HA12CJ (+) - HA32CJ (+)

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 0-
0-INDICE
INDICE

Esta presentacion ayuda al trainer a introducir esta maquina a los tecnicos de campo
Explica en detalle los puntos principales de estos modelos

1. DATOS TECNICOS S3
2. COMANDOS SUPERIOR E INFERIOR S4-S5
3. PLURALIDAD EN LOS MOVIMIENTOS DEPENDIENDO DEL PAIS S6 to S8
4. DESCRIPCION DEL SISTEMA S9
5. COMPONENTES PRINCIPALES S10 to
S13
6. SENSORES S14
7. BANCO HIDRAULICO S15
8. PARTES ELECTRICAS S16
9. CALIBRACION + ALARMAS S17 to
S24
10. SETEOS S25 to S27

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 1-
1-DATOS
DATOSTECNICOS
TECNICOS

* HA12CJ 250 kg / 551Lbs

Hydraulic oil is 32 type ( temporary information) 3
2-
2-CONTROLES
CONTROLESINFERIORES
INFERIORES

El switch de hombre muerto debe ser activado

para todos los movimientos desde los mandos
inferiors (exepto para la calibracion de sobrepeso)

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 2-
2-CONTROL
CONTROLSUPERIOR
SUPERIOR

Algunos movimientos duplicados son posibles (ver mas abajo)

Posibilidad de elevar la velocidad de los movimientos ON/OFF y
visualizar la velocidad seleccionada en el visor
El joystick tipo ITT es el mismo que para la HA16PX

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 3-
3-POSSIBLE
POSSIBLEMOVEMENTS
MOVEMENTSEUR
EURVERSION
VERSION

TURNTABLE ROTATION

CAGE ROTATION

STEERING
JIB ROTATION

LOW SPEED
JIB LIFT

TELESCOPIC BOOM
ARM LIFT

BOOM LIFT

HIGH SPEED
ARM LIFT

BOOM LIFT

JIB LIFT

TELESCOPIC BOOM

TURNTABLE ROTATION

JIB ROTATION

CAGE ROTATION

STEERING

1* : PLURALITY AUTHORISED IN TRANSPORT POSITION ONLY AND FORBIDDEN IF MACHINE IS IN SLOPE

1** : PLURALITY AUTHORISED ONLY IF STEERING IS ACTIVATED FIRST
Note that in drive mode , the steering has the priority compared to the other movements

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 3-
3-POSSIBLE
POSSIBLEMOVEMENTS
MOVEMENTSAUS
AUSVERSION
VERSION

TURNTABLE ROTATION

CAGE ROTATION

STEERING
ARM LIFT

BOOM LIFT

JIB ROTATION

LOW SPEED

HIGH SPEED
TELESCOPIC BOOM
JIB LIFT
ARM LIFT

BOOM LIFT

JIB LIFT

TELESCOPIC BOOM

TURNTABLE ROTATION

JIB ROTATION

CAGE ROTATION

STEERING

Note that in drive mode , the steering has the priority compared to the other movements

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 3-
3-POSSIBLE
POSSIBLEMOVEMENTS
MOVEMENTSUS-CDN
US-CDNVERSION
VERSION

STEERING
TURNTABLE ROTATION

JIB ROTATION

CAGE ROTATION

HIGH SPEED
TELESCOPIC BOOM
ARM LIFT

BOOM LIFT

LOW SPEED
JIB LIFT
ARM LIFT

BOOM LIFT

JIB LIFT

TELESCOPIC BOOM

TURNTABLE ROTATION

JIB ROTATION
CAGE ROTATION

STEERING

Note that in drive mode , the steering has the priority compared to the other movements

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 4-
4-STRUCTURE
STRUCTUREOF
OFTHE
THESYSTEM
SYSTEM Main Contactor
(if KMG = 0 : speed unit
controller is defective)
Upper box
Joysticks Load transducers
0.5/2.5/4.5VDC
Speed variator unit controls the
traction (KM1=0 and pump if
KM1 +KM2=1) communication
made to node B2 through can-
bus network

Lower box + converter

48/12VDC Proximity sensors for KM1
stowed position detection of KM2
Selection
the machine (SQ34 – SQ9)
traction
//movements

Node B2 master module controls Slope

all movements + pump ( KM2) sensor
Node B3 slave module
controls load and
communicate to node B2 CAN BUS CAN BUS
through can bus network

Hydraulic manifold
PWM + ON/OFF

48VDC line

12VDC line

Can-bus

Pump activated if KM1 = 1 +

KM2=1 9
Electrical drive motors
5-
5-THE
THEMAIN
MAINCOMPONENTS
COMPONENTS

ZAPI speed unit + contactors

KMG/KM1/KM2 + fuses (line , pump, speed
unit) : 164P325910
The ZAPI SEM1 CAN 2901015250 is a slave
(it just provides power, all I/O are controlled
by the modules node B)

Battery charger 48VDC/50A (290 101 2740)

SEVCON converter 48/12VDC -15A (290 101 2300) located

behind the lower control box

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 5-
5-THE
THEMAIN
MAINCOMPONENTS
COMPONENTS

Moteurs ADVANCED motors with separate field 48V,

500A + electrical brakes L3/L4 with possible gap
adjustement (~ 0.4 mm)
Maximum ramp 25%

Pump and electrical motor unit HALDEX 4500W

Battery cut out switch 290 100 7510

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 5-
5-THE
THEMAIN
MAINCOMPONENTS
COMPONENTS

Node B3 slave module located in upper box (290 100 3620)

not programmable , controls overload and movements from cage

Node B2 master module located in lower box (290 100 4340)

programmable , it controls all I/O and movements

The hydraulic manifold is controlled by 2 PWM valves YV1

and YV0 piloted by compensation valve set at 9b for the
stability of movements and regulates oil flow
YV1 controls the main movements with big flow and
YV0 the secondary movements with low rate flow
There is 2 manifold ( ha12CJ and HA12CJ+)
2 positions for hand pump depends on the version

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5-
5-THE
THEMAIN
MAINCOMPONENTS
COMPONENTS

The relays in lower control box

KAT : validation for converter ( OFF during battery charge)
KAF : flashing light
KAK : horn
KAV : variator supply ( if OFF no movements , no drive)
KAM : keep power ON after switching OFF the machine

The fuses in lower control box

FUSE 1 (10A ) : protection of the module node B2 ( FU6)
FUSE 2 (10A) : protection of the module node B3 (FU7)
FUSE 3 (3A) : protection of inputs (FU8)
FUSE 4 (3A) : flashing light protection
FUSE 5 (3A) : horn protection

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 66––THE
THESENSORS
SENSORS

SQ9
A1

SQ34

A1 : load relative transducer 290 100 7600 range from 5V (jib in lowest
position) up to around 10V ( jib in upper position)
G1-G2 A2 : load transducer (inclinometer 290 100 7210 (signal ~ 6V cage at
horizontal position)
G1: pressure sensor in jib cylinder small chamber (290 100 3640 ;
range from 0.5 to around 4V )
G2 : pressure sensor in jib cylinder large chamber ( 290 100 3640 ;
A2
signal from 0.5 to around 4V)
SQ34 : ( 290 100 9820) proximity sensor =1 if arm+boom are in stowed
position (gap adjustment between 20 and 30mm)
SQ9 ( 290 100 9820) proximity sensor =1 if telescopic boom extension
is fully IN (gap adjustment between 20 and 30mm)
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 7-
7-THE
THEHYDRAULIC
HYDRAULICMANIFOLD
MANIFOLD

YV6 MAIN BOOM LIFT

YV7 TELESCOPIC BOOM
YV5 ARM LIFT
YV2 STEERING
PWM2 YV1 (main movements)
Y
PWM1 YV0 (secondary movements) V
0
YV8 JIB
YV4 TURNTABLE ROTATION
YV9 CAGE ROTATION
YV3 CAGE COMPENSATION
YV10 JIB ROTATION (for CJ+ only)

This hydraulic manifold is divided in 2 parts , each one is piloted by a PWM valve ( Pulse With Modulation valve)
There is 2 types of movements ( main ones with big oil flow rate and secondary ones with low oil flow rate) , it’s not possible to have 2
movements activated at the same time if they are activated by the same PWM valve.
The main movements ( controlled by PWM YV1) are arm and boom lift , telescopic boom extension and steering
The secondary movements (controlled by PWM YV0) are cage compensation, turntable rotation, jib , cage and jib rotation
The hydraulic pressure is given by the pump which is controlled by the electrical motor and the signal sent by the speed unit controller
When the pump + electric motor is activated for drive , it’s supplied in fixed voltage in order to pluralize the movements with drive 15
 8-
8-ELECTRICAL
ELECTRICALPART
PART

Electrical shematics in both version FR/ENG on the same drawing ( see 164P322210)
Schema :
wire 1xx : inputs lower box / wire 2xx outputs lower box
Wire Bxxx ( upper box from node B3 )
For the movements (even numbers lower box / odd numbers upper box)
YV1 PWM coil 0-1.4A controls all main movements with big flow ( YV2/YV5/YV6/YV7)
YV0 PWM coil 0-1.4A controls all secondary movements with low flow rate (YV3/YV4/YV8/YV9/YV10)
Impossible to pluralize some movements with same flow rate ( example arm and boom lift are not possible at the
same time)

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99––THE
THECALIBRATOR
CALIBRATOR

External RS242 connection for the OPTIMIZER

calibrator or laptop
( not necessary to open the lower control box)

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 99––THE
THECALIBRATOR
CALIBRATOR

One single software version whatever the country is ( the change is possible in OPTION mode access only by level 3)

Validation of the overload calibration by

level 2

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 99––THE
THECALIBRATOR
CALIBRATOR

1. If alarm is permanent ( here OL02 , it appears on main display + in FAILURES menu in RAM)
2. If problem is solved, the alarm ( here OL06) appears OK on display but remains in memory in EEPROM
3. If problem is solved , the alarms remain in memory in EEPROM ( see menu FAILURES)
4. In order to cancel all alarms, go in menu FAILURES and erase them in level 3)
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 99--FAILURES
FAILURES

NB OF FLASHES ASSOCIATED FAILURES

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 - EV10
8
- EV11
9 EP01
10 SM1Y - SM2Y - SM2X - SW01 - SW02
11 SE01-SE02-SE03

Note : If there is no can-bus communication between modules node B2 and B3 ,together with the alarms code ,the overload light HL144
on lower control box is ON fixed

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 99––THE
THECALIBRATOR
CALIBRATOR

The versions of the ECU module B3 and variator could be seen under menu INFORMATIONS
The Cheksum value is calculated after each overload calibration

The detail of Alarms code for the variator could be seen through the menu DIAGNOSTIC/VARIATOR as shown below :

CODE
Internal Variable Alarm code sent by the variator 0 to 255 (detail see additionnal list )
ALARM

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 10
10–– ZAPI
ZAPIALARMS
ALARMSCODE
CODE
13 " EEPROM KO " Fault in the area of memory in which the adjustment parameters are stored; this alarm inhibits machine operation. If the defect
persists when the key is switched OFF and ON again, replace the logic. If the alarm disappears, remember that the parameters stored
previously have been cancelled and replaced by the default values.

18 "LOGIC FAILURE #2" Fault in the hardware section of the logic board which manages the relé of pump.
Possible cause: failure of the logic board

19 "LOGIC FAILURE #1" Problem with Logic or Line Contactor KMG. This test is carried out at the start-up.
Possible cause: failure of the logic board

30 " VMN LOW " The test is carried out during initial diagnosis and in standby.
Possible causes:
a. problem with the motor connections or the motor power circuit;
b. replace the variator

31 " VMN HIGH " The test is carried out during initial diagnosis and in standby.
Possible causes:
a. problem with the motor connections or the motor power circuit;
b. inverter failure, replace it.

37 "CONTACTOR CLOSED" This check is made during the initial diagnosis. With the coil of the line contactor KMG deenergized, the capacitors should not be
charged, unless there is divert resistor across the power poles. Possible causes:
a) The line contactor power poles are welded.
b) This alarm could be generated even if the line contactorKMG has opened, but there is a problem with either the field circuit, or a
problem detected by the safety microprocessor

53 " STBY I HIGH " This test is made during the initial diagnosis and at standby. The test verifies that the current is zero. This Alarm disables the
machine. Possible causes:
a) defective current sensor
b) logic failure. First replace the logic. If fault remains replace the power unit.

57 " HIGH FIELD CUR " Problem detected with the field winding current. Possible causes:
a) Failure of the field current sensor.
b) Field cables not connected or incorrectly connected.
c) Failure of the Field Power Unit.

58 " NO FIELD CURR " Problem detected with the field winding current. Possible causes:
a) Failure of the field current sensor.
b) Field cables not connected or incorrectly connected.
c) Failure of the Field Power Unit.

60 "CAPACITOR CHARGE" This check is made during the initial diagnosis. This Alarm is generated if the Capacitors
are not charged within 500ms after the Key Switch is closed. Probable cause is failure inside the power block.

62 " TH. PROTECTION " If the temperature of the chopper rises higher than 75°C, this alarm is generated.The chopper current is reduced in proportion to the
increase in temperature.At 100°C the chopper totally stops. If this alarm is displayed when the chopper is temperature is the same as
ambient or better than zero degrees:
a) The temperature sensor may be defective.
b) replace the variator.

66 " BATTERY LOW " This Alarm is generated when the battery becomes 20% discharged 22
74 " DRIVER SHORTED " The Contactor Coil Driver KMG is short-circuit
 10
10–– ZAPI
ZAPIALARMS
ALARMSCODE
CODE

75 "CONTACTOR DRIVER" These Alarms are generated if there is a problem with the contactors KMG or KM1 or brakes L3/L4
Possible causes:
76 " COIL SHORTED " a) The coil of the contactor is either short-circuit, open circuit, or not connected.
b) The Contactor Coil Driver is short-circuit.
c) Defect in the wiring to the contactor, or logic failure.

77 "COIL INTERRUPTED" at Key On, the traction μP checks the voltage on the main contactor coil. If it is not high, the alarm is signalled.
First check the MC coil and the MC coil connection.If they are OK ( open or short circuit) , replace the variator

79 "INCORRECT START " Warning generated by an incorrect Starting Sequence.

99 " INPUT ERROR #1 " Stuffing bit doesn't change. Probable cause: problem on vmc ( CAN bus or modules defective)

223 "WAITING FOR NODE" vmc try to start without MC enable request ( CAN bus or modules defective)

233 " SENSOR I KO " armature current sensor NOT OK

234 " HW FAULT " inverter failure, replace it

241 " FORW + LIFT " Double request : traction + lift. Remove all commands.

242 "VALVE COIL SHOR." Probable cause:

a) overvoltage circuit damaged, replace the variator
b) otherwise, wrong wiring or valve damaged

244 "CHECK UP NEEDED " This is a warning. It is an information for the user that the programmed time for maintenance is elapsed (no used by HAULOTTE on this
type of SEM1 variator)

247 "THERMIC SENS. KO" The range of inverter temperature sensor is always checked and a warning is signalled
if it is out of range. When this alarm is signalled, replace the variator.

248 " KEY-OFF "

249 " CAN BUS KO " It is signalled if the inverter does not receive any message from the CAN-BUS line. First of all, check the wiring. If it is ok, the problem is
on the logic board, the variator must be replaced.

250 " VFIELD NOT OK " This test is made at standby with the Line Contactor open. In this condition the voltages on both the connections of field must be to
around ½ VBatt. This alarm is generated if the field voltage is different from this value.
Possible causes:
a) Frame fault on the motor to chassis;
b) Incorrect connection of the field winding to the controller;
c) Failure of the controller in the section relative to the field.

251 " WRONG SET BAT. " wrong type of battery (nominal voltage)

252 " AUX2 OUTPUT KO " The μP checks the driver of the electromechanical brake. If the status of the driver output does not correspond to the signal coming from
the μP, the alarm is signalled.
Replace the logic. 23
253 " AUX1 OUTPUT KO " The μP checks the driver of the contactor KM1. If the status of the driver output does not correspond to the signal coming from the μP,
the alarm is signalled.
 99––THE
THECALIBRATOR
CALIBRATOR
With the DIAGNOSTIC menu , the origin of every malfunction could be clearly identified ( ie here Boom Lifting):

Value of the active limitation .

Int. Set Point 100% f no limitation of the movement (takes in account
LIMITATION From 0 to 100%
Limit even if the movement is modifiable by push speed
buttons SB120/SB121 + and -)

Binary value for the conditions status for activation or

prohibition of the desired movement
Fwd/Up/L= 000000
Rev/Down/R= 000000
Bits reading ( right to left as shown 654321
1: Condition for the validation of the movement
Internal Logical CUTTING OUT From 000000 to 111111
2 :Condition for cutting the movement
3 :Condition for cutting the plurality of the movement
4 :Condition fo cutting the movement in overload mode
5 :Condition for cutting the movement in slope mode
6 :Condition for cutting the movement de coupure in
combined movement

POINT 1 : LIMITATION
Value at 100% from upper control box and automatically set at 80% from lower control box (by software)
If the boom is in overload , the value will be set automatically at 50% (slow down movements)
If the movement speed is set by BP SB120/SB121 à 60% ( ie arm lifting) and if the boom is in overload , the
display will be set automatically at 50% of the maxi value ( and not the 60% selected )
For drive , the display will be at 100% in HS , 50% in LS and 10% in Micro speed ( with joystick fully pulled or
pushed))
POINT 2 : CUTTING OUT
The binary values indicate the variables status which are taken in account for the condition of the desired
movement
Example : display for boom lifting : 0010001 ( machine in slope : reading from right to left)

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 10-
10-SETTINGS
SETTINGS

Cage empty, boom in stowed position:

TRANSDUCERS A1 A2 G1 G2
(mV) (mV) (mV) (mV)
OVERLOAD CALIBRATION (refer TN129)
JIB IN LOWEST POSITION 5000 5940 1290 1290 Menu PARAMETERS
-> CALIBRATION
-> Jib learning: Cal. 1
JIB AT HORIZONTAL POSITION 7495 5960 530 985
Access level 2 : -> OVERLOAD CAL
-> Start Jib learning
JIB AT HIGHEST POSITION 9980 5980 1175 1365

Wear check for lateral wear pads on boom

section
Brakes gap adjustment

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 10-
10-SETTINGS
SETTINGS
MP1

MOVEMENTS Pressure at pump exit

( movements at full stroke)
Plug MP1

Boom Lifting/descent 186b

Arm Lifting/ Descent 195b / 177b
Telescopic boom extension 188b / 175b
(OUT/IN)
Plug MP2

Jib 172b
Jib rotation 169b
Cage compensation ( UP) 155b
Cage compensation (DOWN) 168b
Cage rotation 169b
Steering 210b
Turntable rotation 100b

MP2

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 10-
10-SETTINGS
SETTINGS

MOVEMENT PRESSURES SETTINGS during the movement

LOAD IN CAGE 0 Kg 80 Kg 230 Kg

Main boom lift 77b 84b 113b
Main boom descent 95b 90b 90b
Arm lift 132 à 80b 127 à 83b 158 à 91b
Arm descent 87 à 75b 83 à 67b 84 à 66b
Telescopic boom extension ( exit) 34 à 41b 33 à 40b 34 à 48b
Telescopic boom extension ( IN) 96 à 87b 96 à 84b 110 à 90b
Jib lift 63 à 73b 69 à 85b 101 à 128b
Jib descent 106 à 86b 95 à 77b 87 à 69b
Cage compensation (lift) 58 à 75b 58 à 91b 55 à 1446b
Cage compensation (descent) 75 à 87b 75 à 82b 70 à 110b
Turntable rotation (left/right) 24b 24b 25b
Jib rotation (left/right) 66b 70b 85b
Cage rotation (left/right) 78b 78b 85b
Left steering 72b 70b 70b
Right steering 51b 50b 50b

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 10-
10-SETTINGS
SETTINGS

TERMINALS IMPEDANCE

B – and T (VMNT) 128.6 KΩ

B – and F2 128.9 KΩ

B + and logic connector A1 64 KΩ

F1 and F2 132.7 KΩ

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