TRAINING MANUAL DIAGNOSTIC Level E07-14

Transcription

1 TECHNICAL TRAINING DIAGNOSTIC LEVEL II HA12CJ-CJ E07-14

2 How to use this document? MAINTENANCE AND REPAIR OPERATIONS ON YOUR HAULOTTE MACHINE MUST BE DONE ONLY BY TRAINED,EXPERIENCED AND AUTHORIZED TECHNICIANS You have between the hands the summary given during the HAULOTTE technical training It will enable you to find information necessary for the maintenance and the repair of your HAULOTTE.machine. Thanks to the guide below you will reach the required chapter quickly. Chapter 1: Main features and functions It is a resume of the information contained in the user manual delivered with the machine: components, overall dimensions, working zones, commands, etc Chapter 2: Study of the electric diagram You will find there the elements as following: - A summary of the standardized symbols used by HAULOTTE Group - The complete wiring diagram of the studied model - The non exhaustive list of the electric looms and electronic boards - Localization of the main safety units (tilt, limit switches, sensors,transducers ) - Logical equations of operation: by function, to diagnose the main dysfunctions Chapter 3: Study of the hydraulic diagram You will find there the elements as following: - a summary of the standardized symbols used by HAULOTTE Group - the complete hydraulic diagram of the studied model - the non exhaustive list of the hoses track - a localization of the main hydraulics manifold (proportional block, on/off movements block, ) Chapter 4: Adjustments This is the adjustments and calibrations, hydraulics and electric, necessary to the good maintenance of the material. You will find as well the methods of adjustment with table values. Chapter 5: Guide of breakdown Quick summary of the step to be followed for possible sources of breakdown. In case of any defect or any dysfunction you will be able to identify the elements in question, whatever they are electric or hydraulic. Chapter 6: Summary of the versions This manual treats of the latest version; however this summary table enables you to find the former versions of the material (electric and hydraulics). Chapter 7: Special functions This chapter gathers all the functions and adjustment specific to carry out on the machine. There does not exist for all the materials and depends on the studied model. It must be the subject of a special attention of your share because an intervention badly carried out can deteriorate the good performance of the machine and thus consequently the safety of the users. Only a technician HAULOTTE or approved by HAULOTTE Services is able to carry out this kind of intervention. On this chapter, some special adjustment (sensors) are also explained prior to calibration (depends on the model) Chapter 8 : List of schematics This chapter lists all schematics (electric/hydraulic) of all versions and some layout if required E /123

3 REVISION Revision Edition Subject Created by Validated by Modified by Translated by Language Creation MGD FLH MGD FR/EN Update parameters MGD MGD FR/EN + calibration process Newest parameters MGD MGD EN on diagnostic console Add Diag Pad info + MGD Central MGD MGD EN console alarm list R&D Add chapter MGD EN schematics Add schematics with ASB (Active Shield bar) option MGD EN E /123

4 SUMMARY 1. MAIN FEATURES AND FUNCTIONS CHARACTERISTICS ha12 cj-cj LOADING POINTS HA12CJ-CJ FEATURES HA12CJ-CJ OVERALL DIMENSIONS HA12CJ-CJ WORKING ZONE HA12CJ (HA32CJ) THE LOWER CONTROLS THE UPPER CONTROLS THE ELECTRICAL PART SYMBOLS USED METHODOLOGY OF CONTROL electric continuity control Control of an on/off valve Control of components THE ELECTRIC SCHEMA (164P322210) looms module node b2-b LOCALIZATION OF THE MAIN COMPONENTS STRUCTURE OF THE SYSTEM LIST OF COMPONENTS motor Fuses inputs Outputs LOGICAL EQUATIONS OF OPERATION Power Steering drive boom lift Telescoping boom Lifting arm Turret slewing jib Compensation basket rotation jib rotation (ha12cj+) version eur Options usa /cdn/australia ALARMS CODES CONSOLE OPTIMIZER ALARMS CODE UPPER CONTROLS DETAILS ON ALARMS SE01 SE02 - SE ALARMS CODES ON VARIABLE SPEED UNIT ZAPI THE HYDRAULIC PART SYMBOLS USED HYDRAULIC DIAGRAM MAIN MANIFOLDS Hydraulic block detail of valves THE LOOMS see spr catalog ADJUSTMENTS ADJUSTMENTS WITH CONSOLE OPTIMIZER PARAMETERS SETTING OPTIMIZER MENU CONSOLE DIAG PAD ADJUSTMENT OF THE PRESSURES E /123

5 Procedure BREAKDOWN SERVICE GUIDE NO START NO MOVEMENT NO ARM LIFT NO BOOM LIFT NO TELESCOPING BOOM NO TURRET SLEWING NO JIB NO BASKET ROTATION NO JIB ROTATION NO COMPENSATION NO DRIVE NO HIGH SPEED NO STEERING BATTERY CHARGER SUMMARY OF VERSIONS HA12CJ-HA12CJ SPECIAL FUNCTIONS SYSTEM OF LOAD CONTROL Operation Principle of the load control Angle sensors Management of the nominal load overlap calibration of the pwm valve calibration of load management system Values of the sensors of weighing diagnostic Values of the impedance of the variator unit brake adjustment on drive motors LIST OF SCHEMATICS E /123

6 1. MAIN FEATURES AND FUNCTIONS 1.1. CHARACTERISTICS HA12 CJ-CJ E /123

7 E /123

8 LOADING POINTS HA12CJ-CJ E /123

9 FEATURES HA12CJ-CJ E /123

10 E /123

11 E /123

12 OVERALL DIMENSIONS HA12CJ-CJ E /123

13 WORKING ZONE HA12CJ (HA32CJ) CJ version E /123

14 CJ+ version E /123

15 1.2. THE LOWER CONTROLS E /123

16 E /123

17 1.3. THE UPPER CONTROLS E /123

18 E /123

19 2. THE ELECTRICAL PART 2.1. SYMBOLS USED Battery with one element Alternator Fuse (Here 10 amps) Coil winding roll Electric motor light Diode Hourmeter E /123

20 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 E /123

21 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) E /123

22 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) E /123

23 2.2. METHODOLOGY OF CONTROL Note: during an intervention on a component or a loom, it is important to remember to switch OFF the power supply of the machine in order to avoid any risk ELECTRIC CONTINUITY CONTROL The continuity check of a loom or an electric component determines the resistor of this device, in order to detect a possible interruption of continuity (open circuit, short-circuit ). This control is carried out with a multimeter commutated in position Ohmmeter (Ω). First of all, it is necessary to determine the terminals of the component or the cable to control and insulate them. Then, connect the multimeter in order to record the value. It must indicate a value of resistor close to 0 Ω if continuity is good. In the contrary case (resistor which tends towards the infinite one : ), continuity presents a defect. Control of insulation At the contrary of continuity, insulation represents a non electric 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 : CONTROL OF AN ON/OFF VALVE Note: These tests are to be carried out when power is ON. Also control the state of the terminals or any other connectors (oxidation ) Control supply of the coil Disconnect the plug socket of supply of the valve in order to connect in derivation the multimeter on the terminals of the connector (see below). Select the position to voltmeter (V), then activate the command to the valve which must be tested. The voltage indicated by the voltmeter must be close to the tension of battery E /123

24 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 CONTROL OF COMPONENTS Control of an electric relay Disconnect the relay,then locate its various terminals. Control the resistor of the solenoid terminals 85 and 86 (see manufacturer datas) using a multimeter in Ohmmètre position. If the resistor is null, change the relay. If this test is OK, check continuity between terminals 30 and 87a and insulation between terminals 30 and 87 In the event of dysfunction, replace the relay. supply control of the relay E /123

25 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 E /123

26 Control of a fuse Color code Fuse check Multimeter in Ω position, it must indicate a value near 0 OK NOK 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 E /123

27 2.3. THE ELECTRIC SCHEMA (164P322210) see at the end of the manual LOOMS See SPARE PARTS CATALOG Looms interconnection 164P A Low control box 164P /12A Door lower control box 164P A Upper control box 164P /5/9/11/12/14/16/17A E /123

28 MODULE NODE B2-B3 HA12CJ-CJ E07-14

29 2.4. LOCALIZATION OF THE MAIN COMPONENTS SQ9 A1 SQ34 A2 SQ1 G1-G2 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) E /123

30 2.5. STRUCTURE OF THE SYSTEM 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 ) E /123

31 2.6. LIST OF COMPONENTS In the following tables, the column n 2 gives the coordinates 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 connector 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 MOTOR MOTOR M Left traction motor (T-307) M Right traction motor (T 307) P Electric pump (T -306) L Left electric brake (B2-247) L Right electric brake (B13-248) FUSES FUSES FU Main 500A (301) FU Pump 160A (305) FU Variable speed unit 10A (A1-107) FU Flashing light 3A (905) FU Horn 3A (205) FU Supply module node B2 10A (203) FU Supply module node B3 10A (246) FU Supply actuators 3A (242) FU Supply emergency pump 30A (322) FU Supply lower controls 15A (303) FUxx x 20A on converter I/O not labelled on drawings Converter 2 x20a fuses (I/O) E /123

32 INPUTS INPUTS LOWER CONTROLS (node B2) S Battery main switch (309) SA Selection turret - basket (104) SA Emergency stop button (102) SB CN Option for manual brake release device (174) SA10a 04-4 CN 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 telescopic extension (122) SA22b 04-9 CN telescopic retraction (123) SA30a 04-8 CN104.3 Boom lift (130) SA30b 04-8 CN104.4 boom descent (131) SA40a CN104.9 basket compensation Rise (140) SA40b CN basket compensation Descent (141) SA50a CN jib rise (150) SA50b CN jib descent (151) SA52a CN jib rotation left (152) SA52b CN jib rotation right (153) SA82a 04-5 CN104.5 turret rotation left(182) SA82b 04-5 CN104.6 turret rotation right(183) E /123

33 INPUTS UPPER CONTROLS ( node B3) SA Mushroom-headed button emergency stop (215) SB CN Foot pedal (B141) SA CN104.1 Horn (B106) SA21a 05-8 CN104.7 Arm lift(b112) SA21b 05-8 CN104.8 Arm descent (B113) SA35a CN Telescope extension (B118) SA35b CN Telescope retraction (B119) SA43a CN Basket rotation towards left side (B116) SA43b CN Basket rotation towards right side (B117) SA51a 05-7 CN jib rise (B120) SA51b 05-7 CN jib descent (B121) SA53a CN Jib rotation towards left side(b125) SA53b CN Jib rotation towrads right side (B126) SA CN Selection high speed drive (B122) SB CN104.5 Push-button for speed reduction choice for movements SB CN104.6 Push-button for speed increase choice for movements SB CN105.4 Push-button for emergency pump (option) SM SM CN CN CN104.3 CN104.4 CN CN CN Drive joystick signal Y VDC (B300) neutral (B315) Left steering (B108) Right steering (B109) Movements joystick signal turret rotation X VDC (B303) signal boom lift Y VDC (B302) neutral (B316) V1 B2 B3 MODULES 03-6 Variable speed unit speed 04 ECU Module node B2 (lower controls) 05 ECU Module Node B3 (upper controls) E /123

34 SQ1 SQ34 SQ9 A1 A2 G1 G2 SENSORS CN105.3 Slope sensor (172) CN105.2 Detection arm + boom =1 if presence of metal (171) CN105.4 Detection telescopic IN = 1 if presence of metal (180) CN jib angle sensor on jib (weighing) (B304) CN Absolute angle sensor on jib or inclinometer (weighing) CN Pressure sensor on jib cylinder small chamber CN Pressure sensor on jib cylinder large chamber OUTPUTS KAB KAC KAF KAK KAT KAV KMG KM1 KM2 KMS KAM* RELAYS 04-9 Relay for brakes (for variable speed unit SEVCON only) 02-8 Relay for battery charge (106) 04-6 CN Relay for flashing lights (271) CN Relay for horn (272) Relay for validation supply converter 48/12VDC (106) 04-7 CN Relay for validation variable speed unit (273) 03-8 Main contactor variable speed unit (176) 03-8 Contactor selection traction/movements (178) CN Pump contactor (279) CN Contactor (option emergency pump ) 04-8 CN 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 E /123

35 KMG FU3 FU10 KM2 KM1 VALVES YV CN Secondary PWM1 movements (low flow) (276) YV CN Main PWM2 movements (big flow) (277) YV2a CN Left steering (262) YV2b CN Right steering (263) YV3a CN basket compensation rise (240) YV3b CN basket compensation descent (241) YV4a CN Turret slewing towards left (282) YV4b CN Turret slewing towards right (283) YV5a CN Arm lifting (220) YV5b CN Arm descent (221) YV6a CN Boom lift (230) YV6b CN Boom descent (231) YV7a CN telescope IN (B600) YV7b CN telescope OUT (B601) YV8a CN jib rise (B615) YV8b CN jib descent (B607) YV9a CN Basket rotation towards left side (243) YV9b CN Basket rotation towards right side (244) YV10A CN jib rotation to left side (B602) YV10B CN jib rotation to right side (B603) E /123

36 H1 BG1 BG2 BG3 HA1 HA142 HL1 HL2 HL102 HA141 HL142 HL143 HL144 LIGHTS -BUZZER CN Hour recorder lower controls (173) CN106.2 Battery charge state indicator upper controls CN106.1 speeds movements indicator upper controls CN Battery charge state indicator lower controls Buzzer (207) 04-8 CN Buzzer lower controls (275) Flashing lights (206) 05-3 Work headlight (905) CN Light power supply OK upper controls (B501) 05-8 CN Buzzer upper controls (B508) CN Light overload upper controls (B505) 05-7 CN Light slope (B500) 04-7 CN Light overload lower controls (274) E /123

37 2.7. LOGICAL EQUATIONS OF OPERATION For all these conditions, the fuses will have to be checked as a preliminary The condition of the equations of operation described below refers to the standard EN280, machines known as Standard (for other standards USA, CDN, AUS) thank you to refer to HAULOTTE SERVICES of your sector which will indicate the characteristics of your machine POWER Function Power upper controls Power lower controls Action KMG = 1 (Machine switched ON without alarms) Necessary S1= 1+ SA140=1 + SA1 (side N) =1 Batteries charged + SA141 =1 S1 =1 + SA140 + SA1 (side T) =1 Batteries charged CONDITIONS Prohibiting the function KAC=0 KAT =0 KAV =0 Module node B2 and/or Modifying the function B3 KAM = 0 KAC=0 KAT=0 KAV=0 Module B2 node STEERING Function Right steering Left steering Action KM2 = 1+ YV1 = 1 + YV2B=1 KM2 =1+ YV1=1 +YV2A=1 Necessary SA1 (side N) + SB6 = 1 + SM1d=1 + KM1 =0 SA1 (side N) + SB6 =1 + SM1g=1 + KM1 =0 CONDITIONS Prohibiting the function 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 Modifying the function A movement already in progress before steering command E /123

38 DRIVE Function Low speed forward Low speed reverse High speed forward High speed reverse Action KM1=0 variable speed unit from 0 to 500A KM1=0 variable speed unit from 0 to 500A KM1=0 variable speed unit from 0 to 500A KM1=0 variable speed unit from 0 to 500A Necessary CONDITIONS Prohibiting the function 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 SA1 (side N) + SB6 =1 + SA67 = 0 + SM1HN =1 + signal between 2.5 and 0.5 V SA1 (side N) + SB6=1 + SA67=1+ SM1HN =1 + signal between 2.5 and 4.5 V SA1 (side N) + SB6=1 + SA67=1+ SM1HN =1 + signal between 2.5 and 0.5 V SQ1 = 0 (slope) brakes blocked L3/L4 SQ34=0 SQ9 = 0 (machine unfolded) Modifying the function A movement already in progress before the drive command go in microspeed if SQ1 = 0 (machine in slope) + SA67 = E /123

39 BOOM LIFT Function Action Necessary CONDITIONS Prohibiting the function Modifying the function Rise upper controls Descent upper controls KM1 = 1+ YV1 = 1 YV6A =1 KM1=1 + YV1 = 1 + YV6B =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) 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) Discharged batteries 20% SQ1 =0 (slope) Another movement with big flow in progress (YV2- YV5-YV7) YV2, YV5 or YV7 at fault A1, A2, G1, G2 (overload) Slowed down descent with 50% if In slope Rise lower controls Descent lower controls KM1 = 1+ YV1 = 1 + YV6A =1 KM1=1 + YV1 = 1 + YV6B =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) 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) Another movement with big flow in progress (YV2- YV5-YV7) YV2, YV5 or YV7 at fault Discharged batteries 20% SQ1 = 0 (slope) Another movement with big flow in progress (YV2- YV5-YV7) YV2, YV5 or YV7 at fault overload movement are slowed down Slowed down descent with 50% if In slope E /123

40 TELESCOPING BOOM Function Extension upper controls Retraction upper controls Action KM1 = 1 + YV1= 1+ YV7A=1 KM1 = 1 + YV1 = 1 +YV7B=1 Necessary 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) 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) CONDITIONS Prohibiting the function 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) Another movement with big flow in progress (YV2-YV5- YV6) YV2, YV5 or YV6 at fault A1, A2, G1, G2 (overload) Modifying the function Modifiable speed movement by SB120 - SB121) Retraction slowed down with 50% in slope extension lower controls Retraction lower controls KM1 = 1 + YV1= 1+ YV7A=1 KM1 = 1 + YV1 = 1 +YV7B=1 SA1 (side T) + SA10A = 1+ SA22A=1 + KM2 =1 (if multiple in drive mode) or if not variable speed unit signal from 0 to 500A) SA1 (side T) + SA10A =1 + SA22B=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 Discharged batteries 20% SQ1 = 0 (slope) Another movement with big flow in progress (YV2-YV5- YV6) YV2, YV5 or YV6 at fault overload movement is slowed down Slowed down retraction with 50% in slope E /123

41 LIFTING ARM Function Rise upper controls Descent upper controls Action KM1 = 1 + YV1 = 1 +YV5A=1 KM1 = 1 + YV1 = 1 +YV5B=1 Necessary 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) SA1 (side N) + SB6=1 + SA21B =1 + KM2 =1 (if multiple in drive mode) or if not variable speed unit signal from 0 to 500A) CONDITIONS Prohibiting the function Another movement with big flow in progress (YV2- YV6-YV7) YV2, YV6 or YV7 at fault A1, A2, G1, G2 (overload) Discharged batteries 20% SQ1 = 0 (slope) Another movement with big flow in progress (YV2- YV6-YV7) YV2, YV6 or YV7 at fault A1, A2, G1, G2 (overload) Discharged batteries 20% Modifying the function Modifiable speed movement by (SB120 - SB121) slowed down descent with 50% if in slope Rise lower controls Descent lower controls KM1 = 1 + YV1 = 1 +YV5A=1 KM1 = 1 + YV1 = 1 +YV5B=1 SA1 (side T) + SA10A=1 + SA20A = 1+ KM2 =1 (if multiple in drive mode) or if not variable speed unit signal from 0 to 500A) SA1 (side T) + SA10A=1 + SA20B = 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- YV6-YV7) YV2, YV6 or YV7 at fault Discharged batteries 20% SQ1 = 0 (slope) Another movement with big flow in progress (YV2- YV6-YV7) YV2, YV6 or YV7 at fault Discharged batteries 20% overload movements are slowed down slowed down descent with 50% if in slope E /123

42 TURRET SLEWING Function Right side upper controls Left upper controls Action KM1 = 1 + YV0 =1 +YV4B=1 KM1 = 1 + YV0 =1 +YV4A=1 Necessary 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) 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) CONDITIONS Prohibiting the function 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% Modifying the function Movements of Drive (position transport) and/or steering (if this movement is activated in first Movements slowed down if in slope Right side lower controls Left lower controls KM1 = 1 + YV0 =1 +YV4B=1 KM1 = 1 + YV0 =1 +YV4A=1 SA1 (side T) + SA10A=1 + SA82B = 1 + KM2 =1 (if multiple in drive mode) or if not variable speed unit signal from 0 to 500A) SA1 (side T) + SA10A=1 + SA82A = 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 (YV3-YV8- YV9- YV10) YV3, YV8, YV9 or YV10 at fault Discharged batteries 20% overload movements are slowed down JIB Function Rise upper controls Descent upper controls Action KM1 = 1 + YV0 = 1 +YV8A=1 KM1 = 1 + YV0 = 1 +YV8B=1 Necessary SA1 (side N) + SB6 =1 + SA51A=1 + KM2 =1 (if multiple in drive mode) or if not variable speed unit signal from 0 to 500A) SA1 (side N) + SB6 =1 + SA51B=1 + KM2 =1 (if multiple in drive mode) or if not variable speed unit signal from 0 to 500A) CONDITIONS Prohibiting the function Another movement with low flow in progress (YV3- YV4-YV9- YV10) YV3, YV4, YV9 or YV10 at fault A1, A2, G1, G2 (overload) Discharged batteries 20% SQ1 = 0 (slope) Modifying the function Modifiable speed movement by (SB120 - SB121 Office multiple with the drive (position transport) and/or steering (if this movement is activated in first) E /123

43 Rise lower controls Descent lower controls KM1 = 1 + YV0 = 1 +YV8A=1 KM1 = 1 + YV0 = 1 +YV8B=1 SA1 (side T) + SA10A=1 + SA52A = 1 + KM2 =1 (if multiple in drive mode) or if not variable speed unit signal from 0 to 500A) SA1 (side T) + SA10A=1 + SA52B = 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 (YV3- YV8-YV9- YV10) YV3, YV4, YV9 or YV10 at fault Discharged batteries 20% overload movements are slowed down Descent slowed down if in slope COMPENSATION Function Rise/descent upper controls Action KM1 = 1 + YV0 = 1+ YV3A/B=1 Necessary 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 CONDITIONS Prohibiting the function Another movement with low flow in progress (YV4- YV8-YV9- YV10) YV4, YV8, YV9 or YV10 at fault Modifying the function Movement slowed down if in slope A1, A2, G1, G2 (overload) Discharged batteries 20% emergency mode 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 (overload) Discharged batteries 20% Emergency mode Prohibited movement if telescope OUT E /123

44 BASKET ROTATION Function (left/right movement) Action KM1 = 1 + YV0 = 1 + YV9A/B=1 Necessary SA1 (side N) + SB6 =1 + SA43A/B = 1+ KM2 =1 (if multiple in drive mode) or if not variable speed unit signal from 0 to 500A) CONDITIONS Prohibiting the function Another movement with low flow in progress (YV3- YV4-YV8- YV10) YV3, YV4, YV8 or YV10 at fault A1, A2, G1, G2 (overload) Discharged batteries 20%) SQ1 = 0 (slope) emergency mode Modifying the function Modifiable speed movement by (SB120 - SB121 Movement slowed down if in slope JIB ROTATION (HA12CJ+) Function upper controls (left. /right) Action KM1 = 1 + YV0 = 1 + YV10A/B =1 Necessary SA1 (side N) + SB6 =1 + SA53A/B=1 + KM2 =1 (if multiple in drive mode) or if not variable speed unit signal from 0 to 500A) CONDITIONS Prohibiting the function Another movement with low flow in progress (YV3- YV4-YV8- YV9) YV3, YV4, YV8 or YV9 at fault Modifying the function Modifiable speed movement by (SB120 - SB121 lower controls (left/right) KM1 = 1 + YV0 = 1 + YV10A/B =1 SA1 (side N) + SA10A =1 + SA52A/B = 1+ KM2 =1 (if multiple in drive mode) or if not variable speed unit signal from 0 to 500A) A1, A2, G1, G2 (overload) Discharged batteries 20% Emergency mode SQ1 = 0 (slope) overload low movements slowing down Movement slowing down if in slope E /123

45 VERSION EUR 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 OPTIONS USA /CDN/AUSTRALIA 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 E /123

46 2.8. ALARMS CODES CONSOLE OPTIMIZER 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 AV02 AV03 AV04 AV05 AV06 Problems in main contactor KMG or with the contactor for selection traction/pump KM1 (open circuit, contact stuck or short-circuit) Lack of power or problem in the outputs motors/pump Speed variator unit in thermal security Wrong sequence for starting or error on one speed variator unit input Problem on batteries or batteries too weak CONTACTOR OUTPUTS CODE DESCRIPTION ACTION SC01 Output in open or short circuit : validation relay KAV is defective (or missing) or wire is cut SC02 SC03 Output in open or short circuit: flashing light relay KAF is defective (or missing) or wire is cut Output in open or short circuit: horn relay KAK is defective (or missing) or wire is cut SC04 Output in open or short circuit : pump power coil contactor KM2 is defective (or missing) or wire is cut SC05 Output in short circuit: brakes release relay KAB is defective (or missing) or wire is cut (fault only with SEVCON speed unit) 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) Possible faults on ZAPI (13,18,19,53,57,58,233,234,241,244,247,248,25 2,253 - Possible faults on ZAPI (37,74,75,76,77,242) - Check the state of contactors and/or connections Possible faults on ZAPI (30,31,60,250) - 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 - 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 - Possible faults on ZAPI (66,251) - Reload or replace batteries Change relay KAV, check wiring and equipotential (on wires 273 et 0) Change relay KAF, check wiring and equipotential (on wires 271 et 0) Change relay KAK, check wiring and equipotential (on wires 272 et 0) Change contactor KM2 on speed unit plate, check cable 279 between chassis loom and turret box or wire 203 on coil (+12V) Change relay KAB, check cable 275 between chassis looms and turret box and check the 0 on relay. Change relay KMS, check continuity on wire 208 between turret loom and emergency pump option loom + turret box, check wire 203 on coil (+12V) E /123

47 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 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 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 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 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 YV0, check wire 276 between loom bloc + turret box or wire 203 on coil itself (+12V) Change coil YV1, check wire 277 between loom bloc + turret box or wire 203 on coil itself (+12V) - 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) - 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) - 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) - 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) - 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) E /123

48 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 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 - 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) - Change coil YV8A, check wire B615 between bloc loom + turret box and wire 246 on coil (+12V) - Change coil YV8B, check wire B609 between bloc loom + turret box and wire 246 on coil (+12V) - 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) - Change coil YV10A, check wire B602 between bloc loom + turret box and wire 246 on coil (+12V) - Change coil YV10B, check wire B603 between bloc loom + turret box and wire 246 on coil (+12V) CAN-BUS ERRORS / EEPROM CODE DESCRIPTION ACTION MX01 CAN fault communication check can-bus network (impedance and connections) EP01 EEPROM checksum error E /123

49 JOYSTICKS(CONTROLLERS) TOGGLE SWITCHES CODE DESCRIPTION ACTION SM1Y Signal out of range or inconsistent neutral value on drive joystick Check connection and signal value ( VDC) SM2Y Signal out of range or inconsistent neutral value on rotation /lift joystick Check connection and signal value ( VDC) SM2X Signal out of range or inconsistent neutral value on rotation /lift joystick Check connection and signal value ( VDC) 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 OVERLOAD ALARMS 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 CODE DESCRIPTION ACTION OL01 - Adress fault on slave module doing the load function - Inconsistant values - Problem in checksum parameters validation or overload calibration datas or problem during load calibration - Make again the calibration between EEPROM datas saved between module master B2 and slave B3 OL02 Fault in Jib learning Cal 1 Make or redo the Jib learning Cal 1 calibration OL03 OL04 OL05 OL06 OL07 - Inconsistent values between jib movement and jib angle measurement - Fault in A1 relative angle sensor - Inconsistent value between compensation movement and jib angle - Fault in A2 absolute angle sensor (inclinometer) - Fault in G1 pressure sensor in jib cylinder - Pressure variation too important in the jib small chamber - Fault in G2 pressure sensor in jib cylinder - Pressure variation too important in the jib large chamber Inconsistent values for the calculation of the pressure recorded between modules node B2 master and slave B3 process - 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 - 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 - 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 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 - 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 B E /123

50 CODE DESCRIPTION ACTION OL08 Inconsistent values for the calculation of the pressure reference between modules node B2 master and node B3 slave OL09 Resultant pressure out of range SENSORS ALARMS CODE DESCRIPTION ACTION SE01 Incoherent status of sensors : no change during movement - 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 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 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 SE03 Anti by-pass safety : detection of SQ34 from 0 to 1 without any movement) 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 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 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 E /123

51 2.9. ALARMS CODE UPPER CONTROLS 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 EV01 - EV02 - EV03 - EV04 - EV05 - EV06 - EV07 - EV08 - EV09-8 EV10 - EV11 9 EP01 10 SM1Y - SM2Y - SM2X - SW01 - SW02 11 SE01-SE02-SE DETAILS ON ALARMS SE01 SE02 - SE03 Function fault SQ9 and SQ34 (SE01) Defect detected when machine starts to unfold and no change on sensors state Defect : proximity sensors 0 = no failure 1 = failure Fault if shunt SQ34 on (SE02) Defect shunt and no movement detected, no command and SQ34 state has changed fault SQ34 and SQ9 after power is swithed ON (SE03) Defect if state has changed after power is ON 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 (machine unfolded) 0 (no slope) Micro speed All authorised 0 none (machine unfolded) 1 (dévers) EUR mode no drive/ USA mode micro speed Machine in folded position authorised 0 none (machine folded) 0 Drive in LS and HS speed drive All authorised 0 none E /123

52 (machine folded) 1 Drive in micros and HS speed drive All authorised 0 none Micro speed All authorised 11 lower /lift the boom and retract and extend the telescopic boom extension EUR mode no drive/ USA mode micro speed Machine in folded position authorised 11 lower /lift the boom and retract and extend the telescopic boom extension Micro speed All authorised 11 lower /lift the boom and retract and extend telescopic boom extension EUR mode no drive/ USA mode micro speed Machine in folded position authorised 11 lower /lift the boom and retract and extend telescopic boom extension Function fault SQ9 and SQ34 (SE01) Defect detected when machine starts to unfold and no change on sensors state Defect : proximity sensors 0 = no failure 1 = failure Fault if shunt SQ34 on (SE02) Defect shunt and no movement detected, no command and SQ34 state has changed fault SQ34 and SQ9 after power is swithed ON (SE03) Defect if state has changed after power is ON State of sensor arm/boo m (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 Micro speed All authorised 11 Remove shunt on SQ34 Machine in Remove EUR mode folded shunt on E /123

53 no drive/ USA mode micro speed position authorised SQ Micro speed All authorised 11 Remove shunt on SQ34 Lower/lift the boom EUR mode no drive/ USA mode micro speed All authorised 11 Remove shunt on SQ34 Lower/lift the boom Micro speed All authorised 11 lower /lift the boom and retract and extend telescopic boom extension EUR mode no drive/ USA mode micro speed Machine in folded position authorised 11 lower /lift the boom and retract and extend telescopic boom extension Micro speed All authorised 11 lower /lift the boom and retract and extend telescopic boom extension EUR mode no drive/ USA mode micro speed All authorised 11 lower /lift the boom and retract and extend telescopic boom extension E /123

54 2.11. ALARMS CODES ON VARIABLE SPEED UNIT ZAPI This list of code alarm is shown only on the OPTIMIZER console (see DIAGNOSTIC/VARIATOR /Internal Variable= xx, CODE ALARM Code DEFINITION DIAGNOSTIC OPTIMIZER 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 E /123

55 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 250 VFIELD NOT OK No message coming from the CAN-BUS, check connections If the problem persists, change the variator 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 253 AUX1 OUTPUT KO The system checks the circuit brakes command, if the received signal does not correspond, replace the variator The system checks the commande of KM1 contactor if the received signal does not correspond, change the contactor E /123

56 3. THE HYDRAULIC PART 3.1. SYMBOLS USED 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 E /123

57 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 E /123

58 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 E /123

59 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 E /123

60 3.2. HYDRAULIC DIAGRAM See at the end of this manual 3.3. MAIN MANIFOLDS HYDRAULIC BLOCK E /123

61 DETAIL OF VALVES YV6 YV7 YV5 YV2 YV1 (PWM2) YV0 (PWM1) YV8 YV4 YV9 YV3 YV10 Boom lift Telescoping boom Arm lifting steering Main movements (big flow) Secondary movements (low flow) jib Turret rotation Basket rotation Basket compensation 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 YV7A YV5A YV2A YV6B YV7B YV5B YV2B PWM2 YV1 YV8A YV4A YV9A YV3A PWM1 YV0 YV8B YV4B YV9B YV3B YV10A YV10B* E /123

62 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 3.4. THE LOOMS SEE SPR CATALOG for HA12CJ+ 164P (2 looms) for HA12CJ 164P (2 looms) E /123

63 4. ADJUSTMENTS 4.1. ADJUSTMENTS WITH CONSOLE OPTIMIZER The adjustments, parameter settings and lists of alarms of the machine are accessible only through this console. Use console OPTIMIZER (ref ) with modules node B2/B3 Connection on bottom panel (turret) On RS232 plug socket located outside the lower turret box E /123

64 Description of the console PARAMETER - or CHANGE PARAMETER + or CHANGE PREVIOUS MENU NEXT MENU RECORD/ENTER/VALIDATION BACK TO MAIN MENU NOTE : on any blue key pads, pressing on left, right or in the center have the same result E /123

65 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 Level 2 is registered press following key: Back to main menu The console is in level 2 (access to the calibration menu) once level 2 is set, go to menu : E /123

66 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 E /123

67 List of menus Access to the main menu Parameters setting access Input/output state access Trouble shooting guide per function Machines status Failures list E /123

68 4.2. PARAMETERS SETTING Speeds settings from lower controls Movement type Time Jib rotation full range lock to lock Left 31s +/- 5 sec (HA12CJ+) right 31s +/- 5 sec jib up 22s +/-5 sec down 26s +/-5 sec Arm up 24s +/-5s down 22s +/-5s Turret rotation Left 56s +/-5s (1/2 turn/180 ) 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 Left 43s +/-5s (1/2 turn/180 ) right 43s +/-5s Main boom up 28s +/-5s down 21s +/-5s Braking distances Movement type Theoritical distance Braking distance in High Speed and flat FWD Distance < 1, 5 m ground REV Distance < 1, 5 m Speed control from upper controls (hydraulic 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 Left 25s +/-5s (HA12CJ+) right 25s +/-5s Compensation up 9s +/-5s down 8s +/-5s E /123

69 4.3. OPTIMIZER MENU MOVEMENTS SPEED (%) RAMP DESIGNATION MIN DEFECT MAX ACC DEC JIB UP AT MINIMAL SPEED (JIB LIFT AT 30% OF ITS SPEED) JIB UP AT MAXIMAL SPEED (JIB LIFT AT 100% FULL SPEED) ACCESS CODE LEVEL 2 OR 3 ACCESS CODE LEVEL 2 OR 3 ACCESS CODE LEVEL 2 OR 3 ACCESS CODE LEVEL 2 OR 3 JIB DOWN FWD DRIVE REV DRIVE MICRO FWD DRIVE MICRO REV DRIVE PF. UP LEVEL PF. DOWN LEVEL STEERING LEFT STEERING RIGHT ARM UP ARM DOWN TURRET LEFT TURRET RIGHT BOOM UP BOOM DOWN PF. ROT. LEFT PF. ROT. RIGHT JIB ROT. LEFT JIB ROT. RIGHT OUT TELESCO TELESCO IN Note: the parameters Turret are at 80% of the Platform value E /123

70 MENU OPTIONS OPTIONS COUNTRY TRACTION BATTERIES PROHIB IN TILT SIGNAL TRANS BUZZER MOVEMENT BUZZER TRANS FLASH LIGHT MOVEMENT FLASH LIGHT FLASH LIGHT ON LEVEL LIMIT +10/-10 MANUAL UNBRAKING HA12CJ+ version PWM YV1 setting DESCRIPTION Choice of the country, between the USA, Australia, Europe Choice of the type of batteries, No: Semi-traction, Yes:Traction Selection of CANADA country option only valid from US model (slope sensor active with US country choice) Activation of the buzzer if machine is in drive ( FWD, REV drive) Activation of the buzzer on movements (except steering) Activation of the flash-light if machine is in drive mode ( FWD, REV drive) Activation of the flash-light on movements (except steering) Activation of the flash-light when power is ON on the machine Activation of the limitation of basket compensation (slope range for the basket +10 /-10 ) Authorize the possibility to release the electrical brakes on the drive motors thanks to the remote control box for brake release system Choice of model type (HA12CJ: NO / HA12CJ+ YES) Correction in current command on PWM 100 no correction <100 movements speed are decreased >100 movements speed are increased Default value Level USA 3 No 2 Inactive 3 Inactive 2 Inactive 2 Inactive 2 Inactivate 2 Inactive 2 Active 2 Inactive 2 NO E /123

71 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 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 for the corresponding direction Bits reading ( right to left as shown : 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 Validation Function controls Inputs Securing and formatting of the setpoint Setpoint Validation and formatting of the command Control [0-100]% [0-100]% Application of the command on actuators Outputs Actuator Setpoint Limit E /123

72 Some useful definitions : Controls Inputs Setpoint (0-100%) Validation Validation and formatting the command Setpoint limit /Limitation Control (0-100%) Outputs Actuator all commands coming from lower/upper controls Digitals or analog inputs (ETOR-EANA) In Diagnostic menu,it s the parameter Internal setpoint for the function ( pts) Conditions for cutting the movements Conditions for validation of the movement Condtions for slowing down the movement In Diagnostic menu, it s the parameter Internal control for the internal command of the function (0-1000pts) Digitals or Analog outputs ( STOR-SPWM SANA) Any device like valves/cylinders/motors/relays Some example Example machine in slope and boom lifting mode : Binary code : ( 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 E /123

73 OVERLOAD - PESAGE NAME INFORMATION DESCRIPTION VALUES 0:Absent, 1: jib learning(calibration) Internal Status of the function ModePesage 2: Normal, variable weighing 3:Defect, 4:back up Internal variable Internal variable Internal variable Internal variable Internal variable Internal variable Internal variable Internal variable Internal variable Internal variable A1 A2 G1 G2 Internal Variable Overload Close Diff B2 (0.1b) Close ref. (0.1b) Jib Angle (0.1 deg) ABS Angle (0.1 deg) Rod Presses (0.1b) Bore Presses (0.1b) Press Diff B3 (0.1b) Overload static machine Differential pressure calculated in the module node B2 (turret) Pressure of calculated reference Angle jib/boom Angle of the basket/horizontal position Pressure in jib small chamber Pressure in jib large chamber Differential pressure calculated in the module node B3 (PF) 1: static overload Expressed in bar x 0.1 Expressed in bar x 0.1 Expressed in degree x Near to 0 for the lowest jib position - Near to 1400 for the upper jib position Expressed in degree x 0.1 Around 0 for basket at horizontal Expressed in bar x0.1 Expressed in bar x 0.1 Must be close to Diff B2 if not inconsistency HighStop electric higher limit 1: position reached LowStop Electric lowest limit 1: position reached Angle Angle Cylinder press Cylinder press PesAFault Value of the sensor of relative angle Value of the sensor of absolute angle Value of the pressure sensor jib small chamber Value of the pressure sensor jib large chamber Fault in load system 0V-VbattV If 0V then sensor in open circuit 0V-VbattV If 0V then sensor in open circuit 0V-5V If 0V then sensor in open circuit 0V-5V If 0V then sensor in open circuit 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 OL E /123

74 = 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 Internal variable AngAbsZero AngJibLowEnd Angular value of reference for 0 basket level Angular value of reference for jib at its mechanical lowest position Used to calculate the current basket angle Used to calculate the current jib angle E /123

75 MACHINE STATE ETAT NAME INFORMATION DESCRIPTION VALUES SQ34 ARM/BOOM State of proximity sensor DOWN:1 UP:0 for arm/boom folded State of proximity sensor SQ9 TELESCOPE IN:1 OUT:0 for telescopic boom position SQ1 Internal variable Internal variable Internal variable TILT SENSOR, FLAT:1 State of level sensor < X ON: if arm and boom are in stowed position ON: if telescopic is fully retracted ON: Not in slope OFF: Machine in slope OVERLOAD YES:1 NO:0 State of weighing 1: Machine in weighing DEADMAN OK:1 NOK:0 PF SPEED CONTROL 1-10 DRIVE TRANSLATION State principal dead man switch or dead man and emergency pumps switch (high or low) Value of the bar-graph for speed variation of the upper control box 1: active and validated 0: Inactive or pushed more than 8s without movement 1 to 10 (10% to 100% of speed) NAME INFORMATION DESCRIPTION VALUES SM1 DRIVE JOYSTICK Set point of the joystick in entry of in mv the module node B3 joystick 0,5-2,5-4,5V 0: joystick in neutral Internal OUTPUT CENTER position Information out of neutral position variable POSIT. 1: joystick out of neutral position Internal variable Internal Set.Point Int. Set point Limit Internal Logical BRAKE STATUS DRIVE SETPOINT IN (%) LIMITATION CUTTING OUT Information of the brakes status Signal of the joystick Value of active limitation. 100% if no limitation on the movement (also take into account the system of speed regulation : buttons + and -) Binary value of the state of the conditions of activation and prohibition of the movement Fwd/Up/L= Rev/Down/R= Reading from right to the left Bits: : 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 0: machine with brakes activated 1: machine with brakes released From 0 to 1000 (0% to 100%) From 0 to 100% From to E /123

76 Internal Control Internal variable DRIVE SETPOINT OUT(%) MicroS:1 LS:2 HS:3 Set point applied (according to the adjustments and safety measures in process) Last speed of drive applied. (since power is ON) From 0 to 1000 (0% to 100%) 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 NAME INFORMATION DESCRIPTION VALUES SM1G STEERING LEFT OFF: Inactive Left steering button activated BUTTON ON: Active SM1D STEERING RIGHT OFF: Inactive right steering button activated BUTTON ON: active Set point TOR 0: No signal Internal SETPOINT IN (TOR) (either 0% or 100% 1: left setpoint Set.Point represent) 2: right setpoint Int. Set point Limit Internal Logical Internal Control YV1 LIMITATION CUTTING OUT SETPOINT OUT(%) PWM (YV1) Value of active limitation. 100% if no limitation on the movement (also take into account the system of speed regulation buttons + and -) Binary value of the state of the conditions of activation and prohibition of the movement Fwd/Up/L= Rev/Down/R= Reading from right to left Bits: : 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 YV2A Left steering (TOR) ON/OFF valve YV2B Right steering (TOR) ON/OFF valve Set point applied (according to the adjustments and safety measures in process) Signal applied to the PWM valve From 0 to 100% From to From 0 to 1000 (0% to 100%) 0% to 100% OFF: Inactive ON: Active OFF: Inactive ON: Active E /123

77 PF LEVEL BASKET COMPENSATION NAME INFORMATION DESCRIPTION VALUES SA41A PF:LEVEL BUTTON UP PF: Button basket OFF: Inactive compensation UP ON: Active SA41B PF:LEVEL BUTTON PF: Button basket OFF: Inactive DOWN compensation down ON: Active SA40A TUR:LEVEL BUTTON Turret: Button basket OFF: Inactive UP compensation UP ON: Active SA40B TUR:LEVEL BUTTON Turret: Button basket OFF: Inactive DWN compensation down ON: Active Set point ON/OFF 0: No signal Internal SETPOINT IN (TOR) (either 0% or 100% 1: signal UP Set.Point represented) 2: signal DOWN Int. Set point Limit Internal Logical Internal Control YV0 LIMITATION CUTTING OUT SETPOINT OUT(%) PWM (YV0) Value of active limitation. 100% if not of limitation on the movement (also take into account the system of speed regulation buttons + and -) Binary value of the state of the conditions of activation and prohibition of the movement Fwd/Up/L= Rev/Down/R= Reading from right to left Bits: : 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 Set point applied (according to the adjustments and safety measures in process) Signal applied to the PWM valve YV3A PF.LEVEL UP (TOR) ON/OFF valve YV3B PF.LEVEL DOWN (TOR) ON/OFF valve From 0 to 100% From to From 0 to 1000 (0% to 100%) 0% to 100% OFF: Inactive ON: Active OFF: Inactive ON: Active E /123

78 ARM (PRIMARY BOOM) NAME INFORMATION DESCRIPTION VALUES 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 Turret: Button for arm OFF: Inactive BUTTON DOWN descent ON: Active Set point ON/OFF 0: No signal Internal SETPOINT IN (TOR) (either 0% or 100% are 1: signal UP Set.Point represented) 2: signal DOWN Int. Set point Limit Internal Logical Internal Control YV1 LIMITATION CUTTING OUT SETPOINT OUT (%) PWM (YV1) Value of active limitation. 100% if not of limitation on the movement (also take into account the system of regulation speed: buttons + and -) Binary value of the state of the conditions of activation and prohibition of the movement Fwd/Up/L= Rev/Down/R= Reading from right to left Bits: : 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 Set point applied (according to the adjustments and safety measures in process) Signal applied to the PWM valve YV5A ARM UP (TOR) ON/OFF valve YV5B ARM DOWN (TOR) ON/OFF valve From 0 to 100% From to From 0 to 1000 (0% to 100%) 0% to 100% OFF: Inactive ON: Active OFF: Inactive ON: Active E /123

79 TURRET NAME INFORMATION DESCRIPTION VALUES SM2X JOYSTICK (mv) Signal value of the joystick on in mv module input Joystick 0,5-2,5-4,5V 0: Joystick in neutral Internal OUTPUT CENTER position Information out of neutral variable POSIT. 1: joystick out of neutral position SA82A TURRET ROT Turret: Left button turret OFF: Inactive SA82B Internal Set.Point Int. Set point Limit Internal Logical Internal Control YV0 BUTTON L TURRET ROT BUTTON R SETPOINT IN (%/TOR) LIMITATION CUTTING OUT SETPOINT OUT (%) PWM (YV0) rotation Turret: right button turret rotation Set point value (PF: vary from 0 to 100% Turret: either 0% or 100%) YV4A TURRET ROT. L (TOR) ON/OFF valve YV4B TURRET ROT. R (TOR) ON/OFF valve Value of active limitation. 100% if not of limitation on the movement (also take into account the system of speed regulation buttons + and -) Binary value of the state of the conditions of activation and prohibition of the movement Fwd/Up/L= Rev/Down/R= Reading from right to left Bits: : 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 Set point applied (according to the adjustments and safety measures in process) Signal applied to the PWM valve ON: Active OFF: Inactive ON: Active PF: From 0 to 1000 (0% to 100%) Turret: 0: No signal 1: left setpoint 2: right setpoint From 0 to 100% From to From 0 to 1000 (0% to 100%) 0% to 100% OFF: Inactive ON: Active OFF: Inactive ON: Active E /123

80 JIB - NAME INFORMATION DESCRIPTION VALUES 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 OFF: Inactive Turret: button Jib descent DOWN ON: Active Internal Set.Point Int. Set point Limit Internal Logical Internal Control YV0 SETPOINT IN (TOR) LIMITATION CUTTING OUT SETPOINT OUT(%) PWM (YV0) Set point TOR (either 0% or 100% ) YV8A JIB UP (TOR) ON/OFF valve YV8B JIB DOWN (TOR) ON/OFF valve Value of active limitation. 100% if not of limitation on the movement (also take into account the system of speed regulation buttons + and -) Binary value of the state of the conditions of activation and prohibition of the movement Fwd/Up/L= Rev/Down/R= Reading from right to left Bits: : 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 Set point applied (according to the adjustments and safety measures in process) Signal applied to the PWM valve 0: No signal 1: setpoint UP 2: setpoint DOWN From 0 to 100% From to From 0 to 1000 (0% to 100%) 0% to 100% OFF: Inactive ON: Active OFF: Inactive ON: Active E /123

81 BOOM (SECONDARY OR MAIN BOOM) NAME INFORMATION DESCRIPTION VALUES SM2Y JOYSTICK (mv) Signal input value of the in mv joystick 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 OFF: Inactive Turret: Button boom lift UP ON: Active SA30B TUR:BOOM BUTTON OFF: Inactive Turret: Button boom descent DOWN ON: Active PF: From 0 to 1000 Set point (0% to 100%) Internal SETPOINT IN (%/TOR) (PF: vary from 0 to 100% Turret: Set.Point Turret: either 0% or 100%) 0: No signal 1: setpoint UP 2: setpoint DOWN Int. Set point Limit Internal Logical Internal Control YV1 LIMITATION CUTTING OUT SETPOINT OUT (%) PWM (YV1) YV6A BOOM UP (TOR) ON/OFF valve YV6B BOOM DOWN (TOR) ON/OFF valve Value of active limitation. 100% if not of limitation on the movement (also take into account the system of regulation speed: buttons + and -) Binary value of the state of the conditions of activation and prohibition of the movement Fwd/Up/L= Rev/Down/R= Reading from right to left Bits: : 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 Set point applied (according to the adjustments and safety measures in process) Signal applied to the PWM valve From 0 to 100% From to From 0 to 1000 (0% to 100%) 0% to 100% OFF: Inactive ON: Active OFF: Inactive ON: Active E /123

82 PF - ROT BASKET ROTATION NAME INFORMATION DESCRIPTION VALUES SA43A PF.ROT. BUTTON LEFT PF: Button left basket rotation OFF: Inactive ON: Active SA43B PF.ROT BUTTON OFF: Inactive PF: Button right basket rotation RIGHT ON: Active 0: No signal Internal Set point TOR SETPOINT IN (TOR) 1: left setpoint Set.Point (either 0% or 100% ) 2: right setpoint Int. Set point Limit Internal Logical Internal Control YV0 LIMITATION CUTTING OUT SETPOINT OUT (%) PWM (YV0) Value of active limitation. 100% if not of limitation on the movement (also take into account the system of speed regulation buttons + and -) Binary value of the state of the conditions of activation and prohibition of the movement Fwd/Up/L= Rev/Down/R= Reading from right to left Bits: : 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 Set point applied (according to the adjustments and safety measures in process) Signal applied to the PWM valve YV9A PF. ROT. LEFT (TOR) ON/OFF valve YV9B PF. ROT. RIGHT (TOR) ON/OFF valve From 0 to 100% From to From 0 to 1000 (0% to 100%) 0% to 100% OFF: Inactive ON: Active OFF: Inactive ON: Active E /123

83 JIB ROTATION - NAME INFORMATION DESCRIPTION VALUES SA53A PF:JIB ROT.BUTTON OFF: Inactive PF: button for jib left rotation L ON: Active SA53B PF:JIB ROT.BUTTON PF: Button for jib right OFF: Inactive R rotation ON: Active SA52A TUR:JIB Turret: button for jib left OFF: Inactive ROT.BUTTON L rotation ON: Active SA52B TUR:JIB Turret: button for jib right OFF: Inactive ROT.BUTTON R rotation ON: Active Set point TOR 0: No signal Internal SETPOINT IN (TOR) (either 0% or 100% 1: left setpoint Set.Point represent) 2: right setpoint Int. Set point Limit Internal Logical Internal Control YV0 LIMITATION CUTTING OUT SETPOINT OUT (%) PWM (YV0) YV10A JIB ROT. LEFT (TOR) ON/OFF valve YV10B JIB ROT. RIGHT (TOR) Value of active limitation. 100% if not of limitation on the movement (also take into account the system of speed regulation buttons + and -) Binary value of the state of the conditions of activation and prohibition of the movement Fwd/Up/L= Rev/Down/R= Reading from right to left Bits: : 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 Set point applied (according to the adjustments and safety measures in progress) Signal applied to the PWM valve ON/OFF valve From 0 to 100% From to From 0 to 1000 (0% to 100%) 0% to 100% OFF: Inactive ON: Active OFF: Inactive ON: Active E /123

84 TELESCOPE NAME INFORMATION DESCRIPTION VALUES SA35A PF:TELES BUTTON PF: Button telescopic boom OFF: Inactive OUT OUT ON: Active SA35B PF: TELES BUTTON IN PF: Button telescopic boom OFF: Inactive IN ON: Active SA22A TUR: TELES BUTTON Turret: Button telescopic OFF: Inactive OUT OUT ON: Active SA22B TUR: TELES BUTTON OFF: Inactive Turret: Button telescopic IN IN ON: Active Set point TOR 0: No signal Internal SETPOINT IN (TOR) (either 0% or 100% 1: setpoint OUT Set.Point represent) 2: setpoint IN Int. Set point Limit Internal Logical Internal Control YV1 LIMITATION CUTTING OUT SETPOINT OUT(%) PWM (YV1) Value of active limitation. 100% if not of limitation on the movement (also take into account the system of speed regulation buttons + and -) Binary value of the state of the conditions of activation and prohibition of the movement Fwd/Up/L= Rev/Down/R= Reading from right to left Bits : 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 Set point applied (according to the adjustments and safety measures in process) Signal applied to the PWM valve YV7A JIB ROT. LEFT (TOR) ON/OFF valve YV7B JIB ROT. RIGHT (TOR) ON/OFF valve From 0 to 100% From to From 0 to 1000 (0% to 100%) 0% to 100% OFF: Inactive ON: Active OFF: Inactive ON: Active E /123

85 VARIATOR - NAME INFORMATION DESCRIPTION VALUES Internal Value of the batteries BAT VOLTAGE (mv) Value in mv variable voltage Internal General state of main OFF: Inactive KMG STATUS variable contactor KMG ON: Active Internal speed setpoint received on 0 to 255 SETPOINT (MAX:255) variable the variator (0% to 100%) current sent by the variator Internal OUT POWER AMP (A) on power circuit (pump or xx (A) variable drive motors) Internal variable Internal variable Internal variable Internal variable TOP SPIN STATUS BRAKE STATUS TEMPERATURE (deg. C) CODE ALARM Operation of the variator in mode movements (pump) Information state of the brakes Temperature interns variator Alarm code sent by the variator 0: Inactive 1: active 0: Braked machine with brakes ON 1: machine with brakes released Of -40 c with 100 c 0 to 255 (see detail) Code OPTIMIZER 13 EEPROM KB DEFINITION 18 LOGIC FAILURES # 2 19 LOGIC FAILURES # 1 30 VMN LOW 31 VMN HIGH 37 CONTACTOR CLOSED 53 STBY I HIGH 57 HIGH FIELD CURRENT 58 NO FIELD CURRENT 60 CAPACITOR LOAD DIAGNOSTIC 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 Fault in the hardware system of the logic board which controls the pump contactor KM2 Problem in the logical circuit of the line contactor KMG or in the hardware of the variator (logic board) Problem with the circuit power of the drive motors or connections, Problem with the circuit power of the drive motors or connections, The terminals of the power contactor KMG remain stuck 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 Defect in the circuit energizing F1 /F2 check connections replace the variator if the problem persists Defect in the field circuit F1 /F2 Check connections Replace the variator if the problem persists The capacitors doesnt charge 0.5 after power is ON Defect in the power circuit E /123

86 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 250 VFIELD NOT OK No message coming from the CAN-BUS, check connections If the problem persists, change the variator 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 253 AUX1 OUTPUT KO The system checks the circuit brakes command, if the received signal does not correspond, replace the variator The system checks the command of KM1 contactor if the received signal does not correspond, replace the contactor E /123

87 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 AV02 AV03 AV04 AV05 AV06 Problems in main contactor KMG or with the contactor for selection traction/pump KM1 (open circuit, contact stuck or short-circuit) Lack of power or problem in the motors/pump outputs Speed variator unit in thermal security Wrong sequence for starting or error on one speed variator unit input Problem on batteries or batteries too weak CONTACTOR OUTPUTS CODE DESCRIPTION ACTION SC01 Output in open or short circuit : validation relay KAV is defective (or missing) or wire is cut SC02 SC03 Output in open or short circuit: flashing light relay KAF is defective (or missing) or wire is cut Output in open or short circuit: horn relay KAK is defective (or missing) or wire is cut SC04 Output in open or short circuit : pump power coil contactor KM2 is defective (or missing) or wire is cut SC05 Output in short circuit: brakes release relay KAB is defective (or missing) or wire is cut (fault only with SEVCON speed unit) 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) Possible faults on ZAPI (13,18,19,53,57,58,233,234,241,244,247,248,25 2,253 - Possible faults on ZAPI (37,74,75,76,77,242) - Check the state of contactors and/or connections Possible faults on ZAPI (30,31,60,250) - 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 - Restart the machine in good way ( battery cutout, e-stop buttons then key selector for upper/lower control box) - Check speed variator unit connection - Possible faults on ZAPI (66,251) - Reload or replace batteries Change relay KAV, check wiring and equipotential (on wires 273 et 0) Change relay KAF, check wiring and equipotential (on wires 271 et 0) Change relay KAK, check wiring and equipotential (on wires 272 et 0) Change contactor KM2 on speed unit plate, check cable 279 between chassis loom and turret box or wire 203 on coil (+12V) Change relay KAB, check cable 275 between chassis looms and turret box and check the 0 on relay. Change relay KMS, check continuity on wire 208 between turret loom and emergency pump option loom + turret box, check wire 203 on coil (+12V) E /123

88 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 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 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 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 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 YV0, check wire 276 between loom bloc + turret box or wire 203 on coil itself (+12V) Change coil YV1, check wire 277 between loom bloc + turret box or wire 203 on coil itself (+12V) - 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) - 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) - 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) - 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) - 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) E /123

89 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 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 - 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) - Change coil YV8A, check wire B615 between bloc loom + turret box and wire 246 on coil (+12V) - Change coil YV8B, check wire B609 between bloc loom + turret box and wire 246 on coil (+12V) - 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) - Change coil YV10A, check wire B602 between bloc loom + turret box and wire 246 on coil (+12V) - Change coil YV10B, check wire B603 between bloc loom + turret box and wire 246 on coil (+12V) 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 E /123

90 JOYSTICKS(CONTROLLERS) TOGGLE SWITCHES CODE DESCRIPTION ACTION SM1Y Signal out of range or inconsistent neutral value on drive joystick Check connection and signal value ( VDC) SM2Y Signal out of range or inconsistent neutral value on rotation /lift joystick Check connection and signal value ( VDC) SM2X Signal out of range or inconsistent neutral value on rotation /lift joystick Check connection and signal value ( VDC) 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 OVERLOAD ALARMS 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 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 OL05 OL06 OL07 - Inconsistent value between compensation movement and jib angle - Fault in A2 absolute angle sensor (inclinometer) - Fault in G1 pressure sensor in jib cylinder - Pressure variation too important in the jib small chamber - Fault in G2 pressure sensor in jib cylinder - Pressure variation too important in the jib large chamber Inconsistent values for the calculation of the pressure recorded between modules node B2 master and slave B3 - 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 - 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 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 - 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 B E /123

91 CODE DESCRIPTION ACTION OL08 Inconsistent values for the calculation of the pressure reference between modules node B2 master and node B3 slave OL09 Resultant pressure out of range SENSORS ALARMS CODE DESCRIPTION ACTION SE01 Incoherent status of sensors : no change during movement - 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 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 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 SE03 Anti by-pass safety : detection of SQ34 from 0 to 1 without any movement) 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. Principle of survey : 1 failure if without any movement, the sensor goes from 0 to 1 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 E /123

92 4.4. CONSOLE DIAG PAD It s possible to use the 2 nd 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 (Vehicle Computer Interface) 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) E /123

93 Note : With that 2 nd generation of console, the name of alarm s code has been changed ( not the description and function) New failure code Original failure code F01.01 AV01 F01.03 AV02 F01.05 AV03 F01.06 AV04 F01.07 AV05 F01.08 AV06 F02.01 SC04 F02.02 SC06 F03.03 SC01 F03.04 SC05 F03.05 SC02 F03.06 SC03 F04.01 EV03 F04.02 EV04 F04.03 EV05 F04.04 EV06 F04.05 EV07 F04.06 EV08 F04.07 EV09 F04.08 EV10 F04.09 EV11 F04.11 EV02 F04.12 EV01 F05.01 SM1Y F05.04 SM2Y F05.06 SM2X F06.01 OL01-OL02 F06.02 OL07-OL08 F07.01 SE01 F07.20 OL05 F07.21 OL06 F07.22 OL03 F07.23 OL04 F08.07 SW03 F12.01 MX01 F12.02 EP01 F13.01 SW01 F13.02 SW E /123

94 4.5. ADJUSTMENT OF THE PRESSURES PROCEDURE 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 MP1 MP2 MOVEMENTS Plug socket MP1 Rise/descent boom Rise/descent arm Extension /retraction telescopic boom Main pressure / steering (D) Plug socket MP2 jib Jib rotation compensation lifting (C) Compensation descent Rotation basket Turret slewing (A left / B right) Plug M version 2 Main pressure/steering (D) Pressures taken on pump exit, during movement (+/- 2b) 186b 195b/177b 188b/175b 210b 172b 169b 155b 168b 169b 100b 210b Connection of the pressure gauge in MP1 (movements big flow) or MP2 (movements low flow) E /123

95 Version 2 M B A C D Note: the pressure plug M on version 2 is fitted directly on main pump However the settings are the same as for version E /123

96 5. BREAKDOWN SERVICE GUIDE 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) Note: Some options like ASB (Activ Shied Bar) if installed and activated will stop all movements from upper controls only (except turntable rotation), all movements from lower controls remain active, refer to Haulotte services for more details 5.1. NO START 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, FU NO MOVEMENT 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 E /123

97 5.3. NO ARM LIFT 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 5.4. NO BOOM LIFT Switch low controls SA 30 Joystick SM2 (off neutral and/or signal) Electrovalve YV6 Incompatibility with the multiple of movements of other functions which are connected to the same section of this valve No pressure 5.5. NO TELESCOPING BOOM toggle switch SA22 lower controls or SA35 upper controls Electrovalve YV7 Incompatibility with the multiple of movements of other functions which are connected to the same section of this valve No pressure 5.6. NO TURRET SLEWING 5.7. NO JIB Switch posts SA82 low Joystick SM2 (off neutral and/or signal) Electrovalve YV4 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 Switch SA50 lower controls or SA51 upper controls Electrovalve YV8 Incompatibility with the multiple of movements of other functions which are connected to the same section of this valve No pressure E /123

98 5.8. NO BASKET ROTATION Switch upper controls SA43 Electrovalve YV9 Incompatibility with the multiple of movements of other functions which are connected to the same section of this valve Not adjusted or defective counterbalance 140b valves No pressure 5.9. NO JIB ROTATION - 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 NO COMPENSATION - 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 NO DRIVE - Joystick SM1 (off neutral and/or consigns) - Contactor KM1 - Electromagnets of brake system L3/L4 - Defective motor (M1, m2) - Another movement in progress NO HIGH SPEED - Proximity detectors SQ 34, SQ 9 - Selection High speed SA67 upper controls NO STEERING - 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 E /123

99 5.14. BATTERY CHARGER STATE Fixed RED binkling red FIXED YELLOW blinkling green Fixed green LED In initial load phase Duration of too long load Phase of stabilization In phase of equalization Finished load E /123

100 ZIVAN 110vac 6. SUMMARY OF VERSIONS HA12CJ-HA12CJ+ HA 12 CJ - HA12CJ+ All models from EC - CDN - USA - AUS Wiring diagram 164P Hydraulic diagram 164P E /123

101 7. SPECIAL FUNCTIONS 7.1. SYSTEM OF LOAD CONTROL 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) OPERATION 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 PRINCIPLE OF THE LOAD CONTROL 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 ANGLE SENSORS 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 E /123

102 MANAGEMENT OF THE NOMINAL LOAD OVERLAP 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 CALIBRATION OF THE PWM VALVE 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 calibration 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 the overload calibration E /123

103 CALIBRATION OF LOAD MANAGEMENT SYSTEM 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) E /123

104 Procedure Menu PARAMETRES ->CODE ACCES -> code->2031 Menu PARAMETRES -> CALIBRATION -> Jib learning: Cal. 1 Select Active Press 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. Drain jib cylinder. 5 Movements from low Stop to high stop. Press (*) when done If not OK start again If not OK Display E /123

105 Lowest jib position detection Maintain the toggle switch (jib down) until pump stops running and the following message appears NOTE: It happens several seconds between the end of the movement and the pump stop, so wait until the end of both conditions 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 Jib lifts from step of 5 Note: If you release the button too early, the calibration must be restart from the beginning Jib descent phase E /123

106 Activate and hold the toggle switch (down jib) The jib must be down until its lowest position (full stroke) + Pump stops running If not OK Display If OK End calibration Note: A message may appear 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) E /123

107 VALUES OF THE SENSORS OF WEIGHING 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 JIB HORIZONTAL JIB MAXI POSITION E /123

108 DIAGNOSTIC 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 E /123

109 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 HA12CJ/+ Elements 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 machines CAN CAN replacement of the lower control box X X replacement node B2 X X replacement node B3 X X E /123

110 VALUES OF THE IMPEDANCE OF THE VARIATOR UNIT Before any check, disconnect all wires from the variable speed unit TERMINALS TERMINALS IMPEDANCE VALUE B - T (VMNT) KΩ B- F KΩ B+ Connector A1 64 KΩ F1 F KΩ E /123

111 BRAKE ADJUSTMENT ON DRIVE MOTORS 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 E /123