Entrenamiento Tecnico Diagnostico Nivel 2 PDF

TECHNICAL TRAINING
DIAGNOSTIC LEVEL II
HA120PX
How to use this document?
MAINTENANCE AND REPAIR OPERATIONS ON YOUR HAULOTTE MACHINE
MUST BE DONE ONLY BY TRAINED ,EXPERIENCED AND AUTHORIZED TECHNICIANS
You have between the hands the summary given during the HAULOTTE technical training
It will enable you to find information necessary for the maintenance and the repair of your
HAULOTTE machine .
Thanks to the guide below you will reach the required chapter quickly.
Chapter 1: Main features and functions

It is a resume of the information contained in the user manual delivered with the machine:
components, overall dimensions, working zones, commands, etc…
Chapter 2: Study of the electrical diagram

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 (tilt , limit switches, sensors,transducers…)
- Logical equations of operation: by function, to diagnose the main dysfunctions
Chapter 3: Study of the hydraulic diagram

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 to the good maintenance
of the material. You will find as well the methods of adjustment with table values.
Chapter 5: Guide of breakdown

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

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

This chapter gathers all the functions and adjustment specific to carry out on the machine. There
does not exist for all the materials and depends on the studied model.
It must be the subject of a special attention because an intervention badly carried out can deteriorate
the good performance of the machine and thus consequently the safety of the users.
On this chapter, some special adjustment ( sensors) are also explained prior to calibration (depends
on the model)
Only a technician HAULOTTE or approved by HAULOTTE Services is able to carry out this kind of
intervention.
Chapter 8: List of Schematics

In that chapter, all schematics in A3 size are listed (electric/hydraulic) and if required some extras lay
out
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TRAINING MANUAL DIAGNOSTIC Level 2 HA120PX
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REVISION
Revision Edition Subject Created Validated Modified Translated Language

by by by by
00 03-11 Creation MGD FLH MGD FR/EN
01 03-12 Add accelerator MGD MGD FR/EN
Lombardini adj
02 07-13 Updated MGD EN
schematics
03 02-14 Add chapter MGD EN
schematics
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SUMMARY
1. MAIN FEATURES AND FUNCTIONS .................................................................................................................... 6
1.1. CHARACTERISTICS ................................................................................................................................................. 6
1.1.1. main components .......................................................................................................................................... 6
1.2. OVERALL DIMENSIONS ........................................................................................................................................... 7
1.2.1. working zones ............................................................................................................................................... 8
1.2.2. Features ........................................................................................................................................................ 9
1.3. COMMANDS (UP AND DOWN) ...................................................................................................................... 10
2. THE ELECTRICAL PART ...................................................................................................................................... 14
2.1. SYMBOLS USED .................................................................................................................................................... 14
2.2. METHODOLOGY OF CONTROL............................................................................................................................... 18
2.2.1. electric continuity control........................................................................................................................... 18
2.2.2. Control of an on/off valve ........................................................................................................................... 18
2.2.3. Control of components ............................................................................................................................... 19
2.3. THE WIRING SCHEMATICS .................................................................................................................................... 22
2.4. CONNECTIONS ...................................................................................................................................................... 22
2.5. THE MAIN PRINTED CIRCUIT (LOWER CONTROL BOX)........................................................................... 24
2.6. LOOMS ................................................................................................................................................................. 24
2.7. LOCALIZATION OF MAIN COMPONENTS ................................................................................................................ 24
2.8. LIST OF COMPONENTS .......................................................................................................................................... 28
2.8.1. engine ......................................................................................................................................................... 28
2.8.2. Fuses........................................................................................................................................................... 29
2.8.3. inputs .......................................................................................................................................................... 29
2.8.4. Outputs ....................................................................................................................................................... 31
2.9. LOGICAL EQUATIONS OF OPERATION.................................................................................................................... 34
2.9.1. engine ......................................................................................................................................................... 34
2.9.2. Drive ........................................................................................................................................................... 35
2.9.3. Steering ....................................................................................................................................................... 36
2.9.4. boom ........................................................................................................................................................... 37
2.9.5. Telescoping ................................................................................................................................................. 37
2.9.6. arm ............................................................................................................................................................. 38
2.9.7. Turret slewing ............................................................................................................................................. 38
2.9.8. jib ................................................................................................................................................................ 39
2.9.9. Compensation ............................................................................................................................................. 39
2.9.10. basket rotation ............................................................................................................................................ 40
3. THE HYDRAULIC PART ........................................................................................................................................ 41
3.1. SYMBOLS USED .................................................................................................................................................... 41
3.2. THE HYDRAULIC SCHEMATICS .............................................................................................................................. 45
3.3. MAIN MANIFOLD................................................................................................................................................... 45
3.3.1. hydraulic blocks.......................................................................................................................................... 45
3.3.2. drive block .................................................................................................................................................. 46
3.3.3. block for movements ................................................................................................................................... 49
3.4. LOOMS ................................................................................................................................................................. 52
4. ADJUSTMENTS ........................................................................................................................................................ 52
4.1. ADJUSTMENTS WITH OPTIMIZER CONSOLE........................................................................................................... 52
4.2. PARAMETER SETTINGS ......................................................................................................................................... 56
4.3. ALARMS CODES .................................................................................................................................................... 57
4.4. ADJUSTMENT OF THE PRESSURES ......................................................................................................................... 59
4.4.1. Table of pressures....................................................................................................................................... 59
4.4.2. Plug socket of the pressures ....................................................................................................................... 59
4.4.3. Adjustment .................................................................................................................................................. 60
5. BREAKDOWN SERVICE GUIDE .......................................................................................................................... 61
5.1. NO START ............................................................................................................................................................. 61
5.2. NO MOVEMENT ..................................................................................................................................................... 61
5.3. NO ARM ................................................................................................................................................................ 61
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5.4. NO BOOM .............................................................................................................................................................. 62
5.5. NO TELESCOPIC BOOM EXTENSION ....................................................................................................................... 62
5.6. NO TURRET ROTATION .......................................................................................................................................... 62
5.7. NO JIB ................................................................................................................................................................... 62
5.8. NO COMPENSATION .............................................................................................................................................. 62
5.9. NO CAGE ROTATION.............................................................................................................................................. 62
5.10. NO DRIVE ............................................................................................................................................................. 62
5.11. ONLY LOW SPEED ................................................................................................................................................. 63
5.12. NO STEERING ........................................................................................................................................................ 63
6. SUMMARY OF VERSIONS .................................................................................................................................... 64

7. SPECIAL FUNCTIONS ............................................................................................................................................ 65
7.1. OVERLOAD ADJUSTMENT ..................................................................................................................................... 65
7.2. ACCELERATOR COIL ADJUSTEMENT ...................................................................................................................... 67
8. LIST OF SCHEMATICS .......................................................................................................................................... 68
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1. MAIN FEATURES AND FUNCTIONS
1.1. CHARACTERISTICS
1.1.1. MAIN COMPONENTS
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1.2. OVERALL DIMENSIONS
5500
2270
260
1640
1900
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1.2.1. WORKING ZONES
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1.2.2. FEATURES
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1.3. COMMANDS (UP AND DOWN)
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2. THE ELECTRICAL PART
2.1. SYMBOLS USED
Battery with one element
Alternator
Fuse (Here 10 amps)
Coil winding roll
Electric motor
light
Diode
Hourmeter
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Standard push-button of safety “mushroom-headed
button”
Rotary knob
Push-button
Limit switch
Pressure switch
Key selector with 3 positions

(T turret, O neutral, N platform)
Toggle switch with 2 positions
Electrovalve
relay
horn
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Proportional valve
Proportional valve PWM type ( Pulse Width Modulation)
Controller/joysticks
Foot pedal switch
buzzer
“light”
Electrovalve “ON/OFF » ( bang-bang)
Tilt sensor ( ramp detection)
Angle sensor (reach limitation)
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Contact « mercury » (angle detection)
Resistor (here value 100 ohms, 3 Watts, tolerance of 5%)
Sensor length (reach limitation)
Pressure sensor (weighing)
Angle sensor (weighing)
Standard light “Led”
Strain gauge
Flexible blade switch (ILS) detection of the magnets on

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

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

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

Note: These tests are to be carried out when power is ON .
Also control the state of the terminals or any other connectors (oxidation…)
Control supply of the coil
Disconnect the plug socket of supply of the valve in order to connect in derivation the multimeter on
the terminals of the connector (see below).
Select the position to voltmeter (V), then activate the command to the valve which must be tested.
The voltage indicated by the voltmeter must be close to the tension of battery
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Control intensity of the coil
Disconnect the plug socket of supply of the valve in order to connect in series the multimeter on the
terminals of the connector (example below).
Select the position Ammeter (A), and then activate the command to the valve which must be tested.
The intensity indicated by the voltmeter must be of approximately 2A (to be checked according to the
data manufacturer)
Control resistance of the coil

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

Disconnect the relay,then locate its various terminals.
Control the resistor of the solenoid terminals 85 and 86 (see manufacturer datas) using
a multimeter in Ohmmètre position.
If the resistor is null, change the relay.
If this test is OK, check continuity between terminals 30 and 87a and insulation between
terminals 30 and 87
In the event of dysfunction, replace the relay.
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• supply control of the relay
Locate the relay without disconnecting it and locating it its various terminals.
Control the continuity of terminal 86 with the ground
.(In the event of defect of continuity, check the concerned loom)
Connect the multimeter in position Voltmeter (V) between terminal 30 and the ground and
thus control the power supply of the component (It must be close to the battery voltage Vbat)
Select the function of this relay and check the output voltage between terminal 87 and
ground.
In the event of dysfunction, replace the relay
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• Control of a fuse
Color code
Fuse check
Multimeter in Ω position, it must indicate a value near 0
NOK
OK
• Control of a diode
Locate the diode and disconnect it from the loom.
Control must be done with a multimeter in “diode” position.
Connect the multimeter on each terminal of the diode, in one direction then on the other.
In one direction, the diode should have no continuity,
in the other it must beep
If the diode is beeping in both ways , replace it
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2.3. THE WIRING SCHEMATICS
See at the end of this manual
2.4. CONNECTIONS
LOW CONTROL BOX (S020907)
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UPPER CONTROL BOX (S020902)
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2.5. THE MAIN PRINTED CIRCUIT (LOWER CONTROL BOX)
2.6. LOOMS
for all details refer to part book
2.7. LOCALIZATION OF MAIN COMPONENTS
SQ2
SQ5 SQ3
SQ6
SQ20
SQ21
YV8
SB6 YV10
YV11
YV12
YV14
YV17
YV19
YV20
YV23
SQ4 YV40
YV41
YV42
BT2
SQ1
B1
B2
B3
SQ1 Slope sensor YV1

SQ2 Jib YV2
SQ3 Boom position YV9
SQ4 Arm position YV13
SQ5 Overload YV21
SQ6 Overload YV22
YV24
SQ20 Basket rotation left side
YV25
SQ21 basket rotation right side
YV30
B4
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SQ20
SQ21
SQ5
SQ6
SQ2
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SQ3
SQ4
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SQ1
SB6
G1
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2.8. LIST OF COMPONENTS
In the following tables

The column n°2 gives the coordinates of the compone nts on different the sheets from the wiring
schematics in order to find their position easily.
The first figure corresponds to the number of page and to the second to the column (generally from 1
to 20) of the corresponding page
The column n°3 indicates the position on the connec tor of the printed circuit board or the module
The possible options specific to certain countries are not indexed (for more information, it is
appropriate to refer to the wiring schematic corresponding to your machine
The state noted “0” corresponds to 0V, opened contact or not activated.
The state noted “1” corresponds to the tension of the circuit, closed or activated contact.
2.8.1. ENGINE
ENGINE ELEMENTS
M1 02 - 2 Starter
G2 02 - 8 Alternator
YA2 02 - 16 Accelerator
YA1 02.-18 Stop engine valve coil
K1 02.-13 Relay preheating
H 02 - 19 Hour recorder (242)
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2.8.2. FUSES
FUSES
FU1 02 - 18 engine stop coil 10A (115)

FU3 02 - 14 Accelerator 80A (119)
FU4 03 - 3 + main 30A (120)
FU5 03 - 8 + movements turret 3A (212)
FU6 03.-11 + movements platform 3A (211)
FU7 03.-12 + valves 20A (201) + protection module if output in cc
FU8 03 - 13 + permanent 5A (242)
FU9 03 - 14 + accessories 20A (905)
FU10 03 - 15 + YV1 validation movements except drive (302)
FU11 02 - 6 + option emergency pump 250A (100)
FU13 Option cooler
2.8.3. INPUTS
INPUTS
SA 1 03 - 9 Selection of commands (upper/lower controls)
SA 2 04 - 2 28.7 Accelerator (605)
SA 3 04 - 3 29.11 Differential lock (807)
SA 4 04 - 5 Basket rotation (upper control box)
30.3 SA4a left (3100)
30.4 SA4b right (3110)
SA 5 04 - 6 Basket compensation (upper control box)
30.5 SA5a lift (401)
30.6 SA5b descent (402)
SA 6 04 - 9 Jib (lower control box)
4.9 SA6a lift (405)
SA 7 04 - 10 Jib (upper control box)
30.9 SA7b lift (410)
30.8 SA7a descent (409)
SA 8 04 - 12 Telescope (lower control box)
4.15 SA8a retraction (411)
4.14 SA8b extension (412)
SA9 04 - 13 Telescope (upper control box)
30.10 SA9a Retraction (418)
30.11 SA9b extension (419)
SA 11 04 - 15 Selection drive speed
29.10 Low speed: 805=1 and 804=0
29.9 Medium speed: 805=0 and 804=0
High speed: 805=0 and 804=1
SA 13 06 - 17 Boom lift (lower control box)
28.1 SA13a lift (504)
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SA14 06 - 15 Arm lift (lower control box)
28.3 SA14a lift (510)
28.6 SA14b Descent (511)
SA 15 06 - 14 Orientation (lower control box)
28.4 SA15a Right (516)
28.9 SA15b left (517)
SA17 03 - 7 Basket compensation (lower control box)
30.5 SA17a lift (401)
SA19 03 - 8 Option emergency pump upper control box (620)
SA20 03 - 11 Option emergency pump lower control box (620)
SB 1 03 - 10 Emergency stop turret (102)

SB 2 03 - 10 Emergency stop basket (215)
SB 3 04 - 16 4.12 Engine start lower control box (117a)
SB 4 04 - 17 3.2 Engine star upper control box (117b)
SB 5 04 - 19 29.12 Buzzer (901)
SB 6 03 - 19 Dead man's pedals (917)
SM 4 06 - 10 Joystick for drive
29.6 SM4d right steering (705)
29.5 SM4g left steering (703)
29.2 Off neutral SM4ab (606)
29.4 Y signal drive (612)
FWD from 2.5 to 4.5 V
REV from 2.5 to 0.5 V
SM 31 05 - 3 Joystick for orientation and boom lift
30.12 SM off neutral 31ab (420a)
29.1 X signal orientation (512)
Signal from 0.5 to 2.5 and 2.5 with 4,5V
30.7 Y signal boom lifting (403)
Raise from 2.5 to 4,5V
Descent from 2.5 to 0,5V
SM 2 05 - 6 Joystick arm
30.13 SM off neutral 2ab (420b)
30.15 Y signal (506)
Output from 2.5 to 4,5V/retraction from 2.5 to 0.5V
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SENSORS
SQ1
05 - 4 39.3 Tilt sensor (205 = 0 if in slope)
SQ2
05 - 5 3.3 jib (206 = 0 if jib > 0°)
SQ3
05 - 6 41.2 Boom (207 = 0 if boom unfolded)
SQ4 05 - 7 42.2 Arm (232=0 if arm unfolded)
SQ5
05 - 2 30.2 Overload (214a)
SQ6
05 - 2 30.2 Overload (214)
SQ20
04 - 4 30.4 basket rotation to right (311)
SQ21
04 - 5 30.3 Basket rotation to left (310)
B1
05 - 19 27.2 Air filter clogging (110 = GND if clogged filter)
B2
05 - 18 27.3 Temperature oil engine (111=GND if Temp > 85°C)
B3
05 - 18 27.4 Pressure oil engine (112 = GND if P> 0.5 bars)
B4
05 - 17 40 .2 Temperature hydraulic oil (904 = 0 if T >80°C)
D+
05 - 20 27.1 Alternator (109 = 12V mini if alternator is powered)
W
05 - 20 27.7 Frequency (108)
MODULES
U1
Head node A
2.8.4. OUTPUTS
RELAYS
KP1
05 - 18 Engine start/stop (150)
KT2
05 - 19 Accelerator (605a)
KA2
05 - 20 Starter (146)
KA43
02 - 10 Relay alternator (109)
KMG
03 - 9 Main relay (241)
KM4
03 - 8 Relay option emergency pump (622)
KAK
05 - 9 18 Relay for horn (401a)
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VALVES
YV 1 05 - 12 20 Validation movements except drive (303)

YV2 06 - 17 12.1 Safety valve for movements (415)
YV8 06 - 8 8.11 Arm lift (813)
YV9 04 - 16 15.4 Medium speed drive(807a)

YV10 06 - 14 8.9 telescopic extension (814b)
YV11 03 - 15 8.6 telescopic retraction (814c)
YV12 06 - 8 8.12 Arm descent (814a)
YV13 04 - 17 15.9 High speed drive (807b)
Turret slewing
YV14 04 - 2 31 YV14a Right (417a)
21 YV14b left (414a)
YV17 03 - 14 8.3 Boom lift (309)
YV19a 04 - 13 35 basket rotation right (310a)
YV19b 04 - 14 34 basket rotation left (311a)
YV20 04 - 4 9 jib descent (921a)
YV21a 05 - 5 15.8 REV Drive (307)
YV21b 05 - 6 15.7 FWD Drive (308)
YV22a 05 - 7 15.3 Left steering front axle (304)
YV22b 05 - 8 15.6 right steering front axle (306)
YV23 06 - 12 8.10 boom descent (818)
YV24 05 - 2 11 Differential lock (399)
YV25 06 - 6 13 Validation drive and brake release (903a)
YV30 04 - 18 53 High speed drive(262)
YV40 04 - 3 54 jib raise (263)
YV41 04 - 7 52.2 basket compensation raise (260)
YV42 04 - 8 52.3 basket compensation down (261)
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BUZZER AND SOUNDS
HA1
05 - 13 Buzzer (120b)
HA2
06 - 4 28.15 overload upper control box (914)
HA4
05 - 15 14 Buzzer lower control box (210)
HL1
02 - 9 Light charge on alternator (109)
HL2
05 - 17 4.3 Light air filter clogging (110a)
HL3
05 - 17 4.2 Oil engine temperature (111a)
HL4
05 - 16 4.1 Oil engine pressure (112a)
HL5
03 - 14 Beacon (906) Option
HL6
03 - 16 Work headlight (905) Option
HL7
03 - 17 Light powering (211)
HL9
06 - 3 49.2 Light defect upper control box (253)
HL13
06 - 4 28.15 Light overload upper control box (914)
HL20
02.-10 Indicator of preheating lower control box (121)
HL21
02 11 Indicator of preheating upper control box (121)
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2.9. LOGICAL EQUATIONS OF OPERATION
For all these conditions, the fuses will have to be checked as a preliminary
The condition of the equations of operation described below refers to the standard EN280, machines
known as Standard (for other standards USA , CDN, AUS)
revert to HAULOTTE SERVICES of your sector which will indicate the characteristics of your
machine
2.9.1. ENGINE
CONDITIONS
Function Action Modifying
Prohibiting the
Necessary the
function
function
engine already started
SA1 (side T or N) + SB3=1
Start KA2=1 Movement in progress
or SB4=1 and D+= 1
Emergency stops SB1 (lower control box) and SB2 (upper control box) are supposed = 1 (not
inserted)
CONDITIONS
Prohibiting the
Necessary the
function
function
Defect engine + 6
seconds:
D+=0 and B3=GND
Engine KP1=1 KA2=1 then 0 Clogged filter:
power supply + YA1=1 W=1 B1=GND
T° oil enginer
B2=GND
CONDITIONS
Prohibiting the
Necessary the
function
function
KT2=1 SA1 (side N or T) + SB6=1
Accelerator
+ YA2=1 or SA2=1
The accelerator is time-lag during 0.5 second when released.
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2.9.2. DRIVE
CONDITIONS
Prohibiting the
Necessary the
function
function
SA1 (side N) + SA11a = 1 SQ5=0 and SQ6=0
YV25=1 and SA11b = 0 and (Overload)
Low speed
+ SM4ab=1 and SB6 = 1 and
forward
YV21a=1 SM4 between
2,5V and 4,5V
SA1 (side N) + SA11a = 1 SQ5=0 and SQ6=0

YV25=1 and SA11b = 0 and (Overload)
Low speed
+ SM4ab=1 and SB6 = 1 and
reverse
YV21b=1 SM4 between
2,5V and 0,5V
CONDITIONS
Prohibiting the
Necessary the
function
function
SQ2=0 or SQ3=0 or
SA1 (side N) + SA11a = 0 SQ4=0
YV25=1 (unfolded machine)
and SA11b = 0 and
Medium speed + YV21a=1
SM4ab=1 and SB6 = 1 and
forward + YV9=1
SM4 between SQ5=0 and SQ6=0
2,5V and 4,5V (Overload)
SQ2=0 or SQ3=0 or
SA1 (side N) + SA11a = 0 SQ4=0
YV25=1
and SA11b = 0 and (unfolded machine)
Medium speed + YV21b=1
reverse + YV9=1
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CONDITIONS
Prohibiting the
Necessary the
function
function
SQ2=0 or SQ3=0 or
SQ4=0
SA1 (side N) + SA11a = 0
+ YV21a=1
and SA11b = 1 and
High speed + YV9=1
forward + YV13=1
+ YV30=1
SQ2=0 or SQ3=0 or
SQ4=0
SA1 (side N) + SA11a = 0
+ YV21b=1
and SA11b = 1 and
High speed + YV9=1
reverse + YV13=1
+ YV30=1
CONDITIONS
Prohibiting the
Necessary the
function
function
Selection medium
speed
SA1 (side N) + SA3=1 + Selection high
Differential lock YV24=1
SA11a = 1 and SB6 = 1 speed
2.9.3. STEERING
CONDITIONS
Prohibiting the
Necessary the
function
function
SA1 (side N) + SB6=1 +

Steering YV22a=1 SQ5=0 and SQ6=0
SM4 g=1 or SM4 d=1
front axle or YV22b=1 (Overload)
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2.9.4. BOOM
CONDITIONS
Prohibiting the
Necessary the
function
function
SQ1=0
YV1=1
Raise + YV2=1
SM1ab=1 and SM31y SQ5=0 and SQ6=0
upper control box +
between 2,5V and 4,5V (Overload)
YV17=1
YV1=1+
Descent YV2 =1+ SQ5=0 and SQ6=0
SM1ab=1 and SM31y
upper control box + (Overload)
between 2,5V and 0,5V
YV23=1
CONDITIONS
Prohibiting the
Necessary the
function
function
YV1=1 SQ1=0
Raise
+ YV2=1 SA1 (side T) + SA13a=1
lower control box SQ5=0 and SQ6=0
+ YV17=1
(Overload)
YV1=1
Descent
+ YV2=1 SA1 (side T) + SA13b=1
lower control box
+ YV23=1
2.9.5. TELESCOPING
CONDITIONS
Prohibiting the
Necessary the
function
function
YV1=1 SQ1=0
extension SA1 (side N) + SB6=1
+ YV2=1 SQ5=0 and SQ6=0
upper control box and SA9b=1
+ YV10=1 (Overload)
YV1=1
Retraction SA1 (side N) + SB6=1 SQ5=0 and SQ6=0
+ YV2=1
upper control box and SA9a=1 (Overload)
+ YV11=1
SQ1=0
YV1=1
extension
lower control box SQ5=0 and SQ6=0
+ YV10=1
(Overload)
YV1=1
Retraction
lower control box
+ YV11=1
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2.9.6. ARM
CONDITIONS
Prohibiting the
Necessary the
function
function
SQ1=0
YV1=1 SA1 (side N) + SB6=1 +
Raise
+ YV2=1 SM2ab=1 and SM2y SQ5=0 and SQ6=0
upper control box
+ YV8=1 between 2,5V and 4,5V (Overload)
YV1=1
Descent + YV2=1 SQ5=0 and SQ6=0
SM2ab=1 and SM2y
upper control box + (Overload)
between 2,5V and 0,5V
YV12=1
CONDITIONS
Prohibiting the
Necessary the
function
function
Slowed
down
YV1=1 movement
Raise
+ YV2=1 SA1 (side T) + SA14a=1 SQ1=0 if SQ5=0
lower control box
+YV8=1 and SQ6=0
(Static
Overload)
YV1=1
Descent
lower control box
+ YV12=1
2.9.7. TURRET SLEWING
CONDITIONS
Prohibiting the
Necessary the
function
function
YV1=1 SA1 (side N) + SB6=1 and

Orientation SQ5=0 and
+ YV2=1 SM31ab=1 and SM31y
upper SQ6=0
+YV14a=1 between 2,5V and 4,5V or
control box (Overload)
or YV14b=1 2,5V and 0,5V
Slowed
down
YV1=1
Orientation movement
+ YV2=1 SA1 (side T) + SA15a=1 or
lower if SQ5=0
+YV14a=1 SA15b=1
control box and SQ6=0
or YV14b=1
(Static
Overload)
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2.9.8. JIB
CONDITIONS
Prohibiting the
Necessary the
function
function
SQ1=0
YV1=1
Raise SA1 (side N) + SB6=1
+ YV2=1 SQ5=0 and
upper control box and SA7b=1
+ YV40=1 SQ6=0
(Overload)
YV1=1 SQ5=0 and
Descent SA1 (side N) + SB6=1
+ YV2=1 SQ6=0
upper control box and SA7a=1
+ YV20=1 (Overload)
SQ1=0
YV1=1
Raise SQ5=0 and
lower control box SQ6=0
+ YV40=1
(Overload)
YV1=1
Descent
lower control box
+ YV20=1
2.9.9. COMPENSATION
CONDITIONS
Prohibiting the
Necessary the
function
function
SQ5=0 and
SQ6=0
(Overload)
YV1=1 Telescope in
Raise SA1 (side N) + SB6=1 +
+ YV2=1 progress
upper control box SA5 a=1
+ YV41=1 Orientation in
progress
Lift in progress
SQ5=0 and
SQ6=0
(Overload)
YV1=1 Telescope in
Descent SA1 (side N) + SB6=1 +
+ YV2=1 progress
upper control box SA5 b=1
+ YV42=1 Orientation in
progress
Lift in progress
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Telescope in
progress
YV1=1
Raise Orientation in
lower control box progress
+ YV41=1
Lift in progress
Telescope in
progress
YV1=1
Descent Orientation in
lower control box progress
+ YV42=1
Lift in progress
2.9.10. BASKET ROTATION
CONDITIONS
Prohibiting the
Necessary the
function
function
SQ5=0 and
YV1=1
SQ6=0
Right rotation + YV2=1 SA1 (side N) + SB6=1
(Overload)
upper control box + YV19 and SA4 a=1
a=1 SQ21=0
SQ5=0 and
YV1=1
SQ6=0
Left rotation + YV2=1 SA1 (side N) + SB6=1
(Overload)
upper control box + YV19 and SA4b=1
b=1 SQ20=0
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3. THE HYDRAULIC PART
3.1. SYMBOLS USED
Pump with variable cc flow

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

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

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

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

drive
15 cc for high speed
45 cc for low speed
Filter (normally 10 microns)
check valve
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check calibrated valve
Priority valve /shuttle valve
piloted check valve
Circuit selector switch/shuttle valve
Position hydraulic valve(used for the HA32/41PX)
Adjustable pressure relief valve

(here set at 145 bars/2104 psi)
Fixed flow restrictor or spray nozzle

(here diameter of 0.75 mm)
Adjustable flow restrictor
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Pressure sensor (used for weighing)
Adjustable pressure switch

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

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

lever
Rotary cylinder /jack (here range at 180°)
Piloted valve
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Manual valve with automatic return (used to readjust
the part of compensation on HA32/41PX)
proportional valve 4 ways/3 positions
Pressure balance/flow control valve
Flow regulator
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3.2. THE HYDRAULIC SCHEMATICS
3.3. MAIN MANIFOLD
3.3.1. HYDRAULIC BLOCKS

CYL 4
CYL 5
CYL 3
CYL 6
CYL 7
CYL 1 Steering CYL 2

CYL 2 arm
CYL 3 boom
CYL 4 Compensation emisor
CYL 5 Telescopic boom
CYL 6 Compensation receptor
CYL 7 jib
movements block (1)
drive block (2)
YV2 validation of mouvements CYL 1
YV2
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3.3.2. DRIVE BLOCK
• Front side
YV21B
YV21A
CB2
YV22A YV1
YV22B
FR1
RV1 YV24
PD1
YV30
CV2
YV13
FD3
PD5
YV9
PD2
PD4
Designation Function Characteristics

YV1 Movements validation (0 = in drive)
YV2 Safety valve (1 if movements activated, =0 in drive)
YV9 Medium speed
YV13 High speed drive
YV21A Drive REV
YV21B Drive FWD
YV22A Steering front
YV22B Steering rear
YV24 Differential lock Activated in low speed
YV25 Validation drive + brake release Proportional coil while running
0 - 1500mA standard PWM
(Pulse Wdith Modulation )
YV30 High speed drive motors in serial
PWM : Pulse Width Modulation valve (the signal is square impulse width with current regulation)
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• Back side
FR1
CB2
YV22A
YV22B
YV21B
YV21A PD2
EC1
CV1
CB1
FD1
FD2
YV25
PD1 PD3

EC1 Pressure balance/ maintain a ∆P at constant pressure on YV25
flow control valve (allows to have a constant flow especially in
ramp)
FR1 Flow regulator Limitation of flow for a better flexibility of the
movement
CB1/CB2 counterbalance valves behavior in ramp and the overspeed
preventer
FD1/FD2/FD3 Flow dividers Ensure the division of the discharge between
the axles
PD 1 with Piloted Valve These internal valves with the block
PD4 controlled by YV9 make it possible to
distribute the flow on the wheels
PD5 Piloted Valve This internal valve controlled by YV13 allows
the serialization of the motors
RV1 Pressure relief valve 100b Limit the pressure if steering + High speed
(reduction of the noise)
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3.3.3. BLOCK FOR MOVEMENTS
• 3/4 Side front
YV17
YV23 EC1
YV11
YV10
YV8
YV14B
YV40
YV12
YV19B YV14A
YV41 PR6
YV19A
CB6A
YV42
EC2
YV20
PR5

YV8 Arm lift Type PWM (0-1400mA)
YV12 arm descent Type PWM (0-1300mA)
YV17 Boom lift Type PWM (0-2000mA)
YV23 boom descent Type PWM (0-2000mA)
YV10 Telescopic extension Type PWM (0-1500mA)
YV11 telescopic retraction Type PWM (0-1500mA)
YV20 jib descent Type PWM (0-1400mA)
YV40 jib raise Type PWM (0-1400mA)
YV14A Turret slewing (right) Type PWM (0-1300mA)
YV14B Turret slewing (left) Type PWM (0-1400mA)
YV41 Basket Compensation (up) Type PWM (0-1100mA)
YV42 Basket Compensation (descent) Type PWM (0-1100mA)
YV19A Basket rotation (right) Coil ON/OFF (12V)
YV19B basket rotation (left) Coil ON/OFF (12V)
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• Front view
EC2
CV0 EC1
CV1
FR2
RV0
PR6
CB6B
CB6A

RV0 Pressure relief valve 220b Additional safety of the block
(pressure output pump 210b)
EC1 Flow control valvearm Coupled with circuit selector switch SL1
allows the stability of the movements
(no jerks)
EC2 Flow control valveboom Coupled with circuit selector switch SL2
allows the stability of the movements
(no jerks)
PR5 Flow restrictor 145b provide the necessary pressure by limiting
the input torque on motor
PR6 Flow restrictor 80b Limit pressure in the circuit if the
compensation is at full stroke (risk of
phenomenon of unexpected boom lift)
CB6A Counterbalance valves Avoid the lock of the compensation
/CB6B
FR2 Flow regulator Limit flow thus the speed of the basket
rotation
CV0/CV1 Calibrated check valve To maintain a pressure in the circuit and to
avoid cavitation
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3.4. LOOMS
For all details , refer to parts book
4. ADJUSTMENTS
4.1. ADJUSTMENTS WITH OPTIMIZER CONSOLE
The adjustments, parameter settings and lists of alarms of the machine are accessible only through
this console.
Connection bottom panel (turret)
connect the plug socket on the connector number 6:
Connector n°6 on main board
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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 : on any blue key pads , pressing on left , right or in the center have the same result
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List of menus
Access to the menu
Access code for

restrictive
parameters/calibration
Parameters setting
access
Input/output state access
Trouble shooting guide

per function
Machines status
Failures list
Access to the code for adjustment of the parameters and validation option
Scroll by key
UP/DOWN
Validation by the key: , to enter then the code
Navigation by this key to enter the code (Code following model)
Level 2 is
registered
press the key:

Back to main menu
The console is in level 2 (access to calibration menu)
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Scroll by key UP/DOWN
Speed parameters adjust
ramp parameters adjust
Options setting
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4.2. PARAMETER SETTINGS
Upper control box
Display on console Movements Time (seconds)

PF jib Up jib raise 32 sec
PF jib Down jib descent 30 sec
PF ARM Up Arm lify 30 sec
PF ARM Down arm descent 20 sec
PF Turret Left Left orientation 90 sec/1 turn
PF Turret Right Right orientation 90 sec/1 turn
PF Up Boom Boom lift 23 sec
PF Down Boom boom descent 20 sec
PF Out Telescope extension telescope 12 sec
PF Telescope In Retraction telescope 9 sec
PF Up Level compensation up 40 sec
PF Down Level Compensation down 30 sec
drive FWD Drive FWD high speed 16 sec/20m =5Km/h
drive REV REV drive high speed 16 sec/20m =5Km/h
Micro speed FWD Drive micro speed forward 50 sec/10m = 0,7Km/h
Micro speed REV Drive micro speed reverse 50 sec/10m = 0,7Km/h
ramp of deceleration in High Speed Maximum stop /1, 20m FWD
Maximum stop /1, 20m REV
Lower control box
display on console Movements Time (seconds)

T jib up Jib raise 28 sec
T jib Down Jib descent 20 sec
T ARM Up Arm lift 35 sec
T ARM Down arm descent 23 sec
T Turret Left Left orientation 90 sec /1 turn
T Turret Right Right orientation 90 sec /1 turn
T Up boom Boom lift 28 sec
T Down boom boom descent 20 sec
T Out telescope extension telescope 12 sec
T Telescope In Retraction telescope 9 sec
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4.3. ALARMS CODES
Designation Defect Actions
JY01 (1/37) Defect controller (non correct check joystick SM31
signal compared to the position of (instruction and off neutral)
off neutral)
JY02 (2/37) Defect controller (non correct Check joystick SM2
off neutral)
JY03 (3/37) Defect controller (non correct check joystick SM4
off neutral)
AL01 (4/37) FU5 or FU6 = 0 change fuses
AL02 (5/37) FU7 =0 change fuse
AL03 (6/37) FU8 = 0 change fuse
AU01 (7/37) Defect circuit of emergency stop check relay KMG
KMG
BT01 (8/37) Year in module = 2000 at powxer change Head module
ON
EP01 (9/37) Defect EEPROM Head change Head module
DM01 (10/37) Failure tilt Check slope sensor SQ1
DM02 (11/37) Failure overload check SQ5/SQ6
DM03 (12/37) Failure pedals check SB6
CC01 13/37) Output valve YV1 in short-circuit check coil YV1 if at GND or at + 12V
or open circuit
CC02 (14/37) Output valve YV2 in short-circuit check coil YV2 if at GND or at + 12V
or open circuit
or open circuit
CC04 (16/37 Output valve YV13 in short-circuit check coil YV13 if at GND or at + 12V
or open circuit
or open circuit
or open circuit
CC07 (19/37) Output YV19a valve in short- check YV19a coil if at GND or at + 12V
circuit or open circuit
CC08 (20/37) Output YV19b valve in short- check YV19b coil if at GND or at + 12V
or open circuit
or open circuit
or open circuit
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or open circuit
CC17 (29/37) Output valve YV14 has in short- check YV14a coil if at GND s or at + 12V
CC18 (30/37) Output valve YV14 B in short- check coil YV14 B if at GND or at + 12V
CC19 (31/37) Output valve YV8 in short-circuit check coil YV8 if at GND s or at + 12V
or open circuit
or open circuit
or open circuit
or open circuit
or open circuit
or open circuit
or open circuit
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4.4. ADJUSTMENT OF THE PRESSURES
4.4.1. TABLE OF PRESSURES
DESIGNATION IN BARS
General 210 +-5
Load Sensing (install a plug socket after the hydraulic filter) 22 +-2
Drive (install a plug socket after the hydraulic filter) 210 +-5
Steering 210 +-5
arm lifting 210+/-5
Boom raising 210 +-5
Telescoping 210 +-5
Turret slewing (install a plug socket to the output block OT1/OT2) 80 +-5
Compensation (install an pressure inlet to the output block C1/C02) 145 + 5
4.4.2. PLUG SOCKET OF THE PRESSURES
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4.4.3. ADJUSTMENT
• Load sensing (LS)
• Flow
• Cubic capacity pump
Pump
• The pump is preset with a pressure LS of 22b (+/-2)
• The pump is preset with a general pressure of 210b (+/-5b)
• The cubic capacity of the pump is preset in order to reach the high speed in 14
seconds for 20 meters
LS adjust screw (22b) P maxi adjust screw (210b)
CC adjust screw for High speed)

(rod out at 16mm for 21cc)
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5. BREAKDOWN SERVICE GUIDE
This guide does not replace the logical equations described previously in this manual,
it allows the technician to have a logical step of breakdown service, detailing the successive steps to
follow starting from main points until the details.
The checking of the electric part is carried out in priority because less sensitive to the external
parameters than the hydraulics part (temperature, pollution, viscosity…).
The denomination of the movements describes below implies the 2 phases (ie BOOM UP/DOWN)
5.1. NO START
• Battery (14V)
• Emergency push buttons SB1-SB2
• Start toggle switchs SB3-SB4
• Key switch SA1
• Fuse FU8
• Engine oil Temperature B2
• Engine oil pressure B3
• Air filter clogged B1
• Alternator light HL1
• Relays KA2 –KP1-KMG
• Alternator charge D+ =0
• Drive joystick SM4 ( signal and/or neutral position)
• Head module
5.2. NO MOVEMENT
• Machine in overload and/or in slope
• Fuses FU7 –FU 8-FU10
• Valves YV1/YV2 ( drive and steering OK)
• Foot dead man pedal SB6 / lower box dead man switch SA19
• Head module
• No pressure output pump
• Relief valve RV0 (220b) input of the movements block
5.3. NO ARM
• Signal on SM2 joystick (0.5/2.5/4.5VDC)
• Signal on PWM valve YV8 ( signal from 0 to 1400 mA)
• Toggle switch SA14
• Head module
• Compensated element blocked ( EC1 + LS1 )
• No pressure ( counterbalance valves )
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5.4. NO BOOM
• Signal on SM31 joystick ( 0.5/2.5/4.5VDC)
• Signal on PWM valve YV17 (signal from 0 to 1400 mA)
• Head module
• Compensated element blocked ( EC2 + LS2 )
• No pressure ( counterbalance valves)
5.5. NO TELESCOPIC BOOM EXTENSION

• Toggle switch SA8/SA9
• Head module
5.6. NO TURRET ROTATION

• Valve YV14
• Signal on SM31 (0.5/2.5/4.5VDC)
• Head module
• No pressure (pressure restrictor PR5)
5.7. NO JIB
• toggles switch (SA6/SA7)
• Head module
5.8. NO COMPENSATION
• Toggles switch SA5/SA17
• Head module
• No pressure (pressure restrictor PR6 set à 145b)
5.9. NO CAGE ROTATION

• Valves YV19
• Head module
• No pressure ( flow restrictor FR2 of 3l/mn)
5.10. NO DRIVE
• Signal on joystick SM4 (0.5/2.5/4.5VDC)
• Signal on PWM valve YV25 + flow control valve EC1 ( signal from 0 to 1400mA)
• Valve YV21
• Brake circuit
• Head module
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5.11. ONLY LOW SPEED
• Limit switch SQ2/SQ3/SQ4
• Valves YV9/YV13/YV30
• Head module
• Piloted valves PD1 to PD5
5.12. NO STEERING
• Valves YV22
• Rocker joystick SM4
• Head module
• Flow restrictor FR1 at 4.5l/mn
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6. SUMMARY OF VERSIONS
electrical Hydraulic
Former HA12PX
schematics schematics
upper panel with touch pad keys and pre version
EC+ AUS E545 B16365
EN280 (up to 11/2001)
Upper panel with touch pads keys and version EN
EC+ AUS E545a P20891
280 (from the 05/2003)
upper panel with touch pads keys and basket EC+ AUS
E545c P20891
rotation equipped with SQ20/SQ21 (from 03/2004)
Pre version 280 = Detection overload (threshold of alarm then cut-off movements)
Version IN 280 = detection overload with cut-off movements
HA12DX (previous version < 2000)
Machine equipped card with relays+ cresto module with
valve management and joystick Telemecanique with bowl EC+AUS E400 B15051
and yellow dead man)
Version bi-energy (HA12DE) equipped card with relays+
cresto module with valve management and joystick EC E400 B15090
Telemecanique with bowl and yellow dead man)
Machine equipped card with relays+ with relays+ cresto
EC+
module with valve management and joystick rocker in E493 B15826
AUS
rubber (ITT)
Version bi-energy (HA12DE) equipped card with relays+
+ cresto module with valve management and joystick E493 B15090
rocker in rubber (ITT)
Version HA12D (not 4WD) EC E493 B15089
Current HA120PX
upper panel with multiple movements
EC+AUS 134P296170 134P298150
(from 06/2008)
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7. SPECIAL FUNCTIONS
7.1. OVERLOAD ADJUSTMENT
Procedure :
Adjust the wheels
• Centre the basket with the link part
• Push on the left the 2 plastics wheels
• Tighten 2 screws HM12 on left side
• Put a steel wedge (thickness = 0.1 mm) on the right (between plastics wheels and steel
parts - see photo)
• Push the right part with the 2 screws HM8, and tighten them
• Tighten 2 screws HM12 on the right
• Take out the steel wedge
• the plastics wheels shoud turn freely only by hand
Overload
• Put the a weight in the centre of the basket (weight = 120% x nominal weigh).
• You stop unscrew the part "A" when you hear the buzzer
• The plastic wheel and the screw must be in the same axis
• Check the opening of the contact between 1 & 2
• Lift and lower the weight to check the adjust
• Check the light on the console, the buzzer on, and you can't have movements.
• Block the part "A" with the nut
• Repeat the same operation for the second limit switch
A 2
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• Adjust electrical contactor for the basket rotation
• Put a wedge (thickness = 5 mm) on the mechanic stop of basket rotation
• Turn the basket to put it on this wedge
• Check the light on the console, the buzzer on, and you can't have movements.
• Block the part "A" with the nut
• Repeat operation for the second limit switch
Adjust electrical contactor for the basket rotation

• Put a wedge (thickness = 5 mm) on the mechanic stop of basket rotation
• Turn the basket to put it on this wedge
• Adjust the limit switch, it must activate in this position.
• Do the same thing for the second limit switch
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7.2. ACCELERATOR COIL ADJUSTEMENT
• Procedure
Remove the rubber cover

Adjust it at 33 mm as show below
33 mm
Tight at maxi
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Check the idle/max engine rpm
Low speed adj (idle 1250rpm)
Hight speed adj

Gap 2 mm
Full rpm (2500 rpm)
8. LIST OF SCHEMATICS
See below all schermatics (electric/hydraulic) of the studied model
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LOCATION OF COMPONENTS ON MAIN PRINTED CIRCUIT
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TECHNICAL TRAINING

Chapter 1: Main features and functions

Chapter 2: Study of the electrical diagram

Chapter 3: Study of the hydraulic diagram

Chapter 5: Guide of breakdown

Chapter 6: Summary of the versions

Chapter 7: Special functions

Chapter 8: List of Schematics

Revision Edition Subject Created Validated Modified Translated Language

6. SUMMARY OF VERSIONS .................................................................................................................................... 64

8. LIST OF SCHEMATICS .......................................................................................................................................... 68

1.1.1. MAIN COMPONENTS

Battery with one element

Fuse (Here 10 amps)

Coil winding roll

Key selector with 3 positions

Toggle switch with 2 positions

Proportional valve PWM type ( Pulse Width Modulation)

Foot pedal switch

Electrovalve “ON/OFF » ( bang-bang)

Tilt sensor ( ramp detection)

Angle sensor (reach limitation)

Resistor (here value 100 ohms, 3 Watts, tolerance of 5%)

Sensor length (reach limitation)

Pressure sensor (weighing)

Angle sensor (weighing)

Standard light “Led”

Flexible blade switch (ILS) detection of the magnets on

Level fuel detector (diesel tank)

Proximity detector with impulses (detection teeth slew

2.2.1. ELECTRIC CONTINUITY CONTROL

2.2.2. CONTROL OF AN ON/OFF VALVE

Control resistance of the coil

2.2.3. CONTROL OF COMPONENTS

• Control of an electric relay

LOW CONTROL BOX (S020907)

2.7. LOCALIZATION OF MAIN COMPONENTS

SQ1 Slope sensor YV1

In the following tables

FU1 02 - 18 engine stop coil 10A (115)

SA19 03 - 8 Option emergency pump upper control box (620)

SA20 03 - 11 Option emergency pump lower control box (620)

SB 1 03 - 10 Emergency stop turret (102)

YV 1 05 - 12 20 Validation movements except drive (303)

YV9 04 - 16 15.4 Medium speed drive(807a)

The accelerator is time-lag during 0.5 second when released.

SA1 (side N) + SA11a = 1 SQ5=0 and SQ6=0

SA1 (side N) + SB6=1 +

2.9.7. TURRET SLEWING

YV1=1 SA1 (side N) + SB6=1 and

2.9.10. BASKET ROTATION

Pump with variable cc flow

Pump with fixed cubic capacity flow

Pump with variable flow (used for the hydrostatic

Hydraulic motor with 2 directions of drive

Variable cubic capacity drive motor with 2 directions of

Filter (normally 10 microns)

Priority valve /shuttle valve

piloted check valve

Circuit selector switch/shuttle valve

Position hydraulic valve(used for the HA32/41PX)

Adjustable pressure relief valve

Fixed flow restrictor or spray nozzle