htl4010 Training Manual

TECHNICAL TRAINING
DIAGNOSTIC LEVEL II
HTL3010-3210-3510-4010
How to use this document?
MAINTENANCE AND REPAIR OPERATIONS ON YOUR HAULOTTE MACHINE
MUST BE DONE ONLY BY TRAINED ,EXPERIENCED AND AUTHORIZED TECHNICIANS
You have between the hands the summary given during the HAULOTTE technical
training
It will enable you to find information necessary for the maintenance and the repair of your
HAULOTTE machine.
Thanks to the guide below you will quickly reach the required chapter .
Chapter 1: Main features and functions

It is a resume of the information contained in the user manual delivered with the machine:
components, overall dimensions, load charts, driver's cabin, etc…
Chapter 2: Study of the electrical shematics

You will find there the elements as following:
- A summary of the standardized symbols used by HAULOTTE Group
- The complete wiring diagram of the studied model
- The non exhaustive list of the electric looms and electronic boards
- Localization of the main safety units (limit switches, sensors,transducers…)
- Logical equations of operation: by function, to diagnose the main dysfunctions
Chapter 3: Study of the hydraulic shematics
You will find there the elements following:
- a summary of the standardized symbols used by HAULOTTE Group
- the complete hydraulic diagram of the studied model
- the non exhaustive list of the hoses track
- a localization of the main hydraulics manifold (proportional block , on/off movements
block,…)
Chapter 4: Adjustments
This is the adjustments and calibrations, hydraulics and electric, necessary for the good
maintenance of the material. You will find as well the methods of adjustment with table values.
Chapter 5: Guide of breakdown
Quick summary of the step to be followed for possible sources of breakdown.
In case of any default or any dysfunction you will be able to identify the elements in question,
whatever they are electric or hydraulic.
Chapter 6: Summary of the versions
This manual treats of the latest version , however this summary table enables you to find the
former versions of the material (electric and hydraulics).
Chapter 7: Special functions
This chapter gathers all the functions and adjustment specific to carry out on the machine. There
does not exist for all the materials and depends on the studied model.
It must be the subject of a special attention of your share because an intervention badly carried
out can deteriorate the good performance of the machine and thus consequently the safety of
t h e u s e rs .
Only a technician HAULOTTE or approved by HAULOTTE Services is able to carry out this kind
of intervention.
On this chapter, some special adjustment (sensors) are also explained prior to calibration
(depends on the model)
Chapter 8 : HTL evolution
This chapter describes all modifications made on HTL telehandlers called evolution.
The main modifications are a new dashboard indicating directly the alarms code and a new
master ECU module called SPU.
Chapter 9 : List of schematics
On this chapter, all schematics in different versions are listed in A3 size (electric/hydraulic)
TRAINING MANUAL DIAGNOSTIC Level 2 HTL 10M Range

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REVISION
Revision Edition Subject Created Validated Modified Translated Language

by by by by
00 07-11 Creation MGD FSE MGD FR/EN
01 07-13 Add HTL EVOL MGD MGD EN
version including
HTL 3010 + newest
schematics
02 12-13 Add Diag Pad info + MGD Central MGD MGD EN
console alarm list R&D
03 04-14 Add chapter MGD EN
schematics
04 07-14 Revision on newest MGD EN
alarms code with
HAULOTTE Diag

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SUMMARY
1. MAIN FEATURES AND FUNCTIONS .......................................................................................................... 7
1.1. CHARACTERISTICS ....................................................................................................................................... 7
1.1.1. the models ........................................................................................................................................... 7
1.1.2. main components .............................................................................................................................. 10
1.1.3. Dimensions ....................................................................................................................................... 12
1.1.4. load chart ......................................................................................................................................... 13
1.1.5. Features ............................................................................................................................................ 15
1.2. THE COMMANDS ........................................................................................................................................ 17
1.2.1. cabin overview .................................................................................................................................. 17
1.2.2. Left side in cabin .............................................................................................................................. 25
1.2.3. Joystick ............................................................................................................................................. 26
1.3. LMI SYSTEM .............................................................................................................................................. 27
1.4. SYNOPTIC OF BASIC PRINCIPLES.............................................................................................................. 28
1.4.1. Synoptic for drive ............................................................................................................................ 28
1.4.2. Synoptic for movements .................................................................................................................... 29
1.4.3. the hydrostatic transmission ............................................................................................................. 30
2. THE ELECTRICAL PART ............................................................................................................................ 34
2.1. SYMBOLS USED .......................................................................................................................................... 34
2.2. METHODOLOGY OF CONTROL..................................................................................................................... 39
2.2.1. Control electric continuity ................................................................................................................ 39
2.2.2. Control of an electrovalve on/off (tor).............................................................................................. 39
2.2.3. Control of components ..................................................................................................................... 40
2.3. THE ELECTRICAL SCHEMATICS ................................................................................................................... 43
2.4. LOOMS ....................................................................................................................................................... 43
2.5. THE MODULE NODE B2 .............................................................................................................................. 43
2.6. THE SAUER MODULE .................................................................................................................................. 44
2.7. LOCATION OF MAIN SENSORS ..................................................................................................................... 48
2.7.1. main looms in detail ......................................................................................................................... 50
2.7.2. valve location ................................................................................................................................... 55
2.7.3. preheating circuit ............................................................................................................................. 58
2.7.4. location of fuses and relays in the cabin .......................................................................................... 59
2.8. DESIGNATION OF THE ELECTRIC COMPONENTS .......................................................................................... 61
2.8.1. Definition of the prefixes and suffixes .............................................................................................. 61
2.9. DEFINITIONS OF THE FAMILIES OF COMPONENTS ........................................................................................ 62
2.10. LIST OF COMPONENTS ................................................................................................................................ 63
2.10.1. engine ............................................................................................................................................... 63
2.10.2. Fuses................................................................................................................................................. 64
2.10.3. Signals .............................................................................................................................................. 64
2.10.4. Controls and actuators ..................................................................................................................... 66
2.10.5. Sensors and signalisation ................................................................................................................. 67
2.10.6. Drive ................................................................................................................................................. 67
2.10.7. Others ............................................................................................................................................... 68
2.11. MULTIPLE MOVEMENTS .............................................................................................................................. 69
2.11.1. bypass key sa140 .............................................................................................................................. 70
2.12. LOGICAL EQUATIONS OF OPERATION.......................................................................................................... 71
3. THE HYDRAULIC PART............................................................................................................................ 126
3.1. SYMBOLS USED ........................................................................................................................................ 126
3.2. HYDRAULIC SHEMATICS ........................................................................................................................... 130
3.3. HYDRAULIC BLOCKS................................................................................................................................. 130
3.3.1. perkins engine................................................................................................................................. 130
3.3.2. The hydrostatic motor..................................................................................................................... 135
3.3.3. proportional block .......................................................................................................................... 137
3.3.4. on/off block ..................................................................................................................................... 139
3.3.5. brake system ................................................................................................................................... 142
3.3.6. steering unit .................................................................................................................................... 147
3.3.7. Steering block ................................................................................................................................. 148

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3.3.8. the telescopic cylinder .................................................................................................................... 149
3.4. THE HOSES ............................................................................................................................................... 150
3.4.1. pump circuit htl 3210...................................................................................................................... 150
3.4.2. pump circuit htl 3510...................................................................................................................... 151
3.4.3. pump circuit htl 4010...................................................................................................................... 152
3.4.4. boom ............................................................................................................................................... 153
4. ADJUSTMENTS ............................................................................................................................................ 154
4.1. ADJUSTMENT WITH THE OPTIMIZER CONSOLE........................................................................................... 154
4.1.1. list parameters console (> V1.08) .................................................................................................. 159
4.1.2. failures code ................................................................................................................................... 170
4.1.3. codes alarms for drive .................................................................................................................... 172
4.1.4. Dialogue with sauer module ........................................................................................................... 175
4.1.5. alarm code overload ....................................................................................................................... 177
4.1.6. Parameters adjustments ................................................................................................................. 179
4.2. CONSOLE DIAG PAD .................................................................................................................................. 180
4.3. THE PRESSURES ADJUSTMENT................................................................................................................... 182
4.3.1. Table of pressures........................................................................................................................... 182
4.3.2. Equipment part ............................................................................................................................... 183
4.3.3. Drive part ....................................................................................................................................... 185
5. BREAKDOWN GUIDE ................................................................................................................................ 200
5.1. NO START................................................................................................................................................. 200
5.2. NO DRIVE ................................................................................................................................................. 200
5.3. NO HIGH SPEED ........................................................................................................................................ 200
5.4. NO LOW SPEED ......................................................................................................................................... 201
5.5. NO STEERING ON FRONT AXLE ................................................................................................................. 201
5.6. NO STEERING ON REAR AXLE (SYNCHRO OR CRAB) .................................................................................. 201
5.7. NO MOVEMENT ........................................................................................................................................ 201
5.8. NO BOOM LIFTING .................................................................................................................................... 201
5.9. NO TELESCOPING BOOM ........................................................................................................................... 201
5.10. NO EXCAVATION/DISCHARGE................................................................................................................... 201
5.11. NO OUTRIGGERS (HTL3210-4010) .......................................................................................................... 202
5.12. NO CABIN LEVELLING (HTL3510) ........................................................................................................... 202
6. SUMMARY VERSIONS OF HTL RANGE ................................................................................................ 203
7. SPECIAL FUNCTIONS ................................................................................................................................ 204
7.1. CALIBRATION OF LOAD SYSTEM (LMI) ...................................................................................................... 204
7.1.1. Method with load (2500kg/5500lbs) ............................................................................................... 204
7.1.2. Procedure of calibration (all models) ............................................................................................ 205
7.1.3. “field” procedure with load of 2500kg/5500lbs ............................................................................ 206
7.1.4. “field” procedure without load ...................................................................................................... 207
7.1.5. assembly instruction for load sensor sp140.................................................................................... 208
7.2. INCHING PEDAL...................................................................................................................................... 211
7.2.1. potentiometer inching mounting instructions ................................................................................. 211
7.2.2. Procedure of calibration ................................................................................................................ 213
7.3. BOOM ANGLE SENSOR SR381 .................................................................................................................... 214
7.3.1. Procedure of calibration ................................................................................................................ 215
7.4. DISCS ON BRAKES ..................................................................................................................................... 216
7.4.1. brakes release ................................................................................................................................. 216
7.4.2. brake discs checking ....................................................................................................................... 217
7.4.3. parking brake release instructions ................................................................................................. 218
7.5. TELESCOPIC BOOM EXTENSION OIL BLEEDING .......................................................................................... 221
7.6. CONTROL OF CARDAN AXLE ..................................................................................................................... 222
7.7. CONTROL OF BOOM PADS ......................................................................................................................... 223
7.8. VARIOUS TIGHTENING TORQUES ............................................................................................................... 224
7.9. CONNECTIONS OF THE JOYSTICK............................................................................................................... 225
7.10. STEERING SENSOR .................................................................................................................................... 226

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8. HTL EVOLUTION ........................................................................................................................................ 227
8.1. MAIN DATAS ............................................................................................................................................. 227
8.1.1. htl 3010 (version aus) ..................................................................................................................... 227
8.1.2. The dashboard ................................................................................................................................ 238
8.1.3. The modules .................................................................................................................................... 245
8.1.4. The menus on console ..................................................................................................................... 247
8.1.5. Movements settings......................................................................................................................... 268
9. SCHEMATICS............................................................................................................................................... 268

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1. MAIN FEATURES AND FUNCTIONS
1 .1 . CHARACTERISTICS
1.1.1.THE MODELS
The table attached shows the differences according to the 3 types of models available
for HTL 3210-3510-4010
MODEL DESIGNATION
HTL3210 counterweight
HTL3510-4010
HTL3210 WHEELS 405-70R 20
HTL 3510-4010 WHEELS 405-70R 24

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HTL3210-4010 outriggers
HTL3510 cabin levelling
HTL 3210 2 valves on hydraulic driving motor

1 for speed change High Speed/Low Speed
1 for recognition way of driving

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HTL 3510-4010 Hydraulic drive motor with 1 valve for cubic capacity
change from High Speed drive to Low Speed
HTL 3510 Load cell is deported on rear axle (code ≠ from other
versions)
Rear axle with 4 satellites pinion cages

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1.1.2.MAIN COMPONENTS

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1.1.3. DIMENSIONS
Model Weight
HTL 3210 8200 kg
HTL 3510 8500 kg
HTL 4010 8730 kg

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1.1.4.LOAD CHART

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1.1.5.FEATURES

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1 .2 . THE COMMANDS
1.2.1.CABIN OVERVIEW

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 Right hand side dasboard in cabin

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1.2.2.LEFT SIDE IN CABIN

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1.2.3.JOYSTICK
Note: the movements telescopic and fork tilting (UP/DOWN) could be inverted at the joystick
commands (change through OPTIMIZER console, menu OPTIONS/Country)

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1 .3 . LMI SYSTEM
LMI: Load Moment Indicator

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1 .4 . SYNOPTIC OF BASIC PRINCIPLES
The movements of the machine are separated in two main functions:

1_ drive
2_ movements (boom and accessories)
1.4.1.SYNOPTIC FOR DRIVE
Operator
drive pedal Comodo for drive selection + module Node B2

handbrake command U600
module U600 located on drive pump
drive pump hydraulic motor
electrical link
rear axle cardan shaft hydraulic link

front axle
mechanical link
CAN BUS
wheels
Comodo :or stalk commands/combinations switchs is located on each side of steering wheel in
cabin ( FWD/REV drive , indicators, horn ..;)

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1.4.2.SYNOPTIC FOR MOVEMENTS
Operator
Joystick
module ECU node B2
Equipment gear pump
flow proportionnal ON/OFF

control block Block
valve
(priority
valve)
cabin
boom lift telescopic levelling Accessoiries and outriggers
boom (for HTL3510) (for HTL3210-4010)
Accessoiries (forks –buckets, winch, truss jib …)

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1.4.3.THE HYDROSTATIC TRANSMISSION
The hydrostatic transmission is made of a piston pump (H1) and a motor with double cubic
capacity mounted on the axle which transmits the power directly to the wheels.
The mechanical power mechanical of the main engine is converted into hydraulics power in a
closed loop at high pressure,
This hydraulics power is again converted into mechanical power
The circuit is always in pressure thanks to the charge pump whose prevents any cavitation of
the piston pump
Detail:
The main engine lets the pump running at a certain revolution in command to be sure that it’s
possible to generate a flow which is proportional to the displacement of the hydrostatic pump,
This flow is received by the hydrostatic motor generating a revolution of the motor directly
proportional to the flow and inversely proportional to its displacement.
A resistive torque is generated.
As it is a closed circuit, the pressure in this circuit is directly proportional to the load.
To overtake the pressure created, the engine must have a force proportional to the
displacement of the pump and the pressure generated

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The module (U600) manages the whole system.
According to the pressure applied on the accelerator pedal and thus of the revolution of the
motor, the current sent by the module on the drive valves (YV600 – YV620) will be proportional
consequently, this will modify the flow of the drive pump and consequently the speed of the
machine.
The speed change could be manual (controlled by operator with the “comodo” )
it could also be automatic, in particular in ramp climbing or in descent .
If the machine drives in climbing ramp, the pressure will increase in the circuit, the cubic
capacity of the hydrostatic motor will increase and then makes decrease the speed of drive (the
system never stalls)
Downhill, the overspeed is controlled by the module SAUER which will reduce the speed of the
system preventing any jolt.or overspeed
(see below)
EX1 : Maxi speed, Pressure Min

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EX2 :Automatic reduction in speed and PMaxi
Neutral position
charge pump (20/25b), circuit in flow cancellation

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FWD Drive, the pump gives power, the motor is running
FWD Drive with maxi pressure, the flow control valves are ON

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2. THE ELECTRICAL PART
2 .1 . SYMBOLS USED
Battery with one element
Alternator
Fuse circuit breaker

(Here 10 amps)
Coil with dual roll
Electric motor
light
Diode
hourmeter
Emergency push-button “mushroom-

headed button”

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

O neutral, N platform)
Switch with 2 positions
Electrovalve
Coil of relay
horn
proportional valve
Proportional valve PWM type (Pulse

Width Modulation)

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Foot pedal switch
buzzer
“light”
Electrovalve “ON/OFF »
Slope/tilt sensor
Angle sensor (reach limitation)
angle sensor ( mercury type)
Resistor (here value 100 ohms, 3

Watts, tolerance of 5%)

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Length transducer (reach limitation)
Pressure sensor (weighing)
Angle sensor (weighing)
Standard light “Led”
Strain gauge
Flexible Blade switch (ILS) detection

of the magnets on the telescopic
boom extension
Level detector (diesel tank)
Proximity detector with pulses
Thermal sensor of engine temperature

(HTL)

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Sensor speed (HTL engine)
Detector of wheels alignment (HTL)
Joystick multifunction with rollers and

integrated push button (HTL)

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

The continuity check of a loom or an electric component determines the resistor of this device,
in command to detect a possible interruption of continuity (open circuit, short-circuit…).
This control is carried out with a multimeter commutated in position Ohmmeter (Ω).
First of all, it is necessary to determine the terminals of the component or the cable to control
and insulate them.
Then, connect the multimeter in command to record the value.
It must indicate a value of resistor close to 0 Ω if continuity is good.
In the contrary case (resistor which tends towards the infinite one: ∞), continuity presents a
default.
Control of insulation
At the contrary of continuity, insulation represents a non electric connection between the ground
and the component
The test of insulation consists in obtaining the opposite result of that described for continuity, i.e.
a value of the Ohmmeter which must tend towards the infinite : OL∞
2 .2 .2 . CONTROL OF AN ELECTROVALVE ON/OFF (TOR)

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

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Control of intensity on coil
Disconnect the plug socket of supply of the valve in command to connect in series the
multimeter on the terminals of the connector (example below).
Select the position Ammeter (A), then activate the command to the valve which must be tested.
The intensity indicated by the voltmeter must be of approximately 2A (to be checked according
to the data manufacturer)
)
Control of resistor on solenoid
Disconnect the plug socket of supply of the valve in command to connect the multimeter on the
terminals of the connector industry.
Select the position Ohmmeter (Ω), then compare the value measured with that of the data
manufacturer.
In the event of nonconformity of the coil, replace it
2 .2 .3 . CONTROL OF COMPONENTS
Control of an electric relay

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

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

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

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2 .3 . THE ELECTRICAL SCHEMATICS
(see all versions at the end of this manual)
2 .4 . LOOMS
See all details on parts book
2 .5 . THE MODULE NODE B2

See electrical schematics 107P323510 (folio 06-07)
location of various connectors CN101 with CN107 on module node B2 (U100)
Detail of the connectors

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2 .6 . THE SAUER MODULE
see electric schema 107P323510 (folio 08)
location of the C1 connectors in C6 on module SAUER (U600)
C1 CC1 (Customer connection1) Used by HAULOTTE

C2 CAN (CAN BUS) CAN bus network
C3 PC (transducer Pressure) Not used by HAULOTTE
C4 PSC (Pump valves) Electrovalves FWD/REV
C5 PU (Speed sensor) Speed sensor
C6 CC2 (Customer connection 2) Used by HAULOTTE

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Standard example of SAUER connection diagram:

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Detail of connections
C1 on diagram = CC1 on U600:
CC1 WIRE VALUE FUNCTION

1 0 Negative (-)
2 102 + Vbat
3 606 4,825 to 5.075VDC SV685 speed sensor
hydraulic motor
4 604 (-)
5 165 Frequency at 1000Hz
6 à12
C2 on diagram = CAN on U600:
CAN WIRE FUNCTION

1 1004 CAN dialogues between U100 and
U600 + diagnostic plug
2 1005
3 1006
C3 on diagram = PC on U600:
(not used by HAULOTTE)
C4 on diagram = PSC on U600:
PSC WIRE VALUES FUNCTION

1 600 (+) FWD
2 620 (+) REV
3 Option 40km/h
4 Option 40km/h
5 602 (-) REV
6 601 (-) FWD

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C5 on diagram = PU on U600:
PU WIRE VALUES FUNCTION

1 603 4,825 at SV162 speed sensor
5,075 VDC on hydraulic pump
2 685 Frequency 0
at 1000hz
3 604 (-)
C6 on diagram = CC2 on U600:
CC2 WIRE VALUES FUNCTION

1
2
3 683 0/12VDC YV683 cc change valve
4
5 123 4,825 with RP680 potentiometer
5.075VDC inching
6 122 (-)
7 124 0.5 with
4.5VDC
8 4 0/12VDC YV684 recognition way
of driving
9 0/12VDC
10 B605 (-) YV682 parking brake
11
12

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2 .7 . LOCATION OF MAIN SENSORS
SP691
SR381
ST125 SP114
SQ360
SP690
SQ683
SP140
SP162 SQ720
ST160-ST160/C SQ126 SQ721

SV685 SQ683

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SENSOR DESCRIPTION FUNCTION STATE
Strenght sensor on rear Inform the load indicator
SP140
axle in the cabin (U140)
Indicate that the pressure
If P < 90 bars: alarm
SP690 Safety service brake of the service brake is
in cabin (HL690)
insufficient
Indicate that the pressure Closed if P < 18 bars
Pressure sensor safety
SP691 of the parking brake is not (alarm on cabin
parking brake
sufficient HL691)
Indicate in the cabin that
Detecting hydraulic oil
SQ126 filter is clogged (light (=1 if clogged)
filter clogged
HL126)
If SQ141=0 since
Cut the movements of
SQ141 Contact of seat driver more than 4 seconds
drive if driver not seated
= drive is cut
= 1 if water detected
Detection water Indicate the presence of
SQ163 (engine start is still
presence in the fuel water (light HL163 in the
possible if engine
circuit cabin)
stage 3)
Variable signal
SR381 Sensor boom angle Detection of boom angle
from -2° to +66°
Proximity sensor for
detection telescopic boom
SQ360 telescopic boom =1 if fully IN
position
retracted
detection front axle Detection front axle

SQ682 =1 if axle aligned
centered position
detection rear axle

SQ683 Inform light cabin (HL683) =1 if axle aligned
centered
Detection of front left

Detection lowered drive is cut (if both
SQ720 outriggers position
outriggers SQ720 + SQ721 =1)
Detection of front right Detection lowered drive is cut (if both

SQ721
outriggers position outriggers SQ720 + SQ721 =1)
Temperature sensor Detect the hydraulic oil

ST125 = 1 if T > 80°C
hydraulic tank temperature
Detector speed Detect the real speed of

SV685
hydraulic motor the machine
Sensor speed drive Detects if engine is

SV162 = 1 no drive
pump running
Note: the outriggers can be operational with boom > 30 °
If the alignment of the rear wheels is faulty, it is always possible to align the wheels by using the
by-pass key SA140 on cabin

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2.7.1.MAIN LOOMS IN DETAIL

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ST160 ST160/C
SR381
SQ163
SQ360
HA620
SP162
SP114
SP690
HTL
3210/4010 :SQ720 -
SQ721
RP680
SQ682

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SQ126
HTL3210/4010 :
SP140
SQ683
HTL3510 :
SP140
SV162
SV685
SP691

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ST125

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2.7.2.VALVE LOCATION
HTL 3510/4010
YV683
HTL3210
YV684
HTL3210
YV683

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YV720 YV721 YV123
YV682
YV700 YV701 YV124
HTL3210/4010
YV720 YV123
HTL3510 (no outriggers)
YV700 YV124

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YV681
YV680
YV600
YV620

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Reference Designations
YV340 Telescopic extension
YV360 Telescopic retraction
YV121 Auxiliary validation
YV122 Validation outriggers or cabin levelling
YV400 Excavation closing
YV420 Excavation opening
YV300 Boom lifting
YV320 Boom descent
YV123 Auxiliary towards port A
YV124 Auxiliary towards port B
YV701 Right outriggers lift
YV721 Right outriggers descent
YV700 Left outrigger lifting or cabin levelling
YV720 Left outriggers descent of cabin levelling
YV681 Steering in synchroneous mode
YV682 Steering in crab mode
YV683 Low speed for drive
YV684 Recognition way of drive
YV682 parking brake valve
YV600 FWD Drive
YV620 REV Drive
2.7.3.PREHEATING CIRCUIT
KM160 FU160
Relay Designations
KM160 Preheating relay on PERKINS engine
FU160 Protection for preheating circuit on PERKINS engine

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2.7.4.LOCATION OF FUSES AND RELAYS IN THE CABIN
KM100
KA108
KA107

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Relay Designations
KA104 Flasher unit
KA181 Relay air-conditioning
KA110 Relay working and reverse lights for fog
KA187 Relay emergency stop from radio control
KM101 Relay supply for SAUER and NODE B2 module
KA160 Relay for engine start
KA680 Relay for steering function crab mode
KA681 Relay for steering function synchro mode
KA189 Relay for fans air-conditioning for REV drive
KA620 Relay for light and buzzer in REV drive
KA380 Relay function float
KM100 Main relay
KA107 Relay for crossings lights left and right
KA108 Relay for road lights left and right
Fuses Designations
FU100 Main power supply (20A)
Lighting plate registration, radio car, warning,position lights,
FU110 lighting of dashboard panel, light on button washes de ice, light on
button fan and light on button 12 volts (7.5A)
FU111 Position lights front/back left side (7.5A)
FU112 Position lights front/back right side (7.5A)
FU117 Light anti fog (7.5A)
FU191 Working lights (20A)
FU187 Radio control (15A)
FU140 LMI power supply (0A)
FU161 PERKINS engine power supply (20A)
FU620 Reverse light + buzzer (10A)
FU195 Socket 12 volts (30A)
FU490 Free (1A)
FU101 Warning (15A)
FU107 Road light left and right (15A)
FU108 Crossing lights left and right (15A)
FU102 SAUER and NODE B module power supply (10A)
FU103 Beacon and horn (10A)
FU106 Indicators left and right (10A)
FU109 stop lights (10A)
FU113 sensors and controls power supply (7.5A)
FU114 valves power supply (30A)
FU180 Heating (30A)
FU181 Air-conditioning (5A)
FU182 cigar lighter, car radio and ceiling light (20A)
FU183 Front Windshield and washes deice (10A)
FU184 Rear Wiper (10A)
FU189 air-conditioning fan (30A)

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2 .8 . DESIGNATION OF THE ELECTRIC COMPONENTS
The electrical components are identified by a system of letters and figures.
Designation in command to dispatch each component: per function /family
its nature (relay, contactor,…)
its family (movements boom, movements drive,…)
its sub family (lift, descent, forward,…)
Example:
Y V 7 2 1
valves Family: 700 Sub-family: 720 to 739:

Movements and descent
Thus: valve for outriggers descent outriggers
2.8.1.DEFINITION OF THE PREFIXES AND SUFFIXES

Prefixes Identification of the component Suffix
C Capacitor
D Diode
E Heating H
E Lamp /light L
E Fan V
F Fuse U
G Alternator
G Battery B
H Sound buzzer H
H Light L
K Contactor M
K Auxiliary relay K
K Preheating relay T
M Motor or pump
P Indicator, display
Q Circuit breaker F
Q Disconnecting switch S
R Resistor
R Potentiometer P
S Switch S
S Push button B
S Joystick J
S Controller M
S Pressure sensor P
S Position sensor Q
S Angle sensor R
S Temperature sensor T
S Speed sensor V
T Transformer
U Converter/electronic module/box
X Plug socket P
Y Electrovalve V
Y Coil of command Y
Y Electric brake B

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2 .9 . DEFINITIONS OF THE FAMILIES OF COMPONENTS
Family Sub- family Description

100 to 119 supply
120 to 139 movements
100 General 140 to 159 Safety
160 to 179 engine
180 to 199 Accessories
200 to 219 Lift
220 to 239 descent
240 to 259 extension telescope
200 Movements
260 to 279 Retraction telescope
280 to 289 General
290 to 299 Safety
300 to 319 lift
320 to 339 descent
340 to 359 extension telescope
300 Movements boom
360 to 379 Retraction telescope
380 to 389 General
390 to 399 Safety
400 to 419 Lift
420 to 439 descent
440 to 459 Left
400 Movements basket/bucket
460 to 479 Right
480 to 489 General
490 to 499 safety
500 to 509 lift
510 to 519 Descent
520 to 529 Left
530 to 539 Right
500 Movements jib
540 to 549 extension telescopic boom
550 to 559 Retraction telescopic boom
560 to 569 General
570 to 579 Safety
600 to 619 Front
620 to 639 Back
640 to 659 Left
600 Movements drive
660 to 679 Right
680 to 689 General
690 to 699 safety
700 to 719 Lift
720 to 739 Descent
740 to 759 Left
700 Movements blocking
760 to 779 Right
780 to 789 General
790 to 799 safety
800 Movements rotation

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2 .1 0 . LIST OF COMPONENTS
In the following tables:
The column n°2 gives the location of the components on the different folio on the electrical
schematics, in command to find very easily their position.
The first figure corresponds to the number of page and the second one to the column (generally
from 1 to 20) of the corresponding page.
The column n°3 indicates the position on the connector of the board or the module (if it’s the
case)
The numbered B xxx are connected to the module Node B2.
The state noted “0” corresponds to 0V, open contact or not activated.
The state noted “1” corresponds to the voltage of the circuit, or if it’s a closed or activated
contact.
 Glossary
FWD Forward drive
REV Reverse drive
FL Front Left (AVG)
FR Front right (AVD)
RL Rear left (ARG)
RR Rear right (ARD)
PF Platform
Note comodo is the stalk commands/control unit/combinations switchs on cabin (see below)
2 .1 0 .1 . ENGINE
Code Location Connector Designation
GB100 01 - 2 Battery (1)
QS100 01 - 2 Main Battery cut-off (1A)
YA162 01 - 9 Charge pump coil (gavage motor) (161)
YA160 01 - 5 Starter relay (161)
M160 01 - 3 Starter (1)
G160 01 - 3 Alternator (1)
KM160 01 - 18 Contactor for engine preheating (27)
HL160 01 - 19 Light for preheating engine (27)
ST160 09 - 18 Water temperature sensor on Perkins engine (113)
ST160/C 09 - 19 Probe for temperature water detection on engine (164)
R160 01 - 15 Resistor for Perkins engine preheating (28)
YV160 01 - 17 Engine stop coil on Perkins engine (161)

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2 .1 0 .2 . FUSES
FU100 02 - 8 Main electric equipment (20A) (1A)
FU101 02 - 5 Warning lights (15A) (101)
FU102 02 - 2 Power supply of modules node B2 and Sauer (10A) (102)
FU103 02 - 7 beacon + horn (10A) (103)
FU106 02 - 10 indicators of right/left steering (10A) (106)
FU107 05 - 4 Road lights left/right (15A) (59)
FU108 05 -9 Crossing lights (15A) (66)
FU109 02 - 11 stop lights (10A) (109)
FU110 03 -7 plate of registration (7.5A) (100B)
FU111 03 - 10 Position lights left (7.5A) (100B)
FU112 03 - 12 Position lights right (7.5A) (100B)
FU113 02 - 16 sensors supply + controls (7.5A) (113)
FU114 02 - 19 Valves supply (30A) (114)
FU117 04 - 6 Rear lights fog (7.5A) (118)
FU140 02.-18 Protection LMI (10A) (140)
FU180 02 - 13 heating in cabin (30A) (180)
FU181 02 - 14 Air-conditioning (5A) (181)
FU182 02 - 15 cigar-lighter, ceiling light, car radio (20A) (182)
FU183 02 - 9 Front wipers/defreezes (10A) (183)
FU184 02 - 9 Rear wiper (10A) (184)
FU189 02 - 16 Fan for air-conditioning (30A) (186)
FU191 04 - 3 Work headlights (20A) (197)
FU195 02 - 15 socket 12V (30A) (195)
FU490 02 - 10 Free (1A) (187B)
FU620 02 - 13 Light for REV drive + buzzer (10ª) (622)
2 .1 0 .3 . SIGNALS
HA185 03 - 1 Light beacon (185)
HL185 03 - 2 Voyant on switch beacon (185)
SA185 03 - 2 Switch for beacon (103)
SB105 03 - 3 Push button for horn on comodo (103)
HA105 03 - 3 Horn (105)
EL116 03 - 5 Reverse drive lights (623)
HA620 03 - 6 Sound buzzer for REV drive (623)
SA101 03 -- 7 Switch for position lights on comodo (100B)
EL104 03 - 7 plate of registration light (110)
KA110 03 - 8 Relay working lights (110)
EL100 03 - 10 position lights FL (111)
EL102 03 - 11 position lights RL (111)
EL101 03 - 12 position lights RR (112)
EL103 03 - 13 position lights FR (112)
KA189 03 - 14 Relay fan air-conditioning (43)
HL181 03 - 14 Light on switch for air-conditioning (43)
SA180 03 - 16 Switch for heating (180)
SA181 03 - 16 Commutator for air-conditioning (42)
SP181 03 - 16 Pressure sensor air-conditioning (48)
KA181 03 - 16 Relay for air-conditioning control (41)

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M181 03 - 17 Compressor for air-conditioning (181)
M189 03 - 18 Fans for air-conditioning (50)
R180 03 - 19 Resistor heating cabin (45/46)
SA191 04 - 2 Switch work headlights (197)
EL191 04 - 3 Working light FL (192)
EL192 04 - 3 Working light FR (192)
EL193 04 - 4 Working light RL (193)
EL194 04 - 5 Working light RR (193)
SA183 04 - 5 Switch front wipers (183)
M183 04 - 5 Motor front wipers (188)
SA117 04 - 6 switch for rear fog (118)
EL117 04 - 6 Lamp fog RL (117)
HA117 04 - 7 Lamp fog RR (117)
M186 04 - 8 Motor for front windscreen (51)
SA184 04 - 10 Switch for rear wiper (184)
M184 04 - 10 Motor for rear wiper (54)
SA195 04 - 10 Switch 12V (195)
XP195 04 - 10 Socket 12V (196)
KA104 04 - 13 Relay flasher unit (90)
XP183 04 - 12 plug cigar-lighter (182)
U182 04 - 15 Car radio + loudspeakers (110/182)
SA104 04 - 16 Switch indicator of steering (90)
SA106 04 - 18 Switch for warning lights (90/92)
SA182 04 - 18 Switch ceiling light (182)
EL182 04 - 18 Lighting ceiling light (182)
SA103 05 - 3 Switch for road lights on comodo (100A)
KA107 05 - 3 Relay for road lights (59A)
HL100 05 - 4 Light for position lights (110)
HL111 05 - 4 Light for road lights (59)
EL115 05 - 4 Lighting of dashboard panel (110)
EL111 05 - 4 Light for road light left side (60)
HL186 05 - 5 Light switch washes ice (110)
EL112 05 - 5 Light for road light right side
SA102 05 - 7 Switch for crossings lights on comodo (100B)
KA108 05 - 7 Relay for crossing lights (64)
HL180 05 - 7 Light on heating button (110)
HL191 05 - 8 Light switch 12V (110)
EL109 05 - 9 Light for crossing light left side (66)
EL110 05 - 10 Light for crossing lights right side (66)
SP114 05 - 11 Pressure sensor for rear lights when braking 5b (109)
EL113 05 - 11 indicator for stop lights RL (61)
EL114 05 - 12 indicator for stop lights RR (61)
HL106 05 - 11 Light indicator of steering (70)
EL105 05 - 14 Lamp indicator of steering FL (63)
EL107 05 - 15 Lamp indicator of steering RL (63)
EL106 05 - 17 Lamp indicator of steering FR (62)
EL108 05 - 18 Lamp indicator of steering RR (62)
09.-11 Light indicator presence of water in fuel oil (engine
HL163
version stage3 since end of 2008)

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2 .1 0 .4 . CONTROLS AND ACTUATORS
SA 100 02 - 8 Main contact key start/stop machine (100)
KM100 02 - 8 Main contactor for equipment (11)
SA692 06 - 2 CN105-35 Switch selection road mode (B131)
SB685 06 - 3 CN104-2 Switch parking brake(B107)
SA140 06 - 4 CN104-3 Switch by-pass for overload (B108)
SA187 06 - 5 CN104-4/104-5 Key selector forks/winch (B108)
SA188 02 - 4 Key selector (radio control /emergency pump)
06 - 6 CN105-14/105-15 Commutator steering selection crab/synchro on
SA681
rear axle (B143/B144)
SA780 06 - 7 CN104-1/CN104-17 Left outrigger UP/DOWN (B780A-B780B)
SA781 06 - 8 CN104-19/CN104-20 Right outrigger UP/DOWN(B781A-B781B)
SA782 06 - 9 CN105-1/CN105-6 Cabin levelling (left/right) (B782A-B782B)
06 - 8 CN104-7 Command for High Speed drive on comodo
SA680
(B112)
SA600 06 - 9 CN104-8 Command FWD drive on comodo (B113)
SA620 06 - 10 CN104-9 Command REV drive on comodo (B114)
SA684 06 - 9 CN 104 Neutral drive position on comodo (684)
HL684 06 - 11 Light for comodo drive in neutral position (684)
SJ120 06 - 13 to 17 CN106-10 to 15 Joystick movements
HL161 06 - 18 CN105-12 Light for alternator D+ (B106)
06 - 4 CN105-27 Valve for left outriggers descent or cabin
YV720 levelling right
(HTL3510) (B607)
YV721 06 - 5 CN105-28 Valve for right outriggers descent (B600)
06 - 6 CN105-29 Valve for left outriggers lift or cabin levelling
YV700 (left)
(HTL3510) (B601)
YV701 06 - 7 CN105-34 Valve for right outriggers lift (B606)
YV682 08 - 6 C6-9/C6-10 Valve for parking brake(B605)
YV680 09 - 2 valve for crab steering (B680)
YV681 09 - 2 valve for synchroneous steering (B681)
YV380 06 - 8 CN105-33 Option “Float”
YV300 06 - 9 CN105-19 PWM valve boom lift (B608)
YV320 06 - 10 CN105-20 PWM valve boom descent (B609)
YB340 06 - 11 CN105-21 PWM valve telescopic extension (B610)
YV360 06 - 12 CN105-22 PWM valve telescopic retraction (B611)
YV400 06 - 13 CN105-23 PWM valve compensation/excavation (B612)
YV420 06 - 14 CN105-24 PWM valve compensation/discharge (B613)
YV121 06 - 15 CN105-25 valve validation auxiliaries (B614)
06 - 16 CN105-26 valve validation outriggers + cabin levelling
YV122
(B615)
YV123 06 - 17 CN105-30 valve accessories port A (B602)
YV124 06 - 18 CN105-31 valve accessories port B (B603)
YV780 06 - 18 CN105-32 valve locking axle on left side (B604)
YV781 06 - 19 CN105-32 valve locking axle on right side (B605)
U100 Module node B2

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2 .1 0 .5 . SENSORS AND SIGNALISATION
SQ141 07 - 3 CN104-16 Contact for seat driver (B121)
SQ720 07 - 7 CN104-19 outriggers FL = 1 if down (B115)
SQ721 07 - 5 CN104-20 outriggers FR = 1 if down (B116)
SQ682 07 - 9 CN105-18 front axle alignment sensor (682)
SQ683 07 - 10 CN105-16 Rear axle alignment sensor (685)
SR381 07 - 14 CN106-26/27 boom angle sensor (-2° to +66°) (B403-B404)
07 - 15 CN105-2 Proximity sensor for telescopic boom
SQ360
(= 1 if retracted (B127)
SP140 07 - 18 Load cell on rear axle (113)
U140 07 - 19 CN105-5/13 Indicator of load (LMI) in the cabin (B130/B142)
D101 07 - 1 Diode safety contactor (11)
KM101 07 - 2 CN104-29 Relay supply modules node B2-Sauer (B508)
KA680 07 - 3 CN104-34 Relay validation steering mode crab (B513)
KA681 07 - 4 CN104-35 Relay validation steering mode synchro (B514)
KA160 07 - 5 CN104-28 Relay start-up (B507)
KA620 07 - 6 CN104-22 Relay for REV drive lighting (B501)
07 - 10 CN104-24 Light default CPU or ECU (Electronic Control Unit)
HL143
for module node B2 (B503)
HL380 07 - 10 CN104-25 Light option floating (B504)
07 - 6 CN104-36 Light validation outriggers or cabin levelling for
HL780
HTL3510 (B515)
HL686 07 - 8 CN104-30 Light validation speed 1 work mode (B509)
HL687 07 - 11 CN104-26 Light validation speed 2 road mode (B505)
HL692 07 - 9 CN104-23 Light road mode validation (B132)
2 .1 0 .6 . DRIVE
U600 08 Sauer module
HL685 08 - 1 C6.10 Light on switch parking brake(B605)
YV600 08 - 3 C4.1-C4.6 valve FWD drive (600)
YV620 08 - 4 C4.2-C4.5 valve REV drive (620)
SV162 08 - 14 C5.1 Speed sensor on main engine (685)
SV685 08 - 11 C1.5 Speed sensor on hydraulic drive motor (165)
YV682 08 - 3 C6.10 valve parking brake(B605)
08 - 11 22 valve for cubic capacity change on hydraulic motor
YV683
(High Speed/Low Speed) (683)
08 - 6 C6.8 valve n°2 for recognition way of drive
YV684
(FWD/REV only for HTL3210) – (4)
KA620 08 - 14 26 Relay for REV drive (621)
RP680 08 - 18 C6.7 Potentiometer « inching » pedal (124)

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2 .1 0 .7 . OTHERS
SP162 09 - 6 Oil pressure sensor PERKINS engine (162)
HL162 09 - 10 Light default pressure of oil engine (162)
SQ163 09 -7 Detector of presence of water in the fuel circuit (113)
HL163 09 - 7 Light water presence in fuel (166)
SP690 09 - 8 Pressure sensor 90b safety service brake (690)
HL690 09 - 8 Light default pressure service brake (690)
SP691 09 - 9 Pressure sensor 18b safety parking brake (691)
HL691 09 - 9 Light default pressure parking brake(691)
ST125 09 - 10 Sensor for high temperature hydraulic oil (125)
HL125 09 - 11 Light default temperature hydraulic oil (125)
SQ126 09 - 12 Sensor filter clogged on hydraulic reservoir (126)
HL126 09 - 12 Light for filter clogged on hydraulic tank (126)
SQ189 09 - 17 Fuel level sensor (189)
P161 09 - 14 Hourmeter in cabin (163)
ST160 09 - 18 water temperature sensor engine PERKINS (164)
ST160/c 09 - 19 Water temperature probe engine PERKINS (113)
KA187 10 - 6 Relay for accessories (winch) (194)

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2 .1 1 . MULTIPLE MOVEMENTS
 Fork mode
Movements Functions
Compensation
Mode Fork (Cabin)
Telescoping
Accessories
Stabs/cabin
Road mode
levelling
Lifting
Drive
SA187T = SA187N = B111 = 0
Lifting 1/0* 1/0* 1/0* 0 1 0

Telescoping 1/0* 1/0* 1/0* 0 1 0
Movements
Compensation 1/0* 1/0* 1/0* 0 1 0
in progress
Accessories 1/0* 1/0* 1/0* 0 1 0
Stabs/cabin levelling 0 0 0 0 0 0
Functions Drive 1 1 1 1 0 1
in progress Road mode 0 0 0 0 0 1
1 if the movement or the function required is authorized, 0 if it is prohibited
* by-pass key is activated
 Winch mode or radiocomand
Movements Functions
Winch mode
Compensation
(Cabin or Radio)
Telescoping
Accessories
Stabs/cabin
Road mode
levelling
Drive
SA187T = 1 | SA187N = 1 | B111 = 1

Lift
Lift 0 0 0 0 0 0
Telescoping 0 0 0 0 0 0
Movements
Compensation 0 0 0 0 0 0
in progress
Accessories 0 0 0 0 0 0
Stabs/cabin levelling 0 0 0 0 0 0
Functions Drive 0 0 0 0 0 1
in progress Road mode 0 0 0 0 0 1
1 if the movement or the function required is authorized, 0 if it is prohibited

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2 .1 1 .1 . BYPASS KEY SA140
This bypass key makes it possible to activate functions which are limited or prohibited in
certains configuration of the machine
 Reach limitation:
authorization of certain movements at reduced speed in case of LMI alarm
 Movements of outriggers:
authorization of the outriggers lifting at reduced speed when the angle boom is > 30°
or telescopic boom extension OUT.
 Movements of cabin levelling correction :
authorization of the movements of cabin levelling when the telescopic boom extension is
OUT and boom angle is between 30 and 50°.
 Mode of steering:
forcing of the steering mode selection without having the axle in centered position
The by-pass function is desactivated if the by-pass key SA140 is turned during more than 8s
and no movement has been activated during this interval of time (Lifting Boom, Telescopic
Boom, Compensation, Accessories or Outriggers/cabin levelling).

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2 .1 2 . LOGICAL EQUATIONS OF OPERATION
The conditions hereafteris for all range HTL 4017-4014-3617-3614 with or without the
accessories and refer to the machines known as Standard normalizes EN280 (for the other US
versions, CDN, AUS) thank you to refer to HAULOTTE SERVICES of your zone which will
indicate the characteristics of your machine if it is necessary
When the accessories (winch, truss jib) are monted, the operating conditions could be modified
or prohibited (see “particular conditions” )
 Conditions of I/O- Engine start/stop
Conditions
being able
to disturb
the
Conditions engine start/stop Obligatory
function N° diag
HTL3210/3510/4010 conditions
without
completely
preventing
it
Conditions of outputs
YA162 fuel pump X X 1
M160 starter X 2
KA160 start relay X 3
Power supply SAUER and NODE B2
KM101 X 4
modules
KM160 preheating X X 5
HL160 Indicator preheating X 6
Glow plugs energized for 7s as standard and
R160 X X 7
20s for the cold environment option
YV160 Engine Stop coil X 8
Conditions of inputs
GB100 Battery X 9
QS100 battery cut X 10
SA100 ignition switch X 11
SA187 Switch selection fork/winch X 12
SA188 Switch power radio control X 13
B129 Switch- radio control start X 14
KA187 relay from radio command (by-pass) X 15
SA600
comodo command FWD drive X 16
SA620
SA620 Comodo command REV drive X 17
G160/D+ Alternator X 18
U600 Module SAUER H1 X 19
U100 Module node B2 X 20
KM100 Main contactor X 21
FU100 Fuse (20A) ignition key supply X 22
FU102 Fuse 10A power U100 and U600 X 23
fuse (10A) supply preheating, fuel pump and
FU161 X 24
stop engine
FU160 fuse (200A) supply glowplugs X 25

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 Particular conditions
Particular conditions from the cabin in fork or winch mode

The requirements from the cabin are applicable if the fork mode or winch is selected (B111 = 0)
Ignition key (SA100) turned on the right in position 1 (KM100 = 1) to supply the engine and to begin pre-
heating
Ignition key (SA100) turned on the right in position 2 to start the engine
If the cold environment option is activated, then the time of pre-heating changes from 7s to 20s
Driving starting is not authorized if fwd or rev drive is selected with the control unit
When shutdown (D+ = 0), restarting is forbidden for 3s (the power supply to the modules is maintained)
When starting the machine (KM100 = 1) then power supply to the modules is active (KM101 = 1)
When shutdown (KM100 = 0), the power supply of the modules is maintained (KM101 = 1): for 1s in
command to be able to carry out the recordings in EEPROM and if the engine has just been stopped (D+ =
0) for less 3s in command to prohibit restarting
Driving mode at idle rpm without load: 900 ±- 50 rpm
Maximum speed of the engine without load: 2450 ± 50 rpm
Particular conditions from the radio control for winch option
The requirements from the radio control station are applicable if winch radio control mode is selected
(SA187a = B111 radio control command OK & SA187b = 0)
Ignition key (SA100) turned on the right in position 1 (KM100 = 1) to supply the engine and begin pre-
heating
Radio control start switch activated (B129 = 1) to start the engine
The management of starting, engine stop and the modules is identical from the cabin

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 Diagnostic
Diagnoses
Optimizer
N° Indicator
TESTS Menu
diag ECU
INPUT- Menu FAILURES
OUTPUT
The combined Fuel flow at the 2 outputs of
1 the pump must be at least of 2l/mn (0.53 US
gpm)
1 If flow NOK replace the filter
1 If filter flow is OK replace the pump
Check start circuit connections (battery and
2
on starter)
KA160 = 1 if engine running and alternator DIGITALS
3
OK INPUTS
KM101 = 0 if KM100 = 0 and delay 1s and DIGITALS
4
engine stopped INPUTS
DIGITALS
5 KM160 = 1
OUTPUTS
6 HL160 = 1 if pre heating in progress
7 R160 = 1 if KM160 = 1/ 12V on 28
YV160 = 1 when the contact via the key is
8
established (wire 161)
Weak battery supply voltage 12V
9 SV01
(VBAT < 10V) and (D+ =1)
10 QS100 = 1/12V on 1A
SA100 test the wires: 100 (supply)/11 DIGITAL
11
(contact)/2 (starting) INPUTS
SA187 = 0 selection fork. 0V on 104.4 B109 DIGITAL
12
and 104.5 B110 INPUTS
SA187A = 1 selection winch 12V on 104.4 DIGITAL
12
B109 INPUTS
Selector default mode SA187, incoherence
12 selection mode. Default = 1 if SA187A = 1 3 flashs SW01
and SA187B = 1
SA188 = 1 when radio control powered. 12V
13
on 187A and 12V on B100
DIGITALS
14 B129
INPUTS
KA187 = 1 radio control E-stop not engaged
15
12V on 194
KA187 = 0 radio control E-stop engaged 0V
15
on 194
DIGITALS
16 SA600 = 1 drive FWD
INPUTS
DIGITALS
17 SA620 = 1 drive REV
INPUTS
Engine engine confirmed by 12V on D+
DIGITAL
18 alternator (B106) if light NOK charges
INPUTS
battery HL161 = 1

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Green
Led on
fixed H1
19 Operation OK
module lit
and led
red extinct
Diagnosis
Tension of the battery < 9V or Tension of the H1 Pump
19 0b00001000
battery> 16V System
Status
20 Upload the software or replace B2 Node 6 flashs EP01
Check regulated power supply 5V on B400.
ANALOG
20 Default = 1 if B400 < 4,5V or B400 > 5,5V. to 5 flashs SV02
INPUTS
check if short-circuit or to change B2 Node
Weak battery supply voltage 12V ANALOG
20 5 flashs SV01
(V bat < 10V) & (D+ = 1) INPUTS
Default = 1 if /KM100 DIGITALS
21
(contact open relay) INPUTS
22
23
Check the fuses
24
25
 Conditions of boom lift
Conditions
modifying
Conditions commands boom lift Obligatory speed or
N° diag
HTL3210/3510/4010 conditions prohibiting
the
movement
Conditions from outputs
YV300 Coil command boom lift X 1
SA187 Switch selection fork/winch/platform X 2
SA100 Ignition key X 3
D+ Engine running X X 4
SA692 Switch road mode X X 5
Joystick commands:
SJ120 X 6
raising/crowding/telescope/float
Stabilizing sensor FL on HTL 3210 and 4010
SQ720 X 7
only
Stabilizing sensor FR on HTL 3210 and
SQ721 X 8
4010 only
SR381 Boom angle sensor (from - 2° to 66°) X X 9
SP140 Strain gauge on rear axle X 10
U140 System anti-tipping X X 11
SA140 Bypass- anti-tipping X 12
U100 Module node B2 X X 13
KM100 General relay X X 14
FU100 Ignition key power fuse 20A X 15
FU102 Fuse 10A X 16
FU113 Fuse 7,5A X 17
FU114 Fuse 30A X 18
FU140 Fuse 10A X 19
2420344570 E 07-14 74/311
FU161 Fuse 20A X 20
Additional Conditions of inputs in radio mode for winch
SA187 Switch on selection winch X X 21
SA188 Switch power radio control X X 22
B111 Radio control X X 23
KA187 Relay commands contact X X 24
FU187 Fuse 15A power radio control X 25
Requirements from the cabin
The requirements from the Cabin are applicable whatever the selected mode (Fork, Cabin winch or
Radio control Winch) if all the following conditions are met:
- Main contactor active (KM100 = 1)
- Engine running (D+ = 1)
The following faults prohibit the movement
SV01 (weak battery supply voltage12V),
SV02 (5V voltage supplied from module out-of range)
SW01 (incoherence on key selection for accessories)
The following code needs the use of the by-pass key to carry out the movement at reduced speed.
CA01 (angle sensor not calibrated or no valid calibration),
CA02 (incoherence of angle sensor values),
CA03 (signal from angle sensor 1 out of range)
The movements of Boom Lifting are proportional to the Y axis signal from the cabin joystick while
including acceleration and deceleration ramps applied to electrovalves PWM YV300/YV320:
-Joystick towards the back for the rise of the boom
-Joystick forwards for the descent of the boom
The instruction of the joystick is taken into account only if all the following conditions are met:
- the neutral position was detected after starting of the machine
- the signal out-neutral is active (B118 = 1)
- the instruction is in the authorized operating range
- the signal out-neutral and the instruction are matching
Particular conditions fork mode
SA187A = 0 and SA187B = 0. 0V on 104.4 B109 and 104.5 B110
The speed of the movement is proportional to the signal from the joystick.
The function is prohibited in road mode if SA692 = 1
Time without load: 12s 0/+2s pour HTL4010 / HTL3210/ HTL3510
Movement authorized in pre-alarm and alarm, speed reduced
If SA140 = 1 (by-pass key) multiple movement is prohibited
Multiple movements more than two is prohibited
For version HTL 3210 or 4010 The boom lift is prohibited beyond 60° if the machine does not have
the option blocking rear axle and that it is not stabilized (right or left stabilizer not set). In this case,
the speed of lifting of the boom is gradually reduced beyond 50° (70%) then 55° (50%) in command
to avoid a too abrupt stop of the movement at 60°.

2420344570 E 07-14 75/311
 Diagnostic
Diagnoses
Optimizer
N° Indicator
TESTS Menu
diag ECU Menu
INPUT-
FAILURES
OUTPUT
Default YV300 output in short-circuit (105.19

1 1 flash EV03
B608)
Default YV300 output in open circuit (check

1 1 flash EV04
wiring)
ANALOG
1 YV300 supply 0mA to 1350mA on B608
OUTPUTS
SA187 = 0 selection fork. 0V on 104.4 B109 and DIGITAL
2
104.5 B110 INPUTS
DIGITAL
2 SA187A = 1 selection winch 12V on 104.4 B109
INPUTS
Fault int Selector mode SA187, incoherence in
2 selection mode. Default = 1 if SA187A = 1 and 3 flashs SW01
SA187B = 1
SA100 test the wires: 100 (supply) /11 (contact) DIGITAL
3
/2 (starting) INPUTS
Engine running check 12V on D+ alternator DIGITAL
4
(B106) if light NOK charges battery HL161 = 1 INPUTS
If SA692 = 1 road mode selected (12V on DIGITAL
5
105.35 B131) movement prohibited INPUTS
A default << joystick out of range >> prohibits
6 the movements << boom lift >>.Default = 1 if 2 flashs JY01
B300 < 0.2 V or B300 > 4,8V.
Check stabilized 5V power supply on B400.
ANALOG
6 Default = 1 if B400 < 4,5V or B400 > 5,5V. 5 flashs SV02
INPUTS
check if short-circuit or change Node B2
ANALOG
6 Signal B300 (2.5 volts to 4.5 volts).
INPUTS
B118 = 1 & (2.45V < B300 < 2.55V) & (2.45 <
B301 < 2.55V)
6 2 flashs JY03
B118 = 0 & (B300 < 2.00V or B300 > 3.00V)
B118 = 0 & (B301 < 2.00V or B301 > 3.00V)
Neutral position of the joystick cabin not

6 detected since the starting of the machine: 2 flashs JY04
B300 < 2,35V or B300 > 2,65V
DIGITAL
6 Outside neutral signal activated 12V on B118
INPUTS
DIGITAL
7 SQ720 = 1 proximity sensor
OUTPUTS
DIGITAL
8 SQ721 = 1 proximity sensor
OUTPUTS

2420344570 E 07-14 76/311
Angle Sensor not calibrated or no valid
9 4 flashs CA01
calibration
Incoherence in the 2 signals from the angle
ANALOG
9 sensor (B403 or B404). 4 flashs CA02
INPUTS
Signals output 1 and output 2: 0,5V to 4,5V
Signal from angle sensor 1 out of range (B403):
9 4 flashs CA03
(D+ = 1) & (KM100 = 1)
Signal from angle sensor 2 out of range (B404):
9 4 flashs CA04
(D+ = 1) & (KM100 = 1)
10
Overload system fault = 1 if B130 = 0 & B142 =
and 7 flashs LC02
1 (incoherence in pre-alarm/alarm)
11
10
Alarm LMI shunted with key SA140. B130 = 0 &
and 0 flash LC01
SA140 = 1 & Function (calibration LMI)
11
DIGITAL
12 If SA140 = 1 (12V on B108)
INPUTS
Neutral position switch not detected since the
12 3 flashs SW04
starting of the machine: SA140 = 1
13 Upload program or replace Node B2 EP01

6 flashs
Default 5V stabilized power supply. Default + 1
ANALOG
13 if tension on B400 < 4.5 volts or > 5.5 volts. 5 flashs SV02
INPUTS
weak battery supply voltage 12V ANALOG

13 5 flashs SV01
(V bat < 10V) & (D+ = 1) INPUTS
DIGITAL
14 Default = 1 if /KM100 (contact open relay)
INPUTS
15 to Check the fuses
20
DIGITAL
21 SA187A = 1 winch mode, 12V on B109 (104.4)
INPUTS
Fault selector mode SA187, incoherence
21 selection mode. Default = 1 if SA187a = 1 and 3 flashs SW01
SA187b = 1
SA188 = 1 then radio control is supplied. 12V
22
Radio control command fault, instruction
joystick out of range. Default = 1 if B111 (Radio
23 2 flashs RC01
control) & (B401 (raising signal) < 0,2V or B401
> 4,8V)
Neutral position joystick Radio control not
23 detected since the starting of the machine: 2 flashs RC05
B401 < 2,00V or B401 > 2,50V
Check variation of signal on B401 in rise (2,5V ANALOG

23
to 4,5V) INPUTS
KA187 = 1 Emergency stop Radio controls not

24
engaged 12V on 194
KA187 = 0 Emergency stop Radio controls
24
engaged 0V on 194
25 Check the fuses

2420344570 E 07-14 77/311
 Conditions for boom descent
Conditions
modifying
Conditions commands boom descent Obligatory speed or
N° diag
the
movement
YV320 Coil command boom descent X 1
Joystick commands:
SJ120 X 6
raising/crowding/telescope//float
Stabilizing sensor FL on HTL 3210 and

SQ720 X 7
HTL 4010 only
SQ721 X 8
HTL 4010 only
SR381 Boom angle Sensor (from - 2° to 66°) X X 9
SA140 Bypass anti-tipping X 12

FU100 Ignition key fuse 20A supply X 15
FU102 Fuse 10A X 16
FU114 Fuse 30A X 18
FU140 Fuse 10A X 19
FU161 Fuse 20A X 20
SA187 Switch on winch selection X X 21
KA187 Relay command contact X X 24

2420344570 E 07-14 78/311
Requirements from the cabin
The requirements from the Cabin are applicable whatever the selected mode (Fork, winch Cabin or Winch
Radio operator) if all the following conditions are OK: :
-Main contactor active (KM100 = 1)
-Engine running (D+ = 1)
SV02 (module 5V supply voltage out of range)
SW01 (incoherence in accessory key selection)
The following faults need the use of the by-pass key to make the movement- at reduced speed.
CA02 ( value of the angle sensors inconsistant),
The movements of boom descent are proportional to the Y axis of the cabin joystick while applying
acceleration and deceleration ramps applied to electrovalve PWM YV300/YV320:
- Joystick backwards for boom lift
- Joystick forwards for boom descent
-the neutral position was detected after starting of the machine
- the signal out-neutral and the instruction are coherent

The speed of the movement is proportional to the command applied on the joystick.
Time without load: 10s 0/+1s for HTL4010/ HTL3210/ HTL3510
Movement authorized in pre-alarm, speed reduced
Movement prohibited in alarm
Movement authorized in alarm at speed reduced if outreach limit shunt activated (SA140 =1)
If SA140 = 1 (by-pass key) the multiple movement is prohibited
Multiple movements more than two are prohibited
Particular conditions of the winch mode from the cabin

SA187A = 1. 12V on 104.4 B109 and 0V on 104.5 B110
SV01 (weak battery supply voltage 12V),
SV02 (module 5V supply voltage out of range) and
The following faults need the use of the by-pass key to make the movement at reduced speed.
Movement authorized in pre-alarm, speed reduced
Movement authorized in alarm at speed reduced if outreach limit shunt activated (SA140 = 1)
The multiple movements/functions are prohibited

2420344570 E 07-14 79/311
Particular conditions of the winch mode from the Radio control
SA187A = 1. 12V on 104.4 B109 and 0V on 104.5 B110
SA188 = 1 then radio control is supplied. 12V on 187A
If information radio command = 1 (12V on B111) the movement of boom descent is commanded by the
radio control
If the information of radio command = 1 the commands from the cabin are prohibited
cabin & Radio controls speed identical to the fork mode
The movements of boom lift/descent with radio control are prohibited if the engine is not at idle (< 1200
RPM)
The following faults need the use of the by-pass key to make the movement- at reduced speed.
The movements of boom descent are proportional to the Y axis of the left joystick of the radio control while
applying acceleration and deceleration ramps to electrovalve PWM YV300/YV320:
- Joystick towards the back for the rise of the boom
- Joystick forwards for the descent of the boom
-the neutral position was detected after starting of the machine
Movement authorized in pre-alarm

Movement authorized in alarm at speed reduced if outreach limit shunt is activated
(SA140 = 1)
A radio control command fault prohibited the movements << boom llifting >>
 Diagnostic
Diagnoses
Optimizer
N° Indicator
TESTS Menu
diag ECU Menu
INPUT-
FAILURES
OUTPUT
Default YV320 output short-circuit
1 1 flash EV03
(105.19 B608)
1 Default YV320 output open circuit (check wiring) 1 flash EV04
ANALOG
OUTPUTS
SA187 = 0 selection fork. 0V on 104.4 B109 and DIGITAL
2
104.5 B110 INPUTS
DIGITAL
INPUTS

2420344570 E 07-14 80/311
SA187B = 1
SA100 check the wiring: 100 (supply) /11 DIGITALS
3
4
If SA692 = 1 road mode selected (12V on 105.35 DIGITAL

5
B131) prohibited movement INPUTS
A default << joystick out of range>> prohibits the

6 movements << boom descent>>.Default = 1 if 2 flashs JY01
B300 < 0.2 V or B300 > 4,8V.
Check regulated 5V power supply on B400.

ANALOG
6 Default = 1 if B400 < 4,5V or B400 > 5,5V. to 5 flashs SV02
INPUTS
check if short-circuit or to change B2 Node
ANALOG
6 Consign B300 (2.5 volts to 0.5 volts).
INPUTS
Incoherence between the signal out- of neutral
and the instruction of the joystick:
B118 = 1 & (2.45V < B300 < 2.55V) & (2.45 <
6 2 flashs JY03
B301 < 2.55V)
B118 = 0 & (B300 < 2.00V or B300 > 3.00V)
B118 = 0 & (B301 < 2.00V or B301 > 3.00V)
Neutral position of the joystick cabin not detected
6 since the starting of the machine: B300 < 2,35V 2 flashs JY04
or B300 > 2,65V
DIGITALS
6 Out of neutral activated 12V on B118
INPUTS
DIGITAL
7 SQ720 = 1 proximity detector
OUTPUTS
DIGITAL
OUTPUTS
9 Angle sensor not calibrated or no valid calibration 4 flashs CA01
Incoherence of the 2 calibrated signals of angle
ANALOG
9 sensor (B403 and B404). 4 flashs CA02
INPUTS
Output signals 1 & 2: 0,5V to 4,5V
Corrected signal from angle sensor 1 out of range
9 4 flashs CA03
(B403): (D+ = 1) & (KM100 = 1)

9 4 flashs CA04
(B404): (D+ = 1) & (KM100 = 1)
10 and Fault overload system = 1 if B130 = 0 & B142 =

7 flashs LC02
11 1 (incoherence pre-alarm/alarm)
Alarms LMI shunted with key SA140.

10 and
B130 = 0 & SA140 = 1 & Function (calibration 0 flash LC01
11
LMI)
DIGITALS
12 If SA140 = 1 (12V on B108)
INPUTS

12 3 flashs SW04
13 upload the software or replace Node B2 6 flashs EP01

2420344570 E 07-14 81/311
Default regulated power supply 5V.
Default + 1 if tension on B400 < 4.5 volts or > 5.5 ANALOG
13 5 flashs SV02
volts. INPUTS
check if short-circuit or change B2 Node
Weak battery supply voltage 12V(V drops < 10V) ANALOG
13 5 flashs SV01
& (D+ = 1) INPUTS
DIGITALS
INPUTS
15
16
17
Check the fuses
18
19
20
Diagnoses
Optimizer
N° Indicator
TESTS Menu
diag ECU Menu
INPUT-
FAILURES
OUTPUT
DIGITALS
INPUTS
DIGITALS
INPUTS
SA187b = 1
SA188 = 1 then radio control is supplied. 12V on
22
187A and 12V on B100
Radio control command fault, instruction joystick
23 out of range. Default = 1 if B111 (Radio control) & 2 flashs RC01
(B401 (raising signal) < 0,2V or B401 > 4,8V)

23 detected since the starting of the machine: B401 2 flashs RC05
< 2,00V or B401 > 2,50V
Check variation of signal on B401 in descent ANALOG
23
(2,5V to 0,5V) INPUTS
24
engaged 12V on 194
24
engaged 0V on 194
25 Check the fuses

2420344570 E 07-14 82/311
 Conditions for telescopic boom extension
Conditions
modifying
Conditions command telescope Obligatory speed or
N° diag
the
movement
YV340 Coil command telescopic extension X 1
Joystick commands:
SJ120 X 6
SQ720 X 7
only
SQ721 X 8
4010 only
SR381 Sensor angle of boom (from - 2° to 66°) X X 9
FU102 Fuse 10A X 16
FU114 Fuse 30A X 18
FU140 Fuse 10A X 19
FU161 Fuse 20A X 20
KA187 Relay commands X X 24

2420344570 E 07-14 83/311
Requirements from the Cabin
The requirements from the Cabin are applicable if all the following conditions are met: :
- Fork mode or Winch Cabin selected (B111 = 0)
- Main contactor active(KM100 = 1)
The following faults prohibit the movements of telescoping boom
The following faults need the use of the by-pass key in command to carry out the movements of lifting boom at
reduced speed.
CA03 (signal from angle sensor 1 out of range) and
In version Europe, the movements of telescoping boom are commanded on the left roller of the joystick.
roller to the back and out of neutralboom IN /Roller to the front and out of neutralboom OUT
In version Europe, the instruction of the roller is taken into account only if all the following conditions are met:
In version AUS/USA, the movements of telescoping boom are commanded by the joystick.
Joystick inclined towards the left & and out of neutral boom retraction
Joystick tilted towards right and out of neutral boom extension
In version AUS/USA, the instruction of the joystick is taken into account only if all the following conditions are
OK :
- the neutral position was detected after starting of the machine,
- the signal out-neutral is active (B118 = 1),
- the instruction is in the authorized operating range,
- the signal out-neutral and the instruction is coherent,

The speed of the movement is proportional to the command on the joystick roller
Regulated time: 17s 0/+1s
Movement authorized in pre-alarm reduced speed
Movement of exit prohibited in alarm even if the shunt of limitation is activated (SA140 = 1)
Movement authorized in alarm at speed reduced if outreach limit shunt activated
(SA140 = 1) and calibration LMI in progress
The Multiplemovement is prohibited when the outreach limit shunt is activated (SA140 = 1)
The multiple movements more than 2 is prohibited
The movement is prohibited if <<joystick or roller out of range>>
The movement is prohibited if neutral position of the joystick or roller not detected after starting of the machine
The movement is prohibited if signal out of neutral of the joystick is inactive (B118 = 0)
The movement is prohibited if signal is incoherent between out of neutral and instruction from joystick

2420344570 E 07-14 84/311
Particular conditions of the winch mode from the Cabin
SA187A = 1. 12V on 104.4 B109 and 0V on 104.5 B110
Movement of exit prohibited in alarm even if the shunt of limitation of carried is activated (SA140 = 1)

SA187A = 1. 12V on 104.4 B109 and 0V on 104.5 B110
If information radio command = 1 (12V on B111) the movement of telescope extension is commanded by the
Radio control
If the information of radio command = 1 the commands from the Cabin are prohibited
Post cabin & Radio controls speed identical to the fork mode
The movements of telescope extension of retraction of boom with Radio control are prohibited if the engine is
not at idle statement (< 1200 RPM)
SV01 (weak battery supply voltage 12V),
The following faults need the use of the by-pass key in command to carry out the movement of lifting boom
at reduced speed
CA03 (signal from angle sensor 1 out of range) and
The movements of Telescoping boom are proportional to the Y axis of the right-hand side joystick of the
radio control while applying acceleration and deceleration ramps applied to electrovalve PWM
YV340/YV360:
- Joystick towards the back for the telescope extension
- Joystick forwards for telescope retraction
The movements of Telescoping boom from the Cabin are deactivated. .

Movement of extension prohibited in alarm even if the by-pass key is activated (SA140 = 1)
The multiple movement is prohibited

2420344570 E 07-14 85/311
 Diagnostic
Diagnoses
Optimizer
N° Indicator
TESTS Menu
diag ECU Menu
INPUT-
FAILURES
OUTPUT
1 Default YV340 output in short-circuit (105.21 B610) 1 flash EV03
ANALOG
OUTPUTS
SA187 = 0 selection fork. 0V on 104.4 B109 and DIGITALS
2
104.5 B110 INPUTS
DIGITALS
INPUTS
SA187B = 1
SA100 check the wiring: 100 (supply)/11 (contact)/2 DIGITALS
3
(starting) INPUTS
Engine running check 12V on D+ alternator (B106) DIGITAL
4
if light NOK charges battery HL161 = 1 INPUTS
5
A default << roller out of range>> prohibits the
6 movement << telescopic extension >>.Default = 1 if 2 flashs HD01
B302 < 0.2 V or B302 > 4,7V.
Check regulated 5V power supply on B400. Default
ANALOG
6 = 1 if B400 < 4,5V or B400 > 5,5V. to check if short- 5 flashes SV02
INPUTS
circuit or to change Node B2
ANALOG
6 setpoint B302 (2.5 volts to 0.5 volts).
INPUTS
In version AUS/USA a default << joystick out of

6 range>> prohibits the movements << telescope >>. 2 flashs JY02
Default = 1/if B301 < 0.2 V + B301 > 4,8V.
Incoherence between the signal out-neutral and the

instruction of the joystick :
B118 = 1 & (2.45V < B300 < 2.55V) & (2.45 < B301
6 2 flashs JY03
< 2.55V)
B118 = 0 & (B300 < 2.00V or B300 > 3.00V)
B118 = 0 & (B301 < 2.00V or B301 > 3.00V)
Neutral position of the roller not detected since the
6 starting of the machine: B302 < 0,2V or B302 > 2 flashs HD03
2,70V
DIGITALS
INPUTS
DIGITAL
OUTPUTS
DIGITAL
OUTPUTS

2420344570 E 07-14 86/311

ANALOG
9 sensor (B403 and B404). Output signals 1 & 2: 4 flashs CA02
INPUTS
0,5V to 4,5V
9 4 flashs CA03
(B403): (D+ = 1) & (KM100 = 1)
9 4 flashes CA04
(B404): (D+ = 1) & (KM100 = 1)
10 and Fault overload system = 1 if B130 = 0 & B142 = 1
7 flashs LC02
11 (incoherence pre-alarm/alarm)
10 and Alarms LMI shunted with key SA140. B130 = 0 &
0 flash LC01
11 SA140 = 1 &! Function (calibration LMI)
DIGITALS
12 If SA140 = 1 (12V on B108)
INPUTS
12 3 flashs SW04
13 Upload the software or replace Node B2 6 flashs EP01
Default regulated power supply 5V. Default = 1 if

ANALOG
13 tension on B400 < 4.5 volts or > 5.5 volts. to check 5 flashs SV02
INPUTS
if short-circuit or to change Node B2
Weak battery supply voltage 12V (V battery < 10V) ANALOG

13 5 flashs SV01
& (D+ = 1) INPUTS
DIGITALS
INPUTS
15
16
17 Check the fuses
18
19
20

2420344570 E 07-14 87/311
Diagnoses
Optimizer
N° Indicator
TESTS Menu
diag ECU Menu
INPUT-
FAILURES
OUTPUT
DIGITAL
INPUTS
DIGITAL
INPUTS
SA187b = 1
SA188 = 1 then radio control is supplied. 12V
22
Radio control command fault, instruction
joystick out of range.
23 2 flashs RC03
Default = 1 if B111 (Radio control) & (B402
(raising signal) < 0,2V or B402 > 4,8V)
23 detected since the starting of the machine: 2 flashs RC05
B402 < 2,00V or B402 > 2,50V
Check variation of signal on B402 output (2,5V ANALOG

23
to 0,5V) INPUTS
24
engaged 12V on 194
24
engaged 0V on 194
25 Check the fuses

2420344570 E 07-14 88/311
 Conditions for telescopic boom retraction
Conditions
modifying
Conditions commands telescopic retraction Obligatory speed or N°
HTL3210/3510/4010 conditions prohibiting diag
the
movement
YV360 Coil command telescope retraction X 1
Joystick commands:
SJ120 X 6
SQ720 Stabilizing sensor FL on HTL 3210 and 4010 only X 7
SQ721 Stabilizing sensor FR on HTL 3210 and 4010 only X 8
SR381 Boom angle sensor (- 2° to 66°) X X 9

FU102 Fuse 10A X 16
FU114 Fuse 30A X 18
FU140 Fuse 10A X 19
FU161 Fuse 20A X 20

2420344570 E 07-14 89/311
The Requirements from the Cabin are applicable if all the following conditions are met:
The following faults prohibit the movements of boom telescoping boom
The following faults need the use of the by-pass key in command to carry out the movements of
boom at reduced speed
CA02 (value of the angle sensors inconsistant),
CA04 (signal from angle sensor 2 out of range).
In version Europe, the movements of telescoping boom are commanded by the left roller of the
joystick. Roller to the back and out of neutral boom extension IN /Roller to the front and out of neutral
boom extension OUT
In version Europe, the instruction of the roller is taken into account only if all the following conditions
are met:
In version AUS/USA, the movements of telescoping boom are commanded by the joystick. Joystick
inclined towards the left & and retracts boom, joystick tilted towards the right and out of neutral
boom OUT
In version AUS/USA, the instruction of the joystick is taken into account only if all the following
conditions are met:
- the neutral position was detected after starting of the machine,
- the signal out-neutral is active (B118 = 1),
- the instruction is in the authorized operating range,
- the signal out-neutral and the instruction is coherent

The speed of the movement is proportional to the command on the roller
Regulated time: 10s 0/+1s
Authorized movement alarms speed reduced of it
The Multiplemovement is prohibited when the by-pass key is activated
(SA140 = 1)
The multiple movement more than 2 is prohibited
The movement is prohibited if neutral position of the joystick or roller not detected after starting of the
machine
The movement is prohibited if signal incoherence between out of neutral and instruction joystick

2420344570 E 07-14 90/311
SA187A = 1. 12V on 104.4 B109 and 0V on 104.5 B110
Authorized movement alarms speed reducedof it
The multiple movements/functions is prohibited

SA187A = 1. 12V on 104.4 B109 and 0V on 104.5 B110
If information radio command = 1 (12V on B111) the movement of telescopic retraction is
commanded by the Radio control
If the information of radio command = 1 the commands from the Cabin are prohibited
cabin & Radio controls speed identical to the fork mode
The movements of telescopic extension or retraction with Radio control are prohibited if the engine is
not at idle state (< 1200 RPM)
The following faults need the use of the by-pass key in command to carry out the movement of lifting
boom at reduced speed
CA04 (signal from angle sensor 2 out of range).
The movements of Telescoping Boom are proportional by the Y axis of the right-hand side joystick of
of the radio control while applying acceleration and deceleration ramps to electrovalve PWM
YV340/YV360:
- Joystick towards the back for the telescope extension
- Joystick forwards for telescope retraction
The movements of Telescoping Boom from the Cabin are prohibited.

Authorized movement in alarm (speed reduced)

2420344570 E 07-14 91/311
 Diagnostic
Diagnoses
Optimizer
N° Indicator
TESTS Menu
diag ECU Menu
INPUT-
FAILURES
OUTPUT
ANALOG
OUTPUTS
SA187 = 0 selection fork. 0V on 104.4 B109 and DIGITALS

2
104.5 B110 INPUTS
DIGITALS
INPUTS
Selector default mode SA187, incoherence selection
2 3 flashs SW01
mode. Default = 1 if SA187A = 1 and SA187B = 1
3
(starting) INPUTS
Engine running check 12V on D+ alternator (B106) if DIGITAL
4
light NOK charges battery HL161 = 1 INPUTS
5
A default << roller out of range>> prohibits the

6 movement << telescope retract >>. 2 flashs HD01
Default = 1 if B302 < 0.2 V or B302 > 4,7V.
Check regulated 5V power supply on B400. Default =

ANALOG
6 1 if B400 < 4,5V or B400 > 5,5V. 5 flashs SV02
INPUTS
ANALOG
6 Consign B302 (2.5 volts with 4.5 volts).
INPUTS
In version AUS/USA a default << joystick out of

ANALOG
6 range>> prohibits the movements << telescope 2 flashs JY02
INPUTS
>>.Default = 1/if B301 < 0.2 V + B301 > 4,8V.

instruction of the joystick:
6 B118 = 1 & (2.45V < B300 < 2.55V) & (2.45 < B301 < 2 flashs JY03
2.55V)
B118 = 0 & (B300 < 2.00V or B300 > 3.00V)
B118 = 0 & (B301 < 2.00V or B301 > 3.00V)
Neutral position of the roller not detected since the ANALOG
6 2 flashs HD03
starting of the machine: B302 < 0,2V or B302 > 2,70V INPUTS
DIGITALS
INPUTS
DIGITAL
OUTPUTS

2420344570 E 07-14 92/311
DIGITAL
OUTPUTS
ANALOG
INPUTS
9 4 flashs CA03
(B403): (D+ = 1) & (KM100 = 1)
9 4 flashs CA04
(B404): (D+ = 1) & (KM100 = 1)
10
Fault overload system = 1 if B130 = 0 & B142 = 1
and 7 flashs LC02
(incoherence pre-alarm/alarm)
11
10
Alarms LMI by-passed with key SA140. B130 = 0 &
and 0 flash LC01
SA140 = 1 & Function (calibration LMI)
11
DIGITALS
12 If SA140 = 1 (12V on B108)
INPUTS
Neutral position switch not detected since the starting
12 3 flashs SW04
of the machine: SA140 = 1
Default + 1 if tension on B400 < 4.5 volts or > 5.5 ANALOG
13 5 flashs SV02
volts. INPUTS
Weak battery supply voltage 12V (V battery < 10V) & ANALOG
13 5 flashs SV01
(D+ = 1) INPUTS
DIGITALS
INPUTS
15
16
17
Check the fuses
18
19
20

2420344570 E 07-14 93/311
Diagnoses
Optimizer
N° Indicator
TESTS Menu
diag ECU Menu
INPUT-
FAILURES
OUTPUT
DIGITAL
INPUTS
Fault selector mode SA187, incoherence selection
DIGITAL
21 mode. 3 flashs SW01
INPUTS
Default = 1 if SA187a = 1 and SA187b = 1
22
and 12V on B100
Radio control command fault, instruction joystick out of
range.
23 2 flashs RC03
Default = 1 if B111 (Radio control) &
(B402 (raising signal) < 0,2V or B402 > 4,8V)
Neutral position joystick Radio control not detected
23 since the starting of the machine: 2 flashs RC05
B402 < 2,00V or B402 > 2,50V
ANALOG
23 Check variation of signal on B402 output (2,5V to 0,5V)
INPUTS
24
engaged 12V on 194
24 KA187 = 0 Emergency stop Radio controls engaged 0V

on 194
25 Check the fuses

2420344570 E 07-14 94/311
 Conditions for excavation
Conditions
modifying
Obligatory speed or
Conditions commands HTL3210/3510/4010 N° diag
conditions prohibiting
the
movement
YV420 Coil command excavation X 1
Joystick commands:
SJ120 X 6
raising/excavation/telescope/float
SQ720 X 7
only
Stabilizing sensor FR on HTL 3210 and 4010
SQ721 X 8
only
FU102 Fuse 10A X 16
FU114 Fuse 30A X 18
FU140 Fuse 10A X 19
FU161 Fuse 20A X 20
SA187 Switch on winch selection X X 21

2420344570 E 07-14 95/311
The following Fault prohibit the movements of excavation/digging function:

SV01 (EVE): supply voltage battery 12V weak
SV02 (RAM): supply voltage module 5V out-of-range
SW01 (RAM): incoherence in accessory key selection
If the country selected in the options is “STD/EUR”, then the movements of excavation/digging
function are proportional to X axis of the joystick of the cabin while applying acceleration and
deceleration ramps applied to electrovalve PWM YV400/YV420:
- Joystick towards the left for excavation (tilt back)
- Joystick towards the right for digging (tilt forward)
- the instruction is in the operating range
If the country selected in the options is “STD/EUR”, then the movements of excavation/digging
function are commanded in a proportional way by X axis of the joystick of the cabin while applying
acceleration and deceleration ramps applied to PWM valve YV400/YV420:
- Joystick towards left for excavation (tilt back)
- Joystick towards right for digging (tilt forward)

2420344570 E 07-14 96/311
The speed of the movement is proportional to the command on the joystick
Regulated time: 4,5s -1s/0 max
Movement authorized in alarm at speed reduced if by-pass key is activated (SA140 = 1)
The multiple movement is prohibited when the by-pass key is activated (SA140 = 1)
The multiple more than 2 movements is prohibited
machine

SA187A = 1. 12V on 104.4 B109 and 0V on 104.5 B110
Movement authorized in alarm at speed reduced if by-pass key is activated (SA140 = 1)

SA187A = 1. 12V on 104.4 B109 and 0V on 104.5 B110
cabin & Radio control speeds identical to the fork mode
The movements of excavation or digging with Radio control are prohibited if the engine is not at idle
statement (< 1200 RPM)
The movements of excavation/digging function are commanded in an ON/OFF way (60%) by the 3
position switch of the radio control while applying acceleration and deceleration ramps to electrovalve
PWM YV400/YV420:
- Switch forwards for excavation (tilt back)
- Switch towards the back for digging (tilt forward)
The instruction of the switch is taken into account only if all the following conditions are met:
- the neutral position was detected after the starting of the machine
- only one of the signals before/back of the switch is active
The movements of excavation/digging function from the cabin are deactivated. .
The multiple movement are prohibited

2420344570 E 07-14 97/311
 Diagnostic
Diagnoses
Optimizer
N° Indicator
TESTS Menu
diag ECU Menu
INPUT-
FAILURES
OUTPUT
YV420 supply 0mA to 1600mA ANALOG
1
or 20mV with 6VDC on B613 OUTPUTS
DIGITALS
2 SA187 = 0 selection fork (B109 = 0 and B110 = 0V)
INPUTS
2 3 flashs SW01
mode. Default = 1 if SA187A = 1 and SA187B = 1
3
(starting) INPUTS
4

5
6 movements << compensation >>.Default = 1/if B301 2 flashs JY02
< 0.2 V + B301 > 4,8V.
ANALOG
6 = 1 if B400 < 4,5V or B400 > 5,5V. to check if short- 6 flashs SV02
INPUTS
circuit or change Node B2
ANALOG
6 Consign B301 (2.5 volts to 0.5 volts).
INPUTS
In version AUS/USA signal left roller out of range: ANALOG

6 2 flashs HD01
B302 < 0,2V or B302 > 4,7V INPUTS

6 B118 = 1 & (2.45V < B300 < 2.55V) & 2 flashs JY03
(2.45 < B301 < 2.55V)
B118 = 0 & (B300 < 2.00V or B300 > 3.00V)
B118 = 0 & (B301 < 2.00V or B301 > 3.00V)
DIGITALS
INPUTS
DIGITAL
OUTPUTS
DIGITAL
OUTPUTS
ANALOG
INPUTS
9 4 flashs CA03
(B403): (D+ = 1) & (KM100 = 1)

2420344570 E 07-14 98/311
9 4 flashs CA04
(B404): (D+ = 1) & (KM100 = 1)
7 flashes LC02
10 and Alarms LMI by-passed with the key SA140 : B130 =

0 flash LC01
11 0 & SA140 = 1 & Function (calibration LMI)
Neutral position of switch SA140 (outreach limit
12 shunt) not detected since the starting of the 3 flashs SW04
machine. B140 = 1
DIGITALS
12 If SA140 = 1 (12V on B108) reduced speed opening
INPUTS
Default + 1 if voltage on B400 < 4.5 volts or > 5.5 ANALOG
13 5 flashs SV02
volts. INPUTS

13 5 flashs SV01
(V battery < 10V) & (D+ = 1) INPUTS
DIGITALS
INPUTS
15 to Check the fuses
20
SA187B = 1. 12V on 104.5 B110 and 0V on 104.4 DIGITAL
21
B109 INPUTS
DIGITAL
INPUTS
Default = 1 if SA187a and SA187b
22
Radio control command fault, function out of range.
23 Default = 1 if B111 & B104 = 1 (excavation) & B105 2 flashs RC02
= 1 (digging)
23 check signal on B105 (0V/12V)
ANALOG
23 since the starting of the machine: B402 < 2,00V or 2 flashs RC05
INPUTS
B402 > 2,50V
24
engaged 12V on 194
KA187 = 0 Emergency stop Radio controls engaged

24
0V on 194
25 Check the fuses

2420344570 E 07-14 99/311
Conditions for discharging
Conditions
modifying
Conditions commands discharging Obligatory speed or
N° diag
the
movement
YV400 Coil command discharging X 1
Joystick commands:
SJ120 X 6
raising/excavation/telescope//float
SQ720 X 7
only
SQ721 X 8
only
FU102 Fuse 10A X 16
FU114 Fuse 30A X 18
FU140 Fuse 10A X 19
FU161 Fuse 20A X 20

2420344570 E 07-14 100/311
The following faults prohibit the movements of Crowding/dumping function:

SV01 (EVE): supply voltage battery 12V weak
SV02 (RAM): supply voltage module 5V out-of-range
SW01 (RAM): incoherence in accessory key selection
If the country selected in the options is “STD/EUR”, then the movements of Crowding/dumping function
are proportional to the X axis of the joystick of the cabin while applying acceleration and deceleration
ramps to electrovalve PWM YV400/YV420:
- Joystick towards the left for crowding (tilt back)
- Joystick towards the right for dumping (tilt forward)
-the signal out-neutral and the instruction are coherent
If the country selected in the options is “AUS/USA”, then the movements of Crowding/dumping function
are proportional to the left roller of the joystick of the cabin while following slopes of acceleration and
deceleration:
- Roller towards the back for crowding (tilt back)
- Roller forwards for discharge (tilt forward)
The instruction of the roller is taken into account only if all the following conditions are met: :

2420344570 E 07-14 101/311
The speed of the movement is proportional to the command on the joystick
Regulated time: 4,5s -1s/0 max
Movement authorized in alarm at speed reduced if outreach limit shunt activated (SA140=1)
The multiple movement is prohibited when the outreach limit shunt is activated
(SA140 = 1)
The multiple movement more than 2 is prohibited
machine

SA187A = 1. 12V on 104.4 B109 and 0V on 104.5 B110

SA187A = 1. 12V on 104.4 B109 and 0V on 104.5 B110
If information radio command = 1 (12V on B111) the movement excavation is commanded by the Radio
control
Post cabin & Radio controls speed identical to the fork mode
The movements of dumping or closing with Radio control are prohibited if the engine is not at idle
statement (< 1200 RPM)
The movements of Crowding/dumping function are commanded in an ON/OFF way (60%) by the 3
position switchof the radio control while applying acceleration and deceleration ramps applied to
electrovalve PWM YV400/YV420:
- Switch forwards for crowding (tilt back)
- Switch towards the back for dumping (tilt forward)
- only one of the signals before/back of the switch is active
The movements of Crowding/dumping function from the Cabin are deactivated
Movement authorized in alarm at speed reduced if outreach limit shunt activated
(SA140 = 1)

2420344570 E 07-14 102/311
 Diagnostic
Diagnoses
Optimizer
N° Indicator
TESTS
diag ECU Menu INPUT- Menu
OUTPUT FAILURES

Default YV400 output open circuit
1 1 flash EV04
(check wiring)
1
or 20mV to 6VDC on B613 OUTPUTS
SA187 = 0 selection fork DIGITALS
2
(B109 = 0 and B110 = 0V) INPUTS
2 selection mode. 3 flashs SW01
Default = 1 if SA187A = 1 and SA187B = 1
3
(starting) INPUTS
Engine running check 12V on D+ alternator (B106) DIGITAL
4
if light NOK charges battery HL161 = 1 INPUTS
5
ANALOG
6 movements << compensation >>. 2 flashs JY02
INPUTS
Default = 1/if B301 < 0.2 V + B301 > 4,8V.
ANALOG
6 = 1 if B400 < 4,5V or B400 > 5,5V. 5 flashs SV02
INPUTS
ANALOG
6 Consign B301 (2.5 volts with 4.5 volts).
INPUTS
In version AUS/USA signal left roller out of range: ANALOG

6 2 flashs HD01
B302 < 0,2V or B302 > 4,7V INPUTS

6 B118 = 1 & (2.45V < B300 < 2.55V) & 2 flashs JY03
(2.45 < B301 < 2.55V)
B118 = 0 & (B300 < 2.00V or B300 > 3.00V)
B118 = 0 & (B301 < 2.00V or B301 > 3.00V)
DIGITAL
INPUTS
DIGITAL
OUTPUTS
DIGITAL
OUTPUTS
ANALOG
INPUTS
9 4 flashs CA03
(B403): (D+ = 1) & (KM100 = 1)

2420344570 E 07-14 103/311
9 4 flashs CA04
(B404): (D+ = 1) & (KM100 = 1)

7 flashs LC02
10 and Alarms LMI by-passed with the key: B130 = 0 &

0 flash LC01
11 SA140 = 1 & Function (calibration LMI)
machine. B140 = 1
DIGITALS
12 If SA140 = 1 (12V on B108) reduced speed closing
INPUTS
Default regulated power supply 5V. Default + 1 if

ANALOG
13 tension on B400 < 4.5 volts or > 5.5 volts. 5 flashs SV02
INPUTS

13 5 flashs SV01
(V battery < 10V) & (D+ = 1) INPUTS
DIGITALS
INPUTS
15 -20 Check the fuses
21
B109 INPUTS
DIGITAL
INPUTS
Default = 1 if SA187a and SA187b
22
Radio control command fault, function out of range.
23 Default = 1 if B111 & B104 = 1 (crowding) & B105 = 2 flashs RC02
1 (dumping)
23 check signal on B105 (0V/12V)
ANALOG
23 since the starting of the machine: B402 < 2,00V or 2 flashs RC05
INPUTS
B402 > 2,50V
24
engaged 12V on 194
24
engaged 0V on 194
25 Check the fuses

2420344570 E 07-14 104/311
 Conditions for auxiliary line
Conditions
modifying
Conditions commands auxiliary line port A Obligatory speed or
N° diag
and B HTL3210/3510/4010 conditions prohibiting
the
movement
YV121 Coil auxiliary validation X 1
YV123 Coil command direction A X 2
YV124 Coil command direction B X 3
Joystick commands:
SJ120 X X 8

SQ720 X 9
only
SQ721 X 10
only
FU102 Fuse 10A X 18
FU114 Fuse 30A X 20
FU140 Fuse 10A X 21
FU161 Fuse 20A X 22

2420344570 E 07-14 105/311
The following faults prohibit the additional movements of control:

- SV01 (EVE): supply voltage battery 12V weak
- SV02 (RAM): supply voltage module 5V out-of-range
- SW01 (RAM): incoherence in accessory key selection
The Additional movements of Control are proportional to the roller right of the joystick of the cabin while
following slopes of acceleration and deceleration applied to electrovalve PWM YV121:
- Roller forwards for the direction A
- Roller towards the back for the direction B
The instruction of the roller is taken into account only if all the following conditions are met:

The speed of the movement is proportional to the command applied on the roller
The movement is prohibited if neutral position of the roller not detected after starting of the machine
The movement is prohibited if <<roller out of range>>
Movement authorized in pre-alarm. Reduced speed
The multiple movements is prohibited if activated Bypass- anti-tipping
Possible multiple with movement: lifting, telescoping, excavation and drive

2420344570 E 07-14 106/311
SA187A = 1. 12V on 104.4 B109 and 0V on 104.5 B110

The speed of the movement is proportional to the command on roller
Roller forwards direction A (unwinding cable drum) and roller backwards direction B (rolling up cable
drum)
The movement is prohibited if neutral position of the roller not detected after starting of the machine
The movement is prohibited if <<roller out of range>>

SA187A = 1. 12V on 104.4 B109 and 0V on 104.5 B110
If the information of radio command = 1 the auxiliary command line from the Cabin is prohibited
If information radio command = 1, the movements of the winch drum are commanded by the radio
command. Joystick of radio left commands tilted towards the left, unfolding of the cable. Radio control
switch commands tilted towards the line, rolling up of the cable.
Rolling up or unfolding is prohibited if the engine is not at idle (< 1200 RPM)
The Additional movements of Control are commanded in an ON/OFF way (60%) by the switch of the
joystick (axis X) of the radio control while following slopes of acceleration and deceleration applied to
electrovalvePWM YV121:
- Switch towards the left for direction A/B
- Switch towards the line for direction A/B
- only one of the signals left right-hand side/of the switch is active
The Additional movements of Control from the cabin are deactivated
The movement is prohibited if neutral position of the joystick not detected after starting of the machine
Movement authorized so only one of the signals right-hand side/left of the joystick is active

2420344570 E 07-14 107/311
 Diagnostic
Diagnoses
Optimizer
N° Indicator
TESTS
OUTPUT FAILURES

1 Default YV121 output open circuit 1 flash EV04
1
or 20mV to 6VDC on B614 OUTPUTS
2 1 flash EV02
(check wiring)
3 1 flash EV02
(check wiring)
DIGITAL
4 SA187 = 0 selection fork (B109 = 0 and B110 = 0V)
INPUTS
Default = 1 if SA187A = 1 and SA187B = 1
5
(starting) INPUTS
6
7
A default << roller out of range>> prohibits the supply
8 of the << additional >> outputs hydraulic. 2 flashs HD02
Default = 1 if B303 < 0.2 V + B303 > 4,7V
Check regulated 5V power supply on B400. Default = 1
8 if B400 < 4,5V or B400 > 5,5V. 5 flashs SV02
Consign B303 towards a: 2.5 volts to 0.7 volts and ANALOG
8
towards b: 2.5 volts to 4.3 volts. INPUTS
DIGITAL
OUTPUTS
DIGITAL
OUTPUTS
Incoherence of the 2 calibrated signals of angle sensor

ANALOG
11 (B403 and B404). 4 flashs CA02
INPUTS
11 4 flashs CA03
(B403): (D+ = 1) & (KM100 = 1)
11 4 flashes CA04
(B404): (D+ = 1) & (KM100 = 1)

2420344570 E 07-14 108/311
7 flashs LC02
12 and Alarms LMI shunted with the key: B130 = 0 & SA140 =
0 flashs LC01
13 1 &! Function (calibration LMI)
Neutral position of switch SA140 (outreach limit shunt)

14 not detected since the starting of the machine. B140 = 3 flashs SW04
1
DIGITALS
14 If SA140 = 1 (12V on B108) Reduced speed 0 flashs LC01
INPUTS
Check regulated 5V power supply on B400. Default = 1
ANALOG
15 if B400 < 4,5V or B400 > 5,5V. 5 flashs SV02
INPUTS
ANALOG
15 Weak battery supply voltage 12V(V < 10V) & (D+ = 1) 5 flashs SV01
INPUTS
DIGITALS
INPUTS
23
B109 INPUTS
Fault selector mode SA187, incoherence selection DIGITAL

23 3 flashs SW01
mode. Default = 1 if SA187a and SA187b INPUTS

24
and 12V on B100
Radio control command fault, Défaut = 1si B111 = 1 &

25 B102 = 1 (rotation left basket) and B103 = 1 (rotation 2 flashs RC04
right basket)
DIGITALS
25 check signal B102 or B103 (0V/12V) 2 flashs RC04
INPUTS
26
engaged 12V on 194
KA187 = 0 Emergency stop Radio controls engaged
26
0V on 194
27 Check the fuses

2420344570 E 07-14 109/311
 Conditions for outriggers
Conditions
modifying
Conditions commands stabilizers for Obligatory speed or
N° diag
HTL3210/4010 conditions prohibiting
the
movement
Validation commands stabilizing (authorizes or
YV122 prohibits the movements and regulates the X X 1
speed of the stabilizers)
YV701 stabilizer FR lift X 2
YV721 Stabilizer FR descent X 3
YV700 Stabilizer FL lift X 4
YV720 Stabilizer FL descent X 5
SA780 Switch commands stabilizing front left X 8
SA781 Switch commands stabilizing frontright X 9
Light on switches of stabilizers SA780 and
HL780 10
SA781
SQ720 X X 11
only
SQ721 X X 12
only
SQ360 Sensor telescopes returned X X 13
U140 System anti-tipping X 16
SA140 Bypass- anti-tipping X X 17
FU102 Fuse 10A X 21
FU114 Fuse 30A X 23
FU140 Fuse 10A X 24
FU161 Fuse 20A X 25

2420344570 E 07-14 110/311
Requirements of the cabin
The Requirements from the Cabin are applicable whatever the selected mode (Fork, winch Cabin or
Winch Radio control) if all the following conditions are met:
The following faults prohibit the movements of the stabilizers
SV02 (module 5V supply voltage out of range),
SW05 (Incoherence selector of the movements of stabilizers: HTL3210 or 4010: (SA780M = 1 and
SA780D = 1) or (SA781M = 1 and SA781D = 1))
The movements of Stabilizers are commanded in an ON/OFF way (100%) by the 3 position switches of
cabin SA780 (stab left) and SA781 (stab right) with ramps for acceleration (not for deceleration) applied
to electrovalve PWM YV122:
Selector forwards for the descent of the corresponding stabilizer
Selector towards the back for the raise of the corresponding stabilizer
SA780 and SA781 for the 2 stabilizers simultaneously
The instruction of each switch is taken into account only if all the following conditions are met:
the neutral position was detected on the switch after starting of the machine,
 only one of the signals assembled/descent of the switch is active
The conditions for implementation of the movements are following, whatever the mode ):
Telescope retraction (SQ360 = 1), the movements of stabilizers are authorized at normal speed if the
boom is lower than 15°, and at speed reduced ( 60% modifiable by default with the console) if the
boom is higher than 15° (by actuating the shunt key for the raise if the boom is above 30°).
Telescope retraction (SQ360 = 1), if the 2 stabilizers in position are lowered (SQ720 = SQ721 = 1),
then rise of the stabilizers is prohibited if the boom is with the top of 60° for the machines without
blocking of the rear axle.
Telescope exit (SQ360 = 0), the movements of stabilizers are authorized at speed reduced ( 60%
modifiable by default with the console)
by actuating the key of shunt for the rise if the boom is lower than 30° and prohibited if the boom is
higher than 30°.
The instruction is reduced so only one stabilizer is commanded (R 1 stabilizer) or so at least 1
stabilizer is in low position (SQ720 = 1 or SQ721 =1).
In the event in pre-alarm or of alarm LMI, the movements of stabilizers are prohibited.
 The Multiplemovements is prohibited
In the event of automatic park brake (drivers seat empty> 4s) or the manual activation of the service
brake (position of the pedal of inching ≥ 100%), and that at least one of the stabilizers is in low position
(SQ720 = 1 or SQ721 =1), the movements of the stabilizers are cut in command not to strain the LMI.
If one of the 2 switches is in default (neutral not detected or raise and descent active simultaneously),
then the movement of the 2 stabilizers is not authorized (in command to avoid movement of only one
stabilizer).
The indicators of the 3 positon switches (SA780 and SA781) for finctioning the stabilizers make it possible
to inform the user of the state of these functions. The indicators are connected to same exit HL780 of the
module:
Lit indicators: movement of stabilizers authorized at least in one of the 2 directions
Flashing indicators: movement of stabilizers asked but unauthorized, or switches at fault
 Indicators off: movement of stabilizers prohibited in both directions
Time regulated in descent: 7s +-1s for HTL4010 and HTL3210
Time regulated in rise: 6s +-1s for HTL4010 and HTL3210

2420344570 E 07-14 111/311
 Diagnostic
Diagnoses
Optimizer
N° Indicator
TESTS Menu
diag ECU Menu
INPUT-
FAILURES
OUTPUT
1 1 flash EV03
B615)
1
or 20mV to 6VDC OUTPUTS
3/2/4 YV701 to check supply 12V between 114 (12V) DIGITALS
/5 and 700/720/701/721 (0) during the command OUTPUTS
3/2/4
test in ohmmeter the resistance of the solenoid
/5
6

7
Inconherence selector of the movements of
8 and stabilizers: DIGITAL
3 flashs SW05
9 HTL3210 or 4010: (SA780M = 1 and SA780D INPUTS
= 1) or (SA781M = 1 and SA781D = 1)
DIGITALS
10 HL780 = 1 if 12 V on B515
OUTPUTS
DIGITAL
OUTPUTS
DIGITAL
OUTPUTS
DIGITALS
13 SQ360 = 1 if telescope retraction12V on B127
INPUTS
Angle sensor not calibrated or no valid
14 4 flashs CA01
calibration
ANALOG
14 sensor (B403 and B404). Output signals 1 & 2: 4 flashs CA02
INPUTS
0,5V to 4,5V
Corrected signal from angle sensor 1 out of
14 4 flashs CA03
range (B403): (D+ = 1) & (KM100 = 1)
14 4 flashs CA04
range (B404): (D+ = 1) & (KM100 = 1)
15
Fault overload system = 1 if B130 = 0 & B142 =
and 7 flashs LC02
16
15
Alarms LMI by-passed with key SA140. B130 = 0
and 0 flash LC01
& SA140 = 1 &! Function (calibration LMI)
16
machine. B140 = 1
2420344570 E 07-14 112/311
DIGITALS
17 If SA140 = 1 (12V on B108) Reduced speed 0 flash LC01
INPUTS
ANALOG
INPUTS
Weak battery supply voltage 12V(V beats < 10V) ANALOG
18 5 flashs SV01
& (D+ = 1) INPUTS
DIGITALS
INPUTS
 Conditions for cabin leveling
Conditions
modifying
Obligatory
Conditions chassis level HTL3510 speed or N° diag
conditions
prohibiting
the movement
YV122 Validation commands cabin levelling X 1
YV700 command left side X 2
YV720 command right side X 3
SA782 switch for cabin leveling command X X 5

HL780 Light on level switch SA782 6
U140 System anti-tipping X 9
SQ360 Telescopic boom limit switch retracted X X 11
FU102 Fuse 10A X 14
FU114 Fuse 30A X 16
FU140 Fuse 10A X 17
FU161 Fuse 20A X 18

2420344570 E 07-14 113/311
The Requirements from the Cabin are applicable whatever the selected mode (Fork, Treuil Cabin or
Winch Radio operator) if all the following conditions are met:
The following faults prohibit the movements of correction of chassis levelling
SV02 (module 5V supply voltage out of range),
SW05 (Incoherence selector of chassis level: HTL3510: SA782G = 1 and SA782D = 1)
The movements of Chassis level are commanded in ON/OFF (100%) by the 3 position cabin switch
SA782 while following slopes of acceleration and deceleration applied to electrovalve PWM YV122.
the neutral position was detected on the switch after starting of the machine,
 only one of the signals left right-hand side/of the switch is active
The conditions for implementation of the movements are following whatever the mode
Telescope retraction (SQ360 = 1), the movements of chassis level are authorized at speed
normal if the boom is lower than 30° and speed reduced if the boom is higher than 30°.
Telescope exit (SQ360 = 0), the movements of chassis level are authorized at speed reduced if
the boom is lower than 30° and prohibited if the boom is higher than 30° (except if one actuates
the key of shunt).
If the jib angle is higher than 50°, the movements of chassis level are prohibited whatever the
position of the telescope.
In the event in pre-alarm or of alarm LMI, the movements of chassis level are prohibited.
 The Multiplemovements is prohibited
The indicator of the switch 3 positons (SA782) of the chassis level makes it possible to inform the
user of the state of these functions. The indicators are connected to same exit HL780 of the module:
Lit indicators: movement of chassis levels authorized at least in one of the 2 directions
Flashing indicators: movement of correction asked but unauthorized, or switches at fault
 Extinct indicators: movement of correction prohibited in the 2 directions
Time cabin levelling towards left: 13s +-2s
Time cabin levelling towards right: 10s +-2s

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 Diagnostic
Diagnoses
Optimizer
N° Indicator
TESTS
OUTPUT FAILURES

1 1 flash EV03
B615)
YV122 supply 0mA to 1600mA or 20mV to ANALOG
1
6VDC OUTPUTS
2 and check supply 12V between 114 (12V) and DIGITALS
3 (0) during the command of YV700 or YV720 OUTPUTS
2 and test in ohmmeter the resistance of the
3 solenoid
Engine running check 12V on D+ alternator
DIGITAL
4 (B106) if light NOK charges battery HL161 =
INPUTS
1
Incoherence selector of chassis level: DIGITAL
5 HTL3510: SA782G = 1 and SA782D = 1 3 flashs SW05
INPUTS
DIGITALS
6 HL780 = 1 if 12 V on B515
OUTPUTS
DIGITALS
INPUTS
8 and Fault overload system = 1 if B130 = 0 &

7 flashs LC02
9 B142 = 1 (incoherence pre-alarm/alarm)
8 and Alarms LMI shunted with key SA140. B130 =

0 flash LC01
9 0 & SA140 = 1 & Function (calibration LMI)
Neutral position of switch SA140 (outreach
10 limit shunt) not detected since the starting of 3 flashs SW04
the machine. B140 = 1
DIGITALS
10 If SA140 = 1 (12V on B108) Reduced speed 0 flash LC01
INPUTS
SQ360 = 1 if telescope retraction 12V on DIGITALS
11
B127 INPUTS
Angle sensor not calibrated or no valid
12 4 flashs CA01
calibration
Incoherence of the 2 calibrated signals of
ANALOG
12 angle sensor (B403 and B404). Output 4 flashs CA02
INPUTS
signals 1 & 2: 0,5V to 4,5V
12 4 flashs CA03
range (B403): (D+ = 1) & (KM100 = 1)

12 4 flashs CA04
range (B404): (D+ = 1) & (KM100 = 1)
13 to
Check the fuses
18

2420344570 E 07-14 115/311
 Conditions for drive
Conditions
modifying
Obligatory speed or
Conditions drive HTL3210/3510/4010 N° diag
conditions prohibiting
the
movement
YV620 Drive REV X 1
YV600 Drive FWD X 2
YV683 Low speed HTL3210/3510/4010 X X 3
Recognition direction of drive on HTL3210
YV684 X 4
only
YV682 Parking brake X X 5
HA620 Buzzer of for reverse drive X X 6
EL116 Reversing light X X 7
SQ141 Sensor presence driver on seat X X 10
Joystick commands:
SJ120 X X 12
raising/excavation/auxiliary telescope//float
SB685 Switch parking brake X X 13
SA600 Comodo commands FWD X 14
SA620 Comodo commands REV X 15
SA680 Comodo Low spped/high spped X X 16
HL686 Indicator low speed 1 17
HL687 Indicator high speed 2 18
SA692 Switch commands road mode X 19
HL692 Indicator road mode X 20
B124 Switch commands float on Joystick X X 21
Stabilizing sensor FL on HTL 3210 and
SQ720 X X 22
4010 only
SQ721 X X 23
4010 only
SQ360 telescopic boom limit switch retracted X X 25
RP680 Sensor “inching” X X 26
SV685 Speed sensor on engine X X 27
SV162 Speed sensor on hydraulic drive pump X X 28
SP690 Pressure sensor service brake 90bars X X 29
HL690 Indicator pressure service brake X 30
U600 Module SAUER pump H1 X 31
U100 Module node B2 X 32
FU102 Fuse 10A X 35
FU161 Fuse 20A X 37
FU620 Fuse 10A reversing light buzzer X 38

2420344570 E 07-14 116/311
The Requirements from the Cabin are applicable whatever the selected mode (Fork, Treuil Cabin or
Winch Radio operator) if the contactor of safety is active (KM100 = 1)
In drive low speed (standing start) mode max: 2,5s on 3,5m
In drive High speed(standing start) mode max: 13s on 60m
Braking distance at 25km/h: < 10m
The direction of the drive is commanded by the control unit of the cabin and transmitted to the
module of the H1 pump via the bus CAN:
- Stalk control forwards for FWD drive
- Stalk control towards the REV drive
The instruction of the control unit is taken into account only if all the following conditions are met: :
- only one of the signals before/back of the control unit is active
The speed of drive is commanded by the position of the ECU module of the cabin and is transmitted
to the module of the H1 pump via the CAN bus:
- Control unit turned in position I for Low Speed
- Control unit turned in position II for High speed
Each following condition prohibited the switching to High speed and/or force Low Speed:
- Validated Float
- Unfolded machine: angle boom > 15° or telescopes extended (SQ360 = 0).
- Fault for the pressure of the service brake (SP690 = 1)
- Activated parking brake (or automatic activation of the parking brake at the time of the movements
of stabilizers in low position)
Each following condition prohibited the Drive and forces the Neutral positon:
Movement of stabilizers or corrections of chassis level in progress
Road mode selected but not validated
Active parking brake
Machine set on the 2 stabilizers
 Selected radio control Winch mode

2420344570 E 07-14 117/311
When starting of the machine the parking brake is automatically activated.

The state of the parking brake is reversed every time the switch in the cabin (SB685) is activated, if
all the following conditions are met:
- Contactor of safety activated (KM100 = 1)
- Presence on seat switch detected (SQ141 = 1)
The parking brake is automatically activated when any one of the following conditions is filled:
- Engine stoped (D+ = 0)
- Contactor of safety deactivated (KM100 = 0)
- STD/EUR: No presence on seat switch (SQ141 = 0) for more 4s & no the drive
- AUS/USA: No presence on seat switch (SQ141 = 0) for more 4s
The parking brake is automatically deactivated if all the following conditions are met, in command not
to force the LMI:
- Movements of stabilizers in progress (gone up or descent)
- At least one of the stabilizers in low position (SQ720 = 1 or SQ721 = 1)
- Active parking brake
If the park brakes were deactivated automatically, it is reactivated at the end of the movement of
stabilizers, or when the 2 stabilizers are not any more in low position (SQ720 = SQ721 = 0).
The state of the parking brake is transmitted to the module of the H1 pump via the CAN bus
Each following condition prohibit theroad mode :

- Non stowed machine: angle boom > 15° or telescope extended (SQ360 = 0) .
- Proportional movement in progress (Lifting Boom, Telescopic Boom, Crowding/dumping function,
Accessories, Stabilisors and/or Chassis level).
The drive motor is equipped with a speed sensor SV685.
This sensor informs the SAUER H1 module about the drive speed.
A speed maxi is preset in the module according to the country of destination of the machine. When
maxi speed is reached the H1 module will limit the flow of the pump in command to not exceed it.
Example: 20 km/h for Germany and 25 km/h for France.
The hydraulic pump speed sensor SV162 informs the H1 module of the mode of the engine and the
module according to this information sends current to coils YV620 or YV600 to adapt the flow of the
pump according to the driving mode. If this sensor is not working, drive is not possible
HTL3210 conditions supply YV684 (in SAUER system identified by “'BREAK PRESSURE DEFEAT
VALVE”:
Neutral = 0
FWD = 0
REV = 1
REV - > Neutral = 1 (it remains supplied)
REV - > Neutre - > M. AV = 0 (it passes from 1 to 0 when switching to FWD)
failure will cause a harshe response in deceleration
If sensor “inching” faulty or disconnected, the drive is cut
If the two stabilizers are lowered the drive is prohibited
If the conditions of the road mode are not validated the drive is cut
An incoherence of the direction of drive SA600 = 1 and SA620 = 1 forbids the command. Default
SW03, 3 flashes

2420344570 E 07-14 118/311
 Diagnostic
Diagnoses
Indicator
ECU or Optimizer
H1
N°
TESTS (module
diag
SAUER Menu Code default
on
pump)
The current sent to the coil according to the
1 mode of the engine varies from 0mA to
1500mA
22 flashs Diagnosis
(led red) H1 pump:
1 Failure of the resistance for the valve 0b00000010
on H1 Status
module output
The current sent to the coil according to the
2 mode of the engine varies from 0mA to
1500mA
21 flashs Diagnosis
(led red) H1 pump:
on H1 Status
module output
3 YV683 = 1 low speed. 12V on 683
28 flashs Diagnosis
(led red) H1 pump:
on H1 Status
module output
YV684 = 1 (12 V out of 4) if:

Neutral = 0
30 flashs
FWD = 0
(led red)
4 REV = 1
on H1
REV - > Neutral = 1 (it remains supplied
module
REV - > Neutral - > FWD = 0 (it goes from 1
to 0 when switching to FWD)

5 YV682 = 1 machine unbraked
5 YV682 = 1 if SA685 = 1 and SQ141 = 1
HA620 = 1 (12V out of 623) if SA620 = 1 DIGITALS
6
and KA620 = 1 OUTPUTS
EL116 = 1 (12V out of 623) if SA620 = 1 DIGITALS

7
and KA620 = 1 OUTPUTS
SA187 = 0 selection fork (B109 = 0 and DIGITAL

8
B110 = 0V) INPUTS
3 flashs
8 selection mode. Default = 1 if SA187A = 1 SW01
ECU
and SA187B = 1
SA100 check the wiring: 100 (supply)/11 DIGITALS
9
SQ141 = 1 if presence driver 12V 104.16 DIGITALS
10
B121 INPUTS

2420344570 E 07-14 119/311
SQ141 = 0 if driver presence not detected DIGITALS
10
since 4s INPUTS
Engine running check 12V on D+ alternator
DIGITAL
11 (B106) if light NOK charges battery HL161
INPUTS
=1
B120 button joystick selection stabilizing or DIGITALS
12
chassis level. B120 = 1 active selection INPUTS
SB685 = 1 (parking brake removed ) then DIGITALS

13
YV682 = 1 if SQ141 = 1 INPUTS
SA600 = 1 drive FWD if SB685 = 1 and DIGITALS

14
SQ141 = 1 then YV600 = 1 if RP680 = 0 INPUTS
SA620 = 1 drive REV if SB685 = 1 and DIGITALS

15
SQ141 = 1 then YV600 = 1 if RP680 = 0 INPUTS
14 Incoherence selector of the direction of

3 flashs
and drive: SW03
ECU
15 SA600 = 1 and SA620 = 1
14 Neutral position of the control unit not

3 flashs
and detected since the starting of the machine: SW04
ECU
15 SA600 = 1 or SA620 = 1
14 Diagnosis
Comodo switch FWD or REV in error
and H1 pump: 0b00000001
(F-N-R switch Error)
15 Status input
SA680 = 1 high speed if SP620 = 0 then DIGITALS

16
YV683 = 0 INPUTS
SA680 = 0 low speed if SP620 = 1 or B120 DIGITALS
16
= 1 then YV683 = 1 INPUTS
HL686 = 1 selected Low speed lit (seeing
17
with register 1 above)
HL687 = 1 selected High speed lit (seeing
18
with register 2 above)
HL686 = 1 and HL687= flickering if selected
17
high speed but nonvalid conditions the
and
indicator low speed remains lit and large
18
flashs
SA692 = 1 mode road 12V on (105.35 DIGITALS
19
B131) INPUTS
HL692 = 1 lit fixes road mode selected and DIGITALS
20
validated. 12V on 104.23 B132 OUTPUTS
HL692 flashes if road mode selected but DIGITALS
20
not validated OUTPUTS
B124 button joystick activation function DIGITALS
21
float. B124 = 1 active selection INPUTS
Neutral position of the button not detected

3 flashs
21 since the starting of the machine: SW04
ECU
B124 = 1
DIGITAL
OUTPUTS

2420344570 E 07-14 120/311
DIGITAL
OUTPUTS
Angle sensor not calibrated or no valid 4 flashs
24 CA01
calibration ECU
Incoherence between the 2 calibrated
4 flashs ANALOG
24 signals of angle sensor (B403 and B404). CA02
ECU INPUTS
Corrected signal from angle sensor 1 out of 4 flashs
24 CA03
range (B403): (D+ = 1) & (KM100 = 1) ECU
Corrected signal from angle sensor 2 out of 4 flashs

24 CA04
range (B404): (D+ = 1) & (KM100 = 1) ECU
SQ360 = 1 if telescope retraction12V on DIGITALS
25
B127 INPUTS
RP680 potentiometer “inching” installed on
the brake pedals.
26
The signal varies from 0,5V to 4,5V to be
controlled between 124 and 0S
Diagnostic
H1 pump:
26 Position of the pedal in % 0 to 100%
Inch Pedal
Pos (%)
Diagnosis
H1 pump:
26 Calibration in progress 251
Inch Pedal
Pos (%)
Diagnosis
H1 pump:
26 input error 254
Inch Pedal
Pos (%)
40 flashs
(led red)
on
26 Potentiometer not calibrated
H1/module
8 flashes
DCU
39 flashs
(led red)
26 Potentiometer at fault
on H1
module
Diagnosis
26 Inching Sensor Error H1 pump: 0b00000010
Status input
Diagnosis
H1 pump:
27 Visualization engine speed (optimizer) Engine
Speed
(RPM)
58 flashs
(led red)
27 Sensor at fault if frequency > 8.000HZ
on H1
module
27 Motor RPM Status Error 0b01000000
31 flashs
(led red)
28 Sensor at fault if frequency > 10.000HZ
on H1
module

2420344570 E 07-14 121/311
Diagnosis
28 Pump RPM Status Error H1 pump: 0b00001000
Status input
Regulated 5 volts power supply for the Diagnosis
28 sensors at fault. H1 pump: 0b00010000
voltage < 4,875V or voltage > 5,125V Status input
SP690 = 1 if pressure < 90 bars then DIGITALS
29 30
HL690 = 1 INPUTS
Green Led
on fixed
31 Operation OK H1 module
lit and led
red extinct
Diagnosis
Battery voltage < 9V or Battery voltage >
31 System 0b00001000
16V
Status
ANALOG
INPUTS
Check if short-circuit or change B2 Node
Weak battery supply voltage 12V (V < 10V) ANALOG
32 5 flashs SV01
& (D+ = 1) INPUTS
DIGITALS
INPUTS
34 Check the fuses
 Conditions for steering
Conditions
modifying
the function
Conditions Steering command Obligatory
or N° diag
HTL3210/3510/4010 conditions
prohibiting
the
movement
YV680 Axles crab mode X 1
YV681 Axles synchro mode X 2
KA680 Relay crab command X 3
KA681 Relay synchro command X 4
HL683 Indicator centered rear axle X 5
HL692 Indicator validation road mode X 6
Switch selection steer mode- crab/axle
SA681 X X 7
/synchro/1 axle only
HL692 Indicator road mode X 10
SQ682 Sensor front axle X X 11
SQ683 Sensor rear axle X X 12
FU102 Fuse 10A power U100 and U600 X 17
FU114 Fuse 30A X 18

2420344570 E 07-14 122/311
The Requirements from the Cabin are applicable whatever the selected mode (Fork, winch Cabin or
Winch Radio operator) if the contactor of safety is active (KM100 = 1)
The function direction is commanded by the selector 3 positions of the cabin:

- Selector in the centre (SA681a = SA681b = 0) for the Front mode
- Selector on the left (SA681a = 1 & SA681b = 0) for the Crab mode
- Selector on the right (SA681a = 0 & SA681b = 1) for the Synchro mode
The instruction of the selector is taken into account only so one of the signals of the selector
(SA681a/SA681b) is active.
The conditions of validation of the modes of steering are summarized below:
- The Road Function prohibits the mode switch-over Crabe or Synchro
- The Road Function forces the direction in mode 2 wheel steer (with the the rear axle in position
centered)
- The Crab mode or Synchro is validated in when the front axle passes the centre position (SQ682
= 0 & DPLUS & KM100)
- The 2 wheel steer mode is validated when the rear axle passes the centre position (SQ683 = 0 &
DPLUS & KM100)
- The Outreach limit shunt makes it possible to force the validation of the mode Crabe or Synchro
even if the front axle is not centered
- The Outreach limit shunt makes it possible to force the validation of the 2 wheel steer mode even if
the rear axle is not centered
The validated steering mode is recorded in EEPROM when the engine stops running (KM100 = 0)
while the module remains energised (KM101 = 1).
This mode is uploaded at the startup of the machine and can thus be different from what is selected
on the cabin switch.
Full lock to lock (right to left) 3.5 turns of steering wheel ± 0.5

2420344570 E 07-14 123/311
 Diagnostic
Diagnoses
Optimizer
N° Indicator
TESTS Menu
diag ECU Menu
INPUT-
FAILURES
OUTPUT
1 YV680 = 1 selected crab mode.
2 YV681 = 1 synchro mode.
DIGITALS
3 KA680 = 1 crab mode
OUTPUTS
DIGITALS
4 KA681= 1 synchro mode
OUTPUTS
DIGITALS
5 HL683 = 1 rear axle aligned if SQ683 = 0
OUTPUTS
HL692 = 1 lit fixes road mode selected and DIGITALS
6
HL692 flashes if road mode selected but not DIGITALS
6
validated OUTPUTS
SA681A = 0 and SA681B = 0 then road steering DIGITALS

7
mode validated because SQ683 = 0 INPUTS
SA681A = 1 and SA682B = 0 and SA692 = 0

DIGITALS
7 then crab steering mode validated because of
INPUTS
SQ682 = 0.
SA681A = 0 and SA682B = 1 and SQ692 = 1

DIGITALS
7 then synchro steering mode validated because
INPUTS
of SQ682 = 0.
Selector default direction, incoherence in
7 steering selection. Default = 1 if SA681A = 1 3 flashs SW02
and SA682B = 1
8
DIGITALS
9 SA692 = 1 mode road 12V on (105.35 B131)
INPUTS
HL692 = 1 lit fixed road mode selected and DIGITALS
10
HL692 flashes if road mode selected but not DIGITALS
10
validated OUTPUTS
DIGITALS
11 SQ682 = 0 if front axle aligned
INPUTS
DIGITALS
12 SQ683 = 0 if aligned rear axle
INPUTS
If SA140 = 1 then the steering mode taken into
DIGITALS
13 account will be selected via SA681. 12V on
INPUTS
104.3 B108

2420344570 E 07-14 124/311
13 shunt ) not detected since the starting of the 3 flashs SW04
machine. B140 = 1

ANALOG
INPUTS
Weak battery supply voltage 12V (V battery < ANALOG

14 5 flashs SV01
10V) & (D+ = 1) INPUTS
DIGITALS
INPUTS
16
17
Check the fuses
18
19

2420344570 E 07-14 125/311
3. THE HYDRAULIC PART
3 .1 . SYMBOLS USED
Pump with variable cc flow

(maxi 38 cc/rpm)
Fixed flow gear pump (23 cc/rpm)
Pump with variable flow (used for the

hydrostatic transmission in closed circuit on
HAULOTTE machines equipped on HTL and
machines with Perkins engine)
Hydraulic motor with 2 way of directions (ie

FWD/REV)
Dual variable cubic capacity drive motor

15 cc for high speed drive
45 cc for low speed drive
Filter (normally 10 microns)
Check valve

2420344570 E 07-14 126/311
Calibrated check valve
Priority valve (shuttle valve)
Piloted check valve
Circuit selector switch
Position valve with mechanical control (used

for HA32 PX/HA41PX)
Adjustable relief valve

(here calibrated at 145 bars)
Fixed flow-limiting valve or spray nozzle (here

diameter of 0.75 mm)
Adjustable flow-limiting valve

2420344570 E 07-14 127/311
Pressure sensor (used for weighing)
Adjustable pressure switch

(here set at 170 bars)
Flow divider
Position valve 4 ways, 3 positions in closed

center
Safety valve
Counter balance valve with piloting line of the

opposite circuit (here set at 210bars)
Position valve proportional 5/3 with control

manual by lever (element of PVG used in our
diesel booms)
Rotary cylinder /jack (here coarse at 180°)

2420344570 E 07-14 128/311
Piloted valve
Manual position valve with automatic return

(used to readjust the compensation link part on
HA32PX /HA41PX)
proportional valve 4 ways/3 positions
Flow control valve

(Pressure balance)
Flow regulator

2420344570 E 07-14 129/311
3.2. HYDRAULIC SHEMATICS
(See all versions at the end of this manual)
3 .3 . HYDRAULIC BLOCKS
3.3.1.PERKINS ENGINE
Type of machine Engine power Traction strength

HTL3210 62KW/84CV 4200 daN
HTL 3510/4010 70KW/95CV 6000 daN
Engine at idle position without load 950 rpm

Engine at maxi rpm without load 2450 rpm

2420344570 E 07-14 130/311
Components in detail:
Front view
YV160
engine YA162
temperature probe , coil fuel pump
if T < 40°
information is sent
to injection pump
R160 preheating
spark plug
SP162 engine oil

pressure switch
If cooling Temp
< 40° the
advance
setting of the
pump is
modified in
order to make
the starting
more easier

2420344570 E 07-14 131/311
 Rear side
ST160 water cooling
temperature probe (indicator
in cabin)
ST160/C probe for

temperature maxi is
reached ( light in
cabin)

2420344570 E 07-14 132/311
Motor of the cooling system:
- controls the fan
- mix cooling system (mid--oil, mid--water)
Pump of equipment
2 gears pumps
1 for movements via a flow control valve (priority valve): cubic capacity 44cc
1 for the supply of the cooling and brake circuits cubic capacity 11cc

2420344570 E 07-14 133/311
Drive pump and charge
Hydrostatic pump with variable cubic capacity
HTL 3510-4010: Maximum pressure 480b - maximum cubic capacity 78 cc
HTL3210: Maximum pressure 450b - maximum cubic capacity 68 cc
- It ensures the movements of drive through an hydrostatic motor and a transmission

made by Cardan axle
- the internal charge pump (gavage) (17cc) supplies the general circuit in command to
maintain a pressure of at least 24 bars and thus to avoid pump cavitation
module SAUER U600
YV620
REV
YV600
FWD
SV162
(speed sensor)

2420344570 E 07-14 134/311
3.3.2.THE HYDROSTATIC MOTOR
 HTL3210
Cubic capacity motor: 110cc (Low Speed)/32cc (High Speed)
YV683 YV684
 Principle:
The motor is at variable cubic capacity when low speed is actived via the selector, the SAUER
module (U600 located on pump) commands the valve YV683 (12volts).
In this case the cubic capacity of the motor will be 110cc.
If high speed is selected YV683 is not supplied any more in 12 volts.
if the pressure on the drive circuit does not exceed 210 bars the cubic capacity of the motor will
not exceed 32cc.
If in high speed the torque required in drive will increase, so the pressure will increase when the
value of 210 bars is reached, the valve YV683 will be piloted hydraulically,
The modification of the cubic capacity of the motor is possible and will go from 32cc to the
maximum cubic capacity (if required) of 110cc), where the transmitted torque will be at the maxi
value.
The function of the valve YV684 is to be sure that it’s always the line in pressure which will pilot
the motor cc change ( thanks to this system , it will avoid to have a violent stop in high speed
and especially in lifting or in descent or deceleration during downhill).
In this configuration the motor acts like a pump and the line which is low pressure goes up in
pressure.
If this valve was not there, the valve YV683 could be piloted intempestively and then machine
will go instantly in low speed so a violent stop of the machine.
This sensor informs the SAUER module U600 about the drive speed.
A maximum speed value is programmed in the SAUER module U600 according to the country
of the machine,
2420344570 E 07-14 135/311
When maxi speed is reached the module H1 (U600) will limit the flow of the pump in command
to not exceed it.
Example: 20 km/h for Germany or 25 km/h for France.
In the drive motor a scavenging valve takes out oil always from the circuit in low pressure at a
flow of 15l/mn from the closed circuit.
Thanks to this, there is no overheating in the closed circuit, this loss of oil is compensated by a
constant charge in the circuit through the gear pump of 17cc.
 HTL3510
cubic capacity motor: 160cc (Low Speed)/42cc (High Speed)
 Principle:
The motor is with variable cubic capacity when low speed is engaged through the “comodo”, the
module SAUER (U600 on pump) commands the valve YV683 (12volts).
If high speed is selected the valve YV683 is not supplied any more in 12 volts.
If the pressure on the drive circuit does not exceed 210 bars the cubic capacity of the motor will
not exceed 42cc.
If in high speed the torque required in drive increases, the pressure will increase,
When it reaches the value of 210 bars, the valve YV683 is hydraulically piloted and that will
allow the system to modify the cubic capacity of the drive motor going from 42cc to the
maximum cubic capacity of 160cc where the torque transmitted torque will be at maxi value.
The function of the position valve for the recognition of way of driving is to ensure that is always
the line in pressure which will commute the cc motor change.
The control of this position valve is made by the pump, this will avoid to have a violent stop in
high speed and especially in lifting or in descent or deceleration downhill
In this configuration the motor acts like a pump and the line which is low pressure goes up in
pressure.
If this position valve were not there, the valve YV683 could be piloted intempestively which
could lead to a drop in low speed and then a violent stop of the machine.
The drive motor is equipped with a speed sensor SV685,
This sensor informs the SAUER module U600 about the drive speed.
A maxi speed is programmed in the SAUER module U600 according to the country of
destination of the machine,
When maxi speed is reached the module H1 (U600) will limit the flow of the pump in command
to not exceed it.
Example: 20 km/h for Germany or 25 km/h for France.
In the drive motor a scavenging valve takes out oil from the circuit in low pressure at a flow of
15l/mn from the closed circuit.
Thanks to this, there is no overheating in the closed circuit, this loss of oil is compensated by a
constant charge in the circuit through the 17cc gear pump.

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3.3.3. PROPORTIONAL BLOCK
This block proportional is equipped with PWM valve (Pulse Width Modulation valve)
It controls all the proportional movements of the telehandler (except drive)
Nominal voltage 12 VDC + 10%

Proportional coil Nominal power 30.5 W
PWM In current 0 to 1.5 A
Electric resistor 4.72 Ohm +-5% at 20°C
In volt 50mv to 5V
PWM : Pulse Width Modulation valve : valve supplied by a proportional regulated current square
signal.

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YV340 telescopic extension
YV360 telescopic retraction
YV121 Auxiliary validation
YV122 Validation outriggers/cabin levelling
YV400 Excavation closing/crowding
YV420 Excavation opening/dumping/discharge
YV300 Boom lifting
YV320 Boom descent
 Schematic representation

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3.3.4.ON/OFF BLOCK
This block controls the ON/OFF movements (outriggers or cabin levelling, options) according to
the model
HTL3210-4010
YV720 YV721 YV123
YV700 YV701 YV124
HTL 3510
YV720 YV123
YV700 YV124

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YV123 Auxiliary port A
YV124 Auxiliary port B
Outriggers left lift or cabin levelling on the left-
YV700
hand side
YV701 Outriggers right lift
Outriggers left descent or cabin levelling on the
YV720
right-hand side
YV721 Outriggers right descent
HTL 3210

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HTL 3510
HTL 4010

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3.3.5.BRAKE SYSTEM
relief valve non adjustable 24b
valve conjunction/disjunction
relief valve 170b
Accumulator 30b YV682 SP691
Accumulator
13b

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 PRINCIPLE
Circuit of service brake:
This block integrates a function conjunction/disjunction for supply the circuit of the service
brake.
The pressure sent to the brake pedals will be maintained between 120 and 145 bars.
If the valve is in disjunction the flow is sent towards the hydraulic motor fan of the cooling circuit
(line V)
If the valve is in position of conjunction the flow is sent in priority to the brake system (Serv line)
An accumulator (30b/0,75L) allows it to maintain the service brake active, even in the event of
engine breakdown or a faulty pump (minimum 9 times)
A pressure relief valve calibrated at 170 bars protects the pump
Circuit of parking brake :
A pressure restrictor 24b reduces the pressure supply on the piston of the parking brake
(recommendation coming from the manufacturer of the CARRARO axle).
In the event of pump failure or main engine,an accumulator (1L/13bars) allows the system to
release the brakes discs on front axle when it’s in breakdown (minimum 3 times).
A pressure switch SP691 calibrated at 18 bars informs the operator when the pressure supplied
to the parking brake drops below this value (P182 indicator ignites on the cabin).
Schematic representation
Reference Designation
1 Supply from charging pump17cc to the drive pump
2 Supply from pump 11cc (CASAPPA)
3 To the hydraulic circuit of the fan
4 To the circuit of the service brake (pedal)
5 To the hydraulic reservoir (tank)
6 To the parking brake circuit on front axle
YV682 =1 if brake is not engaged
SP691 = 1 if P < 18b

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SP691
6 1
4 3

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 Brake pedals “inching”:
The valve ensures the oil supply in the brake circuit (service brake) and limits the pressure at
the charging pressure (gavage) which is 25b.
The “inching” brake or hydrostatic brake is linked to the brake pedal itself, which is also
associated with a potentiometer RP680
This potentiometer requires a calibration because it will determine the threshold for which the
operator will determinate the effort applied on the pedals in command to be able to work with
precision by combining force and speed (in particular in excavation or drop an heavy load)
When the operator will press on the brake pedals on the first third coarse of the pedals, the
hydraulics pressure will increase, the resulting energy will be absorbed by the main engine.
On the remaining 2 thirds of the coarse of the pedals, oil will be sent to the brake discs of the
front axle (theesystem is braking)
The inching pedal thus controls gradually the regulation of the drive pump, the motor will
accelerate, the pressure of the pump will reach the stand-by pressure and the machine will
slow down (braking is therefore progressive)
T1 T N
SP690 SP114
RP680

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 Schematic representation:
5 4
Reference Designation
REVk
1 Supply pressure between 120 bars minimum and 145 bars maximum (R)
Pressure switch SP690=1 if pressure drops.
If P < 90b P190 light is ON in the cabin
Potentiometer ` inching' RP680 :progressive of flow cancellation of the drive

3
pump
4 Power supply of the brake on front axle. Maximum pressure 25 bars (T1)
5 Return to tank (N)
6 SP114 Pressure switch for rear stop lights. Closed if P > 5 bars

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3.3.6. STEERING UNIT
oil tank
Load
steering Sensing
block
Pump through
priority valve
This rotary cylinder with double cubic capacity (100 and 200 cc) controls the movements of front
steering wheels
In “normal” mode the cubic capacity of the motor is at 200 cc, which corresponds to 4 turns of
hand wheel lock to lock (left to right).
In “emergency” mode (when the equipment pump is faulty) the cubic capacity is reduced to 100
cc which corresponds to 8 full turns of hand wheel lock to lock
There is no more hydraulics assistance but the steering remains operational.

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3.3.7.STEERING BLOCK
This block controls the 3 modes of steering (road, crab and synchronized)
The selection is carried out via switch SA681 in the cabin which will control the valves
YV680/Y681.
The positioning of the switch on the road mode SA692 automatically involves the realignment of
the rear wheels thanks to SQ683 (alignment sensor on rear axle) as soon as the operator uses
the hand wheel.
YV681
YV680

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3.3.8.THE TELESCOPIC CYLINDER
This cylinder is used for the telescoping of the telescopic extension made of 3 elements.
The cylinder is placed inside the 1st telescopic element,
The lower CYL is fixed between the bottom section and the 1st telescopic element
The upper CYL is fixed between the 1st telescopic element and the 2nd one
The synchronization of extension (OUT) /retraction (IN) of the 1st and 2nd telescopic elements
is ensured by oil transfer between the small chamber of lower CYL and large chamber of upper
CYL (closed circuit).
The counterbalance valve limit the pressure in the big chamber at 240b
Pmax 200 to 240b (extension)

Pmax 250b (retraction)

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3 .4 . THE HOSES
3.4.1.PUMP CIRCUIT HTL 3210

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3.4.2. PUMP CIRCUIT HTL 3510

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3.4.3.PUMP CIRCUIT HTL 4010

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3.4.4.BOOM

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4. ADJUSTMENTS
Two types of adjustment are accessible one by console, and the other one only through a
downloadable application available from laptop (drive)
4 .1 . ADJUSTMENT WITH THE OPTIMIZER CONSOLE

The adjustments, parameter settings and lists of alarms of the machine are accessible only
through this console.
connection on machine
Connect the console on the connector labelled “ACTIA” located inside the cabin (as shown
below)

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 Description of the console
PARAMETER (+) or CHANGE

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

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List menus
Access to the main menu HAULOTTE GROUP

HTL 3210
2901012850 / 1.08
STD/EUR
Parameters setting access
Input/output state access
Trouble shooting guide per

function
Machines status
FAILURES
Detected: 03 Failures list
Active : 02
(+-) Erase Failures

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The PARAMETERS Menu
HAULOTTE GROUP
HTL 4010
2901012850 / 1.08
STD/EUR
Search the menu by

scrolling key pad UP/DOWN
speeds parameters
adjustment
ramp parameters
adjustment
options settings
Validation by the key: , enter then the code

ACCESS CODE
Navigation by this key enter the code (Code following model)
level 2 is registered
Press on key:
Back to main menu
The console is in level 2 (access to the calibration)

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Access to calibration menu
PARAMETERS SPEEDS Enter access code

0000 Level
1
^
ACCESS CODE Enter access Enter access

code code
2031
Level 2
CALIBRATION ^
Angle Sensors Inch Pedal Load Control

calibrated calibration Inactive
(+) To erase calib (+) To calibrate
(-) To return (-) To return

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4 .1 .1 . LIST PARAMETERS CONSOLE (> V1.08)
 Menu PARAMETERS
PARAMETERS
Sub-menu Parameter Code Description
SPEEDS Lifting up speed boom lift
to modify Lifting down Speed boom descent
+ and - for the value by
default Bucket closing Speed excavation
* to save (0 to 100%) Bucket opening Speed discharge
Telescope in Speed telescopic boom retraction
Telescope out Speed telescopic boom extension
Accessory A Fork Speed accessory A for Fork mode
Accessory B Fork Speed accessory B for Fork mode
Accessory A Speed accessory A for Winch mode
Winch (cabin)
Accessory B Speed accessory B for Winch mode
Winch (cabin)
Accessory A Speed accessory A for Winch mode
Radio (radio)
Accessory B Speed accessory B for Winch mode
Radio (radio)
Stabilizers Speed outriggers (3210 Pro and 4010
Premium only)
Frame Level Speed cabin levelling (3510 Medium
only)
Stabilizers limit Percentage of application of the
outriggers setpoint at reduced speed
(3210 Pro and 4010 Premium only)
Frame Level Limit Percentage of application of the cabin
levelling setpoint at reduced speed
(3510 Medium only)
RAMPS Acc lifting up acceleration boom lift
to modify Dec lifting up deceleration boom lift
+ and - for the value by
default Acc lifting down Acceleration boom descent
* to save (1 to 50) Dec lifting down Deceleration boom descent
Acc Bucket Acceleration excavation
closing
Dec Bucket Deceleration excavation
closing
Acc Bucket Acceleration discharge
opening
Dec Bucket Deceleration discharge
opening
Acc Telescope in Acceleration telescope IN
Dec Telescope in Deceleration telescope IN
Acc Telescope Acceleration telescopic OUT
out
DEC Telescope Deceleration telescopic OUT
out
Acc Accessory acceleration Accessory

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Dec Accessory deceleration Accessory
Acc Stabilizers Acceleration outriggers (HTL3210 Pro
and 4010 Premiuim only)
Dec Stabilizers Deceleration outriggers (HTL3210 Pro
and 4010 Premiuim only)
Acc Frame Level Acceleration cabin levelling (HTL3510
Medium only)
Dec Frame Level Deceleration cabin levelling (HTL3510
Medium only)
ACCESS CODE Enter access Code for access to levels 2 & 3 (0 to
code 9999)
+ to modify Modify access 3 Modification of the code of access level
* to save code 2
OPTIONS Float/Hydrau Selection between lifting floating and
+ to modify Lock the hydraulics locking of the
* to save accessories:
(Value by default in bold “None” no option selected
characters) “Float Raising” floating Lifting
“Hydraulic Lock” hydraulics Locking
of the accessories
Cold Country Selection of the option big Cold:
“Inactive” Preheating = 7 seconds
Preheating “Activates” = 20
seconds
Country 3 Choice of the country:
“STANDARD/EUR” Standard
version for the Europe
“AUS/USA” version for Australia
and USA
Machine 3 Choice of the type of machine:
“HTL 3210”
“HTL 3510”
“HTL 4010”
Rear Axle Lock 3 Choice of the rear axle locking
“Inactive” machine without rear
axle locking
 “Active”Machine with locking of
the rear axle
Hydraulic Control 3 Choice of the main hydraulic manifold:
“Walvoil SDM140”
“Walvoil DPX100”
FACTORY SETTINGS Factory Settings? 3 Loading of the factory values for all
(+ and -) or * to validate parameters (slopes, speeds, options
and code of access level 2)
CALIBRATION Load control 2 Launch the calibration of the LMI
How to launch the Angle Sensor 2 Give the status of the calibration of the
calibration angle sensor, and allows to launch it
again
Inch Pedal 2 Launch the calibration of the inching
pedal.
Angle Calib 2 Display the calibration value for boom
values angle (measurements corrected in
points recorded in EEPROM):
Min sensor 1 (758)
Min sensor 2 (758)
Max sensor 1 (300)
Max sensor 2 (300)
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 Menu INPUTS/OUTPUTS
INPUTS - OUTPUTS
Sub-menu Parameter Num Description Type
DIGITALS SA780D 2 button descent left stabiliser (B780A) ON/OFF
INPUTS SQ141 3 Presence seat (B121) ON/OFF
B120 4 Button Joystick floating lifting/Hydraulics ON/OFF
Locking
SP690 5 Default service brake (690) ON/OFF
B118 6 Off neutral Joystick ON/OFF
SA100 7 Key start-up on cabin (2) ON/OFF
SQ721 8 Outrigger right down =ON ON/OFF
SQ720 9 Outrigger left down = ON ON/OFF
SA620 10 Comodo REV drive (B114) ON/OFF
SA600 11 Comodo FWD drive (B113) ON/OFF
SA680 12 Comodo high speed drive (B112 = 1 if ON/OFF
High speed drive)
B111 13 Radiocontrol OK ON/OFF
SA187T 15 Selection winch mode (B110) ON/OFF
SA140 16 By-pass Reach limitation (B108) ON/OFF
SB685 17 Button Parking brake(B107) ON/OFF
SA780M 18 button lift left stab (B780A) ON/OFF
SA781M 19 Button lift right stab (B781A) ON/OFF
SAD81D 20 Button descent right stab (B781B) ON/OFF
SA782G 21 Button cabin levelling left side (B782A) ON/OFF
SQ360 22 Telescopic retracted (B127 =1 so IN) ON/OFF
B129 24 Switch of Radio operator start-up ON/OFF
B130 25 Alarm reach limitation (LMI) ON/OFF
SA782D 26 button for cabin levelling right side ON/OFF
(B782B)
B102 28 Auxiliary Radio on A ON/OFF
B103 29 Auxiliary Radio on B ON/OFF
B104 30 Radio operator excavation ON/OFF
B105 31 Radio operator discharge ON/OFF
DPLUS 32 engine on powered (D+=ON) ON/OFF
B142 33 Pre-alarm reach limitation (LMI) ON/OFF
SA681C 34 Selection Crab Mode (ON if in C) ON/OFF
SA681S 35 Selection Synchro Mode (ON if in S) ON/OFF
SQ683 36 Centered rear axle (B144) ON/OFF
KM100 37 Safety contactor OK (11) ON/OFF
SQ682 38 front axle centered (682) ON/OFF
SA692 40 Selection road mode (if ON outriggers are ON/OFF
prohibited)
DIGITALS HL780 1 Light for validation stabilisers/cabin 200 mA
OUTPUTS levelling
KA681 2 Mode of steering Synchro (B514) 200 mA
KA680 3 Mode of steering Crab (B513) 200 mA
B512 4 Light Radio operator Default 200 mA
B511 5 Light Default D+ Radio 200 mA

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B510 6 Light Radio Alarm LMI 200 mA
HL686 7 Light Validation 1 Speed Drive (B509) 200 mA
KM101 8 Contactor keeps supply on Module (B508) 200 mA
KA160 9 Relay Start-up 200 mA
B506 10 Calibration LMI 200 mA
HL687 11 Indicator validation 2 Speed Drive (B505) 200 mA
flickers in High speed
HL380 12 Light Float (B504) 200 mA
HL143 13 Light ECU (B503) 200 mA
HL692 14 Light road mode (B132) 200 mA
KA620 15 Relay Light/Buzzer for REV drive 200 mA
KM160 16 Command preheating (27) 200 mA
YV720 17 Left Stab Low/Cabin levelling right side 3.5 A
YV721 18 Stab Low Right (B600) 3.5 A
YV700 19 Left Stab High/cabin levelling left side 3.5 A
(B601)
YV123 20 Auxiliary validation to A (B602) 3.5 A
YV124 21 Auxiliary validation to B (B603) 3.5 A
YV780 22 Option Blocking Rear axle 3.5 A
YV780/YV781 (B604)
YV380 23 Floating lifting 3.5 A
YV701 24 Stab High Right 3.5 A
ANALOG B401 1 signal Joystick Radio Lift [0.5 - 4,5V]
INPUTS B402 2 signal Joystick Radio Telescoping [0.5 - 4,5V]
B403 3 boom angle sensor 1 [0.5 - 4,5V]
boom folded at -2 : 3.85V,
boom at +66° : 1.5V
B404 4 boom angle sensor 2 [0.5 - 4,5V]
boom folded at -2° :
3.85V, boom at + 66° : 1.5V
B300 5 signal Joystick Cabin front/back boom lift [0.5 - 4,5V]
(0.5-2.5-4.5)
B301 6 signal Joystick Cabin left/right Tilting or [0.5 - 4,5V]
Telescoping (0.5-2.5-4.5)
B302 7 signal Roller Joystick Cabin to Left [0.5 - 4,5V]
Telescoping or Tilting
(0.7-2.5-4.3)
B303 8 signal Roller Joystick Cabin to Right [0.5 - 4,5V]
Auxiliaries (0.7-2.5-4.3)
B400 12 Second reading supply 5V + 0.1V
VBAT 13 supply 12V
ANALOG YV300 1 PWM valve boom lift(0 - 1.6A) PWM 3,5A
OUTPUTS YV320 2 PWM valve boom descent (0 - 1.6A) PWM 3,5A
YV340 3 PWM valve telescoping extension PWM 3,5A
(0 - 1.6A)
YV360 4 PWM valve telescopic retraction (0 - 1.6A) PWM 3,5A
YV400 5 PWM valve Excavation (0 -1.6A) PWM 3,5A
YV420 6 PWM valve Discharge (0 - 1.6A) PWM 3,5A
YV121 7 PWM valve Auxiliaries (0 - 1.6A) PWM 3,5A
YV122 8 PWM valve Outriggers or cabin levelling (0 PWM 3,5A
- 1.6A)

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 Menu DIAGNOSTIC
DIAGNOSTIC
Internal Flag = indicator being able to take the values “Active” or “Inactive”
Variable Internal = Variable intern who can take any digital value
Internal Bit Field = Fields of 8 bits (to be read from right to left) of value 0bxxxxxxxx where X can take the
value 0 or 1
Internal Set point = protected and formatted signal intern of the function coming from the active control panel.
It will resetted in case of default of the control device (out-of range, incoherence of the neutral or the signals,
and is formatted between 0 and 1000.
Int. Set point Limit = Percentage of application of the internal instruction protected and formatted (100% = not
limited signal).
Internal Control = validated interbnal control generated starting from the signal of the function and sent to
valves and outputs relays.
It integrates the various logics of operation, as well as the dynamic limitations of the signal and
acceleration/deceleration ramps
It’s formatted between a mimimal internal speed (bias) and a maximal modifiable speed with the calibrator.
The way of the commands is also indicated (Dir = Neutral or Fwd/Up/Left or Rev/Down/Right).
Internal Validation = Conditions of validation/forbidden of the movements in each direction (Fwd/Up/L and
Rev/Down/R).
Bit 0: General validation (1 if the movement is validated, 0 if not)
Bit 1: General cut-off (1 if the movement is cut, 0 if not)
Bit 2: Cut-off multiple (1 if the movement is cut due to the logic of the plurality)
Bit 3: Cut-off overload (1 if the movement is cut due to the logic of weighing system)
Bit 4: Cut-off slope (1 if the movement is cut due to the logic of slope or reach limitation)
Bit 5: Cut-off default (1 if the movement is cut due to the logic of the defaults)
Bit 6: Cut-off control (1 if the movement is cut due to the logic of control)
A movement authorized with value 0000001 (reading from right to left)
Sub-menu Parameter Description
Working Variable Internal Mean Angle Average boom angle in degree
State (deg) (- 2° to + 66°)
1/19 Internal Flag Machine Indicator of machine folded
Folded (boom < 15° and telescope IN)
Variable Internal Nb stabs low Number of stabs in lowered position
(SQ720/SQ721): 0.1 or 2
0: UP
1: 1 only in ground
2: both stab on ground
Internal Flag Pre-Alarme Indicator of pre-alarm LMI
LMI
Internal Flag Alarme LMI Indicator of alarm LMI
Internal Flag Prop Indicator of proportional movement in progress (Lift,
mouvement in Telescoping, Compensation, Accessories or
process outriggers/cabin levelling)
Internal Flag Auto brake off Automatic brake release of the parking brake active
Internal Flag Auto brake on Automatic braking of the parking brake
Internal Control Accessory accessory selected
selection 0: Fork (SA187T = SA187N = 0)
1: Winch (SA187T = 1 or SA187N = 1)
Variable Internal Mode Operating process:
1: Fork Cabin
(B111 = SA187T = SA187N = 0)
2:
Winch Cabin (B111 = 0 &
(SA187T = 1 or SA187N = 1))
3: Radio winch (B111 = 1)

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Internal Bit Field Control Panel State of the control boxes
State bit0: KM100
bit1: KM100 & B111 &
Rpm engine < 1200 RPM
Internal Bit Field Valid SW State of the neutrals of the joystick’s switches and
Neutral Cab active buttons of the cabin (1 if the neutral is valid):
bit0: by-pass key (SA140)
bit1: Comodo Drive (SA600/SA620)
bit2: selector left Stab (SA780M/SA780D)
bit3: Selector Right Stab (SA781M/SA781D)
bit4: Selector Cabin levelling (SA782G/SA782D)
bit5: Button Floating Lifting/Hydraulics Locking
(B120)
Internal Bit Field Valid SW State of the neutrals of the switches and joysticks of
Neutral Rad the Radio commands(1 if the neutral is valid):
bit0: Joystick Lift (B401)
bit1: Switch Excavation (B104/B105)
bit2: Joystick telescoping (B402)
bit3: Switch Controls Accessories (B102/B103)
Raising Internal Variable Mean Angle Average boom angle in degree
2/19 (deg) (- 2° to + 66°)
Internal Variable Nb stabs low Number of stabs in lowered position
(SQ720/SQ721): 0/1 or 2
B300 (5/18) Cabin Joystick Rough signal of Boom lifting (Joystick Cabin)
B401 (1/18) Radio Joystick Rough signal of boom lifting
(Radio operator Joystick)
Internal Set Point Raising Internal signal of boom Lifting protected and
formatted
Int. Set Point Limit Raising Percentage of application of the formatted internal
signal
Internal Validation Raising Conditions of validation of the movement (0000001 if
the movement is authorized)
Internal Control Raising Internal signal of boom Lifting validated and
formatted
YV300 (1/12) Boom raising PWM valve for boom lifting
PWM
YV320 (2/12) Boom descent PWM valve for boom descent
PWM
Telescoping SQ360 (22/57) Telescop Telescopic boom retracted
3/19 Folded
STD/EUR: B302 (7/18) Cabin Joystick Rough signal of Telescoping (Joystick/Roller Cabin)
AUX/USA:B301 (6/18)
B402 Radio Joystick Rough signal of telescoping
(Radio operator Joystick)
Internal Set Point Telescoping Internal signal protected and formatted of
Telescoping
Int. Set point Limit Telescoping Percentage of application of the formatted internal
signal
Internal Validation Telescoping Conditions of validation of the movement (0000001 if
Internal Control Telescoping Internal command of Telescoping validated and
formatted
YV340 Telescop Out PWM valve for telescopic extension
PWM
YV360 Telescop In PWM valve for telescopic retraction
PWM
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Bucket STANDARD/EUR: Cabin Joystick Rough signal of Compensation (Joystick/Roller
4/19 B301 (6/18) Cabin)
AUS/USA: B302 (7/18)
B104 (30/57) Radio Switch Rough signal of Excavation
Up (Radio operator switch)
B105 (31/57) Radio Switch Rough signal of Discharge
Down (Radio operator switch)
Internal Set Point Bucket Internal signal of protected and formatted
Compensation
Int. Set point Limit Bucket Percentage of application of the formatted internal
signal
Internal Logical Bucket Conditions of validation of the movement (0000001 if
authorized)
Internal Control Bucket Internal command of compensation validated and
formatted
YV400 (5/12) Bucket Up PWM valve for excavation
PWM
YV420 (6/12) Bucket Down PWM valve for discharging
PWM
Accessories B303 (8/18) Cabin Joystick Rough signal for Accessories
5/19 (Right Roller Joystick Cabin)
B102 Radio Switch Rough signal for Accessories port A (Radio operator
A switch)
B103 Radio Switch Rough signal for Accessories port B (Radio operator
B switch)
Internal Set Point Accessories Internal signal for accessories control secured and
formatted
Int. Set point Limit Accessories Percentage of application of the formatted internal
signal
Internal Logical Accessories Conditions of validation of the movement (0000001 if
Internal Control Accessories Internal command of the Accessories validated and
formatted
YV121 Accessories PWM valve for the control of the Accessories
PWM
YV123 Accessories A ON/OFF valve for validation port A
EV
YV124 Accessories B ON/OFF valve for validation port B
EV
*Stabilizers SA780M (18/57) Left stab up Left switch stab lifting
6/19 SW
SA780D (2/18) Left stab down Left switch descent stab
SW
SA781M (19/18) Right stab up Switch stab right lifting
SW
SA781D (20/18) Right stab Switch descent stab right
down SW
Internal Set Point Stabilizers Internal signal of the outriggers protected and
formatted
Int. Set point Limit Stabilizers Percentage of application of the formatted internal
signal
Internal Validation Stabilizers Conditions of validation of the movement (0000001 if

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Internal Control Stabilizers Internal command of the outriggers validated and
formatted
YV122 (8/12) Stabilizers PWM valve of the Outriggers
PWM
YV700 (19/32) Left stab up ON/OFF valve for left stab lift
EV
YV701 (24/32) Right stab up ON/OFF valve for right stab lift
EV
YV720 (17/32) Left stab left ON/OFF valve for left stab descent
EV
YV721 (18/32) Right stab ON/OFF valve for right stab descent
right EV
Frame Level SA782G (21/57) Frame level Switch cabin levelling towards left side
7/19 left SW
SA 782R (26/18) Frame level Switch cabin levelling towards right side
right SW
Internal Set Point Frame Level Internal signal of cabin levelling protected and
formatted
Int. Set point Limit Frame Level Percentage of application of the formatted internal
signal
Internal Validation Frame Level Conditions of validation of the movement (0000001 if
Internal Control Frame Level Internal command of cabin levelling validated and
formatted
YV122 (8/12) Frame Level Electrovalve PWM valve for cabin levelling
PWM
YV700 (19/32) Frame Level ON/OFF valve for cabin levelling on left side
left EV
YV720 (17/32) Frame Level ON/OFF valve for cabin levelling on right side
right EV
Drive Internal Flag Machine machine in stowed position (Telescope retracted and
8/19 Folded boom angle < 15°)
SA600 (11/57) Forward Selection FWD drive (comodo)
switch
SA620 (10/57) Reverse Selection REV drive (comodo)
switch
SA680 High speed Selection high speed drive (comodo)
switch
Internal Set Point Drive Internal signal FWD/REV drive secured
Fwd/Rev
Internal Set Point Drive High Internal signal HS drive secured
Speed
Internal Control Drive Internal signal FWD/REV drive validated
Fwd/Rev
Internal Control Drive High Internal signal HS drive validated
Speed
HL780 Drive Fwd Lamp for REV drive
buz/light
Internal Bit Field Drive CAN network of emission for FWD/REV drive
Fwd/Rev CAN
Internal Bit Field Drive High CAN network of emission for High Speed drive
Speed CAN

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Park Brake SQ141 (3/57) Seat presence Sensor driver seat
9/19 SB685 Park Break Button of inversion of the parking brake
Switch
Internal Control Park Brake Internal command of the parking brake validated
Internal Bit Field Park Brake CAN network of emission for parking brake state
CAN
Road Internal Flag Machine Machine in stowed position (Telescope retracted
10/19 Folded and boom angle < 15°)
SA692 (40/57) Road switch Selection Road mode
Internal Set Point Road Internal signal of road mode is secured
Internal Control Road Internal command of the road mode validated
Steering SA681a (34/57) Crab selection Selection mode of steering Crab
11/19 SA187N (35/57) Synchro Selection mode of steering Synchro
selection
SQ682 (38/57) Front axle Centered front axle
centered
SQ683 (36/57) Rear axle Centered rear axle
centered
Internal Set Point Steering Internal signal for the steering mode protected
Internal Control Steering Internal control of the steering mode validated
Variable Internal Steering Mode Current mode of steering
KA680 (3/32) Crab Relay Relay mode of steering Synchro
KA681 (2/32) Relay synchro Relay mode of Steering Crab
Startup/Stop KM100 (37/57) Security Contactor of safety OK
12/20 Contactor
SA100 (7/57) Cabin startup Key for start-up (Cabin)
B129 (24/57) Radio startup Istart-up toggle switch (Radio)
Internal Set Point Startup Internal signal for start-up is secured
Internal Control Startup Internal command of is validated
KM160 Pre-heating Pre-heating relay
relay
KA160 Startup relay Relay of start-up
Internal Set Point Module Stop Internal signal of module stop is secured
Internal Control Module Stop Internal control of stop module is validated
KM101 Calc Power Contactor for power supply hold of the module
Relay
Sensor angle B403 (3/18) Measure 1 average signal value of the angle sensor 1 (in ms)
13/19 Row from 3.85V (- 2°) to 1.5V (62°)
Variable Internal Measure 1 Filtered and corrected value signal of the angle
Corrected sensor 1 (in pts) from 758 (- 2°) to 328 (+62°)
Variable Internal Angle 1 angle calibrated 1 (in °)
Calibrated
B404 (4/18) Measure 2 average signal value of the angle sensor 2 (in ms)
Row from 3.85V (- 2°) to 1.5V (62°)
Variable Internal Measure 2 Filtered and corrected value signal of the angle
Corrected sensor 2 (in pts) from 758 (- 2°) to 328 (+62°)
Variable Internal Angle 2 angle calibrated 2 (in °)
Calibrated
Variable Internal Angle Mean Average value of the 2 angles calibrated (in°)
Variable Internal Sensors Incoh counter giving the number of times where the
Count difference between the 2 calibrated angles was too
important
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Variable Internal S1 Out of counter giving the number of times where the filtered
Range Cnt and corrected value signal 1 of the angle sensor is
out of the authorized range
Variable Internal S2 Out of counter giving the number of times where the filtered
Range Cnt and corrected value signal 2 of the angle sensor is
out of the authorized range
Internal Bit Field Calibration State of the calibration:
State bit0 = 1: Calibration done
bit1 = 1: Calibration done and valid
bit2 = 1: Calibration of the low stop done and valid
bit3 = 1: Calibration of the low stop of sensor 1 out
of range
bit4 = 1: Calibration of the low stop of sensor 2 out
of range
bit5 = 1: Calibration of the higher position of sensor
1 out of range
bit6 = 1: Calibration of the higher position of sensor
2 out of range
Variable Internal Sensor 1 Filtered and corrected value signal 1 at lowest
Calib Min position (758 pts)
Variable Internal Sensor 1 Filtered and corrected value signal 1 at highest
Calib Max position (300 pts)
Variable Internal Sensor 2 Filtered and corrected value signal 2 at lowest
Calib Min position (758 pts)
Variable Internal Sensor 2 Filtered and corrected value signal 2 at highest
Calib Max position (300 pts)
LMI SA140 (16/57) Shunt key By-pass switch for reach limitation (LMI)
14/19 B142 (33/57) Pre-Alarm LMI Pre-alarm Reach limitation
(0 if active)
B130 (25/57) Alarme LMI Alarm Reach limitation (0 if active)
Internal Set Point LMI shunt Internal signal of the reach limitation by-pass is
secured
Internal Control LMI shunt Internal signal of the reach limitation by-pass is
validated
Axle Internal Control Axle Internal command of rear axle unlocking
Unlocking Unlocking
15/19 YV780 Axle ON/OFF valve of rear axle unlocking
Unlocking EV
Float Raising B120 (4/57) Selection Button for float raising activation
16/19 button
Internal Set Point Float Raising Internal signal for float raising is secured
Internal Control Float Raising Internal control for float raising is validated
YV380 (23/32) Float EV ON/OFF valve for Float raising validation
Hydraulic B120 (4/57) Selection Button of activation of hydraulics locking
Lock button
17/19 Internal Set Point Hydraulic Internal signal for hydraulic lock is secured
Lock
Internal Control Hydraulic Internal control for hydraulic lock is validated
Lock
KA380 (23/32) Unlocking EV relay of hydraulic unlocking
YV123 (20/32) Unlocking EV Valve of hydraulic unlocking
YV124 (21/32) Locking EV Valve of hydraulic locking
H1 Pump Variable Internal Engine Speed Engine revolution
18/19 (RPM) (from 960 to 2450 rpm)

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Variable Internal Inch Pedal Position of the inching pedal
Pos (%) [0 - 100]: position of the pedal in %
251: invalid parameter
(inching pedal calibration in progress)
254: input error
Internal Bit Field System Status System error on the drive pump
(1 if error)
bit0: Watchdog Error
 bit1: DSP Refers Voltage Error
 bit2: Injection Chanel Error
 bit3: Battery Voltage Error
 bit4: Sensor Voltage Error
Internal Bit Field Input Status Error on drive pump inputs
(1 if error)
bit0: FNR switch Error
 bit1: Inching Sensor Error
 bit2: Driving Sensor Error
 bit3: Pump RPM Status Error
 bit4: Pump Angle Sensor Error
 bit5: Mode Switch 2 Error
 bit6: Motor RPM Sensor Error
 bit7: Motor Steering Sensor Error
Internal Bit Field Output Status Error on drive pump outputs
(1 if error)
bit0: Pump Valve FWD Error
bit1: Pump Valve REV Error
bit2: Prop Motor. Valve Error
bit3: COR Valve Error
bit4: BB Valve Error
bit5: BPD Valve Error
EEPROM Internal Flag E2p Error Flag Error on module E2p
19/19 Variable Internal E2p Pile Number of request not treated are present in the
Status battery
Variable Internal Def Full Stack Counter of quantity of requests for Def module
Cpt
Variable Internal Dir Full Stack Counter of quantity of requests full for Dir module
Cpt
Variable Internal Steering Save Steering mode recorded in EEPROM
0: Front mode
1: Crab mode
2: Synchro mode
 Menu INFORMATION
INFORMATION
Sub-menu Parameter Description
VERSIONS Application Versions of the application
Ident Identifier of the machine for the factory parameters upload
Release for the 1st start (IDENTICALIB)
Date Version of the software
Date of delivery of the software
DRIVERS Versions of the drivers
Node B2 Version of the main module node B2 in cabin (B2: 2.03)
Boot Version of the boot

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4.1.2.FAILURES CODE
The defaults listed below are displayed on dashboard by blinking (flashs) on ECU light
(HL143) and also under codes on OPTIMIZER calibrator display (menu Failures)
FAILURES
* to erase any failure displayed (level code access 2 or 3)
+ and - to erase all failures in memory (level code access 3)
FAIL/OK: “FAIL” if failure has be detected since start-up of machine (even if it is not active any
more), “OK” if not
Status: “activates” if the failure is still active at the current moment , “inactive” if not
Times: counter of failure is saved in EEPROM (reset to zero when alarm is erased or cancellation)
Flashes
Defaults Description
ECU
1 EV01 Short-circuit ON/OFF valve:
EV TOR Short Circuit  All machines: YV720, YV700, YV123 and YV124
Machine with the option of rear axle locking activated: YV780
1 (RAM)
Machines with outriggers (HTL3210 and HTL4010): YV721
and YV701
Machine with the floating lifting option activated: YV380
2 EV02 Open circuit ON/OFF valve:
EV TOR Open Circuit  All machines: YV720, YV700, YV123 and YV124
Machine with the blocking of rear axle option activated:
YV780 1 (RAM)
Machines with outriggers (HTL3210 and HTL4010): YV721
and YV701
Machine with the floating lifting option activated: YV380
3 EV03 Short-circuit PWM:valve
EV PWM Short Circuit  YV300, YV320, YV340, YV360, YV400, YV420, YV121 and 1 (RAM)
YV122
4 EV04 Open circuit PWM valve
EV PWM Open Circuit  YV300, YV320, YV340, YV360, YV400, YV420, YV121 and 1 (RAM)
YV122
5 JY01 Signal on joystick pin Y (front/back) out of range
2 (RAM)
Joy F/R out of range  B300 < 0,2V or B300 > 4,8V
6 JY02 Signal on joystick pin X (right/left) out of range
2 (RAM)
Joy R/L out of range B301 < 0,2V or B301 > 4,8V
7 JY03 Inconherence between out of neutral signal on joystick:
Joy neutral incoh. B118 = 1 & (2.45V < B300 < 2.55V) & (2.45 < B301 < 2.55V)
2 (RAM
B118 = 0 & (B300 < 2.00V or B300 > 3.00V)
B118 = 0 & (B301 < 2.00V or B301 > 3.00V)
8 JY04 Neutral position of the joystick not detected since the start-up of
Joy neutral detect. the machine:
2 (EVE)
B300 < 2.35V or B300 > 2.65V or B301 < 2.35V or B301 >
2.65V
9 HD01 left roller signal out of range
2 (RAM)
Left Roller incoh. B302 < 0,2V or B302 > 4,7V
10 HD02 right roller signal out of range
2 (RAM)
Right Roller incoh. B303 < 0,2V or B303 > 4,7V
11 HD03 Neutral position of one of the rollers of the joystick not detected
Rollers neutral since the start-up of the machine:
2 (EVE)
B302 < 2.30V or B302 > 2.70V
B303 < 2.30V or B303 > 2.70V

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12 RC01 Signal of boom lift on joystick out of range
2 (RAM)
Joy. Radio Raising B401 < 0,2V or B401 > 4,8V
13 RC02 Inconherence signal on compensation (radio)
2 (RAM)
Switch Radio Bucket B104 = 1 and B105 = 1
14 RC03 Signal of telescopic on joystick (radio) out of range
2 (RAM)
Joy. Radio Telescop B402 < 0,2V or B402 > 4,8V
15 RC04 Inconherence signal on auxiliaires (radio)
2 (RAM)
Switch Radio Aux. B102 = 1 and B103 = 1
16 RC05 Neutral position of one of the switches or joystick of the radio
Sw/Joy Radio neutral control not detected since the start-up of the machine:
B401 < 2.00V or B401 > 2.50V
2 (EVE)
B402 < 2.00V or B402 > 2.50V
B102 = 1 or B103 = 1
B104 = 1 or B105 = 1
17 SW01 Inconherence for accessory:selection
3 (RAM)
Switch Accessory SA187T = 1 and SA187N = 1
18 SW02 Inconherence for the steering mode selection
3 (RAM)
Switch Steering Mode SA681a = 1 and SA681b = 1
19 SW03 Inconherence for the selection of the way of drive:
3 (RAM)
Comodo Drive SA600 = 1 and SA620 = 1
20 SW04 Neutral position of one of the switches, selectors or button of the
Switches neutral cabin not detected since the start-up of the machine:
SA600 = 1 or SA620 = 1 3 (EVE)
SA140 = 1
B120 = 1
21 SW05 Inconherence of selection of the movements of outriggers or
Switch Stabs/Level cabin levelling:
HTL3210 or 4010: (SA780M = 1 and SA780D = 1) or 3 (RAM)
(SA781M = 1 and SA781D = 1)
HTL3510: SA782G = 1 and SA782D = 1
22 CA01 Angle sensor not calibrated or calibration not validated
4 (EVE)
Angle calib invalid
23 CA02 Incoherence of both calibrated signals of the angle sensors (B403
Angle sensors incoh. and B404): 4 (RAM)
| > 3°
24 CA03 Corrected signal 1 of the angle sensor out of range (B403):
Angle 1 out of range (D+ = 1) & (KM100 = 1) & (Measure corrected1 > 4 (RAM)
CalMin+20pts or < CalMax-20pts)
25 CA04 Corrected signal 2 of the angle sensor out of range (B404):
Angle 2 out of range (D+ = 1) & (KM100 = 1) & (Measure corrected 2 > 4 (RAM)
CalMin+20pts or < CalMax-20pts)
26 SV01 Weak 12VDC battery voltage
5 (EVE)
Alim 12V Low (VBAT < 10V) & (D+ = 1)
27 SV02 supply 5VDC module out of range:
5 (RAM)
Alim 5V out of range B400 < 4,5V or B400 > 5,5V
28 EP01 Problem of read/write EEPROM
6 (RAM)
E2P Access Failure
29 LC01 Alarm LMI by-passed with the key
LMI Alarm shunted B130 = 0 & SA140 = 1 &Function (CalibrationLMI)
30 LC02 Inconherence between LMI Alarm and Pre-Alarm
7 (RAM)
LMI Alarm incoh. B142 = 1 & B130 = 0
31 PU01 Default system on H1 Pump
8 (RAM)
Pump System Error (cf Diagnostic H1 Pump (18/19) X-ray System Status).
32 PU02 Default on Pump H1inputs
8 (RAM)
Pump input Error (cf Diagnostic H1 Pump (18/19) X-ray Status Input).
33 PU03 Default on Pump H1 outputs
8 (RAM)
Pump Output Error (cf Diagnostic H1 Pump (18/19) X-ray Status Output).
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34 PU04 Inching pedal not calibrated
8 (EVE)
Inch Pedal not calib
35 PU05 H1 pump in safety mode (drive is impossible).
8 (RAM)
Pump in Safe Mode
4.1.3.CODES ALARMS FOR DRIVE

All alarms related to the drive are visualable thanks to the OPTIMIZER calibrator
through menu FAILURES (PU01 to PU05) as well as the detail in menu
DIAGNOSTIC/H1 Pump
Nevertheless a code flash can be read directly on module SAUER if necessary
 Explanation on the flashs codes on green LED :
SAFE-MODE:
the machine stops with an error in slope and the drive is stopped
Alarm could be erased only while switching OFF the contact
LIMITED-MODE:
The machine stops with an error in slope, once the error is registered, the comodo
switch (FNR) must be in neutral position (N).
then if the signal speed is in the right value and present, the drive is possible (in
restricted mode, the current on pump will be reduced and the current on motor will be
maintained at maxi value)

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 Explanation on the codes on red LED:
in detail:
The error codes on the red led have to be interpreted as follows:
Pause Pause
Exemple code 35 :
Break
1S
3s
3 Blinks 5 Blinks
Error code =
35

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 List of errors on drive SAUER module U600

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4.1.4.DIALOGUE WITH SAUER MODULE
It is possible to be connected with a laptop to the SAUER unit
For this it is necessary to have the right program and the interface called SAUER GATEWAY
(Part number 2505006050)
(The access is restrictive, contact HAULOTTE SERVICES of your area in order to know the
methods and necessary authorizations.
.
Connection with gateway between laptop and connector sub-D 9 points labelled SAUER-C
in cabin (see below)

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Examples of screenshot
Total visualisation of the system
the motor at idle speed (so the drive pump) without any speed engaged

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4.1.5. ALARM CODE OVERLOAD
The function of the system of load control (Load Indicator Moment = LMI) is to prevent the swing
of the machine towards front.
For that, a strain gauge is fixed on the axle measures load present on the rear axle.
The system compares then load measured with the safety threshold.
This threshold is defined at the time of a phase of calibration.
The system display this difference with a graph of leds which will ingnite gradually according to
the axle deformation measured.
These leds are green, yellow color and red according to measured load.
In the event of overlap beyond 75% of authorized load, the system goes in pre alarm mode: the
yellow leds ignite and a sound warning is activated.
In the event of overlap above the threshold of authorized load, the system goes in alarm mode:
the leds reds ignite and blink and the sound warning becomes more insistent.
Information alarm and pre alarm is sent to the module B2 node.
The button Test (SW1) is located on the front face of LMI.

The button Setup (SW2) is located on the rear face of the LMI (small hole on box) and non
accessible without disassembling this unit

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Description LMI Solution
Program report: error of

checksum
Writing error EEPROM replace the LMI U140
Error of checksum
EEPROM
Short-circuit on button
Setup (SW2) whereas check the button
the LMI is supplied
Short-circuit on button
Test (SW1) whereas the check the button
LMI is supplied
Error of communication
on the bus LIN with the
sensor
check the sensor or enter in test mode
Sensor SP140 default

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4.1.6.PARAMETERS ADJUSTMENTS
Times indicated below, must be controlled with a machine whose hydraulic oil is standard
(46) , hot and level OK + filters changed
Display on the
Movement Time (seconds)
console
HTL3210 13.5 + 1
lifting up boom lift (telescopic boom IN) HTL3510 12 + 2
HTL4010 12+/- 1
HTL3210 13.5 + 1
lifting down boom descent (telescopic boom IN) HTL3510 14 + 2
HTL4010 10+/- 1
HTL3210 4.5 + 1
Bucket closing Excavation (closing bucket) HTL3510 4.5 + 1
HTL4010 4.5 + 1
HTL3210 4.5 + 1
Bucket opening Discharge (opening bucket) HTL3510 4.5 + 1
HTL4010 4.5 + 1
HTL3210 9 + 1
telescopic retraction without load (boom
Telescopic IN HTL3510 10 + 2
at 66°)
HTL4010 12 +/- 1
HTL3210 17 + 1
telescope extension without load
Telescopic OUT HTL3510 17 + 2
(boom at 66°)
HTL4010 18+/- 1
Accessory A up Fork Accessory 100% without load
Accessory B down Fork Accessory 100% without load
Accessory A up Winch Accessory winch on cabin 70% without load
Accessory B down Winch Accessory winch on cabin 70% without load
Accessory A up radio Accessory winch on remote 0.5m/s without load
Accessory B down radio Accessory winch on remote 0.3m/s without load
HTL3210 6 + 1
Descent
HTL4010 6 + 1
Stabilisers
HTL3210 7 + 1
Lift
HTL4010 7 + 1
Stabilisers limit 9 to 12 without load

12 +/-2 without load
Frame level Command cabin levelling (HTL 3510)
(telescopic slighly out)
20 +/-2 without load
Frame level limit
(telescopic slighly out)
steering hand wheel 3.5 turns from lock to lock
* Version of program installed > V 1.08

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4 .2 . CONSOLE DIAG PAD
It’s possible to use the 2nd generation of diagnostic console (also available through laptop)
The presentation of the main menu will depend of the software’s version of the machine
This diagnostic console could be used in WIFI using a VCI adapter
The full description of how to use that console and their menus is explained in an other technical
note (refer to your nearest HAULOTTE SERVICES of your area)

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

F04.13 EV01
F04.14 EV02
F04.17 EV03
F04.18 EV04
F05.03 JY02 – HD01
F05.04 JY03
F05.06 JY01
F05.07 JY02
F05.08 HD02
F05.09 RC03
F05.10 RC01
F05.11 JY04
F05.12 RC05
F07.03 CA02-CA03-CA04
F07.25 LC02
F08.05 SV02
F08.06 SV01
F10.05 CA01
F11.05 LC01
F12.02 EP01
F13.03 RC02
F13.04 RC04
F13.05 SW01
F13.06 SW02
F13.07 SW03
F13.09 SW05
F13.10 SW04
F13.11 RC05
F14.01 PU01
F14.02 PU02
F14.03 PU03
F14.04 PU05
F14.05 PU04

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4 .3 . THE PRESSURES ADJUSTMENT
4.3.1.TABLE OF PRESSURES
Designation in Bars
Boom lifting (plug in P) 250 + 5
Excavation (full stroke) on equipment pump (plug in P) 200 + 10
Telescopic extension 160 + 15

Auxiliaries (button roller of the joystick to maximum) on equipment pump
250 + 10
(plug in P)
Steering (hand wheel cabin at full right or left ) (plug in P) 175 + 10
Charge pump (pressure port in M3 on drive pump) 24 +-3

Drive FWD/REV (measurement on drive motor in port M5) 460 + 15
(For HTL 3210) (430 + 15)
Change of cubic capacity (measurement on drive motor in port M5) 210 + 5
Drain or pressure of casing (measurement on L4 drive pump) < 4 bars

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4.3.2.EQUIPMENT PART
 Procedure
 Connect pressure gauge 0-600 bars on pressure port on block (photo in M).
 Oil on machine is hot.
 in command to check the setting of the main relief valve , raise or lower the boom at full
stroke.
 Accelerate the engine at maxi rpm and check the adjustment at 250b ±5.
 If pressure NOK, adjust it (mark 2).
 Check the setting of the secondary relief valve on the telescopic extension.
 Extend fully out the telescopic boom, accelerate the engine at full rpm and check the
setting at 160bar+15.
 If pressure NOK, adjust the relief valve ( mark 3)
 Check the setting of the secondary relief valve on the excavation (opening and closing).
 Put the movement at full stroke in one way, accelerate the engine at maxi rpm and
check the setting at 200b +15.
 Then control the other way, if pressure NOK adjust the secondary relief valve
(marks 1 and 2
Pressure plug M

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Mark Designations
1 Secondary relief valve on excavation closing setting 200 bars
2 Secondary relief valve on excavation opening setting 200 bars
3 Secondary relief valve on output telescopic setting 160 bars + 15
4 Main relief valve setting 250 bars + 5
5 Device for emergency boom descent
3
1
2
5 4

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4.3.3.DRIVE PART
 Hydraulic pump HTL3210
Cubic capacity piston pump: 68cc pump
Cubic capacity for charging gearpump: 17cc
Revolutions on thermal engine: 900 to 2400 rpm (2700 rpm maximum overspeed)
Pressure maxi measured: 430 bars + 15b
Charge pressure: 24 bars + 3 B at 1800 rpm
Maxi strength in traction approximately: 4200daN
 Front view
5
3
MARK Designations
1 Drive pump
Relief valve high pressure setting 450 bars (non adjustable) (HTL3210)
2
Relief valve high pressure setting 480 bars (non adjustable) (HTL3510-4010)
Pressure port on M3 : it’s possible to control the charging pressure at 24 bars
3
+ 3b at 1800rpm
4 Adjutement of charge pressure (gavage)
Port L2 drain linked to the hydraulic reservoir, maxi drain pressure 3 bars.
5
At the1st start or after pump replacement , its housing must be filled with oil

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 View from below
A
B
S
SV
L4
Mark Designations
Port A pressure max 430 bars + 15b (HTL3210)
A
Port A pressure max 460 bars + 15b (HTL3510-4010)
S Port S suction charge pump
Port B pressure max 430 bars + 15b (HTL3210)
B
Port B pressure max 460 bars + 15b (HTL3510-4010)
L4 Port L4 drain linked with drive motor drain , pressure maxi on drain 3 bars
SV SV162 speed sensor on pump

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Valves cancellation of flow (setting at 420b for HTL3210 and 450b for HTL3510-4010)
YV620 YV600
REV FWD
valves
(420b)
 Principle of operation
The drive control is monitored by the SAUER module (U600).
The speed sensor of hydraulic pump SV162 informs the module SAUER about the main engine
revolutions.
According to this information, the SAUER module sends more or less current on coils YV620 or
YV600 in command to adaptate the pump flow , so the speed according to the engine
revolutions.
If this speed sensor SV162 fails, no drive is possible.
The charging pressure (24 bars) ensured by the 17cc pump, incline the swatch plate of pump in
a direction or the other in command to adapt its flow according to the current sent on YV600 or
YV620 (the hydraulic motor is then supplied).
When the pressure in the closed loop between pump and motor reaches the value of 430 + 15b,
the valves of cancellation of flow bring back to the neutral by hydraulic pilot of the proportional
valves YV600 or YV620 (according to the line which is in pressure).
by this, the cylinder pump is back to 0cc, the flow is thus cancelled.
this system avoids an overheating of the circuit and lower the charge applied on main engine.
the relief valves calibrated at 450 bars are there in protection of the circuit from the possible
peaks of pressure in the event of failures of the valves of cancellation of flow.
These relief valves also make it possible to ensure the charge of the closed loop between pump
and motor through the pump of 17cc under a pressure of 24bars.
This charge permits to compensate the oil flow at a rate of 15l/mn which is sent by the hydraulic
motor to the exchanger of temperature in command to avoid an overheating of the closed loop.
The function ` inching' integrated in the brake pedals allows according to its position to vary the
current sent on YV600 or YV620 according to the speed selected and then decrease the drive
speed (slow approach for the operations of precise details) and that independently of the
engine revolutions.
It should be noted that when the pedal is at full stroke, the SAUER module sends the maxi
current on YV600 and YV620 in command to quickly bring back to the neutral position the
cylinder of pump control.

2420344570 E 07-14 187/311
charging circuit (gavage)
FWD REV
Tank
recognition of way of
to hydrostatic
drive (FWD/REV)
motor
valves of flow
cancellation protection of the
circuit
Mark P: in the event of failure in the system, this priority valve will switch in command to send
oil in priority to the steering circuit compared of the equipment circuit

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 Hydraulic pump HTL3510-HTL4010
Cubic capacity: 7 8cc
Engine revolutions from 900 to 2400 rpm (2700 rpm maximum downhill)
Pressure maxi measured: 460 bars +-15b
Pressure of charge: 24 bars + 3b with 1800 rpm
Maxi traction strength approximately: 6000daN
The components and the principle of operation remain identical to the HTL3210
Only the values of the check valves and the valves are different (see diagram)
 Schematic representation:
charging circuit (gavage)
FWD REV
Tank
recognition of way of drive
to hyd motor
(FWD/REV)
flow cancellation protection of

valves circuit

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 Hydraulic motor of drive (HTL3510-4010)
Cubic capacity 160cc/42cc

Scavenging valve 16l/mn
Charging pressure 24 bars + 3b
Pressure housing (housing/drain) 2 to 3 bars maximum
Pressure of cubic capacity change 210 bars + 5b
Maxi pressure in FWD or REV 460 bars + 15b
Speed sensor integrated SV685
Maxi strength traction approximately 6000 daN
 Principle of operation
The motor is a variable cubic capacity when low speed is selected via the selector module
SAUER (U600 on pump) , YV683 is supplied (12volts).
If high speed is selected, then YV683 is not supplied any more in 12 volts.
If the pressure on the drive circuit does not exceed 210 bars the cubic capacity of the motor will
not exceed 42cc.
If in high speed the torque required in drive increases, the pressure will increase when it
reaches the value of 210 bars, YV683 is controlled hydraulically what makes it possible to
modify the cubic capacity of the motor,
it will go from 42cc to the maximum cubic capacity of 160cc where the transmitted torque will be
maxi.
The function of the valve for the recognition way of drive is to ensure that it is always the line
under pressure which controls the change of cubic capacity of the motor.
This sensor sends the speed information to the SAUER module.
A maxi speed is programmed in the SAUER module according to the country of destination of
the machine,
When maxi speed is reached the H1 module will limit the flow of the pump in command to not
exceed it.
(Example: 20 km/h for Germany or 25 km/h for France).
In the motor a scavenging valve permits to always take from the line in low pressure, a rate of
15l/mn from the closed loop.
This system avoids an overheating in the circuit, this loss of oil is compensated by the constant
charge of the closed circuit done by the 17cc pump

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 Location on machine
front view 5 6
4
7
9 8
2
Mark Designations
1 L1 drain linked to the hydraulic pump
2 Charging pressure valve , setting at 16b -16l/mn
3 Scavenging valve
4 M3
5 Port A
6 Pressure port on M5
7 XA pilot for recognition way of drive
8 L2 drain housing linked to the hydraulic reservoir
9 M1

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 View from below
1 5
Mark Designations
1 M2
2 Port B
3 M4
4 Setting screw for cubic capacity change in High speed at 210 bars
5 Speed sensor SV685

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 Side view
Mark Designations
1 XB recognition way of driving
2 YV683 if supplied in12 volts then low speed drive is automatically selected
 Control of maxi pressure
in command to control the pressure , put the machine against an obstacle or disconnect or close
the hose which supplies the parking brake on front axlee (see photo A) or remove the parking
brake coil YV685.
Engage a speed FWD or REV then selection Low Speed /High Speed has no influence in the
control.
Don’t press the brake pedal (` inching' function incorporated) and gradually accelerate the
engine until maxi rpm.
The pressure must be at 460 ± 15bars, (430 b for HTL3210)
make the test in both ways of drive

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 Control of cubic capacity commutation
- The cubic capacity change is done at 210b (reading on plugs M4 and M5)
- install a pressure gauge on M5
- install a pressure port on M4 (9/16 UNF ref. 2501000650)
- Install second digital pressure gauge 0/600 bars on M4
- Select on the drive comodo the high speed position (II)
- Engine at idle stage without speed engaged, , on M5 the pressure read must be at charging
pressure (24b) and on M4 the drain pressure approximately 3 bars.
- in command to check the pressure , put the machine against an obstacle or disconnect or
close the hose who supplies the parking brake on front axle (see photo A) or remove the
parking brake coil YV685 .
- do not press on the brake pedals except if ` inching' is disconnected and accelerate the engine
gradually.
if setting of the cubic capacity change is correct, when the pressure of 210 bars is reached on
M5, the pressure goes from from 3b to 210 bars on the M4 port.
This will indicate that the cubic capacity of the motor will coomute from small cylinder High
speed to big CC ( low speed) where the transmttied torque will be at maxi when the pressure
will reach 460 ± 15b on M5 and M4.
if the pressure of commutation is NOK , it’s necessary to adjut the setting screw ( mark 4 on
photo taken from under).
Mark Designations
1 disconnect and close the hoses going to parking brake on front axle

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XA/XB :recognition way

of drive
Y
Mark V : : scavenging valve

this valve will extract oil from closed circuit ( towards port A or B) but always on the line in low
pressure in command to ensure the cooling at16 l/mn
Mark X: Valve of recognition way of drive
the piloting of this valve is done by the pump.
the function of this valve is to ensure that it is always the line under pressure which is piloting
the cubic capacity of the hydrostatic drive motor (port M3 for REV or M4 for FWD)
this will avoid to have a violent stop in high speed in descent and/or decceleration.
In this configuration, the motor is like a pump and the line which is in low pressure goes up in
pressure (without this valve X, the valve YV683 could be supplied inopportunely and cause a
drop in Low speed and a violent risk of machine stop
Mark S: SV685 speed sensor
Mark Y: YV683
valve for cubic capacity change during the speed change (Low speed to High speed)

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Hydraulic motor of drive (HTL3210)
Cubic capacity 110cc/32cc

Scavenging valve 15l/mn
Charging pressure 24 bars + 3b
Pressure housing ( carter/drain) 2 to 3 bars maximum
Pressure for cubic capacity change 210 bars + 5b
Pressure maxi in FWD or REV 4630 bars + 15b
Speed sensor integrated SV685
Maxi traction strength approximately 4200 daN
 Principle of operation of the motor

The motor is with variable cubic capacity when low speed is committed via the selector, module
SAUER (U600 on pump) supplies YV683 (12volts).
If high speed is selected YV683 is not supplied any more in 12 volts
if the pressure on the circuit of drive does not exceed 210 bars the cubic capacity of the motor
will not exceed 32cc.
If in high speed the torque required in drive is maxi, the pressure will increase until reaching the
value of 210 bars,
YV683 valve is controlled hydraulically; it will permit to modify the cubic capacity of the motor
from 32cc to the maximum cubic capacity of110cc where the transmitted torque will be at maxi
value.
the function of the valve YV684 is to be sure that it’s always the line in pressure who will control
the cubic capacity motor change
this will avoid to have a violent stop in high speed in descent and/or decceleration
In this configuration, the motor is like a pump and the line which is in low pressure goes up in
pressure ,without this valve YV684, the valve YV683 could be supplied inopportunely and cause
a drop in Low speed and a violent risk of machine stop
This sensor sends the speed information to the SAUER module.
A maxi speed is programmed in the SAUER module according to the country of destination of
the machine,
When maxi speed is reached the H1 module will limit the flow of the pump in command to not
exceed it.
(Example: 20 km/h for Germany or 25 km/h for France).
In the motor a scavenging valve permist to take from the line in low pressure a flow of 15l/mn
from the closed loop.
This system avoids an overheating in the circuit; this loss of oil is compensated by the constant
charge of the closed circuit done by the 17cc pump

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 View of the components:
Mark Designations
Pressure valve allows the passage of 15l/mn in the housing for tank return
1
through the temperature exchanger if pressure towards port A or B ≥ 16 bars
2
4
Mark Designations
Scavenging valve will extract oil of the closed loop towards port A or B but
1
always on the line in low pressure to ensure cooling
2 YV683 low speed/high speed. If supplied in 12 volts then low speed
YV684 recognition way of drive.
This valve allows that it is always the line in low pressure which commutes
3
the cubic capacity change of the motor in high speed.
It will avoid a violent deceleration
4 Setting screw for mini cubic capacity of the motor

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4
1
3
Mark Designations
Plug M5 permits to check the pilot pressure of the cubic capacity change at
1 210 bars + 5 and pressure maxi at the value of 430 bars +-15b
Pressure port is installed from the origin
2 Plug M4 permits to check the pilot pressure in big CC (low speed)
Install a pressure plug 9/16 UNF ref.: 2501000650 in command to check the
cubic capacity change in High speed
3 Setting screw of the adjustment of cubic capacity change at 210 bars +-5b
4 SV685 speed sensor

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Mark V : scavenging/sweep valve

this valve will extract oil from closed circuit ( towards port A or B) but always on the line in low
pressure in command to ensure the cooling at15 l/mn
YV684: Valve of recognition way of drive

the function of this valve is to ensure that it is always the line under pressure which is piloting
the cubic capacity of the hydrostatic drive motor (port M3 for REV or M4 for FWD)
this will avoid to have a violent stop in high speed in descent and/or decceleration.
Mark S:
SV685 speed sensor
YV683:
valve for cubic capacity change during the speed change (Low speed to High speed)

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5. BREAKDOWN GUIDE
This guide does not replace the logical equations described previously in this manual,
It will help the technician to have a logical step of breakdown guide, detailing the successive
steps to be followed starting from general components up to the detail.
The checking of the electric part is carried out in priority because it’s less sensitive to the
external parameters than the hydraulics part (temperature, pollution, viscosity…).
The denomination of the movements describes below implies the 2 phases (ex no boom lifting,
neither lift, nor descent)
All the fuses have been checked first
5 .1 . NO START
 Battery (GB100)
 No fuel SQ189
 Key of contact (SA100)
 Relay KM100, KA160
 Comodo not in neutral position
 Alternator charge D+
 Modules Sauer and Node B2
 engine stop coil YV160
 Pressure oil on engine SP162
 Oil filter clogged SQ126
 Oil temperature on engine ST160/C
5 .2 . NO DRIVE
 Comodo FNR (left side)
 Sensor for seat (SQ141)
 Switch parking brake (SB685)
 Electrovalve parking brake YV682
 pedal for “inching” brake out of range or not calibrated
 Electrovalves FWD/REV YV600 /YV620
 Speed sensor SV162
 Electrovalves change way of drive YV684 (for HTL3210)
 Both sensors for outriggers (SQ720+SQ721) in ground position (for HTL3210/HTL4010)
 Modules Sauer S1X and node B2 (wires B501+B502)
 Pressure in the brake system (< 90bars: SP690)
 Pump and drive motor
 No pressure on pump output
 Block of service/parking brake
5 .3 . NO HIGH SPEED
 Comodo in road position (SA680)
 Selector mode of steering rear wheels (SA680/SA681)
 Alignment wheels Front/back (detector SQ682/683)
 Position boom > 15° (value angle sensor SR381)
 Position telescope at mid--coarse (limit switchSQ360)
 No pressure in brake circuit (SP690)
 Electrovalve cubic capacity change YV683

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5 .4 . NO LOW SPEED
 Electrovalve cubic capacity change YV683
 Speed sensor (SV162) for overspeed
 Pressure in the brake system (< 90bars: SP690)
5 .5 . NO STEERING ON FRONT AXLE

 Steering selection SA681
 Priority valve (flow control valve)
 Steering block
5 .6 . NO STEERING ON REAR AXLE (SYNCHRO OR CRAB)

 Steering selection SA681a /b
 Switch selection mode road SA692
 relay KA680/KA681
 Electrovalves YV680/YV681
5 .7 . NO MOVEMENT
 Joystick SJ120
 Module Node B2
 No pressure on equipment pump
 Priority valve (flow control valve)
5 .8 . NO BOOM LIFTING
 Joystick SJ120
 Machine in overload (SP140/U140)
 Switch selection road mode SA692
 Boom angle sensor SR381
 Module Node B2
 No pressure on boom lifting
5 .9 . NO TELESCOPING BOOM
 Joystick SJ120
 Electrovalve YV340/YV360
 Module Node B2
 No pressure on telescopic boom extension
5 .1 0 . NO EXCAVATION/DISCHARGE
 Joystick SJ120
 Module node B2
 No pressure

2420344570 E 07-14 201/311
5 .1 1 . NO OUTRIGGERS (HTL3210-4010)
 Switches SA780 (FL) and SA781 (FR)
 Electro-valves YV122 + YV720 (FL) and YV721 (FR)
 Switch SA692 in road mode
 Module node B2
 No pressure
5 .1 2 . NO CABIN LEVELLING (HTL3510)

 Switch SA782 (boom < 35°)
 Machine in road mode SA692
 Electrovalves YV122+ YV700/YV720
 Module node B2
 No pressure

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6. SUMMARY VERSIONS OF HTL RANGE
Electric Hydraulic
HTL 40-14/HTL40 -17
shematics shematics
All
194P264340 194P261380
countries
All
With basket option 194P264340H 194P295920
countries
Electric Hydraulic
HTL 36-14/HTL 36.-17
shematics shematics
All
With winch option 194P264340 172P318440
countries
Electric Hydraulic
HTL 10M
shematics shematics
All
HTL 3210 107P323510 107P324190
countries
HTL 3510 - 4010 with block of All
107P323510 107P315160
proportional valves countries
HTL 3510 - 4010 with block of valves All
107P323510 107P332520
“Flow sharing” type countries
HTL EVOL with SPU module and new All No change
dashboard /cluster for all 10meters countries 107P348330 according to
range the model
HTL 3010 (only for AUS) AUS 107P348330 107P315160
HTL EVOLUTION 4014-4017 Electrical Hydraulic

Perkins engine, new SPU module ,
107P348330 4000022590
new display and dashboard

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7. SPECIAL FUNCTIONS
7 .1 . CALIBRATION OF LOAD SYSTEM (LMI)
The good calibration of the system of load control guarantees the longitudinal stability of the
telehandler.
The system is composed of an indicator LMI in the cabin (U140) and of a strain gauge (SP140)
measuring the deformation of the rear axle
The method of calibration described below is a procedure known as of “ground” requiring the
installation of the forks and a weight of 2500kg/5500lbs and Optimizer console.
Note:
Exceptionally and when it is not possible to get the weight recommended, the service technician
could use a less weight according to the model and be able to carry out all the calibration but
the method remains however approximate
(LMI : Load Moment Indicator)
7.1.1.METHOD WITH LOAD (2500KG/5500LBS)

Place the machine on a flat surface, hand brake engaged,
No strength on rear axle (road position)
Outriggers in road position (UP) for the models equipped with it
Place load as indicated below
H = 0.5 M
HTL 4010 : L = 2200 mm
HTL 3510 : L = 2100 mm
HTL 3210 : L = 1900 mm
P = 2500 kg + 5% (5500 lbs)

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7.1.2.PROCEDURE OF CALIBRATION (ALL MODELS)
 Start the engine
 Engage the hand brake
 Align the rear wheels
 Raise the boom of approximately + 5° (telescopic retracted)
 Put a load 2500 kg/5500lbs on the forks
 With the OPTIMIZER console, go in menu Parameters/Calibration (access in level 2)
HAULOTTE GROUP
HTL 3210 Pro
2901012850 / 1.08
S /

PARAMETERS  SPEEDS


RAMPS

OPTIONS  Enter access  Enter access code
code 0000 Level
1
  ^
 +– 
FACTORY SETTINGS Enter accesscode
2031 Level 2
^
 Code Ok


CALIBRATION  Load control  Load control
Inactive Active
 
Select the following screen
Launch the calibration by pressing on key

The following menu appears:
The red light indicator on indicator LMI will ignite and the LMI indicator is beeping

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7.1.3.“FIELD” PROCEDURE WITH LOAD OF 2500KG/5500LBS
:
HTL 4010 L = 2200 mm

HTL 3010-3510 L = 2100 mm
HTL 3210 L = 1900 mm
1. Prepare a load P = 2500kg + 5%.

(The precision of this load is important)
2. Load the machine with the load P and put the machine on a flat surface and rear axle
free of strength.
3. Align the rear axle and check that the hand brake is engaged
4. The outriggers must be retracted and the boom fully UP and telescopic boom fully IN.
5. Start the engine, with OPTIMIZER console enter the code level 2 (2031)
6. Launch the calibration of the LMI with OPTIMIZER console (see access menu in chapter
7.1.2): the led red ignites.
7. Press on the button “TEST” of the LMI to record the initial position.
8. The led red blinks then the yellow led blinks.
9. The machine is loaded with P (2500kg), lower the boom at horizontal position and
extend the telescopic section until the correct length L (according to the model)
(It could be necessary to use the by-pass key SA140 of the load control system):
10. Check that the forks don’t touch the ground (the height H must be at least 50cm from
ground).
11. Press on the button “TEST” of the LMI to record the load position. The yellow led blinks
then the green led ignites.
12. Retract the telescopic boom and lift again the boom at full height.
13. Press on the button “TEST” of the LMI to check the initial position.
14. The green led blinks then the LMI indicator returns under normal functioning.
15. Unload the machine.
16. Switch OFF the contact on main key SA100 in command to register the calibration.
17. Once the LMI, is calibrated , extend the telescopic boom only with fork and check that it
is possible to telescop at maxi stroke without having the alarm beeping on LMI
18. HTL 4010 / HTL 3010 -3510 / HTL 3210
19. it is possible to leave the telescopic boom to the maxi value (L=6,8 m approximately)

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7.1.4.“FIELD” PROCEDURE WITHOUT LOAD
HTL 4010 L = 6800 mm

HTL 3010 -3510 L = 6800 mm
HTL 3210 L = 6800 mm
1. Same method described in the previous chapter, but in fact the forks act as load
(330kg).
2. This method is not very precise and should be used only in emergency when no load are
available nearby.
3. Put the machine on a flat ground and rear axle free of any strength.
4. Align the rear axle and check that the handbrake is engaged
5. The outriggers must be up and the boom fully UP and telescopic boom fully IN.
6. Engine running, with OPTIMIZER console ,enter the code level 2 (2031) and launch the
calibration of the LMI with the console (see access menu above): the led red ignites.
7. Press on the button “TEST” of the LMI to record the initial position.
8. The led red blinks then the yellow led blinks.
9. The machine with forks only, lower the boom at horizontal position and extend the
telescopic boom at maxi stroke (It could be necessary to use the by-pass key SA140 of
the system of load control)
10. Extend the telescopic boom at maxi stroke (L=6,8 m approximately)
11. Check that the accessories tool does not touch the ground (the height H must be at least
of 50cm).
12. Press on the button “TEST” of the LMI to record the load position.
13. The yellow led blinks then the green led ignites.
14. Retract the telescopic boom and lift again the boom at full height.
15. Press on the button “TEST” of the LMI to check the initial position.
16. The green led blinks then the LMI returns under normal functioning.
17. Switch OFF the machine in command to register the calibration.
18. Once the LMI is calibrated, extend the telescopic boom at maxi stroke and check that
the system never goes in alarm
19. HTL 4010 PREMIUM/HTL 3510 MEDIUM/HTL 3210 PRO: it is possible to extend the
telescopic boom its maxi length (L=6,8 m approximately)

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7.1.5.ASSEMBLY INSTRUCTION FOR LOAD SENSOR SP140
Principle:
The function of the system is to prevent the tilting of the machine towards front .
For that, a strain gauge (SP140) fixed on the rear axle measures the current load on this
axle.
The system compares then the load measured with the safety threshold.
This threshold is defined by a phase of calibration.
The system shows this difference with a graph of leds which ignites gradually according to
the load applied on the rear axle
These leds are green, yellow and red color according to the load measured
When 75% of authorized load is reached, the system goes in pre-alarm mode: the yellow
leds ignite and a sound warning is activated.
When the threshold of authorized load is overlapped, the system goes in alarm mode: the red
led ignites and blinks, the sound warning becomes more insistent.
Information alarm and pre-alarm are sent to the module (B2 Node)
 Structure of the system

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 Preliminary operations
Fold the machine on clear and flat ground
Raise the boom and install the safety stop (U piece) on the lifting cylinder rod
Stop the engine and switch off the battery switch
Lock the wheels with the safety blocks
Important Information : The 2 parts (overload sensor and axle) must be stored at the same
temperature before proceeding to its replacement
Storage time depends on the internal room temperature (overload sensor: 1 hour for ∆T=20°C).
Replacement:
Remove the overload sensor by unscrewing the 2 screws (see picture 3)
Unplug the DEUTSCH connector of the overload sensor (see picture 2) inside the cabin driver.
Clean the threaded holes Ø10 from LOCTITE.
Clean the fixing area of the sensor on the axle as better as possible.
Install the new overload sensor by using LOCTITE (see picture 1 identifying screw A & B)
1. tight screw A at 23Nm

2. tight screw B at 23Nm
7. check that the cover never touch the extensometer (sensor)

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Fig 1: Position of the sensor on the rear axle for HTL 3210-4010
screw A screw B
sensor
Fig 2: Position of the sensor on the rear axle for HTL 3510
( be careful the part number of the sensor for HTL3510 is ≠ from HTL3210-4010)

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7.2. INCHING PEDAL
The purpose of the function “inching” is to gradually cancel the flow of the drive pump for a slow
approach whatever the engine revolution is.
Note : if inching pedal is not or badly calibrated ,there is no drive
7.2.1.POTENTIOMETER INCHING MOUNTING INSTRUCTIONS
Mark Designations
Screw for adjusting the supply pressure on the service brake to 25 bars for a
maximum driving speed of 25km/h.
1 Caution: In any case , the pressure must be higher than this value , otherwise
there is a risk to damage the seals on the pistons of brake on axle
Connector ` inching':
(The voltage must be between 0.5V and 4.5V,)

, while pressing on the pedals, the tension must increase until 4.5VDC
Pedal released and machine under power, adjust the sensor in command to obtain a voltage
between 0.5V and 0.6V.

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If it is not the case, it is enough to regulate the coarse of the “inching as follows”:
unscrew this nut
Slide the potentiometer in order to have the right value then tight again the bolt

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7.2.2.PROCEDURE OF CALIBRATION
The OPTIMIZER console must be in level 2 in command to carry out this operation
Switch ON the machine without starting the engine and follow the instructions on screen:
PARAMETERS ACCESS CODE Enter access code Enter access code
* * * 0000 Level 1
^
++++ ++*
Enter access code
 2031 Level 2
^
Code Ok
CALIBRATION
*
*
Lauch the
Inch Pedal
calibration calibration
(+) To calibrate
(-) To return
+ Calibration of
> Press Inch Pedal lower position
30s of pedal
Inch pedal pressed

> Release Inch Pedal
30s Calibration of
upper position
of the pedal
Inch pedal released
Inch Pedal Inch Pedal

calibration success calibration aborted
Timeout
+–* +–*
Functional check:
 Start the machine (engine running)

 Press at full stroke on inching pedal
 Remove the handbrake
 Accelerate the engine at least at 1500 rpm
 Ensure that the area around the machine is clear and to engage the FWD drive
 The engine revolution must be crushed
 Release gently the brake pedals, the drive speed must increase gradually.

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7 .3 . BOOM ANGLE SENSOR SR381
The information of the boom angle is done via an analogical sensor doubles track.
It is an analogical sensor supplied at 12VDC with an operating range of 120°.
It delivers 2 outputs signals in phase [0.5 - 4,5V] non proportional with an inverted variation
(the signals of the sensors decrease when the boom angle increases).
 Schematic representation and establishment
 Value sensor
+ VBAT
0VDC
Default calibration value Authorised calibration range

Boom
Signal Corrected internal Gross sensor Corrected internal Gross sensor
angle
value value value value
-2° B403/B404 766pts 3,9V 766pts ± 100 [3,387 - 4,295]V
66° B403/B404 314pts 1,4V 314pts ± 100 [0,904 - 1,931]V

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7.3.1.PROCEDURE OF CALIBRATION
set the OPTIMIZER console in level 2 in command to realize this operation
Start the engine (accelerate engine at full rpm) and follow the instructions on screen
PARAMETERS SPEEDS Enter access code
* 0000 Level 1
^
*
 ++++ ++*
ACCESS CODE Enter access code Enter access code
* 2031 Level 2
^
Code Ok

CALIBRATION Angle Sensors
* calibrated
(+) To erase calib
(-) To return
+ Reset /
Launch of the
Angle Sensors calibration
not calibrated
(+) To calibrate
(-) To return
+
> Push joystick
Sensor 1/2 = 506/507
Must be in [666-866]
B300 < 2.35 V
> Keep joy pushed Calibration of

Sensor 1/2 = 765/767 low position of
must be in [666-866]
boom
B300 < 2.35 V
> Keep joy pushed

Sensor 1/2 = 765/767
Low pos detected
..........
B300 < 2.35 V during 3s
Low Position
calibration success
Min 1/2 = 765/767
> Pull Joystick
B300 > 2.65 V
> Keep joy pulled Calibration of
Sensor 1/2 = 314/313 upper position of
must be in [214-414]
boom
B300 > 2.65 V

> Keep joy pulled
Sensor 1/2 = 314/313
High pos detected
..........
B300 > 2.65 V during 3s
High Position
calibration success +–*
Min 1/2 = 314/313
Angle Sensors
+ –   * calibration success
Min 1/2 = 765/767
Max 1/2 = 314/313

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7.4. DISCS ON BRAKES
7.4.1.BRAKES RELEASE
Set of tools /equipment
Key BTR of 8mm
Reversible spanner of 3/8 and one extension of 3''
CAUTION: block the 4 wheels in command to avoid any unexpected movement of the
telehandler when the brake is loosened
Allen Key of 8mm is used to loose correctly the parking brake system.
Make a mark in order to count the number of revolutions made by each bolt for carrying out the
adjustment
Locate the 6 bolts of brake release (3 of each side)
Alternatively tighten by ½ turn the bolts 1-2-3 time until feeling a resistance (~ 5.5 turns)
Park the telehandler
Lock the 4 wheels again and keep going with the procedure
Drain by screws A and B

if intervention on parking
or service brake circuit
A B
Cap to be unscrewed for bolts access (quantity 6 : 3 each side of the flanges

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plug to unscrew in order to have
access to the 6 screws for brake
release system ( 3 on each side)
around the flanges as shown below
7.4.2.BRAKE DISCS CHECKING

by releasing the screw of the oil level , it is possible to check the state of the brake discs

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7.4.3.PARKING BRAKE RELEASE INSTRUCTIONS
When pressure drops, the parking brake is ON (negative brake)

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 Procedure for brake disengagement
Lock the wheels before any intervention on brake release system

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 Procedure for brake engagement

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7 .5 . TELESCOPIC BOOM EXTENSION OIL BLEEDING
In the event of a cylinder replacement or major oil leak, it is absolutely necessary to bleed the
cylinder before extending the boom
Failure to complete this procedure could cause a de-synchronization of the telescope resulting
in deterioration of the flexible hoses.
In order to drain the oil, install 2 minimess fittings (1/4' ' G ref. HAULOTTE 2501000610) in ports
marked 1 and 2 (tightening torque of the plugs 20Nm).
Prepare one hose with minimess plug adaptor and a tray to collect the oil.
 Procedure
 Lower the boom at mini angle - 2°
 Connect the hose with minimess adaptor on the pressure tap 1 and operate the
telescope retraction.
 Maintain the function until air is no longer present in the return chanber via the hose.
Release the function
 Disconnect the flexible hose from pressure tap 1, connect it on the pressure tap 2 and
operate the telescope retraction.
 Maintain the function until air is no longer present in the return chamber via the flexible
hose.
 Release the function.
 Disconnect the hose and extend the telescopic only a few centimetres.
 Retract again the telescopic, and maintain the function for a few seconds after it is fully
retracted.
 Repeat the above step several times.
 When doing this, check that the telescopic sections I and II are synchronized before fully
extending.
 If it is not the case, to repeat the process.
 If the telescope functions OK remove the minimess fittings and refit the plugs, tensioning
to a torque of 20Nm
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7 .6 . CONTROL OF CARDAN AXLE
Control tightening of the fixing screws on cardan axle (check the first 50 hours then each 250H.
Tightening with torque120 Nm

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7 .7 . CONTROL OF BOOM PADS
Worn check (when they are not any more visible, the pads must be replaced)
Tightening torque of the pads
Top pads 130Nm
Side pads 75Nm
Bottom pads 35Nm

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7 .8 . VARIOUS TIGHTENING TORQUES
Tightening Loctite on
Elements
torque fillet
Wheels 300 Nm NO
Cardan (axle) 120 Nm YES
Attachment hydraulic motor on gear
AXLES transfer box
270 Nm YES
Tie rods on front axle 500 Nm YES
Fixing screw on bearings of the rear
axle
500 Nm YES
Fixing screw cabin support on
180 Nm NO
chassis
Fixing screw of the locking axle
CHASSIS cylinders (if option installed)
270 Nm YES
Fixing screw on axle stop (if locking

axle option is installed)
270 Nm NO
CABIN Fixing screw of cabin 410 Nm YES

Fixing engine tray on chassis 173 Nm NO
MOTOR Fixing engine support on engine 78 Nm YES
Crown gear on engine 49 Nm YES
bottom pads support on external
boom extension
60 Nm YES
Fixing of bottom and lateral pads on
external boom extension
80 Nm YES
Screw on stop axle part on lifting
cylinder(rod side)
250 Nm YES
Fixing screw lower pads on external
boom extension
60 Nm YES
BOOM
Fixing screw lateral pads on external
80 Nm YES
boom extension
Fixing screw of stop part on upper
pads on external boom extension
70 Nm YES
Screw on stop axle part of telescopic

cylinder on external boom extension
30 Nm YES

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7 .9 . CONNECTIONS OF THE JOYSTICK
connector M
Lock Signal cable
1 + 12 volts commands float B120
2 + 12 volts supply controls and sensors 113
3 supply 5 volts module B400
4 Signal telescopic B302
5 negative (-) 0
7 signal auxiliary B303
8 negative (-) 0
9 Free B124
connector C
Lock Signal cable

4 negative (-) 0
5 + 12 volts supply controls and sensors 113
6 Off neutral signal B118
9 signal excavation B301
10 negative (-) 0
12 signal boom lift B300

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7 .1 0 . STEERING SENSOR
These sensors located on each axle give the position of wheels by metallic detection

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8. HTL EVOLUTION
8.1. MAIN DATAS
The main datas remains inchanged compared to previous HTL3210-3510-4010
However a new model dedicated to AUS only (HTL3010) has also been developped, the base is
an HTL 3510, for more details refer to the instructions manual
The main differences are the load chart which of course has been decreased as follow :
8.1.1.HTL 3010 (VERSION AUS)

 Fork mode

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 For buckets use

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 Truss jib + Hook option version 1

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 Truss jib + Hook option version 2

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 jib option version 3

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 Side shift fork option

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 Hydraulic winch option 1.2T

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 Hydraulic Winch option 2.4T

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8.1.2.THE DASHBOARD
In the cabin, there is a new dashboard including a cluster indicating the possible failures
 Detail of the cluster
Button

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 Explanation of the indicators and leds
LCD Définition
Gas oil level given by analogical sensor SQ189:
1 segment: tank empty (always at least 1 segment id shown)
LCD1 20 segments: full tank
The segment (s) displayed are flickering when on reserve (SQ189R=1)
Segments: engine mode

1 segment: engine stopped
RPM 31 segments: engine mode at 3100 rpm
x100 Digits: Speed of the telehandler in km/h
LCD2 All segments are flickering if the rpm engine value is not received (bus CAN)
Digits : when power is coming up, the service counter is displayed for 3seconds
Digits : 3seconds after power in ON, the speed of the HTL in km/h is displayed
If there is some defaults (detected or active), they are displayed on the bottom part of the
1 F
screens. Each press on the button permits to display the code of the following failure.
Otherwise if the service counter is equal to 0, it’s displayed on screen ( and the LED 20
2 located beside the screen is flickering). If there is no default, each press on the button
allows swinging between the hour meter and the service counter.
If not , the hourcounter is displayed ( it’s flickering if engine is running , showing that its
3 increasing its value. each press on the button allows to swing between the hour meter
LCD3 and the service counter..
The counters of the machine (hours and et service) are saved in EEPROM in order to
detect any change in the display and then reload automatically the values saved in the
new cluster display.
For this each time power is ON:
 if hour counter (EEPROM) > hour counter (B813) => the counters (hours and
service are reloaded with the values saved in EEPROM
 otherwise the counters values are saved in EEPROM
Temperature of the cooling liquid given by sensor ST160 (Tier III)
or trame CAN J1939 (Tier IV):
LCD4 1 segment: temperature lower or equal at 40°C
20 segments: temperature equal or higher than 120°C
All segments are flickering in case of engine overheating (F09.01)
 Option Radiocomand
Indicators Lits ( fixed) flickering
B510 (D) Winch mode : LMI alarm is active (B130 = 0) Pre-alarm LMI active (B142 = 0)
PF mode : or static overload (weight > 550kg)
B511 (M) Alternator is stopped (DPLUS = 0)
B512 (G) Default active or detected
(refer chapter describing the management of defaults )

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LED Lit (fixed) Flickering
1 Default Parking brake (SP691=1)
2 Default Service brake (SP690=1)
3 Overheating hydraulic oil temperature (ST125=0)
4 Hydraulic oil filter Clogged (SQ126=1)
5 Active Floating lifting ([Float] =1) Floating lifting requested but
not validated
6 Centered rear axle (SQ683 = 0)
7 High speed activated High speed requested but
not validated
8 Drive at Neutral
9 side-lights ON (Poslamps=1)
10 Indicator right or left Flickering right or left lit
11 Lit road lights igh beam=1)
12 Presence seat not detected (SQ141=0)
13 Wait to Start: Pre/Preheating in progress
14 DPF (Diesel Particle Filter) : automatic or manual
regeneration of the necessary particle filter (level of average
or high clogging) => the regeneration of the filter should not
be inhibited by the switch of the cabin (Tier IV).
15 Automatic regeneration of the DPF
16 HEST: high temperature of exhaust smokedue to an active
regeration or a system in cooling phase after a regeneration
(Tier IV)
17 Engine warning: engine default
F09.07: Warning Lamp (Tier IV)
F09.04: Air Filter Sealed
F09.03: water In Fuel
18 Engine Stop: serious engine default
F09.08: Stop Lamp (Tier IV)
F09.01: water Temperature
F09.20: Oil Pressure
F09.10: D+
19 Alternator stopped (DPLUS=0)
20 LMI calibration activated (machine must be restarted in One or more faults detected
command to get out from calibration mode and switch off and/or active
the indicator Service counter at 0
buzzer LMI calibration activated (machine must be restarted in Engine stop , strong failure
command to get out from calibration mode and stop the one engine
buzzer sound F09-08: stop lamp (Tier IV)
F09-01: water temperature
F09-02 :oil pressure
F09.10 :D+

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 Right hand side panel

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Detail of the switchs
Indicators ON/OFF Condition

ON Road mode activated
HL692
500/500ms Road mode selected but not validated
ON Movements of the stabilisers authorized at least in one direction
Toggle switchs of the stabilisers in default
Movement of the right stabiliser requested but not authorized
HL780
HL781 500/500ms Movement of the left stabiliser requested but not authorized
State of the stabilisers on ground (0|1|2 stabs under pressure) different
from the current state of the positions sensors of the stabilisers (=>
loss of one stabiliser after movement has been stopped) :
ON Movement of cabin levelling authorized in one direction
HL782 Toggle switchs of the cabin levelling in default
500/500ms
Movement requested but not authorized

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 Right- hand side panel

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8.1.3.THE MODULES
On that models, there is now 2 ECU modules for equipment (SPU master and node B2 slave) +
+ 1 ECU SAUER H1 module for the drive system
SPU (under joystick in cabin

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 Connection of console and/or laptop
With the new ECU module SPU, a special harness is necessary in command to be able to
connect either the consoles OPTIMIZER either the DIAG PAD or the laptop +CAN adaptor
depending what needs to be checked by the technician (upload a software or just for diagnostic)
OPTIMIZER (for diagnostic) Laptop with SAUER CAN GATEWAY (for

drive diagnostic or upload SAUER + 1
program)

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 Detail of the connectors on SPU module
8.1.4.THE MENUS ON CONSOLE

The structure of the menus accessible through the diagnostic console has been changed (it will
be a standard now for all machines equipped with that kind of ECU module
See example
HAULOTTE GROUP
<machine type>
2901016220 / 2.<version> <country>
Option selected<engine> / <hydraulic>
1 . F A I L U R E S
2 . C O D E
3 . S E T T I N G S
4 . D I A G N O S T I C
5 . I N P U T S / O U T P U T S
6 . I N F O R M A T I O N S

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Menu [FAILURES]:
[+] and [-] to erase all the defaults (access code level 2 or 3): Menu [DETECTED FAILS] or [Al
FAILS]
[+] and [-] to empty the log of the defaults (access code of level 3): Menu [FAILURE LOGS]
[*] to erase the failure (access code level 2 or 3)
<cat>: category of default
<num>: number of default in the category
<status>: NO FAILURE | ACTIVATE (active default) | DETECTED (default detected since
power is activated but no more active)
<code>: internal code of release of the default.
If several conditions are active, the codes are added.
Example: if 2 PWM valves for the compensation YV400 and YV420 are in fault, then the code
will be incremented 003 (001+002).
Times: counter of default saved in EEPROM and reloaded when machine is powered ON
<nbr>: full number of possible default (all categories together)
Parameter Description lev

1.1 DETECTED FAILS Status and counters of active and detected defaults only
F<cat>.<num> 2*
F<cat>.<num> : <status>
<code>
<description>
<précision>
Times: xxxxx
<index>/<nbr>
1.2 ALL FAILS Status and counter of all the defaults displayed by category
F02: CONTACTOR 2*
F03: RELAY 2*
F04: ELECTROVALVES 2*
F05: JOYSTICKS 2*
F07: SENSORS 2*
F08: ELECTRIC CIRC. 2*
F09: ENGINE 2*
F10: FUNCTIONS 2*
F11: SECURITIES 2*
F12: INTERNAL FAULTS 2*
F13: SWITCHS 2*
F14: DRIVE PUMP 2*
F15: J1939 PROTOCOL 2*
1.3 FAILURE LOGS Log of the last 32 defaults activated
F<cat>.<num>.<code> 3*
* Access code necessary only to erase the defaults or to empty the log
EXPLANATION
(A): the failure is announced on display only when it is active
(D): the failure is announced on display when it was detected after start whatever it’s still active
or not.
(N):the failure is never announced ( it’s shown only on display)

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Failures are displayed in LCD 3
Code: Internal code permits to specify the conditions of the apparition of the default, it appears
on the first right line of the console
If several conditions are active, the codes are added.
Example: if both PWM valves for compensation YV400 and YV420 are faulty, then the failure
code will be 003 (001+002).
F03|F04 (CO): a default due to an open circuit could appear or disappear only if the output is
inactive (relay or valve)
F03|F04 (CC): a default due to a short-circuit could appear or disappear only if the output is
active (relay or valve)
A failure which is active when power is OFF then ON, will not increase the counter or menu
1.3 Failure log
FAILURES CODES DESCRIPTION Filter

F02: CONTACTOR
F02.03 (D) Main contactor default (main power supply cut and 400ms
Power Contactor valves supplied => relay KMG is stuck):
Check KMG (12VB < 5V) & (12VC/VD > 5V)
F02.05 (D) Default relay the pre/post-heating: 200ms
Heating relay TIER III: KM160
Check KM160
F03: RELAY
F03.08 (D) Default start-up relay: 200ms
Start relay KA160
Check KA160
F03.09 (D) Default relay of power supply/KeySwitch: 200ms
Supply/KeySwitch rel KA161
Check KA161
F03.12 (D) Default relay of power supply of the PWM valve: 200ms
PWM Validation 1 KA122
Check KA122
F04: ELECTROVALVES
F04.02 (D) Default on PWM valve for compensation : 200ms
Compensation 001 YV400
Check YV400/YV420 002 YV420

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F04.05 (D) Default on PWM valve for boom lifting 200ms
Boom 001 YV300
Check YV300/Y320 002 YV320
F04.06 (D) Default on PWM valve for boom telescoping : 200ms
Telescope 001 YV340
Check YV340/YV360 002 YV360
F04.23 (D) Default on electrovalves for accessories 200ms
Accessories 001 YV121
Check YV121/123/124 002 YV123
003 YV124
F04.24 (D) Default on electrovalves of the front left stabiliser 200ms
Front left stab 001 YV122
Check YV700/YV720 002 YV700
004 YV720
F04.25 (D) Default on the front right stabiliser valve 200ms
Front right stab 001 YV122
Check YV701/YV721 002 YV701
004 YV721
F04.28 (D) Default on cabin levelling valve 200ms
Frame level 001 YV122
Check YV122/740/760 002 YV740
004 YV760
F04.30 (D) Default ON/OFF on floating valve 200ms
Float raising YV380
Check YV380
F04.32 (D) Default ON/OFF valve for unlocking the accessories 200ms
Hydraulic locking YV380
Check YV380
F04.33 (D) Default ON/OFF valve for steering mode 200ms
Steering Mode 001 YV680
Check YV680/YV681 002 YV681
F05: JOYSTICKS
F05.03 (D) STD|AUS: Left default joystick roller (telescoping boom) 400ms
Telescope Joystick B302 < 0,2V | B302 > 4,7V
Check SJ120
USA: Default Joystick Centers X (telescoping boom) 400ms
001 B301 < 0,2V | B301 > 4,8V
002 or B118 = 1 & (2,45V < B301 < 2,55V) or B118 =0 &
(B301 < 2V | B301 > 3V)
F05.04 (D) Default joystick Pin Y (raising): 400ms
Joystick boom 001 B300 < 0,2V | B300 > 4,8V
Check SJ120 002 or B118 = 1 & (2,45V < B300 < 2,55V) or B118 =0 &
(B300 < 2V | B300 > 3V)
F05.07 (D) STD|AUS: Default joystick Axis X (Compensation): 400ms
Joy compensation. 001 B301 < 0,2V | B301 > 4,8V
Check SJ120 002 or B118 = 1 & (2,45V < B301 < 2,55V) or B118 =0 &
(B301 < 2V | B301 > 3V)
USA: Default Joystick left roller (compensation): 400ms
B302 < 0,2V | B302 > 4,7V
F05.08 (D) Default joystick right roller (control of the accessories) 400ms
Accessories Joystick B303 < 0,2V | B303 > 4,7V
Check SJ120

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F05.09 (D) Default radio joystick (telescoping boom): 400ms
Telescope Joystick 2 B402 < 0,2V | B402 > 4,8V
Check Radio operator
B402
F05.10 (D) Default radio joystick (raising): 400ms
Boom Joystick 2 B401 < 0,2V | B401 > 4,8V
Check Radio operator
B401
F05.11 (A) Neutral position of the joystick cabin not detected since 400ms
Joystick neutral the start-up:
Check SJ120 B300 < 2.35V | B300 > 2.65V | B301 < 2.35V | B301 >
2.65V
F05.12 (A) Neutral position of one of the radio joysticks not detected 400ms
Joystick neutral 2 since the start-up:
Check Radio operator 001 B401 < 2.35V | B401 > 2.65V
B401/402 002 B402 < 2.35V | B402 > 2.65V
F05.13 (A) Neutral position of one of the rollers of the cabin joystick 400ms
Joystick neutral 3 not detected since the start-up:
Check B302/B303 001 B302 < 2.30V | B401 > 2.70V
002 B303 < 2.30V | B402 > 2.70V
F07: SENSORS
F07.03 (D) Default angle sensor out-range or incoherent (only if the 1s
Boom Angle angle is calibrated):
Check B403/B404 001 B403 signal out of range (+20points compared to the
value min or max of calibration)
002 B404 signal out of range (+20points compared to the
value min or max of calibration)
004 Inconherence between calibrated angles of the signals
B403 and B404 (+3°)
F07.25 (D) Inconsistency Pre-alarm and Alarm LMI: 400ms
LMI Sensor Incoh  B142 = 1 & B130 = 0
Check B130/B142
F07.26 (D) Default position of the accelerator pedal out of range or 400ms
Accel pedal position incoherent (Tier IV):
Check RP160 001 RP160 < 0.30V | RP160 > 4.5V
002 or RP160 < 0.5 & RP160IVS = 0) |
(RP160 > 0.9 & RP160IVS = 1)
F07.30 (N) Inconherence of the engine oil pressure sensor: 400ms
Engine oil presses (pressure > 400bar engine stopped)
Check SP162 Tier III: SP162 = 0
F07.31 (N) Inconherence of the D+ signal (DPLUS = 1 engine 800ms
D+ signal stopped)
Check DPLUS DPLUS = 1
F07.32 (D) Error on strain gauges from indicator LMI 529 type :
LMI Strain Gauges 001  Gauge n°1 in default
Check LMI Gauges 002  Gauge n°2 in default
004  Incoherency between strain gauges signal (difference is above
1000points (=0,03mV/V) during more than 500msecs
008  the signals on gauges doesn’t vary anymore , the sum of both
signals hasn’t changed (in points) since 500msecs
016  Temperature of gauges in default
032  Temperature of gauges are out of range (must be within -20°C
and + 60°C)
064  Power supply on gauges is in default

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F08: ELECTRIC CIRCUIT
F08.04 (D) Power supply failure of the modules => restrictive mode
Calc. Supply input (12VP - VBAT_B2) > 0,717V (during 4s after switching 960ms
Check power supply ON)
F08.05 (D) Power supply 5V provided by the Node B2 out of range 400ms
Calc. Supply output 001 B400 < 4,5V
Check 5V supplied 002 B400 > 5,5V
F09: ENGINE
F09.01 (D) Engine Overheating:
Water temperature Tier III: T2s ([ST160C & T 15s])
Tier IV: T2s (Frame J1939 DM1 (SPN 110) & T15s
(VAR [engine running]))
F09.02 (D) oil engine pressure low:
Oil pressure Tier III: T6s (SP162 & T15s (VAR [engine running]))
Tier IV: Weave J1939 DM1 (SPN 100)
F09.03 (D) Water in the gas oil:
Water in fuel Tier III: SQ163
Tier IV: CAN J1939 DM1 (SPN 97)
F09.04 (D) Clogged air filter unit:
Air filter sealed Tier IV: CAN J1939 DM1 (SPN 107)
F09.07 (D) Warning lamp:

Amber warning lamp Tier IV: CAN J1939 DM1 (SPN 624)
Check Engine
F09.08 (D) Stop lamp (Tier IV):
Red stop lamp Tier IV: CAN J1939 DM1 (SPN 623)
Stop Engine
F09.10 (D) Default alternator:
D+ T2s (DPLUS = 0 )
Check alternator
F10: FUNCTIONS
F10.05 (A) Angle sensor not calibrated or non valid calibration
Boom sensors calib
Calibrate B403/B404
F10.11 (A) Strain gauges on LMI 259 are configurated but not
LMI sensor calib calibrated
Calibrate LMI
F10.12 (D) Errorr on display of the LMI 259 indicator
LMI Display 001  The LMI is not in operational model
Check LMI Display 002  The LMI hasn’t acquitted the Master Present CAN
(sent by the SPU every 20 msecs ) during more tha
600msecs
F11: SECURITIES
F11.05 (NR) Alarms LMI by-passed with SA140 key (except for the
LMI sensors shunted LMI calibration )
Caution B130 = 0

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F12: INTERNAL FAULTS
F12.01 (D) Default of the communication between master/slave
CAN Fault modules
Check wires (no reception of one or more informations by one of the
modules)
F12.02 (D) Default of reading or writing of the EEPROM of main
E2P Read/Write Error module SPU
Change calc. SPU
F12.04 (D) Identification of the software machine uploaded different
E2P Param Reset from the identification backed up in EEPROM => Reset
Check settings of the parameters from the machine (speeds, slopes,
options, access code level 2, counter default and
calibration of the boom angle).
F13: SWITCHES
F13.03 (D) Inconherence of the position switch radio operator 400ms
Compensation switch Compensation
Check Radio operator B104 = 1 & B105 = 1
B104/105
F13.04 (D) Inconherence of position radio operator switch Controls 400ms
Accessories switch Accessories:
Check Radio operator B102 = 1 & B103 = 1
B102/103
F13.05 (D) Inconherence of position switch cabin Selection of 400ms
Fork/Winch switch Accessory (Fork|Winch|Platform):
Check SA187 SA187T = 1 & SA187N = 1
F13.06 (D) Inconherence of position switch cabin Mode of Steering 400ms
Steering switch mode (Front|Crab|Synchro):
Check SA681 SA681C = 1 & SA681S = 1
F13.07 (D) Inconherence of position switch cabin Drive 400ms
Drive switch (Neutral|FWD/REV):
Check SA600/620 SA600 = 1 & SA620 = 1
F13.08 (D) Inconherence of position switch cabin Outriggers R/L: 400ms
Stablizers switch 001 SA780M = 1 & SA780D = 1 (Left)
Check SA780/SA781 002 SA781M = 1 & SA781D = 1 (Right)
F13.09 (D) Inconherence of position switch cabin cabin levelling: 400ms
Frame level switch SA782D = 1 & SA782G = 1
Check SA782
F13.10 (A) Neutral position of one of the switches of the cabin not 400ms
Switches neutral detected since start:
Check cabin switches 001 SA140 = 1 (by-pass key)
002 SA600 = 1 | SA620 = 1 (control unit drive FWD/REV)
=> not recorded in the diary
004 SA780M = 1 | SA780D = 1 (switchs left stabilizer U/D)
008 SA781M = 1 | SA781D = 1 (switchs right stabiliser U|D)
SA782M = 1 | SA782D = 1 (switchs cabin levelling
016 U|D)
B120 = 1 (button Floating Lifting)
032 B124 = 1 (Joystick enable switch for Australia)
064
F13.11 (A) Neutral position of one of the switches of radio not 400ms
Switches neutral 2 detected since start:
Check radio switches 001 B104 = 1 | B105 = 1
002 B102 = 1 | B103 = 1

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F13.12 (D) Inconsistency position switch cabin DPF Regen 400ms
DPF switch SA161D & SA161F
Check DPF Switch
F14: DRIVE PUMP
F14.01 (D) Default system of the H1 pump
Pump system error 001 Watchdog Error
Check Pump Drive 002  DSP Refers Voltage Error
004 Injection channel Error
008  Voltage Error
016  Sensor Voltage Error
F14.02 (D) Default on the inputs of the H1 pump
Pump input error 001 FNR switch Error
Check Pump Drive 002  Inching Sensor Error
004  Driving Sensor Error
008  Pump RPM Status Error
016  Pump Angle Sensor Error
032  Mode Switch 2 Error
064  Motor RPM Sensor Error
128  Motor Steering Sensor Error
F14.03 (D) Default on outputs of the H1 pump
Pump output error 001 Pump Valve FWD Error
Check Pump Drive 002 Pump Valve REV Error
004 Motor Prop. Valve Error
008 COR Valve Error
016  BB Valve Error
032  BPD Valve Error
F14.04 (D) Pump H1 in security mode => drive impossible
Pump in safe mode ActiveDirectionCode = 23 (Safe Mode)
Check Pump Drive
F14.05 (A) Inching Pedal not calibrated or in error => drive mode is
Pedal inch 001 impossible
Check Pedal Inch 002 Inch pedal not calibrated (ActiveDirectionCode = 24)
004 Parameter fault (InchPedalPosition = 251)
Input error (InchPedalPosition = 254)
F14.06 (D) Default speed sensor for engine rotation 400ms
Engine RPM fault 001 Parameter Fault
Check sensor 002 Input Error
004 Not available
F15: J1939 PROTOCOL
F15.06 (A) Cycle Links Module: x10
Cycle links 001 the maxi number of received messages is overlapped.
Check CAN 2 002 the maxi number of transmitted messages is
overlapped.
004 A registered message wasn’t received in the given time

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MENU DESCRIPTION LEVEL
1.3 Failures Log Detailed list of failures code 3*
Example as shown on display 1.3 FAILURES LOG
: 20 alarms have been
Logged 20 / 20
activated then detected and
registered in memory + and – to erase all
By pushing enter, the detail of

all alarms are shown in
command of appearance
(example 1st alarm is F04.01
code 002 so fault on valve
YV401 and so on
Menu [ACCESS CODES]:

[+] or [-] to modify the value
[*] to record the value
Parameter Description Niv

2.1 Enter Codes
Enter access code Enter the access code level 2 or 3 ] then [OK] to validate 1
2.2 Modify Codes
Modify access code Modification of the access code level 2 ] then [OK] to record it) 3
Note:
Level 2 is 2031
Level 3 is 3165 (if the Haulotte Diag console is used, the level 3 code is a daily code)
Menu [SETTINGS]:
[+] or [-] modify the value within the authorized limits
[+] and [-] restore the default value
[*] record the value
Parameter Description LEV

3.1 SPEEDS Maxi Speed for execution of the proportional movements
Lifting up Speed boom lift 2*
lifting down Speed boom descent 2*
Bucket closing Speed excavation 2*
Bucket opening Speed discharge 2*
Telescope in Speed telescopic boom retraction 2*
Out telescopic boom Speed telescopic boom extension 2*
Accessory A Fork speed for A accessory Fork mode 2*
Accessory B Fork speed for B accessory Fork mode 2*
Accessory A Winch speed for A accessory (rolling up) for the mode Winch Cabin 2*
Accessory B Winch speed for B accessory (unfolding) for the mode Winch Cabin 2*
Radio operator Speed for A accessory (rolling up) for Radio operator the Winch mode 2*
Accessory A
Accessory B Radio speed for B accessory (unfolding) for Radio operator the Winch mode 2*
operator
Stabilizers up speed stabilizer UP (HTL3210 and HTL4010 only) 2*

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Stabilizers down Speed stabiliser Down (HTL3210 and HTL4010 only) 2*
Frame level Speed for cabin levelling (HTL3510 only) 2*
Stabilizers limit Percentage of application of the reduced speed setpoint for stabilisers 2*
(HTL3210 and HTL4010 only)
Frame level limit Percentage of application of the reduced speed setpoint for cabin levelling 2*
(HTL3510 only)
3.2 RAMPS Slopes of acceleration and deceleration of the movements
Acc lift up Acceleration boom lift 2*
DEC lift up Deceleration boom lift 2*
Acc lift down Acceleration boom descent 2*
DEC lift down Deceleration boom descent 2*
Acc Bucket closing Acceleration excavation 2*
DEC Bucket closing Deceleration excavation 2*
Acc Bucket opening Acceleration discharge 2*
DEC Bucket opening Deceleration discharge 2*
Acc Telescopes in Acceleration telescopic boom retraction 2*
DEC Telescopes in Deceleration telescopic boom retraction 2*
Acc Telescopes out Acceleration telescopic boom extension 2*
DEC Telescopes out Deceleration telescopic boom extension 2*
Acc Accessory Acceleration for accesories 2*
DEC Accessory Deceleration for accessories 2*
Acc Stabilizers up acceleration stabiliser UP (HTL3210 and HTL4010 only) 2*
Acc Stabilizers down acceleration stabiliser DOWN (HTL3210 and HTL4010 only) 2*
Acc Frame Level Acceleration cabin levelling (HTL3510 only) 2*
DEC Frame Level Deceleration cabin levelling (HTL3510 only) 2*
3.3 OPTIONS Options of the machine (in fat the default value for each option)
Float/Hydrau Lock Selection of the option lifting floating or hydraulic locking of the 1
accessories:
[None] | [Float Raising] | [Hydraulic Lock]
Country Choice of the country: [STD] | [USA] | [AUS] 3*
Fleet management Management of fleet tracking system) [OFF] | [ON] 2*
3.4 CALIBRATION Calibrations of the machine

Load control Launch the calibration of the LMI (same as STD version) 2
Sensor angle Launch the calibration of the boom angle sensor (same as STD version) 2
Pedal inch Launch the calibration of the inching pedal (same as STD version) 2
3.5 MACHINE CONFIG Configuration of the machine (in fact the default value)
Machine Choice type of machine: [HTL 3210] | HTL 3510] | [HTL 4010] 3*
Hydraulic Control Choice type of hydraulic block: [Walvoil SDM140] | [Walvoil DPX100] 3*
Engine Choice type of engine: [TIER III] | [TIER IV] 3*
LMI Choice LMI type : [VISHAY LMI 524] | CAN [VISHAY LMI 529] 3
3.6 MAINTENANCE Maintenance actions of the machine 
Not used 
3.7 SERVICE COUNTER Service counter of the machine (how many hours remaining before 
the next revision)
Service counter Allows to reset the service counter at 500 hours ([+] and [-] then [OK] to 2*
back up)
Service counter Allows to modify the service counter ([+] and [-] then [OK] to back up)) 3*

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3.8 HOURMETER Hour meter of the machine (number of running hour of the machine)
Hourmeter Allows to modify the hourmeterr ([+] and [-] then [OK] to back up)) 3*
3.9 DATE & HOUR
Not used
3.10 SERIAL NUMBER
Not used
Menu [DIAGNOSTIC]:
Bit Field: Fields of 8 bits (reading from right to left) with value 0bxxxxxxxx where X could take
the value 0 or 1
Setpoint: setpoint secured and formatted intern of the function coming from the active control
panel for a given direction (Dir = Neutral or Fwd/Up/Left or Rev/Down/Right).
The setpoint is resetted in case of fault in the command system (out-or range incoherence
between neutral and signals) and is formatted between 0 and 1000.
Slowdown: Percentage of application of the internal setpoint secured and formatted
(100% = setpoint not slowed down).
Cuttings: Current conditions of movement cut in each direction (Fwd/Up/L and Rev/Down/R).
Each of the 8 bits (reading from right to left) could take the value 0 (movement authorized) or 1
(movement prohibited).
An authorized movement will thus have value 00000000 for the corresponding direction
Bit 0 (E for Enable): Condition for validation of the movement

Bit 1 (G for General): General cut
Bit 2 (S for Simultaneous Mvts): Cut due to the logic of multiple movements
Bit 3 (O for Overload): Cut due to load management system (over or under load)
Bit 4 (T for Tilt): Cut due to the cabin levelling
Bit 5 (R for Reach Limit): Cut due to the range limitation of the machine
Bit 6 (F for Failure): Cut due to one or more failures of the machine
Bit 7 (X for Extra): other specific cut out
F/U/L: F for Forward drive / U for lifting /L for left
R/D/R: R for Reverse drive / D for descent / R for right
See example:
Control = internal command validated generated from the setpoint of the function and sent to
the valves and output relays in a given direction (Dir = Neutral or F/U/L or R/D/R).
It integrates various logics of operation, as well as the dynamic limitations of the setpoint and
the acceleration/deceleration.ramps.
It is formatted between a mini internal speed (bias) and a maxi speed changeable with the
console.

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The direction of the command is normally indicated
Cuttings
Function
ETOR STOR
EANA SANA
Securisation et Setpoint Validation and Control Application of the
controls formatting the formatting of command on Actuators
setpoint [0-100]% the command [0-100]% actuators
Slowdown
4.1 MOVEMENTS Description

Boom Raising (1/6)
Mean Angle mid-sized calibrated angle of the boom in degree (- 2 to 66°)
Nb stabs low Number of stabs in lowered position (SQ720/SQ721): 0.1 or 2
B300 Rough instruction of Lifting (Joystick axis Y Cabin)
B401 Rough instruction of Lifting (Joystick Radio)
Raising setpoint protected and formatted internal Consign of Lifting for a given direction
Raising slowdown Percentage of application program of the formatted internal instruction
Raising cuttings Conditions for cut-off of the mvt (00000000 if the movement is authorized)
Raising control Command intern of Lifting validated and formatted
YV300 PWM valve for boom lift
YV320 PWM valve for boom descent
Telescoping (2/6)
SQ360 Detection of Telescope retracted
B302 EUR/AUS: Rough instruction of Telescoping (Joystick axis X Cabin)
B301 The USA: Rough instruction of Telescoping (left Roller Cabin)
B402 Rough instruction of telescoping (Radio operator Joystick)
Telescoping setpoint protected and formatted internal Consign of Telescoping
Telescoping slowdown Percentage of application program of the formatted internal instruction
Telescoping cuttings Conditions for cut-off of the movement (00000000 if the movement is authorized)
Telescoping control Command intern of Telescoping validated and formatted
YV340 PWM valve for Telescoping boom extension
YV360 PWM valve for Telescoping boom retraction
Compensation (3/6)
B301 EUR/AUS: Rough instruction of Compensation (left Roller Cabin)
B302 The USA: Rough instruction of Compensation (Joystick axis X Cabin)
B104 Rough instruction of Excavation (interruptor Radio operator)
B105 Rough instruction of Discharge (interruptor Radio operator)
B124 Button “enable” joystick for the movements of excavation/discharge with
Australia option
Dead Man AUS valid “Enable” button of the joystick for the movements of excavation/discharge with
the Australia option validated (1 if valid)
Bucket Set point protected and formatted internal Consign Compensation
Bucket slowdown Percentage of application program of the formatted internal instruction
Bucket cuttings Conditions of cut-off of the movement (00000000 if the movement is authorized)
Bucket control Command intern for compensation validated and formatted
YV400 PWM valve for Excavation (close)
YV420 PWM valve for Discharge (open)
Accessories (4/6)
B303 Rough instruction of Check out of the Accessories (Right Roller Joystick Cabin)
B102 Rough instruction of Check out of the Accessories direction A
(interruptor Radio operator)
B103 Rough instruction Check out of the Accessories direction B
(interruptor Radio operator)
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Accessories setpoint protected and formatted internal Consign Check out of the Accessories
Accessories slowdown Percentage of application program of the formatted internal instruction
Accessories cuttings Conditions of cut-off of the movement (00000000 if the movement is authorized)
Accessories control Command intern of the Accessories validated and formatted
YV121 PWM valve Check out of the Accessories
YV123 ON/OFF valve for validation of direction A
YV124 ON/OFF valve for validation of direction B
Stabilizers (5/6)
SA780M Left toggle switch stabiliser up
SA780D Left toggle switch stabiliser down
SA781M Toggle switch lift right stabiliser
SA781D Toggle switch descent right stabiliser
StabR setpoint protected and formatted internal Consign of the right outrigger
StabL setpoint protected and formatted internal Consign of the left outrigger
Stabilizers slowdown Percentage of application program of the formatted internal instruction
Stabilizers cuttings Conditions of cut-off of the movement (00000000 if the movement is authorized)
StabR control validated and formatted internal Command of right outriggers
StabL control validated and formatted internal Command of left outriggers
YV122 PWM valve for the Outriggers
YV700 ON/OFF valve for validation left stabiliser up
YV701 ON/OFF valve for validation right stabiliser up
YV720 ON/OFF valve for validation left stabiliser down
YV721 ON/OFF valve for validation right stabiliser down
Frame Level (6/6)
SA782G Toggle switch cabin levelling towards left
SA 782R Toggle switch cabin levelling towards right
Frame Level setpoint validated and formatted internal Command for cabin levelling
Frame Level slowdown Percentage of application program of the formatted internal instruction
Frame Level cuttings Conditions of cut-off of the movement (00000000 if the movement is authorized)
Frame Level control validated and formatted internal Command fo cabin levelling
YV122 PWM valve for the cabin levelling
YV700 ON/OFF valve for validation of cabin levelling left side
YV720 ON/OFF valve for validation of cabin levelling right side

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4.2 FUNCTIONS Description
Drive (1/11)
SA600 Selection forward drive (control unit)
SA620 Selection reverse drive (control unit)
Drive setpoint Consign intern of drive FWD/REV protected
Drive cuttings Conditions of cut-off of the function (00000000 if the function is authorized)
Drive control Internal validated command of FWD/REV drive
KA620 Relay for REV drive indication
Drive CAN Frame CAN link for drive FWD/REV (example : comodo/commands in neutral position
:000100) , reading from right to left
Bits Datas
Drive Reverse
0-1 0: OFF
1: ON
Drive Neutral
2-3 0: OFF
1: ON
Drive Forward
4-5 0: OFF
1: ON
High Speed (2/11)
Machine folded Indicator of Machine folded (boom < 15° and telescopic boom retracted)
SA680 Selection drive in high speed (control unit)
High Speed setpoint Internal protected Consign for High speed drive
High Speed cuttings Cut off Conditions for drive command (00000000 if the function is authorized)
High Speed control Internal validated Command for high speed drive
High Speed CAN Frame CAN link for high speed drive in 7 bits ( from 7 to 0)
(example 0000010 : High speed selected)
Bits Datas
Mode switch A
0-1 0: OFF ( low speed)
1: ON (High speed)
Park Brake (3/11)
SQ141 Sensor under seat
SB685 Button for Parking brake
Park Brake control Command intern of the Parking brake validated
Park Brake CAN frame CAN link for the state of the Parking brake in 8 bits (7 to 0)
(example parking brake activated 0000100
Bits Datas
Remote brake
3-2 0: OFF
1: ON
Road Mode (4/11)
Machine folded Machine folded (Telescopic boom retracted and boom Angle < 15°)
SA692 Selection Road mode
Road setpoint mode Internal protected Consign road mode
Road cuttings mode Conditions for cut-off of the function (00000000 if the function is authorized)
Road control mode Internal command validated for road mode
Steering Mode (5/11)
SA681C Selection mode of steering Crab mode
SA681S Selection mode of steering Synchro mode
SQ682 Front axle not centered
SQ683 Rear axle not centered
Steering setpoint Internal protected Consign mode of steering
Steering control Internal validated Command mode of steering

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EEPROM steering mode Mode of steering recorded in EEPROM and reloaded at start-up
(0 = Front, 1 = Crab, 2 = Synchro)
YV680 (SPU) Relay for steering Crab mode
YV681 (SPU) Relay for Steering Synchro mode
Engine (6/11)
Cab. emergency stop Status of the Emergency Stop button in cabin : SB801
Accelerator pedal Consign accelerator pedal in RPM (Tier IV)
Engine Speed speed of the engine in RPM
Running engine Driving indicator engine turning (driving mode > 400 rpm)
Vehicle Speed Speed of the telehandler in km/h
Engine temperature Engine temperature (liquid of cooling) of -40°C with 120°C
Engine Oil Pressure Engine oil pressure in kPa
Engine Oil Quality Quality of engine oil managed by engine TIER IV: 500h - > 0
Engine Oil State State of the engine oil managed by engine TIER IV:
0 =Normal, 1 = Oil counter reset in current engine cycles, 2 = oil change is required
Engine Fuel Level Gas oil level in the tank (in liter)
SA100 Main key switch for start-up cabin
B129 Key of radio operator start-up
Startup setpoint Consign protected intern of start-up
Startup control Command intern of start-up validated (current stage at start-up)
KM160 Pre-heating relay (Tier III)
KA160 Relay of start-up
KA161 Relay Keyswitch (supply driving)
DM1 [0] Status Status of the engine lamps , 2 bits per lamp (00 = OFF, 01 = ONE):
Malfunction|Stop|Warning|Protect
DM1 [1] Flash Flash of the engine lamps, 2 bits per code codes
(00 = Slow, 01 = Fast, 11=Fix):
Malfunction|Stop|Warning|Protect
DM1 Failure Count Number of driving default in frame DM1 sent by the engine (Tier IV)
DM1 Length Length (of many bytes) of frame DM1 sent by the engine (Tier IV)
Failure SPN 1 SPN of the 1st default found in frame DM1 sent by the engine (Tier IV)
Failure Mode 1 Mode of the 1st default found in frame DM1 sent by the engine (Tier IV)
Failure Count 1 Meter of the 1st default found in frame DM1 sent by the engine (Tier IV)
Failure SPN 2 SPN of the 2nd default found in frame DM1 sent by the engine (Tier IV)
Failure Mode 2 Mode of the 2nd default found in frame DM1 sent by the engine (Tier IV)
Failure Count 2 Meter of the 2nd default found in frame DM1 sent by the engine (Tier IV)
Failure SPN 3 SPN of the 3rd default found in frame DM1 sent by the engine (Tier IV)
Failure Mode 3 Mode of the 3rd default found in frame DM1 sent by the engine (Tier IV)
Failure Count 3 Meter of the 3rd default found in frame DM1 sent by the engine (Tier IV)
Failure SPN 4 SPN of the 4th default found in frame DM1 sent by the engine (Tier IV)
Failure Mode 4 Mode of the 4th default found in frame DM1 sent by the engine (Tier IV)
Failure Count 4 Meter of the 4th default found in frame DM1 sent by the engine (Tier IV)
Failure SPN 5 SPN of the 5th default found in frame DM1 sent by the engine (Tier IV)
Failure Mode 5 Mode of the 5th default found in frame DM1 sent by the engine (Tier IV)
Failure Count 5 Meter of the 5th default found in frame DM1 sent by the engine (Tier IV)
Angle (7/11)
B403 Gross amount of signal 1 of the angle sensor (in mV)
Measure 1 Corrected Filtered and corrected value signal 1 of the angle sensor (in pts)
Angle 1 Calibrated calibrated angle 1 (in °)
B404 Gross amount of signal 2 of the angle sensor (in mV)
Measure 2 Corrected Filtered and corrected value signal 2 of the angle sensor (in pts)
Angle 2 Calibrated calibrated angle 2 (in °)
Mean angle Average of the 2 calibrated angles (in °)
Sensors Incoh Count Counter giving the number of times where the difference between the 2 calibrated
angles was too important
S1 Out of Range Cnt Counter giving the number of times where the filtered and corrected value signal 1
of the angle sensor was out of range

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S2 Out of Range Cnt Counter giving the number of times where the filtered and corrected value signal 2
of the angle sensor was out of range
Calibration State State of calibration (bits to reading from right to left):
bit0 = 1: Calibration OK
bit1 = 1: Calibration of the low stop carried out and valid
bit2 = 1: Calibration of the high stop carried out and valid
bit3 = 1: Calibration of the low stop of sensor 1 out-range
bit4 = 1: Calibration of the low stop of sensor 2 out-range
bit5 = 1: Calibration of the high stop of sensor 1 out-range
bit6 = 1: Calibration of the high stop of sensor 2 out-range
Sensor 1 Calib Min Filtered and corrected value signal 1 out of low stop (in points)
Sensor 1 Calib max Filtered and corrected value signal 1 out of low stop (in points)
Sensor 2 Calib Min Filtered and corrected value signal 2 in high stop (in points)
Sensor 2 Calib max Filtered and corrected value signal 2 in high stop (in points)
Shunt (8/11)
SA140 By-pass key for reach limitation (LMI)
B142 Pre-alarm Reach limitation (0 if active)
B130 Alarms Reach limitation (0 if active)
Pre-alarm LMI filt. Pre-alarm filtered reach limitation (0 if active)
Alarm LMI filt. Alarms filtered Reach limitation (0 if active)
Shunt setpoint Internal protected Consign for reach limitation by-pass
Shunt control Internal validated Command for reach limitation by-pass
0 = INACTIVE: Instruction inactivates
1 = VALIDATED: Active instruction
2 = DESACTIVATED: Active instruction and no movements during 8secs
Float Raising (9/11)
B120 Button of activation of the float option
Float setpoint Internal protected Consign of the float option
Float control Internal validated Command of the float option
YV380 Electrovalve ON/OFF of validation of the float option
Hydraulic Lock (10/11)
B120 Button of activation of hydraulic locking
Hydraulic Lock setpoint Internal protected Consign of hydraulic locking
Hydraulic Lock control Internal validated Command of hydraulic locking
YV380 Hydraulic relay of unlocking
YV123 Hydraulic valve of unlocking
YV124 Hydraulic valve of locking
DPF (11/11)
DPF Regen Status DPF : Diesel Particle Filter
Status of the regeneration of the particle filter: 0 = Not activates, 1 = Active,
2 = Needed
DPF Regen need level Status of the particle filter:
0 = regeneration not necessary (=> regeneration passivates)
1 = regeneration necessary (low level => automatic regeneration)
2 = regeneration necessary (intermediate level => automatic or manual
regeneration)
3 = regeneration necessary (elevated level => manual regeneration only)
SA161D Switch of desactivation of automatic regeneration
SA161F Switch of activation of manual regeneration (forced)
DPF Regen setpoint Internal protected Consign mode of protected regeneration:
0 = Car, 1 = Forced, 2 = Inhibited
DPF Inhibit request request inhibition of the regeneration of DPF
DPF Forces request request of the regeneration of DPF
DPF Forces regen Lock Prohibition of the mode of regeneration of DPF

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4.3 STATE Description
Machine
PowerON Key turned to the 1st stage and emergency stop not pushed:
WUI = 1 & 12VC > 5V & 12VD > 5V
Mean Angle calibrated average boom angle in degree (- 2 to 66°)
Folded machine Indicator of Machine folded (boom < 15° and telescopic boom retracted)
Nb stabs low Number of stabs in lowered position (SQ720/SQ721): 0.1 or 2
Pre-alarm LMI Indicator of pre-alarm LMI
Alarms LMI Indicator of alarm LMI
prop. mvt in process Indicator of movement proportional in progress (Raising, Telescoping,
Compensation, Accessories or outriggers/cabin levelling)
Accessory selection Selected accessory
0: Fork (SA187T = SA187N = 0) ; 1: Winch (SA187T = 1 or SA187N = 1)
Common functions functions common to the 2 active commands: PowerON
Cabin functions Active functions of cabin: Power ON & B111 = 0
Radio functions functions of the radio: Power ON & B111 = 1 & engine rpm < 1200 rpm
Calibration
Angle sensor 1 Min Filtered and corrected signal value (1) in lowest position (in points)
Angle sensor 1 Max Filtered and corrected signal value (1) in lowest position (in points)
Angle sensor 2 Min Filtered and corrected signal value (2) upper position (in points)
Angle sensor 2 Max Filtered and corrected signal value (2) upper position (in points)
LMI Gauges Min Min calibration value for the strain gauges of LMI (null load on rear axle)
LMI Gauges Max Maxi calibration value for the strain gauges of LMI (maxi load on rear axle)
H1 State
Inch Pedal Pos (%) Position of the inching pedal
[0 - 100]: position of the pedal in %
251: parameter invalidated (calibration of the pedals in progress)
254: error of input
System Status System error of the drive pump (1 if error), reading from right to left
bit0: Watchdog Error
 bit1: DSP Refers Voltage Error
 bit2: Injection Chanel Error
 bit3: Battery Voltage Error
 bit4: Sensor Voltage Error
Status input Error on drive pump inputs (1 if error),reading from right to left
bit0: FNR switch Error
 bit1: Inching Sensor Error
 bit2: Driving Sensor Error
 bit3: Pump RPM Status Error
 bit4: Pump Angle Sensor Error
 bit5: Mode Switch 2 Error
 bit6: Motor RPM Sensor Error
 bit7: Motor Steering Sensor Error
Status output Error on drive pump outputs (1 if error),reading from right to left
bit0: Pump Valve FWD Error
bit1: Pump Valve REV Error
bit2: Motor Propm. Valve Error
bit3: COR Valve Error
 bit4: BB Valve Error
 bit5: BPD Valve Error
Direction Codes Direction Codes active (frame SDS):
00: normal operation (No overruling), Lowest priority
10 : State Shift in progress
12 Remote Neutral Request (RCI)
13 : Halt Brake Request (EBC1) or Brake Request (RCI)
20: FNR not in Neutral
21 high pump RPM
22 : low pump RPM (Low Engine/Pump RPM Monitoring))
23 : system error (Safe Mode like overheating with ST160 sensor out of range)

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24 : Inch pedal not calibrated
25 VBAT not checked because of low pump RPM (Min RPM for Check Voltage)
26 : Pump rpm fault in Automotive Creep-Automotive
254 Highest priority
255 N/A
StepPedal Cal inch Current stage of the calibration of the inching pedal (1 to 9)
LMI
Strain Gauge 1 Gauge n°1 in points
Strain Gauge 1 Gauge n°2 in mV/V
Strain Gauge 2 Gauge n°2 in points
Strain Gauge 2 Gauge n°2 in mV/V
Gauge Temperature Temperature of gauges in °C
Supply Voltage Power supply on gauges in V
Status of the gauges :
 bit0 : Default gauge n°1
 bit1 : Default gauge n°2
Sensor Status  bit2 : Default of incoherence of gauges
 bit3 : Signal on gauges don’t vary
 bit4 : Default of temperature of gauges
 bit5 : Default of power suply of gauges
Function mode of LMI
 0=Init
 1=Pre-operational
LMI Mode
 2=Operational
 3=Stop
 4=Failure
Load Load on rear axle in kg
LMR Load Moment Rate de 0 (Load = maxi) at 100% (charge ≤ alarm = 1750kg)
Status of LMI display :
 bit0 : Pre-alarm active
 bit1 : Alarm active
LMI Status  bit2 : Default of incoherence of gauges
 bit3 : Default « Master Present » (no response from display at the demands of
presence)
 bit4 : the bit of verification hasn’t been inverted in the CAN emissor link
ECU
Exec time Sys:10ms Execution time of the fast task system at 10ms (in µseconds)
Exec time Sys:20ms Execution time of the slow task system at 20ms (in µseconds)
Exec time Sys:40ms Execution time of the task of management of the console at 40ms (in µseconds)
Exec time Fr2:40ms Number max of requests EEPROM in the stack (must be < 32, if not some requests
are lost
Last J1939 Failure Current number of requests EEPROM in the stack
Max EEPROM stack Status current of the EEPROM
-2: Incorrect speed of transfer
-1: Error
0: EEPROM ready
1: EEPROM busy
2: bus SPI busy
3: Incomplete writing
4: Error on the level of the power supply
Current EEPROM stack Quantity of times where the stack was full
(must be = 0, if not the requests have been lost)
Cur. EEPROM status Quantity of times where an error of access to the EEPROM occurred (statuts < 0)
EEPROM stack error Quantity of times where thestack is full ( must be à 0) otherwise some requests will
be lost
EEPROM status error Current number of requests EEPROM in the stack
Shutdown Timeout Time-out of stopping of the module (in µseconds)

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 MENU INPUTS/OUTPUTS
Parameter Description
5.1 DIGITAL INPUTS
SPU 1 RP160IVS Pedal IVS signal Signal IVS of the pedals
2 SB685 Park brake sw Button Parking brake
3 B142 Pre-alarm LMI Pre-alarm on moment (LMI)
4 B130 LMI alarm Alarm on moment (LMI)
5 SA187T Winch sw mode Winch Mode selection
6 SA620 Transfer drive sw Comodo reverse drive
7 SA600 Forward drive sw Comodo forward drive
8 SA140 Security shunt Shunt Reach limitation
9 SA100 Startup key Key start-up cabin
10 SA161D Sayable DPF rege Toggle switch of inhibition of the regeneration of the
DPF
11 SA161F Force DPF regen Toggle switch of activation of the manual
regeneration (forced) of the DPF
12 SA680 High speed drive sw Comodo high speed drive
13 DPLUS Engine running Engine running (D+)
B2 1 SA681S Synchro steering sw Selection Synchro Mode
2 SA681C Crab steering sw Selection Crab Mode
3 B120 Float/Hydrau lock sw Button Joystick floating lifting/Hydraulic Locking
4 SP690 Brake failure Default service brake
5 B118 Out Joy of neutral Off neutral Joystick
6 SA782D Frame level right sw button cabin levelling towards right
7 SA782G Frame level left sw button cabin levelling towards left
8 SA781M Right stab up sw Button stab right side up
9 SA780M Left stap up sw button stab left side up
10 SAD81D Right stab down sw Button descent stab right
11 SA780D Left stab down sw button descent left stab
12 SQ721 Right stab low Right stabilizer low
13 SQ720 Left stab low Left stabilizer low
14 SQ682 frontaxle not centered. Centered front axle
15 SQ683 Rear axle not centered. Centered rear axle
16 B124 Bucket dead man “enable” button joystick for the movements of
excavation/discharge ( Australia)
17 SQ360 Telescope in Telescope Retracted
18 SA692 Road sw mode Selection road mode
19 SQ141 Seat sensor Seat detection
20 B111 Radio OK Radiocontrol OK
21 B104 Radio operator Auxiliary Radio operator Direction A
Accessories A
22 B105 Accessories B radio Auxiliary Radio operator Direction B
operator
23 B102 Bucket radio up Radio operator excavation
24 B103 Bucket radio down Radio operator discharge
25 B129 Startup radio sw Toggle switch of Radio operator start-up
B813 1 SQ126 Oil filter sealed Clogged hydraulic oil filter
2 SP691 Park brake failure Default parking brake

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3 LEFTTURN Left turn Flickering left
4 RIGHTURN Right turn Flickering right
5 HIGHBEAM High beam Road lamps
6 POSLAMPS position lamps Side-lamps
7 SQ163 water in fuel Water in the gas oil (Tier III)
8 ST125 Hydraulic oil high Temperature hydraulic oil OK
9 ST160C water temp. high Overheat Water temperature on engine - TIER3
only
10 SP162 Oil press low Default pressure engine oil - TIER3 only
11 SQ 189R Fuel level low Reserve Gazoil
5.2 DIGITAL OUTPUTS
SPU 1 YV680 Crab steering Mode of steering Crab
2 YV681 Synchro steering Mode of steering Synchro
3 YV380 Float/Hydraulic Lock Floating lifting
B2 1 KA122 PWM Relay Validation Relay of validation of the proportional valves
(HTL 4014-4017 only)
2 B512 Failure radio operator Light Radio operator Default
light
3 B511 No D+ radio operator Light Default D+ Radio
light
4 B510 LMI radio operator light Light Alarms LMI Radio
5 KA161 KeySwitch relay KeySwitch relay
6 KA620 Back light/to buzzer Relay lights/buzzer for REV drive mode
7 KA160 Startup relay Relay Start-up
8 KM160 Pre-heating engine Command Preheating
9 B506 LMI calibration Calibration LMI
10 HL780 Stabilizers light Light for validation stabs
11 HL782 Frame Level light light for validation of cabin levelling
12 HL692 Road light mode Light Road Mode
13 YV720 Left stab down Left Stab Low
14 YV721 Right stab down Right Stab Low
15 YV700 Left stab up Left Stab High
16 YV701 Right stab up Stab High Right
17 YV123 Accessories A Auxiliary validation port A
18 YV124 Accessories B Auxiliary validation port B
19 YV740 Frame Level left Left cabin levelling
20 YV760 Frame Level right Right cabin levelling
B813 1 LED01 Park brake failure Default Parking brake
2 LED02 Service brake fail. Default Service brake
3 LED03 Oil temperature high Temperature high hydraulic oil
4 LED04 Oil filter sealed Clogged oil filter
5 LED05 Float Floating lifting
6 LED06 Rear axle in line Centered rear axle
7 LED07 Speed 2 High speed
8 LED08 Drive in neutral Drive in neutral
9 LED09 Position lamps Side-light
10 LED10 Left/right turn Flashings left/right
11 LED11 High Beam Main-beam headlamp
12 LED12 Seat empty Seat empty

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13 LED13 Wait to start Wait to start (preheating)
14 LED14 DPF Regeneration of the particle filter necessary
15 LED15 DPF Regeneration of the inhibited Particle Filter
16 LED16 HEST HEST (High Exhaust System Temperature)
17 LED17 Engine warning Engine warning (driving warning)
18 LED18 Engine stop Engine stop (motor stop)
19 LED19 No D+ No D+
20 LED20 Failure Default machine
5.3 ANALOG INPUTS
SPU 1 RP160 Accelerator pedal Accelerator pedal
2 WUI Wake-up input Signal of alarm clock of the SPU (Wake-Up Input)
3 12VP 12V permanent 12V Permanent
4 12VB 12V sensors 12V of the sensors
5 12VD 12V HSD01 to 06 12V of outputs HSD01 to 06
6 12VC 12V HSD07 to 11 12V of outputs HSD07 to 11
B2 1 B401 Joy radio raising Consign Joystick Radio Raising
2 B402 Joy telescopes radio Consign Joystick Radio Telescoping
3 B403 Boom angle sensor 1 Boom Angle sensor 1
4 B404 Boom angle sensor 2 Boom Angle sensor 2
5 B300 Joy Y axis Consign Joystick Cabin Front/back boom lift
6 B301 Joy X axis Consign Joystick Cabin L/R Cavage or Telescoping
7 B302 Joy left roller Consign Roller Joystick Cabine Left Telescoping or
Excavation
8 B303 Joy right roller Consign Roller Joystick Cabine Right Auxiliaries
9 B400 5V power read Second reading power supply 5V
10 VBAT 12V power Power supply 12V
B813 1 SQ189 Fuel level gas oil level detection
2 ST160 water temperature Water temperature engine (Tier III)
5.3 ANALOG OUTPUTS
SPU 1 5VREF Refer 5V output Output of the reference 5V
B2 1 YV300 Boom up valve Boom lift electrovalve High
2 YV320 Boom down valve Boom lift electrovalve Low
3 YV340 Telescope extension Telescoping boom electrovalve Front
valve
4 YV360 Telescope retraction Telescoping boom electrovalve Back
valve
5 YV400 Bucket up valve Electrovalve Excavation
6 YV420 Bucket down valve Electrovalve Discharge
7 YV121 Accessories valve Electrovalve Auxiliaries
8 YV122 Stabs/level valve Electrovalve Outriggers or cabin levelling

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 Menu INFORMATIONS
Parameter Description Niv
6.1 VERSIONS
HTL32-35-4010 Version of the application one: <millesime>.<release>.<config 1
console diag.<id machine>
Slave Node B2 Version of the appli loaded in the node B2 slave 1
6.2 EVENT LOG
Not used
6.3 LOG DATED
Not used
6.4 DATE & HOUR
Not used
8.1.5.MOVEMENTS SETTINGS
Execution time of
Movement complete Configuration
movement
Lift up 12 1s Maximum mode without load
Lift down 10 1s Maximum mode without load
Bucket closing 5  1s Maximum mode without load
Bucket opening 5  1s Maximum mode without load
Telescope in 9-12s Maximum mode without load at 60°
Out telescopic boom 17-18s Maximum mode without load at 66°
Accessory A Fork 100% Maximum mode without load
Accessory B Fork 100% Maximum mode without load
Accessory A (up) Winch 100% Maximum mode without load
Accessory B (down) Maximum mode without load
100%
Winch
Accessory A (up) Radio 0.5 m/s Mode at idle without load
Accessory B (down)
0.3 m/s Mode at idle without load
Radio
Stabilizers up 6 1s Maximum mode without load
Stabilizers down 7 1s Maximum mode without load
Maximum mode without load telescopic boom slightly
Stabilizers limit 9-12s
out
Frame level left 13 2s Maximum mode without load
Frame level right 13 2s Maximum mode without load
Frame level limit 20s 3s Maximum mode without load telescopes slightly out
9. SCHEMATICS
This chapter gathers all electric/hydraulic schematics of the different versions of HTL models

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STANDARD VERSION
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HTL equipped with LMI 259 (CAN type)

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htl4010 Training Manual

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TECHNICAL TRAINING

Chapter 1: Main features and functions

Chapter 2: Study of the electrical shematics

TRAINING MANUAL DIAGNOSTIC Level 2 HTL 10M Range

Revision Edition Subject Created Validated Modified Translated Language

TRAINING MANUAL DIAGNOSTIC Level 2 HTL 10M Range

TRAINING MANUAL DIAGNOSTIC Level 2 HTL 10M Range

TRAINING MANUAL DIAGNOSTIC Level 2 HTL 10M Range

TRAINING MANUAL DIAGNOSTIC Level 2 HTL 10M Range

HTL3210 WHEELS 405-70R 20

HTL 3510-4010 WHEELS 405-70R 24

TRAINING MANUAL DIAGNOSTIC Level 2 HTL 10M Range

HTL3510 cabin levelling

HTL 3210 2 valves on hydraulic driving motor

TRAINING MANUAL DIAGNOSTIC Level 2 HTL 10M Range

Rear axle with 4 satellites pinion cages

TRAINING MANUAL DIAGNOSTIC Level 2 HTL 10M Range

TRAINING MANUAL DIAGNOSTIC Level 2 HTL 10M Range

TRAINING MANUAL DIAGNOSTIC Level 2 HTL 10M Range

TRAINING MANUAL DIAGNOSTIC Level 2 HTL 10M Range

TRAINING MANUAL DIAGNOSTIC Level 2 HTL 10M Range

TRAINING MANUAL DIAGNOSTIC Level 2 HTL 10M Range

TRAINING MANUAL DIAGNOSTIC Level 2 HTL 10M Range

TRAINING MANUAL DIAGNOSTIC Level 2 HTL 10M Range

TRAINING MANUAL DIAGNOSTIC Level 2 HTL 10M Range

TRAINING MANUAL DIAGNOSTIC Level 2 HTL 10M Range

The movements of the machine are separated in two main functions:

1.4.1.SYNOPTIC FOR DRIVE

drive pedal Comodo for drive selection + module Node B2

module U600 located on drive pump

drive pump hydraulic motor

rear axle cardan shaft hydraulic link

TRAINING MANUAL DIAGNOSTIC Level 2 HTL 10M Range

module ECU node B2

Equipment gear pump

flow proportionnal ON/OFF

Accessoiries (forks –buckets, winch, truss jib …)

TRAINING MANUAL DIAGNOSTIC Level 2 HTL 10M Range

TRAINING MANUAL DIAGNOSTIC Level 2 HTL 10M Range

EX1 : Maxi speed, Pressure Min

TRAINING MANUAL DIAGNOSTIC Level 2 HTL 10M Range

TRAINING MANUAL DIAGNOSTIC Level 2 HTL 10M Range

TRAINING MANUAL DIAGNOSTIC Level 2 HTL 10M Range

Battery with one element

Fuse circuit breaker

Coil with dual roll

Emergency push-button “mushroom-

TRAINING MANUAL DIAGNOSTIC Level 2 HTL 10M Range

Key selector with 3 positions (T turret,

Switch with 2 positions

Proportional valve PWM type (Pulse

TRAINING MANUAL DIAGNOSTIC Level 2 HTL 10M Range

Angle sensor (reach limitation)

angle sensor ( mercury type)

Resistor (here value 100 ohms, 3

TRAINING MANUAL DIAGNOSTIC Level 2 HTL 10M Range

Pressure sensor (weighing)

Angle sensor (weighing)

Standard light “Led”

Flexible Blade switch (ILS) detection

Level detector (diesel tank)

Proximity detector with pulses

Thermal sensor of engine temperature