MF COMPACT-OPT RTE EN E07.13

TECHNICAL TRAINING
DIAGNOSTIC LEVEL II
All Compact – Optimum

Compact RTE
How to use this document?
MAINTENANCE AND REPAIR OPERATIONS ON YOUR HAULOTTE MACHINE
MUST BE DONE ONLY BY TRAINED, EXPERIENCED AND AUTHORIZED TECHNICIANS
You have between the hands the summary given during the HAULOTTE technical training .
It will enable you to find information necessary for the maintenance and the repair of your
HAULOTTE machine.
Thanks to the guide below you will reach the required chapter quickly.
Chapter 1: Main features and functions
It is a resume of the information contained in the user manual delivered with the machine:
components, overall dimensions, working zones, commands, etc…
Chapter 2: Study of the 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 main safety units (tilt , limit switches, sensors,transducers…)
- Logical equations of operation: by function, to diagnose the main dysfunctions
Chapter 3: Study of the hydraulic schematics
You will find there the elements following:
- a summary of the standardized symbols used by HAULOTTE Group
- the complete hydraulic diagram of the studied model
- the non exhaustive list of the hoses track
- a localization of the main hydraulics manifold (proportional block , on/off movements block,)
Chapter 4: Adjustments
This is the adjustments and calibrations, hydraulics and electric, necessary for 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 specific adjustment in order 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.
Chapter 8: Compact RTE
This chapter treats on C10RTEompact 10 and 12RTE newest models equipped with node B2
module and outriggers.
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. ELECTRICAL PART ........................................................................................................................................... 22
2.1. SYMBOLS USED ................................................................................................................................................ 22
2.2. METHODOLOGY OF CONTROL........................................................................................................................... 26
2.2.1. electric continuity control....................................................................................................................... 26
2.2.2. Control of an on/off valve ....................................................................................................................... 26
2.2.3. Control of components ........................................................................................................................... 27
2.3. THE WIRING SCHEMATICS ................................................................................................................................ 29
2.4. LOOMS ............................................................................................................................................................. 30
2.4.1. variator connector .................................................................................................................................. 30
2.4.2. the serial card ......................................................................................................................................... 31
2.5. LOCALIZATION OF THE MAIN SAFETY COMPONENTS ........................................................................................ 32
2.6. LIST OF COMPONENTS (DIAGRAM E 614G) ....................................................................................................... 35
2.6.1. Fuses....................................................................................................................................................... 35
2.6.2. inputs ...................................................................................................................................................... 35
2.6.3. Outputs ................................................................................................................................................... 36
2.6.4. Others devices ........................................................................................................................................ 37
2.7. LOGICAL EQUATIONS OF OPERATION................................................................................................................ 38
2.7.1. Powering ................................................................................................................................................ 38
2.7.2. Steering ................................................................................................................................................... 38
2.7.3. drive ........................................................................................................................................................ 38
2.7.4. mast ........................................................................................................................................................ 39
2.7.5. options usa .............................................................................................................................................. 40
2.7.6. options australia ..................................................................................................................................... 40
2.7.7. options canada ....................................................................................................................................... 40
2.8. CODES ALARMS................................................................................................................................................ 41
3. THE HYDRAULIC PART .................................................................................................................................... 44
3.1. SYMBOLS USED ................................................................................................................................................ 44
3.2. DETAILS OF HYDRAULIC BLOCK MK5 .............................................................................................................. 48
3.3. DETAILS OF HYDRAULIC BLOCK MK6 .............................................................................................................. 51
4. ADJUSTMENTS .................................................................................................................................................... 53
4.1. ADJUSTMENT OF PRESSURES ............................................................................................................................ 53
4.1.1. Table of pressures................................................................................................................................... 53
4.1.2. Procedure for pressures adjustment ....................................................................................................... 54
4.1.3. overload adjustment pressure switch sp1 ............................................................................................... 57
4.2. SPEEDS ............................................................................................................................................................. 57
4.3. BATTERYCHARGER ........................................................................................................................................... 58
4.4. THE MDI .......................................................................................................................................................... 60
4.4.1. function 1 ................................................................................................................................................ 60
4.4.2. function 2 ................................................................................................................................................ 60
4.5. ZAPI CALIBRATOR...................................................................................................................................... 61
4.5.1. connection console ................................................................................................................................. 61
4.5.2. description of the console ....................................................................................................................... 62
4.6. ALARMS CODES ................................................................................................................................................ 66
4.7. PARAMETERS ZAPI .......................................................................................................................................... 70
4.8. THE SYSTEM OF LOAD CONTROL ....................................................................................................................... 79
4.8.1. principle.................................................................................................................................................. 79
4.8.2. connection of the bpe console ................................................................................................................. 79
4.8.3. calibration of load management system (valid for c14) ......................................................................... 80
4.8.4. code alarms weighing board .................................................................................................................. 81

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4.8.5. control i/o board bpe .............................................................................................................................. 82
5. BREAKDOWN SERVICE GUIDE ...................................................................................................................... 85
5.1. NO START......................................................................................................................................................... 85
5.2. NO LIFT ............................................................................................................................................................ 85
5.3. NO DESCENT ..................................................................................................................................................... 85
5.4. NO DRIVE ......................................................................................................................................................... 86
5.5. NO STEERING .................................................................................................................................................... 86
6. SUMMARY OF THE VERSIONS ....................................................................................................................... 87

7. SENSORS MOUNTING INSTRUCTIONS ........................................................................................................ 88
7.1. PRESSURE SWITCH SP1 .................................................................................................................................... 88
7.2. PRESSURE SENSOR G1 ...................................................................................................................................... 88
7.3. ANGLE SENSOR A1 ........................................................................................................................................... 89
7.4. VARIATOR PPC IMPEDANCE CHECK ................................................................................................................... 90
7.5. NEW LEVEL SENSOR ADJUSTMENT .................................................................................................................... 91
7.6. COMPACT EQUIPPED WITH PWM VALVE ............................................................................................................ 92
8. COMPACT RTE .................................................................................................................................................... 93

8.1. MAIN DATAS .................................................................................................................................................... 93
8.1.1. main components .................................................................................................................................... 93
8.1.2. overall dimensions .................................................................................................................................. 94
8.1.3. Working area .......................................................................................................................................... 95
8.1.4. Working area .......................................................................................................................................... 96
8.1.5. main datas .............................................................................................................................................. 97
8.1.6. Commands (Up/Down) ........................................................................................................................... 99
8.2. THE WIRING SCHEMATICS .............................................................................................................................. 102
8.2.1. location of main items .......................................................................................................................... 102
8.3. LOCALIZATION OF THE MAIN SAFETY COMPONENTS ...................................................................................... 106
8.4. STRUCTURE OF THE SYSTEM .......................................................................................................................... 107
8.5. LIST OF COMPONENTS (SCHEMATICS 129P318500) ........................................................................................ 108
8.5.1. Fuses..................................................................................................................................................... 108
8.5.2. inputs .................................................................................................................................................... 109
8.5.3. Outputs ................................................................................................................................................. 111
8.5.4. Others ................................................................................................................................................... 112
8.6. HYDRAULIC BLOCKS....................................................................................................................................... 113
8.6.1. location of components ......................................................................................................................... 117
8.6.2. pressure adjustment .............................................................................................................................. 118
8.6.3. Outriggers ............................................................................................................................................ 119
8.7. ADJUSTMENTS WITH CONSOLES ...................................................................................................................... 120
8.7.1. console optimizer .................................................................................................................................. 120
8.7.2. list of the optimizer menu...................................................................................................................... 123
8.7.3. overload calibration ............................................................................................................................. 126
8.7.4. outriggers setting .................................................................................................................................. 130
8.7.5. console sevcon can calibrator .............................................................................................................. 131
8.7.6. How to scroll through the parameters .................................................................................................. 132
8.7.7. list of sevcon parameters ...................................................................................................................... 133
8.7.8. i/o board led fault code indicator ......................................................................................................... 137
8.7.9. dip switch setting .................................................................................................................................. 138
8.7.10. Slope 2 ways adjustment ....................................................................................................................... 139
8.7.11. Strain gauges replacement ................................................................................................................... 140
8.8. TROUBLE SHOOTING GUIDE ............................................................................................................................ 141
8.8.1. Logic equations .................................................................................................................................... 141
8.8.2. lifting/descent mode .............................................................................................................................. 141
8.8.3. Drive/steering ....................................................................................................................................... 142

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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. ELECTRICAL PART
2.1. SYMBOLS USED
Battery with one element
Alternator
Fuse (Here 10 amps)
Coil winding roll
Electric motor
light
Diode
Hourmeter
Standard push-button of safety “mushroom-headed

button”

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

platform)
Toggle switch with 2 positions
Electrovalve
relay
horn
Proportional electrovalve

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Proportional valve PWM type ( Pulse Width Modulation)
Controller/joysticks
Pedals “dead man” or “foot dead man” switch
buzzer
“light”
Electrovalve “ON/OFF » ( bang-bang)
Tilt sensor ( ramp detection)
Angle sensor (reach limitation)
Contact « mercury » (angle detection)

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Resistor
(here value 100 ohms, 3 Watts, tolerance of 5%)
Sensor length (reach limitation)
Pressure sensor (weighing)
Angle sensor (weighing)
Standard light “Led”
Strain gauge
Flexible 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 : ∞
2.2.2. CONTROL OF AN ON/OFF VALVE

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

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

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

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

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

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• Control of a fuse
Color code
Fuse check
Multimeter in Ω position, it must indicate a value near 0
NOK
OK
• Control of a diode
locate the diode and disconnect it from the loom.
Control must be done with a multimeter in “diode” position.
connect the multimeter on each terminal of the diode, in one direction then on the
other.
In one direction, the diode should have no continuity,
in the other it must beep
If the diode is beeping in both ways, replace it.
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
Detail of plug in the 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 valve YV8 31 46 Signal hour
command on C12 recorder
descent YV7
4 9 Input + 18 25 valve 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
YV2B REV of drive stop
drive
9 19 Output 23 49 Signal MDI 37 14 Command
commandeYV2 raise frame
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 CARD

• 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 (except C14)
(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
U1
01 -4 Battery charger
U2
01.-15 Electronic variable speed unit/chopper/variator
U4
01.-18 Serial card upper control box
U5
01.-14 BPE weighing card
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 Anti-tipping device (32 + 33 = 0 if potholes ( side gates) are IN
01 - 18
SQ10
01 - 9 Slope detection (12 = 0 if in slope)
SP1 Overload pressure controller (28) if option weighing not installed
01.-15
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 DEVICES
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 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 Modifyin
Prohibiting
Necessary g 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
Function Action Modifyin
Prohibiting
Necessary g 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
Function Action Modifying
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
between 2.5 and 0.5 V
+ YV6=0 and/or G1 out of
range if option
installed
2.7.4.MAST
CONDITIONS
Function Action Modifying
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
SA1 (side PF) + HM=1 + or sensors of
Descent upper + YV9=1
SM1b=1 + SA3=1 + SM1 weighing A1
controls + YV8=1 if C12
between 2.5 and 0.5 V and/or G1 out of
or C14
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)
SP1=1
+ YV7=1 (or sensors of
Descent lower + YV9=1 weighing A1
SA1 (CH side) + SA2=1
controls + YV8=1 if C12 and/or G1 out of
or C14 range if option
installed)

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2.7.5.OPTIONS USA
Sound alarm only on ramp
No stop the 3 seconds on anti-crashing system with the level of SQ1
(option LOWERING BLOCK at OFF but audible signal only)
Sound alarm only if machine is in overload and tilt
2.7.6.OPTIONS AUSTRALIA
Overload and tilt stop movement if PF > 3m
2.7.7.OPTIONS CANADA
Probit in Tilt option for overload detection
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

2420339190 E07.13 41/159
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 E07.13 42/159
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. THE HYDRAULIC PART
3.1. SYMBOLS USED
Pump with variable cc 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)
check valve

2420339190 E07.13 44/159
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)
Fixed flow restrictor or spray nozzle

(here diameter of 0.75 mm)
Adjustable flow restrictor + check valve

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Pressure sensor (used for weighing)
Adjustable pressure switch

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

opposite line (here set at 210bars)
Position valve proportional 5/3 with piloting manual

by lever
Rotary cylinder /jack (here range at 180°)
Piloted valve

2420339190 E07.13 46/159
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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LABEL
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 E07.13 49/159
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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4. ADJUSTMENTS
4.1. ADJUSTMENT OF PRESSURES
Note: for all the adjustments of time and pressure, the oil temperature 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
Machine type
Nominal Load Main hydraulic Steering
pressure (bars) pressure
H8SN
External 120kg 200b 150b
Internal : 350kg
H8W
Internal : 450kg
H10S
Internal : 350kg
H10N
Internal : 230kg 220b 150b
H12SN
Internal : 300kg
H14SN
Internal : 300kg
OPT6
Internal : 270kg
OPT8
Internal : 230kg 230b 100b
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 E07.13 54/159
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 E07.13 55/159
• 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. BATTERYCHARGER

2420339190 E07.13 58/159
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. THE MDI
The MDI (Multi Display indicator) has many functions
4.4.1.FUNCTION 1
4.4.2.FUNCTION 2
EPxx each time power is ON, the MDI shows

the type of EEPROM in variator
EPxx
ALxx

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

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4.5.2.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 E07.13 63/159
TRIPLAT CO 2.00
24V 300A 0000
CONFIG MENU
SET MODEL
CONFIG MENU
SET OPTION
ADJUSTMENT

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ALARM
CLEAR EEPROM
SPECIAL ADJUSTMENT
READ RAM
HARDWARE SETTINGS
READ EEPROM
CLEAR CONSOLE

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4.6. 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 E07.13 66/159
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
microprocessor can open
CONTACTOR
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 E07.13 67/159
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 E07.13 68/159
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)

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4.7. PARAMETERS ZAPI
• Machines settings for all standard version EP V2.25 (except US,CDN)
(For machines with version < EP V2.25, refer to TN142)
Values for Values for

Change
PARAMETERS DESCRIPTION COMPACT OPTIMUM
parameters
(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 E07.13 70/159
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 E07.13 72/159
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)
***TESTER*** Machine in lower 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
Limit switch SQ4 for 8 m
8M BLOCK SWITCH NO height detection for drive OFF GND OFF GND
cut ON / OFF ( only C12 )
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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 DESCRIPTION
parameters (Model type (Model type
#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)
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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

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***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)
***TESTER*** Machine in lower 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)
Emergency stop button
ENABLE SWITCH NO ON ON
SB2
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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

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4.8. THE SYSTEM OF LOAD CONTROL
4.8.1.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
4.8.2.CONNECTION OF THE BPE CONSOLE
Console (part number 2440309320)

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4.8.3. CALIBRATION OF LOAD MANAGEMENT SYSTEM (VALID FOR C14)
NOTE :Check TN092 depends on the version of your machine and the variator EEPROM
as the way to calibrate the machine might vary from one model to the other one
• 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)

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• 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)
• Put the key switch on CH position ( try to hold it)
• Connect the BPE console on J14
• With ZAPI console, scroll for Menu SET OPTION/parameter OVERLEARNING and put
it at ON
• Press and hold the red pushbutton on console at least 3 sec (led SW2 lit ON then
green led is flashing) , a beep will sound in order to confirm it
• Lift the PF until the highest position, the machine will lift step by step (depends of the
version)
• Maintain the lifting switch at least during 3 seconds ( the pump must stop running)
• Lower the PF until its lowest position (the buzzer should beep when reaching SQ1)
and hold the command for at least 3 seconds
• Lift again the platform ( no stop)
• Once the highest position is reached , hold the command for 3 seconds
• Lower the platform until the lowest position ( the red led SW2 on console should be
OFF)
• Calibration is done (if red led SW2 is not OFF or it’s flashing , the calibration has not
been done correctly and the full process must be done again
• If OK switch OFF the machine and remove the BPE console
Adjustment limit switch SQ3
In case the limit switch has been removed for calibratio , 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
4.8.4.CODE ALARMS WEIGHING BOARD

The board has alarms code via 3 LEDS:
D9

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Green LED D19: Error on analogical input
Nb of flashes DESCRIPTION
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 flashes DESCRIPTION
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
4.8.5.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 E07.13 82/159
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 5V
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

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• Pin location for sensors check

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5. BREAKDOWN SERVICE GUIDE
This guide does not replace the logical equations described previously in this manual,
it allows the technician to have a logical step of breakdown service, detailing the successive 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

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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

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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
Compact 8/10 ALL E614 121P251510
C8/C10 with new pump unit and drive Version with overload
4000022940
motors (300cc) management system
Compact 12 ALL E614F 121P251530
Version with overload
C12 with new pump unit 4000019180
management system
ALL E614G
Compact 14 Version with overload 167P326860
management system
Compact 14 equipped with PWM valve Pending
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)

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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 E07.13 88/159
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) )

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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)

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7.5. NEW LEVEL SENSOR ADJUSTMENT
Some machines are now equipped with that kind of level sensors
(Optimum w/serial number >CE145227 + all Optimum w/serial number starting by CE5xxxxx
produced in Archbold(OH) and Optimum w/serial number starting by 8xxxxx produced in Changzhou
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

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7.6. COMPACT EQUIPPED WITH PWM VALVE
pending

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8. COMPACT RTE
8.1. MAIN DATAS
8.1.1.MAIN COMPONENTS

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8.1.2.OVERALL DIMENSIONS

2420339190 E07.13 94/159
8.1.3.WORKING AREA
MACHINE COMPACT 10RTE (COMPACT 2668RTE)

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8.1.4.WORKING AREA
MACHINE COMPACT 12RTE (COMPACT 3368RTE)

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8.1.5.MAIN DATAS

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2420339190 E07.13 98/159
8.1.6.COMMANDS (UP/DOWN)
• Ground controls

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• Upper control box (without outriggers)

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• Upper control box RTE with outriggers.

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8.2. THE WIRING SCHEMATICS
See all versions at the end of this manual
8.2.1. LOCATION OF MAIN ITEMS

They are all located inside the chassis, behind the lower control box door and in the grey box
inside.
NODE B2

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SEVCON I/O BOARD U1
Can connector Negative Positive LED Fault

Only for calibrator connectors connectors indicator
Dip A-in Ci D-out Do D-in Di

switches connector 9 connector 11 connector 10
1–3 1–4 1 – 12 1–8

4–6 5–8 13 – 24 9 – 16

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SEVCON VARIATOR VAR
Connector 3 ai
Pin Wire Function
1 14 Key on B+
2 61 Communication Do 21
5
7
8 64 Communication Ci 2 & 6
9
10 49a Joystick signal
11 41 Selection Lift
12
13
14
15
16

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CONVERTER 48V to 12V
This converter is protected by 2 fuses of 20A each (primary/secondary)
Connector
Pin Wire Function
+ IN 14 Positive 48V supply
- IN 100 Negative ground
+ OUT 114 Postitive 12V output
- OUT 0 Negative ground
PUMP UNIT
BATTERY CHARGER

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8.3. LOCALIZATION OF THE MAIN SAFETY COMPONENTS
COMPACT RTE
SQ4
SQ1
SQ10
* SP1 only on machines without NODE B2

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8.4. STRUCTURE OF THE SYSTEM
The variator SEVCON is the master and receive all informations coming from node B2
Node B2
Strain gauges Commands
SL1-SL2-SL3-SL4
Module Overload
strain
outriggers gauges
Failures
slope
Limit switch
console
Lift/Descent
48V/12V
Tilt
U1
e-stop e-stop SQ1 SEVCON Drive/

low upper steering
Bas
Batteries
48V
Detail of node B2 structure

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8.5. LIST OF COMPONENTS (SCHEMATICS 129P318500)
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 to 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
Note :
The model described below is the Compact RTE equipped with strain gauges and outriggers
8.5.1.FUSES
FUSES
FU1 01 -2 Main 425A

FU3 01 - 5 Electrovalves + horn 15A
FU4 01 - 4 Accessories 10A
02 - 6 12V supply for ECU module node B2 5A
FU5
(2Nd FU5 on door not used)
FU6 02 - 10 Sensors SL1 to SL4 1A
02 - 5 Vout converter 5A without outriggers option
FU7
( otherwise 20A with option stabs)
FU8 02 – 17 Supply upper control outrigger switch 5A + Node B2
FU9 02 – 19 Supply outrigger block valves 20A +
• Fuses location

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ELECTRONIC MODULES (ECU)
U
01 - 4 Battery charger
U1
01 - 15 I/O Board SEVCON
VAR
01 - 3 Motor controller SEVCON
B2
02, 03, 04 -10 Node B2
Converter
02 - 3 Converter 48V/12V with 2 fuses 2x 20A on each
8.5.2.INPUTS
INPUTS
KA3
03 - 14 Differential blocking (807)
SA1
01 - 8 Key selector (CH: chassis/O: neutral/PF: Platform)
SA2
01 - 8 Selector of movement lower control box (26 raise, 27 descent)
SA10
03 - 19 Centralized outriggers (214)
SA11a
03 - 12 Selection low speed (805)
SA12a
03 - 17 Rear left outrigger retract (708)
SA12b
03 - 17 Rear left outrigger extract (707)
SA4a
03 - 15 Front left outrigger retract (311)
SA4b
03 - 15 Front left outrigger extract (310)
SA5a
03 - 13 High speed selection (401)
SA5b
03 - 11 Lift selection (402)
SA7a
03 - 16 Front right outrigger retract (410)
SA7b
03 - 16 Front right outrigger extract (409)
SA9a
03 - 18 Rear right outrigger retract (419)
SA9b
03 - 18 Rear right outrigger extract (418)

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SB1
01 - 2 Emergency stop chassis
SB2
01.-13 Emergency stop platform
SB5
03.-10 Horn upper control box (901)
SM4
01.-17 Controller/joystick
- right steering (705)
- left steering (703)
- HM dead man (611A)
- Off neutral (606)
- signal (612)
Forward or raise from 2.5 to 4.5 V
Reverse or descent from 2.5 to 0.5 V
SAFETY COMPONENTS
SQ1
01 - 11 detection low stop (31 =1 if PF < 3m)
SQ3
01 - 12 high detection (32 = 0 if platform with maximum height)
SQ4
01 - 12 Drive cut with 10 meters on C12RTE
S1
04 - 5 Rear right outrigger retracted (218A)
SQ7
04 - 2 Front left outrigger retracted (115A)
SQ8
04 - 3 Front right outrigger retracted (115B)
SQ9
04 - 4 Rear left outrigger retracted (204)
SQ10
02 - 7 Slope detection (20 = 0 if in slope)
B7
04 – 7 Front left ground detection (517)
B8
04 – 8 Front right ground detection (516)
B9
04 – 9 Rear left ground detection (511)
B10
04 – 10 Rear right ground detection (510)
B11
04 – 11 Front left full stroke detection (915)
B12
04 – 12 Front right full stroke detection (605)
B13
04 – 13 Rear left full stroke detection (255)
B14
04 – 14 Rear right full stroke detection (266)
Level detector
04 – 17 Level detection rear high (505)
SQ
Level detection front high (504)
Level detection left high (920)
Level detection right high (919)

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Note :If machine has no outriggers, a jumper must be installed on connector PB as shown below
8.5.3.OUTPUTS
RELAYS
KA6
02 - 6 selector relay steer or outriggers (6)
RCH
01 - 8 battery charger (60)
SB1
01 - 8 main contactor (23)
VALVES
YV1
01 – 10 Quick descent (> SQ1) (30)
YV2A
01 – 11 Forward drive (33)
YV2B
01 – 12 Reverse drive (35)
YV3
01 – 12 High speed drive (37)
YV4
YV4´
YV5
YV6
01 – 15 Differential brake (44)
YV7a
01 – 16 Steering left (47)
YV7b
01 – 17 Steering right (48)
YV8
01 – 18 Lowering (51)
YV9
01 – 19 Lowering C12RTE (51)
YV10
01 – 20 Pressure enable (dump valve) (56)
YV11 01 – 7 Front axle brake release if steer without traction (54)
YV15a 04 – 3 Outrigger front right (401A)
YV15b 04 – 4 Outrigger front left (402A)
YV18a 04 – 1 Outriggers extract (407A)
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YV18b 04 – 2 Outriggers retract (408A)
YV19a 04 – 5 Outrigger rear right (310A)
YV19b 04 – 5 Outrigger rear left (311A)
YV20
01 – 16 Outriggers chosen (47A)
LIGHTS AND BUZZER

HA1
01 – 9 Klaxon (25)
HA2
01 – 10 Buzzer (28)
HL2
01 – 4 Flashing light (16) (Option)
HL3
01 – 5 Work headlight (18) (Option)
HL7
03 – 10 Power on upper control (114C)
HL10
03 – 13 Outrigger front left (415)
HL11
03 – 16 Outrigger front right (305)
HL12
03 – 17 Outrigger rear right (253)
HL13
03 – 14 Outrigger rear left (914)
HL15
03 – 6 Lift chosen (699)
HL16
03 – 5 Low speed (398)
HL17
03 – 4 High speed (303)
HL19
03 – 18 Overload (304A)
8.5.4.OTHERS
OTHERS
M1
01 – 2 Pump motor unit 48 V
PV
01 – 6 Hour recorder and low battery cut out
R1
02 – 9 Pull up resistor 470 ohm 1W
R2
R3
D ACTIA
03 - 4 Communication port Node B2

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8.6. HYDRAULIC BLOCKS
All hydraulic valve blocks are located under the right side cover
• Front and top view
YV5
YV18
YV2
• Right view
NP
N YV5
YV11
YV4*
YV7a b
YV3 ST
YV4 YV10
SB1
SB2
RV2
RV
YV6 YV1

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• Front view
M1
YV2A
YV2A YV2B
Small block YV18 Small block YV20
YV20
YV18

2420339190 E07.13 114/159
Drive over pressure relief valves
VALVES
YV1
Quick descent (> SQ1)
YV2A
Forward drive
YV2B
Reverse drive
YV3
High speed drive (switch to series drive)
YV4
High speed drive (connect 175 bar relief valve to the circuit)
YV4*
High speed drive (connect 5.5 cm3 pump to drive circuit)
YV5
High speed drive (connect 100 bar relief valve between the motors)
YV6
Differential brake (connect ST to the drive circuit)
YV7a
Steering left
YV7b
Steering right
YV8
Lowering
YV9
Lowering C12RTE (only on cylinder)
YV10
Pressure enable (dump valve)
YV11 Front axle brake release if steer without traction
YV15a Outrigger front right (on outrigger)
YV15b Outrigger front left (on outrigger)
YV18a Outriggers extract (small block)
YV18b Outriggers retract (small block)
YV19a Outrigger rear right (on outrigger)
YV19b Outrigger rear left (on outrigger)
YV20
Outriggers chosen (small block)
ST
Flow divider combinder (differential)
RV
One way check valve for 8.0 cm3 pump

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RV2
One way check valve for 5.5 cm3 pump
SB1
Counter balancing brake valve
SB2
Counter balancing brake valve
DB1
Main pressure relief valve 240 bar
DB2
High speed pressure relief valve 175 bar
DB3
Series between motors pressure relief valve 100 bar
DB4
Lifting pressure relief valve 140 bar
DB5
Steering pressure relief valve 210 bar
DBYV20
On YV20 valve block outriggers pressure relief valve 210 bar
A2
Drive shock over pressure relif valve 220 bar
B2
Drive shock over pressure relif valve 220 bar
FP
Hand pump for brake release
N
Free wheling for brake release (normally closed)
NP
Enable hand pump for brake release (normally open)
M
Minimess connection for 8.0 cc pump functions .(lifting, µspeed ,low speed)
M1
Minimess connection for 5.5 cc pump functions. (steering)

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8.6.1.LOCATION OF COMPONENTS
YV4*
YV4

2420339190 E07.13 117/159
8.6.2.PRESSURE ADJUSTMENT
The following procedure explains how and where to adjust the main pressure of Compact RTE
M1
RELIEF VALVE VALUE in bars

DB1 (low speed drive) 240 +5/0 on M port
DB2 (high speed drive) 175 ± 5 on M port
DB3 (between motors) Sealed at 100b
DB4 (Lift mode) ~ 170b done at nominal load on M port
DB5 (steering) 210 ± 5 on M1 port
Procedure for drive/steering

Connect the pressure gauge on the desired minimess plug (M or M1)
Disconnect the drive valve YV2a/b
Unscrew the counternut of the concerned relief valve
Ask the movement until full lock
Tight or untight the relief valve in order to get the right value
Tight the counternut
Reconnect the valve YV2
Procedure for lifting

Connect the pressure gauge on M port
Put the nominal load (+ 15%) in the center of the platform
Ask for the lifting mode from ground controls
Unscrew the counternut of the relief valve DB4 and adjust the relief valve until the scissors stack start to lift
Remove the extra weight (15%)
Check that lifting at nominal load is OK

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8.6.3.OUTRIGGERS
The 4 outriggers are equiped with sensors, each one have a specific function
SQ7 to SQ9 and S1
B7 to B10
B10 to B14
SQ7
Magnetic detection if outrigger is fully retracted (if OK drive permitted)
SQ8 Magnetic detection if outrigger is fully retracted (if OK drive permitted)
SQ9 Magnetic detection if outrigger is fully retracted (if OK drive permitted)
S1 Magnetic detection if outrigger is fully retracted (if OK drive permitted)
B7
Detection 14 bars front left stab on ground = authorization lifting
B8
Detection 14 bars front right stab on ground = authorization lifting
B9
Detection 14 bars rear left stab on ground = authorization lifting
B10
Detection 14 bars rear right stab on ground = authorization lifting
B11
Full stroke front left stab at 150 bars = lifting forbidden
B12
Full stroke front right stab at 150 bars = lifting forbidden
B13
Full stroke rear left stab at 150 bars = lifting forbidden
B14
Full stroke rear right stab at 150 bars = lifting forbidden

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8.7. ADJUSTMENTS WITH CONSOLES
There are 2 consoles (one is connected to the Sevcon IO board and the other to node B2 module)
all parameters settings and lists of alarms of the machine are accessible through those consoles.
8.7.1.CONSOLE OPTIMIZER
The connection is done directly on the specifc connector located inside the chassis
(behind the cover as shown below)
Description of the console
PARAMETER + or CHANGE
PARAMETER - or CHANGE
PREVIOUS
NEXT MENU
RECORD/ENTER/VALIDATION
BACK TO MAIN MENU
NOTE: on any blue key pads, pressing on left, right or in the center have the same result

2420339190 E07.13 120/159
List of menus
Access to the menu HAULOTTE GROUP

COMPACT RTE EUR
2901010880 V 01.12
Parameters setting access
Input/output state access
Trouble shooting guide per

function
Machines status
Failures list
HAULOTTE GROUP
COMPACT RTE EUR
2901010880 V 01.12
Speed parameters adjust
Ramp parameters adjust
Options setting

2420339190 E07.13 121/159
Validation by the key: , then enter then the code
Navigation by this key in order to enter the code
Level 2 is registered
press key:
Back to main menu
The console is in code level 2 (access to calibration menu)

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8.7.2.LIST OF THE OPTIMIZER MENU
Note: some menus are controlled by the SEVCON variator (ex speed/ramps)
MENU PARAMETERS DESCRIPTION COMMENTS
Menu PARAMETERS
SPEEDS - - Controlled by SEVCON chopper
RAMPS - - Controlled by SEVCON chopper
Enter access +/- for modification
Access code
code Access to level 2 /3
+/- for modification

Stabilisers Activation of outriggers option
(Active or Inactive)
Temporisation de décollement +/- for modification

Ground Lift de la plate-forme (ms), par (Value from 1000 to 2400ms by
défaut 1000ms step of 40 )
Offset value for correction of
the signal sent from node B2 to
Hdl Corr 1 (value by default = 20)
Sevcon when 1 stab is in
OPTIONS Note if NOK failure on joystick )
function)
Sevcon when 2 stabs are in
Note if NOK failure on joystick )
function)
Sevcon when 3 stabs are in
function)
Sevcon when all stabs are in
function)
Cells are
CALIBRATION calibrated Load calibration of the
acess level 2 Calibrate machine equipped with strain See full process at chapter 8.7.3
&3 load cells ? gauges
Use button :(*)

2420339190 E07.13 123/159
MENU PARAMETERS DESCRIPTION COMMENTS
st
Cells current (uA) 1 screen :
C.1:9888 C.2: 9908 value of current in µAmp on the 4 load transducers
C.3:9908 C.4: 9846
nd
2 screen
Load current load on PF
Measure (Kg): +382 Load max acceptable on PF(565kg)
Max (Kg): 565
rd
3 screen : informations on calibration if done or not
Calibration: YES|NO YES if machine calibrated , NO if not
Tare:1928 Tare : offset of the load cells
Gain:382 Gain : gain of the load cells
Load System Machine: C10RTE Machine : type of machine as defined during the calibration
process
th
4 screen : state of the machine
Unfolded: YES|NO Unfolded : YES platforme>SQ1, NO platforme>SQ1
Tilt: YES|NO Tilt : YES tilt active, NO tilt not activaved
Overload: YES|NO Overload : YES static overload, NO : in overload
Def./Tilt: YES|NO Def./Tilt : defalt in progress
th
Links B2 <-> U1 5 screen : state of the network connection between module
Def./Tilt: node B2 and SEVCON variator
OK|FAILURE Def Tilt : OK if slope connection OK
Overload: Def Overload : OK if overload connection OK
OK|FAILURE
st
1 screen : general state of the outriggers
All Stabs Up : Y|N Y if all stabs are retracted , N if at least one is OUT
Scissor blocked: Y|N Y si all stabs are on ground , N if at least one is not on pressure
Scissor Levelled Y|N on ground
Cylndr(s) bottom Y|N Y if machine levelled (sensor 2 ways), N if not
Y if at least one is extended at full stroke , N if the 4 stabs are
not at full lock
nd
Stabilisers YV18A : ON|OFF 2 screen command state on outriggers valves
YV18B : ON|OFF ON command in process on the corresponding valve or relay
YV15A : ON|OFF OFF no command
YV15B : ON|OFF (KA6 = relay for cummutaion between steering<-> outriggers
YV19A : ON|OFF PUMP : command on pump unit
YV19B : ON|OFF
KA6 : ON|OFF
PUMP:ON|OFF
VERSIONS Versions of softwares
JOURNAL 1 Not accessible

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Menu FAILURES
OL01 Strain gauges out of range Check wiring on load cells
Calibration out of range Tare : at 0kg,
value is 1930 +/- 40
OL02
Gain : at 500kg , value is
= 380 +/- 40
Alarme Power supply too weak Check if VBATT>10.5V
Pesage OL03
Chek wiring on load cells
OL04 Strain gauge blocked Check wiring on load cells
Negative overload (static or Check wiring on load cells
OL05 dynamic) or if any obstacle twist
mechanically the PF
KA6 relay in short or open
ST01 Ouput of KA6 in SC or OC
circuit)
Check all 3 sensors on
CA01 Incoherent fault on FR stab
stab
CA02 Incoherent fault on FL stab
stab
CA03 Incoherent fault on RR stab
stab
CA04 Incoherent fault on RL stab
stab
Alarmes Short or open circuit on
EV01 Fault on valve YV18a
stabilisers valve
Short or open circuit on
EV02 Fault on valve YV18b
valve
valve
valve
valve
valve
EEPROM fault during
Do again the overload
overlaod calibration
Alarme EE01 calibration and erase the
registration of the checksum
EEPROM failure
value
calculateur
Wrong reading or writing
EE02 EEPROM fault
datas in EEPROM

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8.7.3.OVERLOAD CALIBRATION
This calibration must be done when the following components have been replaced
• One or more strain gauges
• Module node B2
• Full platform (only tare could be done in emergency)
Prerequisite
• All commands must be done from lower control box
• The machine is not in slope
• During all the calibration (tare and 500Kg), the power supply must not be switched OFF.
• The way to proceed for calibration must be respected.
• The load to be used for 500kg must be within 500 +/-5 Kg.
• The platform must be in stowed position
• In case of problem during calibration process, a message will indicate the type of problem.
Go in menu FAILURES and erase the existing alarms (OL01 to OL05) through code level 2 or 3.
Fit the console in level 2 mode (2031) and follow instructions shown on display
• Connect the Optimizer calibrator on the connector as shown below on photo 1

• ”Go in menu level 2” in sub-menu PARAMETERS/OPTIONS.
• Start the calibration process in sub-menu PARAMETERS/CALIBRATION and validate by (*) :
o If the calibration has already been done, it must be erased using the key (+) (it’s possible to
calibrate only the offset by pushing the key (–)).
o If no calibration has already been registered, the process starts normally.
• Choose the right model : key (+) for the Compact 10 RTE or key (–) for the Compact 12 RTE
• Check that the platform is empty , then confirm the tare by using the validation key (*)
• Charge the platform with 500 +/- 5 kg , then confirm the load by using the validation key (*)
• Check that the following message « Calibration is done » appears on the display.
Note : at the end , check that overload system is working

Nominal load C10RTE 565 kg (threshold cut out at 110% which is 621 kg)
Nominal load C12RTE 450 kg (threshold cut out at 110% which is 495kg)

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Detail of overload calibration process
HAULOTTE GROUP
COMPACT RTE EUR
2901010880 V 01.00
∗
SPEEDS
PARAMETERS

RAMPS
1
∗ ∗ ∗
OPTIONS Enter access code
Enter access code
2031 Level 2

FACTORY SETTINGS 2a 2a
Cells are calibrated ∗ Calibration is done +
∗
CALIBRATION Calibrate (+)Erase calibration
load cells ? (-)Calib. Offset
Use button :(*) Use button :(- +)
2b 3
Cells not calibrated ∗ Choose machine ±
Calibrate (+)C10RTE
load cells ? (-)C12RTE
Use button :(*) Use button :(- +)
INPUTS - OUTPUTS 4 5
Calibrate offset ? ∗ Calibrate gain ? ∗
DIAGNOSTIC Be sure plateform is Be sure plateform is
empty and levelled loaded with 500kg
Use button :(*) OK button :(*)
INFORMATIONS
5
FAILURES Calibration is done

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Check the possible failures
ALARMS CODE DESCRIPTION DIAGNOSTIC

OL01 Strain gauges out of Signal of one the load cell
range is < 3.5mA or > 20.5 mA
OL02 Calibration out of range The calibrated values from tare ou gain are too
far from the default value:
1890 < Tare < 1970 (C10/C12RTE)
340 < nominal load Gain < 420
OL03 Power supply too weak Battery voltage < 10.5V (the information given
by the sensors are not coherent for a too low
voltage)
OL04 Strain gauge blocked No variation on one of the sensor when the real
load is changing
OL05 Negative overload Negative measurement > - 400kg
(static or dynamic)
EE01 EEPROM fault the current CRC (cyclic redundancy check) is
different from the CRC memorised for the
calibration datas (system checked at each
EEPROM access)
EE02 EEPROM fault Wrong reading or writing datas in EEPROM
The overload faults active the output «fault/ slope sensor» (wire B501) on the load system (except in case of
negative overload detected by OL05 , in this case the output “overload” is activated (wire B502))
The wire connections between both calculators node B2 and SEVCON U1 are checked permanently.
1st case: the system goes in overload if a failure is detected on the «fault/ slope sensor» line
(wire B501 = 0)
2nd case: the system goes in fault mode if a failure is detected on « overload » line (wire B502 = 0)
(see DIAGNOSTIC menu)

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How to diagnostic the possible problem during calibration
HAULOTTE GROUP
COMPACT RTE EUR
2901010880 V 01.00

PARAMETERS

INPUTS - OUTPUTS

∗ Cells current (µA)
DIAGNOSTIC C.1:9888 C.2: 9908 Current values given by the 4 strain gauges
C.3:9908 C.4: 9846 ( range 4mA : - 200kg / 20mA : + 1000kg)

Load
Measure (Kg): +382
Current load on platform : measured and maxi
Max (Kg): 565

Calibration: YES|NO
Informations if the calibration has been done or
Tare: 1928
not
Gain: 382
Machine: C10RTE
Inputs / outputs of the load system (Node B) :
• Unfolded (input) : machine unfolded above
SQ1
Unfolded: YES|NO
• Tilt (input): machine in slope (SQ10)
Tilt: YES|NO
• Overload (output) : positive or negative
Overload: YES|NO
overload detected above SQ1
Def./Tilt: YES|NO
• Def. / Tilt (output) : machine in slope or in
INFORMATIONS
failure

Links B2 <-> U1 Connections between node B2 and U1 Sevcon
• Def./Tilt : link « fault/slope » state
FAILURES Def./Tilt: OK|FAILURE • Overload : overload link state
Overload: OK|FAILURE
the sensors values
example Platform empty PF with 500kg

stowed extended stowed
SL1
SL2
SL3
SL4
Meas load
Tare

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8.7.4.OUTRIGGERS SETTING
The setting of the outrigger correction signals must be done when the following components has been
replaced.
• HEAD node B2
• SEVCON VAR variator
• SEVCON I/O board
Procedure
A- Select acces code with the Optimizer
- Connect Optimizer
- Select Parameters
- Select Options
- enter access code 3165
- exit from menu with ‘ ?’
B - Select the machine type
1.Select Parameters
- Options → Enter scroll down untill reach to
- Stabilisers → activate (initialy they are inactive) then press Enter then Save
- Scroll down to HDL CORR
- There are 4 HDL CORR named HDL CORR 1…..HDL CORR 4 their initial parameters are equal to 0 ;
2. Setting parameters procedure :
- 1.HDL CORR 1 = 30→ Save
3. Connect the CAN CALIBRATOR to the control door, then go to menu 2.4.2 and read the tension
(see next page for connections)
4. The correction settings.
- activate one stabilizer (a single one) (extract or retract makes no difference, retract might be easier)
- modify the HDL CORR 1 value so the tension value read to be in the interval 2.28 – 2.32 V* (for
increasing the tension value, the parameter must be decreased, for the opposite you increase the
parameter for decreasing the tension value)
- final value for HDL CORR 1 → Save and record the value for future maintenance. For example 15
- activate two stabilizers (two simultaneosly)

- modify the HDL CORR 2 value so the tension value read to be in the interval 2.28 – 2.32 V*
- activate three stabilizers (three simultaneosly)

- activate four stabilizers (four simultaneosly)

* If the tension value is not between the requested interval, the system will cut and report 6
flashes from the IO boards LED indicator and therefore the CORR must be modified in such a
manner that the resulting tension to be found is in the interval of 2.28 - 2.32V.
If the 6 flashes occurs the system needs to be restarted and proceed thru step a, jump to b3.
NB. There are test done in Scandinavia whith a better negative connection between B- on the VAR to
the negative connection on the NODE B2. This seems to delete the complete HDL CORR procedure.
All settings are tuned to Zero. This gives stable tension of 2.26V normally (2,26V works fine).
Look for updated info on the Haulotte E-training Commuity.
2420339190 E07.13 130/159
8.7.5.CONSOLE SEVCON CAN CALIBRATOR
Navigation in menus 1 Navigation in menus 1

traction and 2 pump traction and 2 pump
Navigation in sub-menus Navigation in sub-menus
Increase and validate the

Decrease and validate the
parameter parameter
Connection of console (connector A : logic board)

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8.7.6.HOW TO SCROLL THROUGH THE PARAMETERS
• Menu drive
Initialising…
1 Traction
OK
1.1Traction 1.2Traction 1.3Traction

Personal… Status Test
1.4Traction 1.5Traction 1.6Traction

BDI FaultLog Setup
1.7Traction 1.8Traction
MotorSetup Display
• Menu movements
Initialising…
1 Traction 2 Pump
OK OK
2.1Pump 2.2Pump
Personal… Status
2.3Pump 2.4Pump 2.5Pump

UpperBox UpperBoxTest LowerBoxPers
2.6Pump
LowerBoxTest

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8.7.7.LIST OF SEVCON PARAMETERS
Some parameters could be displayed on thesevcon console but are not used in RTE models

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Cal. Ref. Parameter Displayed
VALUE
1.3.1 Accelerator %
1.3.2 Accelerator Voltage
1.3.3 Deadman
1.3.4 Joystick Forward no use
1.3.5 Joystick Reverse no use
1.3.6 Steer Left
1.3.7 Steer Right
1.3.8 Horn (SB4)
1.3.9 Traction Select CLOSED in High speed
mode
.3.10 Tilt (KA1) closed
1.3.11 Boom Rest-> SQ1 closed
1.3.12 8m High (SQ4) CLOSED
1.3.13 BRAKE RELEASED OPEN
1.3.14 BDI Input CLOSED
1.3.15 Frame Fault open
1.3.16 Drive Inhibit closed
1.3.17 B2 cut (SQ3 : PF high)) CLOSED
1.3.18 Joystick NTRL sw open
1.3.19 LS traction (SA3 selection Low/High
speed drive)
1.3.20 software
Ex: Ver FR004.6
1.3.21 controller Serial number
1.3.22 controller type

PP745
Traction
1.4.1 charge BDI

0
1.4.2 BDI Battery Voltage (V)
48
1.4.3 BDI Reset Level
2,09/cell
1.4.4 BDI Discharge Level (V)

1,73/cell
emppty
1.4.5 BDI warning Level (%)
30%
1.4.6 BDI cutout Level (%)

20%

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TRACTION DISPLAY VALUE
1.8.1 Display Default Hours KEY/TRACTION/PUMP
1.8.2 Display Status Type OFF
1.8.3 Display contrast Set at 10
1.8.4 ind 1 Normally OFF
1.8.5 ind 2 PUMP I
1.8.6 Display Fault Messages ON : fault errors displayed Fxxxxxx

OFF : no display of error codes
Cal. Ref. Input Displayed VALUE
2.4.1 Y axis Joystick % Range : 0
2.4.2 Y axis Joystick Voltage Range : 2.22V
2.4.3 X axis Joystick % Range 100
2.4.4 X axis Joystick Voltage Range 5.10
2.4.5 Deadman switch Switch OPEN
2.4.6 Joystick Forward Not used
2.4.7 Joystick Reverse Not used
2.4.8 jib extended Not used
2.4.9 cage over (SP1) Switch OPEN
2.4.10 Traction Select Not used
2.4.11 Boom 1 Select Not used
2.4.12 Boom 2 Select Not used
2.4.13 Jib Select (SA3 ) Switch OPEN
2.4.14 Tele Select Not used
2.4.15 Slew Select Not used
2.4.16 Cage Level Select Not used
2.4.17 Cage Rotate Not used
2.6.1 Boom 1 UP PF lift from chassis
2.6.2 Boom 1 Down PF down from chassis

2420339190 E07.13 135/159
In situation of default, the display presents on the hour meter, a fault code
This code is represented like Fxxyyy in the following way
F: Fault
xx: level of defect
yy: number of defect
Level of defect Type of defect

Level 0 Normal functioning
Level 1 Warning message only
Level 2 Defect leading to a reduction of performance
Level 4 Defect prohibiting the start-up
Level 5 Defect causing the opening of the line contactor KM1
Fault code Calibrateur display DESCRIPTION

F05000 Coil s/c overload current fault of line contactor SB1
F05001 EEPROM Fault defect memory parameters
F05003 Internal Fault defect internal in variable speed unit
F05004 12V Supply Low defect in logical power supply
defect of can bus network between printed
F05005 System Fault circuit board /variator
defect of short-circuit of the MOSFETs
F05006 Mosfet s/c transistors of the variable speed units
F05008 P.Up Trac. Weld contactor of line already stuck at start (KM1)
defect of the MOSFET at start
F05009 P.Up Trac. Mos (check the variator)
defect activation output contactor N°0
F05011 Drive 0 one (low speed)
defect activation output contactor N°1
F05012 Drive 1 one (high speed)
defect desactivation output contactor N°0
F05013 Drive 0 off (low speed)
defect desactivation output contactor N°1
F05014 Drive 1 off (high speed)
error internal to variable speed unit: (battery
F05019 Stack Corrupted dysfunction)
F05020 Line Cont o/c defect of closure on line contactor (SB1)
Digital output in short-circuit on the module of
Input/output
F05021 Coil s/c (standard) (chassis CAN board)
Digital output in short-circuit on Input/output
F05022 Coil s/c (ext.) board
F04000 Contactor o/c defect of closure on contactor
F04001 Contactor s/c stuck contactor
defect of sequence of the variator
F04003 Fault sequence command dead man /setpoint)
Time delay of exceeded sequence
(> 5 seconds after push on validation dead
F04005 SRO fault man switch without another action)
F04009 BatteryLow Battery: low charge level (restore charge)
Battery: high charge level
F04010 BatteryHigh (check B+ presence on variable speed unit)
F04012 Pers Error Defect of parameter setting
error of control of the parameters
F04013 CRC Error (switch OFF then ON the machine)

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defect accelerator of the joystick
F02000 Accel. Fault (out of range 0.5-2.5-4.5Vdc)
selection already present at start (joystick
pushed or pullet when power is ON or
F02001 Accel. Fault problem of connection)
Defect of the load management system whe
power is ON (check connection between
F02002 Overload cage output CAN)
cut-off on threshold of discharge battery
F01004 BDI Cutout (charge the battery)
thermal threshold variable speed unit
F01005 Thermal Cutback (> 75°C)
8.7.8.I/O BOARD LED FAULT CODE INDICATOR

Lower left corner of I/O board
Number of flashes Description

Led on fixed NTR. Chopper operation is OK , normal conditions
led off Internal module power fault
1 flash Parameter fault
2 flashes Wrong start sequence / on cabling faults
3 flashes Not used
4 flashes Contactor fault (SC or OC) / cabling fault /motor in open circuit
5 flashes Dead man time out
6 flashes Joystick signal cabling type fault
Low or High battery voltageor BDI (Battery Digital Input) cut
7 flashes out operationg
8 flashes Over temperature
9 flashes Not used
12 flashes Not used

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8.7.9.DIP SWITCH SETTING
This procedure must be done according to the local regulations (EN280/US/CDN or AUS requirements ) or
when the logic borad has been changed

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8.7.10. SLOPE 2 WAYS ADJUSTMENT
This component has as a function to detect on the 2 ways (longitudinal, X and transversal, Y), the physical
position of the platform of the machine
It needs to be adjusted if it has been replaced or it has lost the memory and the automatic platform levelling
is not correct performed.
Procedure:
• put the machine on a ground perfectly flat
• In the lower control box, connect the black wire at a GND (photo 1)
• The green led located under mushroom of the dual level sensor will flicker (photo 2)
• wait for 10 seconds when it starts to flicker
• Once the lit green led is fixed, remove the black wire and insulate it well so that it does not touch any
metal piece
• The calibration is carried out
• check the correct operation of the automatic levelling and see if the platform is levelled ( check with the
water bubble on platform)
Photo 1 Photo 2
Connection of the level sensor:
COLOR Wire FUNCTION CONDITION WIRE on schematics

number
brown 1 + Battery Supply + 114C
Blue 2 - Battery Supply - 0M
purple 4 X back Output + get to 0V if front up 505
white 5 X front Output + get to 0V if rear up 504
yellow 6 Y right Output + get to 0V if left up 919
Grey 7 Y left Output + get to 0V if right up 920
green 3 Tilt signal 0,5° Not connected
black 8 reset Reset

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8.7.11. STRAIN GAUGES REPLACEMENT
This sensor is based on the deformation of the gauge, it will be measured then a signal through operational
electronic amplifiers
The strain gauges deliver a current 4 - 20mA according to load applied to platform, the signal is sent to the
module node B2
Two types of information of weight are elaborated (the instantaneous weight and the average weight), they are
then converted and gauged into kilograms using safeguarded information of tare (strain gauges if platform
empty) and signal (delta of the sums of the gauges from 0 to 500kg)
According to the received signal, the dynamic or static overload conditions will be detected and the machine
will be then out of overload
• How to fix the strain gauges

Use an axle to center the gauge
Be careful as gauges are fragile
Tight the 2 fixations screws with torque wrench (value 85Nm)
Signal of the strain gauges

4 mA for - 200kg
20mA for + 1000kg
Connection on plug

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8.8. TROUBLE SHOOTING GUIDE
8.8.1.LOGIC EQUATIONS
This table is showing which valve(s) is energeised according to the function
Function/valves YV1 YV2 YV3 YV4* YV4* YV5 YV6 YV7 YV8 YV9 YV10 YV11
a/b a/b
LIFTING X X
QUICK DESCENT X X X
LOW DESCENT X X
LOW SPEED X X
HIGH SPEED X X X X X X
STEERING ONLY X X
STEER+DRIVE X X X
DIFF LOCK X
8.8.2.LIFTING/DESCENT MODE
This table is showing the components involved in lifting/descent mode

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8.8.3.DRIVE/STEERING
This table is showing the components involved in drive/steering mode

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MF COMPACT-OPT RTE EN E07.13

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TECHNICAL TRAINING

All Compact – Optimum

TRAINING MANUAL DIAGNOSTIC Level 2 All Electric Compact – Optimum

TRAINING MANUAL DIAGNOSTIC Level 2 All Electric Compact – Optimum

6. SUMMARY OF THE VERSIONS ....................................................................................................................... 87

8. COMPACT RTE .................................................................................................................................................... 93

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

Standard push-button of safety “mushroom-headed

TRAINING MANUAL DIAGNOSTIC Level 2 All Electric Compact – Optimum

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)

Tilt sensor ( ramp detection)

Angle sensor (reach limitation)

Contact « mercury » (angle detection)

TRAINING MANUAL DIAGNOSTIC Level 2 All Electric Compact – Optimum

Sensor length (reach limitation)

Pressure sensor (weighing)

Angle sensor (weighing)

Standard light “Led”

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

2.2.2. CONTROL OF AN ON/OFF VALVE

TRAINING MANUAL DIAGNOSTIC Level 2 All Electric Compact – Optimum

Control resistance of the coil

2.2.3. CONTROL OF COMPONENTS

• Control of an electric relay

TRAINING MANUAL DIAGNOSTIC Level 2 All Electric Compact – Optimum

TRAINING MANUAL DIAGNOSTIC Level 2 All Electric Compact – Optimum

2.3. THE WIRING SCHEMATICS

TRAINING MANUAL DIAGNOSTIC Level 2 All Electric Compact – Optimum

Detail of plug in the Variable speed unit

TRAINING MANUAL DIAGNOSTIC Level 2 All Electric Compact – Optimum

2.4.2.THE SERIAL CARD

TRAINING MANUAL DIAGNOSTIC Level 2 All Electric Compact – Optimum

Compact all models (except C14)

(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

FU1 2 Main 300A (2)

TRAINING MANUAL DIAGNOSTIC Level 2 All Electric Compact – Optimum

TRAINING MANUAL DIAGNOSTIC Level 2 All Electric Compact – Optimum

LIGHTS AND BUZZER

TRAINING MANUAL DIAGNOSTIC Level 2 All Electric Compact – Optimum