Optimum8ac Training Manual PDF

Training manual
OPTIMUM 8 - OPTIMUM 1931 E
Training manual
OPTIMUM 8 -
OPTIMUM 1931 E
USA
4000595920 E 05.17 USA / (1

2 4000595920 E 05.17 USA / (1

Training manual
CONTENTS
A
FOREWORD
1 - Revision. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
B
MAIN FEATURES AND FUNCTIONS
1 - Models description . . . . . . . . . . . . . . . . . . . . . . . 9
2 - Primary machine components . . . . . . . . . . . . 10
2.1 - Working area / Range of motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2 - Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2.1 - Machine layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3 - Ground control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.3.1 - Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.3.2 - HAULOTTE Activ'Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.3.2.1 - LCD screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.4 - Platform control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.4.1 - Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
C
STUDY OF THE WIRING DIAGRAM
1 - System architecture . . . . . . . . . . . . . . . . . . . . . 21
CONTENTS
1.1 - Power circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

1.2 - Logic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.3 - Drive circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.3.1 - Function of the variators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.3.1.1 - Control of the traction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.3.1.2 - Control of the pump (other movements). . . . . . . . . . . . . . . . . . . 27
1.3.1.3 - Details of sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.3.1.4 - System of unbraking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.3.1.5 - Detail of the connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.3.2 - Scissors arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3
Training manual
2 - List of actuators and sensors . . . . . . . . . . . . . 32

2.1 - Sensors and actuators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.2 - Sensors detail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.2.1 - Limit switchs for potholes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.2.2 - Steering potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.2.3 - Angle transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.2.4 - Pressure transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.2.5 - Slope sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.2.6 - Battery charger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.2.7 - Fuses and relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.3 - Actuators and their location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.3.1 - List of actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.3.2 - Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.3.3 - Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.3.4 - Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.3.5 - Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.4 - Cut out conditions of every function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.4.1 - Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.4.2 - Power supply/commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.4.3 - Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.4.3.1 - Validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.4.4 - Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.4.4.1 - Validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.4.4.2 - Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.4.5 - Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.4.5.1 - Validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.4.5.2 - Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.4.6 - Brake release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.4.7 - Potholes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.4.7.1 - Validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.4.7.2 - Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4
Training manual
D
STUDY OF THE HYDRAULIC SCHEMA
1 - Hydraulic units . . . . . . . . . . . . . . . . . . . . . . . . . 65
1.1 - General overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
1.1.1 - The hydraulic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
1.1.1.1 - Pump unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
1.1.1.2 - Selection valve potholes/steering. . . . . . . . . . . . . . . . . . . . . . . . 66
1.1.1.3 - Lifting cylinder valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
E
ADJUSTMENTS
1 - Adjustments with diag pad console . . . . . . . . 69
2 - List of menus . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.1 - Machine settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.1.1 - Speeds and ramps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.1.2 - Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.1.3 - Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.1.4 - Countries and models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.2 - Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.2.1 - Inputs/Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.2.2 - States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3 - Failures list . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3.1 - List of failures per category . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4 - Maximum height adjustment . . . . . . . . . . . . . . 87
5 - Cutback speed position height adjustment . . 88
CONTENTS
6 - Load management system . . . . . . . . . . . . . . . 89

6.1 - Calibration procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
6.2 - Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
6.2.1 - Steering calibration procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
6.3 - Calibration arm angle sensors (HONEYWELL Sensors) . . . . . . . . . 93
6.4 - Calibration arm angle sensors (ELOBAU Sensors) . . . . . . . . . . . . . . 94
7 - Adjustment of pressures . . . . . . . . . . . . . . . . . 95
7.1 - Main pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
7.2 - The speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5
Training manual
F
SIMPLIFIED BREAKDOWN GUIDE
1 - No start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2 - No lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3 - No drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4 - No steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
G
VERSION SUMMARY
1 - Version summary . . . . . . . . . . . . . . . . . . . . . . . 99
2 - List of schematics . . . . . . . . . . . . . . . . . . . . . . 99
3 - List of wiring harnesses . . . . . . . . . . . . . . . . . 99
6
A - Foreword
Foreword
A
How to use this document ?
MAINTENANCE AND REPAIR OPERATIONS ON YOUR HAULOTTE® MACHINE MAY ONLY BE PERFORMED BY
TRAINED AND EXPERIENCED TECHNICIANS
B
You are in possession of the summary document provided during the HAULOTTE® technical training
programme. It will allow you to find the information necessary for performing maintenance and repairs on
your HAULOTTE® machine.
The following guide will help you to rapidly access the required chapter.
C
Section A : Foreword
You will find there the elements as following :

• A resume of any update made since the creation of the manual.
D
Section B : Main characteristics and functions
You will find there the elements as following :

• The list of the models.
E
• Their main datas.
• Their overall dimensions.
• Their working envelop.
• Controls boxes.
• Some maintenance topics on specific components (charger, engine ..).
F
Section C : Study of the wiring diagram
It will include the following elements :

• Structure of the system.
G
• Localization/photo of each safety components.
• The location/function of each component in schematics.
• Cut out conditions of every function.
H
Section D : Study of the hydraulic diagram

• The localization of every manifolds.
• The location/function of each component on block. I
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A - Foreword
Section E : The adjustments

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

• A summary of every function and items to be checked in case of breakdowns.
Section G : Summary of the versions

• A summary of the different versions made per model.
• Any schematics (electric /hydraulic) linked to the models studied.
• Coloured schematics (electric/hydraulic) per function.
• List of main harnesses in the models studied.
1 - Revision
CREATED VALIDATED MODIFIED TRANSLATED
REVISION EDITION SUBJECT LANGUAGE
BY BY BY BY
00 10.16 Creation ASA MGD ASA ITC USA / EN
Add Failures codes, new
schematics, new load
01 05.17 ASA MGD ASA ITC USA / EN
management system
calibration process
8 4000595920 E 05.17 USA / (1

B - Main features and functions
Main features and functions A

1 - Models description
REGULATION MODELS
ANSI and CSA standards OPTIMUM 1931 E B

CE, AS and EAC standards OPTIMUM 8
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2 - Primary machine components

2.1 - WORKING AREA / RANGE OF MOTION
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2.2 - TRANSPORTATION
2.2.1 - Machine layout
A
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2.3 - GROUND CONTROL BOX
2.3.1 - Layout
General view
253 ACTIV’ Screen
92
15
43
105
93
Controls and indicators
MARKING DESCRIPTION FUNCTION

Pulled out : Ground control box energized
15 E-stop button
Pushed in : De-energizes control system
43 Horn button Not used
Right : Ground control box energized
92 Control box activation key selector Center : De-energizes control system
Left : Platform control box energized
93 Battery charging indicator Battery charger status
Move upwards : Flashing light turn ON
105 Beacon light (Optional)
Move downwards : Flashing light turn OFF
253 Diagnostic tool socket Connection to the diagnostic tool (HaulotteDiag)
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2.3.2 - HAULOTTE Activ'Screen
A
Upon starting and during operation of the machine, the LCD screen "Activ'Screen" located on the
ground control box displays in real time the machine operating status.
HAULOTTE Activ'Screen

F
MARKING DESCRIPTION FUNCTION
1 Platform raising control Platform raises
2 LCD screen Display status of operation of the machine
3
4
Navigation button
Confirmation button
Navigation of menu to select function - Scroll up
Confirmation of the selected function G
5 Cancellation button Go back
6 Platform overload indicator Platform overload indicator
7 Machine fault indicator light Constantly lit in the event of an operation malfunction
8
9
Navigation button
'Enable Switch' selector
Navigation of menu to select function - Scroll down
Press in and hold : Enable switch H
10 Platform lowering control Platform lowers
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2.3.2.1 - LCD screen
At startup
At startup with the ground or platform controls selected; system initiates a self check :
• Bar gets filled up.
• Home screen comes on with status icon of the machine - okay to proceed functioning the controls.
SYMBOL DESCRIPTION
1 Information icons
2 Information text
3 Status icon of the machine
SYMBOL DESCRIPTION
Battery status
Maintenance use
Fault / alarms
Hour meter
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• After pressing on :
A
C
SYMBOL DESCRIPTION
1 Software part number
2
Software version + Screen software version + Screen
version
D
3 Screen identification + Screen software version
4 Machine serial number displayed
• After again pressing on

E
• Access code screen comes on - refer to maintenance manual for entering the access code
G
• Validation by pressing on is active only if access code is known and entered - refer to maintenance
manual for the procedure for the different level code useage
H
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Alarm status
Alarm status displayed as applicable - samples shown below
• Tilt
• Overload
• Low battery
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• Present fault
A
C
• Platform control box E-stop button pressed in (de-energized)
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2.4 - PLATFORM CONTROL BOX
2.4.1 - Layout
General view
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A
MARKING NAME DESCRIPTION FUNCTION
27 HL800 Tilt indicator Machine on excessive slope
30 HL802 Overload indicator Platform overloaded
43 SA907 Horn button Move upwards and hold to activate horn B

Pulled out : Platform control box power supply
46 SB802 E-stop button energized
Pushed in : De-energizes control system
85 HL903 Fault indicator Fault indicator Faulty or tilting or overloaded machine

C
100%
Battery charged
D
91 HL904 Battery charging indicator
40%
Flashing : Batteries have 40 % charge left
E
20%
Constantly on : Batteries have only 20 % charge left
Move forward : Forward drive or platform raising
Movement joystick
108 SM901
Move backwards : Reverse drive or platform lowering
Press right side of button : Right-hand steering

F
Front axle steering selector
Press left side of button : Left-hand steering
On : Raising / Lowering selection activated

110 HL420 Raising / lowering selector
Off : Raising / Lowering movement is not selected
On : Driving function activated

G
111 HL100 Driving selection indicator
Off : Driving movement is not selected
Move to the left : Platform raising / lowering

112 SA908 2-position selector
Move to the right : Drive movements
Press in and hold : Associated command is validated

H
123 SA905 'Enable Switch' selector
Release : Associated command movement is halted
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Notes
20 4000595920 E 05.17 USA / (1

C - Study of the wiring diagram
Study of the wiring diagram A

1 - System architecture
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1.1 - POWER CIRCUIT
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1.2 - LOGIC CIRCUIT
A
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1.3 - DRIVE CIRCUIT
The traction is controlled by 2 asynchronous 3 phases motors (24VAC - 1KW).
Each motor is piloted by one variator ( COMBIACX master for RR motor and ACEX slave for RL
motor) through CAN - BUS network.
Each variator consists of :

• One thermistor for temperature control (ST302/ST303).
• One encoder for speed control (SV300/SV301).
• One electromagnetic brake at negative excitation (YB100/YB101).
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The whole unit is located in the chassis (rear side as shown below)
A
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1.3.1 - Function of the variators
• The COMBIACX variator is the master and controls the traction of the RR motor and a chopper for the DC pump
motor and some I/O too.
• The software upload process is done by connecting the DIAG PAD console or HAULOTTE DIAG application.
• The ACEX variator (slave) controls the traction of RL motor (no need to upload software on it).
• The 2 variators has the regenerative braking function (deceleration).
• Each variator is protected with a speed and temperature sensor and electromagnetic brake disc.
• In case of low battery charge, the maximum current is reduced to the half of the maximum current programmed
(an alarm message is displayed).
• The 2 variators are protected against reverse battery polarity.
Overview
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1.3.1.1 - Control of the traction
A
1.3.1.2 - Control of the pump (other movements) D
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1.3.1.3 - Details of sensors
• The speed rotation of each motor is controlled through an encoder with 2 signals shifted at 90° each and 48
impulses per round.
• The temperature of each motor is controlled through a thermistor located inside the winding (from 85°C the
current is reduced in proportion the temperature increases until reaching 105°C where the current is null and
traction stopped).
1.3.1.4 - System of unbraking
The electro magnetic brakes are at negative excitation (remains stuck if not or lack of current).
In case of necessity, it’s possible to release the brakes using the toggle switch SA103 located behind
the variator’s support (see below).
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1.3.1.5 - Detail of the connections
A
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Detail of the connectors on variators.
For any connector, the pin 1 always starts at the lower right corner as shown below.
Connector are labelled as follow :

• CXA/B/C/D for COMBIACX.
• AXA/B/C/D for ACEX.
(See below and refer to electric schematic)
Connectors (power side) :

• U/V/W are the 3 motors phases.
• B+ : positive of the battery.
• BF+ : positive of the battery protected by a Fuse of 160A.
• B- : negative of the battery.
• P+ : output of the pump motor ( COMBIACX only).
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1.3.2 - Scissors arm
A
The arms stack are independent and equipped with standards axles secured by clips and ring (see
below).
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2 - List of actuators and sensors

2.1 - SENSORS AND ACTUATORS
Sensors and actuators
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A
NAME DESCRIPTION
SP400 Pressure sensor
SQ144 Pothole limit sensor
SQ145
SQ800
Pothole limit sensor
Tilt sensor
B
SR150 Steering potentiometer
SR420 Tilt sensor low position
SR722 Arm angle sensor
YV120
YV121
6 tracks / 2 positions for potholes or steering switch (priority for potholes)
Right steering or pothole entry valve C
YV122 Left steering or pothole exit valve
YV420 PWM platform raising/lowering proportional valve
YV903 Valve by-pass (pump pressurization)
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2.2 - SENSORS DETAIL
2.2.1 - Limit switchs for potholes
MARKING FUNCTION DESCRIPTION

1 SQ144
Sensors = 1 when potholes are retracted
2 SQ145
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2.2.2 - Steering potentiometer
A
E
Value 2.5 kΏ, supply in 12 VDC (coming from ACEX variator)
Before to launch the calibration, the pre-setting has to be done at mid-
1 SR150 range value then use the consoles in order to set the potentiometer
values to adjust current/voltage of the internal motor depends the
F
direction of steering (left/right)
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2.2.3 - Angle transducers

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

Analogic transducer (4-20mA), value variable depends of the pressure on
1 SP400 big chamber of the lifting cylinder
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2.2.5 - Slope sensor

Tilt Y = 1.5° / X =3° (wire 12 = Vbat if machine on flat surface)
1 SQ800
1=red=+Batt / 2=white=signal / 3=black=GND
2.2.6 - Battery charger
Version 230VAC - 24V - 20A
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2.2.7 - Fuses and relays
A
E
1
2
FU2
FU3
Protection electrovalve circuit (10A)
Protection main circuit (10A) F
3 FU4 Protection accessories circuit (10A)
4 SA103 Toggle switch for manual brake release function
5 KA1 Relay for horn
6 KAH Relay for main modules power supply
G
4000595920 E 05.17 USA / (1 39


2.3 - ACTUATORS AND THEIR LOCATION
2.3.1 - List of actuators
In the following tables :

• The column n°2 indicates the position on the connector on modules (if required).
• The state noted "0" corresponds to 0 V, opened contact or not activated.
• The state noted "1" corresponds to the tension of the circuit, closed or activated contact.
Glossary
MARKING DESCRIPTION
FWD Forward drive
REV Reverse drive
FL Front left
FR Front right
RL Rear left
RR Rear right
PF Platform
LS Low speed drive
LS valve/adj Load sensing valve/adjustment
MS Medium speed drive
HS High speed drive
ILS Magnet reed sensor
UCB Upper control box
LCB Lower control box
ECU Electronic Control Unit
PWM Pulse Width Modulation
PCB Printed circuit board
2.3.2 - Modules
MODULES
NAME LOCATION FUNCTION

01 Multi function CAN display (Activ screen)
02 COMBIACX Variator (Master)
02 ACEX Variator
U4 03 CAN tiller board (UCB)
40 4000595920 E 05.17 USA / (1


2.3.3 - Fuses
A
FUSES
NAME LOCATION CONNECTOR FUNCTION

FU1A 01 - 03 Protection ACEX variator (125 A)
FU1C 01 - 07 Protection COMBIACX variator (300 A) B

FU2 01 - 08 Protection electrovalve circuit (10 A)
FU3 01 - 05 Protection main circuit (10 A)
FU4 01 - 12 Protection accessories circuit (10 A)
2.3.4 - Inputs
C
INPUTS

SA103 02 - 17 AXC.2 Manual brake release switch (21) D
SA901 01 - 12 Key selection (upper/lower controls) (133/135)
SA903 01 - 15 Flashing light (Option) (32)
SA904 03 - 05 Option working light (134)
SA907
SA907B
03 - 16
02 - 20
B.4
AXB.4
Horn switch (Upper controls) (34)
Horn switch (Lower controls) (Option)

E
SA908 03 - 17 B.12/B.13 Selection function (movements/drive) (76/85)
Foot pedal switch ( US option = 1 for any

SB800 03 - 12 B.1
SB801 01 - 13
movement)(37)
Emergency stop button (Lower controls) (84) F

SB802 03 - 14 Emergency stop button (Upper controls)
SM901 03 - 10 A.10 Joystick ( 39: value 0.5 / 2.5 / 4.5VDC)
4000595920 E 05.17 USA / (1 41

SENSORS

Pressure transducer 4 - 20 mA located in large
SP400 02 - 06 CXC.9
chamber of lifting cylinder (14)
SQ144 / SQ145 02 - 18 AXA.4 Potholes position ( = 1 if retracted; out in lift mode) (15)
Tilt Y = 1.5° / X =3° (wire 12 = Vbat if machine on flat

SQ800 02 - 02 CXA.12 surface)
1=red=+Batt / 2=white=signal / 3=black=GND
Potentiometer for steering wheels angle (value 2.5 O)

SR150 02 - 14 AXC.4
(47)
SR420 02 - 04 CXC.4 Angle transducer for scissors arm position (13)
SR722 02 - 16 AXC.9 Angle transducer for platform height detection (20)
Temperature probe inside AC RR drive motor (if at

ST302 02 - 08 CXD.3/6
105° C current null and no drive)
Temperature probe inside AC RL drive motor (if at

ST303 02 - 15 AXD.3/6
105° C current null and no drive)
ST903 02 - 16 AXC.7 Temperature sensor (Option RUS/UKR)
Controls the motor speed through an encoder with 2

SV300 02 - 09 CXD.1/2/4/5 signals shifted at 90° each and 48 pulses per
revolution
Controls the motor speed through an encoder with 2

SV301 02 - 13 AXD.1/2/4/5 signals shifted at 90° each and 48 pulses per
revolution
42 4000595920 E 05.17 USA / (1


2.3.5 - Outputs
A
RELAYS-MOTORS

KAH 01 - 07 Main relay for commands (115)
KA1 02 - 17 AXB.7 Horn command (70) B

KA2 02 - 20 AXA.8 Flashing light command (89)
KA3 02 - 10 CXB.1/5 Brake release command (remote control)
KA4 04 - 04 Option
KM900 01 - 06
Battery charger relay (If activated, no function on
machine) (98)
C
M370 02 - 06 U/V/W AC drive motor (RR)
M371 02 - 13 U/V/W AC drive motor (RL)
SB801 01 - 13 Main line contactor for ECU modules (84)

D
VALVES
YB100 02 - 11 CXB.1/5
Electromagnetic brake at negative excitation for RR
motor E
Electromagnetic brake at negative excitation for RL
YB101 02 - 12 AXB.1/5
motor
Valve 6 ways/ 2 positions for selection potholes or

YV120 02 - 03 CXB.3
steering (priority for potholes) (56)
YV121 02 - 05 CXA.1 Right steering or potholes retraction (54) F

YV122 02 - 06 CXA.8 Left steering or potholes out/extended (53)
PWM valve for platform lift/descent (Slow descent

YV420 02 - 18 AXB.3
when PF < 3 meters) (19)
YV903 02 - 19 AXA.2 Discharge valve (by-pass: pump is in pressure) (55)

G
4000595920 E 05.17 USA / (1 43

BUZZER AND LIGHTS

HA901 05 - 13 CXA.9 Buzzer (04)
HA907 03 - 13 Horn (184)
EL901/B 06 - 05 Option flashing light (32)
EL904 09 - 19 Option working light (134)
HL100 09 - 11 E.7 Drive selection indicator (94)
HL420 08 - 09 E.6 Movement selection indicator (46)
HL800 09 - 10 F.3 Slope (tilt) indicator (45)
HL802 09 - 10 F.1 Overload indicator (44)
HL903 09 - 10 F.5 Other alarms indicator (43)
HL904 09 - 10 F.2 Battery level indicator (42)
44 4000595920 E 05.17 USA / (1


2.4 - CUT OUT CONDITIONS OF EVERY FUNCTION
2.4.1 - Glossary
A
MARKING DESIGNATION
U Up
D
L
Down
Left
B
R Right
F/FWD Forward
REV/B Reverse/backward
SETP
A IN
Setpoint
Analogic input
C
D IN Digital input
D OUT Digital output
A OUT Analogic output
PWM
VAR
Pulse Width Modulation (Proportionnal valve in current square modulated signal)
Internal variable in the module (not accessible with the console)
D
I/O Inputs/Outputs
I Input
O Output
µS
MS
Micro speed drive
Medium speed drive E
HS High speed drive
2WS 2 wheels steering
4WS 4 wheels steering
4000595920 E 05.17 USA / (1 45


2.4.2 - Power supply/commands
N.B.-:-
• The diagnostic menu is very important on this model as it will permit to the technician to focuse only on the
dysfunction encountered and then save time to repair the machine.
• The explanation done below is built on the same basis for all movements.
COMMANDS ALL COMMANDS COMING FROM LOWER/UPPER CONTROLS

Inputs Digitals or analogic inputs (ETOR-EANA)
In Diagnostic menu, it's the parameter Internal setpoint for the function described Neutral to Fwd/
Setpoint (0-100%) up/left or Rev/down/Right (0-1000pts)
This setpoint is null when no movement is performed or there is a failure on the josytick
Conditions for cutting the movements :
Cuttings • Null movement is authorized
• 1 movement is inhibited
Validation and formatting the
Conditions for validation of the movement
command
Slow down Condtions for slowing down the movement (from 0 to 100%)
In Diagnostic menu, it’s the parameter Internal control for the internal command of the function (0-
Control (0-100%)
1000pts)
Outputs Digitals or Analogic outputs (STOR-SPWM-SANA)
Actuator Any device like valves/cylinders/motors/relays
46 4000595920 E 05.17 USA / (1


Explanation of the cinematic
A
C
Explanation of the Cuttings function
This is valid for every movement including drive mode.
BIT
0
CUT-OFF CONDITIONS
Enable General movement deactivation
DESCRIPTION
D
1 General General Inhibition
2 Simultaneous movements Inhibition due to numerous movements activated at the same time
4
Overload
Tilt
Inhibition due to machine is in overload mode
Inhibition due to machine is in tilt/slope

E
5 Reach limit Inhibition due to machine is in outreach limitation mode
6 Failure Inhibition due to Faliures
7 Specific Inhibition due to specific conditions /options

F
4000595920 E 05.17 USA / (1 47

REQUIREMENTS DEFINITION
Machine is powered ON with key SA901 of lower control box if no emergency stop is pushed
(EMSTOP=ON and PowerON=1). At power on, the relays close : SB801=ON & KAH=ON
• Supply 24 V of power part (motor, pump and electro valves).
PS001.1 • Supply 24 V of lower signal part (switches and sensors).
• Supply the upper part.
During machine use, the SB801 main contactor is controlled through high level software to save some
energy ( 150 mA to 200 mA current consumption) : SB801 = CTRL[MainContactor]
At power ON, the software automatically compares identifier stored into EEPROM with identifier
embedded in the loaded soft. If identifiers are different (blank ECU or new soft type loaded), then :
• All failures are reinitialized (reset of counters and log).
PS002
• Default speed, ramps, options and configurations vales are reloaded.
• Hour-meter stored into EEPROM is set to 0.
• Failure F12.04 is triggered.
If one of the emergency stop is pushed ( EMSTOP = OFF) until end of saves in EEPROM, machine is on
power hold mode.
• SB801=0: supply for power and upper parts is cut.
PS003
• CAN Failure F12.01 is inhibited.
• KAH doesn’t change : Supply 12 V and 24 V for lower signal parts are hold.
• Start of EEPROM saves before stop.
On power hold mode; when all EEPROM saves are done : KAH=ON
PS004
• The machine is switch off when KAH=OFF.
Machine counters (hours and service) are stored into ECU EEPROM in order to detect when the screen is
changed and then to reload automatically the old values stored into the new screen. For that, at machine
power ON :
PS005
• If Hourmeter(EEPROM) > Hourmeter(SCREEN) => Counters (hours and service) are reloaded from
values stored into ECU EEPROM.
• Otherwise current counters values are stored into ECU EEPROM.
48 4000595920 E 05.17 USA / (1


2.4.3 - Drive
2.4.3.1 - Validation
A
The drive movement happens relative to the activated panel, in the specified direction and set point and
DSV01
regarding to validation and slowdown conditions : SETP[Drive]=FWD|N|REV:[0-100]%
B
Forward (F) and/or reverse (R) drive movement is allowed if all validation conditions are satisfied and
none of cut-offs condition is true (see DVR03)
DSV02.1
VALIDATION
1
F
1
R
1
ENABLE CONDITIONS
Machine powered on for more than 3s
C
0 Enable 2 1 1 Machine is set
3 1 1 User is identified
1: The condition enables the movement (All conditions to '1': movement enabled)
D
The following conditions (General to Specific) inhibit the drive movement ( F: forward/ R: reverse)
CUT-OFF F R GENERAL CUT-OFF CONDITIONS
Machine unfolded and potholes not extended out of
1
2
1
1
1
1
production mode
Battery charge level low (< 20%) And machine
E
DSV03 unfolded out of production mode
1 General Machine not low and "Drive restrictions when lifted"
3 1 1
option is set to "0.5m" value
Machine unfolded and "Drive restrictions when
4
5
1
1
1
1
lifted" option is active
Time out after drive movement
F
SIMULTANEOUS MOVEMENTS CUT-OFF

DSV03
CUT-OFF
Simultaneous
F R
CONDITIONS G
2 5 1 1 Manual brake release is active
movements
CUT-OFF F R OVERLOAD CUT-OFF CONDITIONS H

DSV03 1 1 1 Overload alarm is active
3 Overload
2 1 1 Overload learning is running
4000595920 E 05.17 USA / (1 49

CUT-OFF F R TILT CUT-OFF CONDITIONS

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

DSV03
5 Reach limit N/A N/A N/A N/A
CUT-OFF F R FAILURE CUT-OFF CONDITIONS

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

DSV03
Extreme temperature (for Russia country) and
7 Specific 1 1 1
machine unfolded
50 4000595920 E 05.17 USA / (1

REQUIREMENTS DEFINITION A
Following limits are applied on the set point (SETP[Drive]):
DIRECTIONS
MOVEMENT SET POINT LIMIT CONDITIONS
F R
DSV04.2
SPEED[uS Drive Fwd] SPEED[uS Drive Rev] 1
Unfolded machine (micro speed) and not
masked
B
Steer angle not calibrated or steer angle out of
range and not masked
Arm angle function not calibrated or failing and
not masked
( 100% = max speed) C
DSV05 When machine is unfolded, drive speed is set to 'Micro' value
REQUIREMENTS DEFINITION D
The three conditions listed in DSV04 requirement are inhibited in case of :
• Machine serial number is "000000".
• Steer angle must be calibrated.
• Both angle sensors are not electrically out of range (> 100 mV and < 4900 mV) And angle computed is
less than 18°.
DSV06.1
• Pressure sensor indicates low pressure. (< 5 pts)
Serial number="000000" " & F10.16(A) & \F10.14(A) & (SP400 < 50pts)
E
& ( ( (10pts < SR420 < 478pts ) & (10pts < SR722 < 478pts ) & VAR[Angle] < 18° )
| ( (10pts < SR420 < 478pts ) & VAR[Angle_SR420] < 18°)
| ( (10pts < SR722 < 478pts ) & VAR[Angle_SR722] < 18°) )
4000595920 E 05.17 USA / (1 51


2.4.4 - Steering
The steering movement happens in the specified direction and set point, regarding to validation and slow
STV01
down conditions : SETP[Steering]=LEFT|N|RIGHT:[0-100]%
Steering (both directions, each mode) is allowed if all validation conditions are satisfied and none of cut-off
conditions is true (see DRV03)
VALIDATION L R ENABLE CONDITIONS
1 1 1 Machine powered on for more than 3s
STV02.1
2 1 1 Hydraulic pump is ready
0 Enable
3 1 1 Machine is set
The following conditions (General to Specific) inhibit the steering movement ( L: left / R: right)
CUT-OFF L R GENERAL CUT-OFF CONDITIONS
Machine unfolded and potholes not extended out of
1 1 1
production mode
Battery charge level low (< 20%) And machine
STV03 2 1 1
unfolded out of production mode
1 General Machine not low and "Drive restrictions when lifted"
3 1 1
option is set to "0.5m" value
Machine unfolded and "Drive restrictions when
4 1 1
lifted" option is active
5 1 1 Time out after drive movement

CUT-OFF L R
CONDITIONS
STV03
Simultaneous
movements
CUT-OFF L R OVERLOAD CUT-OFF CONDITIONS

STV03 1 1 1 Overload alarm is active
3 Overload
2 1 1 Overload learning is running
52 4000595920 E 05.17 USA / (1

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

STV03
C
CUT-OFF L R FAILURE CUT-OFF CONDITIONS
Machine unfolded and load management
2 1 1
system not calibrated and serial number is set
The two arm angle sensors are out of range
D
3 1 1
and load management is active
STV03 Serious incoherence in measuring arm angle
6 Failure 4 1 1
and load management is active
5 1 1 Machine unfolded and pressure failure
6
7
1
1
1
1
Power failure
Steering valve failure
E
9 1 1 Arm incoherence ( YV903 failure)
REQUIREMENTS DEFINITION F
CUT-OFF L R SPECIFIC CUT-OFF CONDITIONS
1 seconds of left steering control and no variation of
1 1 N/A steering angle OR steering angle < mechanical
limit -1°
STV03
7 Specific
2 N/A 1
1 seconds of right steering control and no variation
of steering angle OR steering angle > mechanical
G
limit +1°
Extreme temperature (for Russia country) and
3 1 1
machine unfolded
4000595920 E 05.17 USA / (1 53

STV04 There is not limitation of steering set point
2.4.4.2 - Actuators
The formatted control (CTRL[Steering]) is applied on the actuators driving the movement
CTRL Pump YV122 YV121 YV903
STA01 LEFT CTRL[PumpSteering] 1 0 1
NEUTRAL 0 0 0 0
RIGHT CTRL[PumpSteering] 0 1 1
54 4000595920 E 05.17 USA / (1


2.4.5 - Arm
A
Steering movements happen in the specified direction and set point regarding to validation and slowdown
AMV01
conditions : SETP[Arm]=UP|N|DOWN:[0-100]%
B
Raise (U:up) or descent (D:down) of arm is allowed if all validation conditions are satisfied
VALIDATION U D ENABLE CONDITIONS
1 1
1
1
N/A
Pump is ready
C
AMV02 2
0 Enable N/A 1 Always true (descent with gravity)
D
The following conditions (General to Specific) inhibit the arm movement ( U: raise / D: descent)
CUT-OFF U D GENERAL CUT-OFF CONDITIONS
AMV03
1 General
1
2
1
1
N/A
N/A
Machine in high position
Low battery level
E
AMV03
CUT-OFF U D
CONDITIONS F
Simultaneous
movements
REQUIREMENTS
CUT-OFF U
DEFINITION
D OVERLOAD CUT-OFF CONDITIONS

G
AMV03 1 1 1 Overload alarm is active
3 Overload Load management system calibration running and
2 1 N/A
stop requested
4000595920 E 05.17 USA / (1 55

CUT-OFF U D TILT CUT-OFF CONDITIONS

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

AMV03
CUT-OFF U D FAILURE CUT-OFF CONDITIONS

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

3 s stop at folded position detection change of state
during descent (scissor unfolded to scissor folded)
1 N/A 1
for STD or RUK countries out of descent speed
setting
AMV03
7 Specific 1.5 s stop at descent set point resumption when
2 N/A 1 scissor is folded for STD or RUK countries out of
descent speed setting
Extreme temperature detected and unfolded
3 1 N/A
machine and Russia/Ukraine country
56 4000595920 E 05.17 USA / (1

Following limits are applied on the set point ((SETP[Arm]))
DIRECTIONS
MOVEMENT SET POINT LIMIT CONDITIONS
U D
AMV04
50% 50% 1 Tilt and machine unfolded
Chassis control box active and load management calibration not in
B
75% 75% 2
progress
N/A 50% 3 Descent when machine is folded machine
N/A 50% 5 Failure F07.06 ( (id 01 and 02) or id 8)
( 100% = max speed)
C
4000595920 E 05.17 USA / (1 57


2.4.5.2 - Actuators
The formatted control (CTRL[Arm]) is applied on the actuators driving the movement
Raise movement :
• Hydraulic pump guarantees the proportionality of raise movement: control pump value (CTRL[PumpArm]) is
computed from the arm raise value (CTRL[Arm]).
• YV420 proportional electro valve is used as digital electro valve (proportionality guaranteed by hydraulic
pump) :
• Its aperture is timed (Ton 100 ms ) after the control of hydraulic pump to avoid over-pressure.
• Its closure is done when pump control value is below VALUE_TO_BE_DEFINED (between acceleration bias
and deceleration bias to be sure movement is stopping).
• YV903 digital electro valve is active to enable the raise movement
AMA01 Descent movement :

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

RAISE CTRL[PumpArm] 100% 1
NEUTRAL 0 0 0
DESCENT 0 CTRL[Arm] 0
With :
• -CTRL[PumpArm] value = CTRL[Arm] Value when arm raise is in progress
58 4000595920 E 05.17 USA / (1

After a movement of raise or descent, if the country is not USA, the arm cylinder valve YV420 is
controlled at low values to suppress the pressure due to dynamics and then enable a reliable and
repetitive measure of pressure for load management system. The values of control are automatically
adjusted during load management system calibration. The duration of the control is height dependant
(longer with the height: from 1500 ms to 3000 ms ) and this control happens 500 ms after the end of arm
raise or arm descent movements.
B
AMA02
C
This special control is inactivated for USA version (no measure of load).
4000595920 E 05.17 USA / (1 59


2.4.6 - Brake release
The release of brake is controlled :
• Automatically during the normal operating mode.
• Or on special conditions during test mode.
• Or manually via the SA103 switch.
Init Machine is powered off

Release of brake is controlled based on the drive
BRV01 Automatic
motion control
Test Test mode for brakes
Wait for falling edge of manual brake releasing set
Wait for confirmation
point
Manual Brake is released
Power ON Machine powered ON
Active test Periodical activation of test
Stop test Test ended
Out of tilt position and with folded scissor, manual
Begin manual activation release of brake set point is active for more than 3 s
consecutively
Manual activation confirmed Falling edge detected in the next 10 s
No falling edge detected in the next 10 s (short
Not detected
circuit to VBAT of the switch)
Manual release of brake set point is active (and has
End of manual activation been detected inactive) or change in control box
selection or joystick out of neutral or switch active
60 4000595920 E 05.17 USA / (1


2.4.7 - Potholes
A
Steering movements happen in the specified direction and set point regarding to validation and slowdown
conditions. The potholes set point is automatically computed based on the control of drive movement or
arm movement :
CTRL[Drive]≠N:0 & \F07.06(D) & (\F10.16(D) | VAR[MaskMicroSpeedForProduction]= 1) -->
B
POV01.1 SETP[Potholes]=IN:100%
CTRL[Arm]=UP:[1;100]% | (SETP[Drive]≠N:0 & (F07.06(D) | (F10.16(A) &
VAR[MaskMicroSpeedForProduction]= 0) ) -->
SETP[Potholes]=OUT:100%
CTRL[Drive]=N:0 & CTRL[Arm]≠UP:[1:100]%--> SETP[Potholes]=N:0
C
Extension (O: out) and/or retraction (I: in) of potholes movement is allowed if all validation conditions are
satisfied and none of cut-offs condition is true (see DRV_03)
POV02
VALIDATION
1
O
1
I
1
ENABLE CONDITIONS
D
0 Enable 2 1 1 Hydraulic pump is ready
1: The condition enables the movement (All conditions to 1: movement enabled)
E
The following conditions (General to Specific) inhibit the potholes movement (O:Out / I:In)
CUT-OFF O I GENERAL CUT-OFF CONDITIONS
Drive is the selected movement when failures
1 1 N/A
POV03.1
1 General 2 N/A 1
F07.06 is not detected and F10.16 not active
Arm is the selected movement
F
3 N/A 1 Scissor is unfolded out of production mode
4 1 N/A Potholes extended (with timer)

G
CUT-OFF O I
CONDITIONS
POV03.1
Simultaneous 2 1 1 Steering is active
2
movements 5 1 1 Manual brake release is active
H
CUT-OFF O I OVERLOAD CUT-OFF CONDITIONS
POV03.1
3 Overload N/A N/A N/A N/A
4000595920 E 05.17 USA / (1 61

CUT-OFF O I TILT CUT-OFF CONDITIONS

POV03.1
4 Tilt N/A N/A N/A N/A
CUT-OFF O I REACH LIMIT CUT-OFF CONDITIONS

POV03.1
CUT-OFF O I FAILURE CUT-OFF CONDITIONS

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

Drive movement is in progress and steering is
1 N/A 1
requested
POV03.1
7 Specific Ended timer (consecutive or discrete) of potholes
retraction since power on or since last extension, the
2 N/A 1
value of the timer is 2 s in normal mode or 10 s in
production mode
STV04 There is not limitation of potholes set point
62 4000595920 E 05.17 USA / (1


2.4.7.2 - Actuators
A
The formatted control (CTRL[Steering]) is applied on the actuators driving the movement
CTRL Pump YV121 YV122 YV903
IN
NEUTRAL
CTRL[PumpSteering]
0
1
0
0
0
1
0
B
OUT CTRL[PumpSteering] 0 1 1
Potholes extension :
D
STA01
Potholes retraction :
E
4000595920 E 05.17 USA / (1 63

Notes
64 4000595920 E 05.17 USA / (1

D - Study of the hydraulic schema
Study of the hydraulic schema

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

G
1 YV903 By-pass valve (pump is in pressure)
2 YV122 Left steering or potholes exit
3 YV121 Right steering or potholes retraction
4000595920 E 05.17 USA / (1 65


1.1.1.2 - Selection valve potholes/steering

Valve 6 ways / 2 positions for selection potholes or steering (priority for
1 YV120
potholes)
66 4000595920 E 05.17 USA / (1


1.1.1.3 - Lifting cylinder valve
A
1 YV420
Valve PWM (Pulse Width Modulation) lift/descent of platform (Slow
descent when PF < 3 meters. Information coming from angle sensor
E
SR420)
4000595920 E 05.17 USA / (1 67

Notes
68 4000595920 E 05.17 USA / (1

E - Adjustments
Adjustments A
1 - Adjustments with diag pad console
The adjustments/parameters settings /list of alarms, calibration of the machine are accessible on on-board activ
screen console, as well as this console below or Haulotte Diag application installed in laptop.
The VCI (Vehicle Computer Interface) adapter could be connected from any controls (turret or in platform) using
B
wireless or cable connection.
The full description of how to use that console and its menus is explained in a technical note PI144 (for more
information refer to your nearest HAULOTTE Services® of your area)
G
VCI
4000595920 E 05.17 USA(1 69

E - Adjustments
2 - List of menus
See end of manual
2.1 - MACHINE SETTINGS

2.1.1 - Speeds and ramps
See end of manual : Annex 1
2.1.2 - Options
2.1.3 - Configurations
2.1.4 - Countries and models
2.2 - DIAGNOSTIC
2.2.1 - Inputs/Outputs
2.2.2 - States
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E - Adjustments
3 - Failures list A
• For any type A (ACTIVE) failure code, it will appear on display in lower control and the warning light will flicker
E
on upper controls (see below).
• For any type D (DETECTED) failure code, it will also appear on display in lower control and the warning light
will flicker on upper controls.
• For any type N failure code, it means that this alarm will never appear on display.
• An internal code (column C) with 5 digits, visible only on the console, allows specifying the trigger conditions of
the failure.
F
Each trigger condition is associated with a single code number (16 possible single codes in decimal format
corresponding to a single bit in binary format) :
• If several conditions are active at the same time, single codes are added to form the resulting code displayed.
For example, il conditions 1 and 4 of single code are active, then the resulting code displayed will be 5 (1+4=5).
All alarms codes are gathered per category (ex F02xxx contactors)
G
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E - Adjustments
3.1 - LIST OF FAILURES PER CATEGORY
FAILURES N C DESCRIPTION
INVERTER
COMBIACX: Failure in the high current hardware protection circuit.
1 • Internal fault.
• Replace the inverter.
COMBIACX: When no current is applied to the traction motor, the current feedbacks are out of
permitted standby range.
2 • Type of default not related to external components.
• Cycle power to clear the fault.
• If the fault is not cleared, replace the controller.
COMBIACX: Driver of main contactor coil is damaged (not able to close).
• Type of default not related to external components.
F01.01 4
Inverter A • If the fault is not cleared, replace the controller.
Master
COMBIACX: The driver of the electromechanical brake coil is not able to drive the load.
• Replace the controller.
COMBIACX: Pump current sensor out of range (at start-up or standby).
COMBIACX: At start-up, the amplifiers voltage (used to measure the motor voltage) is too low or too
high (< 2 V or > 3 V).
32
• Internal fault.
COMBIACX: The software waits for the motor pump to stop at start-up.
• If the motor connected to "-P" is still moving, wait for it to be still.
1
• If not, wait 30 seconds until alarm "PUMP VMN NOT OK" appears.
• Refer to corresponding alarm chapter.
COMBIACX: Pump driving voltage different than the expected one.
2
• Key OFF/ON.
COMBIACX: The pump motor output voltage is lower than expected, considering the control applied.
• Check the motor power wiring and connections.
4 • Check the motor phases for proper insulation with the chassis.
• Check that MC DRIVE power contact close properly, with a good contact.
F01.05
A • If no problem is found on the motors, replace the controller.
Pump failure
COMBIACX: The pump motor output voltage is higher than expected, considering the control applied.
• Check that main contactor drive power contact close properly, with a good contact.
• If no problem is found on the motors, replace the controller.
COMBIACX: The pump current sensor feedback is always 0A, even if pump motor is running.
• Check the pump motor connection and continuity.
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E - Adjustments
FAILURES N C DESCRIPTION A
COMBIACX: The controller has reached thermal cutout (temperature of the controller base plate is
higher than 85°C).
• Power down and allow to cool.
• Do not operate in ambient temperatures over to 60°C.
1
• Check for jammed or obstructed drive motor.
• Check for excessively high drive motor current consumption while driving on the level (over 70A).
• Check controller for proper installation.
B
F01.06 • If the controller is cold when the default appears, replace it.
A
Overheating ACEX: The controller has reached thermal cutout (temperature of the controller base plate is higher
than 85°C).
• Power down and allow to cool.
2
• Do not operate in ambient temperatures over to 60°C.
• Check for jammed or obstructed drive motor.
• Check for excessively high drive motor current consumption while driving on the level (over 70A).
C
• Check controller for proper installation.
• If the controller is cold when the default appears, replace it.
Low battery voltage ( estimated value < 10%).
• Check for damaged batteries, battery cables or connections.
F01.08
Low Battery
A 1
• Recharge batteries.
• Measure batteries voltage and compare it with the value BATTERY VOLTAGE parameter in the
D
TESTER menu.
• If they are different, adjust the value of the ADJUST BATTERY function.
COMBIACX: Short circuit detected on electromechanical brake or main contactor output (overcurrent).
• Main contactor drive coil : Check connections and wiring for interruptions between controller and coil.
1
• Motor brake coil : Check connections and wiring for interruptions between controller coil.
• If the wiring is correct, the problem is in the controller : Replace it.
COMBIACX: The driver of the electromechanical brake coil is shorted.
E
2 • Check if there is a short or a low impedance pulldown between NEB CNA#4 and –BATT.
• The driver circuit is damaged in the controller, which has to be replaced.
COMBIACX: The driver of the electromechanical brake is shorted to +Vbatt.
The output of the built in Smart Driver, which supplies the positive to the electromechanical brake coil is
4
high when the Tiller and the H and S switch are opened.
• Check the harness, in order to verify if a positive is connected to the Smart driver output CNB#1.
• If, even disconnecting the wire from the connector pin, the output stays at high value, the problem is
F
F01.09
Electrical A inside the controller and the Smart Driver is probably shorted.
park brake 1 COMBIACX: A short circuit on the power outputs of the controller has been detected.
• Check the EB driver output for a short circuit with +Vbatt.
8
inside the controller : Replace it.
COMBIACX: Voltage on PEB present but not expected.
G
16 • Check external wiring.
• If the wiring is correct and no problem is found on the coil, replace the controller.
COMBIACX: Internal Smart driver KO and ACEX : internal Smart driver is not KO (if both signals are
KO failure F08.10).
32 • Check the driver output for a short circuit with -Vbatt.
• If, even disconnecting the wire from the connector pin, the output stays at low value, the problem is
H
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E - Adjustments
ACEX: Short circuit detected on electromechanical brake or main contactor output (overcurrent).
• Main contactor drive coil : Check connections and wiring for interruptions between controller and coil.
1
• Motor brake coil : Check connections and wiring for interruptions between controller coil.
• If the wiring is correct, the problem is in the controller : Replace it.
ACEX: The driver of the electromechanical brake coil is shorted.
2 • Check if there is a short or a low impedance pulldown between NEB CNA# and –BATT.
• The driver circuit is damaged in the controller, which has to be replaced.
ACEX: The driver of the electromechanical brake is shorted to +Vbatt.
The output of the built in Smart Driver, which supplies the positive to the electromechanical brake coil is
high when the Tiller and the H and S switch are opened.
4
• Check the harness, in order to verify if a positive is connected to the Smart driver output CNB#1.
F01.10 • If, even disconnecting the wire from the connector pin, the output stays at high value, the problem is
Electrical A inside the controller and the Smart Driver is probably shorted.
park brake 2 ACEX: A short circuit on the power outputs of the controller has been detected.
• Check the EB driver output for a short circuit with +Vbatt.
8
ACEX: Voltage on PEB present but not expected.
16 • Check external wiring.
• If the wiring is correct and no problem is found on the coil, replace the controller.
ACEX: Internal Smart driver KO and ACEX : internal Smart driver is not KO (if both signals are KO
failure F08.10).
32 • Check the driver output for a short circuit with -Vbatt.
COMBIACX: Failure in the high current hardware protection circuit.
• Replace the inverter.
COMBIACX: When no current is applied to the traction motor, the current feedbacks are out of
permitted standby range.
2
• Cycle power to clear the fault. If the fault is not cleared, replace the controller.
COMBIACX: Driver of main contactor coil is damaged (not able to close).
F01.11 • Cycle power to clear the fault. If the fault is not cleared, replace the controller.
Inverter A
COMBIACX: The driver of the electromechanical brake coil is not able to drive the load.
Slave
COMBIACX: Pump current sensor out of range (at start-up or standby).
COMBIACX: At start-up, the amplifiers voltage (used to measure the motor voltage) is too low or too
high (< 2 V or > 3 V).
32
• Internal fault.
F01.12 1 COMBIACX : Hardware version is not the expected one.
Wrong
D
controller 2 COMBIACX : Hardware version is not the expected one.
hardware
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E - Adjustments
CONTACTOR
The driver of main contactor drive coil is shorted, or its coil is disconnected.
• Ensure there is no short or low-impedance pull-down between MC and -Vbatt.
1
• Check connections and wiring for interruptions of MC DRIVE coil.
• If wiring and connection are correct, the problem is in the controller : Replace it.
The main contactor coil has been driven by the controller, but the contactor does not close.
B
F02.04 2 • Check the contact in the main contactor drive contactor and if it is not working, replace the main
Power contactor drive.
D
Contactor
Before driving the LC coil, the controller checks if the contactor is stuck.
SB801
The controller drives the bridge for some tens milliseconds, trying to discharge the capacitors bank.
4
If they don't discharge the fault condition is entered.
• Check the power contact of the main contactor drive and replace it if necessary.
C
Supervisor status is "alarm" or "wait reset" and main contactor is not forced open.
8
• Key OFF/ON.
FAILURES N C
ELECTROVALVES
DESCRIPTION
D
Short circuit detected on steering front left electro valve :
F04.01 1
--> YV121 = FAIL
Steering D
Short circuit detected on steering front right electro valve :
YV121/YV122 2
--> YV122 = FAIL
F04.04
Arm D
Short circuit detected on arm descent electro valve :
E
--> YV420 = FAIL
YV420
F04.11
Principal Short circuit detected on pump discharge electro valve :
D 1
movements
YV903
--> YV903 = FAIL
F
Short circuit detected on pothole extend electro valve :
F04.40 1
--> YV122 = FAIL
Potholes D
YV121/YV122 Short circuit detected on pothole retract electro valve :
2
--> YV121 = FAIL
F04.41
Movement
D
1
Short circuit detected on steering / potholes selection electro valve :
--> YV120 = SHORT CIRCUIT FAILURE
G
Selection Short circuit detected on steering / potholes selection electro valve :
2
valve --> YV120 = OPEN CIRCUIT FAILURE
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E - Adjustments
JOYSTICKS
Analog signal SM901 is out of allowed range :
F05.01 1
--> SM901 < 0.2V | SM901 > 4.8V
Arm/Drive
D Incoherence between analog signal and out of neutral signals for SM901 joystick :
joystick
2 --> SM901N = 1 & (2,45V < SM901Y < 2,55V)
SM901
--> or SM901N = 0 & (SM901Y < 2.0V | SM901Y > 3.0V)
F05.11
Joystick Neutral position of arm and drive joystick SM901 not detected after upper control box selection :
D 1
neutral --> SM901 < 2.35V | SM901 > 2.65V
SM901
LOAD MANAGEMENT SYSTEM
F06.01
No Loading
Cal A Angle/pressure weighting system missing or not calibrated and EU|AU|RUK
Calibration
required
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E - Adjustments
SENSORS
COMBIACX: The motor temperature sensor is not correctly connected or damaged.
F07.05 1 • Key OFF/ON.
Motor
temperature
sensor
D
2
• Check wiring.
ACEX: The motor temperature sensor is not correctly connected or damaged.
• Key OFF/ON.
B
• Check wiring.
SR420 Arm angle sensor is out of allowed range when calibrated :
1
--> VAR[SR722_OutOfRange]=1
F07.06
2
SR722 Arm angle sensor is out of allowed range when calibrated :
--> VAR[SR722_OutOfRange]=1
SR420 and SR722 arm angle measured are not coherent when calibrated (with no error of out of
C
D
Arm Angle 4 range), first level of incoherence :
--> VAR[ArmAngleIncoherent]=1
SR420 and SR722 arm angle measured are not coherent when calibrated (with no error of out of
8 range), second level of incoherence :
--> VAR[ArmAngleIncoherent]=2
Pressure sensor is considered as out of range : Scissor arm angle is above 18° and pressure sensor
D
measures less than 10b (to handle the arm on kickstand --> pressure is null) And arm descent is not
F07.21 1
running :
Pressure D --> SP400 < (=0.2V) & VAR[ArmAngle] > 18 & CTRL[Arm]≠D
sensor
Pressure sensor is considered as out of range: pressure sensor voltage is above 10.5 V :
2
F07.33
D 1
--> SP400 > (=10.5V)
Steer angle sensor is out of range :
E
Steer angle -->VAR[SteerAngle] > 55.65° | VAR[SteerAngle] < -83.19°
From version v2.07: fix issue when driving in 25% ramp and steering at same time : In some cases, failure
F07.35 appeared, now fix.
COMBIACX: Problem on the encoder during drive.
F07.35 1
• Check connections and wiring for interruptions between controller and motor encoder.
• Check the harness for proper installation.
F
• Check the encoder mechanical installation. If the encoder slips inside its compartment, replace the
Motor
encoder or change the drive motor.
encoder D
ACEX: Problem on the encoder during drive.
• Check connections and wiring for interruptions between controller and motor encoder.
2 • Check the harness for proper installation.
• Check the encoder mechanical installation. If the encoder slips inside its compartment, replace the
encoder or change the drive motor.
G
COMBIACX: The ECU thermal sensor is out of range.
1 • Key OFF/ON.
F07.36 • Replace the controller.
ECU D
temperature
2
ACEX: The ECU thermal sensor is out of range.
• Key OFF/ON.
H
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E - Adjustments
ELECTRIC CIRCUIT
COMBIACX: Power capacitors voltage does not increase at start-up.
1 • Ensure that no external device is connected to the batteries.
• Check battery, power cables and connections.
COMBIACX: The controller detects an overvoltage or under voltage condition.
Overvoltage threshold is 35 V, under voltage threshold is 9.5 V.
• If the fault appears at start-up or during standby : Check that no external device (relays switching,
solenoids energizing/de-energizing... ) is connected to the batteries, creating down-going pulses.
• If no voltage transient is detected on the supply line and the alarm appears every time the key is
2
switched ON : Replace the controller.
• Check if the fault appears during driving acceleration (under voltage condition detected) : Check
battery charge ; check for damaged batteries, battery cables and connections.
• Check if the fault appears during release braking (overvoltage condition detected) : Check line
contactor contact, battery power cable connection.
COMBIACX: At start-up, the battery voltage is too low or too high (< 0,8 Vbatt or >1,2 Vbatt).
• Check that the controller SET BATTERY parameter value matches the battery nominal voltage
(24VDC).
4 • Check that the TESTER MENU / BATTERY VOLTAGE parameter shows same value as the battery
voltage measured with a voltmeter.
• If it does not match, then do a ADJUST BATTERY function.
• If the default still appears, replace the battery.
COMBIACX: A low logic level of Key-Off has been detected during start-up diagnosis.
• Check that no external device (relays switching, solenoids energizing/de,energizing...) is connected to
the batteries, creating downgoing pulses.
8 • Check the connection of power cabled to the battery terminal, positive and negative, to MC DRIVE
and to +Batt and -Batt, which must be screwed with a torque comprised in the range 5,6 Nm - 8,4 Nm.
F08.04 switched ON : Replace the controller.
A
Supply ACEX: Power capacitors voltage does not increase at start-up.
16 • Ensure that no external device is connected to the batteries.
• Check battery, power cables and connections.
ACEX: The controller detects an overvoltage or under voltage condition.
Overvoltage threshold is 35 V, under voltage threshold is 9.5 V.
• If the fault appears at start-up or during standby : Check that no external device (relays switching,
solenoids energizing/de-energizing... ) is connected to the batteries, creating down-going pulses.
32
• Check if the fault appears during driving acceleration (under voltage condition detected) : Check
battery charge ; check for damaged batteries, battery cables and connections.
• Check if the fault appears during release braking (overvoltage condition detected) : Check line
contactor contact, battery power cable connection.
ACEX: At start-up, the battery voltage is too low or too high (< 0,8 Vbatt or >1,2 Vbatt).
• Check that the controller SET BATTERY parameter value matches the battery nominal voltage
(24VDC).
64 • Check that the TESTER MENU / BATTERY VOLTAGE parameter shows same value as the battery
voltage measured with a voltmeter.
• If it does not match, then do a ADJUST BATTERY function.
• If the default still appears, replace the battery.
ACEX: A low logic level of Key-Off has been detected during start-up diagnosis.
• Check that no external device (relays switching, solenoids energizing/de,energizing...) is connected to
the batteries, creating downgoing pulses.
128 • Check the connection of power cabled to the battery terminal, positive and negative, to MC DRIVE
and to +Batt and -Batt, which must be screwed with a torque comprised in the range 5,6 Nm - 8,4 Nm.
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E - Adjustments
Two panels are selected : Check selector key :
A
F08.07 1
--> SA901T=ON & S0901PF=ON
Circuit A
No panel is selected : Check selector key :
selector 2
--> SA901T=OFF & S0901PF=OFF
F08.09
1
COMBI ACX: The PEV connector (B2) is not connected to the battery or the voltage is different.
• Check B2 connector is connected to +Vbatt.
• If the harness connections are correct, replace the controller.
B
Common A
ACEX: The PEV connector (B2) is not connected to the battery or the voltage is different.
output supply
2 • Check B2 connector is connected to +Vbatt.
• If the harness connections are correct, replace the controller.
ACEX: Internal Smart driver KO and COMBIACX : Internal Smart driver KO.
1
• Check the driver output for a short circuit with -Vbatt.
C
F08.10 ACEX: Problem on supply.
D
Power supply 2 • Check supply wiring (B+).
• Check wiring between COMBIACX and ACEX.
ACEX: Problem on supply.
4 • Check supply wiring (B+).
• Check wiring between COMBIACX and ACEX.
D
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E - Adjustments
FUNCTIONS
F10.14
Steering Steer angle is not calibrated.
A
angle not Perform steer angle calibration.
calibrated
F10.16
Arm angle is not calibrated.
Arm angle not A
Perform arm angle calibration.
calibrated
SAFETIES
F11.09 Arm raise is controlled and arm angle is decreasing, out of calibration process (arm angle or pressure
Arm D angle table).
incoherence Check YV903 valve (wiring and connection).
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E - Adjustments
INTERNAL FAULTS
For all failure details :
• Check wiring.
• Check the Can Bus connections.
• Ensure that all the connectors pins are properly in place and the connectors are free of moisture or
oxidation.
B
• Machine powered off, measure the resistance between CN03.F and CN03.G. If it is not 60 Ohm ±5%,
check continuity of the bus wires :
F12.01 • CAN LOW / 1001: From CN03.G (diagnostic connector) to ACTIV SCREEN X2.8 to COMBIACX CXC.10
to ACEX AXC.10 to CANTILLER C.4.
CAN Fault A
Check wires
• CAN HIGH / 1002: From CN03.F (diagnostic connector) to ACTIV SCREEN X2.7 to COMBIACX CXC.5
to ACEX AXC.5 to CANTILLER C.6.
1 No data is received from upper control box card.
C
2 No data is received from lower control box screen.
4 COMBIACX Module doesn't receive any CAN messages from ACEX module.
8 ACEX Module doesn't receive any CAN messages from COMBI ACX module.
16 No time (date/hour) update (problem with screen communication).
1 EEPROM failure status error.
D
2 EEPROM failure stack full.
COMBIACX: Wrong slip profile parameters or EEPROM damage.
4 • Perform a CLEAR EEPROM.
• If problem persists, replace the controller.
COMBIACX: Software or hardware error has been detected, default parameters are applied.
• Execute a CLEAR EEPROM operation.
E
• Cycle power to clear the fault :
8
• If the alarm disappears, the previously stored parameters will have been replaced by the default
F12.02 parameters.
E2P Read/ • If the fault is not cleared, replace the controller.
D
Write Error
Change calc.
ACEX: Wrong slip profile parameters or EEPROM damage.
16 • Perform a CLEAR EEPROM.
• If problem persists, replace the controller.
F
ACEX: Software or hardware error has been detected, default parameters are applied.
• Execute a CLEAR EEPROM operation.
• Cycle power to clear the fault :
32
• If the alarm disappears, the previously stored parameters will have been replaced by the default
parameters.
G
Problem reading EEPROM at start-up.
64
Restart machine.
ID of software loaded into machine is different from the ID stored into EEPROM: all machine
1 parameters have been reset and must then be set again (speeds, ramps, options, configs, access code
2
level 2, failure counters and calibration data).
Machine speeds and ramps have been reset and must be set again.
H
F12.04
4 Machine options have been reset and must be set again.
E2P Param
D 8 Machine configurations.
Reset
Check settings 16 Machine maintenance counters have been reset.
32 Machine daily log have been reset.
64 Machine events counters have been reset.
I
128 Machine events log counters have been reset.
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E - Adjustments
Model not set (not possible => always Optimum8)
1
Model = Not Set
Country not set : Set country
2
Country = Not Set
Serial number = 0: set serial number
F12.05 4
SerialNumber = "000000"
E2P Param D
At least one of the parameter used and not set ; Check all speeds and ramps
Not Set 8
SPEED[xxx] = Not Set | RAMP[xxx] = Not Set
At least one option used and not set ; Check all options
16
OPT[xxx] = Not Set
At least one config not set ; Check all configurations
32
CFG[xxx] = Not Set
F12.07
ECU software
A 1 Zapi software version different on COMBIACX and on ACEX.
version
incoherence
COMBIACX: Software watchdog active.
1
• Key OFF/ON.
COMBIACX: Problem on the Analog/Digitial conversion of micro controller.
2
• Key OFF/ON.
COMBIACX: Watchdog circuit output became high due to hardware or software problem (WDG1).
• Alarm caused by a hardware failure in one of two (or both) controllers or due to a software execution
problem.
4
COMBIACX: Watchdog circuit output became high due to hardware or software problem (WDG2).
F12.08 problem.
ECU fault A 8
(master) • Cycle power to clear the fault.
COMBIACX: Current gain acquisition has not been performed or EEPROM damaged.
16 • Key OFF/ON.
• If fault persists, a new current gain acquisition has to be performed.
COMBIACX: Wrong client software.
32
• Load the software to COMBIACX and ACEX controllers.
COMBIACX: RAM checksum failed.
COMBIACX: Timeout of client function (execution time exceed maximum allowable time).
128
• Key OFF/ON.
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E - Adjustments
ACEX: Software watchdog active.
1
• Key OFF/ON.
ACEX: Problem on the Analog/Digitial conversion of micro controller.
2
• Key OFF/ON.
ACEX: Watchdog circuit output became high due to hardware or software problem (WDG1).
B
problem.
4
F12.09
8
ACEX: Watchdog circuit output became high due to hardware or software problem (WDG2).
problem.
C
ECU fault A • Type of default not related to external components.
(slave) • Cycle power to clear the fault.
ACEX: Current gain acquisition has not been performed or EEPROM damaged.
16 • Key OFF/ON.
• If fault persists, a new current gain acquisition has to be performed. D
ACEX: Wrong client software.
32
• Load the software to COMBIACX and ACEX controllers.
ACEX: RAM checksum failed.
128
ACEX: Timeout of client function (execution time exceed maximum allowable time).
• Key OFF/ON.
E
This failure could happen when changing the software of the machine. Check evolution log. If happening,
restart machine.
1 Incoherence of Battery Parameters ; new value forced, restart mandatory.
F12.10
Parameters
reload
A
2
4
Incoherence of Motor Accessories Parameters ; new value forced, restart mandatory.
Incoherence of Motor Parameters ; new value forced, restart mandatory.
F
8 Incoherence of Option Parameters ; new value forced, restart mandatory.
Restart machine
16 Incoherence of Input Output Parameters ; new value forced, restart mandatory.
32 Incoherence of Machine Parameters ; new value forced, restart mandatory.
128 No parameters check / internal use for R and D only.
This failure happens at first power-on when reloaded on machine with software version 2.11 or on machine
G
never loaded before. If happening out of these cases, power off and power on again after 5 s.
F12.11
Parameters 1 Wrong parameter : out of expected range.
A
reload 2 Wrong parameter : EEPROM problem or RAM problem.
Restart machine 4 Wrong parameter : parameter current value is different from parameter initialized value.
8 Wrong parameter : incoherence between master and slave parameter source. H
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E - Adjustments
SWITCHES
F13.02 Incoherence between the 2 signals of front steering switch of platform box (both active) :
1
Platform --> SM901L = 1 & SM901R = 1
D
switches Incoherence between the 2 signals of movement selection :
2
Check switches --> SM903A = 1 & SM903B = 1
Neutral position of arm switch of turret box not detected after power on :
1
--> SA420U = 1 | SA420D = 1
F13.10 Neutral position of enable switch of turret box not detected after power on :
Neutral 2
--> SA905 = 1
switch A
Neutral position of horn switch of turret box not detected after power on :
Check chassis 4
--> SA907B = 1
switches
Neutral position of brake release switch of turret box not detected after power on :
8
--> SA103 = 1
Neutral position of front steering switch of platform box not detected after power on :
1
--> SM901L = 1 | SM901R = 1
Neutral position of enable trigger of platform box not detected after power on :
F13.11 2
--> SM901DM = 1
Switches
Neutral position of movement selection of platform box not detected after power on :
neutral 2 A 4
--> SM908A = 1 | SM908B = 1
Check plat.
switches Neutral position of klaxon switch of platform box not detected after power on :
8
--> SM907 = 1
Neutral position of brake release switch not detected after power on :
16
--> SM103 = 1
CAN J1939
F15.06
D 1 Error on CAN BUS.
J1939
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E - Adjustments
ENGINE
COMBIACX: Motor maximum temperature reached.
• Check the thermal sensor wiring and ohm value.
1
• Improve the air cooling of the motor.
F16.01
Overheating
A
• If the warning is present when the motor is cool, then the problem is inside the controller : Replace it.
ACEX: Motor maximum temperature reached.
B
• Check the thermal sensor wiring and ohm value.
2
• Improve the air cooling of the motor.
• If the warning is present when the motor is cool, then the problem is inside the controller : Replace it.
F16.02 1 COMBIACX: The drive motor has been detected stalled or the encoder is not working.
Speed
problem
A
2 ACEX: The drive motor has been detected stalled or the encoder is not working.
C
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E - Adjustments
COMBIACX: During drive, motor output voltage is lower than expected.
COMBIACX: During drive, motor output voltage is higher than expected.
COMBIACX: Motor voltage feedback circuits are damaged.
4 • Check the motor power wiring and connections.
• If the wiring is correct, the controller is damaged : Replace it.
COMBIACX: The motor output voltage is lower than expected, before MC DRIVE switch ON.
• Check the motor phase to phase impedance.
8 • Check the motor power cables connections.
• Check the motor phases for proper insulation with the chassis.
• If the motor connections are correct, replace the controller.
COMBIACX: The motor output voltage is higher than expected, before MC DRIVE switch ON.
F16.03 • If the motor connections are correct, replace the controller.
A
Motor supply ACEX: During drive, motor output voltage is lower than expected.
ACEX: During drive, motor output voltage is higher than expected.
ACEX: Motor voltage feedback circuits are damaged.
128 • Check the motor power wiring and connections.
• If the wiring is correct, the controller is damaged : Replace it.
ACEX: The motor output voltage is lower than expected, before drive main contactor switches ON.
ACEX: The motor output voltage is higher than expected, before drive main contactor switches ON.
86 4000595920 E 05.17 USA / (1

E - Adjustments
4 - Maximum height adjustment A
4000595920 E 05.17 USA(1 87

E - Adjustments
5 - Cutback speed position height adjustment
88 4000595920 E 05.17 USA / (1

E - Adjustments
6 - Load management system A

6.1 - CALIBRATION PROCEDURES
N.B.-:- B
Before starting the calibration, check that the sensors are well mounted mechanically (Lift the scissors
in order to get access to theses sensors).
Then preset them to the indicated values.
The sensors/fixation screws must be in the same axis as shown below and the support must be parallel
with axis. C
4000595920 E 05.17 USA(1 89

E - Adjustments
Pre setting of the transducers
MARKING SENSORS LOW POSITION UPPER POSITION

1 SR420 ~ 74 pts ~ 530 pts
2 SR722 ~ 420 pts ~ 530 pts
90 4000595920 E 05.17 USA / (1

E - Adjustments
6.2 - STEERING A
The calibration is required for multiple reasons :
• When the variator COMBIACX or one component linked to the steering has been changed.
• When the pump doesn't stop when steering at full lock (left or right).
Machine must be in stowed position and on flat surface ( SQ800 not activated) B
Reminder :
• Machine must be in stowed position and on flat surface.
• When wheel angle is out of range [-5;+5]°, a slowdown is applied on the external wheel (considering the
steering direction) :
• When wheels steer to the left the steer angle decreases : Its limit is set to -75.2°. C
• When wheels steer to the right the steer angle increases : Its limit is set to +47.6°.
4000595920 E 05.17 USA(1 91

E - Adjustments
6.2.1 - Steering calibration procedure
Preadjust the potentiometer so as to obtain the "steer angle" parameter at 0° to Activ’ Screen display
ANGLE SENSORS CALIBRATION VALID RANGE
pts V (approx.)
Left (-75.19°)
SR150 [150 ; 270] [01.539 ; 02.770]
Counter clockwise (CCW)
Right (+47.65°)
SR150 [755 ; 975] [07.746 ; 10.003]
Clockwise (CW)
92 4000595920 E 05.17 USA / (1

E - Adjustments
6.3 - CALIBRATION ARM ANGLE SENSORS (HONEYWELL SENSORS) A

pts V (approx.)
SR420
SR722
Low (0°)
Low (0°)
[60 ; 160]
[320 ; 420]
[0.615 ; 1.641]
[3.283 ; 4.309] B
SR420 High (57°) [320 ; 420] [3.283 ; 4.309]
SR722 High (57°) [60 ; 160] [0.615 ; 1.641]
4000595920 E 05.17 USA(1 93

E - Adjustments
6.4 - CALIBRATION ARM ANGLE SENSORS (ELOBAU SENSORS)
pts V (approx.)
SR420 Low (0°) [60 ; 160] [0.615 ; 1.641]
SR722 Low (0°) [320 ; 420] [3.283 ; 4.309]
SR420 High (57°) [320 ; 420] [3.283 ; 4.309]
SR722 High (57°) [60 ; 160] [0.615 ; 1.641]
94 4000595920 E 05.17 USA / (1

E - Adjustments
7 - Adjustment of pressures A
7.1 - MAIN PRESSURE
The setting and minimess plug is unique for all movements. B
D
MARKING DESIGNATION VALUE
1 Main pressure 180bar +-5b
E
7.2 - THE SPEEDS
MARKING DESIGNATION VALUE

1
2
High speed
Micro speed
9 s for 10 m / 33 ft
31 s for 5 m / 16 ft F
3 PF lift/descent 22 s
4 Steering lock to lock 3.5 s
4000595920 E 05.17 USA(1 95

E - Adjustments
Notes
96 4000595920 E 05.17 USA / (1

F - Simplified breakdown guide
Simplified breakdown guide

This guide does not replace the cut out conditions described previously in this manual. It allows the technician to
have a logical step of breakdown service, detailing the successive steps to be followed starting from general tips
A
until the details. The checking of the electric part is carried out in priority because less sensitive to the external
parameters than the hydraulics part (Temperature, pollution, viscosity). The denomination of the movements
describes below implies the 2 phases (Example not lifting, neither raise, nor descent from both controls, up and
down).
For a quicker diagnostic : B

Do check the failures code on Activ’screen display and refer to the alarms list before scrolling this breakdown
guide.
Do check all fuses.
Beware as some options once activated might prohibit some movements (the option ASB, Active Shield Bar
device). C
1 - No start
• Battery set.
• Emergency stops(SB801/SB802 ). D
• Key selector SA901.
• Relay battery charge KM900.
• Main relay KAH.
• Variators COMBIACX/ACEX.
• Main pump.
• Temperature sensor ST903 ( RUS only).
E
2 - No lift
• Battery set.
• Activ’screen touch pad.
F
• Toggle switch SA908 (Upper controls).
• Joystick SM901 out of range.
• Foot pedal switch SB800 (Upper controls) US option.
• CAN Tiller card.
• Valves YV420/YV903.
G
• Potholes system YV120/SQ144/SQ145.
• Angle transducers SR420/SR722 not adjusted or not calibrated.
• Pressure transducer SP400.
• Machine in slope/tilt mode (SQ800), not for US mode.
• Machine in overload (not for US/CDN mode).
H
• Load Management System not calibrated.
• No lifting pressure.
4000595920 E 05.17 USA / (1 97

F - Simplified breakdown guide
3 - No drive
• Toggle switch SA908.
• Joystick SM901.
• Foot pedal switch SB800( US only).
• AC motor M370 - M371.
• Brakes YB100 - YB101.
• Temperature probes ST301 - ST302.
• Speed sensors SV300 - SV301.
• Angle transducers SR722 - SR420.
• Machine in overload (not for US).
• Machine in tilt (not for US).
4 - No steering
• Toggle switch SA908.
• Joystick SM901 (Rocker).
• Steering calibration.
• Angle sensor SR150.
• Brakes YB100 - YB101.
• Valves YV903 – YV121 – YV122 – YV120.
• Relief valve RV2 (180b - 2520psi).
98 4000595920 E 05.17 USA / (1

G - Version summary
Version summary A
1 - Version summary
OPTIMUM 8 -
STANDARDS WIRING DIAGRAM HYDRAULIC DIAGRAM
OPTIMUM 1931E
Standard version All countries 4000311260 4000349350

B
2 - List of schematics
See end of manual
C
3 - List of wiring harnesses
See end of manual
D
4000595920 E 05.17 USA / (1 99

G - Version summary
Notes
100 4000595920 E 05.17 USA / EN

ANNEX 1
Movement Parameter [Target] Factory tolerance Configuration
Drive forward Min speed [-0 ; +0] Hidden setting
Drive forward Min speed [-0 ; +0] Hidden setting (Australia mode)
Drive forward Max speed [8.000000 ; 10.000000] [-10 ; +0] High speed selected, drive on 10m/33ft length
Drive forward Max speed micro [30.000000 ; 33.000000] [-10 ; +0] Machine unfolded, drive on 5m/16ft
Drive forward Max speed micro [-10 ; +0] Machine unfolded, drive on 5m/16ft
Drive forward Acceleration [-5 ; +5]
Drive forward Deceleration [-5 ; +5] 1 m/3.3 ft ± 0,2 m/0.6 ft in high speed
Drive reverse Min speed [-0 ; +0] Hidden setting
Drive reverse Min speed [-0 ; +0] Hidden setting (Australia mode)
Drive reverse Max speed [8.000000 ; 10.000000] [-10 ; +0] High speed selected, drive on 10m/33ft length
Drive reverse Max speed micro [30.000000 ; 33.000000] [-10 ; +0] Machine unfolded, drive on 5m/16ft
Drive reverse Max speed micro [-10 ; +0] Machine unfolded, drive on 5m/16ft
Drive reverse Acceleration [-5 ; +5]
Drive reverse Deceleration [-5 ; +5] 1 m/3.3 ft ± 0,2 m/0.66 ft in high speed
Steering left Max speed [3.000000 ; 4.000000] [-100 ; +0] Platform controls, from lock to lock (left or right)
Steering right Max speed [3.000000 ; 4.000000] [-100 ; +0] Platform controls, from lock to lock (left or right)
Potholes extend Max speed [-100 ; +10] Hidden setting
Potholes retract Max speed [-100 ; +10] Hidden setting
Arm Raise Min speed [-10 ; +10] Hidden setting
Arm Raise Max speed raise [20.000000 ; 24.000000] [-100 ; +0] Platform controls, from lower to upper stop
Arm Raise Acceleration raise [-5 ; +5]
Arm Raise Deceleration raise [-5 ; +5]
Arm Descent Min speed [-100 ; +10]
Arm Descent Max speed [26.000000 ; 32.000000] [-100 ; +0] Platform controls, from upper to lower stop
Arm Descent Acceleration descent [-5 ; +5]
Arm Descent Deceleration descent [-5 ; +5]
ANNEX 2
Name Description & Values [Level_min]
Buzzer Choose for which movements the buzzer must be activated 1
OFF
Descent / Retract Movements
All Movements
Drive
Drive + All Movements
Flashing light 1
OFF
All Movements
Drive
Drive + All Movements
ON
Tracking system 1
OFF
ON
Drive restriction when lifted If option is active, it allows to cut drive and steering above a lift height depending on the settings 1
OFF
ON if > 0.5m / 1.6ft
ON if > 1.5m / 5.0ft
User Identification inhibited Allows to inhibit user identification in case screen is not usable 3
OFF
ON
ANNEX 3
Name Description & Values Unit Min Max
Batteries type
TROJAN 30XHS
TROJAN T105
TROJAN GEL6V
US BATTERY AGM 2000
US BATTERY 2200
Angle sensors type
HONEYWELL
ELOBAU
ANNEX 4
Country Model 1 Zone
Standard OPTIMUM 8
USA OPTIMUM 1931E North America
Australia OPTIMUM 8
Russia/Ukraine OPTIMUM 8
Canada OPTIMUM 1931E North America
ANNEX 5A
Type: Name Diagnostic instructions: ECU: [Ref] [Pin] [Wire] Type:2
If both emergency stops are pulled, input must be ON (+VBAT). If not:
‐ check frame emergency stop function (SB801)
‐ check platform emergency stop function (SB802)
DIGITAL INPUTS SB801 ‐ Emergency stop (turntable/frame) ‐ check input wire continuity CombiACX ‐ Frame m_I3 B.4 109 Digital input (HS)
If tilt < 3° (longitudinal) / 1.5° (lateral), input must be ON (+VBAT). If not:
‐ check sensor adjustment
‐ check sensor supply fuse (FU3‐10A)
‐ check sensor supply (wires 0=0V and 109=+VBAT)
SQ800 ‐ Tilt sensor ‐ check input wire continuity CombiACX ‐ Frame m_I8 A.12 12 Digital input (HS)
If turret control box is selected, input must be ON (+VBAT). If not:
‐ check switch function
‐ check switch supply fuse (FU3‐10A)
‐ check switch supply (wire 98=+VBAT)
SA901TU ‐ Control box selector ‐ Turret ‐ check input wire continuity CombiACX ‐ Frame m_I2 C.7 135 Digital input (HS)
If platform control box is selected, input must be ON (+VBAT). If not:
SA901PF ‐ Control box selector ‐ Platform ‐ check input wire continuity CombiACX ‐ Frame m_I1 C.2 133 Digital input (HS)
If horn function is activated from turret control box, input must be ON (+VBAT). If not:
SA907TU ‐ Horn switch ‐ Turret ‐ check input wire continuity ACEX ‐ Frame s_I3 B.4 41 (CN0.8) Digital input (HS)
If ambient temperature is inside normal working conditions [‐20;+40]°C, input must be ON (+VBAT). If not:
‐ check sensor
ST903 ‐ Extrem ambiant temperature sensor ‐ check input wire continuity ACEX ‐ Frame s_I2 C.7 40 (CNO.6) Digital input (HS)
If brake release switch is activated, input must be ON (+VBAT). If not:
SA103 ‐ Brake release switch ‐ check input wire continuity ACEX ‐ Frame s_I1 C.2 21 Digital input (HS)
If potholes are extended, input must be ON (+VBAT). If not:
‐ check sensors adjustment
‐ check sensors supply fuse (FU3‐10A)
‐ check power supply (wire 109=+VBAT)
SQ144_145 ‐ Potholes left/right position sensors ‐ check input wire continuity ACEX ‐ Frame s_I5 A.4 15 Digital input (HS)
If platform enable switch is activated, input must be ON (+VBAT). If not:
SM901EN ‐ Enable switch ‐ Enable ‐ check input wire continuity CAN Tiller ‐ Platform ct_IN2 B.1 37 Digital input (HS)
If steering left function is activated from joystick rocker, input must be ON. If not:
‐ check rocker function
‐ check rocker supply fuse (FU3‐10A)
‐ check rocker supply (wire 109=+VBAT)
SM901L ‐ Joystick steering rocker ‐ Left ‐ check input wire continuity CAN Tiller ‐ Platform ct_IN10 B.11 35 (pin 6) Digital input (HS)
If steering right function is activated from joystick rocker, input must be ON. If not:
‐ check rocker function
‐ check rocker supply fuse (FU3‐10A)
‐ check rocker supply (wire 109=+VBAT)
SM901R ‐ Joystick steering rocker ‐ Right ‐ check input wire continuity CAN Tiller ‐ Platform ct_IN3 B.2 36 (pin 3) Digital input (HS)
If horn function is activated from platform control box, input must be ON (+VBAT). If not:
SA907 ‐ Horn switch ‐ check input wire continuity CAN Tiller ‐ Platform ct_IN5 B.4 34 Digital input (HS)
ANNEX 5B
If drive joystick is pulled, out of neutral input must be ON (+VBAT). If not:
‐ check joystick function
‐ check joystick supply fuse (FU3‐10A)
‐ check joystick supply (wire 109=+VBAT)
SM901N ‐ Drive/Arm joystick ‐ Out of Neutral ‐ check input wire continuity CAN Tiller ‐ Platform ct_IN6 B.5 5 Digital input (HS)
If drive selection switch is activated from platform control box, input must be ON (+VBAT). If not:
SA908a ‐ Drive/Arm movement selection switch ‐ ‐ check switch supply (wire 109=+VBAT)
Direction a ‐ check input wire continuity CAN Tiller ‐ Platform ct_IN11 B.12 76 (pin 1) Digital input (HS)
If arm is selected using arm selection switch from platform control box, input must be ON (+VBAT). If not:
SA908b ‐ Drive/Arm movement selection switch ‐ ‐ check switch supply (wire 109=+VBAT)
Direction b ‐ check input wire continuity CAN Tiller ‐ Platform ct_IN12 B.13 85 (pin 3) Digital input (HS)
If Activ' Screen arm up switch is activated, input must be ON. If not:
‐ check Activ' Screen supply fuse (FU3‐10A)
SWITCH1 ‐ Arm Up ‐ check Activ' Screen supply (wires 0=0V and 02=+VBAT) Screen1 ‐ Turret IN_1 Internal / Digital input
If Activ' Screen arm down switch is activated, input must be ON. If not:
SWITCH2 ‐ Arm Down ‐ check Activ' Screen supply (wires 0=0V and 02=+VBAT) Screen1 ‐ Turret IN_2 Internal / Digital input
If Activ' Screen enable switch is activated, input must be ON. If not:
‐ check Activ' Screen supply fuse (Fu3‐10A)
SWITCH3 ‐ Enable switch ‐ check Activ' Screen supply (wires 0=0V and 02=+VBAT) Screen1 ‐ Turret IN_3 Internal / Logic Input

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

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

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

If Activ' Screen navigation cancel switch is activated, input must be ON. If not:
SWITCH8 ‐ Navigation Cancel ‐ check Activ' Screen supply (wires 0=0V and 02=+VBAT) Screen1 ‐ Turret IN_BACK Internal / Logic Input
If machine is powered on with key and no emergency stop is pressed, output must be ON (0V). If not:
‐ check supply fuses (FU3‐10A)
‐ check key position selector (SA901) Logic Output 1.5 A
[DIGITAL_OUTPUTS] KAH ‐ Supply holding relay ‐ check output wire continuity CombiACX ‐ Frame m_O3 B.7 115 (LS) 12A Peak
If steering right or potholes retract function is requested, output must be ON (0V). If not, check Function Diagnostic. If status is
not OK:
‐ check valve power supply fuse (FU2‐10A) Digital output 1.5A
YV121 ‐ Pothole retraction / steering right valve ‐ check valve power supply (103=+VBAT) CombiACX ‐ Frame m_O0 A.1 54 (LS)
ANNEX 5C
If steering left or potholes extend function is requested, output must be ON (0V). If not, check Function Diagnostic. If status is
not OK:
‐ check valve power supply fuse (FU2‐10A)
‐ check valve power supply (103=+VBAT) Digital output 1.5A
YV122 ‐ Pothole extension / steering left valve CombiACX ‐ Frame m_O1 A.8 53 (LS)
If turret control box buzzer function is requested output must be ON (0V). If not, check Function Diagnostic. If status is not OK:
‐ check power supply fuse (FU2‐10A)
‐ check power supply (103=+VBAT) Logic Output 35 mA
HA901 ‐ Buzzer (turret) ‐ check output wire continuity CombiACX ‐ Frame m_O4 A.9 04 (LS)
If horn function is requested, output must be ON (0V). If not, check Function Diagnostic. If status is not OK:
‐ check relay
‐ check power supply (103=+VBAT) Logic Output 1.5 A
KA1 ‐ Horn relay ‐ check output wire continuity ACEX ‐ Frame s_O3 B.7 70 (LS) 12A Peak
If arm raise, potholes or steering movement is requested, output must be ON (0V). If not, check Diagnostic/Function. If status
is not OK:
‐ check power supply fuse (FU2‐10A) Digital output 1.5A
YV903 ‐ Pump unloading valve ‐ check power supply (wire 103=+VBAT) ACEX ‐ Frame s_O2 A.2 55 (LS)
If flashing light function is requested, output must be ON (+VBAT). If not check function diagnostic. If status is not OK:
‐ check power supply fuse (103)
‐ check power supply (FU2‐10A=+VBAT)
‐ check output wire continuity
‐ check relay Digital output 1.5A
KA2 ‐ Flashing light relay ‐ check flashing light ACEX ‐ Frame s_O6 B.6 31 (LS)
If lamp is not active at power ON or if status is not OK:
‐ check LED PCB
‐ check LED supply fuse (Fu3‐10A)
‐ check LED supply (wire 109=+VBAT) Logic Output 18 mA
HL420 ‐ Light lifting mode ‐ check output wire continuity CAN Tiller ‐ Platform ct_LED1 E.6 46 (LS)
‐ check LED PCB
‐ check LED supply fuse (FU3‐10A)
HL100 ‐ Light Drive selection ‐ check output wire continuity CAN Tiller ‐ Platform ct_LED2 E.7 94 (LS)
‐ check LED PCB
HL802 ‐ Light overload ‐ platform ‐ check output wire continuity CAN Tiller ‐ Platform ct_LED4 F.1 44 (LS)
‐ check LED PCB
HL904 ‐ Light Low Battery ‐ check output wire continuity CAN Tiller ‐ Platform ct_LED5 F.2 42 (LS)
‐ check LED PCB
HL800 ‐ Light tilt ‐ check output wire continuity CAN Tiller ‐ Platform ct_LED6 F.3 45 (LS)
‐ check LED PCB
HL903 ‐ Light Impacting Machine Behaviour Failure(s) ‐ check output wire continuity CAN Tiller ‐ Platform ct_LED8 F.5 43 (LS)
ANNEX 5D
Arm angle input voltage value:
‐ must increase when arm is being raised
‐ must be around 1.0V when arm is at 0°
‐ must be around 4.0V when boom is at 57°
If not:
‐ check sensor mounting (ref. instructions)
ANALOG INPUTS SR420 ‐ Arm angle sensor ‐ check input wire continuity CombiACX ‐ Frame m_AN1 C.4 13 Analog input 0‐10V
Arm angle input voltage value:
‐ must increase when arm is being raised
If not:
SR420 ‐ Arm angle sensor ‐ check input wire continuity CombiACX ‐ Frame m_AN1 C.4 13 Analog input 0‐10V
Overload pressure sensor input must be between [0;12]V, If not:
SP400 ‐ Arm pressure load detector ‐ check input wire continuity CombiACX ‐ Frame m_AN2 C.9 14 (CN01.3) Analog input 0‐10V
MOT_D_I ‐ Right engine current ECU CombiACX internal sensor. CombiACX ‐ Frame I_mot_m Internal Internal motor current
If drive forward is ongoing, value must be greater than 0Hz.
If drive reverse is ongoing, value must be lower than 0Hz.
SV300 ‐ Motor speed sensor 1 If no movement is ongoing, value must be equal to 0Hz. CombiACX ‐ Frame V_mot_m D.1/4 63‐64 motor speed
ST302 ‐ Motor temperature sensor 1 Motor 1 (M370) temperature sensor. Temperature must be close to ambient temperature when machine has just been CombiACX ‐ Frame T_mot_m D.3 26‐27 motor temperature
ECU_TEMP ‐ ECU internal temperature ECU CombiACX internal sensor. Temperature must be close to ambient temperature when machine has just been started. CombiACX ‐ Frame T_var_m Internal Internal ECU temperature (in
CombiACX internal variable giving hydraulic pump current consumption.
Variable must be equal to 0mA when no movement is ongoing.
PUMP_I ‐ Pump current Variable must be greater than 0mA when arm raise, steering or potholes movement is ongoing. CombiACX ‐ Frame I_Pump Internal Internal Pump current
Platform position input voltage value:
‐ must decrease when arm is being raised
If not:
SR722 ‐ Overload angle sensor ‐ check input wire continuity ACEX ‐ Frame s_AN2 C.9 20 Analog input 0‐10V
Platform position input voltage value:
‐ must decrease when arm is being raised
If not:
SR722 ‐ Overload angle sensor ‐ check input wire continuity ACEX ‐ Frame s_AN2 C.9 20 Analog input 0‐10V
Steering angle sensor input must be between [0;12]V and increase when wheels are turned on the right. If not:
‐ check sensor supply (wires 49=0V and 48=+12V)
SR150 ‐ Front wheels angle sensor ‐ check input wire continuity ACEX ‐ Frame s_AN1 C.4 47 Analog input 0‐10V
MOT_G_I ‐ Left engine current ECU ACEX internal sensor. ACEX ‐ Frame I_mot_s Internal Internal motor current
If drive forward is ongoing, value must be greater than 0Hz.
If drive reverse is ongoing, value must be lower than 0Hz.
SV301 ‐ Motor speed sensor 2 If no movement is ongoing, value must be equal to 0Hz. ACEX ‐ Frame V_mot_s D.1/4 67‐68 motor speed
ECU_TEMP ‐ ECU internal temperature ECU ACEX internal sensor. Temperature must be close to ambient temperature when machine has just been started. ACEX ‐ Frame T_var_s Internal Internal ECU temperature (in
ST303 ‐ Motor temperature sensor 2 Motor 2 (M371) temperature sensor. Temperature must be close to ambient temperature when machine has just been ACEX ‐ Frame T_mot_s D.3 71‐72 motor temperature
ANNEX 5E
If drive joystick is OK, input is variable between [0.5;4.5]V. If not:
‐ check joystick function
‐ check joystick 5V supply (wires 0=0V and 51=+5V)
‐ check joystick center position (approx. 2.5V)
SM901 ‐ Drive/Arm joystick ‐ check input wire continuity CAN Tiller ‐ Platform ct_AN5 A.10 39 Analogue input 0‐5V
If machine is powered and emergency stops are not pushed, input must be equal to +VBAT. If not:
‐ check input supply fuse (FU3‐10A)
‐ check input supply (wire 109)
‐ check input diode (D2)
AU_INFO ‐ Emergency stop (plateform) status ‐ check input wire continuity Screen1 ‐ Turret AN_4 X2.3 109 Analog input [0‐32V]
If potholes movement is requested, output must be ON (0V). If not:
‐ check valve function
‐ check valve supply fuse (FU2(10A))
‐ check valve supply (wire 103=+VBAT)
ANALOG OUTPUTS YV120 ‐ Potholes / steering selection valve ‐ check output wire continuity CombiACX ‐ Frame m_PWM B.3 56 PWM output
If arm raise function is requested, output must around 1000mA.
If arm descent function is requested, output must increase with arm joystick angle in range [400‐1000]mA. If not, check
Diagnostic/Function. If status is not OK:
‐ check valve
YV420 ‐ Arm valve ‐ check power supply (109=+VBAT) ACEX ‐ Frame s_PWM B.3 19 PWM output
ANNEX 6A
Category Name Item Values Unit Description & References
INTERNAL Power part state Init
Wait
Alarm
Alarm 1
Alarm 2
Alarm 3
Power contactor closing
Power contactor test
Electrovalve
Ready
Movement
Movement selection None
Drive/Steering
Arm
Dynamic calibration index
Static calibration index
Movement selection setpoint None
Drive/Steering [REF_IO] SA908a ‐ Drive/Arm movement selection switch ‐ Direction a
Arm [REF_IO] SA908b ‐ Drive/Arm movement selection switch ‐ Direction b
Movement selection control None
Drive/Steering [REF_IO] SA908a ‐ Drive/Arm movement selection switch ‐ Direction a
Arm [REF_IO] SA908b ‐ Drive/Arm movement selection switch ‐ Direction b
Arm angle SR420 °
Arm angle SR722 °
Dynamic overload angle 0 deg
Dynamic overload pressure 0 bar
ANNEX 6B
Static overload angle 0 deg
Static overload pressure 0 bar
Arm Calibration Minimum Angle SR420 pts
Arm Calibration Maximum Angle SR420 pts
Arm Calibration Minimum Angle SR722 pts
Arm Calibration Maximum Angle SR722 pts
Maximum value of YV420 electro valve control during
decompression %
ANNEX 6C
Minimum value of YV420 electro valve control during
decompression %
Machine unfolded °
Arm in high position °
Overload alarm is activated if estimated load into the platform is greater than 230kg for more
Overload Overload Alarm than 0.8s. It is then deactivated if estimated load into the platform is lower than 230kg for more
Overload Calibration Not done
Done [REF_FAIL] F06.01 ‐ Load Management System not calibrated
Arm Angle deg
[REF_IO_MAIN] SR420 ‐ Arm angle sensor
[REF_IO_MAIN] SR722 ‐ Overload angle sensor
[REF_VARIABLE] Arm angle SR420
[REF_VARIABLE] Arm angle SR722
Pressure bar
[REF_IO_MAIN] SP400 ‐ Arm pressure load detector
Reference pressure b
[REF_VARIABLE] Arm Angle
Machine Active control box None
Chassis [REF_IO] SA901TU ‐ Control box selector ‐ Turret
Platform [REF_IO] SA901PF ‐ Control box selector ‐ Platform
Chassis control box Inactive
Active [REF_IO] SA907TU ‐ Horn switch ‐ Turret
[REF_IO] SA103 ‐ Brake release switch
[REF_IO] SWITCH3 ‐ Enable switch
[REF_IO] SWITCH1 ‐ Arm Up
[REF_IO] SWITCH2 ‐ Arm Down
[REF_VARIABLE] Turret enable switch state
Platform control box Inactive
Active [REF_IO] SA901PF ‐ Control box selector ‐ Platform
[REF_IO] SA907 ‐ Horn switch
[REF_IO] SM901 ‐ Drive/Arm joystick
[REF_IO] SM901N ‐ Drive/Arm joystick ‐ Out of Neutral
[REF_IO] SM901L ‐ Joystick steering rocker ‐ Left
[REF_IO] SM901R ‐ Joystick steering rocker ‐ Right
[REF_IO] SM901EN ‐ Enable switch ‐ Enable
[REF_VARIABLE] Platform enable pedal state
Machine is considered as unfolded if:
‐ Arm angle is not calibrated
‐ or Arm angle analog sensors are out of range
‐ or Arm angle values are incoherent
Machine unfolded ‐ or Arm angle is calibrated and arm angle value is above 10.2°
[REF_VARIABLE] Arm Angle
[REF_FAIL] F07.06 ‐ Arm Angle sensor
[REF_FAIL] F10.16 ‐ Arm angle calibration
Tilt
[REF_IO] SQ800 ‐ Tilt sensor
Hourmeter h
Platform enable pedal state Inactive
Active but not valid (%s)
Active and valid
Turret enable switch state Inactive
Active but not valid (%s)
Active and valid
Battery voltage mV
Battery level %
ANNEX 6D
Unbraking enabled
User identified Not identified
Identified
User identification
ECU Max number of EEPROM queries (R/W) into the stack
Current number of EEPROM queries (R/W) into the stack
Current EEPROM status READY
BUSY
Number of EEPROM stack errors
Number of EEPROM status errors
Number of initialization tries
Execution time of 4ms task ms
CombiACX Zapi failure Code
ACEX Zapi failure Code
CAN Tiller software version
Parameters failure identification Wrong constant parameters failure identifier
Parameter default value failure idenfier
Current value versus initialized value failure identifier
Master/slave incoherence failure identifier
Internal setpoint secured coming from active control box and formatted from 0 to 100% for a
Drive Drive movement setpoint Value % given direction
Direction Neutral [REF_VARIABLE] Movement selection
Forward [REF_VARIABLE] Platform control box
Reverse [REF_IO] SM901 ‐ Drive/Arm joystick
Status OK [REF_IO] SM901N ‐ Drive/Arm joystick ‐ Out of Neutral
Function not active [REF_IO] SM901EN ‐ Enable switch ‐ Enable
Neutral not detected
after power ON
Joystick/switch failure
after engine start
Joystick/switch must be
released
Enable switch/pedal not
valid
Percentage of the internal setpoint really applied from 0 (no movement) to 100% (no
Drive movement slowdown Value % slowdown)
Number [REF_VARIABLE] Machine unfolded
A cutting number nonzero, means that the movement in this direction is prohibited by the
cutting conditions of the operating logic:
‐ 0.00 : no cutting
‐ 0.01 to 0.32 : Enable cuttings
‐ 1.01 to 1.32 : General cuttings
‐ 2.01 to 2.32 : Simultaneous Movement cuttings
‐ 3.01 to 3.32 : Overload cuttings
‐ 4.01 to 4.32 : Tilt cuttings
‐ 5.01 to 5.32 : Reach Limit cuttings
‐ 6.01 to 6.32 : Failure cuttings
Drive forward cuttings Cutting number 1 ‐ 7.01 to 7.32 : Specific cuttings
ANNEX 6E
Cutting number 2 [REF_VARIABLE] Machine unfolded
Cutting number 3 [REF_VARIABLE] Tilt
[REF_VARIABLE] Overload Alarm
[REF_VARIABLE] Overload Calibration
Drive reverse cuttings Cutting number 1 ‐ 7.01 to 7.32 : Specific cuttings
Cutting number 3 [REF_VARIABLE] Tilt
Internal control generated from the internal setpoint (if no cuttings) and formatted from 0% to
100% for a given direction, using ramps and min/max speeds.
Drive movement control Value % The control is sent to the actuators of the machine
Direction Neutral [REF_IO] MOT_G_I ‐ Left engine current
Forward [REF_IO] SV300 ‐ Motor speed sensor 1
Reverse [REF_IO] ST302 ‐ Motor temperature sensor 1
[REF_IO] MOT_D_I ‐ Right engine current
[REF_IO] SV301 ‐ Motor speed sensor 2
[REF_IO] ST303 ‐ Motor temperature sensor 2
[REF_VARIABLE] Movement selection setpoint
[REF_VARIABLE] Movement selection control
Drive speed Micro
High [REF_VARIABLE] Movement selection setpoint
[REF_VARIABLE] Movement selection control
Speed reduction Right motor reduction %
Left motor reduction
Brake release control (drive) Brakes opened OFF/ON
Type Automatic control [REF_VARIABLE] Drive movement control
Automatic control but
possible to force brakes
closure
Manual control
Right motor speed setpoint Requested speed
Real speed [REF_IO] MOT_D_I ‐ Right engine current
[REF_IO_MAIN] SV300 ‐ Motor speed sensor 1
Left motor speed setpoint Requested speed
Real speed [REF_IO] MOT_G_I ‐ Left engine current
[REF_IO] SV301 ‐ Motor speed sensor 2
Steering Steering movement setpoint Value % given direction
Direction Neutral [REF_VARIABLE] Movement selection
Left [REF_VARIABLE] Platform control box
Right [REF_IO] SA102 ‐ Drive selection switch
Status OK [REF_IO] SM901L ‐ Joystick steering rocker ‐ Left
Function not active [REF_IO] SM901R ‐ Joystick steering rocker ‐ Right
ANNEX 6F
after power ON
after engine start
released
valid
Steering movement slowdown Value % slowdown)
Number
Steering left cuttings Cutting number 1 ‐ 7.01 to 7.32 : Specific cuttings
Cutting number 2 [REF_VARIABLE] Power part state
Steering right cuttings Cutting number 1 ‐ 7.01 to 7.32 : Specific cuttings
[REF_IO] SR150 ‐ Front wheels angle sensor
Steering movement control Value % The control is sent to the actuators of the machine
Direction Neutral [REF_IO] YV150L ‐ Steering front left valve
Left [REF_IO] YV150R ‐ Steering front right valve
Right [REF_IO] SR150 ‐ Front wheels angle sensor
Wheels steering angle °
[REF_IO] SR150 ‐ Front wheels angle sensor
Steering left limit
Steering right limit
ANNEX 6G
Steering angle calibration performed
Potholes Potholes movement setpoint Value %
Direction Neutral
Extend
Retract
Status OK
Function not active
after power ON
after engine start
released
valid
Potholes out cuttings Cutting number 1 ‐ 7.01 to 7.32 : Specific cuttings
Cutting number 2
Cutting number 3
Potholes in cuttings Cutting number 1 ‐ 7.01 to 7.32 : Specific cuttings
Cutting number 2
Cutting number 3
Potholes movement control Value %
Direction Neutral
Extend
Retract
Arm Arm movement setpoint Value % given direction
Direction Neutral [REF_VARIABLE] Chassis control box
Raise [REF_VARIABLE] Platform control box
Descent [REF_VARIABLE] Movement selection
Status OK
Function not active
ANNEX 6H
after power ON
after engine start
released
valid
Arm movement slowdown Value % slowdown)
Number [REF_VARIABLE] Chassis control box
[REF_VARIABLE] Platform control box
[REF_VARIABLE] Tilt
[REF_VARIABLE] Machine unfolded
Arm raise cuttings Cutting number 1 ‐ 7.01 to 7.32 : Specific cuttings
Cutting number 3 [REF_VARIABLE] Overload Calibration
[REF_VARIABLE] Tilt
[REF_IO] SQ534 ‐ Mast extended detector
Arm descent cuttings Cutting number 1 ‐ 7.01 to 7.32 : Specific cuttings
Cutting number 2 [REF_VARIABLE] Overload Calibration
Cutting number 3 [REF_VARIABLE] Overload Alarm
Arm movement control Value % The control is sent to the actuators of the machine
Direction Neutral [REF_IO] YV420 ‐ Arm valve
Raise [REF_IO] YV903 ‐ Pump unloading valve
Descent [REF_IO] PUMP_I ‐ Pump current
ELECTRIC SCHEMATIC- 1/3
24VDC
RR
RL
24
HYDRAULIC
HYDRAULIC‐‐ STEERING
Discharge valve YV 903 =1
+
Right steering YV121 =1
Or
Left steering YV122 = 1
HYDRAULIC
HYDRAULIC‐‐ POTHOLE
+
Pothole descent YV121 =1
Or
Pothole retract YV122 = 1
+
P th l /steer
Pothole /t selection
l ti YV120 = 1
YV120 1
HYDRAULIC
HYDRAULIC‐‐ LIFTING
Raise/lower valve YV420 = 1
HYDRAULIC
HYDRAULIC‐‐ LOWERING
Raise/lower valve YV420 = 1
OPTIMUM 8 AC 4000311260.F 01
OPTIMUM 8 AC 4000311260.F 02
OPTIMUM 8 AC 4000311260.F 03
OPTIMUM 8 AC 4000311260.F 04
Potholes 3
Direction Steering
Ø40 Course 114
4
1/4’’ 1/4’’
5 1/4’’
1/4’’
Ø0,8
1/4’’ 1/4’’
e
ag
lev d er 1/4’’
de lin
é rin g cy
V ftin
Li 6
YV120 2
Capteur de pression 0 YV120 : EV selection potholes/dir
Pressure sensor .2
42
Ø1 YV YV121 : potholes up/dir droite
7 YV122 : potholes down/dir gauche
1/4’’
UP
1/4’’ 1/4’’
’’
3/8 A B
YV121 YV122
entrée Pression vérin

5 whithout pressure control
Cylinder pressure input
USA version
YV903
plug
Ø1.2
1
YV420 3/8’’
1/4’’ 6
1d
180 bar RV2
M
3/8’’ 1/4’’
1b
1a
1,7b
3/8’’ M
24VDC / 2,2kW / 3,5cc/tr
1c
Réservoir Tank
4000349350.B
4000246640.F
4000311490.E
4000313340.F
4000313380.B
4000313540.B
4000313760.D
4000421360.B
4000530650.B
G - Version summary
Notes
100 4000595920 E 05.17 USA / GB

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OPTIMUM 8 - OPTIMUM 1931 E

4000595920 E 05.17 USA / (1

2 4000595920 E 05.17 USA / (1

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

2 - List of actuators and sensors . . . . . . . . . . . . . 32

6 - Load management system . . . . . . . . . . . . . . . 89

You will find there the elements as following :

You will find there the elements as following :

It will include the following elements :

It will include the following elements :

4000595920 E 05.17 USA / (1 7

It will include the following elements :

Section F : Repair guide

It will include the following elements :

Section G : Summary of the versions

It will include the following elements :

8 4000595920 E 05.17 USA / (1

B - Main features and functions

Main features and functions A

ANSI and CSA standards OPTIMUM 1931 E B

4000595920 E 05.17 USA / (1 9

B - Main features and functions

2 - Primary machine components

OPTIMUM 8 - OPTIMUM 1931 E

10 4000595920 E 05.17 USA / (1

B - Main features and functions

4000595920 E 05.17 USA / (1 11

B - Main features and functions

253 ACTIV’ Screen

Controls and indicators

MARKING DESCRIPTION FUNCTION

12 4000595920 E 05.17 USA / (1

B - Main features and functions

Controls and indicators

4000595920 E 05.17 USA / (1 13

B - Main features and functions

• Bar gets filled up.

3 Status icon of the machine

14 4000595920 E 05.17 USA / (1

B - Main features and functions

4 Machine serial number displayed

• After again pressing on

4000595920 E 05.17 USA / (1 15

B - Main features and functions

Alarm status displayed as applicable - samples shown below

16 4000595920 E 05.17 USA / (1

B - Main features and functions

4000595920 E 05.17 USA / (1 17

B - Main features and functions

18 4000595920 E 05.17 USA / (1

B - Main features and functions

30 HL802 Overload indicator Platform overloaded

43 SA907 Horn button Move upwards and hold to activate horn B

Pushed in : De-energizes control system

85 HL903 Fault indicator Fault indicator Faulty or tilting or overloaded machine

Press right side of button : Right-hand steering

On : Raising / Lowering selection activated

On : Driving function activated

Move to the left : Platform raising / lowering

Press in and hold : Associated command is validated

4000595920 E 05.17 USA / (1 19

B - Main features and functions