Technical Training Level II HA12CJ_EN_e02-14

TRAINING MANUAL DIAGNOSTIC Level 2 HA12CJ-CJ+ 2420344390 E02-14

TTEECCHHNNIICCAALL TTRRAAIINNIINNGG DDIIAAGGNNOOSSTTIICC LLEEVVEELL IIII

HHAA1122CCJJ((++))//HHAA3322CCJJ((++))

TRAINING MANUAL DIAGNOSTIC Level 2 HA12CJ(+)/HA32CJ(+) 2420344390 E02-14 2/118

HHooww ttoo uussee tthhiiss ddooccuummeenntt?? YYoouu hhaavvee bbeettwweeeenn tthhee hhaannddss tthhee ssuummmmaarryy ggiivveenn dduurr iinngg tthhee HHAAUULLOOTTTTEE tteecchhnniiccaall tt rraaiinniinngg IItt wwii ll ll eennaabbllee yyoouu ttoo ff iinndd iinnffoorrmmaatt iioonn nneecceessssaarryy ffoorr tthhee mmaaiinntteennaannccee aanndd tthhee rreeppaaiirr ooff yyoouurr HHAAUULLOOTTTTEE ..mmaacchhiinnee .. TThhaannkkss ttoo tthhee gguuiiddee bbeellooww yyoouu wwii ll ll rreeaacchh tthhee rreeqquuii rreedd cchhaapptteerr qquuiicckkllyy.. CChhaapptteerr 11:: MMaaiinn ffeeaattuurreess aanndd ffuunncctt iioonnss IItt iiss aa rreessuummee ooff tthhee iinnffoorrmmaattiioonn ccoonnttaaiinneedd iinn tthhee uusseerr mmaannuuaall ddeelliivveerreedd wwiitthh tthhee mmaacchhiinnee:: ccoommppoonneennttss,, oovveerraallll ddiimmeennssiioonnss,, wwoorrkkiinngg zzoonneess,, ccoommmmaannddss,, eettcc…… CChhaapptteerr 22:: SSttuuddyy ooff tthhee eelleecctt rr iicc ddiiaaggrraamm YYoouu wwiillll ffiinndd tthheerree tthhee eelleemmeennttss aass ffoolllloowwiinngg::

-- AA ssuummmmaarryy ooff tthhee ssttaannddaarrddiizzeedd ssyymmbboollss uusseedd bbyy HHAAUULLOOTTTTEE GGrroouupp -- TThhee ccoommpplleettee wwiirriinngg ddiiaaggrraamm ooff tthhee ssttuuddiieedd mmooddeell -- TThhee nnoonn eexxhhaauussttiivvee lliisstt ooff tthhee eelleeccttrriicc lloooommss aanndd eelleeccttrroonniicc bbooaarrddss -- LLooccaalliizzaattiioonn ooff tthhee mmaaiinn ssaaffeettyy uunniittss ((ttiilltt ,, lliimmiitt sswwiittcchheess,, sseennssoorrss,,ttrraannssdduucceerrss……)) -- LLooggiiccaall eeqquuaattiioonnss ooff ooppeerraattiioonn:: bbyy ffuunnccttiioonn,, ttoo ddiiaaggnnoossee tthhee mmaaiinn ddyyssffuunnccttiioonnss

CChhaapptteerr 33:: SSttuuddyy ooff tthhee hhyyddrraauull iicc ddiiaaggrraamm YYoouu wwiillll ffiinndd tthheerree tthhee eelleemmeennttss aass ffoolllloowwiinngg::

-- aa ssuummmmaarryy ooff tthhee ssttaannddaarrddiizzeedd ssyymmbboollss uusseedd bbyy HHAAUULLOOTTTTEE GGrroouupp -- tthhee ccoommpplleettee hhyyddrraauulliicc ddiiaaggrraamm ooff tthhee ssttuuddiieedd mmooddeell -- tthhee nnoonn eexxhhaauussttiivvee lliisstt ooff tthhee hhoosseess ttrraacckk -- aa llooccaalliizzaattiioonn ooff tthhee mmaaiinn hhyyddrraauulliiccss mmaanniiffoolldd ((pprrooppoorrttiioonnaall bblloocckk ,, oonn//ooffff mmoovveemmeennttss

bblloocckk,,……)) CChhaapptteerr 44:: AAddjjuussttmmeennttss TThhiiss iiss tthhee aaddjjuussttmmeennttss aanndd ccaalliibbrraattiioonnss,, hhyyddrraauulliiccss aanndd eelleeccttrriicc,, nneecceessssaarryy ttoo tthhee ggoooodd mmaaiinntteennaannccee ooff tthhee mmaatteerriiaall.. YYoouu wwiillll ffiinndd aass wweellll tthhee mmeetthhooddss ooff aaddjjuussttmmeenntt wwiitthh ttaabbllee vvaalluueess.. CChhaapptteerr 55:: GGuuiiddee ooff bbrreeaakkddoowwnn QQuuiicckk ssuummmmaarryy ooff tthhee sstteepp ttoo bbee ffoolllloowweedd ffoorr ppoossssiibbllee ssoouurrcceess ooff bbrreeaakkddoowwnn.. IInn ccaassee ooff aannyy ddeeffeecctt oorr aannyy ddyyssffuunnccttiioonn yyoouu wwiillll bbee aabbllee ttoo iiddeennttiiffyy tthhee eelleemmeennttss iinn qquueessttiioonn,, wwhhaatteevveerr tthheeyy aarree eelleeccttrriicc oorr hhyyddrraauulliicc.. CChhaapptteerr 66:: SSuummmmaarryy ooff tthhee vveerrssiioonnss TThhiiss mmaannuuaall ttrreeaattss ooff tthhee llaatteesstt vveerrssiioonn;; hhoowweevveerr tthhiiss ssuummmmaarryy ttaabbllee eennaabblleess yyoouu ttoo ffiinndd tthhee ffoorrmmeerr vveerrssiioonnss ooff tthhee mmaatteerriiaall ((eelleeccttrriicc aanndd hhyyddrraauulliiccss)).. CChhaapptteerr 77:: SSppeecciiaall ffuunncctt iioonnss TThhiiss cchhaapptteerr ggaatthheerrss aallll tthhee ffuunnccttiioonnss aanndd aaddjjuussttmmeenntt ssppeecciiffiicc ttoo ccaarrrryy oouutt oonn tthhee mmaacchhiinnee.. TThheerree ddooeess nnoott eexxiisstt ffoorr aallll tthhee mmaatteerriiaallss aanndd ddeeppeennddss oonn tthhee ssttuuddiieedd mmooddeell.. IItt mmuusstt bbee tthhee ssuubbjjeecctt ooff aa ssppeecciiaall aatttteennttiioonn ooff yyoouurr sshhaarree bbeeccaauussee aann iinntteerrvveennttiioonn bbaaddllyy ccaarrrriieedd oouutt ccaann ddeetteerriioorraattee tthhee ggoooodd ppeerrffoorrmmaannccee ooff tthhee mmaacchhiinnee aanndd tthhuuss ccoonnsseeqquueennttllyy tthhee ssaaffeettyy ooff tthhee uusseerrss.. OOnnllyy aa tteecchhnniicciiaann HHAAUULLOOTTTTEE oorr aapppprroovveedd bbyy HHAAUULLOOTTTTEE SSeerrvviicceess iiss aabbllee ttoo ccaarrrryy oouutt tthhiiss kkiinndd ooff iinntteerrvveennttiioonn.. OOnn tthhiiss cchhaapptteerr,, ssoommee ssppeecciiaall aaddjjuussttmmeenntt ((sseennssoorrss)) aarree aallssoo eexxppllaaiinneedd pprriioorr ttoo ccaalliibbrraattiioonn ((ddeeppeennddss oonn tthhee mmooddeell)) CChhaapptteerr 88 :: LLiisstt ooff sscchheemmaatt iiccss TThhiiss cchhaapptteerr lliissttss aallll sscchheemmaattiiccss ((eelleeccttrriicc//hhyyddrraauulliicc)) ooff aallll vveerrssiioonnss aanndd ssoommee llaayyoouutt iiff rreeqquuiirreedd

MMAAIINNTTEENNAANNCCEE AANNDD RREEPPAAIIRR OOPPEERRAATTIIOONNSS OONN YYOOUURR HHAAUULLOOTTTTEE MMAACCHHIINNEE MMUUSSTT BBEE DDOONNEE OONNLLYY BBYY TTRRAAIINNEEDD ,,EEXXPPEERRIIEENNCCEEDD AANNDD AAUUTTHHOORRIIZZEEDD TTEECCHHNNIICCIIAANNSS


RREEVVIISSIIOONN

Revision Edition Subject Created by

Validated by

Modified by

Translated by

Language

00 03- 11 Creation MGD FLH MGD FR/EN 01 09-12 Update parameters

+ calibration process MGD MGD FR/EN

02 07-13 Newest parameters on diagnostic console

MGD MGD EN

03 12-13 Add Diag Pad info + console alarm list

MGD Central R&D

MGD MGD EN

04 02-14 Add chapter schematics

MGD EN


SUMMARY 1. MAIN FEATURES AND FUNCTIONS ............................................................................................................. 6

1.1. CHARACTERISTICS .......................................................................................................................................... 6 1.1.1. ha12 cj-cj+ ............................................................................................................................................ 6 1.1.2. LOADING POINTS HA12CJ-CJ+ ........................................................................................................ 8 1.1.3. FEATURES HA12CJ-CJ+ ..................................................................................................................... 9 1.1.4. OVERALL DIMENSIONS HA12CJ-CJ+ ............................................................................................ 12 1.1.5. WORKING ZONE HA12CJ (HA32CJ) ................................................................................................ 13

1.2. THE LOWER CONTROLS ........................................................................................................................... 15 1.3. THE UPPER CONTROLS ........................................................................................................................... 17

2. THE ELECTRICAL PART ............................................................................................................................... 19

2.1. SYMBOLS USED ............................................................................................................................................. 19 2.2. METHODOLOGY OF CONTROL........................................................................................................................ 23

2.2.1. electric continuity control .................................................................................................................... 23 2.2.2. Control of an on/off valve .................................................................................................................... 23 2.2.3. Control of components ........................................................................................................................ 24

2.3. THE ELECTRIC SCHEMA (164P322210) .......................................................................................................... 27 2.3.1. looms ................................................................................................................................................... 27 2.3.2. module node b2-b3 .............................................................................................................................. 28

2.4. LOCALIZATION OF THE MAIN COMPONENTS .................................................................................................. 29 2.5. STRUCTURE OF THE SYSTEM .......................................................................................................................... 30 2.6. LIST OF COMPONENTS ................................................................................................................................... 31

2.6.1. motor ................................................................................................................................................... 31 2.6.2. Fuses .................................................................................................................................................... 31 2.6.3. inputs ................................................................................................................................................... 32 2.6.4. Outputs ................................................................................................................................................ 34

2.7. LOGICAL EQUATIONS OF OPERATION ............................................................................................................. 37 2.7.1. Power .................................................................................................................................................. 37 2.7.2. Steering ................................................................................................................................................ 37 2.7.3. drive ..................................................................................................................................................... 38 2.7.4. boom lift ............................................................................................................................................... 39 2.7.5. Telescoping boom ................................................................................................................................ 40 2.7.6. Lifting arm ........................................................................................................................................... 41 2.7.7. Turret slewing ...................................................................................................................................... 42 2.7.8. jib ......................................................................................................................................................... 42 2.7.9. Compensation ...................................................................................................................................... 43 2.7.10. basket rotation ..................................................................................................................................... 44 2.7.11. jib rotation (ha12cj+) .......................................................................................................................... 44 2.7.12. version eur ........................................................................................................................................... 45 2.7.13. Options usa /cdn/australia.................................................................................................................. 45

2.8. ALARMS CODES CONSOLE OPTIMIZER .................................................................................................... 46 2.9. ALARMS CODE UPPER CONTROLS ................................................................................................................... 51 2.10. DETAILS ON ALARMS SE01 – SE02 - SE03 ....................................................................................................... 51 2.11. ALARMS CODES ON VARIABLE SPEED UNIT ZAPI ................................................................................... 54

3. THE HYDRAULIC PART ................................................................................................................................. 56

3.1. SYMBOLS USED ............................................................................................................................................. 56 3.2. HYDRAULIC DIAGRAM .................................................................................................................................. 60 3.3. MAIN MANIFOLDS .......................................................................................................................................... 60

3.3.1. Hydraulic block ................................................................................................................................... 60 3.3.2. detail of valves ..................................................................................................................................... 61

3.4. THE LOOMS ................................................................................................................................................... 62 3.4.1. see spr catalog ..................................................................................................................................... 62

4. ADJUSTMENTS ................................................................................................................................................. 63

4.1. ADJUSTMENTS WITH CONSOLE OPTIMIZER ................................................................................................. 63 4.2. PARAMETERS SETTING .................................................................................................................................. 68 4.3. OPTIMIZER MENU .................................................................................................................................... 69 4.4. CONSOLE DIAG PAD....................................................................................................................................... 92 4.5. ADJUSTMENT OF THE PRESSURES .................................................................................................................. 94


4.5.1. Procedure ............................................................................................................................................ 94

5. BREAKDOWN SERVICE GUIDE ................................................................................................................... 96

5.1. NO START ...................................................................................................................................................... 96 5.2. NO MOVEMENT ............................................................................................................................................. 96 5.3. NO ARM LIFT ................................................................................................................................................. 97 5.4. NO BOOM LIFT ............................................................................................................................................... 97 5.5. NO TELESCOPING BOOM ................................................................................................................................ 97 5.6. NO TURRET SLEWING .................................................................................................................................... 97 5.7. NO JIB ........................................................................................................................................................... 97 5.8. NO BASKET ROTATION .................................................................................................................................. 98 5.9. NO JIB ROTATION ........................................................................................................................................... 98 5.10. NO COMPENSATION ....................................................................................................................................... 98 5.11. NO DRIVE ...................................................................................................................................................... 98 5.12. NO HIGH SPEED ............................................................................................................................................. 98 5.13. NO STEERING ................................................................................................................................................ 98 5.14. BATTERY CHARGER ...................................................................................................................................... 99

6. SUMMARY OF VERSIONS HA12CJ-HA12CJ+ ......................................................................................... 100

7. SPECIAL FUNCTIONS ................................................................................................................................... 101

7.1. SYSTEM OF LOAD CONTROL ........................................................................................................................ 101 7.1.1. Operation........................................................................................................................................... 101 7.1.2. Principle of the load control .............................................................................................................. 101 7.1.3. Angle sensors ..................................................................................................................................... 101 7.1.4. Management of the nominal load overlap ......................................................................................... 102 7.1.5. calibration of the pwm valve ............................................................................................................. 102 7.1.6. calibration of load management system ............................................................................................ 103 7.1.7. Values of the sensors of weighing ...................................................................................................... 107 7.1.8. diagnostic .......................................................................................................................................... 108 7.1.9. Values of the impedance of the variator unit ..................................................................................... 110 7.1.10. brake adjustment on drive motors ..................................................................................................... 111

8. LIST OF SCHEMATICS ................................................................................................................................. 112


11.. MMAAIINN FFEEAATTUURREESS AANNDD FFUUNNCCTTIIOONNSS

11..11.. CCHHAARRAACCTTEERRIISSTTIICCSS

11..11..11.. HHAA1122 CCJJ--CCJJ++



11..11..22.. LLOOAADDIINNGG PPOOIINNTTSS HHAA1122CCJJ--CCJJ++


11..11..33.. FFEEAATTUURREESS HHAA1122CCJJ--CCJJ++




11..11..44.. OOVVEERRAALLLL DDIIMMEENNSSIIOONNSS HHAA1122CCJJ--CCJJ++


11..11..55.. WWOORRKKIINNGG ZZOONNEE HHAA1122CCJJ ((HHAA3322CCJJ)) • CJ version


• CJ+ version


11..22.. TTHHEE LLOOWWEERR CCOONNTTRROOLLSS



11..33.. TTHHEE UUPPPPEERR CCOONNTTRROOLLSS



22.. TTHHEE EELLEECCTTRRIICCAALL PPAARRTT

22..11.. SSYYMMBBOOLLSS UUSSEEDD

Battery with one element

Alternator

Fuse (Here 10 amps)

Coil winding roll

Electric motor

light

Diode

Hourmeter


Standard push-button of safety “mushroom-headed button”

Rotary knob

Push-button

Limit switch

Pressure switch

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

Toggle switch with 2 positions

Electrovalve

relay

horn

Proportional electrovalve


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)

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 detector (diesel tank)

Proximity detector with impulses (detection teeth slew ring)


22..22.. MMEETTHHOODDOOLLOOGGYY OOFF CCOONNTTRROOLL 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.

22..22..11.. EELLEECCTTRRIICC CCOONNTTIINNUUIITTYY CCOONNTTRROOLL 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 connectiion 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 : ∞

22..22..22.. CCOONNTTRROOLL OOFF AANN OONN//OOFFFF VVAALLVVEE 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


Control intensity of the coil

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

Control resistance of the coil

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

22..22..33.. CCOONNTTRROOLL OOFF CCOOMMPPOONNEENNTTSS

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

terminals 30 and 87 In the event of dysfunction, replace the relay.

• supply control of the relay


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


• Control of a fuse Color code Fuse check Multimeter in Ω position, it must indicate a value near 0

• 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.

OK NOK


22..33.. TTHHEE EELLEECCTTRRIICC SSCCHHEEMMAA ((116644PP332222221100)) see at the end of the manual

22..33..11.. LLOOOOMMSS

See SPARE PARTS CATALOG Looms interconnection 164P321860 10A Low control box 164P321860 8/12A Door lower contr ol box 164P321860 3A Upper control box 164P321070 3/5/9/11/12/14/16/17A


22..33..22.. MMOODDUULLEE NNOODDEE BB22--BB33


22..44.. LLOOCCAALLIIZZAATTIIOONN OOFF TTHHEE MMAAIINN CCOOMMPPOONNEENNTTSS

SQ1 = 1 if machine not in slope SQ9 =1 if telescopic boom is retracted SQ34 =1 if arm + boom are in stowed position A1 Angle detection weighing

(signal ~ 5V in lowest position and 10V if jib is at highest position) A2 Inclinometer (signal of ~6V if basket is at horizontal position) G1 Pressure small chamber on jib cylinder (signal from 0.5 to 4V) G2 Pressure large chamber on jib cylinder (signal from 0.5 to 4V)

A1

SQ9

A2

A1

SQ34

G1-G2

SQ1


22..55.. SSTTRRUUCCTTUURREE OOFF TTHHEE SSYYSSTTEEMM

The ECU module B2 is the master and controls all functions, it communicates with the interfaces (ECU module B3 and variable speed unit) through can bus network Each movement is controlled by a command varying from 0 to 100% In order to guarantee a progressivity and an optimal comfort of use, 2 systems of regulation speed are used for each movement:

• a variable speed unit speed • 2 proportional PWM valves (PWM : Pulse Width Modulation) for movements

(one for low flow movements such as jib/basket and one for big flow movements such as boom/arm lift/telescopic boom extension…)


22..66.. LLIISSTT OOFF CCOOMMPPOONNEENNTTSS In the following tables, the column n°2 gives the c oordinates of the components 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 the second to the column (generally from 1 to 20) of the corresponding page. The possible options specific to certain countries are not indexed (for more information, it is appropriate to refer to the wiring schematics corresponding to your machine The column n°3 indicates the position on the connec tor of the board or the module if it is necessary 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.

22..66..11.. MMOOTTOORR

MOTOR

M1 03 - 3 Left traction motor (T-307)

M2 03 - 4 Right traction motor (T 307)

P1 03 - 2 Electric pump (T -306)

L3 03 - 8 Left electric brake (B2- 247)

L4 03 -8 Right electric brake (B13- 248)

22..66..22.. FFUUSSEESS FUSES

FU1 02 - 3 Main 500A (301)

FU2 03 - 2 Pump 160A (305)

FU3 03 - 8 Variable speed unit 10A (A1- 107)

FU4 02 - 15 Flashing light 3A (905)

FU5 02.-17 Horn 3A (205)

FU6 02.-11 Supply module node B2 10A (203)

FU7 02.-12 Supply module node B3 10A (246)

FU8 02.-14 Supply actuators 3A (242)

FU9 02 - 5 Supply emergency pump 30A (322)

FU10 02 - 6 Supply lower controls 15A (303)

FUxx 02 - 9 2 x 20A on converter I/O not labelled on drawings Converter 2 x20A fuses (I/O)


22..66..33.. IINNPPUUTTSS INPUTS LOWER CONTROLS (node B2)

S1 02 - 5 Battery main switch (309) SA1 02 - 7 Selection turret - basket (104) SA140 02 - 6 Emergency stop button (102) SB2 04 - 2 CN104.11 Option for manual brake release device (174)

SA10a 04 - 4 CN104.17 Enable toggle switch (110)

SA10b 04 - 4 CN104.1 Selection emergency pump (243)

SA20a 04 - 6 CN104.7 arm lifting (120)

SA20b 04 - 6 CN104.8 arm descent (121)

SA22a 04 - 9 CN 104.13 telescopic extension (122)

SA22b 04 - 9 CN104.14 telescopic retraction (123)

SA30a 04 - 8 CN104.3 Boom lift (130)

SA30b 04 - 8 CN104.4 boom descent (131)

SA40a 04 - 12 CN104.9 basket compensation Rise (140)

SA40b 04 - 12 CN104.10 basket compensation Descent (141)

SA50a 04 - 11 CN104.15 jib rise (150)

SA50b 04 - 11 CN104.16 jib descent (151)

SA52a 04 - 10 CN104.19 jib rotation left (152)

SA52b 04 - 10 CN104.20 jib rotation right (153)

SA82a 04 - 5 CN104.5 turret rotation left(182)

SA82b 04 - 5 CN104.6 turret rotation right(183)


INPUTS UPPER CONTROLS ( node B3)

SA141 05 - 3 Mushroom-headed button emergency stop (215)

SB6 05 - 3 CN105.12 Foot pedal (B141)

SA141 05 - 3 CN104.1 Horn (B106)

SA21a 05 - 8 CN104.7 Arm lift(B112)

SA21b 05 - 8 CN104.8 Arm descent (B113)

SA35a 05 - 10 CN104.13 Telescope extension (B118)

SA35b 05 - 10 CN104.14 Telescope retraction (B119)

SA43a 05 - 12 CN 104.11 Basket rotation towards left side (B116)

SA43b 05 - 12 CN104.12 Basket rotation towards right side (B117)

SA51a 05 - 7 CN104.15 jib rise (B120)

SA51b 05 - 7 CN104.16 jib descent (B121)

SA53a 05.-11 CN104.19 Jib rotation towards left side(B125)

SA53b 05.-11 CN104.20 Jib rotation towrads right side (B126)

SA67 05 - 13 CN104.17 Selection high speed drive (B122)

SB120 05 - 5 CN104.5 Push-button for speed reduction choice for movements

SB121 05 - 6 CN104.6 Push-button for speed increase choice for movements

SB122 05 - 7 CN105.4 Push-button for emergency pump (option)

SM1 05 - 15 CN106.10 CN106.26 CN104.3 CN104.4

Drive joystick signal Y 0.5-2.5-4.5VDC (B300) neutral (B315) Left steering (B108) Right steering (B109)

SM2 05 - 17 CN106.13 CN106.12 CN106.27

Movements joystick signal turret rotation X 0.5-2.5-4.5VDC (B303) signal boom lift Y 0.5-2.5-4.5VDC (B302) neutral (B316)

MODULES

V1 03 - 6 Variable speed unit speed B2

04 ECU Module node B2 (lower controls) B3 05 ECU Module Node B3 (upper controls)


SENSORS

SQ1 04 - 16 CN105.3 Slope sensor (172) SQ34 04 - 15 CN105.2 Detection arm + boom =1 if presence of metal (171) SQ9 04 - 14 CN105.4 Detection telescopic IN = 1 if presence of metal (180) A1 05 - 18 CN106.15 jib angle sensor on jib (weighing) (B304) A2 03 - 20 CN106.16 Absolute angle sensor on jib or inclinometer (weighing)

(B305) G1 03 - 17 CN106.24 Pressure sensor on jib cylinder small chamber G2 03 - 18 CN106.25 Pressure sensor on jib cylinder large chamber

22..66..44.. OOUUTTPPUUTTSS RELAYS

KAB 04 - 9 Relay for brakes (for variable speed unit SEVCON only) (285) KAC 02 - 8 Relay for battery charge (106)

KAF 04 - 6 CN104.21 Relay for flashing lights (271) KAK 04 - 13 CN104.22 Relay for horn (272) KAT 02 - 20 Relay for validation supply converter 48/12VDC (106) KAV 04 - 7 CN104.26 Relay for validation variable speed unit (273) KMG 03 - 8 Main contactor variable speed unit (176) KM1 03 - 8 Contactor selection traction/movements (178) KM2 04.-12 CN105.34 Pump contactor (279) KMS 04 - 13 CN105.33 Contactor (option emergency pump ) KAM* 04 -8 CN104.24 Relay for keeping power during 3 sec after switching off

the power on machine (202)*

Note : * Relay KAM is installed only on machines with software > V3.01

KAM


VALVES

YV0 04 - 11 CN105.19 Secondary PWM1 movements (low flow) (276)

YV1 04 - 11 CN105.20 Main PWM2 movements (big flow) (277)

YV2a 04 - 13 CN105.29 Left steering (262)

YV2b 04 - 14 CN105.30 Right steering (263)

YV3a 04 - 14 CN105.31 basket compensation rise (240)

YV3b 04 - 15 CN105.32 basket compensation descent (241)

YV4a 04 - 15 CN105.21 Turret slewing towards left (282)

YV4b 04 - 16 CN105.22 Turret slewing towards right (283)

YV5a 04 - 17 CN105.23 Arm lifting (220)

YV5b 04 - 18 CN105.24 Arm descent (221)

YV6a 04 - 18 CN105.25 Boom lift (230)

YV6b 04 - 19 CN105.26 Boom descent (231) YV7a

05 - 18 CN105.28 telescope IN (B600)

YV7b 05 - 19 CN105.29 telescope OUT (B601)

YV8a 05 - 16 CN105.26 jib rise (B615)

YV8b 05 - 17 CN105.27 jib descent (B607)

YV9a 04 - 19 CN105.27 Basket rotation towards left side (243)

YV9b 04 - 20 CN105.28 Basket rotation towards right side (244)

YV10A 05 - 19 CN105.30 jib rotation to left side (B602)

YV10B 05.-20 CN105.31 jib rotation to right side (B603)

KMG KM2 KM1 FU3 FU10


LIGHTS -BUZZER

H1 04 - 17 CN104.30 Hour recorder lower controls (173) BG1 05 - 10 CN106.2 Battery charge state indicator upper controls BG2 05 - 14 CN106.1 speeds movements indicator upper controls BG3 04 - 19 CN106.15 Battery charge state indicator lower controls HA1 02 - 17 Buzzer (207) HA142 04 - 8 CN104.28 Buzzer lower controls (275) HL1 02 - 15 Flashing lights (206)

HL2 05 - 3 Work headlight (905)

HL102 05 - 15 CN104.22 Light power supply OK upper controls (B501) HA141 05 - 8 CN104.29 Buzzer upper controls (B508) HL142 05 -12 CN104.26 Light overload upper controls (B505) HL143 05 -7 CN 104.21 Light slope (B500) HL144 04 - 7 CN104.31 Light overload lower controls (274)


22..77.. LLOOGGIICCAALL EEQQUUAATTIIOONNSS OOFF OOPPEERRAATTIIOONN 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) thank you to refer to HAULOTTE SERVICES of your sector which will indicate the characteristics of your machine

22..77..11.. PPOOWWEERR

Function Action

CONDITIONS

Necessary Prohibiting the function

Modifying the

function

Power upper controls

KMG = 1 (Machine

switched ON without alarms)

S1= 1+ SA140=1 + SA1 (side N) =1

Batteries charged + SA141 =1

KAC=0 KAT =0 KAV =0

Module node B2 and/or

B3 KAM = 0

Power lower controls

S1 =1 + SA140 + SA1 (side T) =1

Batteries charged

KAC=0 KAT=0 KAV=0

Module B2 node

22..77..22.. SSTTEEEERRIINNGG

Function Action CONDITIONS


Modifying the function

Right steering KM2 = 1+

YV1 = 1 + YV2B=1

SA1 (side N) + SB6 = 1 + SM1d=1 + KM1 =0

SQ1 = 0 (slope )

A movement with big flow already in progress

(boom, arm or telescoping) or multiple with

the drive Defect CAN

bus Module node

defective B2 or B3

A movement already in progress before

steering command

Left steering KM2 =1+

YV1=1 +YV2A=1

SA1 (side N) + SB6 =1 + SM1g=1 + KM1 =0


22..77..33.. DDRRIIVVEE




Low speed forward

KM1=0 variable

speed unit from 0 to

500A

SA1 (side N) + SB6 = 1 + SA67=0 + SM1 HN =1 +

signal between 2.5 and 4.5 V SQ1 = 0 (slope) brakes

blocked L3/L4

A movement already in progress

before the drive

command go in

microspeed if SQ1 = 0

(machine in slope) + SA67 = 0

Low speed reverse

KM1=0 variable


500A

SA1 (side N) + SB6 =1 + SA67 = 0 + SM1HN =1 +

signal between 2.5 and 0.5 V

High speed forward

KM1=0 variable


500A

SA1 (side N) + SB6=1 + SA67=1+ SM1HN =1 +


SQ1 = 0 (slope) brakes

blocked L3/L4 SQ34=0 SQ9 = 0 (machine unfolded)

High speed reverse

KM1=0 variable


500A

SA1 (side N) + SB6=1 + SA67=1+ SM1HN =1 +



22..77..44.. BBOOOOMM LLIIFFTT

Function Action

CONDITIONS


Modifyin g the

function

Rise upper controls

KM1 = 1+ YV1 = 1

+ YV6A =1

SA1 (side N) + SB6=1 + SM2HN=1 + SM2Y signal

between 2.5 and 4.5 V + KM2 =1 (if multiple in drive mode) or if not variable speed unit signal

from 0 to 500A)

Another

movement with big flow in

progress (YV2-YV5-YV7)

YV2, YV5 or YV7 at fault

A1, A2, G1, G2 (overload) Discharged

batteries 20% SQ1 =0 (slope)

Slowed down

descent with 50%

if In slope

Descent upper controls

KM1=1

+ YV1 = 1 +

YV6B =1

SA1 (side N) + SB6=1 + SM2HN=1 + SM2Y signal

between 2.5 and 0.5 V+ KM2 =1 (if multiple in drive mode) or if not variable speed unit signal

from 0 to 500A)

Another movement with

big flow in progress (YV2-

YV5-YV7) YV2, YV5 or YV7

at fault A1, A2, G1, G2

(overload)

Rise lower controls

KM1 = 1+ YV1 = 1 + YV6A

=1

SA1 (side T) + SA10 = 1 + SA30A = 1 + KM2 =1 (if multiple in drive mode) or if not variable

speed unit signal from 0 to 500A)




at fault Discharged

batteries 20% SQ1 = 0 (slope)

overload movement

are slowed down

Slowed down

descent with 50%

if In slope

Descent lower controls

KM1=1 + YV1 =

1 + YV6B =1

SA1 (side T) + SA10 =1 + SA30B =1 +

KM2 =1 (if multiple in drive mode) or if not variable speed

unit signal from 0 to 500A)




at fault


22..77..55.. TTEELLEESSCCOOPPIINNGG BBOOOOMM




Extension upper controls

KM1 = 1 +

YV1= 1+ YV7A=1

SA1 (side N) + SB6 =1 + SA35A =1 + KM2 =1 (if

multiple in drive mode) or if not variable speed unit signal

from 0 to 500A)

Another movement

with big flow in progress

(YV2-YV5-YV6)

YV2, YV5 or YV6 at fault A1, A2, G1,

G2 (overload) Discharged

batteries 20% SQ1 = 0 (slopel)

Modifiable speed

movement by SB120 -

SB121) Retraction

slowed down with 50% in

slope

overload movement is slowed down

Slowed down

retraction with 50% in

slope

Retraction upper controls

KM1 = 1 + YV1 = 1

+YV7B=1

SA1 (side N) + SB6 =1 + SA35A =1 + KM2 =1 (if


from 0 to 500A)

Another movement


(YV2-YV5-YV6)

YV2, YV5 or YV6 at fault A1, A2, G1,

G2 (overload)

extension lower controls

KM1 = 1 + YV1= 1+ YV7A=1

SA1 (side T) + SA10A = 1+ SA22A=1 + KM2 =1 (if


from 0 to 500A)

Another movement


(YV2-YV5-YV6)

YV2, YV5 or YV6 at fault Discharged


Retraction lower controls

KM1 = 1 +

YV1 = 1 +YV7B=1

SA1 (side T) + SA10A =1 + SA22B=1 + KM2 =1 (if


from 0 to 500A)

Another movement


(YV2-YV5-YV6)

YV2, YV5 or YV6 at fault


22..77..66.. LL IIFFTTIINNGG AARRMM




Rise upper controls

KM1 = 1 + YV1 = 1

+YV5A=1

SA1 (side N) + SB6=1 + SA21A =1 + KM2 =1 (if

multiple in drive mode) or if not variable speed unit signal from 0 to 500A)



YV6-YV7) YV2, YV6 or YV7 at fault

A1, A2, G1, G2 (overload)

Discharged batteries 20%

SQ1 = 0 (slope)

Modifiable speed

movement by (SB120 - SB121)

slowed down descent with

50% if in slope

overload movements are slowed

down

slowed down descent with

50% if in slope


KM1 = 1 + YV1 = 1

+YV5B=1

SA1 (side N) + SB6=1 + SA21B =1 + KM2 =1 (if




YV6-YV7) YV2, YV6 or YV7 at fault



Rise lower controls

KM1 = 1 + YV1 = 1

+YV5A=1

SA1 (side T) + SA10A=1 + SA20A = 1+ KM2 =1 (if




YV6-YV7) YV2, YV6 or YV7 at fault Discharged



KM1 = 1 + YV1 = 1

+YV5B=1

SA1 (side T) + SA10A=1 + SA20B = 1 + KM2 =1 (if




YV6-YV7) YV2, YV6 or YV7 at fault Discharged

batteries 20%


22..77..77.. TTUURRRREETT SSLLEEWWIINNGG




Right side upper controls

KM1 = 1 + YV0 =1

+YV4B=1

SA1 (side N) + SB6 =1 + SM2HN=1 + SM2X signal

between 2.5 and 4.5 V + KM2 =1 (if multiple in drive mode) or if not variable speed unit

signal from 0 to 500A)

Another movement

with low flow in progress (YV3-YV8-YV9- YV10) YV3, YV8,

YV9 or YV10 at fault

A1, A2, G1, G2

(overload) Discharged

batteries 20%

Movements of Drive (position

transport) and/or steering

(if this movement is

activated in first Movements

slowed down if in slope

overload movements are slowed

down

Left upper controls

KM1 = 1 +

YV0 =1 +YV4A=1

SA1 (side N) + SB6 =1 + SM2HN=1 + SM2X signal

between 2.5 and 0.5 V + KM2 =1 (if multiple in drive mode) or if not variable speed unit

signal from 0 to 500A)

Right side lower controls

KM1 = 1 + YV0 =1

+YV4B=1



from 0 to 500A)

Another movement

with low flow in progress (YV3-YV8-YV9- YV10) YV3, YV8,

YV9 or YV10 at fault

Discharged

batteries 20%

Left lower controls

KM1 = 1 + YV0 =1

+YV4A=1

SA1 (side T) + SA10A=1 + SA82A = 1 + KM2 =1 (if


from 0 to 500A)

22..77..88.. JJIIBB




Rise upper controls

KM1 = 1 + YV0 = 1

+YV8A=1

SA1 (side N) + SB6 =1 + SA51A=1 + KM2 =1 (if


from 0 to 500A)


low flow in progress (YV3-

YV4-YV9- YV10)

YV3, YV4, YV9 or YV10 at fault A1, A2, G1, G2



Modifiable

speed movement by

(SB120 - SB121

Office multiple with the drive

(position transport)

and/or steering (if this

movement is activated in

first)


KM1 = 1 + YV0 = 1

+YV8B=1

SA1 (side N) + SB6 =1 + SA51B=1 + KM2 =1 (if


from 0 to 500A)


Rise lower controls

KM1 = 1 + YV0 = 1

+YV8A=1

SA1 (side T) + SA10A=1 + SA52A = 1 + KM2 =1 (if


from 0 to 500A)



YV8-YV9- YV10)

YV3, YV4, YV9 or YV10 at fault


overload

movements are slowed

down Descent

slowed down if in slope


KM1 = 1 + YV0 = 1

+YV8B=1



from 0 to 500A)

22..77..99.. CCOOMMPPEENNSSAATTIIOONN




Rise/descent upper controls

KM1 = 1 + YV0 = 1+

YV3A/B=1

SA1 (side N) + SB6 = 1 + SA41A/B =1 +

KM2 =1 (if multiple in drive mode) or if not variable speed unit

signal from 0 to 500A) speed unit of 0 to 500A



YV8-YV9- YV10) YV4, YV8, YV9 or

YV10 at fault



emergency mode

Movement slowed down

if in slope

Prohibited movement if

telescope OUT

Rise/descent lower controls

KM1 = 1 + YV0 = 1+

YV3A/B=1

SA1 (side T) + SA10A=1 + SA40A/B

= 1+ KM2 =1 (if multiple in drive mode) or if not variable speed

unit signal from 0 to 500A)

Another

movement with low flow in

progress (YV4-YV8-YV9- YV10) YV4, YV8, YV9 or

YV10 at fault A1, A2, G1, G2


batteries 20% Emergency mode


22..77..1100.. BBAASSKKEETT RROOTTAATTIIOONN




(left/right movement)

KM1 = 1 + YV0 = 1 + YV9A/B=1

SA1 (side N) + SB6 =1 + SA43A/B = 1+ KM2 =1 (if




YV4-YV8- YV10) YV3, YV4, YV8 or

YV10 at fault


Discharged batteries 20%)

SQ1 = 0 (slope) emergency mode

Modifiable speed

movement by (SB120 - SB121

Movement slowed down if

in slope

22..77..1111.. JJIIBB RROOTTAATTIIOONN ((HHAA1122CCJJ++))




upper controls (left. /right)

KM1 = 1 + YV0 = 1 +

YV10A/B =1

SA1 (side N) + SB6 =1 + SA53A/B=1 + KM2 =1 (if


from 0 to 500A)


low flow in progress (YV3-YV4-YV8- YV9) YV3, YV4, YV8 or YV9 at fault

A1, A2, G1, G2


batteries 20% Emergency

mode SQ1 = 0 (slope)

Modifiable speed

movement by (SB120 - SB121

overload low movements

slowing down Movement

slowing down if in slope

lower controls (left/right)

KM1 = 1 + YV0 = 1 +

YV10A/B =1

SA1 (side N) + SA10A =1 + SA52A/B = 1+ KM2 =1 (if


from 0 to 500A)


22..77..1122.. VVEERRSSIIOONN EEUURR in the tables below, the multiple movements are defined independently of the controls (except for the drive/steering which is made only from upper controls) Note: in drive, the steering has the priority to the other movements

22..77..1133.. OOPPTTIIOONNSS UUSSAA //CCDDNN//AAUUSSTTRRAALLIIAA USA version: no cut-off of the movements if the machine is in slope > 3° (alarm sounds only), the machine is slowed down in drive mode no movement cut out if machine in overload

CDN version : same as for USA except for slope ( movements are cut if machine is above 3 meters workking height ( SQ34 and/or SQ9 = 1)

in drive mode , the steering has the priority from the other movements


22..88.. AALLAARRMMSS CCOODDEESS CCOONNSSOOLLEE OOPPTTIIMMIIZZEERR All alarms of the system are shown through the console through various menus

SPEED VARIATOR UNIT ALARMS

CODE DESCRIPTION ACTION AV01 Problems in stator/rotor

current , logic, hardware, current probes, or CAN bus network or problems linked to an over or low voltage

Possible faults on ZAPI (13,18,19,53,57,58,233,234,241,244,247,248,252,253

AV02 Problems in main contactor KMG or with the contactor for selection traction/pump KM1 (open circuit, contact stuck or short-circuit)

- Possible faults on ZAPI (37,74,75,76,77,242) - Check the state of contactors and/or connections

AV03 Lack of power or problem in the outputs motors/pump

Possible faults on ZAPI (30,31,60,250)

AV04 Speed variator unit in thermal security

- Possible fault on ZAPI 62 - Let’s cool the speed variator unit until the fault disappears and meanwhile avoid to drive too much time in rising ramps

AV05 Wrong sequence for starting or error on one speed variator unit input

- Restart the machine in good way ( battery cut-out , e-stop buttons then key selector for upper/lower control box) - Check speed variator unit connection

AV06 Problem on batteries or batteries too weak

- Possible faults on ZAPI (66,251) - Reload or replace batteries

CONTACTOR OUTPUTS

CODE DESCRIPTION ACTION SC01 Output in open or short circuit :

validation relay KAV is defective (or missing) or wire is cut

Change relay KAV, check wiring and equipotential (on wires 273 et 0)

SC02 Output in open or short circuit: flashing light relay KAF is defective (or missing) or wire is cut

Change relay KAF, check wiring and equipotential (on wires 271 et 0)

SC03 Output in open or short circuit: horn relay KAK is defective (or missing) or wire is cut

Change relay KAK, check wiring and equipotential (on wires 272 et 0)

SC04 Output in open or short circuit : pump power coil contactor KM2 is defective (or missing) or wire is cut

Change contactor KM2 on speed unit plate , check cable 279 between chassis loom and turret box or wire 203 on coil (+12V)

SC05 Output in short circuit: brakes release relay KAB is defective (or missing) or wire is cut (fault only with SEVCON speed unit)

Change relay KAB, check cable 275 between chassis looms and turret box and check the 0 on relay.

SC06 Output in open or short circuit : emergency pump power coil contactor KMS is defective (or missing) or wire is cut (Fault visible only if the dead man toggle switch SA10b is activated)

Change relay KMS, check continuity on wire 208 between turret loom and emergency pump option loom + turret box, check wire 203 on coil (+12V)


VALVES OUTPUTS CODE DESCRIPTION ACTION EV01 Output in open or short circuit :

PWM valve for secondary movements YV0 is defective (or missing) or wire is cut

Change coil YV0, check wire 276 between loom bloc + turret box or wire 203 on coil itself (+12V)

EV02 Output in open or short circuit : PWM valve for main movements YV1 is defective (or missing) or wire is cut


EV03 - Output in open or short circuit : ON /OFF valve for left steering YV2A is defective (or missing) or wire is cut - Output in open or short circuit : ON /OFF valve for right steering YV2B is defective (or missing) or wire is cut

- Change coil YV2A, check wire 262 between loom bloc + turret box or the 203 on coil itself (+12V) - Change coil YV2B, check wire 263 between loom bloc + turret box or wire 203 on coil itself (+12V)

EV04 - Output in open or short circuit : ON /OFF valve for basket compensation lifting YV3A is defective (or missing) or wire is cut - Output in open or short circuit : ON /OFF valve for basket compensation descent YV3B is defective (or missing) or wire is cut

- Change coil YV3A, check the wire 240 between loom bloc + turret box or the 203 on coil itself (+12V) - Change coil YV3B, check wire 241 between loom bloc + turret box or wire 203 on coil itself (+12V)

EV05 - Output in open or short circuit : ON /OFF valve: for turntable left rotation YV4A is defective (or missing) or wire is cut - Output in open or short circuit : ON /OFF valve: for turntable right rotation YV4B is defective (or missing) or wire is cut

- Change coil YV4A, check the wire le 282 between loom bloc + turret box or the 203 on coil itself (+12V) - Change coil YV4B, check wire 283 between loom bloc + turret box or wire 203 on coil itself (+12V)

EV06 - Output in open or short circuit : ON /OFF valve: for arm lift YV5A is defective (or missing) or wire is cut - Output in open or short circuit : ON /OFF valve: for arm descent YV5B is defective (or missing) or wire is cut

- Change coil YV5A, check the wire 220 between loom bloc + turret box or wire 203 on coil itself (+12V) Change coil YV5B, check wire 221 between loom bloc + turret box or wire 203 on coil itself (+12V)

EV07 - Output in open or short circuit : ON /OFF valve for boom lift YV6A is defective (or missing) or wire is cut - Output in open or short circuit : ON /OFF valve: for boom descent YV6B is defective (or missing) or wire is cut

- Change coil YV6A, check the wire 230 between loom bloc + turret box or wire 203 on coil itself (+12V) - Change coil YV6B, check wire 231 between loom bloc + turret box or wire 203 on coil itself (+12V)


EV08 - Output in open or short circuit : ON /OFF valve for right steering YV7A is defective (or missing) or wire is cut - Output in open or short circuit : ON /OFF valve for left steering YV7B is defective (or missing) or wire is cut :

- Change coil YV7A, check wire B600 between bloc loom + turret box and wire 246 on coil (+12V) - Change coil YV7B, check wire B601 between bloc loom + turret box and wire 246 on coil (+12V)

EV09 - Output in open or short circuit : ON /OFF valve for jib lifting YV8A is defective (or missing) or wire is cut - Output in open or short circuit : ON /OFF valve for jib descent YV8B is defective (or missing) or wire is cut


EV10 - Output in open or short circuit : ON /OFF valve for basket rotation left side YV9A is defective (or missing) or wire is cut - Output in open or short circuit : ON /OFF valve for basket rotation right side YV9B is defective (or missing) or wire is cut

- Change coil YV9A, check wire 234 between bloc loom + turret box and wire 246 on coil (+12V) - Change coil YV9B, check wire 235 between bloc loom + turret box and wire 246 on coil (+12V)

EV11 - Output in open or short circuit : ON /OFF valve for jib rotation left side YV10A is defective (or missing) or wire is cut - Output in open or short circuit : ON /OFF valve for jib rotation right side YV10B is defective (or missing) or wire is cut


CAN-BUS ERRORS / EEPROM

CODE DESCRIPTION ACTION MX01 CAN fault communication check can-bus network

(impedance and connections) EP01 EEPROM checksum error


JOYSTICKS(CONTROLLERS) – TOGGLE SWITCHES

CODE DESCRIPTION ACTION SM1Y Signal out of range or inconsistent

neutral value on drive joystick Check connection and signal value (0.5 -2.5-4.5VDC)

SM2Y Signal out of range or inconsistent neutral value on rotation /lift joystick

Check connection and signal value (0.5 -2.5-4.5VDC)

SM2X Signal out of range or inconsistent neutral value on rotation /lift joystick


SW01 Inconsistent value or neutral position not OK when power is ON , on one of the toggle switch in lower control box

Check toggle switches from lower control box

SW02 Inconsistent value or neutral position not OK when power is ON , on one of the toggle switch in upper control box

Check toggle switches from upper control box

OVERLOAD ALARMS

CODE DESCRIPTION ACTION OL01 - Adress fault on slave

module doing the load function - Inconsistant values between EEPROM datas saved between module master B2 and slave B3

- Problem in checksum parameters validation or overload calibration datas or problem during load calibration - Make again the calibration

OL02 Fault in Jib learning Cal 1 Make or redo the Jib learning Cal 1 calibration process

OL03 - Inconsistent values between jib movement and jib angle measurement - Fault in A1 relative angle sensor

- Check the jib angle sensor value and the direction of variation of this value (should increase when jib is lifting). - Jib angle sensor value out of range - Check sensor and its mounting/connection

OL04 - Inconsistent value between compensation movement and jib angle - Fault in A2 absolute angle sensor (inclinometer)

- Check the jib inclinometer sensor value and the direction of variation of this value (should decrease when basket is elevating) – - Jib inclinometer sensor value out of range - Check sensor and its mounting/connection

OL05 - Fault in G1 pressure sensor in jib cylinder - Pressure variation too important in the jib small chamber

- Pressure sensor out of range - Check the sensor and its connection - Check if the pressure in the small jib chamber is varying in good way - Change the pressure sensor

OL06 - Fault in G2 pressure sensor in jib cylinder - Pressure variation too important in the jib large chamber

Pressure sensor out of range - Check the sensor and its connection - Check if the pressure in the large jib chamber is varying in good way - Change the pressure sensor

OL07 Inconsistent values for the calculation of the pressure recorded between modules node B2 master and slave B3

- Too much difference of calculation regarding the pressure datas between modules node B2 and B3 - Restart the machine - change module node B2 and/or node B3


CODE DESCRIPTION ACTION OL08 Inconsistent values for the

calculation of the pressure reference between modules node B2 master and node B3 slave

- difference more than 2 seconds between the reference pressure ( calibration value) registered by module node B3 and the current one registered by the master module node B2

OL09 Resultant pressure out of range

Pressure registered in node B2 out of range compared to the threshold value ( low and high) The fault appears if the difference between the registered value and the recordered value is above 2 seconds

SENSORS ALARMS

CODE DESCRIPTION ACTION SE01

Incoherent status of sensors : no change during movement

Check wiring and sensors SQ9 and SQ34 : Telescopic IN SQ9=1 Boom+arm stowed , SQ34 = 1 Move both movements (telescopic then arm + boom) and check if failure has disappeared.

SE02

Anti by-pass safety : detection of SQ34 from 0 to 1 without any movement)

Check wiring and sensors SQ9 and SQ34 : Telescopic IN SQ9=1 Boom+arm stowed , SQ34 = 1 Move both movements (telescopic then arm + boom) and check if failure has disappeared. Principle of survey : 1 –failure if without any movement , the sensor goes from 0 to 1

SE03 E-stop safety : detection position before power OFF and check position when power is ON again (sensor state should not have changed)



22..99.. AALLAARRMMSS CCOODDEE UUPPPPEERR CCOONNTTRROOLLSS These alarms are the same as the previous table but they are gathered by category and appear in the form of flash code in upper controls for the operator (visible on power supply light HL102) The operator could quickly diagnoses the origin of the failure and solves the problem sometimes without using the OPTIMIZER console

FLASH CODE FAILURES CODE ON OPTIMIZER

1 AV01

2 AV02

3 AV03

4 AV04

5 AV05

6 AV06

7 SC01 - SC02 - SC03 - SC04 - SC05 - SC06

8 EV01 - EV02 - EV03 - EV04 - EV05 - EV06 - EV07 - EV08 - EV09 - EV10 - EV11

9 EP01

10 SM1Y - SM2Y - SM2X - SW01 - SW02

11 SE01-SE02-SE03

22..1100.. DDEETTAAIILLSS OONN AALLAARRMMSS SSEE0011 –– SSEE0022 -- SSEE0033

Defect : proximity sensors 0 = no failure

1 = failure

State of sensor

arm/boom (SQ34=0 unfolded, SQ34=1 folded)

State of slope

sensor (SQ1=0 no tilt, SQ1=1

in slope)

Drive authorised

Movement authorised

Number of flashs

code

Reset if defect

Function fault SQ9 and SQ34

(SE01)

Fault if shunt SQ34 on (SE02)

fault SQ34 and SQ9

after power is swithed

ON (SE03)

Defect detected

when machine starts to

unfold and no change on sensors

state

Defect shunt

and no movement

detected , no command and SQ34 state has changed

Defect if state has changed

after power is

ON

0 0 0

0 (machine unfolded)

0 (no slope) Micro speed All

authorised 0 none

0 0 0 0 (machine unfolded)

1 (dévers)

EUR mode no drive/

USA mode micro speed

Machine in folded position

authorised

0 none

0 0 0 1 (machine folded) 0

Drive in LS

and HS speed drive

All authorised 0 none


0 0 0 1 (machine folded) 1

Drive in

microS and HS speed

drive

All authorised 0 none

1 0 0 0 0 Micro speed

All authorised 11

lower /lift the

boom and retract and extend the telescopic

boom extension

1 0 0 0 1

EUR mode no drive/



authorised

11

lower /lift the boom and retract and extend the telescopic

boom extension

1 0 0 1 0

Micro speed

All authorised 11

lower /lift the

boom and retract and

extend telescopic

boom extension

1 0 0 1 1

EUR mode no drive/



authorised

11

lower /lift the


extend telescopic

boom extension

Defect : proximity sensors 0 = no failure

1 = failure

State of sensor

arm/boom

(SQ34=0 unfolded, SQ34=1 folded)

State of slope

sensor (SQ1=0 no tilt,

SQ1=1 in slope)

Drive authorised

Movement authorised

Number of flashs

code

Reset if defect

Function fault SQ9 and SQ34

(SE01)

Fault if shunt

SQ34 on (SE02)

fault SQ34 and SQ9

after power is swithed ON (SE03)

Defect detected

when machine starts to

unfold and no change

on sensors

state

Defect

shunt and no

movement detected ,

no command and SQ34 state has changed

Defect if state has changed

after power is ON

0 1 0 0 0

Micro speed

All authorised 11

Remove shunt on

SQ34

0 1 0 0 1 EUR mode

Machine in folded 11 Remove

shunt on


no drive/ USA mode

micro speed

position authorised

SQ34

0 1 0 1 0

Micro speed

All authorised 11

Remove shunt on

SQ34 Lower/lift the

boom

0 1 0 1 1

EUR mode no drive/


All authorised 11

Remove shunt on

SQ34 Lower/lift the

boom

0 0 1 0 0 Micro speed

All authorised 11

lower /lift the


extend telescopic

boom extension

0 0 1 0 1

EUR mode no drive/


Machine in folded

position authorised

11

lower /lift the


extend telescopic

boom extension

0 0 1 1 0

Micro speed

All

authorised 11

lower /lift the boom and retract and

extend telescopic

boom extension

0 0 1 1 1

EUR mode no drive/


All authorised

11

lower /lift the boom and retract and

extend telescopic

boom extension


22..1111.. AALLAARRMMSS CCOODDEESS OONN VVAARRIIAABBLLEE SSPPEEEEDD UUNNIITT ZZAAPPII This list of code alarm is shown only on the OPTIMIZER console (see DIAGNOSTIC/VARIATOR /Internal Variable= xx, CODE ALARM

Code OPTIMIZER

DEFINITION DIAGNOSTIC

13 EEPROM KB

The parameters have been altered and the movements are impossible If the problem has been solved when power is switched OFF then ON (the values are from now the default values) If the defect persists: change the variator

18 LOGIC FAILURES # 2 Fault in the “hardware “ system of the logic board which controls the pump contactor KM2

19 LOGIC FAILURES # 1 Problem in the logical circuit of the line contactor KMG or in the hardware of the variator

30 VMN LOW Problem with the circuit power of the drive motors or connections,

31 VMN HIGH Problem with the circuit power of the drive motors or connections,

37 CONTACTOR CLOSED The terminals of the power contactor KMG remain stuck

53 STBY I HIGH Failure in the current detection as it didn’t drop to 0 when the variator is not activated Change the variator if the problem persists

57 HIGH FIELD CURRENT Defect in the circuit energizing F1 /F2 check connections replace the variator if the problem persists

58 NO FIELD CURRENT Defect in the field circuit F1 /F2 Check connections Replace the variator if the problem persists

60 CAPACITOR LOAD The capacitors doesnt charge 0.5 after power is ON Defect in the power circuit

62 TH PROTECTION

The internal temperature of the variator exceeds 75°C Defect in the temperature sensor Let’s cooling the variator before changing it

66 BATTERY LOW batteries discharged more than 80% 74 DRIVER SHORTED The line contactor KMG is in short-circuit

75 CONTACTOR DRIVER Problem on contactors KM1 or KMG or brakes L3/L4

76 COIL SHORTED Short-circuit or open circuit on contactors or circuit brakes L3/L4

77 COIL INTERRUPTED When power is ON, the voltage applied on contactor is not correct Check connections before changing the variator


79 INCORRECT START

Starting was not carried out correctly, start again the sequence in the correct order (battery cut out, emergency stop, selection movement then joystick.)

99 INPUT ERROR # 1 No change of state on input (Problem on modules) Problem on VMC (Volt Motor Controller),

223 WAITING FOR NODE VMC voltage tries to start without agreement of the variator (CAN bus problem or modules)

233 SENSOR I KO Current field sensor NOT OK 234 HW FAULT Problem of inverter, change KM1

241 FORW + TOP SPIN Dual command (drive + movements) , release all command

242 VALVE COIL SHORTED Not used for HAULOTTE, change variator if alarm appears again

244 CHECK UP NEEDED Warning that the maintenance scheduled is exceeded (not used by HAULOTTE on this kind of SEM1 variator )

247 THERMIC SENSOR KB

With power is ON, the variator checks if the values of the temperature sensor are in the tolerances If the problem persists,change the variator

248 KEY-OFF No power on system

249 CAN BUS KO No message coming from the CAN-BUS, check connections If the problem persists, change the variator

250 VFIELD NOT OK

With power ON, the system checks that the voltage on field circuit is at 50% Vbat with line contactor open Check connections Mass fault between chassis and variator

251 WRONG SET BATTERY Wrong type of batteries

252 AUX2 OUTPUT KO The system checks the circuit brakes command, if the received signal does not correspond, replace the variator

253 AUX1 OUTPUT KO The system checks the commande of KM1 contactor if the received signal does not correspond, change the contactor


33.. TTHHEE HHYYDDRRAAUULLIICC PPAARRTT

33..11.. SSYYMMBBOOLLSS UUSSEEDD

Pump with variable cubic capacity flow

(here maximum 38 cc /rpm)

Pump fixed flow cubic capacity

(here 23 cc/rpm)

Pump with variable flow (used for the hydrostatic transmission in closed circuits on HAULOTTE big booms like HA32PX, HA41PX, H28TJ+, H43TPX)

Hydraulic motor with 2 directions of drive

(ex FWD/REV)

Variable cubic capacity drive motor with 2 directions of drive

15cc for high speed

45 cc for low speed

Filter (normally 10 microns)

check valve


calibrated check 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 + check valve


Pressure sensor (used for weighing)

Adjustable pressure switch

(here set at 170 bars)

Flow divider

Position valve 4 ways, 3 positions in closed center

Distribuitor/ safety valve

Counter balance valve with piloting line of the opposite line (here set at 210bars)

Position valve proportional 5/3 with piloting manual by lever

Rotary cylinder /jack (here range at 180°)

Piloted valve


Manual valve with automatic return (used to readjust the part of compensation on HA32PX/HA41PX)

Position valve proportional 4 ways/3 positions

Pressure balance/flow control valve

Flow regulator


33..22.. HHYYDDRRAAUULLIICC DDIIAAGGRRAAMM See at the end of this manual

33..33.. MMAAIINN MMAANNIIFFOOLLDDSS

33..33..11.. HHYYDDRRAAUULLIICC BBLLOOCCKK


33..33..22.. DDEETTAAIILL OOFF VVAALLVVEESS

YV6 Boom lift YV7 Telescoping boom YV5 Arm lifting YV2 steering YV1 (PWM2) Main movements (big flow) YV0 (PWM1) Secondary movements (low flow) YV8 jib YV4 Turret rotation YV9 Basket rotation YV3 Basket compensation YV10 jib rotation (for model HA12CJ+)

• YV10 mounted between compensation block and emergency block with lever if option

HA12CJ+ • Attention 2 types of hydraulic blocks (1 for HA12CJ and 1 for HA12CJ+) with different part

numbers

YV6A

YV6B YV7A

YV5A

YV2A

PWM2 YV1

YV8A

YV4A

YV9A

YV7B

YV5B

YV2B

PWM1 YV0

YV8B

YV4B

YV9B

YV3B

YV3A

YV10A YV10B*


For this machine, the hydraulic block is divided into two parts, each one controlled by a PWM proportional valve

• Main movements (proportional valve PWM2 YV1): Lifting Arm, boom lift, Telescoping boom and steering

• Secondary movements (proportional valve PWM1 YV0): Compensation, Orientation, jib, basket rotation, jib rotation

The hydraulics pressure is obtained by a pump motor unit supplied with a variable speed unit speed. When it’s used to control the drive motors, the pump motor unit is supplied in ON/OFF in order to have the possibilty to multiply the movements in drive mode

33..44.. TTHHEE LLOOOOMMSS

33..44..11.. SSEEEE SSPPRR CCAATTAALLOOGG for HA12CJ+ 164P335310 (2 looms) for HA12CJ 164P335320 (2 looms)


44.. AADDJJUUSSTTMMEENNTTSS

44..11.. AADDJJUUSSTTMMEENNTTSS WWIITTHH CCOONNSSOOLLEE OOPPTTIIMMIIZZEERR The adjustments, parameter settings and lists of alarms of the machine are accessible only through this console. Use console OPTIMIZER (ref. 2440320080) with module s node B2/B3 Connection on bottom panel (turret) On RS232 plug socket located outside the lower turret box


Description of the console NOTE : on any blue key pads , pressing on left , right or in the center have the same result

PPAARRAAMMEETTEERR ++ oorr CCHHAANNGGEE

PPRREEVVIIOOUUSS MMEENNUU PPAARRAAMMEETTEERR -- oorr CCHHAANNGGEE

NNEEXXTT MMEENNUU

RREECCOORRDD//EENNTTEERR//VVAALLIIDDAATTIIOONN

BBAACCKK TTOO MMAAIINN MMEENNUU


List of menus Access to main menu Access to calibration menu (level 2) Access to the code level 2

Validation by key: , then enter the code

Navigation by this key then enter the code

press following key:

The console is in level 2 (access to the calibration menu) once level 2 is set , go to menu :

Back to main menu

Level 2 is registered


2 .PARAMETERS/CALIBRATION/Jib Learning Cal 1 2.PARAMETERS/CALIBRATION First set the calibration 1 Go in menu OVERLOAD CAL in order to launch the calibration


List of menus Access to the main menu

Parameters setting access

Input/output state access

Trouble shooting guide per function

Machines status

Failures list


44..22.. PPAARRAAMMEETTEERRSS SSEETTTTIINNGG

Speeds settings from lower controls

Movement type Time Jib rotation full range lock to lock (HA12CJ+)

Left 31s +/- 5 sec right 31s +/- 5 sec

jib up 22s +/-5 sec

down 26s +/-5 sec

Arm up 24s +/-5s

down 22s +/-5s Turret rotation (1/2 turn/180°)

Left 56s +/-5s right 56s +/-5s

Main boom up 30s +/-5s

down 22s +/-5s

Telescopic boom IN 17s +/-5s

OUT 17s +/-5s

Compensation up 39s +/-2s

down 38s +/-2s speed control from lower control box

Movement type Time

Drive Micro speed FWD 54s +/-5s on 10 meters REV 55s +/-5s on 10 meters

Drive High Speed FWD 30s +/-5s on 50 meters REV 31s +/-5s on 50 meters

Drive Low Speed FWD 30s +/-5s on 20 meters REV 31s +/-5s on 20 meters

Arm up 21s +/-5s

down 20s +/-5s Turret rotation (1/2 turn/180°)


Main boom up 28s +/-5s

down 21s +/-5s Braking distances

Movement type Theoritical d istance Braking distance in High Speed and flat ground

FWD Distance < 1, 5 m REV Distance < 1, 5 m

Speed control from upper controls (hydrauli c oil T> 30°C) Movement type time

steering Left 3s +/-1s right 3s +/-1s

Telescopic boom IN 16s +/-5s

OUT 14s +/-5s

jib up 20s +/-5s

down 23s +/-5s

Basket rotation full range (lock to lock) Left 20s +/-5s right 20s +/-5s

Jib rotation full range lock to lock (HA12CJ+)


Compensation up 9s +/-5s

down 8s +/-5s


44..33.. OOPPTTIIMMIIZZEERR MMEENNUU

MOVEMENTS SPEED (%) RAMP

DESIGNATION MIN DEFECT MAX ACC DEC

JIB UP AT MINIMAL SPEED (JIB LIFT AT 30% OF ITS SPEED) 75.2 90 100

ACCESS CODE

LEVEL 2 OR 3

ACCESS CODE

LEVEL 2 OR 3

JIB UP AT MAXIMAL SPEED (JIB LIFT AT 100% FULL SPEED) 75.2 90 100

ACCESS CODE

LEVEL 2 OR 3

ACCESS CODE

LEVEL 2 OR 3

“JIB DOWN” 0 95.2 100 8 3

“FWD DRIVE” 0 100 100

“REV DRIVE” 0 100 100

“MICRO FWD DRIVE” 0 100 100

“MICRO REV DRIVE” 0 100 100

“PF. UP LEVEL” 0 95.2 100 10 10

“PF. DOWN LEVEL” 0 95.2 100 10 10

“STEERING LEFT” 0 95.2 100 3 3

“STEERING RIGHT 0 95.2 100 3 3

“ARM UP” 0 95.2 100 10 10

“ARM DOWN” 0 95.2 100 10 10

“TURRET LEFT” 0 95.2 100 10 10

“TURRET RIGHT” 0 95.2 100 10 10

“ BOOM UP” 0 95.2 100 10 10

“BOOM DOWN” 0 95.2 100 10 10

“PF. ROT. LEFT” 0 95.2 100 2 3

“PF. ROT. RIGHT” 0 95.2 100 2 3

“JIB ROT. LEFT” 0 95.2 100 12 6

“JIB ROT. RIGHT 0 95.2 100 12 6

“OUT TELESCO” 0 95.2 100 10 10

“TELESCO IN” 0 95.2 100 10 10 Note: the parameters “Turret” are at 80% of the “Pl atform”value


MENU OPTIONS

OPTIONS DESCRIPTION Default value Level

COUNTRY Choice of the country, between “the USA”, “Australia”, “Europe” USA 3

TRACTION BATTERIES Choice of the type of batteries, No: Semi-traction, Yes:Traction No 2

PROHIB IN TILT SIGNAL Selection of “CANADA” country option only valid from US model (slope sensor active with US country choice)

Inactive 3

TRANS BUZZER Activation of the buzzer if machine is in drive ( FWD, REV drive) Inactive 2

MOVEMENT BUZZER Activation of the buzzer on movements (except steering) Inactive 2

TRANS FLASH LIGHT Activation of the flash-light if machine is in drive mode ( FWD, REV drive) Inactive 2

MOVEMENT FLASH LIGHT

Activation of the flash-light on movements (except steering) Inactivate 2

FLASH LIGHT ON Activation of the flash-light when power is ON on the machine Inactive 2

LEVEL LIMIT +10/-10 Activation of the limitation of basket compensation (slope range for the basket +10°/-10°)

Active 2

MANUAL UNBRAKING

Authorize the possibility to release the electrical brakes on the drive motors thanks to the remote control box for brake release system

Inactive 2

HA12CJ+ version Choice of model type (HA12CJ: NO / HA12CJ+ YES) NO 2

PWM YV1 setting

Correction in current command on PWM • 100 no correction • <100 movements speed are

decreased • >100 movements speed are

increased

100 2


MENU DIAGNOSTIC Thanks to this menu , all functions could be tested

• How to understand the logic of DIAGNOSTIC mode •

Bit Field: Fields of 6 bits (read from right to left) of value 0bxxxxxx where X can take the value of 0 or 1

Internal Set point : Protected and formatted setpoint command coming from the active control desk for a given direction (Dir = Neutral or Fwd/Up/Left or Rev/Down/Right).

It could be at zero value in the event of defect of the control device (out of range, inconsistency of the neutral or the signals) and is formatted between 0 and 1000.

Int. Set Point Limit: Porcentage of application of the internal setpoint protected and formatted (100% = setpoint not slowed down). Internal Validation: Current conditions of authorization and cut-off of the movement in each

direction (Fwd/Up/L and Rev/Down/R). Each of the 7 bits (read from right to left) can take the value of 0 or 1. The 1st bit on the right is a condition for movement authorisation (1 if it’s authorized, 0 if it’s

prohibited), whereas the 6 other bits represents a particular condition of movement cut-off (1 if the movement is cut, 0 if it is authorized).

An authorized movement will thus have value of 0000001 for the corresponding direction Bits reading ( right to left as shown 654321

• 1: Condition for the validation of the movement • 2 :Condition for cutting the movement • 3 :Condition for cutting the multiple movement • 4 :Condition fo cutting the movement in overload mode • 5 :Condition for cutting the movement in slope mode • 6 :Condition for cutting the combined movement •

Internal Control = internal command validated starting from the setpoint of the function and sent towards the electrovalves and output relay for a given direction (Dir = Neutral or Fwd/Up/Left or Rev/Down/Right).

It integrates various logics of operation, and also the dynamic limitations of the instruction and the slopes of acceleration/deceleration.

It is formatted between a minimal internal speed (bias) and a modifiable maxi speed which could be modified with the OPTIMZER console

The direction of the command is also indicated

Function

Validation and

formatting of the command

Act uator Securing and formatting of the setpoint

Validatio n

Setpoint Limit

Setpoint Application of the command on actuators

Control controls

Inputs Outputs

[0-100]% [0-100]%


Some useful definitions :

Controls all commands coming from lower/upper controls Inputs Digitals or analog inputs (ETOR-EANA) Setpoint (0 -100%) In Diagnostic menu ,it’s the parameter Internal setpoint

for the function ( 0-1000pts) Valida tion Conditions for cutting the movements Validation and formatting the command

Conditions for validation of the movement

Setpoint limit /Limitation Condtions for slowing down the movement Control (0 -100%) In Diagnostic menu , it’s the parameter Internal control

for the internal command of the function (0 -1000pts) Outputs Digitals or Analog outputs ( STOR-SPWM –SANA) Actuator Any device like valves/cylinders/motors/relays

Some example Example machine in slope and boom lifting mode :

Binary code : 001 0001 ( machine in slope : reading from right to left) Functions available through DIAGNOSTIC MODE

ELEMENT DESCRIPTION NUMBER

Overload Variables, inputs and outputs relating to weighing 1

Machine state Variables, inputs and outputs relating to the state of the machine. 2

Drive Variables inputs and outputs relating to the drive mode 3

Steering Variables, inputs and outputs relating to the steering 4

PF. Level Variables, inputs and outputs relating to the basket compensation 5

ARM Variables, inputs and outputs relating to arm lifting 6

Turret Variables, inputs and outputs relating to the orientation of the turret 7

Jib Variables, inputs and outputs relative to the jib 8

Boom- Variables, inputs and outputs relating to boom raising 9

PF. Rot. Variables, inputs and outputs relating to basket rotation 10

Jib rot. Variables, inputs and outputs relating to jib rotation 11

Telescope Variables, inputs and outputs relating to the telescopic boom 12

Variator Variables, messages CAN, inputs and outputs relating to the variable speed transmission

13


OVERLOAD - PESAGE NAME INFORMATION DESCRIPTION VALUES

Internal variable ModePesage Status of the function

weighing

0:Absent, 1: jib learning(calibration) 2: Normal, 3:Defect, 4:back up

Internal variable Overload Overload static

machine 1: static overload

Internal variable Close Diff B2 (0.1b)

Differential pressure calculated in the module node B2 (turret)

Expressed in bar x 0.1

Internal variable Close ref. (0.1b) Pressure of

calculated reference Expressed in bar x 0.1

Internal variable Jib Angle (0.1 deg) Angle jib/boom

Expressed in degree x 0.1 - Near to 0 for the lowest jib

position - Near to 1400 for the upper jib

position

Internal variable ABS Angle (0.1 deg)

Angle of the basket/horizontal position

Expressed in degree x 0.1 Around 0 for basket at horizontal

Internal variable Rod Presses (0.1b) Pressure in jib small

chamber Expressed in bar x0.1

Internal variable Bore Presses (0.1b) Pressure in jib large

chamber Expressed in bar x 0.1

Internal variable Press Diff B3 (0.1b)

Differential pressure calculated in the module node B3 (PF)

Must be close to Diff B2 if not inconsistency

Internal variable HighStop electric higher limit 1: position reached

Internal variable LowStop Electric lowest limit 1: position reached

A1 Angle Value of the sensor of relative angle

0V-VbattV If 0V then sensor “in open circuit”

A2 Angle Value of the sensor of absolute angle

0V-VbattV If 0V then sensor “in open circuit”

G1 Cylinder press Value of the pressure sensor jib small chamber

0V-5V If 0V then sensor “in open circuit”

G2 Cylinder press Value of the pressure sensor jib large chamber

0V-5V If 0V then sensor “in open circuit”

Internal Variable PesAFault Fault in load system

0: no defect in progress =0: Detected defect Similar to OL0x defects = 1 if defect incremental position transducer in progress ==>defect OL03 = 2 if defect absolute position sensor in progress ==>defect OL04


= 4 if defect pressure sensor small jib chamber in progress ==>defect OL05 = 8 if defect pressure sensor large jib chamber in progress ==>defect OL06 = 16 if defect not of jib learning ==>defect OL01 = 32: none = 256: none = 512: inconsistency between command of the movement and evolution of the absolute position sensor ==>defect OL04 =1024: none = 2048: none =4096: inconsistency between calculations of pressures main B2 node/node B3 slave ==> defect OL07 =8192: inconsistency between pressures of reference and current pressure (too much distant) ==> defect OL08 = 16384: inconsistency calculated pressure ==> defect OL09

Internal variable AngAbsZero

Angular value of reference for 0° basket level

Used to calculate the current basket angle

Internal variable AngJibLowEnd

Angular value of reference for jib at its mechanical lowest position

Used to calculate the current jib angle


MACHINE STATE – ETAT

NAME INFORMATION DESCRIPTION VALUES

SQ34 ARM/BOOM DOWN:1 UP:0

State of proximity sensor for arm/boom folded

ON: if arm and boom are in stowed position

SQ9 TELESCOPE IN:1 OUT:0 State of proximity sensor for telescopic boom position

ON: if telescopic is fully retracted

SQ1 TILT SENSOR, FLAT:1 State of level sensor < X°

ON: Not in slope OFF: Machine in slope

Internal variable OVERLOAD YES:1 NO:0 State of weighing 1: Machine in weighing

Internal variable DEADMAN OK:1 NOK:0

State principal dead man switch or dead man and emergency pumps switch (high or low)

1: active and validated 0: Inactive or pushed more than 8s without movement

Internal variable

PF SPEED CONTROL 1-10

Value of the bar-graph for speed variation of the upper control box

1 to 10 (10% to 100% of speed)

DRIVE – TRANSLATION NAME INFORMATION DESCRIPTION VALUES

SM1 DRIVE JOYSTICK Set point of the joystick in entry of the module node B3

in mV joystick 0,5-2,5-4,5V

Internal variable

OUTPUT CENTER POSIT. Information out of neutral position

0: joystick in neutral position 1: joystick out of neutral position

Internal variable BRAKE STATUS Information of the brakes status

0: machine with brakes activated 1: machine with brakes released

Internal Set.Point

DRIVE SETPOINT IN (%) Signal of the joystick From 0 to 1000

(0% to 100%)

Int. Set point Limit

LIMITATION

Value of active limitation. 100% if no limitation on the movement (also take into account the system of speed regulation : buttons + and -)

From 0 to 100%

Internal Logical CUTTING OUT

Binary value of the state of the conditions of activation and prohibition of the movement Fwd/Up/L= 000000 Rev/Down/R= 000000 Reading from right to the left Bits: 654321 1: Condition of validation of the movement 2:Condition of cut of the movement 3:Condition of cut in movements in multiple mode 4:Condition of cut in overload 5:Condition of cut in slope 6:Condition of cut in controlled movements

From 000000 to 111111


Internal Control

DRIVE SETPOINT OUT(%)

Set point applied (according to the adjustments and safety measures in process)

From 0 to 1000 (0% to 100%)

Internal variable MicroS:1 LS:2 HS:3 Last speed of drive applied. (since

power is ON)

0: No drive speed applied 1: Microspeed applied at the last step 2: Low speed applied at the last step 3: High speed applied at the last step

STEERING - DIRECTION


SM1G STEERING LEFT BUTTON Left steering button activated OFF: Inactive

ON: Active

SM1D STEERING RIGHT BUTTON right steering button activated OFF: Inactive

ON: active

Internal Set.Point SETPOINT IN (TOR)

Set point TOR (either 0% or 100% represent)

0: No signal 1: left setpoint 2: right setpoint


LIMITATION

Value of active limitation. 100% if no limitation on the movement (also take into account the system of speed regulation buttons + and -)

From 0 to 100%


Binary value of the state of the conditions of activation and prohibition of the movement Fwd/Up/L= 000000 Rev/Down/R= 000000 Reading from right to left Bits: 654321 1: Condition of validation of the movement 2:Condition of cut of the movement 3:Condition of cut in in movements in multiple mode 4:Condition of cut in overload 5:Condition of cut in slope 6:Condition of cut in controlled movements

From 000000 to 111111

Internal Control SETPOINT OUT(%)


From 0 to 1000 (0% to 100%)

YV1 PWM (YV1) Signal applied to the PWM valve 0% to 100%

YV2A Left steering (TOR) ON/OFF valve OFF: Inactive ON: Active

YV2B Right steering (TOR) ON/OFF valve OFF: Inactive ON: Active


PF LEVEL – BASKET COMPENSATION


SA41A PF:LEVEL BUTTON UP PF: Button basket compensation UP

OFF: Inactive ON: Active

SA41B PF:LEVEL BUTTON DOWN

PF: Button basket compensation down


SA40A TUR:LEVEL BUTTON UP

Turret: Button basket compensation UP


SA40B TUR:LEVEL BUTTON DWN

Turret: Button basket compensation down



Set point ON/OFF (either 0% or 100% represented)

0: No signal 1: signal UP 2: signal DOWN


LIMITATION

Value of active limitation. 100% if not of limitation on the movement (also take into account the system of speed regulation buttons + and -)

From 0 to 100%



From 000000 to 111111



From 0 to 1000 (0% to 100%)


YV3A PF.LEVEL UP (TOR) ON/OFF valve OFF: Inactive ON: Active

YV3B PF.LEVEL DOWN (TOR) ON/OFF valve OFF: Inactive

ON: Active


ARM – (PRIMARY BOOM)


SA21A PF:ARM BUTTON UP PF: Button for arm lift OFF: Inactive ON: Active

SA21B PF:ARM BUTTON DOWN PF: Button for arm descent OFF: Inactive ON: Active

SA20A TUR:ARM BUTTON UP Turret: Button for arm lift OFF: Inactive ON: Active

SA20B TUR:ARM BUTTON DOWN

Turret: Button for arm descent



Set point ON/OFF (either 0% or 100% are represented)

0: No signal 1: signal UP 2: signal DOWN


LIMITATION

Value of active limitation. 100% if not of limitation on the movement (also take into account the system of regulation speed: buttons + and -)

From 0 to 100%



From 000000 to 111111

Internal Control SETPOINT OUT (%)


From 0 to 1000 (0% to 100%)


YV5A ARM UP (TOR) ON/OFF valve OFF: Inactive ON: Active

YV5B ARM DOWN (TOR) ON/OFF valve OFF: Inactive ON: Active


TURRET –


SM2X JOYSTICK (mV) Signal value of the joystick on module input

in mV Joystick 0,5-2,5-4,5V

Internal variable

OUTPUT CENTER POSIT. Information out of neutral

0: Joystick in neutral position 1: joystick out of neutral position

SA82A TURRET ROT BUTTON L

Turret: Left button turret rotation


SA82B TURRET ROT BUTTON R

Turret: right button turret rotation


Internal Set.Point SETPOINT IN (%/TOR)

Set point value (PF: vary from 0 to 100% Turret: either 0% or 100%)

PF: From 0 to 1000 (0% to 100%) Turret: 0: No signal 1: left setpoint 2: right setpoint


LIMITATION


From 0 to 100%



From 000000 to 111111



From 0 to 1000 (0% to 100%)


YV4A TURRET ROT. L (TOR) ON/OFF valve OFF: Inactive ON: Active

YV4B TURRET ROT. R (TOR) ON/OFF valve OFF: Inactive ON: Active


JIB -


SA51A PF:JIB BUTTON UP PF: button Jib UP OFF: Inactive ON: Active

SA51B PF:JIB BUTTON DOWN PF: button Jib Descent OFF: Inactive ON: Active

SA50A TUR:JIB BUTTON UP Turret: button Jib lift OFF: Inactive ON: Active

SA50B TUR:JIB BUTTON DOWN Turret: button Jib descent OFF: Inactive

ON: Active

Internal Set.Point SETPOINT IN (TOR) Set point TOR

(either 0% or 100% )

0: No signal 1: setpoint UP 2: setpoint DOWN

Int. Set point Limit LIMITATION


From 0 to 100%



From 000000 to 111111



From 0 to 1000 (0% to 100%)


YV8A JIB UP (TOR) ON/OFF valve OFF: Inactive ON: Active

YV8B JIB DOWN (TOR) ON/OFF valve OFF: Inactive ON: Active


BOOM – (SECONDARY OR MAIN BOOM)


SM2Y JOYSTICK (mV) Signal input value of the joystick

in mV Joystick 0,5-2,5-4,5V

Internal variable

OUTPUT CENTER POSIT.

Information out of neutral position

0: Joystick in neutral 1: joystick out of neutral

SA30A TUR:BOOM BUTTON UP Turret: Button boom lift OFF: Inactive

ON: Active

SA30B TUR:BOOM BUTTON DOWN Turret: Button boom descent OFF: Inactive

ON: Active

Internal Set.Point SETPOINT IN (%/TOR)

Set point (PF: vary from 0 to 100% Turret: either 0% or 100%)

PF: From 0 to 1000 (0% to 100%) Turret: 0: No signal 1: setpoint UP 2: setpoint DOWN


LIMITATION

Value of active limitation. 100% if not of limitation on the movement (also take into account the system of regulation speed: buttons + and -)

From 0 to 100%



From 000000 to 111111



From 0 to 1000 (0% to 100%)


YV6A BOOM UP (TOR) ON/OFF valve OFF: Inactive ON: Active

YV6B BOOM DOWN (TOR) ON/OFF valve OFF: Inactive ON: Active


PF - ROT – BASKET ROTATION


SA43A PF.ROT. BUTTON LEFT PF: Button left basket rotation OFF: Inactive ON: Active

SA43B PF.ROT BUTTON RIGHT PF: Button right basket rotation OFF: Inactive

ON: Active

Internal Set.Point SETPOINT IN (TOR) Set point TOR

(either 0% or 100% )



LIMITATION


From 0 to 100%



From 000000 to 111111



From 0 to 1000 (0% to 100%)


YV9A PF. ROT. LEFT (TOR) ON/OFF valve OFF: Inactive ON: Active

YV9B PF. ROT. RIGHT (TOR) ON/OFF valve OFF: Inactive ON: Active


JIB ROTATION -


SA53A PF:JIB ROT.BUTTON L PF: button for jib left rotation OFF: Inactive

ON: Active

SA53B PF:JIB ROT.BUTTON R

PF: Button for jib right rotation


SA52A TUR:JIB ROT.BUTTON L

Turret: button for jib left rotation


SA52B TUR:JIB ROT.BUTTON R

Turret: button for jib right rotation






LIMITATION


From 0 to 100%



From 000000 to 111111


Set point applied (according to the adjustments and safety measures in progress)

From 0 to 1000 (0% to 100%)


YV10A JIB ROT. LEFT (TOR) ON/OFF valve OFF: Inactive ON: Active

YV10B JIB ROT. RIGHT (TOR) ON/OFF valve OFF: Inactive

ON: Active


TELESCOPE


SA35A PF:TELES BUTTON OUT

PF: Button telescopic boom OUT


SA35B PF: TELES BUTTON IN PF: Button telescopic boom IN


SA22A TUR: TELES BUTTON OUT

Turret: Button telescopic OUT


SA22B TUR: TELES BUTTON IN Turret: Button telescopic IN OFF: Inactive

ON: Active



0: No signal 1: setpoint OUT 2: setpoint IN


LIMITATION


From 0 to 100%


Binary value of the state of the conditions of activation and prohibition of the movement Fwd/Up/L= 000000 Rev/Down/R= 000000 Reading from right to left Bits 654321 1: Condition of validation of the movement 2:Condition of cut of the movement 3:Condition of cut in in movements in multiple mode 4:Condition of cut in overload 5:Condition of cut in slope 6:Condition of cut in controlled movements

From 000000 to 111111



From 0 to 1000 (0% to 100%)


YV7A JIB ROT. LEFT (TOR) ON/OFF valve OFF: Inactive ON: Active

YV7B JIB ROT. RIGHT (TOR) ON/OFF valve OFF: Inactive ON: Active


VARIATOR -

NAME INFORMATION DESCRIPTION VALUES Internal variable BAT VOLTAGE (mV) Value of the batteries

voltage Value in mV

Internal variable KMG STATUS General state of main

contactor KMG OFF: Inactive ON: Active

Internal variable SETPOINT (MAX:255) speed setpoint received on

the variator 0 to 255 (0% to 100%)

Internal variable OUT POWER AMP (A)

current sent by the variator on power circuit (pump or drive motors)

xx (A)

Internal variable TOP SPIN STATUS Operation of the variator in

mode movements (pump) 0: Inactive 1: active

Internal variable BRAKE STATUS Information state of the

brakes

0: Braked machine with brakes ON 1: machine with brakes released

Internal variable TEMPERATURE (deg. C) Temperature interns

variator Of -40°c with 100°c

Internal variable CODE ALARM Alarm code sent by the

variator 0 to 255 (see detail)

Code

OPTIMIZER DEFINITION DIAGNOSTIC

13 EEPROM KB

The parameters have been altered and the movements are impossible If the problem has been solved when power is switched OFF then ON (the values are from now the default values) If the defect persists:change the variator

18 LOGIC FAILURES # 2 Fault in the “hardware “ system of the logic board which controls the pump contactor KM2

19 LOGIC FAILURES # 1 Problem in the logical circuit of the line contactor KMG or in the hardware of the variator (logic board)

30 VMN LOW Problem with the circuit power of the drive motors or connections,

31 VMN HIGH Problem with the circuit power of the drive motors or connections,

37 CONTACTOR CLOSED The terminals of the power contactor KMG remain stuck

53 STBY I HIGH Failure in the current detection as it didn’t drop to 0 when the variator is not activated Change the variator if the problem persists

57 HIGH FIELD CURRENT Defect in the circuit energizing F1 /F2 check connections replace the variator if the problem persists

58 NO FIELD CURRENT Defect in the field circuit F1 /F2 Check connections Replace the variator if the problem persists

60 CAPACITOR LOAD The capacitors doesnt charge 0.5 after power is ON Defect in the power circuit


62 TH PROTECTION

The internal temperature of the variator exceeds 75°C Defect in the temperature sensor Let’s cooling the variator before changing it

66 BATTERY LOW batteries discharged more than 80%

74 DRIVER SHORTED Short-circuit or open circuit on contactors KMG/KM1 or circuit brakes L3/L4

75 CONTACTOR DRIVER Problem on contactors KM1 or KMG or brakes L3/L4

76 COIL SHORTED Short-circuit or open circuit on contactors KMG/KM1 or circuit brakes L3/L4

77 COIL INTERRUPTED

When power is ON, the voltage applied on contactor is not correct Check connections /open and/or short circuit on coil before changing the variator

79 INCORRECT START

Starting was not carried out correctly, start again the sequence in the correct order (battery cut out, emergency stop, selection movement then joystick.)

99 INPUT ERROR # 1 No change of state on input (Problem on modules Problem on VMC (Volt Motor Controller),

223 WAITING FOR NODE VMC voltage tries to start without agreement of the variator (CAN bus problem or modules)

233 SENSOR I KO Current field sensor NOT OK 234 HW FAULT Problem of inverter, change KM1

241 FORW + TOP SPIN Dual command (drive + movements) , release all command

242 VALVE COIL SHORTED Not used for HAULOTTE, change variator if alarm appears again

244 CHECK UP NEEDED Warning that the maintenance scheduled is exceeded (not used by HAULOTTE on this kind of SEM1 variator )

247 THERMIC SENSOR KB

With power is ON, the variator checks if the values of the temperature sensor are in the tolerances If the problem persists,change the variator

248 KEY-OFF No power on system

249 CAN BUS KO No message coming from the CAN-BUS, check connections If the problem persists, change the variator

250 VFIELD NOT OK

With power ON, the system checks that the voltage on field circuit is at 50% Vbat with line contactor open Check connections Mass fault between chassis and variator

251 WRONG SET BATTERY Wrong type of batteries

252 AUX2 OUTPUT KO The system checks the circuit brakes command, if the received signal does not correspond, replace the variator

253 AUX1 OUTPUT KO The system checks the command of KM1 contactor if the received signal does not correspond, replace the contactor


SPEED VARIATOR UNIT ALARMS

CODE DESCRIPTION ACTION AV01 Problems in stator/rotor

current , logic, hardware, current probes, or CAN bus network or problems linked to an over or low voltage

Possible faults on ZAPI (13,18,19,53,57,58,233,234,241,244,247,248,252,253

AV02 Problems in main contactor KMG or with the contactor for selection traction/pump KM1 (open circuit, contact stuck or short-circuit)

- Possible faults on ZAPI (37,74,75 ,76 ,77,242) - Check the state of contactors and/or connections

AV03 Lack of power or problem in the motors/pump outputs

Possible faults on ZAPI (30,31,60,250)

AV04 Speed variator unit in thermal security

- Possible fault on ZAPI 62 - Let’s cool the speed variator unit until the fault disappears and meanwhile avoid to drive too much time in rising ramps

AV05 Wrong sequence for starting or error on one speed variator unit input

- Restart the machine in good way ( battery cut-out , e-stop buttons then key selector for upper/lower control box) - Check speed variator unit connection

AV06 Problem on batteries or batteries too weak

- Possible faults on ZAPI (66,251) - Reload or replace batteries

CONTACTOR OUTPUTS

CODE DESCRIPTION ACTION SC01 Output in open or short circuit :

validation relay KAV is defective (or missing) or wire is cut

Change relay KAV, check wiring and equipotential (on wires 273 et 0)

SC02 Output in open or short circuit: flashing light relay KAF is defective (or missing) or wire is cut

Change relay KAF, check wiring and equipotential (on wires 271 et 0)

SC03 Output in open or short circuit: horn relay KAK is defective (or missing) or wire is cut

Change relay KAK, check wiring and equipotential (on wires 272 et 0)

SC04 Output in open or short circuit : pump power coil contactor KM2 is defective (or missing) or wire is cut

Change contactor KM2 on speed unit plate , check cable 279 between chassis loom and turret box or wire 203 on coil (+12V)

SC05 Output in short circuit: brakes release relay KAB is defective (or missing) or wire is cut (fault only with SEVCON speed unit)

Change relay KAB, check cable 275 between chassis looms and turret box and check the 0 on relay.

SC06 Output in open or short circuit : emergency pump power coil contactor KMS is defective (or missing) or wire is cut (Fault visible only if the dead man toggle switch SA10b is activated)

Change relay KMS, check continuity on wire 208 between turret loom and emergency pump option loom + turret box, check wire 203 on coil (+12V)


VALVES OUTPUTS

CODE DESCRIPTION ACTION EV01 Output in open or short circuit :

PWM valve for secondary movements YV0 is defective (or missing) or wire is cut


EV02 Output in open or short circuit : PWM valve for main movements YV1 is defective (or missing) or wire is cut


EV03 - Output in open or short circuit : ON/OFF valve for left steering YV2A is defective (or missing) or wire is cut - Output in open or short circuit : ON /OFF valve for right steering YV2B is defective (or missing) or wire is cut

- Change coil YV2A, check wire 262 between loom bloc + turret box or wire 203 on coil itself (+12V) - Change coil YV2B, check wire 263 between loom bloc + turret box or wire 203 on coil itself (+12V)

EV04 - Output in open or short circuit : ON /OFF valve for basket compensation lifting YV 3A is defective (or missing) or wire is cut - Output in open or short circuit : ON/OFF valve for basket compensation descent YV 3B is defective (or missing) or wire is cut

- Change coil YV3A, check wire 240 between loom bloc + turret box or the 203 on coil itself (+12V) - Change coil YV3B, check the wire 241 between loom bloc + turret box or wire 203 on coil itself (+12V)

EV05 - Output in open or short circuit : ON /OFF valve: for turntable left rotation YV4A is defective (or missing) or wire is cut - Output in open or short circuit : ON /OFF valve: for turntable right rotation YV4B is defective (or missing) or wire is cut

- Change coil YV4A, check wire 282 between loom bloc + turret box or wire 203 on coil itself (+12V) - Change coil YV4B, check the wire le 283 between loom bloc + turret box or wire 203 on coil itself (+12V)

EV06 - Output in open or short circuit : ON /OFF valve: for arm lift YV5A is defective (or missing) or wire is cut - Output in open or short circuit : ON /OFF valve: for arm descent YV5B is defective (or missing) or wire is cut

- Change coil YV5A, check wire 220 between loom bloc + turret box or wire 203 on coil itself (+12V) Change coil YV5B, check wire 221 between loom bloc + turret box or wire 203 on coil itself (+12V)

EV07 - Output in open or short circuit : ON /OFF valve for boom lift YV6A is defective (or missing) or wire is cut - Output in open or short circuit : ON /OFF valve: for boom descent YV6B is defective (or missing) or wire is cut

- Change coil YV6A, check wire 230 between loom bloc + turret box or the 203 on coil itself (+12V) - Change coil YV6B, check wire 231 between loom bloc + turret box or wire 203 on coil itself (+12V)


EV08 - Output in open or short circuit : ON /OFF valve for right steering YV7A is defective (or missing) or wire is cut - Output in open or short circuit : ON /OFF valve for left steering YV7B is defective (or missing) or wire is cut :


EV09 - Output in open or short circuit : ON /OFF valve for jib lifting YV8A is defective (or missing) or wire is cut - Output in open or short circuit : ON /OFF valve for jib descent YV8B is defective (or missing) or wire is cut


EV10 - Output in open or short circuit : ON /OFF valve for basket rotation left side YV9A is defective (or missing) or wire is cut - Output in open or short circuit : ON /OFF valve for basket rotation right side YV9B is defective (or missing) or wire is cut

- Change coil YV9A, check wire 234 between bloc loom + turret box and wire 246 on coil (+12V) - Change coil YV9B, check wire 235 between bloc loom + turret box and wire 246 on coil (+12V)

EV11 - Output in open or short circuit : ON /OFF valve for jib rotation left side YV10A is defective (or missing) or wire is cut - Output in open or short circuit : ON /OFF valve for jib rotation right side YV10B is defective (or missing) or wire is cut


CAN-BUS ERRORS / EEPROM

CODE DESCRIPTION ACTION MX01 CAN fault communication check can-bus network

( impedance and connections) EP01 EEPROM checksum error Chang ECU module


JOYSTICKS(CONTROLLERS) – TOGGLE SWITCHES

CODE DESCRIPTION ACTION SM1Y Signal out of range or inconsistent

neutral value on drive joystick Check connection and signal value (0.5 -2.5-4.5VDC)

SM2Y Signal out of range or inconsistent neutral value on rotation /lift joystick


SM2X Signal out of range or inconsistent neutral value on rotation /lift joystick


SW01 Inconsistent value or neutral position not OK when power is ON , on one of the toggle switch in lower control box

Check toggle switches from lower control box

SW02 Inconsistent value or neutral position not OK when power is ON , on one of the toggle switch in upper control box

Check toggle switches from upper control box

OVERLOAD ALARMS

CODE DESCRIPTION ACTION OL01 - Adress fault on slave

module doing the load function - Inconsistant values between EEPROM datas saved between module master B2 and slave B3

- Problem in checksum parameters validation or overload calibration datas or problem during load calibration - redo the calibration

OL02 Fault in Jib learning Cal 1 Make or make again the Jib learning Cal 1 process OL03 - Inconsistent values

between jib movement and jib angle measurement - Fault in A1 relative angle sensor

- Check the jib angle sensor value and the direction of variation of this value (should increase when jib is lifting). - Jib angle sensor value out of range - Check sensor and its mounting/connection

OL04 - Inconsistent value between compensation movement and jib angle - Fault in A2 absolute angle sensor (inclinometer)

- Check the jib inclinometer sensor value and the direction of variation of this value (should decrease when basket is elevating) - Jib inclinometer sensor value out of range - Check sensor and its mounting/connection

OL05 - Fault in G1 pressure sensor in jib cylinder - Pressure variation too important in the jib small chamber

- Pressure sensor out of range - Check the sensor and its connection - Check if the pressure in the small chamber is varying in good way - Change the pressure sensor

OL06 - Fault in G2 pressure sensor in jib cylinder - Pressure variation too important in the jib large chamber

Pressure sensor out of range - Check the sensor and its connection - Check if the pressure in the large chamber is varying in good way - Change the pressure sensor

OL07 Inconsistent values for the calculation of the pressure recorded between modules node B2 master and slave B3

- Too much difference of calculation regarding the pressure datas between modules node B2 and B3 - Restart the machine - change module node B2 and/or node B3


CODE DESCRIPTION ACTION OL08 Inconsistent values for the

calculation of the pressure reference between modules node B2 master and node B3 slave

- difference more than 2 seconds between the reference pressure ( calibration value) registered by module node B3 and the current one registered by the master module node B2

OL09 Resultant pressure out of range

Pressure registered in node B2 out of range compared to the threshold value (low and high) The fault appears if the difference between the registered value and the recordered value is above 2 seconds

SENSORS ALARMS

CODE DESCRIPTION ACTION SE01

Incoherent status of sensors : no change during movement


SE02

Anti by-pass safety : detection of SQ34 from 0 to 1 without any movement)

Check wiring and sensors SQ9 and SQ34 : Telescopic IN SQ9=1 Boom+arm stowed , SQ34 = 1 Move both movemenst (telescopic then arm + boom) and check if failure has disappeared. Principle of survey : 1 –failure if without any movement , the sensor goes from 0 to 1

SE03 E-stop safety : detection position before power OFF and check position when power is ON again (sensor state should not have changed)

Check wiring and sensors SQ9 and SQ34 : Telescopic IN SQ9=1 Boom+arm stowed , SQ34 = 1 Move both movemenst (telescopic then arm + boom) and check if failure has disappeared.


44..44.. CCOONNSSOOLLEE DDIIAAGG PPAADD

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)


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

Original failure code New failure code AV01 F01.01 AV02 F01.03 AV03 F01.05 AV04 F01.06 AV05 F01.07 AV06 F01.08 SC04 F02.01 SC06 F02.02 SC01 F03.03 SC05 F03.04 SC02 F03.05 SC03 F03.06 EV03 F04.01 EV04 F04.02 EV05 F04.03 EV06 F04.04 EV07 F04.05 EV08 F04.06 EV09 F04.07 EV10 F04.08 EV11 F04.09 EV02 F04.11 EV01 F04.12 SM1Y F05.01 SM2Y F05.04 SM2X F05.06 OL01-OL02 F06.01 OL07-OL08 F06.02 SE01 F07.01 OL05 F07.20 OL06 F07.21 OL03 F07.22 OL04 F07.23 SW3 F08.07 MX01 F12.01 EP01 F12.02 SW01 F13.01 SW02 F13.02


44..55.. AADDJJUUSSTTMMEENNTT OOFF TTHHEE PPRREESSSSUURREESS

44..55..11.. PPRROOCCEEDDUURREE Note: the adjustment of the pressures is always done with a hydraulic oil temperature higher than 20°C The adjustment of the pressure relief valve is always done in the lift way (Note: It’s always better to constrain the spring rather than slacken it, the precision is better)

• Version 1

MOVEMENTS Pressures taken on pump exit ,

during movement (+/- 2b) Plug socket MP1 Rise/descent boom 186b Rise/descent arm 195b/177b Extension /retraction telescopic boom 188b/175b Main pressure / steering (D) 210b Plug socket MP2 jib 172b Jib rotation 169b compensation lifting (C) 155b Compensation descent 168b Rotation basket 169b Turret slewing (A left / B right) 100b Plug M version 2 Main pressure/steering (D) 210b

Connection of the pressure gauge in MP1 (movements big flow) or MP2 (movements low flow)

MP1

MP2


Version 2 Note: the pressure plug M on version 2 is fitted directly on main pump However the settings are the same as for version 1

M

A

B

C

D


55.. BBRREEAAKKDDOOWWNN SSEERRVVIICCEE GGUUIIDDEE

This guide does not replace the logical equations described previously in this manual, it makes it possible to the technician to have a logical step of breakdown service, detailing the successive stages, while going from main one 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 (ex not arm lift: neither raise, nor descent from both controls)

55..11.. NNOO SSTTAARRTT • Battery (GB1 48 volts)

• Converter GC1 48VDC /12VDC (+ 2 x20A fuses)

• Emergency stops (S1, SA140 and/or SA141)

• Key selector (SA1)

• contactor KMG

• relays KAT, KAV

• Relay KAC (battery charger)

• Variable speed unit

• Modules node B2 and/or B3

• Fuses FU1, FU2, FU3, FU6, FU7, FU10

55..22.. NNOO MMOOVVEEMMEENNTT • No pump (P1)

• No CAN BUS (wires 1001 and 1002)

• contactors KM1 and/or KM2

• machine in slope

• machine in overload

• Components of the system of weighing

• (angle sensors A1 and A2, pressure sensors G1 and G2)

• Calibration of weighing not carried out

• Pedal SB6 upper controls or switch “man dead” SA10 lower controls defective

• joysticks SM1 and/or SM2 (off neutral and/or signals)

• Defective 3.2cc gear pump

• General pressure relief valve190b not adjusted or defective

• Electrovalves YV0 or YV1

• By-pass valve 15b


55..33.. NNOO AARRMM LLIIFFTT • Switches SA21, SA20

• Electrovalve YV5

• Incompatibility with the multiple of movements of other functions which are connected to the same section of the position valve as this one

• No pressure

55..44.. NNOO BBOOOOMM LLIIFFTT • Switch low controls SA 30

• Joystick SM2 (off neutral and/or signal)


• Incompatibility with the multiple of movements of other functions which are connected to the same section of this valve

• No pressure

55..55.. NNOO TTEELLEESSCCOOPPIINNGG BBOOOOMM • toggle switch SA22 lower controls or SA35 upper controls



• No pressure

55..66.. NNOO TTUURRRREETT SSLLEEWWIINNGG • Switch posts SA82 low

• Joystick SM2 (off neutral and/or signal)


• Incompatibility with the multiple movements of other functions which are connected to the same section of this valve

• Not adjusted or defective pressure relief 100b valve

• No pressure

55..77.. NNOO JJIIBB • Switch SA50 lower controls or SA51 upper controls



• No pressure


55..88.. NNOO BBAASSKKEETT RROOTTAATTIIOONN • Switch upper controls SA43



• Not adjusted or defective counterbalance 140b valves

• No pressure

55..99.. NNOO JJIIBB RROOTTAATTIIOONN - Switch SA52 lower controls or SA53 upper controls - Electrovalve YV10

- Incompatibility with the multiple of movements of other functions which are connected to the same section of this valve

- Not adjusted or defective counterbalance valves 210 B - No pressure

55..1100.. NNOO CCOOMMPPEENNSSAATTIIOONN - Toggle switchs SA40 lower controls or SA41 upper controls

- Electrovalve YV3

Incompatibility with the multiple of movements of other functions which are connected to the same section of this valve

- Not adjusted or defective counterbalance valves 210b

55..1111.. NNOO DDRRIIVVEE - Joystick SM1 (off neutral and/or consigns)

- Contactor KM1

- Electromagnets of brake system L3/L4

- Defective motor (M1, m2)

- Another movement in progress

55..1122.. NNOO HHIIGGHH SSPPEEEEDD - Proximity detectors SQ 34, SQ 9

- Selection High speed SA67 upper controls

55..1133.. NNOO SSTTEEEERRIINNGG - Rocker on joystick SM1

- Electrovalve YV2

- Incompatibility with the multiple of movements of other functions if they’ve started before the steering

- Contactor KM1 or KM2

- No pressure


55..1144.. BBAATTTTEERRYY CCHHAARRGGEERR

STATE LED

Fixed RED In initial load phase binkling red Duration of too long load FIXED YELLOW Phase of stabilization blinkling green In phase of equalization Fixed green Finished load


ZIVAN 110vac

66.. SSUUMMMMAARRYY OOFF VVEERRSSIIOONNSS HHAA1122CCJJ--HHAA1122CCJJ++

HA 12 CJ - HA12CJ+ Wiring diagram

Hydraulic diagram

All models from 01-2010 EC - CDN - USA - AUS 164P322210 164P316940


77.. SSPPEECCIIAALL FFUUNNCCTTIIOONNSS

77..11.. SSYYSSTTEEMM OOFF LLOOAADD CCOONNTTRROOLL The load management system has as a function to detect an overlap of nominal load, to inform the user and to prohibit certain movements. For that, the jib of the machine equipped with a cylinder for double purpose, must be instrumented by 2 angular sensors and 2 pressure sensors (1 in each chamber of the jib cylinder)

77..11..11.. OOPPEERRAATTIIOONN The system uses four sensors:

• A pressure sensor who measures the pressure in the large chamber of the jib cylinder (G2)

• A pressure sensor who measures the pressure in the small chamber of the jib cylinder (G1)

• A relative angle sensor who measures the angle between the link piece and jib (A1)

• An absolute angle sensor (or inclinometer) who measures the angle of the link piece compared to gravity (A2)

• A module B3 node located in upper control box specific to the model

77..11..22.. PPRRIINNCCIIPPLLEE OOFF TTHHEE LLOOAADD CCOONNTTRROOLL The module node B3 compares the current resulting pressure with the maximum pressure authorized in the position given by the relative angle sensor. In the event of overload, it informs the module node A via can bus network According to this information, the main module node A controls the actuators and forbidden some movements. The authorized maximum pressure is determined by a calibration carried out in factory, or within the maintenance routine check A jib cycle with nominal load controls the system by several automatic stops, during which the module records at each step, the angle and the static pressure. The software limits the clearance of jib to its two positions also called electric stops so that the cylinder is never at full mechanical stroke

77..11..33.. AANNGGLLEE SSEENNSSOORRSS Relative angle sensor (A1) This potentiometric sensor measures the relative angle of a moving part compared to the structure on which it is fixed, The pin of output of the potentiometer makes it possible to follow the movement of jib and thus delivers signals according to the position of this one. Absolute angle sensor (A2) Another geometrical parameter has an impact raised on the pressure: the absolute angle (compensation) of jib, therefore the slope of the basket The sensor delivers angular information of position between the part holder and an “absolute” reference This sensor consists of a beam in an oil bath whose position is imposed by gravity, oil has as a function to deaden the movements of the pendulum. A mathematical formula corrects the pressure according to the measured angles, bring back it to a value corresponding to the horizontal basket. The correction of the absolute angle is limited to a range from - 10° to +10°.


77..11..44.. MMAANNAAGGEEMMEENNTT OOFF TTHHEE NNOOMMIINNAALL LLOOAADD OOVVEERRLLAAPP An overlap of nominal load involves:

• The activation of the sound buzzer,

• The activation of lights for overload (HL 13) and for defect (HL 1)

• The forbidden of all the movements from platform.

• The deceleration of all the movements from turret.

77..11..55.. CCAALLIIBBRRAATTIIOONN OOFF TTHHEE PPWWMM VVAALLVVEE PWM valve: Pulse Width Modulation Valve

Note: due to the coil hysterisis on PWM valve YV0 and the sensitivity of the overload sensors , the overload detection could be affected even if the basket is empty , that’s why if this valve is changed , it’s strongly recommended to calibrate it

Attention this procedure will erase the overload ca libration

• Prerequisites

• Main switch SA1 on turret position (T) • Machine under power • Tilt sensor SQ1 not activated • Oil temperature > 10°C • Machine in stowed position : (proximity switchs arm + boom SQ34 = 1 + telescopic boom

extension SQ9 = 1) • Jib in the axis and basket at horizontal position (no checkings are done by the system) • Jib cylinder purge done ( proceed to lift/down the jib 5 times) • Batteries must be charged (≥ 40% load)

• PWM setting

o Setting of jib lowering speed at minimun speed If not already done : Menu PARAMETERS -> CODE ACCESS level 2 -> Code->2031 Menu : PARAMETERS -> SPEEDS -> jib up Minimum speed (remain in this menu during all this adjustment)

• As long as the console displays this menu, the speed of the jib is set up automatically on minimum speed. The default setting is 90.0%. The electrical stops are no longer present. • Change the setting, use the "+" and "-" in the console. It is imperative to confirm the setting by pressing the * key, otherwise the value is not taken into account. Procedure

Set the jib min speed Lift the jib from full height and record the time , it must be 68 +/- 2 sec ( if not in the range , adjust the jib up minimum speed parameters Set the jib max speed Menu : PARAMETERS -> SPEEDS -> jib up Maximum speed and stay in this menu during this adjustment Lift the jib from full height and record the time , it must be 21 +/- 2 sec ( if not in the range , adjust the jib up maximum speed parameters) END of PWM settting

• IMPORTANT : even if the overload calibration has already been done , the fact to calibrate the PWM valve will automatically cancel t he overload calibration


77..11..66.. CCAALLIIBBRRAATTIIOONN OOFF LLOOAADD MMAANNAAGGEEMMEENNTT SSYYSSTTEEMM • Prerequisites • Main key selector toggle switch SA1 on turret position (T) • Machine always switched ON • Tilt sensor SQ1 not activated • PWM adjustment done

(if not see PWM adjustment process) • Machine in stowed position : (proximity switches arm + boom SQ34 = 1 + telescopic

boom extension SQ9 = 1) • Jib in the axis and basket on horizontal position (no checks are done by the system) (the basket compensation is possible with the dead man button in the calibration menu) • No failures OL01 to OL09 Weighing (failures erase only in code level 3)

Lift the jib UP and DOWN lock to lock (without load) before starting the procedure (oil temperature > 10°)

• Basket at horizontal position ( When the load is in the basket , check basket level 0° +/- 0.5°)

• Put load on basket (see below)

ATTENTION : the load in the basket must correspond to the required load for each model: (HA12CJ + = 240kg (529lbs) et HA12CJ = 260kg (573lbs) , (no control are made by the system).


• Procedure

Select Active

Menu PARAMETRES ->CODE ACCES -> code->2031 Menu PARAMETRES -> CALIBRATION -> Jib learning: Cal. 1

Press

If not OK Display

Drain jib cylinder . 5 Movements from low

Stop to high stop. Press (*) when done

The setting or checking the PWM must be made before the calibration load. If this is not the case see the procedure for adjusting the PWM

These 5 mouvements purge the jib cylinder.

If not OK start again


Maintain the toggle switch (jib down) until pump stops running and the following message appears

Activate and hold the toggle switch (jib UP) (Full duration is around 10 minutes and it’s necessary to stabilize pressure at each level (stop at least 10 seconds at each level) to:

In highest position with jib at full stroke and pump stops running

NOTE: It happens several seconds between the end of the movement and the pump stop, so wait until the end of both conditions

Note: If you release the button too early, the calibration must be restart from the beginning

Lowest jib position detection

Jib lifts from step of 5°

Jib descent phase


Activate and hold the toggle switch (down jib) The jib must be down until its lowest position (full stroke)

+

Pump stops running

If OK Display

If not OK Display

End calibration

Note: A message may a ppear OL05 or OL06, do not take care about this and make a movement to swing out from the mechanical stop

END OF CALIBRATION (JIB LEARNING ) Remove the load. Raise the jib from the lower control box of about 20 ° and down it until the lowest electric stop Check that the jib stops before the full mechanical stroke (the rod cylinder must be visible at about 10 mm) Switch OFF and ON again the power on the machine and check that the load failures is present in the menu FAILURES If necessary, remove the errors in OL01 OL09 stored in EEPROM (menu access by level 3).


77..11..77.. VVAALLUUEESS OOFF TTHHEE SSEENNSSOORRSS OOFF WWEEIIGGHHIINNGG

The normal range of operation of the relative sensor A1 is of approximately of

5V (+-0.5V) out of jib lowest stop and with 10V (+-0.5V) out of jib high stop

The signal of the absolute sensor (or inclinometer) A2 with basket at flat level must be around 6V (+-0.5V)

The normal operating range of the pressure sensors G1 (small chamber of the jib cylinder) and G2 (large chamber of the jib cylinder) is between 500mV and 4000mV.

These sensors work into opposite during the jib movement

Indicative values:

SENSORS A1 (mV)

A2 (mV)

G1 (mV)

G2 (mV)

JIB MINI POSITION 5000 5940 1290 1290

JIB HORIZONTAL 7495 5960 530 985

JIB MAXI POSITION 9980 5980 1175 1365


77..11..88.. DDIIAAGGNNOOSSTTIICC It’s a summary of the main faults noted during the load management control, with the actions to be done for erase the problem:

DEFECT ACTION DIAGNOSTIC Alarm during more 10sec after the stop of the movement at 100% of load following a movement of rise (step 2 and/or 3) More generally presence of alarm at 100% of load whatever the position

decrease the adjustment “Jib Up minimum Speed” (thus speed is slower between low stop and high stop) calibrate again. control the load system. note the modifications in the machine’s file

charge the machine with 240kg (HA12CJ+) or 260kg (HA12CJ). enter the code level 3. In menu “ PARAMETERS SPEEDS” select “Jip Up minimum speed”. take 3 measurements of jib lifting from low stop to high stop:

- lower the jib to lowest position - wait for a few seconds - lift the jib - when jib starts to move launch the

stop watch, and stop it when the machine arrives at full position If the measured times are stable (less than 3 seconds between maximum value and measured value minimum), decrease speed “Jip Up minimum speed” Put 70 sec. take at least two new measurements. check that the time is slower. If the time is slower, calibrate again then control the load system


No alarm at 120% of nominal load at highest position (step 3) More generally no alarm at 120% of load whatever the position is

increase the adjustment “Jib Up minimum Speed” (thus speed is faster between low stop and high stop). Calibrate again control the load system. note the modifications in the file machine’s file.

charge the machine with 240kg (HA12CJ+) or 260kg (HA12CJ). enter the code level 3. In menu “PARAMETERS SPEEDS” select “Jip Up minimum speed”. take 3 measurements of jib lifting from low stop to high stop:

- lower the jib to lowest position - wait for a few seconds - lift the jib - when jib starts to move launch the

stop watch, and stop it when the machine arrives at full position If the measured times are stable (less than 3 seconds between maximum value and measured value minimum), decrease speed “Jip Up minimum speed” ”. put 66 sec To take at least two new measurements. To check that time is faster. If time is faster, calibrate again and control the load system. Before calibration , possibility of checking that the jib makes a light reverse movement after a movement of lift near the highest position with 100% of load + 10kg.

Summary cases where some actions must be done according to the symptom

Elements HA12CJ/+

PWM adjustment drain calibration

calibration badly made X X X change of hydraulic block X X X change of PWM valve X X X leak on the hydraulics circuit of jib cylinder X Element of the ON/OFF jib block X The jib cylinder X X X modification of the version of machine (having an impact on the permitted load ) X X

loss of parameters X X Replacement of hose on jib cylinder X X X replacement of the absolute angle sensor X replacement of the relative angle sensor X replacement of the pressure sensor X

replacement of the platform controls box machines CAN machines

CAN replacement of the lower control box X X replacement node B2 X X replacement node B3 X X


77..11..99.. VVAALLUUEESS OOFF TTHHEE IIMMPPEEDDAANNCCEE OOFF TTHHEE VVAARRIIAATTOORR UUNNIITT Before any check, disconnect all wires from the variable speed unit

TERMINALS TERMINALS IMPEDANCE VALUE B - T (VMNT) 128.6 KΩ B- F2 128.9 KΩ B+ Connector A1 64 KΩ F1 F2 132.7 KΩ


77..11..1100.. BBRRAAKKEE AADDJJUUSSTTMMEENNTT OONN DDRRIIVVEE MMOOTTOORRSS

In case the engine and/or brake is changed, the procedure described below explains how to readjust or check the brakes gap Photo A: with a Allen key of 4mm, check the 3 screws (tightening torque of these screws 5,6 - 6,8 Nm). These 3 screws are assembled to with loctite 242. Photo B: checking of the gap between brake and flask

A

B


88.. LLIISSTT OOFF SSCCHHEEMMAATTIICCSS

See below all schematics (electric/hydraulic) of all versions







Documents

Technical Training Level II HA12CJ_EN_e02-14