MF COMPACT-OPTIMUM EN E03.12

TECHNICAL TRAINING
DIAGNOSTIC LEVEL II
All Compact - Optimum

How to use this document?
MAINTENANCE AND REPAIR OPERATIONS ON YOUR HAULOTTE MACHINE
MUST BE DONE ONLY BY TRAINED ,EXPERIENCED AND AUTHORIZED TECHNICIANS
You have between the hands the summary given during the HAULOTTE technical training .
It will enable you to find information necessary for the maintenance and the repair of your
HAULOTTE machine .
Thanks to the guide below you will reach the required chapter quickly.
Chapter 1: Main features and functions

It is about a recall of the information contained in the user manual delivered with the machine:
components, overall dimensions, working zones , commands, etc…
Chapter 2: Study of the wiring schematics

You will find there the elements following:
- A summary of the standardized symbols used by HAULOTTE Group
- The complete wiring diagram of the studied model
- The non exhaustive list of the electric looms and electronic boards
- Localization of the principal safety units (tilt , limit switches, sensors,transducers…)
- Logical equations of operation: by function, to diagnose the main dysfunctions
Chapter 3: Study of the hydraulic schematics

You will find there the elements following:
- a summary of the standardized symbols used by HAULOTTE Group
- the complete hydraulic diagram of the studied model
- the non exhaustive list of the hoses track
- a localization of the principal hydraulics manifold (proportional block , on/off movements
block,…)
- Logical equations of operation: by function, to diagnose the main dysfunctions
Chapter 4: Adjustments
This is the adjustments and calibrations, hydraulics and electric, necessary to the good
maintenance of the material. You will find as well the methods of adjustment with table values.
Chapter 5: Guide of breakdown

Quick summary of the step to be followed for possible sources of breakdown.
In case of any defect or any dysfunction you will be able to identify the elements in question,
whatever they are electric or hydraulic.
Chapter 6: Summary of the versions

This manual treats of the latest version , however this summary table enables you to find the former
versions of the material (electric and hydraulics).
Chapter 7: Special functions

This chapter gathers all the functions and adjustment specific to carry out on the machine.
This does not exist for all the models and depends on the studied model.
It must be the subject of a special attentionbecause an intervention badly carried out can
deteriorate the good performance of the machine and thus consequently the safety of the users.
On this chapter, some special adjustment (sensors) are also explained prior to calibration
(depends on the model)
Only a technician HAULOTTE or approved by HAULOTTE Services is able to carry out this kind of
intervention.
TRAINING MANUAL DIAGNOSTIC Level 2 All Electric Compact – Optimum

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SUMMARY
1. MAIN FEATURES AND FUNCTIONS ................................................................................................................ 5
1.1. CHARACTERISTICS ............................................................................................................................................. 5
1.1.1. main components ...................................................................................................................................... 5
1.1.2. overall dimensions.................................................................................................................................... 6
1.1.3. working zones ........................................................................................................................................... 8
1.1.4. main datas .............................................................................................................................................. 14
1.2. COMMANDS (DOWN/UP) ............................................................................................................................ 20
2. STUDY OF THE WIRING SCHEMATICS ....................................................................................................... 22
2.1. SYMBOLS USED ................................................................................................................................................ 22
2.2. METHODOLOGY OF CONTROL........................................................................................................................... 27
2.2.1. electric continuity control....................................................................................................................... 27
2.2.2. Control of an on/off valve....................................................................................................................... 28
2.2.3. Control of components ........................................................................................................................... 29
2.3. THE WIRING SCHEMATICS ................................................................................................................................ 31
2.4. LOOMS ............................................................................................................................................................. 32
2.4.1. variator connector .................................................................................................................................. 32
2.4.2. The serial board ..................................................................................................................................... 33
2.5. LOCALIZATION OF THE MAIN SAFETY COMPONENTS ........................................................................................ 34
2.6. LIST OF COMPONENTS (DIAGRAM E 614G) ....................................................................................................... 37
2.6.1. Fuses....................................................................................................................................................... 37
2.6.2. inputs ...................................................................................................................................................... 37
2.6.3. Outputs ................................................................................................................................................... 38
2.6.4. Others ..................................................................................................................................................... 39
2.7. LOGICAL EQUATIONS OF OPERATION................................................................................................................ 40
2.7.1. Powering ................................................................................................................................................ 40
2.7.2. Steering................................................................................................................................................... 40
2.7.3. drive........................................................................................................................................................ 40
2.7.4. mast ........................................................................................................................................................ 41
2.7.5. Options usa............................................................................................................................................. 42
2.7.6. options australia..................................................................................................................................... 42
2.7.7. Options canada....................................................................................................................................... 42
2.8. CODES ALARMS................................................................................................................................................ 43
3. STUDY OF THE HYDRAULIC SCHEMATICS ............................................................................................... 46
3.1. SYMBOLS USED ................................................................................................................................................ 46
3.2. DETAILS OF HYDRAULIC BLOCK MK5.............................................................................................................. 50
3.3. DETAILS OF HYDRAULIC BLOCK MK6.............................................................................................................. 53
3.4. LOGICAL EQUATIONS OF HYDRAULICS OPERATION .......................................................................................... 55
4. ADJUSTMENTS.................................................................................................................................................... 57
4.1. ADJUSTMENT OF PRESSURES ............................................................................................................................ 57
4.1.1. Table of pressures................................................................................................................................... 57
4.1.2. Procedure for pressures adjustment....................................................................................................... 58
4.1.3. overload adjustment pressure switch sp1 ............................................................................................... 61
4.2. SPEEDS ............................................................................................................................................................. 61
4.3. BATTERY CHARGE ........................................................................................................................................ 4.4.
ZAPI CALIBRATOR...................................................................................................................................... 64
4.4.1. connection console ................................................................................................................................. 64
4.4.2. description of the console ....................................................................................................................... 65
4.5. ALARMS CODES ................................................................................................................................................ 69
4.6. PARAMETERS ZAPI .......................................................................................................................................... 73
4.7. THE SYSTEM OF LOAD CONTROL ....................................................................................................................... 82
4.7.1. principle.................................................................................................................................................. 82
4.7.2. connection of the bpe console................................................................................................................. 82
4.7.3. calibration of load management system (valid for compact 14)............................................................. 83
4.7.4. code alarms weighing board .................................................................................................................. 84
4.7.5. control i/o board bpe .............................................................................................................................. 85
5. BREAKDOWN SERVICE GUIDE...................................................................................................................... 88

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5.1. NO START......................................................................................................................................................... 88
5.2. NO LIFT ............................................................................................................................................................ 88
5.3. NO DESCENT ..................................................................................................................................................... 88
5.4. NO DRIVE ......................................................................................................................................................... 89
5.5. NO STEERING .................................................................................................................................................... 89
6. SUMMARY OF THE VERSIONS ....................................................................................................................... 90

7. SENSORS MOUNTING INSTRUCTIONS ........................................................................................................ 91
7.1. PRESSURE SWITCH SP1 .................................................................................................................................... 91
7.2. PRESSURE SENSOR G1...................................................................................................................................... 91
7.3. ANGLE SENSOR A1........................................................................................................................................... 92
7.4. VARIATOR PPC IMPEDANCE CHECK ................................................................................................................... 93
7.5. NEW LEVEL SENSOR ADJUSTMENT .................................................................................................................... 94
7.6. COMPACT EQUIPPED WITH PWM VALVE ............................................................................................................ 95

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

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1.1.2.OVERALL DIMENSIONS

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1.1.3.WORKING ZONES

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1.1.4. MAIN DATAS

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1.2. COMMANDS (DOWN/UP)

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2. STUDY OF THE WIRING SCHEMATICS
2.1. SYMBOLS USED
Battery with one element
Alternator
Fuse (Here 10 amps)
Coil winding roll
Electric motor
light
Diode

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Hourmeter
Standard push-button of safety “mushroom-headed

button”
Rotary knob
Push-button
Limit switch
Pressure switch
Key selector with 3 positions (T turret, O neutral, N

platform)
Toggle switch with 2 positions
Electrovalve

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relay
horn
Proportional electrovalve
Controller/joysticks
Pedals “dead man” or “foot dead man” switch
buzzer
“light”
Electrovalve “ON/OFF » ( bang-bang)

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Tilt sensor ( ramp detection)
Angle sensor (reach limitation)
Contact « mercury » (angle detection)
Resistor
(here value 100 ohms, 3 Watts, tolerance of 5%)
Sensor length (reach limitation)
Pressure sensor (weighing)
Angle sensor (weighing)

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Standard light “Led”
Strain gauge
Flexible Lame switch (ILS) detection of the magnets on

the telescopic boom/arm extension
Level fuel detector (diesel tank)
Proximity detector with impulses (detection teeth slew

ring)

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

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

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

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

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

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

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

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

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2.3. THE WIRING SCHEMATICS
See all versions at the end of this manual

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2.4. LOOMS
2.4.1.VARIATOR CONNECTOR
COMPACT - OPTIMUM (equipped weighing board BPE)
1 14
15 28
29 42
Variable speed unit Plug socket of variable speed unit
Terminal wire Terminal wire Terminal wire

1 Not used 15 Not used 29 30 Input limit
switch for
HS drive
(SQ3)
2 58 Input - coming 16 50 Output lifting 30 45 Signal hour
from the board valve YV9 recorder
series upper
control box
3 26 Electrovalve 17 27 Electrovalve 31 46 Signal hour
command YV8 on C12 recorder
descent YV7
4 9 Input + 18 25 Electrovalve 32 47 Signal hour
command recorder
anti-tipping
over device
YV6
5 16 Negative input 19 24 Output 33 48 Signal hour
command SB1 command recorder
left steering
valve YV5b
6 22 Output 20 23 Output 34 11 Validation
command command command
YV4 not ok right steering upper
valve YV5a controls
7 21 Output 21 43 Input signal 35 Not used
command series
YV3 not ok
8 20 Output 22 12 Not used 36 31 +
command Battery/End
YV 2 B REV of drive stop
drive
9 19 Output 23 49 Signal MDI 37 14 Command
commandeYV2 raise frame
a
FWD
10 18 Output supply 24 33 Input anti- 38 15 Input
YV1: selection tipping (SQ5 descent
movement of and SQ6) frame
drive
11 54 Input - light 25 29 Input (SQ1) 39 Not used
indicator of
defect
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12 44 Command light 26 28 Input board 40 61 Not used
overload BPE
overload
weighing
version Std
13 9 Input + 27 12 Signal of the 41 Not used
indicator of
slope sensor
14 Not used 28 Not used 42 42 Output
command
SB1
2.4.2.THE SERIAL BOARD

• latest version
1 7
1 5 8 14
6 10 B
A
3 6
1 4
C

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2.5. LOCALIZATION OF THE MAIN SAFETY COMPONENTS
Compact all models
(if overload option installed)

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• C14 model
G1
SQ1
SQ3
A1
SQ5 SQ6

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Optimum all models

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2.6. LIST OF COMPONENTS (DIAGRAM E 614G)
In the following tables, the column n°2 gives the c oordinates of the components on the sheets from
the wiring schematics in order to find easily their position.
The first figure corresponds the number of page and to the second to the column (generally from 1
to 20) of the corresponding page.
The possible options specific to certain countries are not indexed (for more information, it is
appropriate to refer to the wiring schematics corresponding to your machine
The state noted “0” corresponds to 0V, opened contact or not activated.
The state noted “1” corresponds to the tension of the circuit, closed or activated contact.
2.6.1.FUSES
FUSES
FU1 2 Main 300A (2)
FU2 01 -3 Electrovalves + horn 10A (7)
FU3 01 -3 Command 10A (5)
FU4 01 - 4 Accessories 10 A (59)
2.6.2.INPUTS
INPUTS
SA1 01 - 8 Key selector (CH: chassis/O: neutral/PF: Platform)
SA 2 8 Selector of movement lower control box (14 raise, 15 descent)
SA 3 01.-20 Selector drive (35)/lifting (34)
SB 1 01 -2 Emergency stop chassis (2)

SB 2 01.-13 Emergency stop platform (6)
SB 3 01.-15 Horn upper control box (9)
SM 1 01.-17 Controller/joystick
- right steering (41
- left steering (40)
- HM dead man (37)
- Off neutral (38)
- signal (39 - 51-52)
- Forward or raise from 2.5 to 4.5 V
Reverse or descent from 2.5 to 0.5 V

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ELECTRONIC MODULES (ECU)
U1 01 -4 Battery charger
U2 01.-15 Electronic variable speed unit
U4 01.-18 Board series upper control box
U5 01.-14 Weighing BPE board
SAFETY COMPONENTS
SQ1 01 - 19 detection low stop (29 =1 if PF < 3m)
SQ3 01 - 19 high detection (30 = 0 if platform with maximum height)
SQ4 Drive cut with 10 meters on certain models of C12)

SQ5 and SQ6 01 - 18 Anti-tipping device (32 + 33 = 0 if potholes ( side gates) are IN
SQ10 01 - 9 Slope detection (12 = 1 if in slope)

SP1 01.-15 Overload pressure controller (28) if option weighing not installed
A1 01 - 11 Relative angle sensor (384) for option weighing

G1 01 - 11 Pressure sensor G1 (382) for option weighing
2.6.3.OUTPUTS
RELAYS
KA1 01 - 2 horn (36)
RCH 01 - 5 battery charger (5a)
SB1 01 - 8 main contactor (16)
battery charger 220VAC_24V – 35A (290 100 9770) compatible all models

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VALVES
YV1 01 - 10 Selection drive/lifting (18)
YV2A 01 - 11 Forward drive (19)
YV2B 01 - 12 Reverse drive (20)
YV3 01 - 13 High speed drive (21)
YV4 01 - 14 High speed drive (22)
YV5a 01 - 16 Left steering (23)
YV5b 01 - 17 Right steering (24)
YV6 01 - 19 Command anti-tipping devices - potholes (25)
YV7 01 - 20 Descent (26)
YV8 01 - 21 Descent (27) (C12 only)
YV9 01.-16 quick descent (> SQ1) (50)
LIGHTS AND BUZZER

HA1 01 - 7 Buzzer (101)
HL1 01 - 17 Light defect (platform) (54)
HL2 01 - 6 Flashing light (60) (Option)
HL3 01 - 5 Work headlight (59) (Option)
HL4 01 - 21 Light selection lifting (platform) (34)
HL5 01 - 21 Light selection drive (platform) (58)
HL6 01 - 13 Overload (platform) (44)
2.6.4.OTHERS
M1 01 - 2 Pump motor unit 24 V 3000 W

PT1 01 - 11 Hour recorder and indicator of codes alarm (MDI)

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2.7. LOGICAL EQUATIONS OF OPERATION
The state noted “0” corresponds to 0V, opened contact or not activated.
The state noted “1” corresponds to the tension of the circuit, closed or activated contact.
The logical equations described below refer to C14 (with weighing option installed)
For C12, drive cut SQ4 is included in the diagnostic (to be removed if the machine is not equipped
with)
For all these conditions, the fuses will have to be checked as a preliminary
The condition of the equations of operation described below refers to the standard EN280, (for
other standards USA, CDN, AUS) thank you to refer to HAULOTTE SERVICES of your area which
will indicate you the characteristics of your machine
2.7.1.POWERING
CONDITIONS
Function Action Modifying
Prohibiting
Necessary the
the function
function
Powering upper SA1 (side PF) + SA1=1 RCH=0
controls Batteries charged SB2=0
SB1=1 SA1=1 (hold in chassis
Powering lower
position ) RCH=0
controls
Batteries charged
2.7.2.STEERING
CONDITIONS
Prohibiting
Necessary the
the function
function
SA1 (side PF) + HM=1 +
Right steering YV5b=1
SM1d=1 + SA3=1 SB1=0
SA1 (side PF) + HM=1 + SB2=0
Left steering YV5a=1
SM1g=1 + SA3=1
2.7.3.DRIVE
CONDITIONS
Prohibiting the
Necessary the
function
function
SA1 (side PF) + HM=1 + Machine in slope
Low speed YV2a=1
SM1a=1 + SA3=1 + SM1 (SQ10 = 0)
forward + YV6=1 if > SQ1
between 2.5 and 4.5 V SQ4=0 (C12)
SP1=1
or sensors of
SA1 (side PF) + HM=1 + weighing A1
Low speed YV2b=1
SM1b=1 + SA3=1 + SM1 and/or G1 out of
reverse + YV6=1 if > SQ1
between 2.5 and 0.5 V range if option
installed
(if PF> SQ1)

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YV2a=1 SP1=1
High speed + YV3=1 SQ1=1
SM1a=1 + SA3=1 + SM1
forward + YV4=1 SQ5=1
between 2.5 and 4.5 V
+ YV6=0 SQ6=1
SQ10=0
SQ4=0 (C12)
YV2b=1 SP1=1
High speed + YV3=1 or sensors of
SM1b=1 + SA3=1 + SM1
reverse + YV4=1 weighing A1
+ YV6=0 and/or G1 out of
range if option
installed
2.7.4.MAST
CONDITIONS
Prohibiting the
Necessary the
function
function
Machine in
slope
(SQ10=0)
YV9=1
YV1=1 SA1 (side PF) + HM=1 + SQ3=0
Raise upper + YV7=1 SM1a=1 + SA3=1 + sensors of
controls + YV8=1 if C12 SQ5=1 + SQ6=1 + SM1 weighing A1
or C14 between 2.5 and 4.5 V and/or G1 out
of range if
option
installed
(if PF > SQ1)
YV1=1
SP1=1
+ YV7=1 or sensors of
Descent upper + YV9=1 weighing A1
SM1b=1 + SA3=1 + SM1
controls + YV8=1 if C12 and/or G1 out
or C14 of range if
option
installed
Machine in
slope
(SQ10=0)
YV9=1
YV1=1 SQ3=0
Raise lower + YV7=1 SA1 (CH side) + SA2=1 + sensors of
controls + YV8=1 if C12 SQ5=1 + SQ6=1 + weighing A1
or C14 and/or G1 out
of range if
option
installed
(if PF > SQ1)

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SP1=1
(or sensors of
+ YV7=1
weighing A1
Descent lower + YV9=1
SA1 (CH side) + SA2=1 and/or G1 out
controls + YV8=1 if C12
of range if
or C14
option
installed)
2.7.5.OPTIONS USA
Sound alarm only on ramp
No stop the 3 seconds on anti-crashing system with the level of SQ1
(audible signal only)
Sound alarm only if machine is in overload
2.7.6.OPTIONS AUSTRALIA
Overlaod and tilt stop moveùment if PF > 3m
2.7.7.OPTIONS CANADA
Sound alarm only if machine is in overload
Ramp detection is active and stop movements if PF>3m

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2.8. CODES ALARMS
CODE
FLASH PROBABLE CAUSES ACTION
ALARM
Battery below 5% or variable speed
0
unit defective
check the cable connected between the
coil YV7 (descent) and the U2 variable
voltage supply of YV7, YV9 and wire speed unit
n°3 (input B+, see if wires 100 and 3
AL 01 3 are not inverted)/ check the connection of wire 26
Bad connection wires 26 and 01
variable speed unit defective
change the variable speed unit
Serial board or cable or plug socket of

supply of the upper controls (wire check connection upper panel
AL 06 6 n°58/ Cables of the M.D.I or
M.D.I/loom 7 wires (37; B5/38; B5/39. change serial card
A3/40; B1/41; B12/51; A7/52; A6/
Contact already closed when start
problem weighing board
(wire 28 or 31)
AL 10 2
Passage key selection lower/upper Make again the calibration by leaving
controls too fast an interval of 5 sec between each step
Problem on the EEPROM (Variable
AL 13 6 change the variable speed unit
speed unit defective)
Low VMN at rest or not coherent with
the PWM applied (variable speed unit)
Stuck general contactor (auxiliary main contact in always closed SB1
AL 37 4
contact of the open battery group (change SB1)
General contactor opened by the
microphone of control (battery cut-off)
I=0 always when motor unit is running change the variable speed unit and
AL 49 5
(variable speed unit) check the pump and its cable
Current high at rest change the variable speed unit and
AL 53 5
(variable speed unit) check the pump and its cable
check connection between the pump
and the variable speed unit
The capacitors do not start to charge
check the main fuse of FU1 300A
AL 60 3 at start up (key ON)
check the internal impedance in the
(fuse 250A - Connection on motor)
variable speed unit between terminals
P and B (lower value 65Kohms)
Too high temperature inside variable
speed unit (> 75° variable speed unit)
Short-circuit on the valves check the line and the valve coil
AL 73 1 Short-circuit on the general contactor check the coil of main contactor SB1
Short-circuit on the sound buzzer check the horn

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Pilot of the general contactor in short-
check the coil of the relay SB1a (cable
circuit (problem variable speed unit or
or cut coil)
coil contactor)
Pilot of the general contactor in short-
check the coil of the relay SB1a (circuit
circuit (problem variable speed unit or
and coil OK
coil contactor)
(wires 19 on terminal 9 disconnected,
check the coil YV2 and the wire 19
FWD drive on hydraulic block)
(Start of the variable speed unit without
AL 74 4 (variable speed unit defective if the
delay; line and coil OK)
relay stick immediately without delay)
(wires 19 on terminal 9 disconnected,
FWD drive on hydraulic block) check the coil YV2 and wire 19
(variable speed unit defective if the (line and cut coil)
relay stick immediately without delay)
check the contact of battery charger
(plug of the contact on charger badly
RCH
engaged)
(make a shunt to test)
Pilot of the general contactor does not check the coil of relay SB1 has
close itself (problem coil contactor) (defective coil)
AL 75 4
Pilot of the general contactor does not check the coil of relay SB1 has
close it (problem variable speed unit) (coil OK)
High accelerator at rest (problem
joystick)
check joystick SM1
check the potentiometer supplied in
51/52 output at 39
AL 78 2
High accelerator at rest (problem
check the input voltage wires 51 and 52
joystick)
(instruction potentiometer) or change
check the potentiometer supplied in
serial card
51/52 output at 39
Erroneous sequence of start
AL 79 2 check or change joystick SM1
(connection joystick)
Double request for power ON
AL 80 2 check or change joystick SM1
(serial card or joystick)
Coil YV6 defective or badly connected
(wires 25/7 theoretical resistor 75 check coil YV6
ohms)
AL 90 4
Coil YV6 defective or badly connected
(inversion wires 25 & 27 with terminals
18 & 19)
Version (standard or Europe) is not
Al 91 2 OK, the two parameters, “version” and Problem of adjustment (console)
“ok for version” are different.
Drivers 2KO SIC Problem of small check the short-circuit in weighing
AL 93 loom between MDI and control board board of the bottom panel and switch
lower control box SA2 the bottom panel
The microspeed of control does not
answer (variable speed unit)
If weak Horn Change the main
contactor coil
Overload in the weighing board
(cable 28 with 0V)
AL 95 7 Alarm pressure controller
Input voltage J4.6 =0V
BPE Weighing board defective
open contactor SQ3 (normal if platform
AL 96 7 The platform is at maximum height
is at maximum height)

2420339190 E03.12 44/102
High level of current at the input coming
from the pump ( check the pressure
Maximum current during braking or if
AL 97 5 and the pump in intensity and
the platform is in drive
insulation),
check the brakes
Difference in recording between the
Discordance between hour from hours variable speed units & the hours
variable speed unit and M.D.I (hour of the MDI or change hour recorder
AL 98 0 recorder) difference in recording between the
Contact auxiliaries of the emergency hours variable speed units & the hours
stop chassis defective of the MDI or change variable speed
unit
check the parameter setting “OPTION
AL 99 6 Maintenance required check up needed and check up done”
(must be OFF with HG)

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3. STUDY OF THE HYDRAULIC SCHEMATICS
3.1. SYMBOLS USED
Pump with variable flow

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

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

transmission in closed circuits on HAULOTTE
superior booms like HA32PX, HA41PX, H28TJ+,
H43TPX)
Hydraulic motor with 2 directions of drive

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

of drive
15cc for High speed drive
45 cc for Low speed drive
Filter (normally 10 microns)

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

(used for the HA32PX/HA41PX)
Adjustable pressure relief valve

(here set at 145 bars/2104 psi)

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Fixed flow restrictor or spray nozzle
(here diameter of 0.75 mm)
Adjustable flow restrictor + check valve
Pressure sensor (used for weighing)
Adjustable pressure switch

(here set at 170 bars)
Flow divider
Position valve 4 ways, 3 positions in closed center
Distribuitor/ safety valve
Counter balance valve with piloting line of the

opposite line (here set at 210bars)

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Position valve proportional 5/3 with piloting manual
by lever
Rotary cylinder /jack (here range at 180°)
Piloted valve
Manual valve with automatic return (used to readjust

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

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3.2. DETAILS OF HYDRAULIC BLOCK MK5
YV9
YV2a/b
RV3
YV4 FD1 RV2

YV1
FRT
YV6
RV1 YV5a/b
YV3
YV9
CB2
FR CB1
NV1 NV2
PUMP

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Name Function
YV3
Selection High Speed drive
YV4
Selection High Speed drive
YV2
Selection of drive (FWD/REV)
YV6
anti-tipping over (pothole)
YV1
Selection drive/lift
FRT
Priority valve/ Flow control valve
RV2
Main pressure relief valve
RV3
relief valve for lifting
YV5
Steering
RV1
relief valve for steering
FD1
Flow divider for drive
CB2
Counterbalance valve drive circuit
CB1
Counterbalance valve drive circuit
Pump Manual pump for free wheel (brake release) for towing
FR
Output supply of the rear brakes circuit
YV9
Lift valve
NV1
Valve of discharge of the brake release circuit
NV2
Valve of by-pass of the brake release circuit

2420339190 E03.12 51/102
FD1
NV2
CB1
CB2
NV1
POMPE A MAIN
YV9
ORF1
RV2
RV3
RV1
FRT

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3.3. DETAILS OF HYDRAULIC BLOCK MK6

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RV2
RV3
YV2
NV2 NV1
FR1
RV1
YV4 YV3

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3.4. LOGICAL EQUATIONS OF HYDRAULICS OPERATION
The equations below bring a supplement of assistance for the service technician after having
electrically tested the function,
they will enable him to continue the diagnosis with more facility.
Information which appears between brackets in the heading “prohibiting the function” refers either
to the blockks of the hydraulic diagram, or with the internal parts of these blockks.
All functions described, implies both ways (ie arm lift/descent)
CONDITIONS
Function
Necessary Prohibiting the function
Pressure insufficient pump:
- Level oil insufficient
- Defective pump motor
unit
Defective or not adjusted
pressure relief valve (RV2)
Pump 3.8 cc (3.2 cc for the other Clogged priority valve FRT
models) Leak on flexible/fitting of the
(pressure according to model) circuit
Drive + position valve YV2 Leak on valves
+ position valve YV3
+ position valve YV4 Internal leak in motors
+ motor 300 cc Blocked brake system (FR)
counterbalance valves
(CB1/CB2)
Clogged or defective flow divider
FD1
CONDITIONS
Function
Pump 3.8 cc (3.2 cc for the other unit
models) Defective or not adjusted
(pressure according to model and pressure relief valve (RV3)
load) Cylinders defective anti-tipping
Lifting scissors + position valve YV1 over devices
+ position valve YV3 Leak on flexible/fitting of the
+ position valve YV6 circuit
+ cylinder (stroke1250 mm) Leak on valves
+ cylinder 2 stroke 1250 mm) (> C12)
One-way valves on defective
cylinder (11a and/or 6a)
Internal leak in the cylinder
position valve YV6 Leak on flexible/fitting of the
+ position valve YV7 circuit
Descent + position valve YV9
scissors + position valve YV 8 (C12)
+ cylinder (stroke 1250 mm) Leak on valves
+ cylinder 2 (stroke 1250 mm) (> C12)
CONDITIONS
Function
unit
Pump 3.8 cc (3.2 cc for the other
models)
Steering pressure relief valve (RV1)
+ position valve YV5
Leak on flexible/fitting of the
+ cylinder (stroke 114 mm)
circuit
Leak on valve
Internal leak in the cylinder

2420339190 E03.12 56/102
4. ADJUSTMENTS
4.1. ADJUSTMENT OF PRESSURES
Note: for all the adjustments of time and pressure, the temperature of oil must be sufficiently hot
according to the ambient temperature
(in general 2 to 3 cycles of lifting and drive on a few meters are sufficient on this kind of machines)
4.1.1.TABLE OF PRESSURES
Nominal Load Main hydraulic Steering pressure
pressure (bars)
H8SN External 120kg 200b 150b

Internal : 350kg
H8W External 120kg 220b 150b

Internal : 450kg
H10S External 120kg 220b 150b

Internal : 350kg
H10N Internal : 230kg 220b 150b

Internal : 300kg

Internal : 300kg
OPT6 External 115kg 230b 100b

Internal : 270kg
OPT8 Internal : 230kg 230b 100b

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4.1.2.PROCEDURE FOR PRESSURES ADJUSTMENT
connect the pressure gauge on the minimess port M as indicated below
• Bloc MK5
Steering pressure : RV1

connect the pressure gauge on the port of the hydraulic block
unscrew the upper part with the wrench of 19 mm
select low speed and bring the steering lock to lock
Adjust the pressure: (key of ¼)
OPTIMUM: between 95 and 105 bars.
COMPACT: between 145 and 155 bars.
tighten back the whole unit
Relief valve
for steering
Drive pressure (or main): RV2

block the axle motodirector with câles and to unscrew with the wrench of 19 mm
select high speed and to command the drive
Adjust the pressure:
OPT6 and OPT8: between 225 and 235 bars
H8SN: between 195 and 205 bars
H10S - H8SW - H10N: between 215 and 225 bars
H12SN and C14: between 235 and 245 bars
Tighten back the whole unit

2420339190 E03.12 58/102
Relief valve for Pmax
.Lifting pressure : RV3 (see value according to table of the adjustments)

Put the correct load corresponding to the model
unscrew the cap with the Allen key CHC
check the separation of the scissors arms if not adjust the pressure relief valve
Relief valve
for lifting
extension retracted: place the weights in the center of the platform:
OPT6 OPT8 C8 C8 CU
297Kg 253Kg 385Kg 330Kg
C10N C8W C10 C12 C14
253Kg 495Kg 330Kg 405Kg

2420339190 E03.12 59/102
• For block MK6 (normally for C14)
RV3 Relief valve

for lifting
RV2 Relief valve

for main pressure
RV1 Relief valve

for steering

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4.1.3. OVERLOAD ADJUSTMENT PRESSURE SWITCH SP1
Note that the following procedure is valid for machines equipped with the overload pressure switch
SP1 only
Procedure:
• All process must be done from low control box
• put the nominal load corresponding to the model of the machine
• raise the scissors from approximately 1 meter in order to reach the setting screw of the
pressure switch SP1
• unscrew the setting screw in order to make it more sensitive
• lift the scissors until the movement stops (at SQ1) and buzzer sounds
• Adjust the setting screw until the buzzer stops sounding
• Lower the platform below SQ1 then lift it again and check that the buzzer sounds a short
moment with a short stop of the lifting movement (if not readjust the screw by turning each
time of 1/8 turn)
• Lower the platform and to put an additional load of 50kg (C10N, C8W and 8) or of 60kg
(C8, C10 and C12)
• Lift the scissors in order to check that the lifting stops at SQ1 and with buzzer sounds
• check that descent is stopped and microspeed automatically engaged when the buzzer
sounds.
• End of the adjustment
Mid-range
Mid-range
+15°
No
buzzer buzzer
buzzer
4.2. SPEEDS
C8 C8W C10 C10N C12 C14 OPT6 OPT8
Lift(s) 37 44 45 46 75 66 21 23
Descent(s) 41 56 49 49 52 50 37 29

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4.3. BATTERY CHARGE

2420339190 E03.12 62/102
Red led phase 1
Blinking red in case of failure ( disconnect and
reconnect the battery charger for reset
Yellow led phase U, I2 and stop before
equalisation
Green led at the end of this phase
Blinking green led in equalisation phase
OFF no power
When batteries are fully charged, the led is green fixed

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4.4. ZAPI CALIBRATOR
The specific adjustments, parameter settings and options are accessible only through this
calibrator ZAPI
4.4.1.CONNECTION CONSOLE
the console must be connected at hourmeter connector ( inside the chassis of the machine)
Model 1 Model 2:

2420339190 E03.12 64/102
4.4.2.DESCRIPTION OF THE CONSOLE
Confirmation of
selection
Option selection or
access to next menu Parameter increase or
access to special functions
Option selection or go
back to previous menu Parameter decrease or
access to special functions
Exit or function
execution

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• Menu description
PPC CO 2.03 ALARM

24V 350A 0000
PARAMETERS CHANGE RESTORE

PARAMETER
MOTOR DATA SAVE

PARAMETER
PROGRAM VACC TEST

2420339190 E03.12 66/102
TRIPLAT CO 2.00
24V 300A 0000
CONFIG MENU
SET MODEL
CONFIG MENU
SET OPTION
ADJUSTMENT

2420339190 E03.12 67/102
ALARM
CLEAR EEPROM
SPECIAL ADJUSTMENT
READ RAM
HARDWARE SETTINGS
READ EEPROM
CLEAR CONSOLE

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4.5. ALARMS CODES
ALARM FLASH
DESCRIPTION DIAGNOSTIC
CODE CODE POSSIBLE CAUSES
Batteries below 5% of
charge Put in charge the batteries
0 to the Adjust the voltage with the value of
BATTERY Bad adjustment of adjust
MDI + Red 8 batteries by the parameter adjust
LOW battery parameter
LED battery
check specific gravity + voltage
Change ZAPI variator
batteries if Ok replace ZAPI variator
ABSENT (pin 3 is for ON/OFF valve)
See option: Parameter
default PRESENT (pin 3 is for
"AUX FUNCTION 2"
proportional valve)
Check continuity wires between
Voltage on YV7 + YV9
YV7,YV9 and ZAPI variator
Wire n°3 (Input B+, verify
if wires 100 & 3 are not Visually verify if the wire 3 coming from
AL 01 3 EVP NOT OK mixed) SB1 is on the terminal B+
SB1 (battery cut off) in
short circuit Check continuity of SB1 coil
If Al 01 + all LED on the
MDI are switch ON
change ZAPI Variator Replace ZAPI variator
Wire n°3 on P instead to
B+ Change wire
Change MDI or check continuity on
MDI wires 45,46,49 between MDI and ZAPI
variator
Loom between MDI and 1a) Connect console instead MDI, if
ZAPI Variator "NO COMMUNICATION" see step 2.
SERIAL
AL 06 6 ZAPI variator change DC motor controller (variator)
ERROR #1
1b) if no alarm in the console, check
Loom between upper
serial line wire 43 between upper
control box and variator
control box and variator
ZAPI variator or serial if same problem, check serial card or
card variator
Too quickly selection
between high and low Switch OFF the machine, wait for a few
box with key selector seconds then switch ON the machine
If machine without
WEIGHING overload system :on
AL 10 2 spécial adjust parameter
CARD KO
the value of parameters
"version" et "ok for
version" are in mode #1 Change the 2 parameters and insert #2
Change weighing card Replace BPE weighing card
1.Do a clear eeprom and recycle the
key
2. If the fault disappears, the previously
Problem on EEPROM stored parameters will be replaced by
AL 13 6 EEPROM KO
(variator KO) the default parameters
3. If the fault continues when the Key
switch is turned OFF and ON
again,replace ZAPI variator

2420339190 E03.12 69/102
Short circuit on unit motor
pump Vérify continuity on electric motor
Incorrect motor Check motor connection Wires 3 and 4
connection
AL 32 3 VMN NOT OK Frame fault of motor to Check isolation between motor and
chassis. chassis.
Check wire 4 (VMNP) with multimeter
(between VMNP an B- Batteries),
Defect in the power unit
At STARTUP it must have around 24V.
If no replace the variator.
Battery cut off stuck Check power contact on SB1

CONTACTOR
AL 37 4 Check SB1 coil
CLOSED
Check SB1 wirings (wire 16 or wire 42)
ZAPI variator Replace ZAPI variator
Check power contact SB1a (wire16 or
Battery cut off open
wire42)
The safety
CONTACTOR microprocessor can open
AL 38 4 the Main Contator if it is
OPEN
broken or if there is
dangerous situation 1.Replace the main contactor and
detected by the safety check the contactor wiring
microprocessor 2. Replace variator
Electric motor Vérify continuity on M1 electric motor
Check continuity and states of M1
M1 motor power cables
motor power cables
AL 49 5 I = 0 EVER Defective current sensor, Replace variator
Feed back circuit failure
or logic failure or power
unit failure Replace variator
Electric motor
Vérify continuity on M1 electric motor
Check continuity and states of M1
M1 motor power cables
motor power cables
AL 53 5 STBY I HIGH
Defective current sensor, Replace variator
Feed back circuit failure
or logic failure or power
unit failure Replace variator
Fuse 300A Visually check the fuse
Vérify condition and cleaned
Unit motor pump
connections between electric motor and
connexion
CAPACITOR ZAPI variator
AL 60 3
CHARGE Horn relay in short circuit Disconnect the coil of horn relay
Measure the internal impedance of
Change ZAPI variator ZAPI variator between P et B- (around
65 KOhms)
This alarm is displayed
TH when the chopper’s Temperature is not calibrated.
AL 62 9
PROTECTION temperature is the same Calibrate the "SET TEMPERATURE"
as ambient temp in SPECIAL ADJUSTMENT menu

2420339190 E03.12 70/102
Switch off the machine in order to cool
down the variator (running time too
long)
This alarm is generated if
The temperature sensor may be
the chopper temperature
defective (test can not be done)
raises above 75°C
replace variator
The logic may be defective. (test could
not be done) replace variator
Horn in short circuit or
Horn relay coil in short
circuit Disconnect the horn
Battery cut off coil in short Check continuity of SB1 coil (check if it
POWER circuit is shorted) + check wires 16 and 42
AL 73 1
FAILURE #1 Vérify if the valves coils are shorted +
ON / OFF or PWM valves
check wires
coil in short circuit
16,18,19,20,21,22,23,24,25,26
If any of previous causes, than replace
ZAPI variator
the variator
Measure voltage on wire 42 & 16 of
Driver of battery cut off in
SB1 0V replace ZAPI variator 24V
short circuit
vérify the continuity on SB1 coil
Problems in the feed
back circuit of the battery
DRIVER
AL 74 4 cut off driver SB1 Replace the variator
SHORTED
RCH battery charger
relay failing (machines
produced before april
2008). It cuts the positive
of SB1 install a shunt on RCH and make test
Defect in the battery cut
CONTACTOR If SB1 and wiring are OK , replace the
AL 75 4 off SB1 coil driver feed
DRIVER variator
back circuit.
1. the track of the potentiometer has
become open
2. the potentiometer is not wired
correctly
3. the potentiometer itself is defective.
Release accelerator
4. wire 38 (null position) is open when
AL 78 2 VACC NOT OK (joystick) to neutral
move the cursor
position
For test (1,2,3,4) You need to check
with a multimeter between the track of
the potentiometer and the GND, and
see it the analog value follows the
joystick movement.
INCORRECT Check the deadman switch (wire 37)
AL 79 2 Incorrect start sequence
START Check the joystick. SM1
Failure on joystick Replace joystick
AL 80 2 FORW+BACK
Failure on serial card Replace serial card
Bad connexion on YV6 Check continuity of coil on YV6

AL90 4 DRIVER 1 KO
coil or coil broken
Vérifier continuity of wire 25 between
coil and ZAPI variator
With ZAPI IN SPECIAL Check if the 2 parameters have the
ADJUSTMENT MENU same values (#1 =>Overload sensor et
VERSION NOT
AL 91 2 the values of parameters #2=> overload electronic system).If
OK
"version" et "ok for different, then set both at the correct
version" are différent value
2420339190 E03.12 71/102
Lift from chassis (wire14) Check wire 14 and 34.
and enable (wire 34) There is a not allowed input
WRONG active at same time. configuration
AL 93 0
INPUT CONF. Lower from chassis Check wire 15 and 34.
(wire15) and enable (wire There is a not allowed input
34) active at same time. configuration
If low horn change battery
cut off coil in short circuit
MICRO Try to change SB1 cut battery
AL 94 6
CONTROL KO Mismatch between
master/slave micro
controllers. If alarm persists change the variator.
Overloaded platform Check if the platform is not in overload
check the continuity weighing loom
(wires 9, 28)
check the continuity on the loom
PRESSURE Problem with loom
AL 95 7 between angle sensor and pressure
NOT OK connexion
sensor
If machine without overload system
check weighing jump
Fault on calibration Make new calibration + adjustments
If C12, normal fonction before on (not
Cut traction after 8 high all models)
meter (only C12) Vérify continuity on line of terminal
switch SQ4 if other machines to C12
If machine with overload system ,
check continuity on line terminal switch
HEIGHT 8
AL 96 7 SQ7
METERS
If machine with overload check
Machine with option load
continuity traction cut line (wires 9 and
on extension platform
386)
If machine with overload make new
calibration for overload extension
platform
Variator detect a peak of Check if motor is mechanically locked +
current. Check with other motor
CURR. Problem in motor
AL 97 5
PROTECT. connection Check the motor wiring
Problem in feeback
current sensor. Replace variator
It appens at startup, when
you change the variatior
Switch ON the machine and wait for at
or the MDI.
least, than AL98 should disappear
AL 98 0 NONE The hourcounters Hourmeter MDI shows the hourcounter
(variator and MDI) of the variator.
differes more than
10hours.
This alarm can be erased by setting
CHECK UP "Check Up Done" = OFF in SET
AL 99 6 Maintenance request
NEEDED OPTION MENU ( put OFF with HG
machines)

2420339190 E03.12 72/102
4.6. PARAMETERS ZAPI
• Machines settings for all standard version EP V2.25 (except US,CDN)
(For machines with version < EP V2.25, refer to TN142)
Change Values for Values for

PARAMETERS parameter DESCRIPTION COMPACT OPTIMUM
s (Model type #1) (Model type #2)
***PARAMETRE
CHANGE***
Acceleration ramp for
ACCELER. DELAY YES 4 9
traction
Decceleration ramp for
DECELER. DELAY YES 5 0
traction
Speed reduction
CUTBACK SPEED YES 9 9
( microspeed)
Minimum speed for
CREEP SPEED YES 2 3
traction
Maximum speed for
MAX SPEED FORW YES 9 7
traction (FWD)
Maximum speed for
MAX SPEED BACK YES 9 7
traction (REV)
Compensation between
battery voltage and
COMPENSATION YES 7 7
value read by the speed
variator unit
Maximum current on
TRACTION IMAX YES 9 9
traction motors
1ST SPEED
YES Lifting speed 9 9
COARSE
1ST SPEED COMP YES the lift speed and load 5 5
on platform
STEERING SPEED YES Steering speed 1 5
ADJ TR + ST Traction and steering
YES 2 0
SPEED speed adjustement
Delay to close the
ADJ ST VALVE DEL YES 5 5
steering valve
Minimum speed for
CREEP PUMP YES 9 2
pump and lifting
PU. ACCELER. DEL YES 5 5
lifting
PU. DECELER DEL YES 4 4
lifting
proportional valve
EV. ACCELER DEL YES 5 5
(not used by Haulotte
Group)
EV. DECELER DEL YES proportional valve 5 5
(not used by HG)
Minimum voltage on
MIN VALVE VOLT YES proportional valve 5 5
(not used by HG)
2420339190 E03.12 73/102
Maximum voltage on
MAX VALVE VOLT YES proportional valve 5 5
(not used by HG)
Intensity limit with micro
AUX CURRENT #1 YES 4 2
speed + steering
Speed difference of
STEER
YES steering right/left and 127 127
CORRECTION
left/right
***ADJUSTMENTS*
Battery voltage Under battery Under battery
ADJUST BATTERY YES
adjustement voltage voltage
Parameters for the
temporisation of 200 (0 with BPE 0 (200 with BPE
TIME UP WAIT YES
overload calibration board Board
when system is installed 2901001750) 2901012820)
Parameters for the
temporisation of 100 (0 with BPE 0 (100 with BPE
TIME UP YV7 YES
overload calibration board Board
Parameters for the
TIME DOWN temporisation of 800 (0 with BPE 0 (800 with
YES
START overload calibration board BPE Board
Parameters for the
temporisation of 400 (0 with BPE 0 (400 with
TIME DOWN YV7 YES
overload calibration board BPE Board
Acquisition time
LOWER DELAY YES 5 5
weighing card
***SET OPTIONS***
Hourmeter : SB1 key
ON=> it's counting
HOUR COUNTER YES RUNNING=> it's RUNNING RUNNING
counting only when
pump is running
Control the discharge of
batteries ( lift is cut if
BATTERY CHECK YES ON ON
batteries are
discharged)
Proportional valve :
AUX FUNCTION 2 YES PRESENT/ABSENT ABSENT ABSENT
(no used by HG)
Buzzer is active during
traction FWD or REV
BUZZER OPTION YES ABSENT ABSENT
(choice PRESENT :
YES /ABSENT : NO)
Buzzer is active for all
BUZZER OPTION movements (choice
YES ABSENT ABSENT
#2 PRESENT : YES
/ABSENT : NO)
Activation for sheduled
CHECK UP maintenance routine
YES OFF OFF
ENABLE check
(no used by H G)

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Manutention routine
CHECK UP DONE YES check done OFF OFF
(no used by H G)
SET BATTERY Selection of battery type
YES 24V 24V
TYPE ( 24V/48V)
Activation of the
scissors arm descent
ON ON
LOWERING BLOCK YES stop when reaching
(version EUR) (version EUR)
SQ1 limit switch (OFF
for AUS)
Validation of the OFF (ON for OFF ( ON for
YES if overload process with calibration calibration
OVER. LEARNING overload lower control box from upper or from upper or
option (Automatically OFF lower control lower control
after reset machine) box) box)
Authorization of sudden
release during an
overload. The operator
can lower the scissor.
SURCH SECU YES Only available with ON ON
weighing card
2901012810 Compact
and 2820 Optimum
Option choice for

flashing light ( from 1 to
4 depends customer's
choice)
FLASHING LIGHT YES #1:Stopped Option #1 Option #1
#2:Traction only
#3:Lift and lower +
traction + steer
#4:All time
***SET MODEL***
Validation for model
OPTION #
OPTION # YES choice (if bad setting : OPTION # 2
1
problem on microspeed)
***SPECIAL ADJUST***
Thermal probe adjustment
SET TEMPERATURE YES Variable Variable
on speed variator unit
Fiedl I max setting on drive
MAXIMUM CURRENT NO motors (not used for
scissors machines)
Overload option (#1
VERSION YES pressure sensor; #2 Option #1 Option #1
overload sensor)
Overload option (#1
OK FOR VERSION YES pressure sensor; #2 Option #1 Option #1
overload sensor)
***HARDWARE SETTING
Impose the maximum
SET COURANT YES current on speed unit 350 A 350 A
variator

2420339190 E03.12 75/102
Maximum correction on
ADJUSTMENT #01 YES discharge battery indicator Level = 5 Level = 5
curve
Minimum correction on
ADJUSTMENT #02 YES discharge battery indicator Level = 5 Level = 5
curve
Habilitation for hours
priority when MDI or
variator has been changed
AUX FUNCTION 1 YES ON ON
(OFF hours from variator
hours /ON hours from
MDI)
Machine in lower
***TESTER*** Machine in lower position
position
Battery voltage reading
Under
(reading between Under battery
BATTERY VOLTAGE NO battery
terminals B+ and B - in voltage
voltage
VOLTS
Voltage on drive motor in
MOTOR VOLTAGE NO 0.0 v 0.0 v
Volts
Current on drive motors in
MOTOR CURRENT NO 0.0 A 0.0 A
Amp
Tension on proportional Between 0 Between 0
EVP VOLTAGE NO
valve and 1V and 1V
Temperature on the speed Under Under outside
TEMPERATURE NO
unit variator in °C outside T° T°
Joystick signal in Volts and
% (display is at 5,00V
maxi only if joystick handle
ACCELERATOR NO is pushed without trigger 0.00 v / 0% 0.00 v / 0%
and 100% if joystick
trigger is pushed) in both
ways
FWD movement when
FORWARD SWITCH NO joystick is pushed forward OFF GND OFF GND
(ON/OFF)
REV movement when
BACKWARD SWITCH NO joystick is pulled OFF GND OFF GND
backwards (ON/OFF)
Emergency stop button
ENABLE SWITCH NO ON ON
SB2
Speed reduction SA3 ,
CUTBACK SWITCH NO ON ON
ON / OFF
Lift demand (SA3 + push
LIFTING SWITCH NO on joystick without trigger) OFF GND OFF GND
ON / OFF
Descent demand (SA3 +
DESCENT SWITCH NO pull on joystick without OFF GND OFF GND
trigger) ON / OFF
Limit switch SQ3 for lift
STOP UP SWITCH NO OFF GND OFF GND
stop , ON / OFF
Limit switch SQ1 for low
STOP DOWN SWITCH NO detection and high speed ON ON
cut, ON / OFF

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Limit switch SQ4 for 8 m
8M BLOCK SWITCH NO height detection for drive OFF GND OFF GND
cut ON / OFF ( only C12 )
Pothole ( stabilisers) SQ5 -
SIDES GATES NO ON ON
SQ6 , ON /OFF
Right steering switch on
RIGHT STEER SW NO OFF GND OFF GND
joystick, ON / OFF
Left steering switch on
LEFT STEER SW NO OFF GND OFF GND
joystick, ON / OFF
Pressure switch input SP1
PRESSURE SWITCH NO ON / OFF ( if overload OFF GND OFF GND
system is not installed)
Slope sensor input SQ10,
INCLINAISON SW NO OFF GND OFF GND
ON / OFF
Joystick trigger
DEADMAN NO OFF GND OFF GND
HM ON / OFF
Under
Under battery
BATTERY CHARGE NO Battery charge indicator battery
charge
in % charge

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• Machines settings EP V1.31 (only for US,CDN)
(For machines with versions < EPV1.31, refer to TN142)
Values for Values for

Change
COMPACT OPTIMUM
PARAMETERS paramete DESCRIPTION
(Model type (Model type
rs
#1) #2)
***PARAMETRE
CHANGE***
ACCELER. DELAY YES 4 9
traction
DECELER. DELAY YES 4 0
traction
Speed reduction
CUTBACK SPEED YES 2 9
(microspeed)
Minimum speed for
CREEP SPEED YES 2 3
traction
Maximum speed for
MAX SPEED FORW YES 9 7
traction (FWD)
Maximum speed for
MAX SPEED BACK YES 9 7
traction (REV)
battery voltage and
COMPENSATION YES 7 7
value read by the
speed variator unit
Maximum current on
TRACTION IMAX YES 9 9
traction motors
1ST SPEED COARSE YES Lifting speed 9 9
1ST SPEED COMP YES the lift speed and load 5 5
on platform
STEERING SPEED YES Steering speed 4 5
Traction and steering
ADJ TR + ST SPEED YES 2 0
speed adjustement
Delay to close the
ADJ ST VALVE DEL YES 5 5
steering valve
Minimum speed for
CREEP PUMP YES 9 2
pump and lifting
PU. ACCELER. DEL YES 5 5
lifting
PU. DECELER DEL YES 4 4
lifting
proportional valve
EV. ACCELER DEL YES 5 5
(not used by Haulotte
Group)
EV. DECELER DEL YES proportional valve 5 5
(not used by HG)
Minimum voltage on
MIN VALVE VOLT YES proportional valve 5 5
(not used by HG)
Maximum voltage on
MAX VALVE VOLT YES proportional valve 5 5
(not used by HG)
2420339190 E03.12 78/102
Intensity limit with
AUX CURRENT #1 YES 4 2
micro speed + steering
***ADJUSTMENTS***
Battery voltage Under battery Under battery
ADJUST BATTERY YES
adjustement voltage voltage
***SET OPTIONS***
Hourmeter : SB1 key
ON=> it's counting
HOUR COUNTER YES RUNNING=> it's RUNNING RUNNING
counting only when
pump is running
Control the discharge
of batteries ( lift is cut if
BATTERY CHECK YES ON ON
batteries are
discharged)
Proportional valve :
AUX FUNCTION 2 YES PRESENT/ABSENT ABSENT ABSENT
(not used by HG)
Buzzer is active during
traction FWD or REV
BUZZER OPTION YES ABSENT ABSENT
(choice PRESENT :
YES /ABSENT : NO)
Buzzer is active for all
movements (choice
BUZZER OPTION #2 YES ABSENT ABSENT
PRESENT : YES
/ABSENT : NO)
Activation for sheduled
maintenance routine
CHECK UP ENABLE YES OFF OFF
check
(not used by HG)
Manutention routine
CHECK UP DONE YES check done OFF OFF
(not used by HG)
Selection of battery
SET BATTERY TYPE YES 24V 24V
type ( 24V/48V)
Activation of the
scissors arm descent
OFF (US OFF (US
LOWERING BLOCK YES stop when reaching
version) version)
SQ1 limit switch (OFF
for AUS)
Validation for CANADA
regulations (slope
YES OFF OFF
activated , no overload)
OPT CANADA for US version is OFF
Option choice for
flashing light ( from 1 to
4 depends customer's
choice)
FLASHING LIGHT YES #1:Stopped Option #1 Option #1
#2:Traction only
#3:Lift and lower +
traction + steering
#4:All time

2420339190 E03.12 79/102
***SET MODEL***
Validation for model
OPTION # YES choice ( if bad setting : OPTION # 1 OPTION # 2
problem on microspeed)
***SPECIAL ADJUST***
Thermal probe
SET TEMPERATURE YES adjustment on speed Variable Variable
variator unit
Field I max setting on
MAXIMUM CURRENT NO drive motors (not used
for scissors machines)
***HARDWARE
SETTING***
Impose the maximum
SET COURANT YES current on speed unit 350 A 350 A
variator
Maximum correction on
ADJUSTMENT #01 YES discharge battery Level = 5 Level = 5
indicator curve
Minimum correction on
ADJUSTMENT #02 YES discharge battery Level = 5 Level = 5
indicator curve
Habilitation for hours
priority when MDI or
variator has been
AUX FUNCTION 1 YES ON ON
changed (OFF hours
from variator hours /ON
hours from MDI)
Machine in lower
***TESTER*** Machine in lower position
position
Battery voltage reading
Under
( reading between Under battery
BATTERY VOLTAGE NO battery
terminals B+ and B - in voltage
voltage
VOLTS
Voltage on drive motor in
MOTOR VOLTAGE NO 0.0 v 0.0 v
Volts
Current on drive motors
MOTOR CURRENT NO 0.0 A 0.0 A
in Amp
Tension on proportional Between 0 and Between 0
EVP VOLTAGE NO
valve 1V and 1V
Temperature on the Under outside Under
TEMPERATURE NO
speed unit variator in °C T° outside T°
Joystick signal in Volts
and % (display is at
5,00V maxi only if
ACCELERATOR NO joystick handle is pushed 0.00 v / 0% 0.00 v / 0%
without trigger and 100%
if joystick trigger is
pushed) in both ways
FWD movement when
FORWARD SWITCH NO joystick is pushed OFF GND OFF GND
(ON/OFF)
REV movement when
BACKWARD SWITCH NO joystick is pulled OFF GND OFF GND
(ON/OFF)
2420339190 E03.12 80/102
Emergency stop button
ENABLE SWITCH NO ON ON
SB2
Speed reduction SA3 ,
CUTBACK SWITCH NO ON ON
ON / OFF
Lift demand (SA3 +
LIFTING SWITCH NO push on joystick without OFF GND OFF GND
trigger) ON / OFF
Descent demand (SA3
DESCENT SWITCH NO + pull on joystick without OFF GND OFF GND
trigger) ON / OFF
Limit switch SQ3 for lift
STOP UP SWITCH NO OFF GND OFF GND
stop , ON / OFF
Limit switch SQ1 for low
STOP DOWN SWITCH NO detection and high ON ON
speed cut, ON / OFF
Limit switch SQ4 for 8 m
height detection for drive
8M BLOCK SWITCH NO OFF GND OFF GND
cut ON / OFF
( only C12 )
Pothole ( stabilisers)
SIDES GATES NO ON ON
SQ5 - SQ6 , ON /OFF
Right steering switch on
RIGHT STEER SW NO OFF GND OFF GND
joystick, ON / OFF
Left steering switch on
LEFT STEER SW NO OFF GND OFF GND
joystick, ON / OFF
Pressure switch input
SP1 ON / OFF ( if
PRESSURE SWITCH NO OFF GND OFF GND
overload system is not
installed)
Slope sensor input
INCLINAISON SW NO OFF GND OFF GND
SQ10, ON / OFF
Joystick trigger
DEADMAN NO OFF GND OFF GND
HM ON / OFF
Under
Under battery
BATTERY CHARGE NO Battery charge indicator battery
charge
in % charge

2420339190 E03.12 81/102
4.7. THE SYSTEM OF LOAD CONTROL
4.7.1.PRINCIPLE
the potentiometric sensor measures the relative angle of a moving part compared to the structure
on which it is fixed
the potentiometer axle follows the movement of the scissors arms and delivers a signal
proportional to the position of the platform.
so the pressure is representative of load on platform, the lift cylinder should never be at full
mechanical stroke
the stroke of this cylinder is thus limited by 2 electric stops (position retracted - position
extended)
this information is sent to the variable speed unit via 2 relays located in the BPE weighing board
4.7.2.CONNECTION OF THE BPE CONSOLE

2420339190 E03.12 82/102
4.7.3. CALIBRATION OF LOAD MANAGEMENT SYSTEM (VALID FOR COMPACT 14)
(check TN092 depends on the version of your machine and the variator EPROM )
• put the load at the center of the platform ( value depends on the model)
Check that overload parameters are correctly set according to the model , type of BPE boad and
type of EPROM version ( for mode details see below and ask to HAULOTTE Services of your area
in order to get the technical note TN092)

2420339190 E03.12 83/102
• Calibration process ( for C14 )
Note : during all the calibration , the toggle switch for upper/lower control box selection
must not be released ( hold it with a tie wrap for example)
Adjustment limit switch SQ3
In case the limit switch has been removed for calibration , it must be readjusted:
Put scissors full UP and adjust to regulate the height compared to the ground (see values on
following table according to the model)
OPT6 OPT8 C8- C8W C10 C10N C12 C14

4.23 + 0.15 5.8 + 0.15 6.15 + 0.15 8,015 + 8.05 + 0.15 9.90 + 0.05 11.82 + 0.02
m m m 0.15 m m m
• Note: any change of component in the weighing circuit automatically involves the
cancellation of the calibration of weighing made before
4.7.4.CODE ALARMS WEIGHING BOARD

The board has alarms code via 3 LEDS:
D9

2420339190 E03.12 84/102
Green LED D19: Error on analogical input
Nb of
DESCRIPTION
flashes
0 No error
1 Error line pressure sensor
2 Error line angle sensor
3 Value of too low pressure
4 Too low value of angle
5 Inactive
6 Value of too high pressure at angle 0
7 Inactive
Orange LED D21: Board error
Nb of
DESCRIPTION
flashes
0 No error
1 Loss of communication between microprocessors
2 Error on test of control on inputs
Error on the polarity of connections to the relays
3 (check J4.4 and J4.6 even J4.1 tension)
4 Inactive
5 Loss of communication micro/memory
LED D20 red: State of the calibration

State DESCRIPTION
Extinct calibration validated
Flickering Calibration not carried out or procedure not OK
Continuous Calibration in progress
4.7.5.CONTROL I/O BOARD BPE

• Control state of supply of the board
Measure on weighing board

with machine powered voltage D9 light
Between J4.1 and J4.2 24V ON
• Control BPE outputs
In order to measure the outputs the solution is to measure the voltage on terminals J4.3 and J4.5
When the contacts are closed
Between J4.3 and J4.2 (-) voltage of +24 V
Between J4.5 and J4.2 (-) voltage of +24 V
J4.3 J4.5 DESCRIPTION
OPEN OPEN In overload , no drive , no lift , no steering
OPEN CLOSED In overload , no drive , no lift , no steering
CLOSED OPEN Overload on extension , lift OK but no drive, no
steering
CLOSED CLOSED Normal , lift and drive OK

2420339190 E03.12 85/102
Control of the analogical inputs
• Pressure sensor G1
Measure pressure sensor Voltage
Between J11.1 and J4.2 24V
Between 0 and 5 V
Between J11.3 and J4.2 according to the pressure
• Angle sensor A1
Measure angle sensor Value

Between J15.1 and J15.2 board BPE 24V
Between 0,5V and 4.5 V
for an angle of 120°
Between J15.2 and J15.3 of board Low position ~ 3.44VDC
BPE mini/maximum range Higher position ~ 1.38VDC
• Table value according to the pressure in G1

2420339190 E03.12 86/102
• Pin location for sensors check

2420339190 E03.12 87/102
5. BREAKDOWN SERVICE GUIDE
This guide does not replace the logical equations described previously in this manual,
it allows the technician to have a logical step of breakdown service, detailing the successive step to
be followed starting from the main point until the detail.
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 machine of reference is Compact 14, the other models are relatively similar
All fuses have been checked, all movements described below implies both ways ( ex UP/DOWN)
5.1. NO START
• Batteries (GB1)
• Buttons emergency stops SB1 and/or SB2
• Key SA1 selector
• Relay charger RCH
• U2 variable speed unit/serial card
5.2. NO LIFT
(if PF < SQ1)
• Sélecteur SA3 upper control box
• Limit swich SQ3
• joystick SM1 (off neutral and/or signal)
• Electrovalve YV1If PF > SQ1
• Sélecteur SA3 upper control box
• Limit swich SQ3
• Anti-tipping over devices /potholes SQ5 – SQ6
• Machine in slope (SQ10 = 0)
• Electrovalves YV1 – YV6
• Pressure switch SP1 (if not equipped with BPE weighing board)
• Sensors of weighing A1 – G1 (signal)
• weighing board BPE (U5)
• overload calibration not carried out
• Pressure relief valve RV3
• Lifting cylinder
5.3. NO DESCENT
• Electrovalves YV6 – YV7 (+ YV8 if > C12)
• Limit swich SQ3

2420339190 E03.12 88/102
5.4. NO DRIVE
• Selection SA3 upper control box
• Electrovalve YV2 + (YV3 – YV4 for HS)
• Limit swich SQ1 (for going in Low Speed)
• Limit swich SQ4 (if machine equipped)
• Brake blocked (open knob NV2)
• Pressure relief valve general RV2
• Defective flow control valve FRT
• Defective counterbalance valves CB1-CB2
• Defective flow divider FD1
• Drive motors
5.5. NO STEERING
• joystick SM1 (rocker)
• Electrovalve YV5
• Pressure relief valve RV1
• Priority valve FRT
• Steering cylinder

2420339190 E03.12 89/102
6. SUMMARY OF THE VERSIONS
Hydraulic
Compact – Optimum Country Wiring diagram
diagram
E501
Compact 8/10 (until July 2003) ALL Variable speed unit B15785
244 220 1730
ALL E501
Compact 12 (until July 2003) Variable speed unit B16188
244 220 1730
ALL E591
Compact 8/10 (until September 2005) Variable speed unit B16187
244 220 1920
ALL E591
Compact 12 (until September 2005) Variable speed unit B15940
244 220 1920
ALL E614
Compact 8/10 121P251510
Version weighing
ALL E614F
Compact 12 121P251530
Version weighing
ALL E614G
Compact 14 167P326860
Version weighing
Compact 14 equipped with PWM valve
Hydraulic blocks Comments Code

Head of the valves equipped
Block MK2 (until March 2003) 242 020 9290
with LED
Head of the valves not
Block MK3 (until July 2003) equipped with LED but 242 021 0470
separate coils
Block MK4 Loom of valves with wires in 242 021 2090
Block MK4 Weighing color 242 021 2090
Block MK5
Block identical to the MK4
(starting from the serial number CE 250 300 2330
(smaller size)
139454)
Identical block with different
location for certain components
Block MK6
and CB different settings 250 300 3980
(for C14)
(compatible to all compact
models)

2420339190 E03.12 90/102
7. SENSORS MOUNTING INSTRUCTIONS
7.1. PRESSURE SWITCH SP1
All models equipped with pressure switch
7.2. PRESSURE SENSOR G1

It must be tight with torque wrench (30-35Nm)

2420339190 E03.12 91/102
7.3. ANGLE SENSOR A1
Be sure that the pin is correctly mounted on its bracket (see below)
Fix on plate (the screws should be in the center of the oblong holes)
(when the bracket of the angle sensor is aligned , the signal should be at 2.5VDC
( if < 0.5 or > 4.5V alarm comes on BPE board) )

2420339190 E03.12 92/102
7.4. VARIATOR PPC IMPEDANCE CHECK
Before any impedance control, remove all connections to the variator
TERMINALS TERMINALS IMPEDANCE VALUE

B -- B+ Measure not stable (impossible to read)
B -- P 47.4 KΩ
B+ B- Measure not stable (impossible to read)
B+ P Measure not stable (impossible to read)

2420339190 E03.12 93/102
7.5. NEW LEVEL SENSOR ADJUSTMENT
Some machines are now equipped with that kind of level sensors (OPTIMUM machine serial
number > CE145227)
On that kind of sensor, an adjustment must be done
• Procedure
• Position the machine on a perfect flat ground
• Switch ON the machine (Red and green LEDs will be lit or flashing)
• Press and hold the button “SET ZERO” during 3 seconds (both LEDs will be OFF)
• Red and Green LEDs will now flash. Launch the calibration within 5 seconds
• Press (and release) 3 times the button with a small plastic pen
• The calibration program is now in process for approximately 4 seconds (red LED blinking)
• After, the green LED will turn on solid, indicating unit is calibrated and unit is ready for
normal operation

2420339190 E03.12 94/102
7.6. COMPACT EQUIPPED WITH PWM VALVE
pending

2420339190 E03.12 95/102
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2420339190 E03.12 99/102
2420339190 E03.12 100/102
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2420339190 E03.12 102/102

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TECHNICAL TRAINING

All Compact - Optimum

Chapter 1: Main features and functions

Chapter 2: Study of the wiring schematics

Chapter 3: Study of the hydraulic schematics

Chapter 5: Guide of breakdown

Chapter 6: Summary of the versions

Chapter 7: Special functions

TRAINING MANUAL DIAGNOSTIC Level 2 All Electric Compact – Optimum

TRAINING MANUAL DIAGNOSTIC Level 2 All Electric Compact – Optimum

6. SUMMARY OF THE VERSIONS ....................................................................................................................... 90

TRAINING MANUAL DIAGNOSTIC Level 2 All Electric Compact – Optimum

TRAINING MANUAL DIAGNOSTIC Level 2 All Electric Compact – Optimum

TRAINING MANUAL DIAGNOSTIC Level 2 All Electric Compact – Optimum

TRAINING MANUAL DIAGNOSTIC Level 2 All Electric Compact – Optimum

TRAINING MANUAL DIAGNOSTIC Level 2 All Electric Compact – Optimum

TRAINING MANUAL DIAGNOSTIC Level 2 All Electric Compact – Optimum

Battery with one element

Fuse (Here 10 amps)

Coil winding roll

TRAINING MANUAL DIAGNOSTIC Level 2 All Electric Compact – Optimum

Standard push-button of safety “mushroom-headed

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

Toggle switch with 2 positions

TRAINING MANUAL DIAGNOSTIC Level 2 All Electric Compact – Optimum

Pedals “dead man” or “foot dead man” switch

Electrovalve “ON/OFF » ( bang-bang)

TRAINING MANUAL DIAGNOSTIC Level 2 All Electric Compact – Optimum

Angle sensor (reach limitation)

Contact « mercury » (angle detection)

Sensor length (reach limitation)

Pressure sensor (weighing)

Angle sensor (weighing)

TRAINING MANUAL DIAGNOSTIC Level 2 All Electric Compact – Optimum

Flexible Lame switch (ILS) detection of the magnets on

Level fuel detector (diesel tank)

Proximity detector with impulses (detection teeth slew

TRAINING MANUAL DIAGNOSTIC Level 2 All Electric Compact – Optimum

2.2.1. ELECTRIC CONTINUITY CONTROL

TRAINING MANUAL DIAGNOSTIC Level 2 All Electric Compact – Optimum

Control intensity of the coil

TRAINING MANUAL DIAGNOSTIC Level 2 All Electric Compact – Optimum

2.2.3. CONTROL OF COMPONENTS

• Control of an electric relay

• supply control of the relay

TRAINING MANUAL DIAGNOSTIC Level 2 All Electric Compact – Optimum

TRAINING MANUAL DIAGNOSTIC Level 2 All Electric Compact – Optimum

TRAINING MANUAL DIAGNOSTIC Level 2 All Electric Compact – Optimum

Variable speed unit Plug socket of variable speed unit

Terminal wire Terminal wire Terminal wire

2.4.2.THE SERIAL BOARD

TRAINING MANUAL DIAGNOSTIC Level 2 All Electric Compact – Optimum

Compact all models

(if overload option installed)

TRAINING MANUAL DIAGNOSTIC Level 2 All Electric Compact – Optimum

TRAINING MANUAL DIAGNOSTIC Level 2 All Electric Compact – Optimum

TRAINING MANUAL DIAGNOSTIC Level 2 All Electric Compact – Optimum

SB 1 01 -2 Emergency stop chassis (2)