2.2.2. Control of an on/off valve ........................................................................................................................ 20
2.2.3. Control of components ............................................................................................................................. 21
2.3. THE WIRING DIAGRAM ....................................................................................................................................... 24
2.4. THE MAIN PRINTED CIRCUIT (LOWER CONTROL BOX)......................................................................................... 24
2.4.1. The weighing board (bpe) ........................................................................................................................ 24
2.4.2. slip ring (157P248040) ............................................................................................................................ 25
2.5. THE MAIN SAFETY COMPONENTS ........................................................................................................................ 26
2.6. LIST OF COMPONENTS ....................................................................................................................................... 27
2.6.1. engine ....................................................................................................................................................... 28
2.6.2. Fuses ........................................................................................................................................................ 28
2.6.3. inputs ........................................................................................................................................................ 29
2.6.4. Outputs ..................................................................................................................................................... 31
2.7. LOGICAL EQUATIONS OF OPERATION ................................................................................................................. 33
2.7.1. engine ....................................................................................................................................................... 33
2.7.2. drive ......................................................................................................................................................... 34
2.7.3. Steering .................................................................................................................................................... 36
2.7.4. boom lift ................................................................................................................................................... 37
2.7.5. Telescoping .............................................................................................................................................. 38
2.7.6. arm lift ...................................................................................................................................................... 39
2.7.7. Turret slewing .......................................................................................................................................... 40
2.7.8. Jib ............................................................................................................................................................. 40
2.7.9. Compensation........................................................................................................................................... 41
2.7.10. basket rotation.......................................................................................................................................... 42
3. THE HYDRAULIC PART ..................................................................................................................................... 43
3.1. SYMBOLS USED .................................................................................................................................................. 43
3.2. THE HYDRAULIC DIAGRAM (157P243400)......................................................................................................... 47
3.3. MAIN HYDRAULIC MANIFOLDS ........................................................................................................................... 47
3.3.1. chassis ...................................................................................................................................................... 47
3.3.2. turret ........................................................................................................................................................ 48
3.3.3. Detail drive block ..................................................................................................................................... 50
3.3.4. Detail steering block ................................................................................................................................ 52
3.3.5. Detail block on/off .................................................................................................................................... 53
3.3.6. Detail proportional block pvg .................................................................................................................. 54
3.4. THE HYDRAULIC HOSES ..................................................................................................................................... 55
3.5. HELP GUIDE FOR HYDRAULIC LEAKS .................................................................................................................. 55
4. ADJUSTMENTS ..................................................................................................................................................... 77
4.1. ADJUSTMENTS WITH CONSOLE OPTIMIZER ........................................................................................................ 77
4.1.1. Parameter settings (HA260PX) ................................................................................................................ 82
4.1.2. parameters menu optimizer ...................................................................................................................... 83
4.2. LOAD MANAGEMENT SYSTEM ................................................................................................................... 92
4.2.1. principle ................................................................................................................................................... 92
4.2.2. Angle sensors ........................................................................................................................................... 93
4.2.3. overload board bpe .................................................................................................................................. 94
4.2.4. Management of nominal load overlap ..................................................................................................... 95
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4.2.5. Procedure of standard calibration (machine < ad122967) ..................................................................... 95
4.2.6. alarms code of the weighing board .......................................................................................................... 96
4.2.7. sensors valuess ......................................................................................................................................... 96
4.2.8. Limitation of the angle of inclination ....................................................................................................... 97
4.2.9. how to check the sensors on bpe board .................................................................................................... 97
4.3. ADJUSTMENT OF THE PRESSURES ....................................................................................................................... 98
4.3.1. Table of pressures .................................................................................................................................... 98
4.3.2. Plug port for pressures check................................................................................................................... 98
4.3.3. Adjustment................................................................................................................................................ 99
1. PRESSURE INCREASE ....................................................................................................................................... 100
4.4. ACCELERATOR ENGINE COIL ............................................................................................................................ 102
5. BREAKDOWN SERVICE GUIDE ..................................................................................................................... 104
5.1. NO START ..................................................................................................................................................... 104
5.2. NO MOVEMENT ........................................................................................................................................... 104
5.3. NO ARM LIFT ............................................................................................................................................... 104
5.4. NO BOOM LIFT .................................................................................................................................................. 105
5.5. NO TELESCOPING ............................................................................................................................................. 105
5.6. NO TURRET ROTATION ............................................................................................................................. 105
5.7. NO JIB ............................................................................................................................................................ 105
5.8. NO BASKET ROTATION ................................................................................................................................ 105
5.9. NO COMPENSATION................................................................................................................................... 105
5.10. NO DRIVE...................................................................................................................................................... 105
5.11. LOW SPEED ONLY ...................................................................................................................................... 106
5.12. NO STEERING .............................................................................................................................................. 106
6. SUMMARY OF VERSIONS HA20PX-HA260PX ............................................................................................. 107
7. SPECIAL FUNCTIONS ....................................................................................................................................... 108
7.1. SYSTEM OF REACH LIMITATION (HA260PX ONLY) ........................................................................................... 108
7.1.1. Principle of operation ............................................................................................................................ 108
7.1.2. Procedure of calibration machine < ad122967 ..................................................................................... 108
7.1.3. sensors values ........................................................................................................................................ 110
7.1.4. Procedure of outreach calibration ( > software V1.09)......................................................................... 111
8. MODELS EQUIPPED WITH ECU MODULE NODE B .................................................................................. 114
8.1. DIFFERENCES ................................................................................................................................................... 114
8.1.1. the upper control box ............................................................................................................................. 114
8.1.2. the can bus ............................................................................................................................................. 115
8.1.3. the module node b1 ................................................................................................................................ 116
8.1.4. components upper control box ............................................................................................................... 117
8.1.5. list of optimizer menu ............................................................................................................................. 119
8.1.6. list of alarms........................................................................................................................................... 125
8.1.7. angle sensors value ................................................................................................................................ 126
8.1.8. overload calibration ............................................................................................................................... 127
8.1.9. reach limit calibration............................................................................................................................ 129
8.2. CONSOLE DIAG PAD .......................................................................................................................................... 131
8.3. PROCEDURE FOR SENSORS ADJUSTEMENT......................................................................................... 133
8.3.1. angle sensor A1 ...................................................................................................................................... 133
8.3.2. absolute angle A2 (inclinometer) ........................................................................................................... 133
8.3.3. pressure sensors G1- G2 ........................................................................................................................ 134
8.3.4. angle sensor SL1-SL2............................................................................................................................. 134
8.3.5. length sensor SL3-SL4............................................................................................................................ 136
8.3.6. telescopic boom ils detection SQ7 .......................................................................................................... 137
8.3.7. How to understand the sensors value at the console ............................................................................. 138
9. LIST OF SCHEMATICS ...................................................................................................................................... 138

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

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1.1.2. OVERALL DIMENSIONS

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1.1.3. WORKING ZONES
HA20PX

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HA260PX

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1.2. COMMANDS (UP AND DOWN)

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2. THE ELECTRICAL PART
2.1. SYMBOLS USED
Battery with one element
Alternator
Fuse (Here 10 amps)
Coil winding roll
Electric motor
indicator
Diode
Hourmeter

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

(T turret, O neutral, N platform)
Toggle switch with 2 positions
Electrovalve
relay
horn

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Proportional electrovalve
Proportional valve PWM type ( Pulse Width Modulation)
Controller/joysticks
Foot pedal switch
buzzer
“indicator”
Electrovalve “ON/OFF » ( bang-bang)
Tilt sensor ( ramp detection)
Angle sensor (reach limitation)
Contact « mercury » (angle detection)

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Resistor (here value 100 ohms, 3 Watts, tolerance 5%)
Sensor length (reach limitation)
Pressure sensor (weighing)
Angle sensor (weighing)
Standard indicator “Led”
Strain gauge
Flexible Blade Switch (ILS) detection of the magnets on

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

(detection teeth slew ring)

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2.2. METHODOLOGY OF CONTROL
Note: During an intervention on a component or a loom, it is important to 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, to carry out its replacement
2.2.3. CONTROL OF COMPONENTS
• Control of an electric relay

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

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In the event of dysfunction, replace the relay.
• 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 WIRING DIAGRAM
See all versions at the end of this manual
For all details regarding harnesses/looms, refer to parts book
2.4. THE MAIN PRINTED CIRCUIT (LOWER CONTROL BOX)

See at the end of this manual
2.4.1. THE WEIGHING BOARD (BPE)

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2.4.2. SLIP RING (157P248040)
cables
terminal
blockk Electrovalve Cables color
1 0 (GND) - orange
2 YV22A red
3 YV22B 306 - purple
4 YV21A 307 - white
5 YV21B 308 - brown
6 YV9 807A - pink
7 YV13 807 B - yellow
8 YV8 813 green
9 YV10-YV23 814A dark blue
10 YV12-YV17 814 B indicator brown
11 YV11 814C black
12-17 + EV (positive) 201 blue

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2.5. THE MAIN SAFETY COMPONENTS
SENSORS LOCATION
SQ1 slope detection
SQ2 jib
SL1-SL2 SQ3 Arm lift detection
SQ4 Detection arm /boom stowed
position
SQ7 ILS magnet detection zone
telescope (HA260PX)
SQ9 Telescopic retraction
SL1-SL2 angle boom transducers
(only HA260PX)
SL3-SL4 telescopic length transducer
(only HA260PX)
SL3-SL4
A1 Angle sensor (load system)
A2 Inclinometer (load system)
G1 Pressure sensor small chamber
G2 pressure sensor large chamber
SQ1
SQ9
SQ7
SQ2
SQ4
SQ3 A2
A1
G2 G1

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2.6. LIST OF COMPONENTS
KT2 FU5 FU9 FU10 FU8 FU6
FU4
KMG
KA46
FU3
FU7
KA2
KP1
FU1
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.

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• Glossary
FWD Forward (drive)

REV Reverse (drive)
FL Front Left
FR Front Right
RL Rear Left
RR Rear Right
PF Platform
LS Low Speed drive
LS valve/adj Load sensing valve/adjustment
MS Medium Speed drive
HS High Speed drive
ILS Magnet sensor (Interrupteur Lame Souple)
2.6.1. ENGINE
ENGINE ELEMENTS
M3 01 - 7 Starter
G2 01.-12 Alternator
YA2 01 - 16 Accelerator coil
YA1 01 - 19 Start/stop engine coil
U1 Head module
2.6.2. FUSES
FUSES
FU1 01 - 19 Stop engine 10A (115)

FU3 01 - 16 Accelerator 80A (119)
FU4 02 - 3 + general line 30A (120)
FU5 02 - 7 + turret line 30 A(212)
FU6 02 -9 + platform line 3A (211)
02 - 12 + valve supply 20A (201)
FU7
if a valve is supplied permanently: FU7 is destroyed
FU8 02 - 13 + permanent 5A (242)
FU9 02 - 14 + accessories line 20A (905)
FU10 04 - 3 + YV1 Load Sensing 3A (302)
FU13 01 -2 + emergency pump 250A (100)
FUxx 01 - 16 Fuse 30A inside harness YA2 coil – no label

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2.6.3. INPUTS
INPUTS
SA1 02 - 8 Selection of commands (upper/lower control box)
SA2 03 - 4 28.7 Accelerator (605)
SA3 05 - 11 29.3 Differential lock (611A)
SA4 05 - 12 basket rotation
30.3 SA4a left (310)
30.4 SA4b right (311)
SA5 05 - 14 basket compensation (upper control box)
30.6 SA5a descent (402)
30.5 SA5b lift (401)
SA6 03 - 5 Jib (lower control box)
4.6 SA6b lift (406)
SA7 05 - 16 Jib (upper control box)
30.9 SA7b lift (410)
SA8 03 - 6 Telescopic boom (lower control box)
4.15 SA8a retraction (411)
4.14 SA8b extension (412)
SA9 05 - 17 Telescopic boom (upper control box)
30.10 SA9a retraction (418)
30.11 SA9b extension (419)
SA11 05 - 2 Selection of drive speed
30.14 Low speed: SA11a=1 (918) and SA11b=0 (611c)
29.14 Medium speed: SA11a=0 (918) and SA11b=0 (611c)
High speed: SA11a=0 (918) and SA11b=1 (611c)
SA12 05 - 18 Steering rear axle
29.6 SA12a Right (705)
29.5 SA12b Left (703)
SA13 03 - 10 Boom lift (lower control box)
28.1 SA13a lift (504)
28.2 SA13b descent (505)
SA14 03 - 8 Lifting arm (lower control box)
28.3 SA14a lift (510)
28.6 SA14b Descent (511)
SA15 03 - 7 Turret rotation (lower control box)
28.9 SA15a Right (517)
28.4 SA15b Left (516)
SA17 03 - 11 basket compensation (lower control box)
50.4 SA17a lift (256)
50.3 SA17b descent (255)
SA19 02 - 7 Enable switch/ Emergency pump lower control box (620)

SA20 02 - 8 Emergency pump upper control box (620)
SB1 02 - 7 Emergency stop turret (120)
SB2 02 - 9 Emergency stop basket (102)
SB3 03 - 14 4.12 Start-up lower control box (117a)

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SB4 05 - 1 3.2 Start-up upper control box (117b)
SB5 05 - 20 43.2 Buzzer (115a)
SB6 05 - 9 29.13 Dead man's pedals (917)
SM4 05 - 8 Drive joystick
29.7 SM4d right steering (707)
29.8 SM4g left steering (708)
29.2 Off neutral SM4ab (606)
29.4 Y signal drive (612)
FWD from 2.5 to 4.5 V
Reverse from 2.5 to 0.5 V
SM31 05 - 4 turret rotation and boom lift joystick
30.12 SM off neutral 31ab (420a)
29.1 X signal turret rotation (512)
Signal from 0.5 to 2.5 and 2.5 with 4,5V
30.7 Y signal boom lift (403)
Raise from 2.5 to 4,5V
Descent from 2.5 to 0,5V
MODULES
U1
Module Head (node A)
U2
04 - 15 Weighing board BPE
SENSORS
SQ1
04 - 3 39.3 Tilt sensor (205 = 0 if in slope)
SQ2
04 - 7 3.3 Jib (206 = 0 if jib > 3 meters)
SQ3
04 - 6 41.2 Arm (207 = 0 if arm out)
SQ4 04 - 7 42.2 Arm and boom (232=0 if out)
SQ7
04 - 5 38.2 ILS magnet detection of telescopic length (222)
SQ9
04 - 8 45.2 Telescopic boom length position (204 = 0 if OUT)
A1
04 - 20 J15.3 Relative angle sensor weighing (384)
A2
04 - 20 J7.G Absolute angle sensor weighing (inclinometer) (383)
G1
04 - 19 J7.B Pressure sensor small chamber jib cylinder (380)
G2
04 - 20 J11.3 Pressure sensor large chamber jib cylinder (382)
SL1
04 - 9 29.15 detection boom angle (611b)
SL2
04 - 12 29.10 detection boom angle (805)
SL3
04 - 13 29.9 detection boom length (804)
SL4
04 - 14 29.11 detection boom length (807)
B1
04 - 19 27.2 Air filter clogging (110 = 0 if filter clogged)

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B2
04 - 18 27.3 Oil engine Temperature (111=0 if T > 85°C)
B3
04 - 17 27.4 Oil engine Pressure (112 = 0 if P > 0.5 bars)
B4
04 - 17 40.2 Hydraulic oil Temperature (904=1 if T >80°C)
D+
04 - 19 27.1 Alternator (109 = 12V) if alternator is powered
W
04 - 20 27.7 Frequency (108)
2.6.4. OUTPUTS
RELAYS
KP1
04 - 12 Engine start/stop (150)
KT2
04 - 13 Accelerator (605a)
KA2
04 - 14 Starter (146)
KA43
01 - 13 alternator (109)
KMG
02 - 10 General (241)
KM4
02 - 7 Emergency pump (622)
VALVES
YV1 04 - 3 20 Load Sensing (303)

05 - 18 51.4
Telescope
YV2 YV2a extension (259)
YV2b retraction (259)
05 - 16 22.3
Boom lift (403a)
YV3 Raise: from 50 to 75% of the tension of battery
Descent: from 50 to 25% of the tension of battery
05 - 14 23.3
Arm lift (506a)
YV4 lift: from 50 to 75% of the tension of battery
descent: from 50 to 25% of the tension of battery
05 - 12 24.3
Turret slewing (512a)
YV5
from 50 to 75% of the tension of battery
05 - 10 26.3
Drive (612a)
YV6 FWD from 50 to 75% of the tension of battery
REV from 50 to 25% of the tension of battery
YV8 03 - 19 8.11 High speed drive (813)

YV9 03 - 20 15.4 Differential lock front axle (807a)
YV10 03 - 14 8.12/8.10 Medium and high speed drive (814a)
YV11 03 - 18 8.6 Brake release (814c)
YV12 03 - 15 8.9/8.3 Medium and high speed drive (814b)

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YV13 03 - 19 15.9 High speed drive (807b)
03 - 1 Turret slewing
YV14 31 Right YV14a (414a)
21 Left YV14b (417a)
YV15a 03 - 7 18 Basket compensation descent (401a)
YV15b 03 - 7 19 Basket compensation raise (402a)
YV17 03 - 17 8.3/8.9 medium and high speed drive(814b)
YV18a 03 - 5 17 Jib descent (407a)
YV18b 03 - 6 10 Jib raise (408a)
YV19a 03 - 8 35 basket rotation right (310a)
YV19b 03 - 9 34 basket rotation left (311a)
YV21a 03 - 10 15.8 right steering rear axle (307)
YV21b 03 - 11 15.7 Left steering rear axle (308)

YV22a 03 - 12 15.3 right steering front axle (304)
YV22b 03 - 13 15.6 Left steering front axle (306)
YV23 03 - 15 8.10/8.12 Medium and high speed drive (814A)
YV26 03 - 4 33 safety valve for boom (304a) (only on HA260PX)
BUZZER AND INDICATORS
HA1 04 - 7 52.2/52.3 Buzzer (260 and 261)
HA2 05 - 3 9.2 overload buzzer upper control box (921a)
HA4 04 - 8 14 Buzzer lower control box (210)
HL1 01 - 13 Indicator operation alternator (109)
HL2 04 - 11 4.3 air filter clogging indicator (110a)
HL3 04 - 10 4.2 oil engine temperature indicator (111a)
HL4 04 - 9 4.1 Oil pressure engine indicator (112a)
HL5 02 - 14 Beacon (906) Option
HL6 02 - 16 Spot lights (905) Option
HL7 02 - 18 Power indicator upper control box (211)
HL8 05 - 9 52.3 Flashing indicator (262) Option
HL9 05 - 2 49.2 overload indicator upper control box (253)
HL13 05 - 5 28.15 alarm indicator upper control box (914)
HL14 05 - 7 56.2 reach limitation indicator upper control box (398)
HL15 05 - 8 16.3 reach limitation indicator lower control box (698)
HL16 05 - 6 16.2 overload indicator lower control box (699)

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2.7. LOGICAL EQUATIONS OF OPERATION
For all these conditions, the fuses will have to be checked as a preliminary
The condition of the equations of operation described below refers to the standard EN280,
machines known as Standard,
For the other versions (USA,CDN,AUS) thank you to refer to you to HAULOTTE SERVICES of your
sector which will indicate the characteristics of your machine
All fuses have been checked
2.7.1. ENGINE
CONDITIONS
Function Action Prohibiting the Modifying the
Necessary
function function
engine already
SA1 (side N or T) + SB3=1 started
Start-up KA2=1
or SB4=1 and D+= 1 Movement in
progress
CONDITIONS
Necessary
function function
Defect engine> + 6
seconds:
D+=0 and B3=GND
Engine power KP1=1 KA2=1 then 0 Clogged filter:
supply + YA1=1 W=1 B1=GND
Temp engine oil
B2=GND
CONDITIONS
Necessary
function function
KT2=1 SA1 (side N or T) + SB6=1
Accelerator
+ YA2=1 or SA2=1
The accelerator remains 0.5 second ON when command is released.

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2.7.2. DRIVE
CONDITIONS
Function Action Modifying
Prohibiting the
Necessary the
function
function
SQ7, SL1, SL2, SL3
and SL4
SA1 (side N) + SQ2= 0 + (reach limitation)
SQ3=0 + SQ4= 0 + SQ9=0 G1, G2, A1 and A2
YV1=1
Microspeed (machine unfolded) (Overload)
+ YV6=1
+ Phase of load
SM4ab=1 and SB6 = 1 calibration
YV11= 0
(brake release)
CONDITIONS
Prohibiting the
Necessary the
function
function
SQ7, SL1, SL2, SL3
and SL4
(reach limitation)
SA1 (side N) + SA11a = 1
G1, G2, A1 and A2
Low speed YV1=1 and SA11b = 0 and
(Overload)
forward + YV6=1 SM4ab=1 and SB6 = 1 and
Phase of load
SM4 between 2,5V and 4,5V
calibration
YV11= 0
(brake release)
SQ7, SL1, SL2, SL3
and SL4
(reach limitation)
G1, G2, A1 and A2
Low speed YV1=1 and SA11b = 0 and
(Overload)
reverse + YV6=1 SM4ab=1 and SB6 = 1 and
Phase of load
SM4 between 2,5V and 0,5V
calibration
YV11= 0
(brake release)

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CONDITIONS
Function Action Prohibiting the Modifying
Necessary
function the function
SQ2=0 or
YV1=1
SQ3=0 or
+ YV6=1
SA1 (side N) + SA11a = 0 SQ4=0 or
+ YV10=1
Medium speed and SA11b = 0 and SQ9=0
+ YV11=1
forward SM4ab=1 and SB6 = 1 and (unfolded
+ YV12=1
SM4 between 2,5V and 4,5V machine)
+ YV17=1
YV11= 0
+ YV23=1
(brake release)
SQ2=0 or
YV1=1
SQ3=0 or
+ YV6=1
SA1 (side N) + SA11a = 0 SQ4=0 or
+ YV10=1
Medium speed and SA11b = 0 and SQ9=0
+ YV11=1
reverse SM4ab=1 and SB6 = 1 and (unfolded
+ YV12=1
SM4 between 2,5V and 0,5V machine)
+ YV17=1
YV11= 0
+ YV23=1
(brake release)
CONDITIONS
Prohibiting the
Necessary the
function
function
YV1=1 SQ2=0 or SQ3=0
+ YV6=1 or SQ4=0 or
+ YV8=1 SQ9=0
+ YV10=1 (unfolded
High speed and SA11b = 1 and SM4ab=1
+ YV11=1 machine)
forward and SB6 = 1 and SM4
+ YV12=1
between 2,5V and 4,5V
+ YV13=1 YV11= 0
+ YV17=1 (brake release)
+ YV23=1
YV1=1 SQ2=0 or SQ3=0
+ YV6=1 or SQ4=0 or
+ YV8=1 SQ9=0
+ YV10=1 (unfolded
High speed and SA11b = 1 and SM4ab=1
+ YV11=1 machine)
reverse and SB6 = 1 and SM4
+ YV12=1
+ YV13=1 YV11= 0
YV17=1 (brake release)
+ YV23=1
CONDITIONS
Prohibiting the
Necessary the
function
function
Selection
high speed
SA1 (side N) + SA3=1 and
Differential lock YV9=1 Unfolded machine
SA11a = 1
YV11= 0
(brake release)

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2.7.3. STEERING
CONDITIONS
Prohibiting the
Necessary the
function
function
G1, G2, A1, A2
YV22a=1 SA1 (side N) + SB6=1 + (Overload)
Steering
or SM4c=1 or SM4d=1
front axle Load calibration in
YV22b=1 + YV1=1 + YV5a=1
process
CONDITIONS
Prohibiting the
Necessary the
function
function
G1, G2, A1 ,A2
YV21a=1 SA1 (side N) + SB6=1 + (Overload)
Steering
or SA12a=1 or SA12b=1
rear axle
YV21b=1 + YV1=1 + YV5a=1 load calibration in
process

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2.7.4. BOOM LIFT
CONDITIONS
Prohibiting the
Necessary the
function
function
SQ1=0
YV1=1
Arm angle > 60°
+ YV3=1 (calibration mode) Reduced
Raise SA1 (side N) + SB6=1 +
speed if
upper control SM1ab=1 and SM31y U2 or A1 or A2
+ angle boom
box between 2,5V and 4,5V or G1 or G2
YV26=1 >73°
(dynamic overload)
(HA260)
load calibration in
process
SQ1=0
Reduced
YV1=1
Angle arm < 65° speed
+ YV3=1
Descent SA1 (side NR) + SB6=1 + (calibration mode) according
upper control SM1ab=1 and SM31y SQ7, SL1, SL2, SL3 to position
+
box between 2,5V and 0,5V and SL4 in the
YV26=1
(reach limitation) working
(HA260)
Load calibration in zone
process
CONDITIONS
Necessary
Reduced
speed if
SQ1=0 + SQ9=0
angle boom
YV1=1
73°
+ YV3=1
Raise Reduced
SA1 (side T) + SA13a=1 Arm angle > 60°
lower control box + speed if
YV26=1 (calibration mode)
U2 or A1 or
(HA260) A2 or G1 or
load calibration in G2
process (dynamic
overload)
SQ1=0 + SQ9=0 Reduced

YV1=1
speed if
+ YV3=1
U2 or A1 or
Descent Arm angle < 65°
SA1 (side T) + SA13b=1 A2 or G1 or
lower control box + (calibration mode)
G2
YV26=1
SQ7, SL1, SL2, (dynamic
(HA260)
SL3 and SL4 overload)
(reach limitation)

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2.7.5. TELESCOPING
CONDITIONS
Necessary
SQ1=0
Arm angle < 65°
(calibration
mode) Reduced
U2 or A1 or A2 speed if
extension YV1=1 SA1 (side N) + SB6=1 and
or G1 or G2 stroke
upper control box + YV2=1 SA9b=1
(dynamic telescope
overload) 6715 mm
weighing
calibration in
process
U2 or A1 or A2
Reduced
or G1 or G2
speed if
Retraction YV1=1 SA1 (side N) + SB6=1 and (dynamic
stroke
upper control box + YV2=1 SA9a=1 overload)
telescope
Load calibration
< 200 mm
in process
SQ1=0
Reduced
Arm angle < 65° speed if
extension YV1=1 (calibration
SA1 (side T) + SA8b=1 stroke
lower control box + YV2=1 mode) telescope
Load calibration 6715 mm
in process
Reduced
speed if
Retraction YV1=1 Load calibration
SA1 (side T) + SA8a=1 stroke
lower control box + YV2=1 in process
telescope
< 200 mm
SQ7, SL1, SL2, SL3 and

Automatic YV=1
SL4 SQ9=1
retraction + YV2=1
(reach limitation)

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2.7.6. ARM LIFT
CONDITIONS
Necessary
SQ1=0
SA1 (side N) + SB6=1 + U2 or A1 or A2
Raise YV1=1 or G1 or G2
SM2ab=1 and SM2y
upper control box + YV4=1 (dynamic overload)
Load calibration in
process
Boom angle > 60°
(calibration mode)
SQ7, SL1, SL2, SL3
SA1 (side N) + SB6=1 + and SL4
Descent YV1=1 (reach limitation)
SM2ab=1 and SM2y
upper control box + YV4=1 U2 or A1 or A2
or G1 or G2
(dynamic overload)
Load calibration in
process
CONDITIONS
Necessary
function function
SQ1=0
Reduced
SQ7, SL1, SL2, speed if
Raise YV1=1 SL3 and SL4 U2 or A1 or A2
SA1 (side T) + SA14a=1
lower control box + YV4=1 (reach limitation) or G1 or G2
(dynamic
Load calibration in overload)
process
SQ7, SL1, SL2, Reduced

SL3 and SL4 speed if
Descent YV1=1 (reach limitation) U2 or A1 or A2
SA1 (side T) + SA14b=1
lower control box + YV4=1 or G1 or G2
Load calibration in (dynamic
process overload)

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2.7.7. TURRET SLEWING
CONDITIONS
Necessary
U2 or A1 or A2
Turret or G1 or G2
YV1=1 SA1 (side N) + SB6=1 +
rotation (dynamic overload)
+ YV5=1 SM1ab=1 and SM31x
upper control
+ YV14ab=1 between 2,5V and 4,5V Load calibration in
box
process
SQ7, SL1, SL2, SL3 Reduced
and SL4 speed if
Turret
YV1=1 (reach limitation) U2 or A1 or
rotation SA1 (side T) + SA15a=1
+ YV5=1 A2 or G1 or
lower control or SA15b=1
+ YV14ab=1 Load calibration in G2
box
process (dynamic
overload)
2.7.8. JIB
CONDITIONS
Necessary
SQ1=0
U2 or A1 or A2
or G1 or G2
(dynamic overload)
Raise YV1=1 G1
SA1 (side N) + SB6=1 and
upper control + YV5=1 (high stop)
SA7b=1
box + YV18b=1
A1
(high electric stop)
Load calibration in
process
U2 or A1 or A2
or G1 or G2
(dynamic overload)
Descent YV1=1 G2
SA1 (side N) + SB6=1 and
upper control + YV5=1 (low stop )
SA7a=1
box + YV18a=1 A1
(Low electric Stop)
weighing calibration in
process

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SQ1=0
U2 or A1 or A2 Reduced
or G1 or G2 speed if
Raise YV1=1 (dynamic overload) U2 or A1 or
lower control + YV5=1 SA1 (side T) + SA6b=1 G1 A2 or G1 or
box + YV18b=1 (high stop ) G2
A1 (dynamic
(High electric Stop) overload)
Load calibration in
process
U2 or A1 or A2
or G1 or G2
(dynamic overload)
Descent YV1=1 G2
lower control + YV5a=1 SA1 (side T) + SA6a=1 (low stop)
box + YV18b=1 A1
(Low electric Stop)
Load calibration in
process
2.7.9. COMPENSATION
CONDITIONS
Necessary
U2 or A1 or A2
or G1 or G2
(static overload)
SA1 (side NR) + SB6=1 +
YV1=1
Raise SA5b=1 Any other movement
+ YV5=1
upper control box + pc board U2 (J6.1=1 - in progress
+ YV15b=1
basket < +15°)
Load calibration in
process
U2 or A1 or A2
or G1 or G2
(static overload)
SA1 (side NR) + SB6=1 +
YV1=1
Descent SA5b=1 Any other movement
+ YV5=1
upper control box + board U2 (J6.2=1 - in progress
+ YV15a=1
basket < with -15°)
Load calibration in
process

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Any other movement Reduced
in progress speed if
YV1=1 U2 or A1 or
Raise
+ YV5=1 SA1 (side T) + SA17b=1 A2 or G1 or
lower control box Load calibration in
+ YV15b=1 G2
process
(dynamic
overload)
Any other movement Reduced
in progress speed if
YV1=1 U2 or A1 or
Descent
+ YV5=1 SA1 (side T) + SA17a=1 A2 or G1 or
lower control box Load calibration in
+ YV15a=1 G2
process
(dynamic
overload)
2.7.10. BASKET ROTATION
CONDITIONS
Prohibiting the
Necessary the
function
function
U2 or A1 or A2
or G1 or G2
YV1=1 (static overload)
Right rotation SA1 (side N) + SB6=1 and
+ YV5=1
upper control box SA4b=1
+ YV19a=1 Load calibration in
process
U2 or A1 or A2
or G1 or G2
YV1=1 (static overload)
Left rotation SA1 (side N) + SB6=1 and
+ YV5=1
upper control box SA4a=1
+ YV19b=1 Load calibration in
process

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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
superior booms like HA32PX, HA41PX, H28TJ+,
H43TPX)
Hydraulic motor with 2 directions of drive

(ex FWD/REV)
Variable cubic capacity drive motor with 2

directions of drive
15cc for high speed
45 cc for low speed
Filter (normally 10 microns)

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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 DIAGRAM (157P243400)
See at the of this manual
3.3. MAIN HYDRAULIC MANIFOLDS
3.3.1. CHASSIS
steering block
drive block

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3.3.2. TURRET
• version 1
Bloc ON/OFF
YV26 safety valve

for boom
(only on HA260PX)
Proportionnal block PVG

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• Version 2 (model equipped with ECU module node B1)
Block ON/OFF
YV26

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3.3.3. DETAIL DRIVE BLOCK
YV 9: diff lock YV 8: High Speed
YV 23: Medium
YV 17: medium and High speed
and high speed
YV 10 Medium
YV 11: brake and High Speed
release
YV 13: High speed
YV 12: medium
and High Speed
1 BLOCK
2 VALVE
3 CIRCUIT SELECTOR SWITCH
4 Pressure relief valve(100 bars)
5 COIL
6 COIL
7 SOLENOID VALVE
7-1 COIL
8 SOLENOID VALVE
9 FLOW DIVIDER
10 SOLENOID VALVE
11 SOLENOID VALVE
12 PLUG
13 FLOW DIVIDER

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3.3.4. DETAIL STEERING BLOCK
YV 21 A: rear left
YV 22 A: front left
YV 22 B: front right YV 21 B: rear right
1 BLOCK
2 PLUG
3 CIRCUIT SELECTOR
4 SOLENOID VALVE
4-1 COIL
5 SOLENOID VALVE
5-1 COIL

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3.3.5. DETAIL BLOCK ON/OFF
Rear side YV19B YV18B YV15B YV14B
Front side YV19A YV18A YV15A YV14A
Turret rotation compensation jib Basket rotation

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3.3.6. DETAIL PROPORTIONAL BLOCK PVG
YV5 YV3 YV4 YV2 YV6 YV1
YV1 Electrovalve (Load sensing)

YV2 Telescope
YV3 boom
YV4 arm
YV5 Functions ON/OFF
(turret rotation, jib,basket rotation, compensation, steering)
YV6 drive

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3.4. THE HYDRAULIC HOSES
for all details reagrding hoses , refer to parts book
3.5. HELP GUIDE FOR HYDRAULIC LEAKS

The next diagram will help the technician to search for hydraulic leaks on hoses
Each page describes a specific function indicated in red (ex arm lift)
In order to detect the leak, it’s necessary to activate the command at full stroke

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LOW SPEED DRIVE
(YV11 disconnected)

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LOW SPEED DRIVE
(YV11 disconnected)

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DRAIN RETURN

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DRAIN RETURN
HA20PX

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DRAIN RETURN
HA260PX

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STEERING
(YV11 connected)

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STEERING
(YV11 connected)

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ARM LIFT
(HA20PX)

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ARM LIFT
(HA260PX)

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BOOM LIFT
(HA20PX)

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BOOM LIFT
(HA260PX)

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TELESCOPIC BOOM
(HA20PX)

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TELESCOPIC BOOM
(HA260PX)

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TURRET ROTATION
(HA20PX)

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TURRET ROTATION
(HA260PX)

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JIB (HA20PX)

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JIB (HA260PX)

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BASKET ROTATION
(HA20PX)

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BASKET ROTATION
(HA260PX)

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BASKET COMPENSATION
(HA20PX)

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BASKET COMPENSATION
(HA260PX)

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4. ADJUSTMENTS
4.1. ADJUSTMENTS WITH CONSOLE OPTIMIZER
The adjustments, parameters setting and list of alarms of the machine are accessible only with this
console.
Use OPTIMIZER console with HEAD module

Connection bottom panel (turret)
connect the plug socket on the connector number 6:
Connector n°6 on main printed circuit

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Description of the console
PARAMETER (+) or CHANGE

PARAMETER ( -) or CHANGE
PREVIOUS MENU
NEXT MENU
RECORD/ENTER/VALIDATION
BACK TO MAIN MENU
NOTE : on any blue key pads , pressing on left , right or in the center have the same result

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List of menus
Access to the main menu
Parameters setting access
Input/output state access
Trouble shooting guide per

function
Machines status
Failures list

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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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Access to calibration menu
Search the menu by scrolling key

pad UP/DOWN

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4.1.1. PARAMETER SETTINGS (HA260PX)
Display on
Movement Time (seconds)
console
p jib up jib raise 38+/- 4s
pjib down jib descent 35+/- 4s
p plat rotate Basket rotation 15 + 2 S
p plat level Basket compensation 6+2S
p arm up lifting arm 30 + 4s

p arm down descent arm 30+/- 4s
(maximum accelerator)
p boom up Boom Lifting 61+/- 4s

p boom
Upper control box
Boom Descent 50+/- 4s

down
the 65 + 5s 1/2
p turret left Left turret rotation
telescope turn
must be 65 + 5s f 1/2
p turret right Right turret rotation
retracted turn
p boom ext.
retraction telescope 46+/- 4s
in
p boom ext.
extension telescope 44+/- 4s
out
Drive FWD High speed drive FWD 40 + 2s on 50 m

drive REV High speed drive REV 40 + 2s on 50 m
Micro speed
Micro speed drive FWD 35 + 2s on 5 m
FWD
Micro speed
Micro speed drive REV 35 + 2s on 5 m
REV
T jib up jib raise 38+/- 4s

T jib down jib descent 35+/- 4s
(maximum accelerator)
T plat level compensation 20 + 4 S

Lower control box
T ARM up Arm lifting 30 + 4s

T ARM down Arm descent 30+/- 4s
T boom up Boom Lift 55+/- 4s

T boom
Boom Descent 45+/- 4s
down
T turret right Right turret rotation 65 + 5s out of 1/2 turn

T turret left Left turret rotation 65 + 5s out of 1/2 turn

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T boom ext.
retraction telescope 46+/- 4s
in
T boom out
extension telescope 44+/- 4s
ext.
Checking of the movements
Drive ramp
DEC Trans deceleration ramp High

FWD speed FWD Stop into 1,20m
DEC Trans deceleration ramp High maxi
REV speed REV
4.1.2. PARAMETERS MENU OPTIMIZER
Menu 2. PARAMETERS
P. Jip Up From basket , jib lifting speed
P. Jib Down From basket , jib descent speed
P. Plat Rotate From basket , basket rotation speed
P. Plat Level From basket , basket compensation speed
P. Arm Up From basket , arm lifting speed
P. Arm Down From basket , arm descent speed
P. Boom Up From basket , main boom lifting speed
P. Boom Down From basket , main boom descent speed
P. Turret Left From basket , turret rotation speed (left)
P. Turret Right From basket , turret rotation speed (right)
P. Boom Ext. In From basket , telescopic boom IN speed
P. Boom Ext. Out From basket , telescopic boom OUT speed
P. Trans Fwd FWD drive speed +/- FOR
MODIFY AND
2.1 SPEEDS P. Trans Rev REV drive speed
FROM 0 TO
P. Trans Fwd MicroS FWD drive microspeed
100 %
P. Trans Rev MicroS REV drive microspeed
T. Jip Up From turret , jib lifting speed
T. Jib Down From turret , jib descent speed
T. Plat Level From turret, basket compensation speed
T. Arm Up From turret , arm lifting speed
T. Arm Down From turret , arm descent speed
T. Boom Up From turret , main boom lifting speed
T. Boom Down From turret , main boom descent speed
T. Turret Left From turret , turret rotation speed (left)
T. Turret Right From turret , turret rotation speed (right)
T. Boom Ext. In From turret , telescopic boom IN speed
T. Boom Ext. Out From turret , telescopic boom OUT speed
ACC Jib Up Acceleration jib lifting
DEC Jib Up Decceleration jib lifting
ACC Jib Down Acceleration jib descent
DEC Jib Down Decceleration jib descent +/- FOR
ACC Plat. Rot. Acceleration basket rotation MODIFY AND
2.2 RAMPS
DEC Plat. Rot. Decceleration basket rotation VALUE FROM
ACC Plat. Level Acceleration basket compensation 1 TO 50)
DEC Plat. Level Decceleration basket compensation
ACC Arm Up Acceleration arm lifting
DEC Arm Up Decceleration arm lifting

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ACC Arm Down Acceleration arm descent
DEC Arm Down Decceleration arm descent
ACC Boom Up Acceleration main boom lifting
DEC Boom Up Decceleration main boom lifting
ACC Boom Down Acceleration main boom descent
DEC Boom Down Decceleration main boom descent
ACC Turret Right Acceleration turret orientation right
DEC Turret Right Decceleration turret orientation right
ACC Turret Left Acceleration turret orientation left
DEC Turret Left Decceleration turret orientation left
ACC Boom Ext. In Acceleration telescopic boom retraction
DEC Boom Ext. In Decceleration telescopic boom retraction
ACC Boom Ext. Out Acceleration telescopic boom extension
DEC Boom Ext. Out Decceleration telescopic boom extension
ACC Trans FWD Acceleration FWD drive
DEC Trans FWD Decceleration FWD drive
ACC Trans REV Acceleration REV drive
DEC Trans REV Decceleration REV drive
+/- FOR
Enter access code Acess for code level 2 and 3
MODIFY
2.3 OPTIONS BUZZ-TRANS Drive buzzer +/- FOR
MODIFY
BUZZ-MVTS Movements buzzer (Active or
Inactive)
Cancel overload Cancel the overload (machine switched ON)
2.4
+/- pour active
MAINTENANCE Factory tolerances Reduction of tolerances from 30%
2.5 FACTORY
SETTINGS Factory parameters for
Factory Settings ? * for validation
Access by (ramps, speeds , options)
level 2 and/or 3
Reach Limit: Pos. 1 Calibration position 1(machine stowed)
2.6 Reach Limit: Pos. 2 Calibration position 2 (machine full height)

CALIBRATION +/- for
Access by calibration
level 2 and/or 3 Reach Limit: Cancel Cancel the reach limit calibration
Jib learning Overload calibration
2.7 SERIAL
Serial number of the machine
NUMBER +/- FOR
AD xxxxxx (comes back to 000000 if new software is
Access only by MODIFY
installed)
level 3

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Menu 3.INPUTS - OUTPUTS
SQ2 jib limit switch position "ON" if jib folded
Neutral check for rotation/boom lift
SM1ab "ON" if joystick pushed
joystick
SA13a turret toggle switch for boom lift "ON" if pushed
turret toggle switch for boom
SA13b "ON" if pushed
descent
neutral position check for arm lift
SM2ab joystick "ON" if joystick pushed
SA14a turret togle switch for arm lift "ON" if pushed
SA14b turret toggle swict for arm descent "ON" if pushed
toggle switch for drive speed
SA11a selection "ON" if low speed selected
SA15a toggle switch for left turret rotation "ON" if pushed
SA15b toggle switch for right turret rotation "ON" if pushed
BPE_J4_5 Overload BPE board "ON" if no overload
DPLUS Alternator "ON" if alternator is powered
SURV_AU KMG check "ON" if KMG energised
toggle switch for basket levelling
"ON" if pushed
SA17a down (descent)
"ON" if pushed
SA17b up( lift)
SB3 start from basket control box "ON" if pushed
SB4 start from turret control box "ON" if pushed
SA2 Accelerator "ON" if pushed
SB5 Klaxon "ON" if pushed
3.1 DIGITALS
"ON" if telescopic boom is
INPUTS
SQ9 telescopic limit switch position retracted
Proximity sensor for telescopic
SQ7 boom position "ON" if magnet is present
SQ1 slope sensor switch "OFF" if in slope
B4 oil temperature sensor "OFF" if oil overheating
SQ3 upper arm limit switch "ON" if arm is up
SQ4 limit switch for arm and boom down "ON" if arm and boom folded
"ON" if pushed
SA5b down ( descent)
basket toggle switch for basket
"ON" if pushed
SA4b rotation left
BPE_J4_3 Overload BPE board ON if no overload
SA12a rear steering "ON" if pushed
SA3 differential lock "ON" if pushed
SM4ab neutral position for drivng joystick "ON" if joystick pushed
SA12b rear steering "ON" if pushed
SM4d Front steering "ON" if pushed
SM4c Front steering "ON" if pushed
Fu7_12V FU8 fuse state "OFF" if fuse blown
V12Nacelle key position "ON" if basket position
V12Tourelle key position "ON" if turret position
SB6 foot dead man switch "ON" if pushed
"ON" if pushed
SA4a rotation right
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SA5a "ON" if pushed
levelling up
toggle switch for drive speed
SA11b "ON" if High speed selected
selection
SA6a turret toggle switch for jib descent "ON" if pushed
SA6b turret toggle switch for jib lift "ON" if pushed
SA7a basket toggle switch for jib lift "ON" if pushed
SA7b basket toggle switch for jib descent "ON" if pushed
turret toggle switch for telescopic
SA8a "ON" if pushed
boom out
SA8b "ON" if pushed
boom in
SB33 Generator "ON" if pushed
B1 clogged filter sensor "ON" if clogged
B2 engine oil temperature sensor "ON" if overheating
B3 oil pressure switch "ON" if lack of oil pressure
basket toggle switch telescopic
SA9a "ON" if pushed
boom out
basket toggle switch telescopic
SA9b "ON" if pushed
boom in
YV1 Load Sensing Valve
YV26 safety valve for boom lift
YV22b rear right steering valve
YV22a rear left steering valve
YV13 Diffrential lock valve
YV21a front left steering valve
YV21b front right steering valve
YV19b left basket rotation valve
YV19a right basket rotation valve
YV15a lift levelling valve
YV15b descent levelling valve
YV18a jib lift valve
YV18b jib descent valve
YV9 differential lock valve
HL9 overload indicator or slope sensor
3.2 DIGITALS HL15 turret outreach limitation indicator
OUTPUTS HL16 overload turret indicator
HL13 slope sensor indicator
HA4 Beep
KP1 Engine stop relay
KT2 Accelerator relay
KA2 Starter relay
HL4 oil pressure indicator
HL3 oil temperature indicator
HL2 Air filter indicator
HL14 basket outreach limitation indicator
YV25 Generator
HA1A horn
HA1B Horn
YV14a right turret rotation valve
YV14b left turret rotation valve
YV17 medium and high speed valve
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YV8 high speed valve
YV11 brakes release valve for drive
HA2 basket Buzzer
SM4 drive joystick setpoint values 0,5 - 2,5 - 4,5 Volts
turret rotation joystick setpoint
SM3 0,5 - 2,5 - 4,5 Volts
values
3.3 ANALOG SM2 arm lift joystick setpoint values 0,5 - 2,5 - 4,5 Volts
INPUTS SM1 boom lift joystick setpoint values 0,5 - 2,5 - 4,5 Volts
first telescopic boom lenght section
SL3 0 à Vbatt (12V)
sensor setpoint values
second telescopic boom lenght
SL4 0 à Vbatt (12V)
section sensor setpoint values
first angle transducer setpoint
SL1 4 - 20mA
values
second angle transducer setpoint
SL2 4 - 20mA
values
VBAT Battery voltage 12 à 14V
3.4 ANALOG YV5 PVG setpoint values 25% - 50% - 75% of Vbatt
OUTPUTS YV6 PVG setpoint values 25% - 50% - 75% of Vbatt
YV3 PVG setpoint values 25% - 50% - 75% of Vbatt
Menu 4. DIAGNOSTIC
SQ1 sensor state
SQ2 sensor state
Tilt SQ9 sensor state Fonction relative : "slope"
SQ4 sensor state
HA4 2 sound beeper state function
Stat. Overload static overload variable state "ON" if in overload
Dyn. Overload dynamic overload variable state "ON" if in overload
"ON if calibration is in
BPE learning calibration variable state
process
calibration output on BPE board "GND" level sent to BPE
Overload BPE_J10_2
(wire 607) board
input state on overload BPE board
BPE_J4_5
( wire 213) the both inputs are at "OFF" if
input state on overload BPE board overload
BPE_J4_3
( wire 214)
ModeHA20 ModeHA20 variable state Machine in HA20 mode
ModeHA26 Machine in HA260 and
ModeHA26 calibration state mode
Calibration Calibration mode
Machine in HA260 and
ModeHA26 ModeHA26 restrictive mode
restrictive mode
Reach Lim. Failure variable state
(see FAILURES menu)
Teles stroke coarse variable state telescopic rod coarse in mm
telescopic boom angle in
Boom angle angle variable state
degrees (x100)
boom outreach compared to
Boom radius outreach variable state
the link part( without jib)
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telescopic boom coarse in
Stroke before variable state
mm before outreach limitation
lim. (error, 0 if error< 0)
cut out
variable state
Stroke error Coarse error after cut out
(- error, 0 if error > 0)
value acquisition angle boom
SL1 sensor state
transducer
value acquisition angle boom
SL2 sensor state
transducer
value acquisition lenght boom
SL3 sensor state
sensor
SL4 sensor state
sensor
SQ9 sensor state Aquisition SQ9
telescopic boom area
between 0 and 11 (0
ZoneTeles variable state
telescopic boom fully
retracted)
no matching acquisition value
ErrIncohAngle variable state between SL1 and SL2 angle
transducers(in degrees x100)
SB3 toggle switch
Front step on one of them
SB4 toggle switch
Dplus Alternator 0V
Start YV1 Load Sensing (by-pass) valve No action
no action from more than 3
KA2 starting relay
sec
KP1 accelerator relay -
SM2ab neutral position of the joystick > 6V
SB6 foot dead man switch state 12V
SM2 joystick setpoint > 2,5V or < 2,5
Arm SA14a toggle switch on turret control box 12V
SA14b toggle switch on turret control box 12V
YV4 PVG valve arm lift above or lower than Vbatt/2
YV1 Load sensing valve Active
SM1 joystick setpoint > 2,5V or < 2,5
Boom SA13a toggle switch on turret control box 12V
YV3 PVG element boom lift above or lower than Vbatt/2
SM3 joystick setpoint > 2,5V or < 2,5 V
Slewing SA15a toggle switch on turret control box 12V
YV5 PVG turret rotation above or lower than Vbatt/2
Translation

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SM4 joystick setpoint > 2,5V or < 2,5V
SA11a "ON" if low speed is selected
Selection of drive speed
SA11b "ON" if high speed is selected
Micro Speed Variable "ON" if micro speed
YV6 PVG drive above or lower than Vbatt/2
Active in medium and high
YV17 valve
speed
YV12 valve
speed
YV23 valve
speed
YV10 valve
speed
YV8 valve Active in high speed
YV13 valve Active in high speed
YV11 brakes release valve Active
SA12a toggle switch on panel 12V
YV22a valve Active
Steering front SA12b toggle switch on panel 12V
YV22b valve Active
YV5 PVG steering Iower than Vbatt/2
SM4c toggle switch on panel 12V
YV21a valve Active
Steering back SM4d Interrupteur pupitre 12V
YV21b valve Active
YV5 PVG steering Iower than Vbatt/2
SA3 toggle switch on panel 12V
Dif lock Micro Speed Variable "ON" if micro vitesse
YV9 valve Active
YV1 Load sensing valve
YV19a valve Active
Rotation SA4b toggle switch on panel 12V
YV19b valve Active
YV5 PVG basket rotation Iower than Vbatt/2
YV18a valve Active
Jib SA6b toggle switch on panel 12V
SA7b toggle switch on panel 12V
YV18b valve Active
YV5 PVG jib Iower than Vbatt/2

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Telescope SA9a toggle switch on panel 12V
YV2 PVG telescopic boom Iower than Vbatt/2
YV15a valve Active
Basket level SA5b Toggle switch on panel 12V
YV15b valve Active
YV5 PVG basket level Iower than Vbatt/2
Menu 5. INFORMATIONS
DATE AND HOUR Date and hour * for modify
VERSIONS Versions softwares
JOURNAL 1 not available
Menu 6. FAILURES
(420A at 12V and (2,35V < 403 <
2,65V) and (2,35V < 512 < 2,65V)) or
(((2,8V < 403 < 4,5V) or (0,5V < 403 <
JY01 2,2V) and 420A at 0V) or (2,8V < 512 check joystick SM31
< 4,5V) or (0,5V < 512 < 2,2V) and
420A at 0V) or (403 > 4,8V or 403 <
0,2V or 512 > 4,8V or 512 < 0,2V)
joystick alarms (420B at 12V and (2,35V < 506 <
2,65V)) or (2,8V < 506 < 4,5V) or (0,5V
JY02 check joystick SM2
< 506 < 2,2V) and 420B at 0V) or (506
> 4,8V or 506 < 0,2V)
(606 at 12V and (2,35V < 612 <
2,65V)) or (2,8V < 612 < 4,5V) or (0,5V
JY03 check joystick SM4
< 612 < 2,2V) et 606 à 0V) or (612 >
4,8V or 612 < 0,2V)
lenght transducer calibration value out
of range or wrong
Telescopic boom in : 6,7% of Vbat check SL3, SL4, and wires
CB01
(allowance is 4% of Vbat) harness
Telescopic boom out : 65% of Vbat
(allowance is 4% of Vbat)
outreach limitation angle transducer value is out of range
calibration alarms or wrong
boom at 0° : SL1 at 17,73mA (4,22V)
and SL2 at 6,56mA (1,563V) check SL1, SL2 and wires
CB02
boom at 75° : SL1 at 6,48mA (1,54V) harness
and SL2 at 17,58mA (4,188V)
allowance on the mini and maxi values
is +/- 0,4 mA (+/- 0,1V)
(804 or 807) out of calibration range Check SL3, SL4 and wires
CA01
sensor position (+/-1% from the range : +/-120mm) harness
alarms (611B or 805) out of calibration range check SL1, SL2 and wires
CA02
(+/-3% from the range : +/- 3,6°) harness

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Difference between 804 and 807
check SL3, SL4 and wires
CA03 above 3% from the range (3% of
harness
Vbatt)
Difference between 611B and 805 check SL1, SL2 and wires
CA04
above 3% of the range harness
CA05 SQ7 closed and SQ9 closed check SQ7 and SQ9
CA06 SQ3 closed and SQ4 closed check SQ3, SQ8 and SQ4
CA07 SQ7 area incompatible with the coarse check SL3,SL4, SQ9, SQ7
CA08 angle > 5° and SQ4 closed check SL1, SL2, SQ4
check outreach limitation
outreach limitation system : outreach limitation
LP01 engine outreach limitation
alarms transducers (SL1,SL2, SL3,
SL4), valve YV3 and YV2
short circuit with the earth on 607,
open circuit on 607, 213 at 12V or 214 check BPE board and
BPE overload alarm OL01
at 12V within 400ms and 1sec after connection on harnesses
power is ON
AL01 FU7 at 0 check fuse FU7
fuses alarms AL02 FU8 at 0 check fuse FU8
AL03 FU6 at 0 and FU5 at 0 check fuses FU6 and FU5
emergency circuit check emergency stop
AU01 254 at 0V
alarm circuit, KMG
year given by the internal clock equal

BT01 change Head module
module battery alarm to 2000 at the first time
EEPROM module EP01 Fault on EEPROM module change Head module

alarm

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4.2. LOAD MANAGEMENT SYSTEM
The function of the load management system is to detect an extra load, informs the user and forbids
certain movements.
For that, the jib of the machine which is equipped with a cylinder for double purpose, must be
instrumented through 2 angle sensors ( in knuckle jib link part ) and of 2 pressure sensors (1 in
each chamber of the jib cylinder)
In the description below, there are 2 versions of load control system (the version equipped weighing
BPE board for the models made before mid-2010 whith serial number lower than AD122967)
4.2.1. PRINCIPLE
The system uses four sensors:
• A pressure sensor measures the pressure in the large chamber of the jib cylinder
(G2)
• A pressure sensor measures the pressure in the small chamber of the jib cylinder
(G1)
• A relative angle sensor measures the angle between the link piece and an arm of jib
(A1)
• An absolute angle sensor (or inclinometer) measures the angle of the link piece
compared to gravity (A2)
• An electronic overload board BPE specific to the model
(for models HA20PX - HA260PX if serial number is < AD122967)
• A module node B1 for machines with serial number is > AD 122967
The electronic board (or the module) compares the current resulting pressure with the maximum
pressure authorized in the position given by the relative angle sensor.
In the event of overlap it informs the main module of the machine either via two relays for BPE
board, or via CAN BUS if it is a module node B1
The module of the machine controls the valves and forbids the movements.
The authorized maximum pressure is determined by a calibration carried out in factory, or during
maintenance routine check
Several stops are automatically carried out, during which the module records the angle and the
static pressure.
The software limits the clearance of jib to its two limits so that the cylinder never reaches its
mechanical stop

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4.2.2. ANGLE SENSORS
Relative angle sensor (A1)
This potentiometric sensor measures the relative angle of a moving part compared to the
structure on which it is fixed,
The pin of output of the potentiometer makes it possible to follow the movement of jib and
thus delivers signals according to its position.
Absolute angle sensor (A2)

Another geometrical parameter has an impact raised on the pressure: the absolute angle
(compensation) of jib, therefore the slope of the basket
The sensor delivers an angular information of the position between the part and an
“absolute” reference
This sensor consists of a system constitued by an oil bath whose position is imposed by
the gravity, oil has as a function to stop the jib movements.
For this reason, there is a preset correction of the pressure according to the absolute
angle.
A mathematical formula corrects the pressure according to the measured angles, to bring
back it to a value corresponding to the horizontal basket.
The correction of the absolute angle is limited to an angular jib range from - 15° to +15°.
• Electric stop
As the pressure is representative of embarked load, the jib cylinder should not be at full
stroke (up and down).
For that, the stroke of the cylinder is limited by 2 electric stops
This information is sent to the Head module of the machine via two relays (or through CAN
bus).
• Relays status ( only with machines equipped wth BPE board)
The state of the two relays of output of the weighing board is interpreted by the main module
node Head:
J4.3 J4.5 DESCRIPTION
Open Open Overload or defect, raise and descent prohibited
Open Close Bottom detection , descent prohibited
Close Open Full stroke high, lift prohibited
Close Close Authorized normal functioning, raise and descent OK

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4.2.3. OVERLOAD BOARD BPE
Wire 607 drops to 0 only when
calibration is requested
+ 16VDC*
+ 16VDC *
+ 5 VDC
+ VBAT
** Voltage between 15 and 22VDC

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4.2.4. MANAGEMENT OF NOMINAL LOAD OVERLAP
A going beyond nominal load involves:
The activation of the sound buzzer,
The activation of indicators of overload (HL 16) and alarm (HL 13 or LTB06)
All the movements are forbidden from the upper control box.
All the movements are slowing down from turret control box.
4.2.5. PROCEDURE OF STANDARD CALIBRATION (MACHINE < AD122967)

This procedure is compulsory if the system of weighing or a part of it has been removed :
• pressure sensor on the cylinder of jib,
• sensor inclinometer (absolute sensor)
• angle sensor (relative sensor) assembled on the axle point.
Complementary materials
It is necessary for this calibration to have the right weights according to nominal load of the
machine.
1. Initial Start for the machine for calibration process : Put 275kg in basket if the nominal
load is 250kg (option) or 250kg for 230kg nominal load
2. ,Select the key selector SA1 towards turret position and start the engine : the engine will
run during the whole calibration process
3. Stabilise the pressures in the jib cylinder by asking 3 times the lift and descent functions
and basket levelling at 0°, leave the jib at the l owest position
4. Access to the calibration menu : with the OPTIMIZER calibrator, go in menu
PARAMETERS / OPTION ( push ENTER) then enter the code 2031 (level 2 : for field
technician) validate with * then return to main menu with the key ?
5. Activate the process calibration : in menu parameters/calibration , activate the function
« jib learning » with green pad and validate with * ( the lower box indicators will
flash)
6. Put the boom in calibration position : put the jib in the lowest position ( mechanical
stop) during 5 seconds
7. Perform the calibration : lift the jib continuously by holding the toggle switch, the jib will
lift by step of 5° up to the maximum position
8. Wait for value record : in the maximum position (mechanical stop) , hold the toggle
switch 5 seconds more .
9. End of calibration : put down the jib at the lowest position
10. Put back the boom in normal use : Stop the engine, start it again , remove the extra
weight ( 25kg for 275 kg or 20 kg for 250kg) then lift sindicatorly the jib and when all
indicators are OFF (the system will give a beep), put down again the jib (it should stop
approximately 5 mm from the bottom cylinder rod) , machine is ready , the total weight
can be removed .
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11. Note : if one previous step has not been done correctly , start again the whole procedure
( switch off the machine first )
4.2.6. ALARMS CODE OF THE WEIGHING BOARD

• Green LED D19: Error on analogical inputs
Nb of
DESCRIPTION
flashs
0 No error
Error line pressure sensors.
1 Short-circuit or open circuit on one of connections of a pressure sensor.
Error line angle sensors.
2 Short-circuit or open circuit on one of connections of an angle sensor.
Value of too low pressure.
The resulting pressure is negative: the effort applied to the cylinder tends to
3 raise the basket.
Too low value of angle.
The jib angle is lower than the stop recorded low mechanical.
4 Bad attachment of the sensor or defect of the component.
5 Inactive
6 Value of too high pressure to angle 0
7 Inactive
• Orange LED D21: Board errors
Nb of
DESCRIPTION
flashs
0 No error
1 Loss of communication between microprocessors
2 Error on test of control of the inputs
3 Error on the polarity of connections to the relays
4 Inactive
5 Loss of communication micro/memory
• LED D20 red: State of the calibration
State DESCRIPTION
Extinct Validated calibration.
Calibration not carried out or procedure not respected
Flickering
Continuous Calibration in progress
4.2.7. SENSORS VALUESS

• Pressure sensors:
Jib stop Large chamber(G2) Small chamber(G1)
Low 0.8 V = 0 bar 3.5 V = 210 bar
High 3.5 V = 210 bar 0.8 V = 0 bar
o Angle sensor:
The angle sensors are supplied with 5V.
For the relative angle sensor (A1), the signal of ratiometric output east 0,5-4,5 V for
300°. The signal must increase gradually when the j ib goes up.
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For the absolute angle sensor, the signal of ratiometric output east 0,5-4,5 V for 320°.
When the indication “0°” is directed towards the gr ound, the signal is 2,5V. The signal
must increase when the angle of compensation increases.
4.2.8. LIMITATION OF THE ANGLE OF INCLINATION

This function is completely independent of the load control. The state of the digital outputs
J6.1 and J6.2 varies according to the angle measured by the absolute angle sensor.
The output J6.1: limitation positive slope (positive output if OK, negative if the angle is too
high)
The output J6.2: limitation negative slope (positive output if OK, negative if the angle is too
weak)
4.2.9. HOW TO CHECK THE SENSORS ON BPE BOARD

• Pressure sensors G1-G2
G2 Large chamber : Voltage between J11.3 and a ground

G1 Small chamber : Voltage between J7.B and a ground
• Value of the sensors
G1 G2 A1 A2
Jib at lowest position 3.5 VDC 0.8 VDC 1.6 VDC
Jib at 0° 2.6 VDC
Jib at position max 0.8 VDC 3.5 VDC 3.9 VDC
Basket at 0° 2.5 VDC

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4.3. ADJUSTMENT OF THE PRESSURES
4.3.1. TABLE OF PRESSURES
DESIGNATION IN BARS
General 240 +-5
Load Sensing 30 +-5
Standby unit 130 +-2
Lifting arm full stroke 240 +-5
arm bottom position 140+/-5
Boom lift full stroke 240 +-5
Boom in stowed position 150 +-5
Telescoping extension 100 +-5
Telescoping extraction 240 +-5
Turret slewing 100 +-5
Movements ON/OFF 240 +-5
4.3.2. PLUG PORT FOR PRESSURES CHECK

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4.3.3. ADJUSTMENT
• Load sensing (LS)
• Flow
• Cubic capacity pump
• Pump model 1
• The pump is preset at a Load Sensing pressure of 30b (+-2b)
• The pump is preset at a general pressure of 240b (+-5b)
• The cubic capacity of the pump is preset in order to reach the high speed at 20
seconds for 25 meters
High speed adjustment

At maxi cubic capacity
LS adjustment P maxi adjustment

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LS adj (turn CW in order to increase the Stop screw to be unlocked for
pressure adjustment
Pmaxi adj (turn CW in order to Stop screw to be unlocked for

increase the pressure adjustment

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• Pump model 2
• The pump is preset with a pressure LS of 30b (+-2b)
• The pump is preset with a general pressure of 240b (+-5b)
• The cubic capacity of the pump is preset in order to reach the high speed at 20
seconds for 25 meters
• unscrew the cap (wrench)
• turn the 6 BTR screw until obtaining the desired value
CC adjustment ( for High speed) LS adjustment
P maxi
adjustment
Note : if no pressure , check

coupling between pump and engine

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4.4. ACCELERATOR ENGINE COIL
This adjustment must be done when the accelerator coil has been replaced
fuel /diesel pump
30A fuse + RC filter

(not labelled on shematics)
oil filter diesel coil
YA1
diesel pre filter diesel filter acccelerator coil YA2

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Fuse 30A on accelerator coil
• Procedure
the coil rod A must be aligned straight with coil
the clearance D must be adjusted at +/- 0.5mm when accelerator is at maxi stroke
( it must never touch the stop screw mark D )

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5. BREAKDOWN SERVICE GUIDE
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 arm:
neither raise, nor descent and this from both control box (up and down)
It takes account of the 2 versions of machines (version before mid--2010 with upper control box in
metal and after mid--2010 with new control box + joystick and module node B1)
All fuses must be checked first
5.1. NO START
• Battery (14 V)
• Emergency stops (SB1 and SB2)
• Buttons of engine start (SB3 - SB4 or SWB16)
• Key SA1 selector
• Temperature oil engine (B2)
• Pressure oil engine (B3)
• Clogged air filter (B1)
• Bulb indicator for alternator (HL1)
• Relay KA2, KMG
• Load alternator (D+ Off)
• drive joystick SM4 or JYB01 (off neutral)
• Relay KP1 (start-up then stop)
• Head modules (and/or B1 node)
5.2. NO MOVEMENT
• Overload platform (weighing board BPE , A1 sensors, A2, G1, G2 or problem in load
management system or wrong calibration)
• Platform in slope (SQ1)
• Fuse FU7 (or FU70 for HA260PXNB)
• Fuse FU10 (or FU16 supply module node B1 for HA260PXNB in upper control box)
• Load sensing valve YV1
• Switch dead man low control box SA19 (for model Node B)
• Pedals SB6 (upper box only) blockked or defective
• Head module (or B1 Node)
• No pressure LS (25/30bars) or no output pump (240bars)
5.3. NO ARM LIFT

• Switch SA14 (lower control box)
• joystick SM2 (or JYB02) off neutral and/or signal
• Electrovalve YV4
• No pressure

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5.4. NO BOOM LIFT
• Head module (or node B1)
• No pressure
• (if boom stops lifting at 60°: telescopic boom is not out)
5.5. NO TELESCOPING
• Switch SA9 or SWB10 (upper control box)
• No pressure
5.6. NO TURRET ROTATION

• joystick SM31 (or JYB03) off neutral and/or setpoint
• Electrovalves YV5 or YV14
• No pressure
5.7. NO JIB
• Toggle switch SA7 (or SWB11) upper control box
• Electrovalves YV5 ouYV18
• No pressure
5.8. NO BASKET ROTATION

• Switch SA4 (or SWB13)
• No pressure
5.9. NO COMPENSATION
• No pressure
5.10. NO DRIVE
• Electrovalve YV11 (brake release)
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• No pressure on output pump
• Circuit brake release circuit
5.11. LOW SPEED ONLY

• Limit switchs SQ3/SQ4/SQ9 (+ SQ2 for models not NB)
• Electrovalves YV8-YV12-YV13-YV17-YV23
5.12. NO STEERING
• Rocker of joystick SM4 (or JYB01)
• Toggle switch SA12 (or SWB06) if problem on rear wheels only
• Circuit of brake release circuit
• Electrovalves YV5 - YV21 or YV22 if problem on rear wheels only

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6. SUMMARY OF VERSIONS HA20PX-HA260PX
HA20PX - HA26PX until March 2004 Hydraulic

(machines without progressivity) electric
Without dead man's pedals Standard EC E448D B15390
With dead man's pedals Standard EC E448F B15390
Without dead man's pedals Australia E448D B15390
With dead man's pedals Australia E448F B15390
Without dead man's pedals USA E448D B15390
With dead man's pedals USA E448F B15390
HA20PX - HA26PX Hydraulic
until October 2005
(machines with progressivity
and conform to EN 280) electric
All versions E596 B17074
HA20PX - HA260 PX Hydraulic
With new load management system
using BPE board (starting normally
from S/N AD111168) electric
All versions E615 157P243400
HA20PX - HA260PX Hydraulic
starting from May 2008 electric
With option of the engine choice All versions E615E 157P243400
HA20PX_HA260PXNB Hydraulic
version 2010
from S/N AD122967 electric
With upper control box with new 157P243400
joysticks + module node B1 + can bus All versions 157P309330
Drive motors Danfoss 157P256130
Drive motors Eaton 157P301080
Pre version 280 = Detection overload (threshold of alarm then cut-off movements)
Version EN 280 = detection overload with cut-off movements

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7. SPECIAL FUNCTIONS
7.1. SYSTEM OF REACH LIMITATION (HA260PX ONLY)

7.1.1. PRINCIPLE OF OPERATION
A sensor (SL3-SL4) equipped with a cable measures a linear drive of the telescope and thus
determines its length
Two sensors (SL1-SL2) measure the angle of the boom permanently
A sensor ILS (Interrupteur Lame Souple in French that’s mean Flexible Blade Switch here SQ7)
fixed on the telescopic section thanks to the 5 magnets laid out along the telescopic boom
extension and is in redundancy for the measurement taken by the sensors length boom SL3 and
SL4.
All these informations are transmitted to the Head module.
7.1.2. PROCEDURE OF CALIBRATION MACHINE < AD122967

This procedure is reserved to HAULOTTE Services staff or to the persons having followed and
passed the qualification “big Heights”(superior) booms training
1. Initial start for the machine for calibration process : the machine should be completely
folded , all movements are in the lowest position (mechanical stop)
2. Select the key selector SA1 towards turret position and start the engine : the engine will
run during the whole calibration process. The indicators will flash and the buzzer will
sound
3. Access to the calibration menu : with OPTIMIZER in the menu PARAMETER / OPTION
enter the code (level 3 : for field Haulotte technicians) validate with then return
to the main menu with ?
4. With OPTIMIZER in FAILURES mode, check that there are no failures before calibration
can be done.
5. Note: If indicators are not blinking, go to PARAMETER / CALIBRATION / REACH LIMIT:
CANCEL, change to Enable.
6. Put the boom in calibration position 1 ( see next page) , the Arm ( primary boom) is in
upper position , put down the main boom and telescopic boom fully retracted .
7. Activate function 1 for outreach limitation calibration : in menu parameters /calibration
activate the function « reach limit pos 1 » with the green pad and validate with
8. Perform the calibration ( position 2 see next page) : Lift the main boom continuously up
to the maximum height first and then extend the telescopic boom ( hold the switch during
the whole process)
9. Activate the function 2 for outreach limitation calibration : in the menu parameters/
calibration activate the function « reach limit pos 2 » with green pad and validate with

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10. calibration checking : Be sure all indicators and buzzer will be OFF, lower upper boom
to ensure auto retract is functioning. When the main boom will be in the lowest position
and the telescopic boom fully retracted, check DIAGNOSTIC / REACH LIM / STROKE
ERROR to ensure the Optimizer reading is lower than 300mm
11. Machine is ready for use.
12. Check that there is no alarms (see with Optimizer calibrator that the parameters CB01
and CB02 : outreach limitation calibration parameters are not out of range)
Note : If one of the previous step has not be done correctly , start again the whole procedure by
switching off the machine first , then go in menu parameter /option, enter code level 3 , then go in
parameters/calibration menu , and go to the parameter Reach Limit cancel and validate it in order
to cancel the previous values which has been recorded
• Position of the machine for outreach calibration

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POSITION 1
7.1.3. SENSORS VALUES
+ Vbat
• Angle transducers value ( +/- 0.1V)
SL1 ( wire 611B) SL2 ( wire 805)

Main boom at 0° 4.22 V (18.1 mA) 1.56 V ( 6.31 mA)
Main boom at 75° 1.54V (6.85mA ) 4.19 V (17.45mA)
Value for calibration (in points) 856 359
with boom at 0° (+/- 3 %)
Value for calibration (in points) 355 848
with boom at 75° (+/- 3 %)
• Length transducers value ( +/- 5% of Vbat)
SL3 ( wire 804) SL4 (wire 807)

Telescopic boom IN 6.7% of Vbat Same as for SL3
Telescopic boom OUT 65% of Vbat Same as for SL3
Note : All values measured with a voltmeter must be taken between a 0VDC and the signal
wire

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7.1.4. PROCEDURE OF OUTREACH CALIBRATION ( > SOFTWARE V1.09)
This procedure is reserved to HAULOTTE Services or to the persons who have followed and
passed the qualification “big Heights”( superior booms)
contact your HAULOTTE subsidiary company on which you depend for further information
if your machine has a different software version , contact your HAULOTTE services
This procedure must be done if one of the transducers or sensors have been changed or
dismantled: (length transducers, relative angle transducer ).
Initial start for the machine for calibration process : the machine should be completely
folded, all movements are in the lowest position (mechanical stop)
Select the key selector SA1 towards turret position and start the engine : the engine will run
during the whole calibration process. The indicators will flash and the buzzer will sound
Access to the calibration menu : with OPTIMIZER in the menu 1. CODE enter the daily code
according to the serial number written on the main display as shown above (level 3 for
Haulotte field technicians only) validate with * then return to the main menu with ?
NOTE :if the indicators indicators are not blinking , put in calibration menu the parameter
Reach limit to cancel ( change to Enable) ,then switch off the machine, then switch on
again ( don’t forget to re-enter the calibration code in order to continue the calibration
process
Put the boom in calibration position 1 ( see next page) , the Arm ( primary boom) is in upper
position , put down the main boom and telescopic boom fully retracted .
Activate function 1 for outreach limitation calibration : in menu parameters /calibration

activate the function « reach limit pos 1 » with the green pad and validate with

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Note: If the transducers are well mounted and give the right values according to the current boom
angle , the display shows O for OK , if not it will appear N for NOT OK (NOK)
In this case, solve the problem and proceed again to the full calibration from the beginning.
Perform the calibration ( position 2 see next page) : Lift the main boom continuously up to
the maximum height and extract the telescopic boom ( hold the switch during the whole
process)
Activate the function 2 for outreach limitation calibration : in the menu parameters/
calibration activate the function « reach limit pos 2 » with green pad and validate with *
• Note: If the transducers are well mounted and give the right values according to the current
boom angle, the display shows O for OK , if not it will appear N for NOT OK (NOK)
• In this case, solve the problem and proceed again to the full calibration from the beginning.
• calibration checking :
• all indicators and buzzer will be OFF,
• go in menu Diagnostic/ Reach Lim and when the main boom will be in the lowest position
and the telescopic boom fully retracted automatically, check that the parameter stroke Error
read in Optimizer is lower than 300mm
• Machine is ready for use.
Check that there is no alarms (see with Optimizer calibrator that the parameters CB01 and CB02 :
outreach limitation calibration parameters are not out of range)
• If one of the previous step has not be done correctly , start again the whole procedure from
the beginning ,
Note : if the serial number doesn’t appear on main display go in menu 2.7 ( access level 3) then
enter the right serial number.

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• Boom position outreach calibration (HA260PX)
Position 2 Position 1

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8. MODELS EQUIPPED WITH ECU MODULE NODE B
This chapter is only for HA260PXNB with serial numbers above AD122967)
8.1. DIFFERENCES
The module node B1 is installed in the upper control box and controls alll movements linked to
upper box,
This module behaves in “slave”, all informations collected are transmitted to the main module Head
module in lower control box through a standard canbus network .
8.1.1. THE UPPER CONTROL BOX

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8.1.2. THE CAN BUS
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 which
• CAN BUS LINE CHECK
Lower control box in parallel on the line (shunt between 501.2 and 501.4) = reading 60 Ω
Upper control box in parallel on the line (shunt between 102.1et 102.3) = reading 60 Ω
Note
one shunt removed = 120 Ω.
Two shunts removed = 240 Ω

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8.1.3. THE MODULE NODE B1

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8.1.4. COMPONENTS UPPER CONTROL BOX
(cf diagram ref. 157P309330)
The elements connected to the lower control box remain unchanged compared to the
previous version
(except for fuse FU7 of 20A which has been removed from the main printed circuit
and is now replaced by the FU70 of 20A located normally on the lower control box
door
Elements connected to the module B1 node

SWB01
06 - 3 Emergency stop (215)
3
FU16 03 - 4 Fuse protection module node B1 (246)
SWB16 5 CN105.3 Switch start-up/stop engine (B128)
SWB17 6 CN105.4 Switch emergency pump (B129)
SWB08 06 - 7 CN104.1 Switch horn (B106)
06 - 8 CN104.5/104.6 Selection of speed
Low speed B110 = 1
SWB05
Medium speed B110/B111=0)
High speed B111 = 1
SWB07 06 - 9 CN104.2 Switch differential lock (B107)

SWB02 06 - 10 CN104.11 Option generator
SWB10 06 - 11 CN104.13/104.14 Telescoping boom (B118 extension/B119 retraction)
SWB13 06 - 12 CN104.18/104.17 Rotation basket (left B124/right B123)
SWB03 06 - 14 CN104.9/104.10 Compensation basket (B114 lift /B115 descent)
SWB11 06 - 15 CN104.15/104.16 jib (B120 lift /B121 descent
SWB06 06 - 17 CN105.11/105.10 Rear steering (left B105 /right B104)
SB6 06 - 20 Dead man's pedals (B141)
LTB01 06 - 12 CN104.21 Indicator presence of dead man's pedals (B500 = 1 in support)
LTB02 06 - 12 CN104.22 Indicator presence of power
LTB03 06 - 13 CN104.23 Indicator level fuel (B502=1 IF on reserve)
LTB04 06 - 14 CN104.24 Indicator danger (B503)
LTB05 06 - 15 CN104.25 Indicator slope detection (B504 =1 so in slope)
LTB06 06 - 16 CN104.26 Indicator overload (B505 = 1 out of overload)
LTB07 06 - 17 CN104.27 Indicator reach limitation (B506 =1 fixed if outreach is reached)
LTB08 06 - 17 CN104.28 Free indicator
LTB09 06 - 18 CN104.30 Free indicator
BZB01 06 - 19 CN104.29 Buzzer (B508)

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• Location of new fuses in the lower control box
FU70
FU16
VALVES
Joystick /boom lift / turret rotation

07 - 3 CN106.13 signal X : B303 (turret rotation from 4.5 V to 0.5V)
JYB03
CN106.12 signal Y : B 302 (lift of 4.5v with 0.5V)
105.9 off neutral B103
Joystick arm Lif

JYB02 07 - 5 CN106.11 signal Y - B301 (lifting from 4.5 to 0.5V)
CN105.8 off neutral B102
Joystick Drive
CN106.10 signal Y - B300 (FWD 2.5 - 0.5V/REV 2.5 -4.5VDC)
07 - 9 CN105.6 Off neutral front (B100)
JYB01
CN105.7 Off neutral back (B101)
CN104.4 Steering Front left (B109)
CN104.3 Steering front right (B108)
07 - 12 CN106.16
Absolute angle sensor for weighing (inclinometer)
A2
B305 (signal of 0 with 12V)
Angle sensor for weighing

A1 07 - 14 CN106.15
B304 (signal of 0 with 12V)
Pressure sensor small chamber jib cylinder

G1 07 - 15 CN106.24
B306 (signal from 0 to 5 V)

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07 - 19 CN106.25
Pressure sensor large chamber jib cylinder
G2
B307 (signal from 0 to 5 V)
Joysticks JYB03/ JYB02/ JYB01 Axis X or Y

Values read on voltmeter 4.5 – 2.5 – 0.5 VDC *
Values read on OPTIMIZER ~ 4500 – 2500 - 500
Note :
the signal value are inverted compared to the previous models
joystick pushed 0.5VDC / pulled 4.5VDC
8.1.5. LIST OF OPTIMIZER MENU
Menu 2. PARAMETERS
P. Jip Up From basket , jib lifting speed
P. Jib Down From basket , jib descent speed
P. Plat Rotate From basket , basket rotation speed
P. Plat Level From basket , basket compensation speed
P. Arm Up From basket , arm lifting speed
P. Arm Down From basket , arm descent speed
P. Boom Up From basket , main boom lifting speed +/- FOR
P. Boom Down From basket , main boom descent speed MODIFY AND
2.1 SPEEDS
P. Turret Left From basket , turret rotation speed (left) FROM 0 TO
P. Turret Right From basket , turret rotation speed (right) 100 %
P. Boom Ext. In From basket , telescopic boom IN speed
P. Boom Ext. Out From basket , telescopic boom OUT speed
P. Trans Fwd FWD drive speed
P. Trans Rev REV drive speed
P. Trans Fwd MicroS FWD drive microspeed
P. Trans Rev MicroS REV drive microspeed
ACC Jib Up Acceleration jib lifting
DEC Jib Up Decceleration jib lifting
ACC Jib Down Acceleration jib descent
DEC Jib Down Decceleration jib descent
ACC Plat. Rot. Acceleration basket rotation
DEC Plat. Rot. Decceleration basket rotation
ACC Plat. Level Acceleration basket compensation
DEC Plat. Level Decceleration basket compensation +/- FOR
ACC Arm Up Acceleration arm lifting MODIFY AND
2.2 RAMPS
DEC Arm Up Decceleration arm lifting VALUE FROM
ACC Arm Down Acceleration arm descent 1 TO 50)
DEC Arm Down Decceleration arm descent
ACC Boom Up Acceleration main boom lifting
DEC Boom Up Decceleration main boom lifting
ACC Boom Down Acceleration main boom descent
DEC Boom Down Decceleration main boom descent
ACC Turret Right Acceleration turret orientation right
DEC Turret Right Decceleration turret orientation right
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ACC Turret Left Acceleration turret orientation left
DEC Turret Left Decceleration turret orientation left
ACC Boom Ext. In Acceleration telescopic boom retraction
DEC Boom Ext. In Decceleration telescopic boom retraction
ACC Boom Ext. Out Acceleration telescopic boom extension
DEC Boom Ext. Out Decceleration telescopic boom extension
ACC Trans FWD Acceleration FWD drive
DEC Trans FWD Decceleration FWD drive
ACC Trans REV Acceleration REV drive
DEC Trans REV Decceleration REV drive
+/- for
Country Country choice (Europe/Australia/USA)
modification
2.3 OPTIONS
Select then
BUZZ-TRANS Drive / movement buzzer
right choice
Cancel the overload ( machine is switched
Cancel overload
ON)
2.4
+/- pour active
MAINTENANCE
Factory tolerances Reduction of tolerances from 30%
2.5 FACTORY
SETTINGS Factory parameters for
Factory Settings ? * for validation
Access by (ramps, speeds , options)
level 2 and/or 3
Reach Limit: Pos. 1 Calibration position 1 (stowed position)

2.6.1 CAL
REACH LIMIT +/- for
Reach Limit: Pos. 2 Calibration position 2 (maxi height)
Access by calibration
level 3
Reach Limit: Cancel Cancel the reach limit calibration
2.6.2 CAL
OVERLOAD Calibration of the overload management Follow
Access only by system (start jib learning ?) proceudre
level 2 or 3
2.7 SERIAL Set the serial number ( 000000 by default or +/- for
NUMBER when new software is uploaded) modification

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Menu 3.INPUTS - OUTPUTS
turret toggle switch for boom
SA13b "ON" if pushed
descent
SA13a turret toggle switch for boom lift "ON" if pushed
SA14b turret toggle switch for arm descent "ON" if pushed
SA14a turret toggle switch for arm lift "ON" if pushed
SA15b toggle switch for right turret rotation "ON" if pushed
SA15a toggle switch for left turret rotation "ON" if pushed
DPLUS Alternator "ON" if alternator is powered
SURV_AU KMG check "ON" if KMG energised
"ON" if pushed
SA17a down (descent)
toggle switch for basket levelling up
"ON" if pushed
SA17b ( lift)
Toggle switch emergency
"ON" if pushed
SA19 mode/dead man in turret
SB3 Engine start/stop "ON" if pushed
"ON" if telescopic boom is
SQ9 telescopic limit switch position retracted
Proximity sensor for telescopic boom
SQ7 position "ON" if magnet is present
SQ1 slope sensor switch "OFF" if in slope
B4 Hydraulic oil temperature sensor "OFF" if oil overheating
SQ3 upper arm limit switch "ON" if arm is up
SQ4 limit switch for arm and boom down "ON" if arm and boom folded
SA3 differential lock "ON" if pushed
3.1 DIGITALS
INPUTS
V12Nacelle key position "ON" if basket position
V12Tourelle key position "ON" if turret position
SA6b turret toggle switch for jib lift "ON" if pushed
SA6a turret toggle switch for jib descent "ON" if pushed
SA8a "ON" if pushed
boom out
SA8b "ON" if pushed
boom in
B1 clogged air filter sensor "ON" if clogged
B2 engine oil temperature sensor "ON" if overheating
B3 Engine oil pressure switch "ON" if lack of oil pressure
NODE B1
SWB11b Jib descent ON" if pushed
SWB11a Jib up ON" if pushed
SWB10b Telescopic boom retraction ON" if pushed
SW10a Telescopic boom extension ON" if pushed
SWB02 Generator ( option) ON" if pushed
SWB03b Basket compensation up ON" if pushed
SWB03a Basket compensation down ON" if pushed
SWB05b Speed selection ( LS/MS/HS) 1 in Low speed
SWB05a Speed selection ( LS/MS/HS) 1 in High speed
JYB01c Rocker for steering on left side
JYB01d Rocker for steering on right side
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SWB07 Toggle switch diff lock ON" if pushed
SWB08 Toggle switch for horn
SWB16 Toggle switch for engine start/stop
SWB17 Toggle switch for emergency pump ON" if pushed
JYB01ab Neutral position of drive joystick
JYB01cd steering
JYB02ab Neutral position of arm joystick
JYB03ab Neutral position of boom joystick
SWB06a Toggle switch for rear steering (left)
SWB06b Toggle switch for rear steering (right)
SB6 foot dead man switch "ON" if pushed
SB4 Engine start/stop "ON" if pushed
SB5 Klaxon "ON" if pushed
SWB13a toggle switch for basket rotation left
SWB13b toggle switch for basket rotation right
YV1 Load Sensing Valve

YV26 safety valve for boom lift
YV22b rear right steering valve
YV22a rear left steering valve
YV13 Differential lock valve
YV21a front left steering valve
YV21b front right steering valve
YV19b left basket rotation valve
YV19a right basket rotation valve
YV15a lift levelling valve
YV15b descent levelling valve
YV18a jib lift valve
YV18b jib descent valve
Masse YV6 Drive PVG GND
YV9 differential lock valve
HL8 Flashing indicator
Masse YV5 On/off movements PVG GND
3.2 DIGITALS
SA19-KA43 Emergency pump relay
OUTPUTS
HL16 overload turret indicator
HL17 Reach limit indicator
HA4 buzzer
KP1 Engine start/stop relay
KT2 Accelerator relay
KA2 Starter relay
HL4 Engine oil pressure indicator
HL3 Engine oil temperature indicator
HL2 Air filter indicator
YV25 Generator
HA1A Horn
HA1B Horn
YV14a right turret rotation valve
YV14b left turret rotation valve
YV12- YV17 medium and high speed valve
YV10- YV23 medium and high speed valve
YV8 high speed valve
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YV11 brakes release valve for drive
Masse YV4 GND for PVG arm
Masse YV3 GND for PVG boom
Masse YV2 GND for PVG telescopic boom
NODE B1
LTB09 Not used
BZB01 Buzzer on basket
LTB08 Not used
LTB07 Reach limit indicator
LTB06 Overload indicator
LTB05 Slope indicator
LTB04 Warning indicator
LTB03 Fuel level indicator
LTB02 Power indicator
LTB01 Dead man pedal indicator
first telescopic boom lenght section

SL3 0 to Vbatt (12V)
sensor setpoint values
second telescopic boom lenght
SL4 0 to Vbatt (12V)
section sensor setpoint values
SL1 first angle transducer setpoint values 4 - 20mA
second angle transducer setpoint
SL2 4 - 20mA
values
VBAT battery voltage 12 to 14V
G1 Pressure sensor small chamber 0–5V
G2 Pressure sensor large chamber 0–5V
JYB01Y drive joystick setpoint values 4,5 - 2,5 - 0,5 Volts
JYB02Y arm joystick setpoint values 4,5 - 2,5 - 0,5 Volts
JYB03Y Boom joystick setpoint values 4,5 - 2,5 - 0,5 Volts
Turret rotation joystick setpoint
JYB03X 4,5 - 2,5 - 0,5 Volts
values
A2 Absolute jib angle sensor value 0 – 12V
A1 Relative jib angle sensor value 0 -12V
YV5 PVG setpoint values 25% - 50% - 75% de Vbatt
3.4 ANALOG
OUTPUT
Menu 4. DIAGNOSTIC
ModeHA26 Machine in HA260 and
ModeHA26 calibration state mode
Calibration Calibration mode
Machine inHA260 mode and
ModeHA26 ModeHA26 restrictive mode variable
restrictive mode (failures ,
Failure state
Reach Lim. see FAILURES menu)
Teles stroke coarse variable state telescopic rod coarse in mm
telescopic boom angle in
Boom angle angle variable state
degrees (x100)
boom outreach compared to
Boom radius outreach variable state
the link part( without jib)

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telescopic boom coarse in
Stroke before variable state
mm before outreach limitation
lim. (error, 0 if error< 0)
cut out
variable state
Stroke error Coarse error after cut out
(- error, 0 if error > 0)
value acquisition boom angle
SL1 sensor state
transducer
value acquisition boom angle
SL2 sensor state
transducer
value acquisition boom length
SL3 sensor state
sensor
SL4 sensor state
sensor
telescopic boom area
between 0 and 11 (0
ZoneTeles variable state
telescopic boom fully
retracted)
no matching acquisition value
ErrIncohAngle variable state between SL1 and SL2 angle
transducers(in degrees x100)
Stat overload Variable state for static overload “ON” if in overload
Dyn Overload Variable state for dynamic overload ON” if in overload
Overload
Variable state for overload calibration ON” if in calibration
learning
Jib Angle Jib relative angle in degree x10 Displayed in degree x10
Overload
Abs Angle Jib absolute angle (basket level) Displayed in degree x10
Rod pressure Pressure in small jib cylinder (G1) Displayed in bar x10
Bore pressure Pressure in large jib cylinder (G2) Displayed in bar x10
Result Result of the pressure between G1
Displayed in bar x10
pressure and G2
Software reference of module node
Node B
Other B1
Pes A Type of Load management system
Menu 5. INFORMATIONS
5.1 DATE AND HOUR Date and hour * for modify in level 3
5.3 VERSIONS Versions softwares

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8.1.6. LIST OF ALARMS
MENU 6. FAILURES
check mini maxi signal 0.2 V - 4.8
Joystick of drive out of signal or
JY01 VDC and central position at 2.5 +/-
inconsistency with off neutral
0.15 VDC
Alarms check mini maxi signal
Central Joystick out of signal or
joysticks (2F) JY02 0.2 V - 4.8 VDC and central position
at 2.5 +/- 0.15 VDC
check mini maxi signal
Left Joystick out of signal or
JY03 0.2 V - 4.8 VDC and central position
at 2.5 +/- 0.15 VDC
Comparison of current value
CB01 Check values and connections
between sensors SL3 and SL4
Comparison of current value
CB02 Check values and connections
between sensors SL1 and SL2
SL3 or SL4 out of range (+-1% of the
CA01 check SL3, SL4, electric bundles
range: +-120mm)
SL1 or SL2 out of range (+-3% of the
CA02 check SL1, SL2, electric bundles
Alarms range: + 3,6°)
position Difference between SL3 and SL4
check SL3, SL4,
sensors (1F) CA03 higher than 3% of the range (3% of
electric bundles
Vbat)
Difference between SL1 and SL2 check SL1, SL2,
CA04
higher than 3% of the range electric bundles
CA05 Closed SQ7 and closed SQ9 check SQ7 and SQ9
CA06 Closed SQ3 and closed SQ4 check SQ3, SQ8 and SQ4
CA07 Zone SQ7 incompatible with stroke check SL3, SL4, SQ9, SQ7
CA08 angle > 5° and closed SQ4 check SL1, SL2, SQ4
sensors reach limitation
Alarm reach
LP01 Reach limitation motor (SL1, SL2, SL3, SL4), valves YV3
limitation (8F)
and YV2
OL01 No Load managment system present check the module B1 node
OL02 Calibration not carried out make the calibration
OL03 Relative sensor A1 out of range check the sensor
OL04 Absolute sensor A2 out of range check the sensor
Sensor G1 pressure small chamber
OL05 check the sensor
out of range
Sensor G2 pressure large chamber
OL06 check the sensor
out of range
Alarm overload
(9F) OL07 Cancelled from serial number
Comparision of calculated values
Ol08 AD124613 or with software > V1.06
Inversion between G1 and G2 has
been detected (only if basket is
between – 20° and + 20°)
OL09 If basket at full inclination (up or Put back the connections as original
down) the pressure could be
negative

Alarms fuses
(6F)
AL03 FU6 at 0 and FU5 at 0 check fuse FU6 and FU5

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Alarm circuit of
check circuit of emergency stop,
emergency AU01 254 at 0V
KMG
stop (5F)
Alarm battery Year provided by the clock equal to
BT01 replace Head module
computer 2000 to the powering
Alarm
EEPROM EP01 Defect EEPROM module replace Head module
computer
check FU16, CAN bus connection,
MX01 Defect CAN bus
CAN bus ECU modules Node A, Node B1
8.1.7. ANGLE SENSORS VALUE
• Angle sensors value (Tolerance +/- 0.1V)
SL1 (wire 611B) SL2 (wire 805)

Boom at 0° 4.22 V (18.1 mA) 1.56 V ( 6.31 mA)
Boom at 75° 1.54V (6.85mA ) 4.19 V (17.45mA)
Value required for calibration (in 841 296
points) boom at 0° (+/- 3 %)
Value required for calibration (in 302 842
points) boom at 75° (+/- 3 %)
• Length sensors value (Tolerance +/- 4% of Vbat)
SL3 ( wire 804) SL4 (wire 807)

Telescopic boom retracted 6.7% of Vbat Same for SL3
Telescopic boom extended 65% of Vbat Same for SL4
Note : All values measured with a voltmeter must be taken between a 0VDC and the signal wire

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8.1.8. OVERLOAD CALIBRATION
NOTE:
During the procedure:
the machine is never switched OFF
the engine is always running
the machine should not be in slope.
the machine must be in stowed position, turret aligned , jib down
no failures like OL03, OL04, OL05 and OL06
all movements must be done from low control box
For the calibration, the OPTIMIZER calibrator is in level 2.
Read first and wait for the messages before any validation
Don’t release any command until the message on display will authoraise it
Perform the movements in the right order, any mistake will cancel the calibration and the procedure
must be done again since the beginning
Preparation of the calibration:
• Put the basket at 0° using an electronic level (by activating the compensation if necessary).
• go up sindicatorly the jib at 20° approximately so that it is not out of low stop.
Calibration:
Go in the menu 2.Parameters > 2.6.2 Cal Overload
put 250 kg/550 lbs in the basket and press on the validation key 250kg/550lbs
launch the procedure while pressing on the key
If the conditions described at the beginning of the procedure are not correct the message will be as
follow:
If not the procedure continues and the following message appears:
Lower the jib and hold the switch until getting the following message:
[During the procedure, if a defect starts, an error message will appear and the procedure will have
to be cancelled.]

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If not keep going and press key
Lift the jib until maxi height (don’t release the toggle switch during the full movement)
During this process, the message will be like that:
continue and hold the toggle switch until getting the following message:
press on the key in order to continue.
Lower the jib one and hold the switch until getting the following message:
press on the key in order to continue.
Switch OFF and ON the machine and lift the jib at 20°.
Lower the machine again until the low electric cut-off.
Remove the weights,
END of the procedure
If the recording of the calibration did not proceed correctly, the following message will be carried
out.
Erase the possible failures in memory from OL01 to OL09.
The procedure is over.
Codes Error:
Code 1 Error in the detection of the high stop: stop not found .
Code 2 Error in the detection of the low stop: stop not found .
Code 3 Error of control of the low stop.
Code 4 Error at the time of the writing of the calibration check sum parameters in EEPROM. Or
disfunction of the EEPROM in node B.
Code 16 Movement stopped during the process

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8.1.9. REACH LIMIT CALIBRATION
During the procedure:
- The ignition key must remain switched ON.
- The engine is always running.
- The machine is on a flat floor.
- The calibration process must be done from the turret control box.
- During all movements, the dead man switch must be activated.
Caution, it is necessary to use the optimizer with the daily code level 3.
The respect of the positioning of all elements of the machine is very important.
If these rules are not respected, the sensors would make some wrong measurements and create
some risks for the stability of the machine.
The module is in calibration mode: The engine and reach limit indicators are flashing, the buzzer is
beeping.
If the machine is not in calibration mode, cancel the old calibration in the menu
2.PARAMETERS/2.6.1 CAL REACH LIM/Reach Limit: Cancel, push the green button on
OPTIMIZER.
• POSITION 1: Arm lifted, boom down, telescope retracted.
- Raise the arm up to the maximum.
- Lower the boom down to the minimum.
- Retract completely the telescope.
- Validate the position 1 in the menu

2.Parameters/Calibration/Reach Limit: Pos. 1 by
pushing the green button.
- If OK appears, go to the next step.
- In case of error, retract completely the machine, repair the faulty sensor and restart the calibration
from the beginning.
Note: In this position, the signals of the sensors must be at the following values:
SL1 4,22V +/0.1V

SL2 1,56V +/0,1V
SL3 6,7 % de Vbat +/- 4 %
SL4 6,7 % de Vbat +/- 4 %

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• POSITION 2: Boom lifted, telescopic boom fully extended.
- Lift the boom at full stroke
- Extend the telescope at full stroke.
- Validate the position 2 in the menu Parameters/Calibration/Reach Limit:

Pos. 2 by pushing the green button on OPTIMIZER.
- If OK appears, check that the calibration is finished: the indicators must

not flash anymore and the buzzer must not beep too.
- In case of error, fold completely the machine, repair the faulty sensor and
restart the calibration from the beginning.
In this position, the signals of the sensors must be as the following values:
SL1 1,54V +/ - 0.1V

SL2 4,19V +/ - 0,1V
SL3 65 % de Vbat +/- 4 %
SL4 65 % de Vbat +/- 4 %
• Checking of the sensors :
From the turret control box:
- Activate the function “Factory tolerances” in the menu 2.Parameters/2.4 Maintenance.

(This function reduces all the tolerances of the failures activation at 1.6%)
- Fully raise the arm.
- Fully raise the boom and extend the telescopic boom extension at full stroke.
- Then fully lower the boom.
- Put back the machine in stowed position.
- Check that no failure appeared. If so, repair the faulty sensor and restart the calibration from the
beginning.

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8.2. CONSOLE DIAG PAD
It’s possible to use the 2nd generation of diagnostic console (also available through laptop)
The presentation of the main menu will depend of the software’s version of the machine
This diagnostic console could be used in WIFI using a VCI adapter
The full description of how to use that console and their menus is explained in an other technical
note (refer to your nearest HAULOTTE SERVICES of your area)

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

AU01 F02.03
JY03 F05.01
JY02 F05.02
JY01 F05.06
OL01-OL02 F06.01
OL07-OL08 F06.02
CH01 F07.02
CA02 F07.03
CA04-CA08 F07.04
CA05 F07.06
CA09 F07.09
CA01 F07.10
CA07 F07.11
CA05 F07.12
OL05 F07.20
OL06 F07.21
OL03 F07.22
OL04 F07.23
AL03 F08.01
AL01 F08.02
AL02 F08.03
CB01 F10.04
LP01 F11.04
MX01 F12.01
EP01 F12.02
BT01 F12.03

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8.3. PROCEDURE FOR SENSORS ADJUSTEMENT
8.3.1. ANGLE SENSOR A1
Fit the axle in front of the lock screw (as shown below)
8.3.2. ABSOLUTE ANGLE A2 (INCLINOMETER)
•
Fit the sensor on plate

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8.3.3. PRESSURE SENSORS G1- G2
Tight the sensors with torque wrench (30-35Nm)
8.3.4. ANGLE SENSOR SL1-SL2

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Fix the rods on the sensors (flat surface towards the sensor, see picture A )
- Assemble the other rods (2326001940) on the previous
Fitting (don’t forget the rods’ axles (see mark 1) so as the main rods could rotate freely) ,
- Connect the sensors and pre-set the values then fix them on the machine as shown on
photos B1 and B2
- Control the transducers values and readjust if necessary before the final tightening
B1
B2

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8.3.5. LENGTH SENSOR SL3-SL4
Note :the support type and the location of the reel could change compared to the pictures shown
below but the procedure is the same
Remove the safety cable from the new item
- Fix the reel on its support (photo A)
- Install it on its location according to the machine’s model (picture B)
- Fix the carabineer (hook) on the cable at the back side of the telescopic boom section (photo C)

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8.3.6. TELESCOPIC BOOM ILS DETECTION SQ7
Fit the sensor so as the distance between magnets and sensor will be ideally
between 7 and 15mm
• Position of magnets on telescopic boom (mm)
MAGNET POSITION BOOM EXTENSION

1 3412 mm ( zone 2)
2 4112 mm ( zone 4)
3 4812 mm ( zone 6)
4 5512 mm ( zone 8
5 6212 mm ( zone 10)

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8.3.7. HOW TO UNDERSTAND THE SENSORS VALUE AT THE CONSOLE
when connecting the OPTIMIZER console , the values of the sensors are sometimes in
points
see below the explanation for the sensors supplied in 4-20mA
9. LIST OF SCHEMATICS
See below all schematics (electric/hydraulic) of all versions

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LOCATION OF COMPONENTS ON MAIN PRINTED CIRCUIT

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MF - HA20-260 PX - EN - E02-14

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TECHNICAL TRAINING

Chapter 1: Main features and functions

TRAINING MANUAL DIAGNOSTIC Level 2 HA20PX-HA260PX

Revision Edition Subject Created Validated Modified Translated Language

TRAINING MANUAL DIAGNOSTIC Level 2 HA20PX-HA260PX

2. THE ELECTRICAL PART.................................................................................................................................... 16

TRAINING MANUAL DIAGNOSTIC Level 2 HA20PX-HA260PX

1.1.1. MAIN COMPONENTS

TRAINING MANUAL DIAGNOSTIC Level 2 HA20PX-HA260PX

TRAINING MANUAL DIAGNOSTIC Level 2 HA20PX-HA260PX

TRAINING MANUAL DIAGNOSTIC Level 2 HA20PX-HA260PX

TRAINING MANUAL DIAGNOSTIC Level 2 HA20PX-HA260PX

TRAINING MANUAL DIAGNOSTIC Level 2 HA20PX-HA260PX

2.1. SYMBOLS USED

Battery with one element

Fuse (Here 10 amps)

Coil winding roll

TRAINING MANUAL DIAGNOSTIC Level 2 HA20PX-HA260PX

Key selector with 3 positions

Toggle switch with 2 positions

TRAINING MANUAL DIAGNOSTIC Level 2 HA20PX-HA260PX

Proportional valve PWM type ( Pulse Width Modulation)

Foot pedal switch

Electrovalve “ON/OFF » ( bang-bang)

Tilt sensor ( ramp detection)

Angle sensor (reach limitation)

Contact « mercury » (angle detection)

TRAINING MANUAL DIAGNOSTIC Level 2 HA20PX-HA260PX

Sensor length (reach limitation)

Pressure sensor (weighing)

Angle sensor (weighing)

Standard indicator “Led”

Flexible Blade Switch (ILS) detection of the magnets on

Level detector (diesel tank)

Proximity detector with impulses

TRAINING MANUAL DIAGNOSTIC Level 2 HA20PX-HA260PX

2.2.1. ELECTRIC CONTINUITY CONTROL

2.2.2. CONTROL OF AN ON/OFF VALVE

TRAINING MANUAL DIAGNOSTIC Level 2 HA20PX-HA260PX

Control resistance of the coil

2.2.3. CONTROL OF COMPONENTS

• Control of an electric relay

TRAINING MANUAL DIAGNOSTIC Level 2 HA20PX-HA260PX

• supply control of the relay

TRAINING MANUAL DIAGNOSTIC Level 2 HA20PX-HA260PX

TRAINING MANUAL DIAGNOSTIC Level 2 HA20PX-HA260PX

2.4. THE MAIN PRINTED CIRCUIT (LOWER CONTROL BOX)

2.4.1. THE WEIGHING BOARD (BPE)

TRAINING MANUAL DIAGNOSTIC Level 2 HA20PX-HA260PX

TRAINING MANUAL DIAGNOSTIC Level 2 HA20PX-HA260PX

TRAINING MANUAL DIAGNOSTIC Level 2 HA20PX-HA260PX

KT2 FU5 FU9 FU10 FU8 FU6

In the following tables:

TRAINING MANUAL DIAGNOSTIC Level 2 HA20PX-HA260PX

FWD Forward (drive)

FU1 01 - 19 Stop engine 10A (115)

TRAINING MANUAL DIAGNOSTIC Level 2 HA20PX-HA260PX

SA19 02 - 7 Enable switch/ Emergency pump lower control box (620)

TRAINING MANUAL DIAGNOSTIC Level 2 HA20PX-HA260PX

TRAINING MANUAL DIAGNOSTIC Level 2 HA20PX-HA260PX

YV1 04 - 3 20 Load Sensing (303)

YV8 03 - 19 8.11 High speed drive (813)