Training manual

OPTIMUM 8 - OPTIMUM 1931 E

Training manual

OPTIMUM 8 -
OPTIMUM 1931 E
USA

4000595920 E 10.16 USA / GB

OPTIMUM 8 - OPTIMUM 1931 E

2 4000595920 E 10.16 USA / GB

 Training manual

CONTENTS

A
FOREWORD
1 - Revision. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

B
MAIN FEATURES AND FUNCTIONS
1 - Models description . . . . . . . . . . . . . . . . . . . . . . . 9
2 - Primary machine components . . . . . . . . . . . . 10
2.1 - Working area / Range of motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2 - Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2.1 - Machine layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3 - Ground control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.3.1 - Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.3.2 - HAULOTTE Activ'Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.3.2.1 - LCD screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.4 - Platform control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.4.1 - Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

C
STUDY OF THE ELECTRIC SCHEMATICS
1 - System architecture . . . . . . . . . . . . . . . . . . . . . 21
CONTENTS

1.1 - Power circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

1.2 - Logic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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2 - List of actuators and sensors . . . . . . . . . . . . . 24

2.1 - Sensors and actuators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.2 - Drive circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.2.1 - Function of the variators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.2.1.1 - Control of the traction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.2.1.2 - Control of the pump (other movements). . . . . . . . . . . . . . . . . . . 29
2.2.1.3 - Details of sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.2.1.4 - System of unbraking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.2.1.5 - Detail of the connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.3 - Scissors arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.4 - The sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.4.1 - Limit switchs for potholes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.4.2 - Steering potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.4.3 - Angle transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.4.4 - Pressure transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.4.5 - Slope sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.4.6 - Battery charger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.4.7 - Fuses and relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.5 - Actuators and their location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.5.1 - List of actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.5.2 - Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.5.3 - Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.5.4 - Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.5.5 - Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.6 - Cut out conditions of every function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.6.1 - Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.6.2 - Power supply/commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.6.3 - Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.6.3.1 - Validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.6.4 - Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.6.4.1 - Validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.6.4.2 - Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.6.5 - Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.6.5.1 - Validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.6.5.2 - Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.6.6 - Brake release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.6.7 - Potholes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.6.7.1 - Validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.6.7.2 - Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

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D
STUDY OF THE HYDRAULIC SCHEMA
1 - Hydraulic units . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.1 - General overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.1.1 - The hydraulic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.1.1.1 - Pump unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.1.1.2 - Selection valve potholes/steering. . . . . . . . . . . . . . . . . . . . . . . . 68
1.1.1.3 - Lifting cylinder valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

E
ADJUSTMENTS
1 - Adjustments with diag pad console . . . . . . . . 71
2 - List of menus . . . . . . . . . . . . . . . . . . . . . . . . . . 72
2.1 - Machine settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
2.1.1 - Speeds and ramps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
2.1.2 - Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
2.1.3 - Countries and models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
2.2 - Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
2.2.1 - Inputs/Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
2.2.2 - States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3 - Failures list . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.1 - List of failures per category . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4 - Maximum height adjustment . . . . . . . . . . . . . . 87
5 - Cutback speed position height adjustment . . 88
6 - Load management system . . . . . . . . . . . . . . . 89
CONTENTS

6.1 - Calibration procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

6.2 - Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
6.2.1 - Steering calibration procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
6.3 - Angle transducers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
7 - Adjustment of pressures . . . . . . . . . . . . . . . . . 94
7.1 - Main pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
7.2 - The speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

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F
SIMPLIFIED BREAKDOWN GUIDE
1 - No start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2 - No lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3 - No drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4 - No steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

G
VERSION SUMMARY
1 - Version summary . . . . . . . . . . . . . . . . . . . . . . . 97
2 - List of schematics . . . . . . . . . . . . . . . . . . . . . . 98
3 - List of wiring harnesses . . . . . . . . . . . . . . . . . 98

6
OPTIMUM 8 - OPTIMUM 1931 E

A - Foreword
Foreword How to use this document ?
A
MAINTENANCE AND REPAIR OPERATIONS ON YOUR HAULOTTE® MACHINE MAY ONLY BE PERFORMED BY
TRAINED AND EXPERIENCED TECHNICIANS

B
You are in possession of the summary document provided during the HAULOTTE® technical training
programme. It will allow you to find the information necessary for performing maintenance and repairs on
your HAULOTTE® machine.

The following guide will help you to rapidly access the required chapter.
C
Section A : Foreword

You will find there the elements as following :

• A resume of any update made since the creation of the manual.

Section B : Main characteristics and functions D

You will find there the elements as following :
• The list of the models.
• Their main datas.
• Their overall dimensions.
• Their working envelop. E
• Controls boxes.
• Some maintenance topics on specific components (charger, engine ..).

Section C : Study of the wiring diagram

It will include the following elements: :

• Structure of the system.
F
• Localization/photo of each safety components.
• The location/function of each component in schematics.
• Cut out conditions of every function.

Section D : Study of the hydraulic diagram

G
It will include the following elements: :
• The localization of every manifolds.
• The location/function of each component on block.
H

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A - Foreword
Section E : The adjustments

It will include the following elements: :

• The way to use/connect the console of diagnostic.
• The list of main menus and its architecture.
• The list of alarms with their explanation.
• Any calibration/settings required for the model of the machine.
• The way to check/adjust the pressures for the model.

Section F : Repair guide

It will include the following elements: :

• A summary of every function and items to be checked in case of breakdowns.

Section G : Summary of the versions

It will include the following elements: :

• A summary of the different versions made per model.
• Any schematics (electric /hydraulic) linked to the models studied.
• Coloured schematics (electric/hydraulic) per function.
• List of main harnesses in the models studied.

1 - Revision
CREATED VALIDATED MODIFIED TRANSLATED
REVISION EDITION SUBJECT LANGUAGE
BY BY BY BY
00 10.16 Creation ASA MGD ASA ITC USA / GB

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B - Main features and functions

Main features and functions A

1 - Models description
REGULATION MODELS

ANSI and CSA standards OPTIMUM 1931 E

B
CE, AS and EAC standards OPTIMUM 8

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B - Main features and functions

2 - Primary machine components

2.1 - WORKING AREA / RANGE OF MOTION

OPTIMUM 8 - OPTIMUM 1931 E

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B - Main features and functions

2.2 - TRANSPORTATION
2.2.1 - Machine layout
A

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B - Main features and functions

2.3 - GROUND CONTROL BOX
2.3.1 - Layout

General view

253 ACTIV’ Screen

92
15

43

105

93

Controls and indicators

MARKING DESCRIPTION FUNCTION

Pulled out : Ground control box energized
15 E-stop button
Pushed in : De-energizes control system
43 Horn button Not used
Right : Ground control box energized
Control box activation key
92 Center : De-energizes control system
selector
Left : Platform control box energized
93 Battery charging indicator Battery charger status
Move upwards : Flashing light turn ON
105 Beacon light (Optional)
Move downwards : Flashing light turn OFF
253 Diagnostic tool socket Connection to the diagnostic tool (HaulotteDiag)

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B - Main features and functions

2.3.2 - HAULOTTE Activ'Screen
A
Upon starting and during operation of the machine, the LCD screen "Activ'Screen" located on the
ground control box displays in real time the machine operating status.
HAULOTTE Activ'Screen

E
Controls and indicators

MARKING DESCRIPTION FUNCTION

1 Platform raising control Platform raisess F
2 LCD screen Display status of operation of the machine
3 Navigation button Navigation of menu to select function - Scroll up
4 Confirmation button Confirmation of the selected function
5
6
Cancellation button
Platform overload indicator
Go back
Platform overload indicator G
7 Machine fault indicator light Constantly lit in the event of an operation malfunction
8 Navigation button Navigation of menu to select function - Scroll down
9 'Enable Switch' selector Press in and hold : Enable switch
10 Platform lowering control Platform lowers
H

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B - Main features and functions

2.3.2.1 - LCD screen

At startup

At startup with the ground or platform controls selected; system initiates a self check :

• Bar gets filled up.

• Home screen comes on with status icon of the machine - okay to proceed functioning
the controls.

SYMBOL DESCRIPTION

1 Information icons

2 Information text

3 Status icon of the machine

SYMBOL DESCRIPTION

Battery status

Maintenance use

Fault / alarms

Hour meter

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B - Main features and functions

• After pressing on : A

C
SYMBOL DESCRIPTION

1 Software part number

3
Software version + Screen software version + Screen version

Screen identification + Screen software version

D
4 Machine serial number displayed

• After again pressing on E

• Access code screen comes on - refer to maintenance manual for entering the access
code

• Validation by pressing on is active only if access code is known and entered - refer to
maintenance manual for the procedure for the different level code useage
H

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B - Main features and functions

Alarm status

Alarm status displayed as applicable - samples shown below

• Tilt

• Overload

• Low battery

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B - Main features and functions

• Present fault
A

• Platform control box E-stop button pressed in (de-energized)

C

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B - Main features and functions

2.4 - PLATFORM CONTROL BOX
2.4.1 - Layout

General view

Controls and indicators

MARKING NAME DESCRIPTION FUNCTION

27 HL800 Tilt indicator Machine on excessive slope

30 HL802 Overload indicator Platform overloaded

43 SA907 Horn button Move upwards and hold to activate horn

Pulled out : Platform control box power supply

energized
46 SB802 E-stop button
Pushed in : De-energizes control system

Fault indicator Faulty or tilting or overloaded

85 HL903 Fault indicator
machine

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B - Main features and functions

MARKING NAME DESCRIPTION FUNCTION
A
100%
Battery charged
B
Battery charging
91 HL904
indicator
40%
Flashing : Batteries have 40 % charge left

C
20%
Constantly on : Batteries have only 20 % charge
left

Move forward : Forward drive or platform raising D

Movement joystick
Move backwards : Reverse drive or platform
lowering
108 SM901
Press right side of button : Right-hand steering
Front axle steering
selector
Press left side of button : Left-hand steering E
On : Raising / Lowering selection activated
Raising / lowering
110 HL420
selector Off : Raising / Lowering movement is not
selected

111 HL100
Driving selection
indicator
On : Driving function activated
F
Off : Driving movement is not selected

Move to the left : Platform raising / lowering

112 SA908 2-position selector
Move to the right : Drive movements

Press in and hold : Associated command is

validated
G
123 SA905 'Enable Switch' selector
Release : Associated command movement is
halted

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B - Main features and functions

Notes

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C - Study of the electric schematics

Study of the electric schematics A

1 - System architecture

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C - Study of the electric schematics

1.1 - POWER CIRCUIT

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C - Study of the electric schematics

1.2 - LOGIC CIRCUIT
A

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C - Study of the electric schematics

2 - List of actuators and sensors
2.1 - SENSORS AND ACTUATORS

Sensors and actuators

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C - Study of the electric schematics

A
NAME DESCRIPTION
SP400 Pressure sensor
SQ144 Pothole limit sensor
SQ145
SQ800
Pothole limit sensor
Tilt sensor
B
SR150 Steering potentiometer
SR420 Tilt sensor low position
SR722 Pothole limit sensor
YV120
YV121
6 tracks / 2 positions for potholes or steering switch (priority for potholes)
Right steering or pothole entry valve C
YV122 Left steering or pothole exit valve
YV420 PWM platform raising/lowering proportional valve
YV903 Valve by-pass (pump pressurization)

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C - Study of the electric schematics

2.2 - DRIVE CIRCUIT

The traction is controlled by 2 asynchronous 3 phases motors (24VAC - 1KW).

Each motor is piloted by one variator ( COMBIACX master for RR motor and ACEX slave for RL
motor) through CAN - BUS network.

Each variator consists of :

• One thermistor for temperature control (ST302/ST303).
• One encoder for speed control (SV300/SV301).
• One electromagnetic brake at negative excitation (YB100/YB101).

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C - Study of the electric schematics

The whole unit is located in the chassis (rear side as shown below)
A

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C - Study of the electric schematics

2.2.1 - Function of the variators

• The COMBIACX variator is the master and controls the traction of the RR motor and a chopper for the DC pump
motor and some I/O too.
• The software upload process is done by connecting the DIAG PAD console or HAULOTTE DIAG application.
• The ACEX variator (slave) controls the traction of RL motor (no need to upload software on it).
• The 2 variators has the regenerative braking function (deceleration).
• Each variator is protected with a speed and temperature sensor and electromagnetic brake disc.
• In case of low battery charge, the maximum current is reduced to the half of the maximum current programmed
(an alarm message is displayed).
• The 2 variators are protected against reverse battery polarity.
Overview

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C - Study of the electric schematics

2.2.1.1 - Control of the traction
A

D
2.2.1.2 - Control of the pump (other movements)

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C - Study of the electric schematics

2.2.1.3 - Details of sensors

• The speed rotation of each motor is controlled through an encoder with 2 signals shifted at 90° each and 48
impulses per round.
• The temperature of each motor is controlled through a thermistor located inside the winding (from 85°C the
current is reduced in proportion the temperature increases until reaching 105°C where the current is null and
traction stopped).

2.2.1.4 - System of unbraking

The electro magnetic brakes are at negative excitation (remains stuck if not or lack of current).

In case of necessity, it’s possible to release the brakes using the toggle switch SA103 located behind
the variator’s support (see below).

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C - Study of the electric schematics

2.2.1.5 - Detail of the connections
A

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C - Study of the electric schematics

Detail of the connectors on variators.

For any connector, the pin 1 always start at the lower right corner as shown below.

Connector are labelled as follow :

• CXA/B/C/D for COMBIACX.
• AXA/B/C/D for ACEX.

(See below and refer to electric schematic)

Connectors (power side) :

• U/V/W are the 3 motors phases.
• B+ : positive of the battery.
• BF+ : positive of the battery protected by a Fuse of 160A.
• B- : negative of the battery.
• P+ : output of the pump motor ( COMBIACX only).

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C - Study of the electric schematics

2.3 - SCISSORS ARM
A
The arms stack are independent and equipped with standards axles secured by clips and ring (see
below).

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C - Study of the electric schematics

2.4 - THE SENSORS
2.4.1 - Limit switchs for potholes

MARKING FUNCTION DESCRIPTION

1 SQ144
Sensors = 1 when potholes are retracted
2 SQ145

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2.4.2 - Steering potentiometer
A

F
MARKING FUNCTION DESCRIPTION
Value 2.5 kΏ, supply in 12 VDC (coming from ACEX variator)
Before to launch the calibration, the pre-setting has to be done at mid-range
1 SR150
value then use the consoles in order to set the potentiometer values to adjust
current/voltage of the internal motor depends the direction of steering (left/right) G

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2.4.3 - Angle transducers

MARKING FUNCTION DESCRIPTION

Analogic sensor (0.5/4.5VDC), detection of low position
1 SR420 Value adjustable according to scissors angle (~ 74 – 535 pts)
Calibration system angle/pressure through consoles or active screen
Detection of upper position
2 SR722 Value adjustable according to scissors angle (~ 420 – 135 pts)
Calibration system angle/pressure through consoles or active screen

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2.4.4 - Pressure transducer
A

MARKING FUNCTION DESCRIPTION G

Analogic transducer (4-20ma), value variable depends of the pressure on big
1 SP400 chamber of the lifting cylinder
Calibration system angle/pressure through consoles or active screen

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2.4.5 - Slope sensor

MARKING FUNCTION DESCRIPTION

Tilt Y = 1.5° / X =3° (wire 12 = Vbat if machine on flat surface)
1 SQ800
1=red=+Batt / 2=white=signal / 3=black=GND

2.4.6 - Battery charger

Version 230VAC - 24V - 20A

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2.4.7 - Fuses and relays
A

MARKING FUNCTION DESCRIPTION G

1 FU2 Protection electrovalve circuit (10A)
2 FU3 Protection main circuit (10A)
3 FU4 Protection accessories circuit (10A)
4
5
SA103
KA1
Toggle switch for manual brake release function
Relay for horn H
6 KAH Relay for main modules power supply

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2.5 - ACTUATORS AND THEIR LOCATION
2.5.1 - List of actuators

In the following tables :

• The column n°2 indicates the position on the connector on modules (if required).
• The state noted "0" corresponds to 0 V, opened contact or not activated.
• The state noted "1" corresponds to the tension of the circuit, closed or activated contact.

Glossary

MARKING DESCRIPTION
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 reed sensor
UCB Upper control box
LCB Lower control box
ECU Electronic Control Unit
PWM Pulse Width Modulation
PCB Printed circuit board

2.5.2 - Modules

MODULES
NAME LOCATION FUNCTION
01 Multi function CAN display (Activ screen)
02 COMBIACX Variator (Master)
02 ACEX Variator
U4 03 CAN tiller board (UCB)

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2.5.3 - Fuses
A
FUSES
NAME LOCATION CONNECTOR FUNCTION
FU1A 01 - 03 Protection ACEX variator (125 A)
FU1C
FU2
01 - 07
01 - 08
Protection COMBIACX variator (300 A)
Protection electrovalve circuit (10 A)
B
FU3 01 - 05 Protection main circuit (10 A)
FU4 01 - 12 Protection accessories circuit (10 A)

2.5.4 - Inputs C
INPUTS

NAME LOCATION CONNECTOR FUNCTION

SA103

SA901
02 - 17

01 - 12
AXC.2 Manual brake release switch (21)

Key selection (upper/lower controls) (133/

D
135)

SA903 01 - 15 Flashing light (Option) (32)

SA904 03 - 05 Option working light (134)

SA907

SA907B
03 - 16

02 - 20
B.4

AXB.4
Horn switch (Upper controls) (34)

Horn switch (Lower controls) (Option)

E
SA908 03 - 17 B.12/B.13 Selection function (movements/drive) (76/85)

Foot pedal switch ( US option = 1 for any

SB800 03 - 12 B.1
movement)(37)

SB801 01 - 13 Emergency stop button (Lower controls) (84) F

SB802 03 - 14 Emergency stop button (Upper controls)

SM901 03 - 10 A.10 Joystick ( 39: value 0.5 / 2.5 / 4.5VDC)

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SENSORS
NAME LOCATION CONNECTOR FUNCTION
Pressure transducer 4 - 20 mA located in
SP400 02 - 06 CXC.9
large chamber of lifting cylinder (14)
Potholes position ( = 1 if retracted; out in lift
SQ144 / SQ145 02 - 18 AXA.4
mode) (15)
Tilt Y = 1.5° / X =3° (wire 12 = Vbat if
SQ800 02 - 02 CXA.12 machine on flat surface)
1=red=+Batt / 2=white=signal / 3=black=GND
Potentiometer for steering wheels angle
SR150 02 - 14 AXC.4
(value 2.5 O) (47)
Angle transducer for scissors arm position
SR420 02 - 04 CXC.4
(13)
Angle transducer for platform height
SR722 02 - 16 AXC.9
detection (20)
Temperature probe inside AC RR drive
ST302 02 - 08 CXD.3/6
motor (if at 105° C current null and no drive)
Temperature probe inside AC RL drive motor
ST303 02 - 15 AXD.3/6
(if at 105° C current null and no drive)
ST903 02 - 16 AXC.7 Temperature sensor (Option RUS/UKR)
Controls the motor speed through an
SV300 02 - 09 CXD.1/2/4/5 encoder with 2 signals shifted at 90° each
and 48 pulses per revolution
Controls the motor speed through an
SV301 02 - 13 AXD.1/2/4/5 encoder with 2 signals shifted at 90° each
and 48 pulses per revolution

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2.5.5 - Outputs
A
RELAYS-MOTORS
NAME LOCATION CONNECTOR FUNCTION
KAH 01 - 07 Main relay for commands (115)
KA1
KA2
02 - 17
02 - 20
AXB.7
AXA.8
Horn command (70)
Flashing light command (89)
B
KA3 02 - 10 CXB.1/5 Brake release command (remote control)
KA4 04 - 04 Option

KM900 01 - 06
Battery charger relay (If activated, no
function on machine) (98) C
M370 02 - 06 U/V/W AC drive motor (RR)
M371 02 - 13 U/V/W AC drive motor (RL)
SB801 01 - 13 Main line contactor for ECU modules (84)

VALVES
D
NAME LOCATION CONNECTOR FUNCTION
Electromagnetic brake at negative excitation
YB100 02 - 11 CXB.1/5
for RR motor

YB101 02 - 12 AXB.1/5
Electromagnetic brake at negative excitation
for RL motor E
Valve 6 ways/ 2 positions for selection
YV120 02 - 03 CXB.3 potholes or steering (priority for potholes)
(56)
YV121 02 - 05 CXA.1 Right steering or potholes retraction (54)
YV122 02 - 06 CXA.8 Left steering or potholes out/extended (53)
PWM valve for platform lift/descent (Slow
F
YV420 02 - 18 AXB.3
descent when PF < 3 meters) (19)
Discharge valve (by-pass: pump is in
YV903 02 - 19 AXA.2
pressure) (55)

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BUZZER AND LIGHTS
NAME LOCATION CONNECTOR FUNCTION
HA901 05 - 13 CXA.9 Buzzer (04)
HA907 03 - 13 Horn (184)
EL901/B 06 - 05 Option flashing light (32)
EL904 09 - 19 Option working light (134)
HL100 09 - 11 E.7 Drive selection indicator (94)
HL420 08 - 09 E.6 Movement selection indicator (46)
HL800 09 - 10 F.3 Slope (tilt) indicator (45)
HL802 09 - 10 F.1 Overload indicator (44)
HL903 09 - 10 F.5 Other alarms indicator (43)
HL904 09 - 10 F.2 Battery level indicator (42)

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2.6 - CUT OUT CONDITIONS OF EVERY FUNCTION
A
2.6.1 - Glossary

MARKING DESIGNATION
U Up
D
L
Down
Left
B
R Right
F/FWD Forward
REV/B Reverse/backward
SETP
A IN
Setpoint
Analogic input
C
D IN Digital input
D OUT Digital output
A OUT Analogic output
PWM
VAR
Pulse Width Modulation (Proportionnal valve in current square modulated signal)
Internal variable in the module (not accessible with the console)
D
I/O Inputs/Outputs
I Input
O Output
µS
MS
Micro speed drive
Medium speed drive
E
HS High speed drive
2WS 2 wheels steering
4WS 4 wheels steering

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EC standards

1 2 3 4 5 6 7 8 9

PLATFORM ROTATION
TURRET ROTATION

PLATFORM LEVEL
TELESCOPE
STANDARD

BOOM
ARM
STEERING

JIB
SIMULTANEOUS MOVEMENTS DRIVE
( 2WS OR 4WS)
VAR[AUTHORIZEDMVT]=1

µS LS MS-HS µS LS MS-HS
µS 0 0 0 0 0 0 0
1 Drive LS 1 1 1 1 1 1 1 0
MS-HS 1 0 0 0 1 1 0
µS 0 0 0 0
Steering
2 LS 1 1 1 1 0
( 2WS or 4WS)
MS-HS 1 0 0 0
3 Turret rotation 1 1 1 1 1 0
4 Arm 1 1 1 0 0
5 Boom 1 1 0 0
6 Telescope 1 0 0
7 Jib 0 0
8 Platform rotation 0
9 Platform level

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Australia standards
A
1 2 3 4 5 6 7 8 9

PLATFORM ROTATION
TURRET ROTATION

PLATFORM LEVEL
TELESCOPE
AUSTRALIA
B

BOOM
ARM
STEERING

JIB
SIMULTANEOUS MOVEMENTS DRIVE
( 2WS OR 4WS)
VAR[AUTHORIZEDMVT]=1

µS LS MS-HS µS LS MS-HS

1 Drive
µS
LS 1
1
1
1
1
1
1
1
1
1
1
1
1
0
0
C
MS-HS 1 0 0 0 1 1 0
µS 1 1 1 1 1
Steering
2 LS 1 1 1 1 1 0
( 2WS or 4WS)
MS-HS 1 0 0 0 1
3
4
Turret rotation
Arm
1 1
1
1
1
1
1
1
0
0
0
D
5 Boom 1 1 0 0
6 Telescope 1 0 0
7 Jib 0 0
8 Platform rotation 0
9 Platform level
E
N.B.-:-THE MACHINE GETS A DEDICATED HYDRAULIC BLOCK TO ALLOW THE COMBINATION OF JIB AND
STEERING MOVEMENTS.

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USA standards

1 2 3 4 5 6 7 8 9

PLATFORM ROTATION
TURRET ROTATION

PLATFORM LEVEL
USA
STEERING

TELESCOPE
SIMULTANEOUS MOVEMENTS DRIVE
( 2WS OR 4WS)
VAR[AUTHORIZEDMVT]=1

BOOM
ARM

JIB
µS LS MS-HS µS LS MS-HS
µS 1 1 1 1 1 1 0
1 Drive LS 1 1 1 1 1 1 1 0
MS-HS 1 0 0 0 1 1 0
µS 1 1 1 1
Steering
2 LS 1 1 1 1 0
( 2WS or 4WS)
MS-HS 1 0 0 0
3 Turret rotation 1 1 1 1 1 0
4 Arm 1 1 1 0 0
5 Boom 1 1 0 0
6 Telescope 1 0 0
7 Jib 0 0
8 Platform rotation 0
9 Platform level

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2.6.2 - Power supply/commands
A
N.B.-:-

• The diagnostic menu is very important on this model as it will permit to the technician to focuse only on the
dysfunction encountered and then save time to repair the machine.

COMMANDS
• The explanation done below is built on the same basis for all movements.

ALL COMMANDS COMING FROM LOWER/UPPER CONTROLS

B
Inputs Digitals or analogic inputs (ETOR-EANA)
In Diagnostic menu, it's the parameter Internal setpoint for the function described Neutral to Fwd/up/
Setpoint(0-100%) left or Rev/down/Right (0-1000pts)
This setpoint is null when no movement is performed or there is a failure on the josytick
Conditions for cutting the movements :
C
Cuttings • Null movement is authorized
• 1 movement is inhibited
Validation and formatting the
Conditions for validation of the movement
command
Slow down

Control(0-100%)
Condtions for slowing down the movement (from 0 to 100%)
In Diagnostic menu, it’s the parameter Internal control for the internal command of the function(0-
D
1000pts)
Outputs Digitals or Analogic outputs (STOR-SPWM-SANA)
Actuator Any device like valves/cylinders/motors/relays

Explanation of the cinematic

E

F
Explanation of the Cuttings function

This is valid for every movement including drive mode.

BIT
CUT-OFF
DESCRIPTION
G
CONDITIONS
0 Enable General movement deactivation
1 General General Inhibition

2
Simultaneous
movements
Inhibition due to numerous movements activated at the same time H
3 Overload Inhibition due to machine is in overload mode
4 Tilt Inhibition due to machine is in tilt/slope
5 Reach limit Inhibition due to machine is in outreach limitation mode
6
7
Failure
Specific
Inhibition due to Faliures
Inhibition due to specific conditions /options
I

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REQUIREMENTS DEFINITION
Machine is powered ON with key SA901 of lower control box if no emergency stop is pushed
(EMSTOP=ON and PowerON=1). At power on, the relays close : SB801=ON & KAH=ON
• Supply 24 V of power part (motor, pump and electro valves).
PS001.1 • Supply 24 V of lower signal part (switches and sensors).
• Supply the upper part.

During machine use, the SB801 main contactor is controlled through high level software to save some
energy ( 150 mA to 200 mA current consumption) : SB801 = CTRL[MainContactor]
At power ON, the software automatically compares identifier stored into EEPROM with identifier
embedded in the loaded soft. If identifiers are different (blank ECU or new soft type loaded), then :
• All failures are reinitialized (reset of counters and log).
PS002
• Default speed, ramps, options and configurations vales are reloaded.
• Hour-meter stored into EEPROM is set to 0.
• Failure F12.04 is triggered.
If one of the emergency stop is pushed ( EMSTOP = OFF) until end of saves in EEPROM, machine is on
power hold mode.
• SB801=0: supply for power and upper parts is cut.
PS003
• CAN Failure F12.01 is inhibited.
• KAH doesn’t change : Supply 12 V and 24 V for lower signal parts are hold.
• Start of EEPROM saves before stop.
On power hold mode; when all EEPROM saves are done : KAH=ON
PS004
• The machine is switch off when KAH=OFF.
Machine counters (hours and service) are stored into ECU EEPROM in order to detect when the screen is
changed and then to reload automatically the old values stored into the new screen. For that, at machine
power ON :
PS005
• If Hourmeter(EEPROM) > Hourmeter(SCREEN) => Counters (hours and service) are reloaded from
values stored into ECU EEPROM.
• Otherwise current counters values are stored into ECU EEPROM.

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2.6.3 - Drive

2.6.3.1 - Validation
A
REQUIREMENTS DEFINITION
The drive movement happens relative to the activated panel, in the specified direction and set point and
DSV01
regarding to validation and slowdown conditions : SETP[Drive]=FWD|N|REV:[0-100]%
B
REQUIREMENTS DEFINITION
Forward (F) and/or reverse (R) drive movement is allowed if all validation conditions are satisfied and
none of cut-offs condition is true (see DVR03)

DSV02.1
VALIDATION
1
F
1
R
1
ENABLE CONDITIONS
Machine powered on for more than 3s
C
0 Enable 2 1 1 Machine is set
3 1 1 User is identified
1: The condition enables the movement (All conditions to '1': movement enabled)

REQUIREMENTS DEFINITION
D
The following conditions (General to Specific) inhibit the drive movement ( F: forward/ R: reverse)
CUT-OFF F R GENERAL CUT-OFF CONDITIONS
Machine unfolded and potholes not extended out of
1 1 1

DSV03 2 1 1
production mode
Battery charge level low (< 20%) And machine E
unfolded out of production mode
1 General Machine not low and "Drive restrictions when lifted"
3 1 1
option is set to "0.5m" value
Machine unfolded and "Drive restrictions when
4 1 1

5 1 1
lifted" option is active
Time out after drive movement F
REQUIREMENTS DEFINITION
SIMULTANEOUS MOVEMENTS CUT-OFF
CUT-OFF F R
DSV03
2
Simultaneous
5 1 1
CONDITIONS

Manual brake release is active

G
movements

REQUIREMENTS DEFINITION

DSV03
CUT-OFF
1
F
1
R
1
OVERLOAD CUT-OFF CONDITIONS
Overload alarm is active
H
3 Overload
2 1 1 Overload learning is running

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REQUIREMENTS DEFINITION
CUT-OFF F R TILT CUT-OFF CONDITIONS
DSV03 Tilt activated with unfolded machine and tilt cut-off
4 Tilt 1 1 1 activated (some countries or tilt safety configuration)
out of production mode

REQUIREMENTS DEFINITION
CUT-OFF F R REACH LIMIT CUT-OFF CONDITIONS
DSV03
5 Reach limit N/A N/A N/A N/A

REQUIREMENTS DEFINITION
CUT-OFF F R FAILURE CUT-OFF CONDITIONS
1 1 1 Power contactor stuck
Machine unfolded and load management system
2 1 1
not calibrated and serial number is set
The two arm angle sensors are out of range and
3 1 1
load management is active
DSV03 Serious incoherence in measuring arm angle and
6 Failure 4 1 1
load management is active
5 1 1 Machine unfolded and pressure failure
6 1 1 Power failure
7 1 1 Steering valve failure
8 1 1 Movement selection valve YV120 shorted
9 1 1 Arm incoherence ( YV903 failure)

REQUIREMENTS DEFINITION
CUT-OFF F R SPECIFIC CUT-OFF CONDITIONS
DSV03 Extreme temperature (for Russia country) and
7 Specific 1 1 1
machine unfolded

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REQUIREMENTS DEFINITION A
Following limits are applied on the set point (SETP[Drive]):
DIRECTIONS
MOVEMENT SET POINT LIMIT CONDITIONS
F R

DSV04.2
SPEED[uS Drive Fwd] SPEED[uS Drive Rev] 1
Unfolded machine (micro speed) and not
masked B
Steer angle not calibrated or steer angle out
SPEED[uS Drive Fwd] SPEED[uS Drive Rev] 2
of range and not masked
Arm angle function not calibrated or failing
SPEED[uS Drive Fwd] SPEED[uS Drive Rev] 3
and not masked
( 100% = max speed)
C
REQUIREMENTS DEFINITION
DSV05 When machine is unfolded, drive speed is set to 'Micro' value

REQUIREMENTS DEFINITION
The three conditions listed in DSV04 requirement are inhibited in case of :
D
• Machine serial number is "000000".
• Steer angle must be calibrated.
• Both angle sensors are not electrically out of range (> 100 mV and < 4900 mV) And angle computed is
less than 18°.
DSV06.1
• Pressure sensor indicates low pressure. (< 5 pts)
Serial number="000000" " & F10.16(A) & \F10.14(A) & (SP400 < 50pts)
& ( ( (10pts < SR420 < 478pts ) & (10pts < SR722 < 478pts ) & VAR[Angle] < 18° )
E
| ( (10pts < SR420 < 478pts ) & VAR[Angle_SR420] < 18°)
| ( (10pts < SR722 < 478pts ) & VAR[Angle_SR722] < 18°) )

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2.6.4 - Steering

2.6.4.1 - Validation

REQUIREMENTS DEFINITION
The steering movement happens in the specified direction and set point, regarding to validation and slow
STV01
down conditions : SETP[Steering]=LEFT|N|RIGHT:[0-100]%

REQUIREMENTS DEFINITION
Steering (both directions, each mode) is allowed if all validation conditions are satisfied and none of cut-off
conditions is true (see DRV03)
VALIDATION L R ENABLE CONDITIONS
1 1 1 Machine powered on for more than 3s
STV02.1
2 1 1 Hydraulic pump is ready
0 Enable
3 1 1 Machine is set
4 1 1 User is identified
1: The condition enables the movement (All conditions to '1': movement enabled)

REQUIREMENTS DEFINITION
The following conditions (General to Specific) inhibit the steering movement ( L: left / R: right)
CUT-OFF L R GENERAL CUT-OFF CONDITIONS
Machine unfolded and potholes not extended out of
1 1 1
production mode
Battery charge level low (< 20%) And machine
STV03 2 1 1
unfolded out of production mode
1 General Machine not low and "Drive restrictions when lifted"
3 1 1
option is set to "0.5m" value
Machine unfolded and "Drive restrictions when
4 1 1
lifted" option is active
5 1 1 Time out after drive movement

REQUIREMENTS DEFINITION
SIMULTANEOUS MOVEMENTS CUT-OFF
CUT-OFF L R
CONDITIONS
STV03
Simultaneous
2 5 1 1 Manual brake release is active
movements

REQUIREMENTS DEFINITION
CUT-OFF L R OVERLOAD CUT-OFF CONDITIONS
STV03 1 1 1 Overload alarm is active
3 Overload
2 1 1 Overload learning is running

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REQUIREMENTS DEFINITION A
CUT-OFF L R TILT CUT-OFF CONDITIONS
STV03 Tilt activated with unfolded machine and tilt cut-off
4 Tilt 1 1 1 activated (some countries or tilt safety configuration)
out of production mode

REQUIREMENTS DEFINITION
B
CUT-OFF F R REACH LIMIT CUT-OFF CONDITIONS
STV03
5 Reach limit N/A N/A N/A N/A

Requirements Definition C
CUT-OFF L R FAILURE CUT-OFF CONDITIONS
1 1 1 Power contactor stuck
Machine unfolded and load management system
2 1 1

3 1 1
not calibrated and serial number is set
The two arm angle sensors are out of range and
load management is active
D
STV03 Serious incoherence in measuring arm angle and
6 Failure 4 1 1
load management is active
5 1 1 Machine unfolded and pressure failure
6
7
1
1
1
1
Power failure
Steering valve failure E
8 1 1 Movement selection valve YV120 shorted
9 1 1 Arm incoherence ( YV903 failure)

REQUIREMENTS
CUT-OFF L
DEFINITION
R SPECIFIC CUT-OFF CONDITIONS
F
1 seconds of left steering control and no variation of
1 1 N/A steering angle OR steering angle < mechanical
limit -1°
STV03 1 seconds of right steering control and no variation
7 Specific
2 N/A 1 of steering angle OR steering angle > mechanical
limit +1°
G
Extreme temperature (for Russia country) and
3 1 1
machine unfolded

REQUIREMENTS
STV04 There is not limitation of steering set point
DEFINITION
H

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2.6.4.2 - Actuators

REQUIREMENTS DEFINITION
The formatted control (CTRL[Steering]) is applied on the actuators driving the movement
CTRL PUMP YV122 YV121 YV903
LEFT CTRL[PumpSteering] 1 0 1
STA01
NEUTRAL 0 0 0 0
RIGHT CTRL[PumpSteering] 0 1 1

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2.6.5 - Arm

2.6.5.1 - Validation
A
REQUIREMENTS DEFINITION
Steering movements happen in the specified direction and set point regarding to validation and slowdown
AMV01
conditions : SETP[Arm]=UP|N|DOWN:[0-100]%
B
REQUIREMENTS DEFINITION
Raise (U:up) or descent (D:down) of arm is allowed if all validation conditions are satisfied
VALIDATION U D ENABLE CONDITIONS
1 1
1
1
N/A
Machine powered on for more than 3s
Pump is ready
C
AMV02 2
0 Enable N/A 1 Always true (descent with gravity)
3 1 1 Machine is set
4 1 1 User is identified
1: The condition enables the movement (All conditions to '1': movement enabled)
D
REQUIREMENTS DEFINITION
The following conditions (General to Specific) inhibit the arm movement ( U: raise / D: descent)
CUT-OFF U D GENERAL CUT-OFF CONDITIONS
AMV03
1 General
1
2
1
1
N/A
N/A
Machine in high position
Low battery level
E
REQUIREMENTS DEFINITION
SIMULTANEOUS MOVEMENTS CUT-OFF
AMV03
CUT-OFF

Simultaneous
U D
CONDITIONS F
2 5 1 1 Manual brake release is active
movements

REQUIREMENT
DEFINITION
S
OVERLOAD CUT-OFF
G
CUT-OFF U D
CONDITIONS
AMV03 1 1 1 Overload alarm is active
3 Overload Load management system calibration
2 1 N/A
running and stop requested
H

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REQUIREMENTS DEFINITION
CUT-OFF U D TILT CUT-OFF CONDITIONS
AMV03 Tilt activated with unfolded machine and tilt cut-off
4 Tilt 1 1 N/A activated (some countries or movement tilt safety
option)

REQUIREMENTS DEFINITION
CUT-OFF U D REACH LIMIT CUT-OFF CONDITIONS
AMV03
5 Reach limit N/A N/A N/A N/A

REQUIREMENTS DEFINITION
CUT-OFF U D FAILURE CUT-OFF CONDITIONS
1 1 1 Power contactor stuck
Machine unfolded and load management system
2 1 1 not calibrated and upper controls and serial number
is set
The two arm angle sensors have been detected out
3 1 1 of range and load management is active and upper
AMV03 controls
6 Failure Serious incoherence in measuring arm angle and
4 1 1
load management is active and upper controls
Machine unfolded and pressure failure has been
5 1 N/A
detected and angle sensor calibrated
6 1 1 Power failure
7 1 1 Movement selection valve YV120 shorted
8 1 N/A Arm incoherence detected

REQUIREMENTS DEFINITION
CUT-OFF U D SPECIFIC CUT-OFF CONDITIONS
3 s stop at folded position detection change of state
during descent (scissor unfolded to scissor folded)
1 N/A 1
for STD or RUK countries out of descent speed
setting
AMV03
7 Specific 1.5 s stop at descent set point resumption when
2 N/A 1 scissor is folded for STD or RUK countries out of
descent speed setting
Extreme temperature detected and unfolded
3 1 N/A
machine and Russia/Ukraine country

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REQUIREMENTS DEFINITION A
Following limits are applied on the set point ((SETP[Arm]))
DIRECTIONS
MOVEMENT SET POINT LIMIT CONDITIONS
U D

AMV04
50%

75%
50%

75%
1

2
Tilt and machine unfolded
Chassis control box active and load management calibration not in
B
progress
N/A 50% 3 Descent when machine is folded machine
N/A 50% 5 Failure F07.06 ( (id 01 and 02) or id 8)
( 100% = max speed)
C

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2.6.5.2 - Actuators

REQUIREMENTS DEFINITION
The formatted control (CTRL[Arm]) is applied on the actuators driving the movement
Raise movement :
• Hydraulic pump guarantees the proportionality of raise movement: control pump value
(CTRL[PumpArm]) is computed from the arm raise value (CTRL[Arm]).
• YV420 proportional electro valve is used as digital electro valve (proportionality guaranteed by hydraulic
pump) :
• Its aperture is timed (Ton 100 ms ) after the control of hydraulic pump to avoid over-pressure.
• Its closure is done when pump control value is below VALUE_TO_BE_DEFINED (between acceleration
bias and deceleration bias to be sure movement is stopping).
• YV903 digital electro valve is active to enable the raise movement

AMA01

Descent movement :
• Hydraulic pump is unused (CTRL[PumpArm] = 0).
• YV420 proportional electro valve enables the descent movement and guarantees the proportionality
• YV903 digital electro valve is unused => set to 0.

CTRL PUMP YV420 YV903

RAISE CTRL[PumpArm] 100% 1
NEUTRAL 0 0 0
DESCENT 0 CTRL[Arm] 0
With :
• -CTRL[PumpArm] value = CTRL[Arm] Value when arm raise is in progress

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REQUIREMENTS DEFINITION A
After a movement of raise or descent, if the country is not USA, the arm cylinder valve YV420 is
controlled at low values to suppress the pressure due to dynamics and then enable a reliable and
repetitive measure of pressure for load management system. The values of control are automatically
adjusted during load management system calibration. The duration of the control is height dependant
(longer with the height: from 1500 ms to 3000 ms ) and this control happens 500 ms after the end of arm
raise or arm descent movements. B
AMA02

This special control is inactivated for USA version (no measure of load). D

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2.6.6 - Brake release

REQUIREMENTS DEFINITION
The release of brake is controlled :
• Automatically during the normal operating mode.
• Or on special conditions during test mode.
• Or manually via the SA103 switch.

BRV01 Init Machine is powered off

Release of brake is controlled based on the drive
Automatic
motion control
Test Test mode for brakes
Wait for falling edge of manual brake releasing set
Wait for confirmation
point
Manual Brake is released
Power ON Machine powered ON
Active test Periodical activation of test
Stop test Test ended
Out of tilt position and with folded scissor, manual
Begin manual activation release of brake set point is active for more than 3 s
consecutively
Manual activation confirmed Falling edge detected in the next 10 s
No falling edge detected in the next 10 s (short
Not detected
circuit to VBAT of the switch)
Manual release of brake set point is active (and has
End of manual activation been detected inactive) or change in control box
selection or joystick out of neutral or switch active

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2.6.7 - Potholes

2.6.7.1 - Validation
A
REQUIREMENTS DEFINITION
Steering movements happen in the specified direction and set point regarding to validation and slowdown
conditions. The potholes set point is automatically computed based on the control of drive movement or
arm movement : B
CTRL[Drive]≠N:0 & \F07.06(D) & (\F10.16(D) | VAR[MaskMicroSpeedForProduction]= 1) →
POV01.1 SETP[Potholes]=IN:100%
CTRL[Arm]=UP:[1;100]% | (SETP[Drive]≠N:0 & (F07.06(D) | (F10.16(A) &
VAR[MaskMicroSpeedForProduction]= 0) ) →
SETP[Potholes]=OUT:100%
CTRL[Drive]=N:0 & CTRL[Arm]≠UP:[1:100]%→ SETP[Potholes]=N:0
C
REQUIREMENTS DEFINITION
Extension (O: out) and/or retraction (I: in) of potholes movement is allowed if all validation conditions are
satisfied and none of cut-offs condition is true (see DRV_03)

POV02
VALIDATION
1
O
1
I
1
ENABLE CONDITIONS
Machine powered on for more than 3s
D
0 Enable 2 1 1 Hydraulic pump is ready
3 1 1 Machine is set
1: The condition enables the movement (All conditions to 1: movement enabled)

REQUIREMENTS DEFINITION
E
The following conditions (General to Specific) inhibit the potholes movement (O:Out / I:In)
CUT-OFF O I GENERAL CUT-OFF CONDITIONS
Drive is the selected movement when failures
1 1 N/A
POV03.1
1 General 2 N/A 1
F07.06 is not detected and F10.16 not active
Arm is the selected movement F
3 N/A 1 Scissor is unfolded out of production mode
4 1 N/A Potholes extended (with timer)

REQUIREMENTS

CUT-OFF O
DEFINITION

I
SIMULTANEOUS MOVEMENTS CUT-OFF
G
CONDITIONS
POV03.1
Simultaneous 2 1 1 Steering is active
2
movements 5 1 1 Manual brake release is active

REQUIREMENTS DEFINITION
H
CUT-OFF O I OVERLOAD CUT-OFF CONDITIONS
POV03.1
3 Overload N/A N/A N/A N/A

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REQUIREMENTS DEFINITION
CUT-OFF O I TILT CUT-OFF CONDITIONS
POV03.1
4 Tilt N/A N/A N/A N/A

REQUIREMENTS DEFINITION
CUT-OFF O I REACH LIMIT CUT-OFF CONDITIONS
POV03.1
5 Reach limit N/A N/A N/A N/A

REQUIREMENTS DEFINITION
CUT-OFF O I FAILURE CUT-OFF CONDITIONS
POV03.1 1 1 1 Power contactor stuck
6 Failure
2 1 1 Failure on pothole/steering selection valve

REQUIREMENTS DEFINITION
CUT-OFF O I SPECIFIC CUT-OFF CONDITIONS
Drive movement is in progress and steering is
1 N/A 1
requested
POV03.1
7 Specific Ended timer (consecutive or discrete) of potholes
retraction since power on or since last extension,
2 N/A 1
the value of the timer is 2 s in normal mode or 10 s
in production mode

REQUIREMENTS DEFINITION
STV04 There is not limitation of potholes set point

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2.6.7.2 - Actuators
A
REQUIREMENTS DEFINITION
The formatted control (CTRL[Steering]) is applied on the actuators driving the movement
CTRL PUMP YV121 YV122 YV903
IN
NEUTRAL
CTRL[PumpSteering]
0
1
0
0
0
1
0
B
OUT CTRL[PumpSteering] 0 1 1
Potholes extension :

STA01
E
Potholes retraction :

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Notes

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D - Study of the hydraulic schema

Study of the hydraulic schema A

1 - Hydraulic units
1.1 - GENERAL OVERVIEW
1.1.1 - The hydraulic components B
1.1.1.1 - Pump unit

H
MARKING FUNCTION DESCRIPTION
1 YV903 By-pass valve (pump is in pressure)
2
3
YV122
YV121
Left steering or potholes exit
Right steering or potholes retraction I

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D - Study of the hydraulic schema

1.1.1.2 - Selection valve potholes/steering

MARKING FUNCTION DESCRIPTION

Valve 6 ways / 2 positions for selection potholes or steering (priority for
1 YV120
potholes)

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1.1.1.3 - Lifting cylinder valve
A

E
MARKING FUNCTION DESCRIPTION

1 YV420
Valve PWM (Pulse Width Modulation) lift/descent of platform (Slow descent
when PF < 3 meters. Information coming from angle sensor SR420) F

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Notes

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E - Adjustments

Adjustments A
1 - Adjustments with diag pad console
The adjustments, parameter settings and lists of alarms of the machine are accessible either through this console
or either with the laptop version.

The VCI (Vehicle Computer Interface) adapter could be connected from any controls (turret or in platform) using
B
wireless or cable connection.

The full description of how to use that console and its menus is explained in a technical note PI144 (for more
information refer to your nearest HAULOTTE Services® of your area)

G
VCI
H

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E - Adjustments

2 - List of menus
See end of manual

2.1 - MACHINE SETTINGS

2.1.1 - Speeds and ramps

See end of manual : Annex 1

2.1.2 - Options

See end of manual : Annex 2

2.1.3 - Countries and models

See end of manual : Annex 3

2.2 - DIAGNOSTIC
2.2.1 - Inputs/Outputs

See end of manual : Annex 4

2.2.2 - States

See end of manual : Annex 5

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3 - Failures list A

C
• For any type A (ACTIVE) failure code, it will appear on display in lower control and the warning light will flicker
on upper controls (see below).
• For any type D (DETECTED) failure code, it will also appear on display in lower control and the warning light
will flicker on upper controls.
• For any type N failure code, it means that this alarm will never appear on display. D
• An internal code (column C) with 5 digits, visible only on the console, allows specifying the trigger conditions of
the failure.

Each trigger condition is associated with a single code number (16 possible single codes in decimal format
corresponding to a single bit in binary format) :
• If several conditions are active at the same time, single codes are added to form the resulting code displayed.
For example, il conditions 1 and 4 of single code are active, then the resulting code displayed will be 5 (1+4=5). E
All alarms codes are gathered per category (ex F02xxx contactors)

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E - Adjustments
3.1 - LIST OF FAILURES PER CATEGORY

FAILURES N C DESCRIPTION
INVERTER
COMBIACX: Failure in the high current hardware protection circuit
1 • Internal fault
• Replace the inverter
COMBIACX: When no current is applied to the traction motor, the current feedbacks are out of
permitted standby range
2 • Type of default not related to external components
• Cycle power to clear the fault
• If the fault is not cleared, replace the controller
COMBIACX: Driver of main contactor coil is damaged (not able to close)
• Type of default not related to external components
4
F01.01 • Cycle power to clear the fault
A
Inverter Master • If the fault is not cleared, replace the controller
COMBIACX: The driver of the electromechanical brake coil is not able to drive the load
8 • Internal fault
• Replace the controller
COMBIACX: Pump current sensor out of range (at start-up or standby)
16 • Internal fault
• Replace the controller
COMBIACX: At start-up, the amplifiers voltage (used to measure the motor voltage) is too low or too
high (< 2 V or > 3 V)
32
• Internal fault
• Replace the controller
COMBIACX: The software waits for the motor pump to stop at start-up
• If the motor connected to "-P" is still moving, wait for it to be still
1
• If not, wait 30 seconds until alarm "PUMP VMN NOT OK" appears
• Refer to corresponding alarm chapter
COMBIACX: Pump driving voltage different than the expected one
2
• Key OFF/ON
COMBIACX: The pump motor output voltage is lower than expected, considering the control applied
• Check the motor power wiring and connections
4 • Check the motor phases for proper insulation with the chassis
F01.05 • Check that MC DRIVE power contact close properly, with a good contact
A • If no problem is found on the motors, replace the controller
Pump failure
COMBIACX: The pump motor output voltage is higher than expected, considering the control applied
• Check the motor power wiring and connections
8 • Check the motor phases for proper insulation with the chassis
• Check that main contactor drive power contact close properly, with a good contact
• If no problem is found on the motors, replace the controller
COMBIACX: The pump current sensor feedback is always 0 A, even if pump motor is running
• Check the pump motor connection and continuity
16 • Type of default not related to external components
• Cycle power to clear the fault
• If the fault is not cleared, replace the controller

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FAILURES N C DESCRIPTION
COMBIACX: The controller has reached thermal cutout (temperature of the controller base plate is
A
higher than 85°C)
• Power down and allow to cool
• Do not operate in ambient temperatures over to 60°C
1
• Check for jammed or obstructed drive motor

F01.06
Check for excessively high drive motor current consumption while driving on the level (over 70 A)
• Check controller for proper installation
• If the controller is cold when the default appears, replace it
B
A
Overheating ACEX: The controller has reached thermal cutout (temperature of the controller base plate is higher
than 85°C)
• Power down and allow to cool
• Do not operate in ambient temperatures over to 60°C
2
• Check for jammed or obstructed drive motor
Check for excessively high drive motor current consumption while driving on the level (over 70 A)
• Check controller for proper installation
C
• If the controller is cold when the default appears, replace it
Low battery voltage ( estimated value< 10%)
• Check for damaged batteries, battery cables or connections
F01.08 • Recharge batteries
A 1
Low Battery • Measure batteries voltage and compare it with the value BATTERY VOLTAGE parameter in the
TESTER menu
• If they are different, adjust the value of the ADJUST BATTERY function
D
COMBIACX: Short circuit detected on electromechanical brake or main contactor output (overcurrent)
• Main contactor drive coil : Check connections and wiring for interruptions between controller and coil
1
• Motor brake coil : Check connections and wiring for interruptions between controller coil
• If the wiring is correct, the problem is in the controller : Replace it
COMBIACX: The driver of the electromechanical brake coil is shorted
2 • Check if there is a short or a low impedance pulldown between NEB CNA#4 and –BATT
• The driver circuit is damaged in the controller, which has to be replaced
E
COMBIACX: The driver of the electromechanical brake is shorted to +VbattThe output of the built in
Smart Driver, which supplies the positive to the electromechanical brake coil is high when the Tiller
and the H and S switch are opened
4
• Check the harness, in order to verify if a positive is connected to the Smart driver output CNB#1
F01.09
Electrical park
brake 1
A
• If, even disconnecting the wire from the connector pin, the output stays at high value, the problem is
inside the controller and the Smart Driver is probably shorted
COMBIACX: A short circuit on the power outputs of the controller has been detected
F
• Check the EB driver output for a short circuit with +Vbatt
8
• If, even disconnecting the wire from the connector pin, the output stays at high value, the problem is
inside the controller : Replace it
COMBIACX: Voltage on PEB present but not expected
16 • Check external wiring
• If the wiring is correct and no problem is found on the coil, replace the controller
G
COMBIACX: Internal Smart driver KO and ACEX : internal Smart driver is not KO (if both signals are
KO failure F08.10)
32 • Check the driver output for a short circuit with -Vbatt
• If, even disconnecting the wire from the connector pin, the output stays at low value, the problem is
inside the controller : Replace it
H

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FAILURES N C DESCRIPTION
ACEX: Short circuit detected on electromechanical brake or main contactor output (overcurrent)
• Main contactor drive coil : Check connections and wiring for interruptions between controller and coil
1
• Motor brake coil : Check connections and wiring for interruptions between controller coil
• If the wiring is correct, the problem is in the controller : Replace it
ACEX: The driver of the electromechanical brake coil is shorted
2 • Check if there is a short or a low impedance pulldown between NEB CNA# and –BATT
• The driver circuit is damaged in the controller, which has to be replaced
ACEX: The driver of the electromechanical brake is shorted to +VbattThe output of the built in Smart
Driver, which supplies the positive to the electromechanical brake coil is high when the Tiller and the
H and S switch are opened
4
• Check the harness, in order to verify if a positive is connected to the Smart driver output CNB#1
F01.10 • If, even disconnecting the wire from the connector pin, the output stays at high value, the problem is
Electrical park A inside the controller and the Smart Driver is probably shorted
brake 2 ACEX: A short circuit on the power outputs of the controller has been detected
• Check the EB driver output for a short circuit with +Vbatt
8
• If, even disconnecting the wire from the connector pin, the output stays at high value, the problem is
inside the controller : Replace it
ACEX: Voltage on PEB present but not expected
16 • Check external wiring
• If the wiring is correct and no problem is found on the coil, replace the controller
ACEX: Internal Smart driver KO and ACEX : internal Smart driver is not KO (if both signals are KO
failure F08.10)
32 • Check the driver output for a short circuit with -Vbatt
• If, even disconnecting the wire from the connector pin, the output stays at low value, the problem is
inside the controller : Replace it
COMBIACX: Failure in the high current hardware protection circuit
1 • Internal fault
• Replace the controller
COMBIACX: When no current is applied to the traction motor, the current feedbacks are out of
permitted standby range
2
• Type of default not related to external components
• Cycle power to clear the fault. If the fault is not cleared, replace the controller
COMBIACX: Driver of main contactor coil is damaged (not able to close)
4 • Type of default not related to external components
F01.11 • Cycle power to clear the fault. If the fault is not cleared, replace the controller
A
Inverter Slave COMBIACX: The driver of the electromechanical brake coil is not able to drive the load
8 • Internal fault
• Replace the controller
COMBIACX: Pump current sensor out of range (at start-up or standby)
16 • Internal fault
• Replace the controller
COMBIACX: At start-up, the amplifiers voltage (used to measure the motor voltage) is too low or too
high (< 2 V or > 3 V)
32
• Internal fault
• Replace the controller
F01.12 1 COMBIACX Hardware version is not the expected one
Wrong
D
controller 2 COMBIACX Hardware version is not the expected one
harware

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E - Adjustments

FAILURES N C
CONTACTOR
DESCRIPTION
A
The driver of main contactor drive coil is shorted, or its coil is disconnected
• Ensure there is no short or low-impedance pull-down between MC and -Vbatt
1
• Check connections and wiring for interruptions of MC DRIVE coil
• If wiring and connection are correct, the problem is in the controller : Replace it
F02.04
Power
2
The main contactor coil has been driven by the controller, but the contactor does not close
• Check the contact in the main contactor drive contactor and if it is not working, replace the main
B
D contactor drive
Contactor
Before driving the LC coil, the controller checks if the contactor is stuckThe controller drives the
SB801
bridge for some tens milliseconds, trying to discharge the capacitors bankIf they don't discharge the
4
fault condition is entered

8
• Check the power contact of the main contactor drive and replace it if necessary
Supervisor status is "alarm" or "wait reset" and main contactor is not forced open
• Key OFF/ON
C
FAILURES N C DESCRIPTION
ELECTROVALVES

F04.01
Steering D
1
Short circuit detected on steering front left electro valve :
--> YV121 = FAIL
D
Short circuit detected on steering front right electro valve :
YV121/YV122 2
--> YV122 = FAIL
F04.04
Short circuit detected on arm descent electro valve :
Arm D
--> YV420 = FAIL
YV420
F04.11 E
Principal Short circuit detected on pump discharge electro valve :
D 1
movements --> YV903 = FAIL
YV903
Short circuit detected on pothole extend electro valve :
F04.40 1
Potholes
YV121/YV122
D
2
--> YV122 = FAIL
Short circuit detected on pothole retract electro valve :
--> YV121 = FAIL
F
Short circuit detected on steering / potholes selection electro valve :
F04.41 1
--> YV120 = SHORT CIRCUIT FAILURE
Movement D
Short circuit detected on steering / potholes selection electro valve :
Selection valve 2
--> YV120 = OPEN CIRCUIT FAILURE
G

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E - Adjustments

FAILURES N C DESCRIPTION
JOYSTICKS
Analog signal SM901 is out of allowed range :
F05.01 1
--> SM901 < 0.2V | SM901 > 4.8V
Arm/Drive
D Incoherence between analog signal and out of neutral signals for SM901 joystick :
joystick
2 --> SM901N = 1 & (2,45V < SM901Y < 2,55V)
SM901
--> or SM901N = 1 & (2,45V < SM901Y < 2,55V)
F05.11
Joystick Neutral position of arm and drive joystick SM901 not detected after upper control box selection :
D 1
neutral --> SM901 < 0.2V | SM901 > 4.8V
SM901

FAILURES N C DESCRIPTION
LOAD MANAGEMENT SYSTEM
F06.01
No Loading Cal
A Angle/pressure weighting system missing or not calibrated and EU|AU|RUK
Calibration
required

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E - Adjustments

FAILURES N C
SENSORS
DESCRIPTION
A
COMBI ACX: The motor temperature sensor is not correctly connected or damaged
F07.05 1 • Key OFF/ON
Motor • Check wiring
D
temperature
sensor 2
ACEX: The motor temperature sensor is not correctly connected or damaged
• Key OFF/ON
• Check wiring
B
SR420 Arm angle sensor is out of allowed range when calibrated :
1
--> VAR[SR722_OutOfRange]=1
SR722 Arm angle sensor is out of allowed range when calibrated :
2

F07.06
Arm Angle
D
4
--> VAR[SR722_OutOfRange]=1
SR420 and SR722 arm angle measured are not coherent when calibrated (with no error of out of
range), first level of incoherence :
C
--> VAR[ArmAngleIncoherent]=1
SR420 and SR722 arm angle measured are not coherent when calibrated (with no error of out of
8 range), second level of incoherence :
--> VAR[ArmAngleIncoherent]=2

1
Pressure sensor is considered as out of range : Scissor arm angle is above 18° and pressure sensor
measures less than 10 b (to handle the arm on kickstand --> pressure is null) And arm descent is not
D
F07.21 running :
Pressure D --> SP400 < (=0.2V) & VAR[ArmAngle] > 18 & CTRL[Arm]≠D
sensor
Pressure sensor is considered as out of range: pressure sensor voltage is above 10.5 V :
2
--> SP400 > (=10.5V)
F07.33
Steer angle
D 1
Steer angle sensor is out of range :
-->VAR[SteerAngle] > 55.65° | VAR[SteerAngle] < -83.19°
E
From version v2.07: fix issue when driving in 25% ramp and steering at same time : In some cases, failure
F07.35 appeared, now fix
COMBI ACX: Problem on the encoder during drive
• Check connections and wiring for interruptions between controller and motor encoder

F07.35
Motor encoder
1 • Check the harness for proper installation
• Check the encoder mechanical installation. If the encoder slips inside its compartment, replace the
encoder or change the drive motor
F
D
ACEX: Problem on the encoder during drive
• * Check connections and wiring for interruptions between controller and motor encoder
2 • * Check the harness for proper installation
• * Check the encoder mechanical installation. If the encoder slips inside its compartment, replace the
encoder or change the drive motor
COMBI ACX: The ECU thermal sensor is out of range
G
1 • Key OFF/ON
F07.36 • Replace the controller
ECU D
ACEX: The ECU thermal sensor is out of range
temperature
2 • Key OFF/ON
• Replace the controller
H

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E - Adjustments

FAILURES N C DESCRIPTION
ELECTRIC CIRCUIT
COMBI ACX: Power capacitors voltage does not increase at start-up
1 • Ensure that no external device is connected to the batteries
• Check battery, power cables and connections
COMBI ACX: The controller detects an overvoltage or under voltage conditionOvervoltage threshold
is 35 V, under voltage threshold is 9.5 V
• If the fault appears at start-up or during standby : Check that no external device (relays switching,
solenoids energizing/de-energizing... ) is connected to the batteries, creating down-going pulses
• If no voltage transient is detected on the supply line and the alarm appears every time the key is
2
switched ON : Replace the controller
• Check if the fault appears during driving acceleration (under voltage condition detected) : Check
battery charge ; check for damaged batteries, battery cables and connections
• Check if the fault appears during release braking (overvoltage condition detected) : Check line
contactor contact, battery power cable connection
COMBI ACX: At start-up, the battery voltage is too low or too high (< 0,8 Vbatt or >1,2 Vbatt)
• Check that the controller SET BATTERY parameter value matches the battery nominal voltage
(24VDC)
4 • Check that the TESTER MENU / BATTERY VOLTAGE parameter shows same value as the battery
voltage measured with a voltmeter
• If it does not match, then do a ADJUST BATTERY function
• If the default still appears, replace the battery
COMBI ACX: A low logic level of Key-Off has been detected during start-up diagnosis
• Check that no external device (relays switching,, solenoids energizing/de,energizing...) is connected
to the batteries, creating downgoing pulses
• Check the connection of power cabled to the battery terminal, positive and negative, to MC DRIVE
8
and to +Batt and -Batt, which must be screwed with a torque comprised in the range 5,6 Nm - 8,4
Nm
• If no voltage transient is detected on the supply line and the alarm appears every time the key is
F08.04 switched ON : Replace the controller
A
Supply ACEX: Power capacitors voltage does not increase at start-up
16 • Ensure that no external device is connected to the batteries
• Check battery, power cables and connections
ACEX: The controller detects an overvoltage or under voltage conditionOvervoltage threshold is 35 V,
under voltage threshold is 9.5 V
• If the fault appears at start-up or during standby : Check that no external device (relays switching,
solenoids energizing/de-energizing... ) is connected to the batteries, creating down-going pulses
• If no voltage transient is detected on the supply line and the alarm appears every time the key is
32
switched ON : Replace the controller
• Check if the fault appears during driving acceleration (under voltage condition detected) : Check
battery charge ; check for damaged batteries, battery cables and connections
• Check if the fault appears during release braking (overvoltage condition detected) : Check line
contactor contact, battery power cable connection
ACEX: At start-up, the battery voltage is too low or too high (< 0,8 Vbatt or >1,2 Vbatt)
• Check that the controller SET BATTERY parameter value matches the battery nominal voltage
(24VDC)
64 • Check that the TESTER MENU / BATTERY VOLTAGE parameter shows same value as the battery
voltage measured with a voltmeter
• If it does not match, then do a ADJUST BATTERY function
• If the default still appears, replace the battery
ACEX: A low logic level of Key-Off has been detected during start-up diagnosis
• Check that no external device (relays switching,, solenoids energizing/de,energizing...) is connected
to the batteries, creating downgoing pulses
• * Check the connection of power cabled to the battery terminal, positive and negative, to MC DRIVE
128
and to +Batt and -Batt, which must be screwed with a torque comprised in the range 5,6 Nm - 8,4
Nm
• * If no voltage transient is detected on the supply line and the alarm appears every time the key is
switched ON : Replace the controller

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E - Adjustments
FAILURES N C
1
DESCRIPTION
Two panels are selected : Check selector key
A
F08.07 --> SA901T=ON & S0901PF=ON
A
Circuit selector No panel is selected : Check selector key
2
--> SA901T=OFF & S0901PF=OFF
COMBI ACX: The PEV connector (B2) is not connected to the battery or the voltage is different
F08.09
Common A
1 • Check B2 connector is connected to +Vbatt
• * If the harness connections are correct, replace the controller
ACEX: The PEV connector (B2) is not connected to the battery or the voltage is different
B
output supply
2 • Check B2 connector is connected to +Vbatt
• * If the harness connections are correct, replace the controller
ACEX: Internal Smart driver KO and COMBIAC : Internal Smart driver KO
• Check the driver output for a short circuit with -Vbatt
1
• If, even disconnecting the wire from the connector pin, the output stays at low value, the problem is
inside the controller : Replace it
C
F08.10 ACEX: Problem on supply
D
Power supply 2 • Check supply wiring (B+)
• Check wiring between COMBIACX and ACEX
ACEX: Problem on supply
4 • Check supply wiring (B+)
• Check wiring between COMBIACX and ACEX D
FAILURES N C DESCRIPTION
FUNCTIONS
F10.14
Steering angle
not calibrated
A
Steer angle is not calibrated
Perform steer angle calibration E
F10.16
Arm angle is not calibrated
Arm angle not A
Perform arm angle calibration
calibrated

FAILURES N C
SAFETIES
DESCRIPTION F
F11.09 Arm raise is controlled and arm angle is decreasing, out of calibration process (arm angle or pressure
Arm D angle table)
incoherence Check YV903 valve (wiring and connection)

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E - Adjustments

FAILURES N C DESCRIPTION
INTERNAL FAULTS
For all failure details :
• Check wiring
• Check the Can Bus connections
• Ensure that all the connectors pins are properly in place and the connectors are free of moisture or
oxidation
• Machine powered off, measure the resistance between CN03.F and CN03.G. If it is not 60 Ohm ±5%,
check continuity of the bus wires :
F12.01 • CAN LOW / 1001: From CN03.G (diagnostic connector) to ACTIV SCREEN X2.8 to COMBIACX
CXC.10 to ACEX AXC.10 to CANTILLER C.4
CAN Fault A
• CAN HIGH / 1002: From CN03.F (diagnostic connector) to ACTIV SCREEN X2.7 to COMBIACX CXC.5
Check wires
to ACEX AXC.5 to CANTILLER C.6
1 No data is received from upper control box card
2 No data is received from lower control box screen
4 COMBI ACX Module doesn't receive any CAN messages from ACEX module
8 ACEX Module doesn't receive any CAN messages from COMBI ACX module
16 No time (date/hour) update (problem with screen communication)
1 EEPROM failure status error
2 EEPROM failure stack full
COMBI ACX: Wrong slip profile parameters or EEPROM damage
4 • Perform a CLEAR EEPROM
• If problem persists, replace the controller
COMBI ACX: Software or hardware error has been detected, default parameters are applied
• Execute a CLEAR EEPROM operation
• Cycle power to clear the fault :
8
• If the alarm disappears, the previously stored parameters will have been replaced by the default
F12.02 parameters
E2P Read/Write • If the fault is not cleared, replace the controller
D
Error ACEX: Wrong slip profile parameters or EEPROM damage
Change calc. 16 • Perform a CLEAR EEPROM
• If problem persists, replace the controller
ACEX: Software or hardware error has been detected, default parameters are applied
• Execute a CLEAR EEPROM operation
• Cycle power to clear the fault :
32
• If the alarm disappears, the previously stored parameters will have been replaced by the default
parameters
• If the fault is not cleared, replace the controller
Problem reading EEPROM at start-up
64
Restart machine
ID of software loaded into machine is different from the ID stored into EEPROM: all machine
1 parameters have been reset and must then be set again (speeds, ramps, options, configs, access
code level 2, failure counters and calibration data)
2 Machine speeds and ramps have been reset and must be set again
F12.04
4 Machine options have been reset and must be set again
E2P Param
D 8 Machine configurations
Reset
Check settings 16 Machine maintenance counters have been reset
32 Machine daily log have been reset
64 Machine events counters have been reset
128 Machine events log counters have been reset

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E - Adjustments

FAILURES N C

1
DESCRIPTION
Model not set (not possible => always Optimum 8)
A
Model = Not Set
Country not set : Set country
2
Country = Not Set

F12.05
E2P Param Not D
4
Serial number = 0: set serial number
SerialNumber = "000000"
At least one of the parameter used and not set ; Check all speeds and ramps
B
Set 8
SPEED[xxx] = Not Set | RAMP[xxx] = Not Set
At least one option used and not set ; Check all options
16
OPT[xxx] = Not Set

F12.07
32
At least one config not set ; Check all configurations
CFG[xxx] = Not Set C
ECU software
A 1 Zapi software version different on COMBIACX and on ACEX
version
incoherence

1
COMBI ACX: Software watchdog active
• Key OFF/ON
COMBI ACX: Problem on the Analog/Digitial conversion of micro controller
D
2
• Key OFF/ON
COMBI ACX: Watchdog circuit output became high due to hardware or software problem (WDG1)
• Alarm caused by a hardware failure in one of two (or both) controllers or due to a software execution
problem
4
• Type of default not related to external components
• Cycle power to clear the fault
E
• If the fault is not cleared, replace the controller
COMBI ACX: Watchdog circuit output became high due to hardware or software problem (WDG2)
• Alarm caused by a hardware failure in one of two (or both) controllers or due to a software execution
F12.08 problem
ECU fault A 8
(master)
• Type of default not related to external components
• Cycle power to clear the fault
• If the fault is not cleared, replace the controller
F
COMBI ACX: Current gain acquisition has not been performed or EEPROM damaged
16 • Key OFF/ON
• If fault persists, a new current gain acquisition has to be performed
COMBI ACX: Wrong client software
32
• Load the software to COMBIACX and ACEX controllers
COMBI ACX: RAM checksum failed
G
64 • Internal fault
• Replace the controller
COMBI ACX: Timeout of client function (execution time exceed maximum allowable time)
128
• Key OFF/ON
H

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E - Adjustments
FAILURES N C DESCRIPTION
ACEX: Software watchdog active
1
• Key OFF/ON
ACEX: Problem on the Analog/Digitial conversion of micro controller
2
• Key OFF/ON
ACEX: Watchdog circuit output became high due to hardware or software problem (WDG1)
• Alarm caused by a hardware failure in one of two (or both) controllers or due to a software execution
problem
4
• Type of default not related to external components
• Cycle power to clear the fault
• If the fault is not cleared, replace the controller
ACEX: Watchdog circuit output became high due to hardware or software problem (WDG2)
• Alarm caused by a hardware failure in one of two (or both) controllers or due to a software execution
F12.09 problem
ECU fault A 8
• Type of default not related to external components
(slave) • Cycle power to clear the fault
• If the fault is not cleared, replace the controller
ACEX: Current gain acquisition has not been performed or EEPROM damaged
16 • Key OFF/ON
• If fault persists, a new current gain acquisition has to be performed
ACEX: Wrong client software
32
• Load the software to COMBIACX and ACEX controllers
ACEX: RAM checksum failed
64 • Internal fault
• Replace the controller
ACEX: Timeout of client function (execution time exceed maximum allowable time)
128
• Key OFF/ON
This failure could happen when changing the software of the machine. Check evolution log. If happening,
restart machine.
1 Incoherence of Battery Parameters ; new value forced, restart mandatory
F12.10 2 Incoherence of Motor Accessories Parameters ; new value forced, restart mandatory
Parameters 4 Incoherence of Motor Parameters ; new value forced, restart mandatory
A
reload
8 Incoherence of Option Parameters ; new value forced, restart mandatory
Restart machine
16 Incoherence of Input Output Parameters ; new value forced, restart mandatory
32 Incoherence of Machine Parameters ; new value forced, restart mandatory
128 No parameters check / internal use for R and D only ; new value forced, restart mandatory
This failure happens at first power-on when reloaded on machine with software version 2.11 or on
machine never loaded before. If happening out of these cases, power off and power on again after 3 s.
F12.11
Parameters 1 Wrong parameter : out of expected range
A
reload 2 Wrong parameter : EEPROM problem or RAM problem
Restart machine 4 Wrong parameter : parameter current value is different from parameter initialized value
8 Wrong parameter : incoherence between master and slave parameter source

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FAILURES N C
SWITCHES
DESCRIPTION
A
F13.02 1
Incoherence between the 2 signals of front steering switch of platform box (both active) :
Platform --> SM901L = 1 & SM901R = 1
D
switches Incoherence between the 2 signals of movement selection :
2
Check switches

1
--> SM903A = 1 & SM903B = 1
Neutral position of arm switch of turret box not detected after power on :
--> SA420U = 1 | SA420D = 1
B
F13.10 Neutral position of enable switch of turret box not detected after power on :
2
Neutral switch --> SA905 = 1
A
Check chassis Neutral position of horn switch of turret box not detected after power on :
4
switches --> SA907B = 1

8
Neutral position of brake release switch of turret box not detected after power on :
--> SA103 = 1
C
Neutral position of front steering switch of platform box not detected after power on :
1
--> SM901L = 1 | SM901R = 1
Neutral position of enable trigger of platform box not detected after power on :
F13.11 2
--> SM901DM = 1
Switches
neutral 2
Check plat.
A 4
Neutral position of movement selection of platform box not detected after power on :
--> SM908A = 1 | SM908B = 1 D
switches Neutral position of klaxon switch of platform box not detected after power on :
8
--> SM907 = 1
Neutral position of brake release switch not detected after power on :
16
--> SM103 = 1

FAILURES N C DESCRIPTION E
CAN J1939

F15.06
D 1 Error on CAN BUS
J1939

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E - Adjustments

FAILURES N C DESCRIPTION
ENGINE
COMBI ACX: Motor maximum temperature reached
• Check the thermal sensor wiring and ohm value
1
• Improve the air cooling of the motor
F16.01 • If the warning is present when the motor is cool, then the problem is inside the controller : Replace it
A
Overheating ACEX: Motor maximum temperature reached
• Check the thermal sensor wiring and ohm value
2
• Improve the air cooling of the motor
• If the warning is present when the motor is cool, then the problem is inside the controller : Replace it
F16.02 1 COMBI ACX: The drive motor has been detected stalled or the encoder is not working
A
Speed problem 2 ACEX: The drive motor has been detected stalled or the encoder is not working
COMBI ACX: During drive, motor output voltage is lower than expected
• Check the motor power wiring and connections
1 • * Check the motor phases for proper insulation with the chassis
• * Check that MC DRIVE power contact close properly, with a good contact
• * If no problem is found on the motors, replace the controller
COMBI ACX: During drive, motor output voltage is higher than expected
• Check the motor power wiring and connections
2 • Check the motor phases for proper insulation with the chassis
• Check that MC DRIVE power contact close properly, with a good contact
• If no problem is found on the motors, replace the controller
COMBI ACX: Motor voltage feedback circuits are damaged
4 • Check the motor power wiring and connections
• If the wiring is correct, the controller is damaged : Replace it
COMBI ACX: The motor output voltage is lower than expected, before MC DRIVE switch ON
• Check the motor phase to phase impedance
8 • * Check the motor power cables connections
• * Check the motor phases for proper insulation with the chassis
• * If the motor connections are correct, replace the controller
COMBI ACX: The motor output voltage is higher than expected, before MC DRIVE switch ON
• Check the motor phase to phase impedance
16 • Check the motor power cables connections
• Check the motor phases for proper insulation with the chassis
F16.03 • If the motor connections are correct, replace the controller
A
Motor supply ACEX: During drive, motor output voltage is lower than expected
• Check the motor power wiring and connections
32 • * Check the motor phases for proper insulation with the chassis
• * Check that MC DRIVE power contact close properly, with a good contact
• * If no problem is found on the motors, replace the controller
ACEX: During drive, motor output voltage is higher than expected
• Check the motor power wiring and connections
64 • Check the motor phases for proper insulation with the chassis
• Check that MC DRIVE power contact close properly, with a good contact
• If no problem is found on the motors, replace the controller
ACEX: Motor voltage feedback circuits are damaged
128 • Check the motor power wiring and connections
• If the wiring is correct, the controller is damaged : Replace it
ACEX: The motor output voltage is lower than expected, before drive main contactor switches ON
• Check the motor phase to phase impedance
256 • * Check the motor power cables connections
• * Check the motor phases for proper insulation with the chassis
• * If the motor connections are correct, replace the controller
ACEX: The motor output voltage is higher than expected, before drive main contactor switches ON
• Check the motor phase to phase impedance
512 • Check the motor power cables connections
• Check the motor phases for proper insulation with the chassis
• If the motor connections are correct, replace the controller

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E - Adjustments

4 - Maximum height adjustment A

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E - Adjustments

5 - Cutback speed position height adjustment

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E - Adjustments

6 - Load management system A

6.1 - CALIBRATION PROCEDURES

N.B.-:-

Before starting the calibration, check that the sensors are well mounted mechanically (Lift the scissors
B
in order to get access to theses sensors).

Then preset them to the indicated values.

The sensors/fixation screws must be in the same axis as shown below and the support must be parallel
with axis.
C

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E - Adjustments
Pre setting of the transducers

MARKING SENSORS LOW POSITION UPPER POSITION

1 SR420 ~ 74 pts ~ 530 pts

2 SR722 ~ 420 pts ~ 530 pts

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E - Adjustments
6.2 - STEERING
A
The calibration is required for multiple reasons :
• When the variator COMBIACX or one component linked to the steering has been changed.
• When the pump doesn’t stop when steering at full lock (left or right).

Machine must be in stowed position and on flat surface ( SQ800 not activated) B
Reminder :
• Machine must be in stowed position and on flat surface.
• When wheel angle is out of range [-5;+5]°, a slowdown is applied on the external wheel (considering the
steering direction) :
• When wheels steer to the left the steer angle decreases : Its limit is set to +47.6°.
• When wheels steer to the right the steer angle increases : Its limit is set to -75.2°.
C

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E - Adjustments
6.2.1 - Steering calibration procedure

Preadjust the potentiometer so as to obtain the "steer angle" parameter at 0° to Activ’ Screen display.

ANGLE SENSORS CALIBRATION VALID RANGE

V
pts
(approx.)
Left (-75.19°)
SR150 [150 ; 270] [01.539 ; 02.770]
Counter clockwise (CCW)
Right (+47.65°)
SR150 [755 ; 975] [07.746 ; 10.003]
Clockwise (CW)

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E - Adjustments
6.3 - ANGLE TRANSDUCERS
A
N.B.-:-BEFORE LAUNCHING THE CALIBRATION, CHECK AND ADJUST IF NECESSARY THE SENSORS VALUE.

ANGLE SENSORS CALIBRATION VALID RANGE

pts
V
(approx.) B
SR420 Low (0°) [60 ; 160] [0.615 ; 1.641]
SR722 Low (0°) [320 ; 420] [3.283 ; 4.309]
SR420 High (57°) [320 ; 420] [3.283 ; 4.309]
SR722 High (57°) [60 ; 160] [0.615 ; 1.641]
C

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E - Adjustments

7 - Adjustment of pressures
7.1 - MAIN PRESSURE

The setting and minimess plug is unique for all movements.

VALUE
MARKING DESIGNATION
(BARS)
1 Main pressure 180 +-5

7.2 - THE SPEEDS

VALUE
MARKING DESIGNATION
(SECONDS)
1 High speed 9 seconds for 10 meters/33ft
2 Micro speed 31 seconds for 5 meters/16ft
3 PF lift/descent 22 seconds
4 Steering lock to lock 3.5 seconds

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F - Simplified breakdown guide

Simplified breakdown guide

This guide does not replace the cut out conditions 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
A
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 (Example not lifting, neither raise, nor descent from both controls, up and
down).

For a quicker diagnostic : B

Do check the failures code on Activ’screen display and refer to the alarms list before scrolling this breakdown
guide.

Do check all fuses.

Beware as some options once activated might prohibit some movements (the option ASB, Active Shield Bar
device). C
1 - No start
• Battery set.
• Emergency stops(SB801/SB802 ). D
• Key selector SA901.
• Relay battery charge KM900.
• Main relay KAH.
• Variators COMBIACX/ACEX.
• Main pump.
• Temperature sensor ST903 ( RUS only).
E
2 - No lift
• Battery set.
• Activ’screen touch pad.
F
• Toggle switch SA908 (Upper controls).
• Joystick SM901 out of range.
• Foot pedal switch SB800 (Upper controls) US option.
• CAN Tiller card.
• Valves YV420/YV903.
G
• Potholes system YV120/SQ144/SQ145.
• Angle transducers SR420/SR722 not adjusted or not calibrated.
• Pressure transducer SP400.
• Machine in slope/tilt mode (SQ800), not for US mode.
• Machine in overload (not for US/CDN mode).
H
• Load Management System not calibrated.
• No lifting pressure.

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F - Simplified breakdown guide

3 - No drive
• Toggle switch SA908.
• Joystick SM901.
• Foot pedal switch SB800( US only).
• AC motor M370 - M371.
• Brakes YB100 - YB101.
• Temperature probes ST301 - ST302.
• Speed sensors SV300 - SV301.
• Angle transducers SR722 - SR420.
• Machine in overload (not for US).
• Machine in tilt (not for US).

4 - No steering
• Toggle switch YV903.
• Joystick SM901 (Rocker).
• Steering calibration.
• Angle sensor SR150.
• Brakes YB100 - YB101.
• Valves YV6903 – YV121 – YV122 – YV120.
• Relief valve RV2 (180b - 2520psi).

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G - Version summary

Version summary A
1 - Version summary

Compact - Optimum Standards Wiring diagram Hydraulic diagram B

Compact 8/10
E501
(Until July 2003)
Variable speed calculator 244 B15785
Europe, USA and Australia
version
220 1730
C
Compact 12
E501
(Until July 2003)
Variable speed calculator 244 B16188
Europe, USA and Australia
version
220 1730 D
Compact 8/10
E591
(Until September 2005)
Europe, USA and Australia
version
Variable speed calculator 244
220 1920
B16187
E
Compact 12
E591
(Until September 2005)
Europe, USA and Australia
version
Variable speed calculator 244
220 1920
B15940
F

Compact 8/10
Europe, USA and Australia
E614
Weighing version
121P251510 G
version

Compact 12
Europe, USA and Australia
E614
121P251530
H
Weighing version
version

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G - Version summary

HYDRAULIC UNITS COMMENTS CODES

Hydraulic unit - MK2 (Until March 2003) Solenoid valve heads with indicator 242 020 9290
Solenoid valve heads without lamps but with
Hydraulic unit - MK3 (Until July 2003) 242 021 0470
separate coils
Hydraulic unit - MK4 242 021 2090
Solenoid valve wiring harness with colour wires
Hydraulic unit - MK4 - Weighing 242 021 2090
Hydraulic unit - MK5 - From serial
Bloc identical to the MK4 but smaller size 250 300 2330
number CE 139454

2 - List of schematics
See end of manual

3 - List of wiring harnesses

See end of manual

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 ANNEX 1
Movement Parameter [Target] Factory tolerance Configuration
Drive forward Min speed [-0 ; +0] Hidden setting
Drive forward Min speed [-0 ; +0] Hidden setting (Australia mode)
Drive forward Max speed [8.000000 ; 10.000000] [-10 ; +0] High speed selected, drive on 10m/33ft length
Drive forward Max speed micro [30.000000 ; 33.000000] [-10 ; +0] Machine unfolded, drive on 5m/16ft
Drive forward Max speed micro [-10 ; +0] Machine unfolded, drive on 5m/16ft
Drive forward Acceleration [-5 ; +5]
Drive forward Deceleration [-5 ; +5] 1 m/3.3 ft ± 0,2 m/0.6 ft in high speed
Drive reverse Min speed [-0 ; +0] Hidden setting
Drive reverse Min speed [-0 ; +0] Hidden setting (Australia mode)
Drive reverse Max speed [8.000000 ; 10.000000] [-10 ; +0] High speed selected, drive on 10m/33ft length
Drive reverse Max speed micro [30.000000 ; 33.000000] [-10 ; +0] Machine unfolded, drive on 5m/16ft
Drive reverse Max speed micro [-10 ; +0] Machine unfolded, drive on 5m/16ft
Drive reverse Acceleration [-5 ; +5]
Drive reverse Deceleration [-5 ; +5] 1 m/3.3 ft ± 0,2 m/0.66 ft in high speed
Steering left Max speed [3.000000 ; 4.000000] [-100 ; +0] Platform controls, from lock to lock (left or right)
Steering right Max speed [3.000000 ; 4.000000] [-100 ; +0] Platform controls, from lock to lock (left or right)
Potholes extend Max speed [-100 ; +10] Hidden setting
Potholes retract Max speed [-100 ; +10] Hidden setting
Arm Raise Min speed [-10 ; +10] Hidden setting
Arm Raise Max speed raise [20.000000 ; 24.000000] [-100 ; +0] Platform controls, from lower to upper stop
Arm Raise Acceleration raise [-5 ; +5]
Arm Raise Deceleration raise [-5 ; +5]
Arm Descent Min speed [-100 ; +10]
Arm Descent Max speed [26.000000 ; 32.000000] [-100 ; +0] Platform controls, from upper to lower stop
Arm Descent Acceleration descent [-5 ; +5]
Arm Descent Deceleration descent [-5 ; +5]

ANNEX 2
Name Description & Values [Level_min]
Buzzer Choose for which movements the buzzer must be activated 1
OFF
Descent / Retract Movements
All Movements
Drive
Drive + All Movements
Flashing light 1
OFF
ANNEX 3
All Movements Country Model 1 Zone
Drive Standard OPTIMUM 8
Drive + All Movements USA OPTIMUM 1931E North America
ON Australia OPTIMUM 8
Tracking system 1 Russia/Ukraine OPTIMUM 8
OFF Canada OPTIMUM 1931E North America
ON
Drive restriction when lifted If option is active, it allows to cut drive and steering above a lift height depending on the settings 1
OFF
ON if > 0.5m / 1.6ft
ON if > 1.5m / 5.0ft
User Identification inhibited Allows to inhibit user identification in case screen is not usable 3
OFF
ON
 ANNEX 4A
Type: Name Diagnostic instructions: ECU: [Ref] [Pin] [Wire] Type:2
If both emergency stops are pulled, input must be ON (+VBAT). If not:
‐ check frame emergency stop function (SB801)
‐ check platform emergency stop function (SB802)
DIGITAL INPUTS SB801 ‐ Emergency stop (turntable/frame) ‐ check input wire continuity CombiACX ‐ Frame m_I3 B.4 109 Digital input (HS)
If tilt < 3° (longitudinal) / 1.5° (lateral), input must be ON (+VBAT). If not:
‐ check sensor adjustment
‐ check sensor supply fuse (FU3‐10A)
‐ check sensor supply (wires 0=0V and 109=+VBAT)
SQ800 ‐ Tilt sensor ‐ check input wire continuity CombiACX ‐ Frame m_I8 A.12 12 Digital input (HS)
If turret control box is selected, input must be ON (+VBAT). If not:
‐ check switch function
‐ check switch supply fuse (FU3‐10A)
‐ check switch supply (wire 98=+VBAT)
SA901TU ‐ Control box selector ‐ Turret ‐ check input wire continuity CombiACX ‐ Frame m_I2 C.7 135 Digital input (HS)
If platform control box is selected, input must be ON (+VBAT). If not:
‐ check switch function
‐ check switch supply fuse (FU3‐10A)
‐ check switch supply (wire 98=+VBAT)
SA901PF ‐ Control box selector ‐ Platform ‐ check input wire continuity CombiACX ‐ Frame m_I1 C.2 133 Digital input (HS)
If horn function is activated from turret control box, input must be ON (+VBAT). If not:
‐ check switch function
‐ check switch supply fuse (FU3‐10A)
‐ check switch supply (wire 109=+VBAT)
SA907TU ‐ Horn switch ‐ Turret ‐ check input wire continuity ACEX ‐ Frame s_I3 B.4 41 (CN0.8) Digital input (HS)
If ambient temperature is inside normal working conditions [‐20;+40]°C, input must be ON (+VBAT). If not:
‐ check sensor
‐ check sensor supply fuse (FU3‐10A)
‐ check sensor supply (wires 0=0V and 109=+VBAT)
ST903 ‐ Extrem ambiant temperature sensor ‐ check input wire continuity ACEX ‐ Frame s_I2 C.7 40 (CNO.6) Digital input (HS)
If brake release switch is activated, input must be ON (+VBAT). If not:
‐ check switch function
‐ check switch supply fuse (FU3‐10A)
‐ check switch supply (wire 109=+VBAT)
SA103 ‐ Brake release switch ‐ check input wire continuity ACEX ‐ Frame s_I1 C.2 21 Digital input (HS)
If potholes are extended, input must be ON (+VBAT). If not:
‐ check sensors adjustment
‐ check sensors supply fuse (FU3‐10A)
‐ check power supply (wire 109=+VBAT)
SQ144_145 ‐ Potholes left/right position sensors ‐ check input wire continuity ACEX ‐ Frame s_I5 A.4 15 Digital input (HS)
If platform enable switch is activated, input must be ON (+VBAT). If not:
‐ check switch function
‐ check switch supply fuse (FU3‐10A)
‐ check switch supply (wire 109=+VBAT)
SM901EN ‐ Enable switch ‐ Enable ‐ check input wire continuity CAN Tiller ‐ Platform ct_IN2 B.1 37 Digital input (HS)
If steering left function is activated from joystick rocker, input must be ON. If not:
‐ check rocker function
‐ check rocker supply fuse (FU3‐10A)
‐ check rocker supply (wire 109=+VBAT)
SM901L ‐ Joystick steering rocker ‐ Left ‐ check input wire continuity CAN Tiller ‐ Platform ct_IN10 B.11 35 (pin 6) Digital input (HS)
If steering right function is activated from joystick rocker, input must be ON. If not:
‐ check rocker function
‐ check rocker supply fuse (FU3‐10A)
‐ check rocker supply (wire 109=+VBAT)
SM901R ‐ Joystick steering rocker ‐ Right ‐ check input wire continuity CAN Tiller ‐ Platform ct_IN3 B.2 36 (pin 3) Digital input (HS)
If horn function is activated from platform control box, input must be ON (+VBAT). If not:
‐ check switch function
‐ check switch supply fuse (FU3‐10A)
‐ check switch supply (wire 109=+VBAT)
SA907 ‐ Horn switch ‐ check input wire continuity CAN Tiller ‐ Platform ct_IN5 B.4 34 Digital input (HS)
 ANNEX 4B
Type: Name Diagnostic instructions: ECU: [Ref] [Pin] [Wire] Type:2
If drive joystick is pulled, out of neutral input must be ON (+VBAT). If not:
‐ check joystick function
‐ check joystick supply fuse (FU3‐10A)
‐ check joystick supply (wire 109=+VBAT)
SM901N ‐ Drive/Arm joystick ‐ Out of Neutral ‐ check input wire continuity CAN Tiller ‐ Platform ct_IN6 B.5 5 Digital input (HS)
If drive selection switch is activated from platform control box, input must be ON (+VBAT). If not:
‐ check switch function
‐ check switch supply fuse (FU3‐10A)
SA908a ‐ Drive/Arm movement selection switch ‐ ‐ check switch supply (wire 109=+VBAT)
Direction a ‐ check input wire continuity CAN Tiller ‐ Platform ct_IN11 B.12 76 (pin 1) Digital input (HS)
If arm is selected using arm selection switch from platform control box, input must be ON (+VBAT). If not:
‐ check switch function
‐ check switch supply fuse (FU3‐10A)
SA908b ‐ Drive/Arm movement selection switch ‐ ‐ check switch supply (wire 109=+VBAT)
Direction b ‐ check input wire continuity CAN Tiller ‐ Platform ct_IN12 B.13 85 (pin 3) Digital input (HS)
If Activ' Screen arm up switch is activated, input must be ON. If not:
‐ check Activ' Screen supply fuse (FU3‐10A)
SWITCH1 ‐ Arm Up ‐ check Activ' Screen supply (wires 0=0V and 02=+VBAT) Screen1 ‐ Turret IN_1 Internal / Digital input
If Activ' Screen arm down switch is activated, input must be ON. If not:
‐ check Activ' Screen supply fuse (FU3‐10A)
SWITCH2 ‐ Arm Down ‐ check Activ' Screen supply (wires 0=0V and 02=+VBAT) Screen1 ‐ Turret IN_2 Internal / Digital input
If Activ' Screen enable switch is activated, input must be ON. If not:

‐ check Activ' Screen supply fuse (Fu3‐10A)

SWITCH3 ‐ Enable switch ‐ check Activ' Screen supply (wires 0=0V and 02=+VBAT) Screen1 ‐ Turret IN_3 Internal / Logic Input
If Activ' Screen navigation up switch is activated, input must be ON. If not:

‐ check Activ' Screen supply fuse (FU3‐10A)

SWITCH5 ‐ Navigation Up ‐ check Activ' Screen supply (wires 0=0V and 02=+VBAT) Screen1 ‐ Turret IN_UP Internal / Logic Input
If Activ' Screen navigation down switch is activated, input must be ON. If not:

‐ check Activ' Screen supply fuse (FU3‐10A)

SWITCH6 ‐ Navigation Down ‐ check Activ' Screen supply (wires 0=0V and 02=+VBAT) Screen1 ‐ Turret IN_DOWN Internal / Logic Input
If Activ' Screen navigation confirm switch is activated, input must be ON. If not:

‐ check Activ' Screen supply fuse (FU3‐10A)

SWITCH7 ‐ Navigation Confirm ‐ check Activ' Screen supply (wires 0=0V and 02=+VBAT) Screen1 ‐ Turret IN_OK Internal / Logic Input
If Activ' Screen navigation cancel switch is activated, input must be ON. If not:
‐ check Activ' Screen supply fuse (FU3‐10A)
SWITCH8 ‐ Navigation Cancel ‐ check Activ' Screen supply (wires 0=0V and 02=+VBAT) Screen1 ‐ Turret IN_BACK Internal / Logic Input

If machine is powered on with key and no emergency stop is pressed, output must be ON (0V). If not:
‐ check supply fuses (FU3‐10A)
‐ check key position selector (SA901) Logic Output 1.5 A
[DIGITAL_OUTPUTS] KAH ‐ Supply holding relay ‐ check output wire continuity CombiACX ‐ Frame m_O3 B.7 115 (LS) 12A Peak
If steering right or potholes retract function is requested, output must be ON (0V). If not, check Function Diagnostic. If status is
not OK:
‐ check valve power supply fuse (FU2‐10A) Digital output 1.5A
YV121 ‐ Pothole retraction / steering right valve ‐ check valve power supply (103=+VBAT) CombiACX ‐ Frame m_O0 A.1 54 (LS)
 ANNEX 4C
Type: Name Diagnostic instructions: ECU: [Ref] [Pin] [Wire] Type:2
If steering left or potholes extend function is requested, output must be ON (0V). If not, check Function Diagnostic. If status is
not OK:

‐ check valve power supply fuse (FU2‐10A)

‐ check valve power supply (103=+VBAT) Digital output 1.5A

YV122 ‐ Pothole extension / steering left valve CombiACX ‐ Frame m_O1 A.8 53 (LS)
If turret control box buzzer function is requested output must be ON (0V). If not, check Function Diagnostic. If status is not OK:
‐ check power supply fuse (FU2‐10A)
‐ check power supply (103=+VBAT) Logic Output 35 mA
HA901 ‐ Buzzer (turret) ‐ check output wire continuity CombiACX ‐ Frame m_O4 A.9 04 (LS)
If horn function is requested, output must be ON (0V). If not, check Function Diagnostic. If status is not OK:
‐ check relay
‐ check power supply fuse (FU2‐10A)
‐ check power supply (103=+VBAT) Logic Output 1.5 A
KA1 ‐ Horn relay ‐ check output wire continuity ACEX ‐ Frame s_O3 B.7 70 (LS) 12A Peak
If arm raise, potholes or steering movement is requested, output must be ON (0V). If not, check Diagnostic/Function. If status
is not OK:
‐ check power supply fuse (FU2‐10A) Digital output 1.5A
YV903 ‐ Pump unloading valve ‐ check power supply (wire 103=+VBAT) ACEX ‐ Frame s_O2 A.2 55 (LS)
If flashing light function is requested, output must be ON (+VBAT). If not check function diagnostic. If status is not OK:
‐ check power supply fuse (103)
‐ check power supply (FU2‐10A=+VBAT)
‐ check output wire continuity
‐ check relay Digital output 1.5A
KA2 ‐ Flashing light relay ‐ check flashing light ACEX ‐ Frame s_O6 B.6 31 (LS)
If lamp is not active at power ON or if status is not OK:
‐ check LED PCB
‐ check LED supply fuse (Fu3‐10A)
‐ check LED supply (wire 109=+VBAT) Logic Output 18 mA
HL420 ‐ Light lifting mode ‐ check output wire continuity CAN Tiller ‐ Platform ct_LED1 E.6 46 (LS)
If lamp is not active at power ON or if status is not OK:
‐ check LED PCB
‐ check LED supply fuse (FU3‐10A)
‐ check LED supply (wire 109=+VBAT) Logic Output 18 mA
HL100 ‐ Light Drive selection ‐ check output wire continuity CAN Tiller ‐ Platform ct_LED2 E.7 94 (LS)
If lamp is not active at power ON or if status is not OK:
‐ check LED PCB
‐ check LED supply fuse (FU3‐10A)
‐ check LED supply (wire 109=+VBAT) Logic Output 18 mA
HL802 ‐ Light overload ‐ platform ‐ check output wire continuity CAN Tiller ‐ Platform ct_LED4 F.1 44 (LS)
If lamp is not active at power ON or if status is not OK:
‐ check LED PCB
‐ check LED supply fuse (FU3‐10A)
‐ check LED supply (wire 109=+VBAT) Logic Output 18 mA
HL904 ‐ Light Low Battery ‐ check output wire continuity CAN Tiller ‐ Platform ct_LED5 F.2 42 (LS)
If lamp is not active at power ON or if status is not OK:
‐ check LED PCB
‐ check LED supply fuse (FU3‐10A)
‐ check LED supply (wire 109=+VBAT) Logic Output 18 mA
HL800 ‐ Light tilt ‐ check output wire continuity CAN Tiller ‐ Platform ct_LED6 F.3 45 (LS)
If lamp is not active at power ON or if status is not OK:
‐ check LED PCB
‐ check LED supply fuse (FU3‐10A)
‐ check LED supply (wire 109=+VBAT) Logic Output 18 mA
HL903 ‐ Light Impacting Machine Behaviour Failure(s) ‐ check output wire continuity CAN Tiller ‐ Platform ct_LED8 F.5 43 (LS)
 ANNEX 4D
Type: Name Diagnostic instructions: ECU: [Ref] [Pin] [Wire] Type:2
Arm angle input voltage value:
‐ must increase when arm is being raised
‐ must be around 1.0V when arm is at 0°
‐ must be around 4.0V when boom is at 57°
If not:
‐ check sensor mounting (ref. instructions)
‐ check sensor supply fuse (FU3‐10A)
‐ check sensor supply (wires 0=0V and 109=+VBAT)
ANALOG INPUTS SR420 ‐ Arm angle sensor ‐ check input wire continuity CombiACX ‐ Frame m_AN1 C.4 13 Analog input 0‐10V
Arm angle input voltage value:
‐ must increase when arm is being raised
‐ must be around 1.0V when arm is at 0°
‐ must be around 4.0V when boom is at 57°
If not:
‐ check sensor mounting (ref. instructions)
‐ check sensor supply fuse (FU3‐10A)
‐ check sensor supply (wires 0=0V and 109=+VBAT)
SR420 ‐ Arm angle sensor ‐ check input wire continuity CombiACX ‐ Frame m_AN1 C.4 13 Analog input 0‐10V
Overload pressure sensor input must be between [0;12]V, If not:
‐ check sensor mounting (ref. instructions)
‐ check power supply fuse (FU3‐10A)
‐ check sensor supply (wires 0=0V and 109=+VBAT)
SP400 ‐ Arm pressure load detector ‐ check input wire continuity CombiACX ‐ Frame m_AN2 C.9 14 (CN01.3) Analog input 0‐10V
MOT_D_I ‐ Right engine current ECU CombiACX internal sensor. CombiACX ‐ Frame I_mot_m Internal Internal motor current
If drive forward is ongoing, value must be greater than 0Hz.
If drive reverse is ongoing, value must be lower than 0Hz.
SV300 ‐ Motor speed sensor 1 If no movement is ongoing, value must be equal to 0Hz. CombiACX ‐ Frame V_mot_m D.1/4 63‐64 motor speed
ST302 ‐ Motor temperature sensor 1 Motor 1 (M370) temperature sensor. Temperature must be close to ambient temperature when machine has just been CombiACX ‐ Frame T_mot_m D.3 26‐27 motor temperature
ECU_TEMP ‐ ECU internal temperature ECU CombiACX internal sensor. Temperature must be close to ambient temperature when machine has just been started. CombiACX ‐ Frame T_var_m Internal Internal ECU temperature (in
CombiACX internal variable giving hydraulic pump current consumption.
Variable must be equal to 0mA when no movement is ongoing.
PUMP_I ‐ Pump current Variable must be greater than 0mA when arm raise, steering or potholes movement is ongoing. CombiACX ‐ Frame I_Pump Internal Internal Pump current
Platform position input voltage value:
‐ must decrease when arm is being raised
‐ must be around 4.0V when arm is at 0°
‐ must be around 1.0V when boom is at 57°
If not:
‐ check sensor mounting (ref. instructions)
‐ check sensor supply fuse (FU3‐10A)
‐ check sensor supply (wires 0=0V and 109=+VBAT)
SR722 ‐ Overload angle sensor ‐ check input wire continuity ACEX ‐ Frame s_AN2 C.9 20 Analog input 0‐10V
Platform position input voltage value:
‐ must decrease when arm is being raised
‐ must be around 4.0V when arm is at 0°
‐ must be around 1.0V when boom is at 57°
If not:
‐ check sensor mounting (ref. instructions)
‐ check sensor supply fuse (FU3‐10A)
‐ check sensor supply (wires 0=0V and 109=+VBAT)
SR722 ‐ Overload angle sensor ‐ check input wire continuity ACEX ‐ Frame s_AN2 C.9 20 Analog input 0‐10V
Steering angle sensor input must be between [0;12]V and increase when wheels are turned on the right. If not:
‐ check sensor mounting (ref. instructions)
‐ check sensor supply (wires 49=0V and 48=+12V)
SR150 ‐ Front wheels angle sensor ‐ check input wire continuity ACEX ‐ Frame s_AN1 C.4 47 Analog input 0‐10V
MOT_G_I ‐ Left engine current ECU ACEX internal sensor. ACEX ‐ Frame I_mot_s Internal Internal motor current
If drive forward is ongoing, value must be greater than 0Hz.
If drive reverse is ongoing, value must be lower than 0Hz.
SV301 ‐ Motor speed sensor 2 If no movement is ongoing, value must be equal to 0Hz. ACEX ‐ Frame V_mot_s D.1/4 67‐68 motor speed
ECU_TEMP ‐ ECU internal temperature ECU ACEX internal sensor. Temperature must be close to ambient temperature when machine has just been started. ACEX ‐ Frame T_var_s Internal Internal ECU temperature (in
ST303 ‐ Motor temperature sensor 2 Motor 2 (M371) temperature sensor. Temperature must be close to ambient temperature when machine has just been ACEX ‐ Frame T_mot_s D.3 71‐72 motor temperature
 ANNEX 4E
Type: Name Diagnostic instructions: ECU: [Ref] [Pin] [Wire] Type:2
If drive joystick is OK, input is variable between [0.5;4.5]V. If not:
‐ check joystick function
‐ check joystick 5V supply (wires 0=0V and 51=+5V)
‐ check joystick center position (approx. 2.5V)
SM901 ‐ Drive/Arm joystick ‐ check input wire continuity CAN Tiller ‐ Platform ct_AN5 A.10 39 Analogue input 0‐5V
If machine is powered and emergency stops are not pushed, input must be equal to +VBAT. If not:
‐ check input supply fuse (FU3‐10A)
‐ check input supply (wire 109)
‐ check input diode (D2)
AU_INFO ‐ Emergency stop (plateform) status ‐ check input wire continuity Screen1 ‐ Turret AN_4 X2.3 109 Analog input [0‐32V]

If potholes movement is requested, output must be ON (0V). If not:

‐ check valve function
‐ check valve supply fuse (FU2(10A))
‐ check valve supply (wire 103=+VBAT)
ANALOG OUTPUTS YV120 ‐ Potholes / steering selection valve ‐ check output wire continuity CombiACX ‐ Frame m_PWM B.3 56 PWM output
If arm raise function is requested, output must around 1000mA.
If arm descent function is requested, output must increase with arm joystick angle in range [400‐1000]mA. If not, check
Diagnostic/Function. If status is not OK:
‐ check valve
‐ check power supply fuse (FU3‐10A)
YV420 ‐ Arm valve ‐ check power supply (109=+VBAT) ACEX ‐ Frame s_PWM B.3 19 PWM output
 ANNEX 5A
Category Name Item Values Unit Description & References
INTERNAL Power part state Init
Wait
Alarm
Alarm 1
Alarm 2
Alarm 3
Power contactor closing
Power contactor test
Electrovalve
Ready
Movement
Movement selection None
Drive/Steering
Arm
Dynamic calibration index
Static calibration index
Movement selection setpoint None
Drive/Steering [REF_IO] SA908a ‐ Drive/Arm movement selection switch ‐ Direction a
Arm [REF_IO] SA908b ‐ Drive/Arm movement selection switch ‐ Direction b
Movement selection control None
Drive/Steering [REF_IO] SA908a ‐ Drive/Arm movement selection switch ‐ Direction a
Arm [REF_IO] SA908b ‐ Drive/Arm movement selection switch ‐ Direction b
Arm angle SR420 °
Arm angle SR722 °
Dynamic overload angle 0 deg
Dynamic overload pressure 0 bar
Dynamic overload angle 1 deg
Dynamic overload pressure 1 bar
Dynamic overload angle 2 deg
Dynamic overload pressure 2 bar
Dynamic overload angle 3 deg
Dynamic overload pressure 3 bar
Dynamic overload angle 4 deg
Dynamic overload pressure 4 bar
Dynamic overload angle 5 deg
Dynamic overload pressure 5 bar
Dynamic overload angle 6 deg
Dynamic overload pressure 6 bar
Dynamic overload angle 7 deg
Dynamic overload pressure 7 bar
Dynamic overload angle 8 deg
Dynamic overload pressure 8 bar
Dynamic overload angle 9 deg
Dynamic overload pressure 9 bar
Dynamic overload angle 10 deg
Dynamic overload pressure 10 bar
Dynamic overload angle 11 deg
Dynamic overload pressure 11 bar
Dynamic overload angle 12 deg
Dynamic overload pressure 12 bar
Dynamic overload angle 13 deg
Dynamic overload pressure 13 bar
Dynamic overload angle 14 deg
Dynamic overload pressure 14 bar
Dynamic overload angle 15 deg
 ANNEX 5B
Category Name Item Values Unit Description & References
Dynamic overload pressure 15 bar
Dynamic overload angle 16 deg
Dynamic overload pressure 16 bar
Dynamic overload angle 17 deg
Dynamic overload pressure 17 bar
Dynamic overload angle 18 deg
Dynamic overload pressure 18 bar
Dynamic overload angle 19 deg
Dynamic overload pressure 19 bar
Static overload angle 0 deg
Static overload pressure 0 bar
Static overload angle 1 deg
Static overload pressure 1 bar
Static overload angle 2 deg
Static overload pressure 2 bar
Static overload angle 3 deg
Static overload pressure 3 bar
Static overload angle 4 deg
Static overload pressure 4 bar
Static overload angle 5 deg
Static overload pressure 5 bar
Static overload angle 6 deg
Static overload pressure 6 bar
Static overload angle 7 deg
Static overload pressure 7 bar
Static overload angle 8 deg
Static overload pressure 8 bar
Static overload angle 9 deg
Static overload pressure 9 bar
Static overload angle 10 deg
Static overload pressure 10 bar
Static overload angle 11 deg
Static overload pressure 11 bar
Static overload angle 12 deg
Static overload pressure 12 bar
Static overload angle 13 deg
Static overload pressure 13 bar
Static overload angle 14 deg
Static overload pressure 14 bar
Static overload angle 15 deg
Static overload pressure 15 bar
Static overload angle 16 deg
Static overload pressure 16 bar
Static overload angle 17 deg
Static overload pressure 17 bar
Static overload angle 18 deg
Static overload pressure 18 bar
Static overload angle 19 deg
Static overload pressure 19 bar
Arm Calibration Minimum Angle SR420 pts
Arm Calibration Maximum Angle SR420 pts
Arm Calibration Minimum Angle SR722 pts
Arm Calibration Maximum Angle SR722 pts
Maximum value of YV420 electro valve control during
decompression %
 ANNEX 5C
Category Name Item Values Unit Description & References
Minimum value of YV420 electro valve control during
decompression %
Machine unfolded °
Arm in high position °
Overload alarm is activated if estimated load into the platform is greater than 230kg for more
Overload Overload Alarm than 0.8s. It is then deactivated if estimated load into the platform is lower than 230kg for more
Overload Calibration Not done
Done [REF_FAIL] F06.01 ‐ Load Management System not calibrated
Arm Angle deg
[REF_IO_MAIN] SR420 ‐ Arm angle sensor
[REF_IO_MAIN] SR722 ‐ Overload angle sensor
[REF_VARIABLE] Arm angle SR420
[REF_VARIABLE] Arm angle SR722
Pressure bar
[REF_IO_MAIN] SP400 ‐ Arm pressure load detector
Reference pressure b
[REF_VARIABLE] Arm Angle
Machine Active control box None
Chassis [REF_IO] SA901TU ‐ Control box selector ‐ Turret
Platform [REF_IO] SA901PF ‐ Control box selector ‐ Platform
Chassis control box Inactive
Active [REF_IO] SA907TU ‐ Horn switch ‐ Turret
[REF_IO] SA103 ‐ Brake release switch
[REF_IO] SWITCH3 ‐ Enable switch
[REF_IO] SWITCH1 ‐ Arm Up
[REF_IO] SWITCH2 ‐ Arm Down
[REF_VARIABLE] Turret enable switch state
Platform control box Inactive
Active [REF_IO] SA901PF ‐ Control box selector ‐ Platform
[REF_IO] SA907 ‐ Horn switch
[REF_IO] SM901 ‐ Drive/Arm joystick
[REF_IO] SM901N ‐ Drive/Arm joystick ‐ Out of Neutral
[REF_IO] SM901L ‐ Joystick steering rocker ‐ Left
[REF_IO] SM901R ‐ Joystick steering rocker ‐ Right
[REF_IO] SM901EN ‐ Enable switch ‐ Enable
[REF_VARIABLE] Platform enable pedal state
Machine is considered as unfolded if:
‐ Arm angle is not calibrated
‐ or Arm angle analog sensors are out of range
‐ or Arm angle values are incoherent
Machine unfolded ‐ or Arm angle is calibrated and arm angle value is above 10.2°
[REF_VARIABLE] Arm Angle
[REF_FAIL] F07.06 ‐ Arm Angle sensor
[REF_FAIL] F10.16 ‐ Arm angle calibration
Tilt
[REF_IO] SQ800 ‐ Tilt sensor
Hourmeter h
Platform enable pedal state Inactive
Active but not valid (%s)
Active and valid
Turret enable switch state Inactive
Active but not valid (%s)
Active and valid
Battery voltage mV
Battery level %
 ANNEX 5D
Category Name Item Values Unit Description & References
Unbraking enabled
User identified Not identified
Identified
User identification
ECU Max number of EEPROM queries (R/W) into the stack
Current number of EEPROM queries (R/W) into the stack
Current EEPROM status READY
BUSY
Number of EEPROM stack errors
Number of EEPROM status errors
Number of initialization tries
Execution time of 4ms task ms
Execution time of 8ms task ms
Execution time of 32ms task ms
Execution time of 128ms task ms
Execution time of 1000ms task ms
CombiACX Zapi failure Code
ACEX Zapi failure Code
CAN Tiller software version
Parameters failure identification Wrong constant parameters failure identifier
Parameter default value failure idenfier

Current value versus initialized value failure identifier

Master/slave incoherence failure identifier
Internal setpoint secured coming from active control box and formatted from 0 to 100% for a
Drive Drive movement setpoint Value % given direction
Direction Neutral [REF_VARIABLE] Movement selection
Forward [REF_VARIABLE] Platform control box
Reverse [REF_IO] SM901 ‐ Drive/Arm joystick
Status OK [REF_IO] SM901N ‐ Drive/Arm joystick ‐ Out of Neutral
Function not active [REF_IO] SM901EN ‐ Enable switch ‐ Enable
Neutral not detected
after power ON
Joystick/switch failure
Neutral not detected
after engine start
Joystick/switch must be
released
Enable switch/pedal not
valid
Percentage of the internal setpoint really applied from 0 (no movement) to 100% (no
Drive movement slowdown Value % slowdown)
Number [REF_VARIABLE] Machine unfolded
A cutting number nonzero, means that the movement in this direction is prohibited by the
cutting conditions of the operating logic:
‐ 0.00 : no cutting
‐ 0.01 to 0.32 : Enable cuttings
‐ 1.01 to 1.32 : General cuttings
‐ 2.01 to 2.32 : Simultaneous Movement cuttings
‐ 3.01 to 3.32 : Overload cuttings
‐ 4.01 to 4.32 : Tilt cuttings
‐ 5.01 to 5.32 : Reach Limit cuttings
‐ 6.01 to 6.32 : Failure cuttings
Drive forward cuttings Cutting number 1 ‐ 7.01 to 7.32 : Specific cuttings
 ANNEX 5E
Category Name Item Values Unit Description & References
Cutting number 2 [REF_VARIABLE] Machine unfolded
Cutting number 3 [REF_VARIABLE] Tilt
[REF_VARIABLE] Overload Alarm
[REF_VARIABLE] Overload Calibration
A cutting number nonzero, means that the movement in this direction is prohibited by the
cutting conditions of the operating logic:
‐ 0.00 : no cutting
‐ 0.01 to 0.32 : Enable cuttings
‐ 1.01 to 1.32 : General cuttings
‐ 2.01 to 2.32 : Simultaneous Movement cuttings
‐ 3.01 to 3.32 : Overload cuttings
‐ 4.01 to 4.32 : Tilt cuttings
‐ 5.01 to 5.32 : Reach Limit cuttings
‐ 6.01 to 6.32 : Failure cuttings
Drive reverse cuttings Cutting number 1 ‐ 7.01 to 7.32 : Specific cuttings
Cutting number 2 [REF_VARIABLE] Machine unfolded
Cutting number 3 [REF_VARIABLE] Tilt
[REF_VARIABLE] Overload Alarm
[REF_VARIABLE] Overload Calibration
Internal control generated from the internal setpoint (if no cuttings) and formatted from 0% to
100% for a given direction, using ramps and min/max speeds.
Drive movement control Value % The control is sent to the actuators of the machine
Direction Neutral [REF_IO] MOT_G_I ‐ Left engine current
Forward [REF_IO] SV300 ‐ Motor speed sensor 1
Reverse [REF_IO] ST302 ‐ Motor temperature sensor 1
[REF_IO] MOT_D_I ‐ Right engine current
[REF_IO] SV301 ‐ Motor speed sensor 2
[REF_IO] ST303 ‐ Motor temperature sensor 2
[REF_VARIABLE] Movement selection setpoint
[REF_VARIABLE] Movement selection control
Drive speed Micro
High [REF_VARIABLE] Movement selection setpoint
[REF_VARIABLE] Movement selection control
Speed reduction Right motor reduction %
Left motor reduction
Brake release control (drive) Brakes opened OFF/ON
Type Automatic control [REF_VARIABLE] Drive movement control
Automatic control but
possible to force brakes
closure
Manual control
Right motor speed setpoint Requested speed
Real speed [REF_IO] MOT_D_I ‐ Right engine current
[REF_IO_MAIN] SV300 ‐ Motor speed sensor 1
Left motor speed setpoint Requested speed
Real speed [REF_IO] MOT_G_I ‐ Left engine current
[REF_IO] SV301 ‐ Motor speed sensor 2
Internal setpoint secured coming from active control box and formatted from 0 to 100% for a
Steering Steering movement setpoint Value % given direction
Direction Neutral [REF_VARIABLE] Movement selection
Left [REF_VARIABLE] Platform control box
Right [REF_IO] SA102 ‐ Drive selection switch
Status OK [REF_IO] SM901L ‐ Joystick steering rocker ‐ Left
Function not active [REF_IO] SM901R ‐ Joystick steering rocker ‐ Right
 ANNEX 5F
Category Name Item Values Unit Description & References
Neutral not detected
after power ON
Joystick/switch failure
Neutral not detected
after engine start
Joystick/switch must be
released
Enable switch/pedal not
valid
Percentage of the internal setpoint really applied from 0 (no movement) to 100% (no
Steering movement slowdown Value % slowdown)
Number
A cutting number nonzero, means that the movement in this direction is prohibited by the
cutting conditions of the operating logic:
‐ 0.00 : no cutting
‐ 0.01 to 0.32 : Enable cuttings
‐ 1.01 to 1.32 : General cuttings
‐ 2.01 to 2.32 : Simultaneous Movement cuttings
‐ 3.01 to 3.32 : Overload cuttings
‐ 4.01 to 4.32 : Tilt cuttings
‐ 5.01 to 5.32 : Reach Limit cuttings
‐ 6.01 to 6.32 : Failure cuttings
Steering left cuttings Cutting number 1 ‐ 7.01 to 7.32 : Specific cuttings
Cutting number 2 [REF_VARIABLE] Power part state
Cutting number 3 [REF_VARIABLE] Machine unfolded
[REF_VARIABLE] Overload Calibration
[REF_VARIABLE] Overload Alarm
A cutting number nonzero, means that the movement in this direction is prohibited by the
cutting conditions of the operating logic:
‐ 0.00 : no cutting
‐ 0.01 to 0.32 : Enable cuttings
‐ 1.01 to 1.32 : General cuttings
‐ 2.01 to 2.32 : Simultaneous Movement cuttings
‐ 3.01 to 3.32 : Overload cuttings
‐ 4.01 to 4.32 : Tilt cuttings
‐ 5.01 to 5.32 : Reach Limit cuttings
‐ 6.01 to 6.32 : Failure cuttings
Steering right cuttings Cutting number 1 ‐ 7.01 to 7.32 : Specific cuttings
Cutting number 2 [REF_VARIABLE] Power part state
Cutting number 3 [REF_VARIABLE] Machine unfolded
[REF_VARIABLE] Overload Calibration
[REF_VARIABLE] Overload Alarm
[REF_IO] SR150 ‐ Front wheels angle sensor
Internal control generated from the internal setpoint (if no cuttings) and formatted from 0% to
100% for a given direction, using ramps and min/max speeds.
Steering movement control Value % The control is sent to the actuators of the machine
Direction Neutral [REF_IO] YV150L ‐ Steering front left valve
Left [REF_IO] YV150R ‐ Steering front right valve
Right [REF_IO] SR150 ‐ Front wheels angle sensor
Wheels steering angle °
[REF_IO] SR150 ‐ Front wheels angle sensor
Steering left limit
Steering right limit
 ANNEX 5G
Category Name Item Values Unit Description & References
Steering angle calibration performed
Potholes Potholes movement setpoint Value %
Direction Neutral
Extend
Retract
Status OK
Function not active
Neutral not detected
after power ON
Joystick/switch failure
Neutral not detected
after engine start
Joystick/switch must be
released
Enable switch/pedal not
valid
A cutting number nonzero, means that the movement in this direction is prohibited by the
cutting conditions of the operating logic:
‐ 0.00 : no cutting
‐ 0.01 to 0.32 : Enable cuttings
‐ 1.01 to 1.32 : General cuttings
‐ 2.01 to 2.32 : Simultaneous Movement cuttings
‐ 3.01 to 3.32 : Overload cuttings
‐ 4.01 to 4.32 : Tilt cuttings
‐ 5.01 to 5.32 : Reach Limit cuttings
‐ 6.01 to 6.32 : Failure cuttings
Potholes out cuttings Cutting number 1 ‐ 7.01 to 7.32 : Specific cuttings
Cutting number 2
Cutting number 3
A cutting number nonzero, means that the movement in this direction is prohibited by the
cutting conditions of the operating logic:
‐ 0.00 : no cutting
‐ 0.01 to 0.32 : Enable cuttings
‐ 1.01 to 1.32 : General cuttings
‐ 2.01 to 2.32 : Simultaneous Movement cuttings
‐ 3.01 to 3.32 : Overload cuttings
‐ 4.01 to 4.32 : Tilt cuttings
‐ 5.01 to 5.32 : Reach Limit cuttings
‐ 6.01 to 6.32 : Failure cuttings
Potholes in cuttings Cutting number 1 ‐ 7.01 to 7.32 : Specific cuttings
Cutting number 2
Cutting number 3
Potholes movement control Value %
Direction Neutral
Extend
Retract
Internal setpoint secured coming from active control box and formatted from 0 to 100% for a
Arm Arm movement setpoint Value % given direction
Direction Neutral [REF_VARIABLE] Chassis control box
Raise [REF_VARIABLE] Platform control box
Descent [REF_VARIABLE] Movement selection
Status OK
Function not active
 ANNEX 5H
Category Name Item Values Unit Description & References
Neutral not detected
after power ON
Joystick/switch failure
Neutral not detected
after engine start
Joystick/switch must be
released
Enable switch/pedal not
valid
Percentage of the internal setpoint really applied from 0 (no movement) to 100% (no
Arm movement slowdown Value % slowdown)
Number [REF_VARIABLE] Chassis control box
[REF_VARIABLE] Platform control box
[REF_VARIABLE] Tilt
[REF_VARIABLE] Machine unfolded
[REF_VARIABLE] Overload Calibration
A cutting number nonzero, means that the movement in this direction is prohibited by the
cutting conditions of the operating logic:
‐ 0.00 : no cutting
‐ 0.01 to 0.32 : Enable cuttings
‐ 1.01 to 1.32 : General cuttings
‐ 2.01 to 2.32 : Simultaneous Movement cuttings
‐ 3.01 to 3.32 : Overload cuttings
‐ 4.01 to 4.32 : Tilt cuttings
‐ 5.01 to 5.32 : Reach Limit cuttings
‐ 6.01 to 6.32 : Failure cuttings
Arm raise cuttings Cutting number 1 ‐ 7.01 to 7.32 : Specific cuttings
Cutting number 2 [REF_VARIABLE] Power part state
Cutting number 3 [REF_VARIABLE] Overload Calibration
[REF_VARIABLE] Overload Alarm
[REF_VARIABLE] Machine unfolded
[REF_VARIABLE] Tilt
[REF_IO] SQ534 ‐ Mast extended detector
A cutting number nonzero, means that the movement in this direction is prohibited by the
cutting conditions of the operating logic:
‐ 0.00 : no cutting
‐ 0.01 to 0.32 : Enable cuttings
‐ 1.01 to 1.32 : General cuttings
‐ 2.01 to 2.32 : Simultaneous Movement cuttings
‐ 3.01 to 3.32 : Overload cuttings
‐ 4.01 to 4.32 : Tilt cuttings
‐ 5.01 to 5.32 : Reach Limit cuttings
‐ 6.01 to 6.32 : Failure cuttings
Arm descent cuttings Cutting number 1 ‐ 7.01 to 7.32 : Specific cuttings
Cutting number 2 [REF_VARIABLE] Overload Calibration
Cutting number 3 [REF_VARIABLE] Overload Alarm
[REF_VARIABLE] Machine unfolded
Internal control generated from the internal setpoint (if no cuttings) and formatted from 0% to
100% for a given direction, using ramps and min/max speeds.
Arm movement control Value % The control is sent to the actuators of the machine
Direction Neutral [REF_IO] YV420 ‐ Arm valve
Raise [REF_IO] YV903 ‐ Pump unloading valve
Descent [REF_IO] PUMP_I ‐ Pump current
 ELECTRIC SCHEMATIC‐
SCHEMATIC‐ 1/3

2
24VDC
23
 ELECTRIC SCHEMATIC‐
SCHEMATIC‐ 2/3

RR
RL

24
ELECTRIC SCHEMATIC‐
SCHEMATIC‐ 3/3
HYDRAULIC SCHEMATIC
HYDRAULIC
HYDRAULIC‐‐ STEERING

Discharge valve YV 903 =1

+
Left steer YV121 =1
Or
Right steer YV122 = 1
HYDRAULIC
HYDRAULIC‐‐ POTHOLE

Discharge valve YV 903 =1

+
Pothole descent YV121 =1
Or
Pothole retract YV122 = 1
+
P th l /steer
Pothole /t selection
l ti YV120 = 1
 HYDRAULIC
HYDRAULIC‐‐ LIFTING

Discharge valve YV 903 =1

Raise/lower valve YV420 = 1
 HYDRAULIC
HYDRAULIC‐‐ LOWERING

Raise/lower valve YV420 = 1

 Potholes 3
Direction Steering
Ø40 Course 114
4
1/4’’ 1/4’’

5 1/4’’
1/4’’
Ø0,8

1/4’’ 1/4’’

e
ag
lev d er 1/4’’
de lin
é rin g cy
V ftin
Li 6
YV120 2
Capteur de pression 0 YV120 : EV selection potholes/dir
Pressure sensor .2
42
Ø1 YV YV121 : potholes up/dir droite
7 YV122 : potholes down/dir gauche
1/4’’

UP
1/4’’ 1/4’’
’’
3/8 A B

YV121 YV122

entrée Pression vérin

5 whithout pressure control
Cylinder pressure input
USA version
YV903
plug

Ø1.2
1
YV420 3/8’’

1/4’’ 6

1d
180 bar RV2
M
3/8’’ 1/4’’

1b
1a
1,7b
3/8’’ M
24VDC / 2,2kW / 3,5cc/tr

1c

Réservoir Tank

4000349350.B
4000246640.F
4000311490.E
4000313340.F
4000313380.B
4000313540.B
4000313760.D
4000421360.B
4000530650.B
4000079890.B