Liebherr Lehr Buch

description Gomponent

of electricity UW01- Fundamentals i'-l--'

',

.

U R

unir A=+

Gomponent description UW 01 - Fundamentalsof electricity fudmedby:|mpim/Edfujl9'u07/ve€d:1

Li€bher-W€rkEhln96nGmbH- T€chnlcaltralning

Onlyfor LIEBHERR servicepersonnel

-3-

UBIIIRR

description Component of electricity UW01 - Fundamentals 1. Introductionto electricity/ electronics 1.1Definitions >1.1.1Voltage ifthercarea different twopoints(e.9.theterminals ona battery) Anelectdcal voltage isproduced between poinb. ateachofthese number ofeleclrons thesizeofthevoltage. inelectrons determines Themagnitude ofthisdifierence ofanelectrical voltage. Forexaminthegeneration separation inthevoltage sourc€(fig'l) results Charge ple,thechemical to migraie tolhe causes negatively charged electrons insidea dlargingbattery reaction negative terminal. respectively. atthepositive andnegative lerminals andsuelusofelectrons Thismeans lhereisa shortage thehigherthe Thehigherthe charge differenlial, ina voltage between thetwopoles. Thisresults diference (potential diference involtage difference).

1 '

., t-.t

l-

d.rg rdc It J

by chargeseparation Fig.1:Voltagegenerated

thesedifferent-sized charges. in an attemptto compensate Electrical voltageis produced Voltagecausescurrentto flow. Theunitof voltageU is givenin Volt(V).

Li€bhetr-W€kEhing€nGnbB -T6chni€ t.ainlng


-4-

UTBIIIR

Componentdescription of electricity UW01 - Fundamentals

>1.1.2Current voltagedifferences. Electrons attemptto compensate Curentcanonlyflowin closedcircuits.Voltagecauseselectricalcurrentto flow. movementof freeelectrons. Electrical currentis the dlrectional Closinga circuitby applyinga voltageforcesall freeelectronsto movein a certain direction. Thiscauseselectricalcurrentto flowfromthe negativeterminalthroughthe loadsandwiresto the positiveterminal.Electronsperformelectricalwork.

.:lr

,;r

-r

-

*

r

-rtr,I-

Convenlionalcunentflow

Fio.2: Flow ofelecttonsin an electricalcitcuil

Everyelect calcircuitmusthave: . Voltagegenerator .

.

LOaO

Wres

lMovementof eLectrons+

Fig.3: Electrical circuit

Note; suchas switches,relaysor fusesmightalsobe included. Othercomponents state. Switchesaredrawnin thelrnon-actuated andoverload. Fusesarefittedto protectelectricalcircuitsagainstshort-circuits

Li6bher-WsrkEhingenGmbH- Tecnnl@ltEining

personnel OnlyforLIEBHERR service

-5-

TIEIIIRR

Gomponentdescription UW01 - Fundamentals of electricity

current",currentflowsfromthe positiveto Accordingto the definitionof "conventional thenegative terminal. The unitof currentstrengtht is givenin Ampere(A).

il

Conventional

I

-__>

Fig.4: Batteryas an electrcnPumP

DirectCurrent"DC"flowsin onlyone directionthrougha circuit. are constant; Thecurrentis steadyprovidingvoltageandresistance

'rl

II E Time [ -------->5: Diroctcurrent

anddirection: Alternating curentAC alwayschangesin its magnitude Movement of electrons

IVlovement ol elechons Period Fig.6:Altemating c!nent Liebheii-WekEhingenGmbH

Onlyfor LIEBHERR servrcepersonnel

-6-

UIBHIRR


>1.1.3Electricalresistance Electrons do notflowfreelywhena voltageis appliedto an electricalconductor. materialshavedifferentnumbersof freeelectrons. Depending on theircomposition, provide whichopposethe differentlevelsof resistance Consequently thesematerials current.The movementof electronsis thereforesloweddownat differentrates.

of theflowof electronsis referredto as electricalresistance. Obstruction R is givenin Ohm(O). The unitof resistance = 1VA). = (1 Ohm= 1 o 1 VoltAmpere Thereare differenttypesof resistors: . Fixedresistors . Variableresistors ' Potentiometers (resistors witha slidingcontact)

--z-

-G reslsrcr

I --f --rresistorwiih slidingcontact

resistorwith taps

--G

vadable resistor

li

tully-variable resistorwith slidingcontact

step-cnange resistorwith slidingcontact

Fig. 7: Resisiorsymbols

Unwantedresistance: ' Poorlysolderedconnections . Badpluggedcontacts . Faultywiresandconnections . Rustedgroundconnections (corrosion resistance) Resistancedesignations: = 500f) 500R = 0.5o 0R5 = 200000 2OK = 1K5 1 , 5 K o= 1 5 0 0 K o

Li€bher-WerkEhlngenGmbH- T6chn€l lralning

servicepersonnel Onlyfor LIEBHERR

UBIIIRR

Componentdescription UW01 - Fundamentals of electricity

>1.1.3Ohm'slaw TheappliedvoltageU in a closedcircuitwillcausea currentlto flowthroughresistorR (fiSl). the resistanceR. Theratioof voltageU to currentI determines Georg Simon Ohm,namely"Ohm'slaw". Thislaw is namedafterits discoverer

Derivation: Fora constantresistance, currentwill increaseas the voltageincreases. to one another(U - l). Thismeansthal cunentI andvoltageU are proportional R increases. Fora constantvoltageU, currentwilldecreaseas resistance proportional R areinversely to oneanother(l - 1/R). Thismeansthatcunentlandresistanc€ of Ohm'slaw (U=R-l). theaboveresults in thedellnition Combining

Unit;

R = V

o

in an eleclrical Fig.8: Vadables circuil

theequation: The followingaid can be usedto remember

Note: Simplyuseyourfingerto coverthe desiredsymbol! Liebheii-Wei

-8-

IIIBilTNR

Componentdescriplion UW01 - Fundamentals of electricity

Measurement examples:

Resistance

UinV

0

2

R , = 2 Q Irin A

0

I

R z =1 Q Irin A

n

2

0

z

Shortcircuit

z,a

6

B

i0

2

e

4

5

+

o

8

10

b

8

i0

Fig.9:Currentversusvollage

Voltage

BinO

Ur=5V I . , i n A

Uz=1ov Irin A

Shortcircuit

1 , 2 5 0,83 0,675 2,5

1,66

t,Jc

U,C

1,0

Fig.10:Currentversusresistance

Liebhetr-We*EhingenGmbH- Techn@l tralning


-9-

IITBHIRR

Gomponentdescription UW0'l - Fundamentals of electricity

>1.1,4Resistornetworks Seriesresistors:

R1

R2

R3

Fig.11:Seriesnetwork

Seriesnetworksserveas voltagedividers. LEDs(e.9.witha nominal voltage ol2.4V)to Pre-resistors are requiredwhenconnecting the 24Von-boardsupplyon mobilecranes. Thefollowinglawsapply: |

- t - t -

Thesamecurrentflowsthroughall the resistofs.

Ubt= Ur+ U, +...

Thetotalvoltageis the sumof all partialvoltages.

R.. = R,+ R,+...

is the sumof all partialresistances. Thetotalresistance

Liebher-W€ft Ehing€nGnbH - T€chnlcallbining


- t0 -

ITBIITRR

Componentdescription UW01 - Fundamentalsof electricitlr

Parallelresistors:

l', Fig. 12:Parallelnetwork

Parallelnetworksserveto dividethe current. Thefollowinglawsapply: l,"c= lr + lr+ ...

All the resistorshavethe samevoltage.

U,.,= U,= U,= ...

Thetotalcurrentis the sumof all partialcurrents.

of thetotalresistance isthesumofall recipro1,/R*=t76,*17*,*... Thereciprocal catedoartialresistances.

Ll6bh6r-W6rkEhlng€nGmbH- Techni€l tEining


- 1 1-

TTEHINR

Componentdescription UW01 - Fundamentals of electricity

1.2Measuremeni technology inslruments >1.2.1Typesof measurement Thereare twotypesof measurement instruments: . Analogue multimeter . Digitalmultimeter

Analoguemultimeter: ,.t,. _-.--;;-- .f

'; ,,r''= -ll;:t

Fig.13:Analoguemultimeter

Connections: groundconnection COM: v/o: voltageand resisiancemeasurement inAmpere-range currentmeasurement currentmeasurement in milli-Ampere range

Advantages: . Rapidchanges in measured vari dursn drv vdrry

.

nEcr r.

If correctlyused,often moreaccurate.

Disadvantages: . Whenusing movingcoilmechanisms, it is only possible DCvoltageand to measure current. . Measurement rangemustalwaysbe manually selected.

Note: Themeasurement depending on thevariable beingmeasured. leadsmustbe re-plugged Alwaysselectthehighest measurement rangewhenmeasuring an unknown variable. Thenselectthemeasurement rangewheretheneedleis in theupperthirdof thescale.

Liebheir-Werk EhingenGmbH- Technicaltraining

personnel Onlyfor LIEBHERR service

-12-

ITBHTRR


1,2.1Typesof measurementinstrumenls Digitalmultimeter:

Fig. 14: [.4etrixMX22

Fig.15:chauvin AmouxMM3000

Fig.16:chauvin Arnoux Conpa2010

Connections: grounoconneqton coM: measurement V/O: voltageand resistance in Ampere-range currentmeasurement range mA: cun-entmeasurement in milli-Ampere

Disadvantages: Advantages: . Rapidindication of measuredvalues . Difficultto noticemeasurement . The measurement ran9ecnanges. rangeis often automatically selectedby the measurement instrument. . On someinstruments the measured valuescanbe storedor transferred to a PC for further analysis. Note: depending on the variablebeingmeasured. Themeasurement leadsmustbe re-plugged

Liebheir-Werk EhingenGmbH- Techni@ll€ining


-13-

lTIBIITRR


>1.2.2Using measurementinstruments Measuring electricalvoltages: Thevoltmeter(fig 1) is switchedin Theelectricalvoltageis measuredusinga voltmeter. parallelto thevoltagesourceor load.A voltmeteralwaysmeasuresthe voltagedifference points.ThetypeofvoltageAC- or DC must - be selected. betweentwo measurement

I

lu Fig.17rVoltagemeasurement

Fig.18:Voltage measurement

Note: probes Thevoltageacrosseachloadcanbe individually measured. The measurement mustbe applieddirectlyin frontof and behindthe loads(fig2). Caution: whenmaking Theredandblackleadsmustbe connected to V and COMrespectively voltagemeasurements. Liobhon-Werk Ehingen lraining GmbH- Technica

OnlyforLIEBHERR servicepersonnel

-14-

UEBilENR

Componentdescription of electricity UW01 - Fundamentals Pdu€dby'*pI0/Edfton

Measuringelectricalcu enls: Theammeteris placedin the circuit,t . e . Electrical currentis measuredusingan ammeter. it is switchedin seriesin eitherthe supplyor returnlineto the load.

.<-

Fig.19:Currentmeasurement

Fig,20:Currentmeasurement

Caution: to mA(orA) andCOMrespectively when The redand blackleadsmustbe connected makinocurrentmeasurements. Liebh€rr'w€*Ehlnssn GmbH- Technl€llEinins


_ 15 _

I.TIBHINN


Resistancemeasurements: Theresistance valueis determined usinoa director indirectmeasurement or the compomeasurements eitherrequirethe circuitto be interrupted Directresistance of measurement is very imprecisenentto be removed.Thistype

measurement Fio,21: Directresistance

at the resistor. Indirectmeasurements are basedon voltageandcurrentmeasurements fromthe measuredvaluesusingohm's law. Theresistance is calculated Therearedifferentootionsfor oerformino an indirectmeasurement;

l u t p

I

measurement / voltageerrorcircuit Fig.22:Indirectresjstance

Fig.23: Indirectresislance measurement/ curentenorcircuit

Caution: The redand blackleadsmustbe connected to R andCOI\4respectively whenmaking resistance measurements. Liebher-W€* Ehhgon GmbH-Technicaltraining


- 16 -

UIBlIINR

Componentdescription

UW04- Driveunit / dieselengine

Onlvfor LIEBHERR Service oersonnel

Glossary: pressure pressure Absolute sensor:Theabsolute sensoralwaysrelatesitsmeasurement to a referencepoinl AGR:

Exhaustrelurn

ECU:

ControlUnit(enginecontrolunit) Electronic

EDC:

DieselControl Electronic (injection systemfor Dieselengines)

OT

Topdeadcenter

PLD:

Pumplinanozzle

pressure pressure sensormeasures thepressure difference Relative sensor: A relative betweentwotestvalu€s UT

Bottomdeadcenter

ZMEi

Unilto bs measured

(

Componentdescription UW04 - Driveunit / dieselengine

Liebher-Werk Ehingen GmbH- Techni€ltraining

personnel OnlyforLIEBHERR-Service

- J -

ITIBIIRR

Component description UW04 - Driveunit / dieselengine

Liebhetr-We* Ehingen GmbH - Techni@l t€inhg

personnel Onlyfor LIEBHERR-Service

-4-

UIBHNR


uw041. Inlineengine >1.1General Inlineengineis the namegivento an enginewhosecylindersare arrangedin a line.

>1.2Motordesignation

I

Model emissions Optimised Supplementary designation Numberof cylinders Production series Dieselengine

Supplementarydesignations: NA Suctionengine TB Turbo-charged engine"slightlycharged" T Turbo-charged engine Tl Turbo-charged enginewithchargeair cooling S Short(shortpistonstroke) L Long(longpistonstroke) Model: A3 M A5 A6 A7

injectionpump Distributor-type MW-/ P3000 Injectionpump P7'100- Injectionpump pump+ EDC P7100- lnjection (EDC= Electronic DieselControl)with LH ECUl PistonvalveinjectionpumpEDCwith LH ECU4or ECUS PLD(PumpLineNozzle)withLH ECU-UP/cR CR (CommonRail)withLH ECU-UP/CR

Typedesignations for inlineengines: .D924 .D926 .D846 .D934 .D936 Distinguishingcharacteristicsof inline engineswhich can be determinedfrom their type designation: Production series+ no.of cylinders= 3-digit! ftaininq Liebhen-Werk Ehinsen GmbH- Technical


_5 _

UIBIIIRN

Componentdescription UW04 - Driveunit / dieselengine >1.3Layout Overview: Rockerlever Injectionnozzle Intakevalve

Pushrod

Dipstick

Oilfilter Piston lnjection pump Connecting roo Crankshaft

Oilpan

Plunger

Liebher-Wei

-6-

Camshaft

Starter motor

lIEHINR

Componentdescription UW04 - Driveunit / dieselengine >1.4Installedenginetypes

D846- A5 / 6 CylinderDieselInlineEngine:

Exhaustgas

FSC(FuelService Center) . Suctionfilter . Finefilter . Manualdelivery pump Flameglowplug

EnginecontrolunitECU5

generator

Liebher-W€rkEhingenGmbH- Techni@ltraining


- 7-

lTIBHINR

Componentdescription UW04 - Driveunit/ dieselengine

D846- A7 / 6 CylinderDiesetInlineEngine: FSC{FuelService Centef) . Suciionfilter . IVanual delvery pump

Enginecontrolunil ECU UP/CR

High-pressure pump(railpump)

air Compressed pump FueldeTivery

Exhaustwatercooler

Oilfilier

Liebher-werkEh ngen GdbH - Technicalt€iring

personnel Onlyfor LlEBHERR-Service

-8-

Flameglowplug

Gene€tor

lTIBHIRR


D924- A4 / 4 CylinderDieselInlineEngine(ow engine); EnginemntroluniiECU1

Fuelpreliminary filterunit Fuelllnefilter

D926- A5 / 6 CylinderDieselInlineEngine:

EnginecontrolunitECU4

Heatingflange

FLrel finefilter Oilfilter

Fuelpreliminary filterunit

Liebher-Werk Ehingen GmbH' Techni€lhaining


-9-

UIBHTNR


D934-A6 / 4 CylinderDieselInlineEngine(ow engin€): Enginecontrolunit ECUUP/CR

Fuelfinefilter

Oilfilter

Plug-inpr.rmps

Coolant pump Fuelprelimin filterunil Fueldeliverypun Starter molor pressedair compressor Oilcooler Exhauslgas turbocharger

D936-AO / 6 CylinderDiesellnline Engine: Engine control unit ECU UP/CR

Fuelfinefilter

Fu€lpreliminary filtorunit Uebher-We* Ehingen GmbH - Techni€l Aaining


-10-

HIBHNR

Gomponentdescription UW04 - Driveunit / dieselengine 2. V-engine >2.1General givento an enginewhosecylindersare anangedin a V-forV-engineis the designation matron-

>2.2 Motordesignation

Model emissions Optimised designation Supplementary Numberof cylinders Production series Dieselengine

Supplementarydesignations: TB Turbo-charged engine"slightlycharged" T Turbo-charged engine enginewithchargeair cooling Tl Turbo-charged Model: A3 A4 A5

-

A7

-

P7800- Injectionpump P7800- Injectionpump + EDC(electronic drivecontrol) Piston valve injectionpump H-RP43 + EDC(electronic drivecontrol) CR (CommonRail)withLH ECU-UP/CR

Typedesignationfor V-engines: .D9306 .D9308 .D9406 .D9408 .D9508 Distinguishingcharacteristicsof V-engineswhich can be determinedfrom their type designation: Production series+ no.of cylinders= 4-digit! UebheFWei< EhinsenGmbH- Techni@lt alning


_f

_

lTIBITIRR

Gomponent description UW04 - Driveunit/ dieselengine >2.3Layout Overview: Oilseparator Pushrod

pump Injection Plunger

Rockerlever Dipstick lntakevalve

Rockerlever

Outletvalve Injection nozzle Piston Camshaft

Oilcooler Connecting rod Crankshaft

Oilfilier

Oilpan Connecting rod

Exhaust 9as turbocharger Injectionnozzle

Startermotor

Liebher-werk Ehingen tralring GmbH- Technlcal


-12-

IIIBIIIRR

Componentdescription UW04 - Driveunit / dieselengine 2.4Installedenginetypes D9406-A5 / 6 CylinderDieselV-Engine: EnginecontrolunitECU4

Fuelfine filter

Generator

Coolantpump

D9408- A5 / 8 CylinderDieselV-Engine; Oilfilter Engineconlrcl unitECU4 Coolantpump

Fuelflnefilter

Fuelprcliminary filterunit

Air conditionrngsysiem

Generalor Liebher-We* EhlngenGmbH- Techncal lraining


- ' t 3-

IIIBHRR


D9508- A7 / 8 CylinderDieselV-Engine: Oil separalor

Heatingflange Exhaust gas

turbochargef Actuating cylinder exhaustflap (enginebrake)

Generalor

Aircondilioning compressor

High-pressure pump

Enginecontrolunit ECUUP/CR

FSC(FuelService Center)

D9508- A7 / 8 CylinderDieselV-Engine: Heatingflange Exhaustgas turhochaQer

Oilseparator

Enginecontrolunit ECUUP/CR

Oilseparator

Oil filter

Starter motor Coolantpurnp Generator

Airconditioning compressor

Liebher-Werk Ehingen GmbH- Techni€llralning


-14-

FSC (FuelService Center)

lIIBIIIRR

Componentdescription UW04 - Driveunit / dieselengine 3. Dieselengine,general >3.'l Modeof operation and self-ignition of the fuel/ air TheDieselenginealwaysworkswith internalcarburation mixture.Dieselenginesworkmostoftenaccordingto thefourcyclesystem.

>3.2Work cycles(supplyphases)of the four cycle system Fuelinjector

Suctioncycle (1. cycle): The pistonmovesdownwardin direction of the bottomdead center(UT position). The intakevalvesare open and air flows into the combustionchamber. Note: At the start of the 1. cycle,the exhaustvalves are also open for a shorttime. Due to this valve overlap,the incomingfresh air flushesthe combustionchamber.

Compressioncycle (2. cycle)

Fuelinjeclor

Thepistonmovesup andthe air is compressed.Thecompressed air heatsup dueto heat is the compression and far abovethe selfignitiontemperature.

lntakevalve

Towardsthe endof the compression cycle,Jlliquid fuel is injected. This forms Fuelis nelyatomized, injected a fuel/ airmixture, Afterthe ignitiondelay(timefromwarmup to self-ignition), the fuelmixtureignitesby itself. Theintakeandexhaustvalvesare closed.

Ll6bhe(-WerkEhi.genGmbH- Technicalfiaining


- 15 -

lTIBHINR

Gomponent description UW04 - Driveunit / dieselengine

Workingcycle (3. cycle): Theignition,whichoccursshortlybeforethe Fuel, top deadcentertriggersthe combustion. whichis stillinjectedafterthe startof ignition, burnscompletely. pressurepushesthe Theresultingcombustion pistonin directionof the bottomdeadcenter (uT position). Theintakeandexhaustvalvesare closed.

Piston moving

gases(hydrocarbon, Combustible nitrogen oxide,carbonmonoxideand carbonparticles) are created.

Fuelinjector

Exhaustcycle (4. cycle): The intakevalvesare closed. Theexhaustvalvesareopen. The pistonmovesupwardand pushesthe burntgasesintothe exhaustsystem.

Liebheii-Werk Ehingen GmbH - Techniel lraining


Exhaust

- 16 -

lTIBIIIRR

Component description UW04 - Driveunit/ dieselengine 4. Injectionsystem >4.1 Electronicdieselcontrolsystem EDCwith pistonvalve pump - A5 Layout: Theelectronic dieselcontrolsystemwith pistonvalvepump- A5 comprisesan withinjectionadjuster(regulatiinlineinjectionpump(pumphousingand pumpelements) of the injectionstarttimeand extremelyexactsupply on).Thispermitspreciseregulation of thefuel. Fig.1: Overview ofpistonvalvepump Injection nozzleouUets

[,4agnet to adjuststartof supply

"Pistonvalve"actuator (changestadof supply) Pistonvalve Regulationrcd

Camshaft

quantityactuator- EDC Injection (regulation rodcontrol)

Fig.2: Pistonvalvepump

Li€bh€r-we* Ehing€nGnbH - Technicataining

personnel OnlyforLlEBHERR-Service

Fig.3: D846-A5withpistonvalvepump

ITEHIRR


Fig.4:Engine control unit(ECU)

Function: . The pumpelementsare controlled via the camshaftof the injectionpump. . Theinjection pressure is dependent on theengineRPM. . Variablestartof supply(startof injection)andvariableinjectionquantity (injection duration). - Thestartof injectionis modiJled by regulating the pistonvalve. (closed-loop controlled regulation circuit)andactuated Thisis electronically by meansof the pistonvalveactuator. - The needlemovementsensorsignalsto the EDCcontrolunitthe actual injectiontime. - Thefunction oftheEDCsupplyquantity controlis thesameas forconventional rod is actuatedby the EDC EDCinlineinjectionpumps.The regulation quantityactuator.Thecontrolsystemusesan electronic controlunittogether withan inductiveacknowledgement device(regulation transducer).

Liebher-Werk Ehingen GmbH-Techni€ training


-18-

lIIAHRR

Componentdescription UW04 - Driveunit / dieselengine >4.2 PLD(PumpLineNozzle)- A6 Layout: . ThePumpLineNozzle(PLD)systemis a modular injectionsystem. regulatedhigh-pressure electronically . Thiscomprises injectionlineand a nozzle an injectionpump,a shorthigh-pressure per (figure 1). cylinder, see holdercombination

Fig. 1: OverviewPLD engine I\,4anualbleeding pump

UniiPump Solenoidvalve on prugrn pump

Fuelpreliminary filterunit

Fueldelivery pump

Fuelfinefilter

Solenoidvalveon prugrnpump

Liebhe(-WerkEhi.genGmbH-Technicaltraining


-19-

UIBIIERR


Fig.2:Overview PLDengine

1 Nozle holder(claw) 2 Cylinderhead 3 lnjectionIine Nozzle 5 Solenoidvalve 6 Fu€lfeed 7 P!mp a Camson camshaft

Function: . The injectionpumpsare drivenby the camshaft. . Thestartof injectionand injectionquantityare adjustedusinga solenoidvalve for eachcylinder. The solenoidvalveon the injectionpumpis controlledby the enginecontrolunit. . Theinjectionpressureis dependent on the engineRPM. . Moderndistributor-type injectionpumpscangeneratea maximumpumppressureof 800-1000bar.The useof currentPLDsystemsallowsan increase to a maximumpumppressureof approx.1500bar.

Fig.3: D936-A6PLDongine Enginecontrolunit ECUUP/CR cooledJuel

Liebheri-W€kEhing€nGmbH- TechnicallEining


-20-

lTIBIIRR

Component description UW04 - Driveunit/ diesele ngrne >4.3CommonRail - 47 Layout: . The CommonRailSystemis an electronically regulatedhigh-pressure injection pipe(CommonRail). systemwitha commondistribution Low pressurecircuit: Thisconsistsof a fuelsuctionsection,feedpressuresectionandfuelreturnfuelfilter,fuelfeedpumpand Thisincludesthefueltank,fuelpre-heating, (ZME). electricalrailpressureregulation Highpressuresection: pump,thehigh-pressure lines, Thiscomprises the high-pressure per (Rail), reservoir andan injector cylinder thehigh-pressure Electroniccontrols: the railpressure the electronic controlunit,the sensorequipment, Thiscomprises shut-off valve. regulation valve,the solenoidvalvesfor the injectorsandthe Fio.2: D846-A7- Overviewof commonrail

FuelServiceCenter (FSC)withfine fuelandsuction 2-step filter,manualfeed High-pressure reseNok high-pressure DBV pumpandfuel (Rail)/ manifold withhigh- (RailDBV) p.e-heating pressureregulation circuit 1

R"it or"""rr" (RDS) sensor

\ \ \

\ , ,

, +\ \ +\ t r

To injector Relumlinefrom injectors 0.5bar

r lr

t

e # \ ' * , t i= u

controlunit (cooledby fuel) etectt ratlpressure regulation valve(zME)

-

RailPressure 5 barfeedpressLlre 1.5bar- Flamestarting -

Liebhen-Werk EhingenGmbH- Techni€l Laining


Fuelsuctionline

High-pressure pump

Fuelreturnlineto tank 0.5bar- lnjectorreturnline

-21 -

lTTBIIIRR

Componentdescription UW 04 - Driveunit / dieselengine

Function: pumpprovidesthe requ'redfuel pressureunderall operating The high-pressure reservoir. conditions andfeedsthefuel intothe high-pressure The high-pressure diesel. reservoir(CommonRail)storesthe pressurised Sincethe high-pressure reservoir(Rail)storesa largeamountof fuel,the injectorsand pressurefluctuation. combustion chambersare suppliedwilhoutanysignificant pressure The injection is thereforenotdependent on the engineRPM.

The pointedinjectorlip on the CR nozzlecloses ifthe systempressureis veryhigh. automatically Thehigh-pressure regulation and controlofthe injectionstaruduration are completely independent of one anotherand havea variableadiustment.

Fig.2: fuelcooled engine controlunit ECU UP/CR

Fig.3: D846-A7- Commonrail engine

LiebheE-Werk EhingenGmbH- Techn'callraining


-22-

Componentdescription UW04 - Driveunit / dieselengine 5. Sensors speedsensor >5.1Rotational Purpose: the RPMandcrankanThe impulsetransmitters arefittedto theflywheelanddetermine gle.Thesevaluesare requiredfor the correctactuationof the injeetors(startand durationof injection*). Additional tasks: . Engineshutoff viathe controlunitat overspeed . Monitoring for gradientviolationof RPMdifference (forexampleif distancebetweensensorandflywheelis too Iarge) . Recognition of ignitionpointposition,,topdeadcentei'(OT)on engineswith versionA5. Layout: The RPMsensorscaneitherbe inductivesensorsor hallsensors. provide lines. havetwoconnection an analogue signaland Inductive impulse transmitters provide have lines. threeconnection Hallimpulsetransmitters a digitalsignaland sensors. BothRPMsensorsare usedas incremental aresometimesusedto determine Forsafetyreasons,two identicalimpulsetransmitters is theworkingsensor;in casethisfails,the the engineRPM.Theflrstimpulsetransmitter second auxiliary impulsetransmittetThe engineis switchesto the systemautomatically fail. stoppedif bothimpulsetransmitters

.

InductiveRPMsensor:

RPMsensor Fig.1;Wiringdiagramexcerptinductive

Fig.3: Originalillustraton, inductive RPN4 sensor

Flywheel

Teeth

lnductive RPMsensor

Liebher-Werk Ehingen GnbH-T€ch.icaltrainlng


-23-

lTIBIIIRR

Gomponent description UW04 - Driveunit / dieselengine

Schematicdiagram,inductive RPMsensor

.

HallRPMsensor:

HallRPMsensor Fig.4rWingdiagrcm excerpt

Fig.3: Originalilluslration,HallRP[/ sensor

Hall RPI\4sensor

Teeth

Flywheel

Liebhed-WeA lraining Ehing€n GmbH- Technical


-24-

UEBHINR

Componentdescription UW04 - Driveunit / dieselengine >5.2 RPMsensoras camshaftsensor* Task; the position"Ziind-OTZylinder1" (= lgnilisn The camshaftsensoris usedto recognize = 1). OT topdeadcentercylinder Thecamshaftsensoris locatedon engines,versionA6 andA7 on the camshaft. Design: sensor. Thecamshaftsensoris a Hallsensor,whichis usedas an incrementat Fig.1: Widngdiagramexcerpt sensor Camshaft

Note; Hallsensorsmaynotbe usedfor inductivetests(Dangerof destruction).

view,camshaft Fig.3: Schematic sensorD846-A7

Fig.2: Originalillustration, camshaft sensorD846-A7

Camshaft gear

Flywheel

Function: the engine Thecamshafisensoris installedon the camshaft.Forthe startingprocedure, requiresa certaininitialposition.Thisso-calledignitionoT (topdeadcenter)is detected by the camshaftsensor. Note: Thecamshaftgearturnsduringthe courseof the4 cycles 1 x by 360', theflywheel2 x 360". ' = onlyon engineswithPLDor CommonRaillechnology training LiebheF-Werk Ehingen GmbH-Tochnical


-25 -

ITIBIIIRR

Gomponentdescription UW04 - Driveunit / dieselengine EE|.|fM4id/fusgab1ol

>5.3 Oil Dressuresensor Puroose: . Wamsusersaboutlowoil pressure . lmorovedmotororotection . Recordsoil pressurewarningsin the errormemoryof the controlunit.

Layout: Theoil pressuresensormeasuresretal|veDressure. Supply: Pressurerange: Outputvoltage:

lmax= 15 mA 0 to 10 bar relative 0.5V = 0 bar/ 4.5V = 10 barlinear

Fig.2: Oil pressure sensoa

Fig.1: Extractof circuitdiagramforoil

IJ

Fig.3: Originalpictureof oil pressure

Fig.4:Oilpressuredisplay Display engineoil pressure, (1-1obar, lLED=1bar) Oilpressure Engineoil pressure warning (dependent on RPMandenginetype)

Liebheii-We* Ehing€nGmbH- Techni€l lraining


-26-

lTIBHINR

Gomponentdescription UW04 - Driveunit / dieselengine E6|d|er|*epid/lE!,e

Function: variesas its shapechanges. Theelectricalresistance of the coatedmembrane Thechangesin shapecausedby increasedsystempressurealterthe electricalresistanceandeffecta changein voltageacrossthe resistorbridge(5Vsupply). (depending on theappliedpressure). Thisis amThisvoltageis in therange0.....70mV plifiedbythemeasurement V circuitto a valuein therange0.5........4.5

Electical connectrons lvleasurement circuit

l\,4embrane with sensotetement Pressure connection Fastening thread

Fig6: Principle sensor design- oil pressure Membrane: '1Piezo-resistive bridge 2 Thicklayermembrane 3 Pressure chamber(,,Bubble") 4 Ceramicsubsfate

Liebher-We* EhingenGmbH-Techni€ training

personnel OnlyforLlEBHERR-Service

-27 -

ITBIIIRR

Gomponentdescription UW04 - Driveunit / dieselengine >5.4 Chargeair pressuresensor Purpose: (LDAfunction) injectionlimitation is usedto Chargeair-dependent in thelowRPMrange(upto approx.1500rpm). limitsmokeemissions At speedsabove1500rpm,thereis no injection (restricted Thishashelpedimprovethe dynamic limitation smokeemissions). regulation systems,one alwaysassume responseof the unit.In contrastwith mechanical quantity the maximuminjection whichis thenlimited. Layout: Thechargeair pressuresensormeasuresabsolutepressure pressure) (Thesensoralsotakesintoaccountthe atmospheric Supply: Pressurerange: Outputvoltage:

lmax= 5 mA 0.5to 4 barabsolute = 0.5V 0.5bar/ 4.5V = 4.5barlinear pressure sensor

Fig.2:Originalpiciureof chargeairpressure sensor0846-45

Chargeair pressure sensor

Function:Seeoil oressuresensor Ll6bh6-WelkEhln96n GmbH-Tsch.icaltraining


-28 -

lIIBHINR

Componentdescription UW 04 - Driveunit / dieselengine >5.4 Chargeair pressuresensor Purpose: (LDAfunction) is usedto Chargeair-dependent injectionlimitation limitsmokeemissions in thelowRPMrange(upto approx.1500rpm). At speedsabove'1500rpm,thereis no injection (restricted Thishashelpedimprovethe dynamic limitation smokeemissions). regulation systems,one alwaysassume responseof the unit.In contrastwith mechanical quantity whichis thenlimited. the maximuminjection Layout: Thechargeair pressuresensormeasuresabsolutepressure pressure) (Thesensoralsotakesintoaccountthe atmospheric Supply: Pressure range: Outputvoltage:

lmax=smA 0.5to 4 barabsolute = 0.5V 0.5bar/ 4.5V = 4.5barlinear pressure sensor

Fig.2: OriginalpictureofchargeairpressuresensorD846-A5

Chargeair pressure sensor

Function:Seeoil oressuresensor Liebher-We*Ehinsen GmbH- Iechni€ltraininq

personnet Onlyfor LIEBHERR-Service

-2a -

lIIBIITRR

Gomponentdescription UW04 - Driveunit / dieselengine >5.5 Coolanttemperaturesensor Purpose: . Warnsuserswhenthe coolanttemperature warningthresholdis reached. . Reducesenginepowerwhenthewamingthresholdis exceeded. (e.g.for safetyreasonsthe regulation systemautomatically reducesenginepowerif the coolanttemperature is too high). . Errormessage. Layout; Fig.2: Overviewofcoolant

Figl: Extractof circuitdiagramfor cooanilemperature sensor

temperalure sensor

Fig.3: O.iginalpictureofcoolantlernperaturesensorD846-A5

Fig-4: Coolanttemperature disptay

Coolanttempeaature (30-120'C,1LED=10')

Coolanttemperatu re sensor

Dieselengineoverheating

(LEDon=T>120'C) Function: js monjtoredby a temperature Thetemperature sensorwithan NTCcharacteristic (semiconductor), i.e.the measuredresistance willdecreaseas the temperature rises. Thecurveis notlinear.

Liebh6(-Werk Ehingen cmbH- Technietrraining

OnlyforLIEBHERR-Service personnel

-29-

UIBTIINR

Gomponent description UW04 - Driveunit / dieselengine 5.6 Chargeair temperaturesensor Purpose: in the chargeair TheChargeair temperature sensormeasuresthe temperature is Forsafetyreasonsthe regulatormustreducethe powerif the chargeair temperature toohigh. Layoul: Fig.2: Overview ofchargeair temperauresensor

Fig.1: Extractof circuitdiagramfor chargeairtemperature sensor

sensorD846-47 Fig.3: Originalpictureof chargoairtemperature

Chargeak temporature sensor

Function: Thetemperature is monitoredby a temperature sensorwithan NTCcharacteristic (semiconductor), willdecreaseas the temperature rises. i.e.the measuredresistance Thecurveis not linear. Example: = 75"C = 0% reduction Tl = 17%reduction T3 = 90"C

Liobheii-W€rkEhingenGmbH- Techni@ltEining


-30-

lTIBIIIRR

Componentdescription UW04 - Driveunit / dieselengrne >5.7Atmosphericpressuresensor Puroose: Lessair is suckedin at altitudedueto the lowerair density. Theinjectedfullloadquantitycannotbe combusted. of smokeand increasedenginetemperatures. Thiswill resultin the development problem whichcouldoverspeed dueto the lower is the exhaustturbocharger Afurther air density/ exhaustcounterpressureat constantinjectionvolume. Thisis preventedby meansof injectionreduction. Layout: pressuresensoris integratedin the regulator FrommodelsAOonwardsthe atmospheric part (Figure1). unit of the engine control andtherefore or is defective; the altimetercannot Thewholeunitmustbe replacedif thismalfunctions be orderedseparately. Fig.2: A5 withallitudepressure sensor

Fig.1: ECU UP-CR/A6 /A7 with Atmosphericpressuresensor

pfes6ure Atmospheric

sensor Function: pressurewillchangedeThealtitudevaluesare onlyrelative,becausethe atmospheric pending on theweather andaltitude. pressure(ambientpressure) fallsbelow840mbar Onlywhenthe atmospheric (approx.1550m abovesea level)willthe regulatorstartto reducethe injectedfull load volumeaccording to the specifiedcharacteristics. Powerreduction example: 1000 130!l

(mbar)

Li€bh€tr-Werk ng Ehingen GfrbH-Tech.ic€ltrain


- 3 1-

550 4850;

23.1

24.1

EZE 3S50.

19.5

19.6

5S0 3100,

'14.2

774 2250i 040 1550'

l EDO '1S00 2104 24.4

?3.3

1S.1

1S.1

18.0

14.8

13.S

13.6

12.6

10.0

10.1

8.9

8.4

72

00

0.0

0.0

0.0

0rl

IIBHIRR

Componentdescription UW04 - Driveunit/ dieselengine >5.8Air filter underpressuresensor"Air filter OK" Purpose: Theairflter underpressure on thedisplayunitin thedriver's sensorseryesto indicate cabif thereare highlevelsof dirtin the air filter Thisindicatesto the driverthatthe air filtermustbe exchanged or cleaned Layout: Theair lllterunderpressure sensor(opener)openswhenan underpressure situationoccurs. Fig.2: Originalpictureot airfilter Underpressure sensorD846-A5

Fig. 1: Exkactofcircuit diagram for air filter underpressufesensor

Displaydirtin airfilter

Function: closed)is in theairsuctionlineof the Theairfilterunderpressure sensor(normally engine.The underpressure sensoris normallyclosed.lf thefllteris clogged,an underpressurewillformafterthe filterandthe switchwill open. A dirtyair filteris indicatedby display"Dirtin air filter"(Fig3).

Liebheir-Wer* Ehingen l6inin9 GmbH- Technical


-32-

lTIBHRR

Gomponentdescription UW04 - Driveunit / dieselengine 6. Enginepreheating >6.1Enginepreheatingvia flamestartingdevice Puroose; Theinjectedfuelignitesin the hot,highlycompressed Dieselengineswithself-ignition. witlbecomeprogressively morediffidropsself-ignition air.lf the suctionair temperature is no longerpossible. cult.At a certainpointknownas the coldstartlimit,self-ignition preheat purpose the sucked in air to ensurethatthe The of theflamestartingdeviceis to dieselenginewillstartevenat lowoutdoortemperatures. suchas whiteand the suckedin air willminimisethe amountof pollutants Preheating whenstartingthe engineat lowtemperatures. coldsmokeemissions

Layout: Fig.1: Extractofcircuitdiagramforflamestartingdevice

ng.

z. vrg

d, P,L'urc

u, ,,.,,,E

Jd,u,iv

vcv,LL

\--

V A

ln Itl I

Flameglowplug

Solenoidvalve,releases fuelto flameglowplug

Flamestartingdevicescompriseone or moreflameglowplugs,a coolanttemperature lampandif sensor,electromagnetic valvefor fuelrelease,an engineECU,an indicator requireda pressurereducerfor thefuelsupply.

Fig.3. Flameglowplug

glowplug Pencil-type withheatingspiral

Fuelfeed

Coatpipe

Liebheir-Werk EhingenGmbH- Techniel training


-33-

UIBIIIRR

Componentdescription UW04 - Driveunit/ dieselengine

Funclion: Theflameglowplugis screwedintothe suctionmanifoldpipe. glowplugwhichis surrounded by a coat Theflameglowplugconsistsof a pencil-type oioe. Thefuelis dosedvia a solenoidvalveand nozzleand sprayedintothe heaterplug.lf fuel glowplug, in the coatpipethencomesintocontactwiththe hot shaftof the pencil-type thiswill be evaporated andflowto the outletopeningon the coatpipedueto a lackof air, Thefuel is mixedwiththe suckedin air and ignitedby the glowingdomeon the flame glowplug.Theheatof theflamejet heatsihe suckedin airtherebypermitting thediesel engineto be startedevenin coldoutdoortemperatures. Nole: is below20'C, flamestartcontrolis switchedon andtheflame lf the coolanttemperature "l") (preheating glowplugmustbe pre-heated time). switch(inposition usingignition time controllamp(Figure4) is lit. Oncethe preheating Thisis indicatedif the preheating preheating to flash until the engine is started. lamp will start expires,the control Fig.4:Preheating controllight

Preheaiing controllight

Fig.5: Schematic of a flamestartsystem 6 5 4

1

Prefilter

3 4 5 6 7 I I 10

Leakoil line pump Supply Overflow valve Solenoid valve- releaseoffuel Flameglowplug pump Injection Suclionline Fueltank

3

Liebher-Wei

-34-

IIIBIIIRR

Componentdescription UW04 - Driveunit/ dieselengine via heatingflange )6.2 Enginepreheating PurDose: The purposeof the heatingflangeis to preheatthe suckedin air to ensurethatthe diesel enginewillstartevenat lowoutdoortemperatures. suchaswhiteand theamountof pollutants Preheating thesuckedin airwillminimise In contrastto the coldsmokeemissions whenstartingthe engineat lowtemperatures. flamesta.tingdevice,the heatingflangedoesnotcombustanyoxygen.Thisleavesmore oxygenfor ignitingthe fuel. Layout: Fig.2: Originalpictureof heatingflange:

Fig. 1: Exlractof circuitdiagramfor LTM1070-4.1:

I R9

NEIZFLANSCH I ,9kt4

-M5P1

Heatingspiral

/1ll,l

Flange housrng

R I . l A S S EM O T O

Function: Theheatingflangeis builtintothe suctionpipeandconsistsof a flangehousingwith integratedheating ofapprox.1000'Cand spiral.Theheating spiralcanreachtemperatures servesto oreheatthe suctionair. Note: is below10'C,the heatingflangecontrolis switchedon and lf the coolanttemperature usingignitionswitch(in position"l") (preheating the heatingflangemustbe pre-heated time).Heatingflangecontrolis alsoactivatedif the coolant is below-10 "C is below25 "C andthe chargeair temperature temperature whenthe preheating conirollamp(Figure3) is lit.Once Thepreheating timeis indicated timeexpires,the preheating controllampwillstartto flashuntilthe engithe preheating ne is started.Whenthe engineis startedwithheatingflangecontrol,the idlingspeedof increased to supportthe battery. somedeviceswill be automatically Fig.3: Prehealingconirollight UW engine

Fig.4: PrehealingconlrollightOW engine

Preheating conlrollight Liebher-WerkEhingenGnbH - Techni@llralning


-35-

lIIBTIRR

Gomponentdescription UW04 - Driveunit / dieselengine >7.Chargeair coolingwith turbocharger(exhaustturbocharger) 7.1Task Thechargeair coolingwithturbochargeis usedto increaseperformance.

Oil pressureline for lubrication

7.2Design

Chargeair (compressedair flow) to chargeair cooler

Fig.1: Exhaust turbocharger D 846TlAT wiihWastegate

lntakeair fromairfiller (freshajr)

Exhaustoutlet (to exhaustpipe)

Turbinehousing (drive)with bypassflap

Chargepressure conlrol valve(prcssure dispense0 to controllhe bypassflap

Compressor housrng

lineto Bypass pressure charge regulalion

Li€bhen-Werk training Ehing€n GmbH- Technlcai


-JO-

lTIBITIRR

Componentdescription UW04 - Driveunit / dieselengine 7.3Function Fig.1: Functional schematic of chargoak coolingwithturbochargeon inlineenginoD846 J

1 2 3 4

4

lntakeairfromairfilter (freshair) Exhausttubocharger lntakemanifold Chargeairapprox. '120'Ccompressed airflow) Chargeaircooler

5 6 7 Coolair Chargeak approx.50 C' I I 1 0 Coolantcircuit 1 1 Exhalstmanifold / exhaustflow 1 2 Exhaustemission, approx.600'

enginedependson the amountof air andfuel,which Theperformance ofthe combustion is availablefor combustion. Toincreasethe performance of the engine,moreair andmorefuelmustbe therefore suoDlied. However, to supplymorefuelis onlyeffectiveif alsosufficientoxygenis availablefor its combustion. of the necessaryoxygen,it willcause lf additional fuelis supplied,withoutthe availability the engineto smokesignifcantly. (charged)in an exhaustturbocharger and Forthisreason,thefreshair is precompressed is obtainedat the Thisway,a higherspecificperformance thendirectedto the cylinders. RPM. and at the same engine samedisplacement

Liebh€n-WerkEhingenGmbH-Technielt alning


-37-

lIIBHINR


Fig.3: Functionalschematic oi an exhaustlurbocharger 1 2 3 4 5 6 7 8 9 '10 '11 12 13 '14

Oildischarge Shaft Radialbeadng Axialbearing airflow) Chargeair (compressed to chaeeaircoolef lntakeak fromairfilter (freshair) Compressorgear Comprcssor housing Oilsupply Bea ng housing Turbinegear Exhaustoutlet Turbinehousing Exhaustmanifold / exhaustflow

5

(aircompressor). lt consistsmainlyof a comA turbocharger is in principlea compressor pressorgear(5) anda one-stageturbinegear(9),whichare connected witha common (2) rotate the same rotational speed. shaft andtherefore at exThe turbinegear(9) transfersa largepartof the normallyuselesslydeflagrating haustenergyinlo rotationalenergyand drivesthe compressorgear (5).The compresair to the individualengine sor geardrawsin freshair and suppliesthe precompressed cylinders. On Dieselengineswithturbochargeand chargeair cooling,to furtherincreasethe cylinder chargingandfor thermalrelieve,a chargeair cooleris set in frontof the watercooler To intakeair requiredfor combustion is thereforedirectedto the cylindersafterprecompressionin the chargeair cooler,cooledto approx.50" C. Fig.4: FLncliona' withWaslegate schematc of anerhaustturbocharger

1 2 3

Chargepressure controlvalve (pressure dispenser) Bypassline/ chargepressure Bypassflap

To limitthe chargepressure(peakpressure), on someexhaustturbochargers, a bypass pfessure (Wastegate) (pressure is installed. A charge controlvalve dispenser)is actuated withchargeair and controlsthe bypassflap.The chargepressureis limitedby the openingbypassflap,by directingpartof the exhaustflowpastthe turbinegearanddirectly intothe exhaustsystem. Llebhsr-Werk lraining Ehingen GmbH- T€chnical


-38-

I.TIBilINR

Componentdescription UW04 - Driveunit / dieselengine -

>8.AGRlexhaustreturn) 8.1Task Theexhaustreturn(AGR)is usedto limitthe nitrogenoxydes(NOX)in the exhaust, of fuel. whichare createdduringthe combustion to obtainthe specifiedemissionlimitvaluesfor combustion Thisreductionis necessary enginesin vehicles.

8.2 Design Fig1: Exhauslreturnon D 846TlAT .,fl02 AGR-Modulo: AGR-Valvewith electro-pneumatic shutofi flap(pn cylindernot energized = clos€dd€mper)

lntakemanifold

Exhaustmanifold AGRheal€xchang€r Liebhen-werkEhinggnGmbH- Technicallraining


-39-

ITIBIIRR

Componentdescription UW04 - Driveunit / dieselengine 8.3Function

Fig.1: Functional schematic ofan exhaustret!m

1 2 3 5 6 7 I 10 11 12

Exhaust turbocharger Exhaustmanifold Intakeair(freshair) Air filter Intakemanifold with incoming chargeair Dieselengine Chafgeaircooler AGRvalve Electro-pneumatic shulofi flap peakvalves Pressure AGRheatexchanger Exhaustoutlei

Partof the exhaustis directedagainthrougha pipeto the freshair for combustion. Dueto thig.ririxture of cooledexhaustand the resultinglackof oxygen,the combustion tempera.tuie is lowered. Basedon this measure,the portionof carbonmonoxideand unburnthydrocarbons increases.Thiscanbe reducedagainby an exhaust-gas catalyticconverter. An evenbetterreductionof nitrogenoxidesis obtainedby coolingthe exhaustgasesoff. ln thatcase,the heatis discharged to the ambientair via anAGRheatexchangerbefore mrxng. Fromtwo dischargepointsin frontof theturbocharger, the exhaustis directedin s;parate pipesthroughthe heatexchanger, whichis connected to the coolantcircuit. Thecooledoff exhaustis mixedto the addedair in the intakemanifoldvia oressureoeak valves,whichutilizethe pulsatingpressureofthe exhaustflow Theexcessoxygenof the chargeair is therebyreducedand its specificheatcapacityis increased. Bothinfluences lowerthe combustion temperature andtherebythe nitrogenoxydeformationin the exhaust.

Liebheii-Werk Ehing€n GmbH- Technical l€ining


-40-

lTIBHRR

Componentdescription UW04 - Driveunit / dieselengine >9. Exhaustflap (enginebrake) 9.1Task fuelsupply,thenthe bralf the machineis drivendowna downhillslopewithinterrupted kingactionof the engineis greater,the smallerlhe placedgearis. flap is utilized. ofthe engine,the restrictor To increasethe brakeperformance Thisrelievesthe standardbrakesand reducestheirwear. 9.2Design Fig.1: Restrictorflap D 846TlAT

to exhaust

Workingcylindef Restdctorflap Restrictor flap

Pae6sudzed a;rconnection

Fig.2:ExhauslflapD 9508A7

Reslrictorflap

Workingcylinder Exhaustflap

Ll€bh€n-Wsi( Ehlng€n GmbH' Techni€ltraining


- 4 1-

ITETIBR

Component description UW04 - Driveunit / dieselengine 9.3 Function Fig.1: Functional .estrictor flap schematic Back€dup

gases combustion

connection Air pressure Workingcylinder Exhaustflaprestrictor flap

Restrictorflap

to the Therestrictorflapis installedin the exhaustline,whichleadsfromthe turbocharger mufflerToincreasethe brakingactionof the engine,the4th cylinder(exhaustcycle)is alsoused for comDression. Whenmovingthe steeringcolumnleverall theway back,the restrictorflap is almost closedvia the pneumatically actuatedworkingcylinder. completely gasesaretherebybackedup in frontof the restrictorflap. Thecombustion the engineis sloweddown resistance on the pistons!n the cylinder, Dueto the increasing more. Simultaneous withthe closingof the restrictorflap,the fuelsupplyis shutoff or reduced.

- = upllon Liebher-Weft EhingenGmbH- Techni@llEining


-42-

lIBlmn

Componentdescription UW04 - Driveunit / dieselengine >10Auxiliarybrakesystem(ZBS) 10.1Task in additionto the exhaustflap,an Toincreasethe Dieselenginebrakingperformance, brakesystem(ZBS)is installed.

10.2Function is createdin the exhaustmalf the exhaustflapis closed,an exhaustcounterpressure nifolddueto the backup of exhaustgases.Duringthe exhaustcycleof the neighboring cylinder, shortlyafterthe intakecycle,an exhaustpressurewaveis createdin the area Thisexhaustpressurewave,with of the bottomdeadcenterin the exhaustmanifold. pushes piston, The the exhaust valvesopenmomentarily. thesupportof the hydraulic by the hydraulicpistonfromclosingagain.Theexhaust exhaustvalvesare prevented cycleandthe working held open a gapwideduringthe compression valvesare therefore cycle. Note: occursdueto the Eventhoughthe exhaustvalvesareopena smallgap, a compression actionon theengine. of thepistonin cycle2. lt hasa braking dynamic upwardmovement gets it reducesits upward piston center area, the more into the top death Thefurtherthe Thistimespanin the speedandat the top deadcenter,it initiatesits reversemovement. pressure its throughthe slightly is to reduce compression top deadcenterarea enough openedexhaustvalveto a largeextent. pressure(cycle3) is thereof the pistondueto the compression Thedrive(acceleration) (increased brakingaction). fore eliminated

Liebheii-WerkEhingenGmbH- Techni@llralning


-43-

UIBHINR


Fig.1: Functional schematic cylinderheadin brakeoperation

1

4

lllt leverpiston(4)lies againsttheoutletvalve, dle to lubeoil prcssure (3)Sealedthrough (2) counterholder

Dueto the cam (9),the tilt lever(10) swingsawayfromthe (2). counterholder Therelievebore(8) is clearedand prevents theclosingof the piston(4) abutsinsideon the tilt the oulletvalve(3) lever('10). Afier openingof the outletvalve (3) in enginebrakeo the extendedpiston(4

E

lntakecycle

Compression cycle

Liebher-Wsrk Ehing€n GmbH- Technlcal lrainlng


-44-

Workingcycle

Exhaustcycle

1IIBHRN

descriPtion Gomponent

UW05- Goolingsystem/ Fandrive

)

servicepersonne Onlyfor LIEBHERR

Gomponent description UW05 - Coolingsystem/ Fandrive

Liebhetr-weft Ehingen GmbH- Technical lralning


ITBHIRR

Gomponentdescription UW05 - Coolingsystem/ Fandrive 1. Cooling system, general >1.1Purpose fan drivefulfilsthefollowingfunctions: Thecoolingsystemwithintegrated . Hydraulic oil cooling . Cooling theenginecoolantandgearoilheatexchanger . Chargeair coolingfor the turbocharger . Coolingthe coolantin the air conditioning system* >1.2Layout fan driveessentially comprises the followingcompoThecoolingsystemwithintegrated nents: . Fanpump . 2 fan motorswithfan impellers . Chargeair cooler . Watercooler . l\ilultiple oil coolers/ heatexchangers . Liquefierair cond.system* Liquefier Aif conditioningsystem

(condenser) Oilcooler Hydraulics (airloilcooler)

Oilcooler

gearbox(airl Transfer oil cooler)

Heatexchanger gearorl (airloilcooler)

Watercooler(airl coolantcoole4

Coolanttank

Chargeair cooler (air/aircooler)

Fanmotor

Fanmotor

Fig.'1:LT[,,] 1100-4.1 Fandrivelayout

* = option aainrg Liebher-werk Ehingen GmbH- Technical


-4-

UEBIIIRR

Gomponentdescription UW05 - Goolingsystem/ Fandrive

Pumpoil press!re Replenishing

Fanmotor Tankreturn

Hydra!licoiltank Fig. 3: Overview- fan motor

Fig.2: Fan motor

>1.3Function Thisforcesair to flowpastand Thefan pumpdrivesthefan motorsandiheirimpellers. air cooler, water coolerand liquefier*. coolthe heatexchangers, oil coolers,charge oil cooler. Thehydraulicoil or lubrication oil is cooledwhenit flowsthroughits respective Thewatercoolerservesto coolthe engineandgearoil heatexchangerusinga coolantis cooledby air flowingthroughthe chargeair cooler watermixture.The turbocharger gaseous in cooling system*flowsthrougha liquefer(condenser) where The coolant the preventsanyof the systemsfromoverheating whilstalsoimproving it condenses.This performance. A replenishing valveis fittedto protectthe fan motor.lf thedieselengineis switched off,the fan motoris no longerdrivenby thefan pump.The inertiaof thefan willcauseit to runon untilit comesto a siandstillby itself.Thefan motornowactsas a pump.The pumpedoil for thefan motor(pump)candirectlyreturnfromthe pumpingsidevia the replenishing valve(non-return valve)to the suctionside.Thispreventsthe collapseof the oil columnwhichwouldotherwiseseverelydamagethe fan drive.

* = option Ehing€n Liebhen-Wsrk GmbH- Techni€ltrainlng


- 5 -

ITBHIR

Componentdescription UW 05 - Coolingsystem/ Fandrive 2. Coolingsystems 2.1Coolingsystemwiththermalpressurevalves >2.1.1Purpose: Cooling systems withthermalpressure valvesregulate thespeedof thefanmotorand impelleraccordingto the temperature of the hydlaulicoil,chargeair and enginecoolant.

>2.1.2Design

Fig.4: Overuiew of coolingsystemswiththermalpressure valves

Pressure spdng

Valveblock Pressure spring

Thermoelement

Fig.5: Culawayviewotthermalprcssurcvalve

Liebher-Werk Ehing€n GmbH- Technical llaining


-6-

lTIBHIRR

Componentdescription UW05 - Coolingsystem/ Fandrive

Chargeair pipe

Thermalpressure valvechargeair pipe Controlpressure valve forthemal pressure Retumfromthermal pressure valve valve Fig.6: Thermalpressure

lraining Liebher-werk Ehing€n GmbH- Techni@l

personnel service OnlyforLIEBHERR

UBTIIRR

Componentdescription UW 05 - Goolingsystem/ Fandrive

chaqe ajrcooler

Thermalprd&lThemalp surevalve Tl surevalve

Replenishingvalve

- coolingsys{emwithlhermalpressure valves Fig.8: Overview

)2.1.3Function Thermalpressurevalvesare on thewatercooler,oil heatexchangerandchargeair pipe togetherby a controlpressurepipe. andconnected pressure measureeachof thetemperatures andset the Thethermal valvespropofiionally controlpressurefor regulating the pump. pump to drivethe fan motoris dependenton the control Theflowratedeliveredby the pressure. Thethermalpressurevalvesare openat lowcoolant,chargeair and clutchconverteroil Thepumpproduces minimalflow. temperatures. Thefan doesnot run or onlyrunsslowly. lf the temperature of the coolant,chargeair or clutchconverteroil risesintothe regulation zonefor the respective thermalpressurevalve,the valveclosesdueto the increasthermoelementexpanding whichincreases the pumpflowrateand continuously es the fan sDeed. The pumpregulatorservesto regulatetheworkingpressurein the hydraulicsystem withinthe adjustablerangeof the pump.The pressurecanbe fullyadjustedat the control vatve. Thepressurelimitingvalvelimitstheworkingpressureto its maximumpermittedvalue whilstalsoreducingthe flowrate.

Liebher-Wek EhingenGmbH- Technicall€ining


-8-

ITBHIRR

Componentdescription UW05 - Coolingsystem/ Fandrive 2.2 Coolingsystemwith bypasscontrol >2.2.1Purpose: Coolingsystemswithbypasscontrolregulatethe speedof thefan motorand of the hydraulicoil, chargeair andenginecoolant. impelleraccordingto thetemperature )2-2-2 Design

Proportional solenoidvalve(bypass Pressure limitingvalve (DBV)

Fig.9: Bypass

5 C| l i L T BE D ] N G U N G EII

Fig.'10jExcerptfromeleclrical circuitdiagramL,WLTM1045-3.1

LTM1045-3.1 Fig.11:Excerptfromhydraulic schematic Liebher-Werk Ehinsen GmbH- Technic€l traininq


- g -

1IIBHINR

Componentdescription UW05 - Coolingsystem/ Fandrive

I_l I.:,.:;.]ll''-r',

,.rl

Fig.12:Coolerschematic LTM1045-3.1

Proportional solenoidvalve (bypassvalve) Pump

- Coolingsystemwiihbypasscontrol Fig.13:Overview

Liebher-Werk training Ehing€n GmbH-Tschnical


- 10 -

lIIBHIRR

Component description UW05 - Coolingsystem/ Fandrive

>2.2.3Function sensorsto monitorthe engineoil temThe ECU(enginecontrolunit)usestemperature perature,coolanttemperature andchargeair temperature. requirements, the ECUcontrolsthefan coolingsystemand Depending on the cooling (bypassvalve). solenoidvalveaccordingly actuatesthe proportional solenoidvalveis actuated(bypassvalve),someof the lf the proportional oilflowsthroughthe bypassanddirectlyintothetankwithoutflowingthroughthefan motot Thisreducesthefan sDeed. The pressurelimitingvalvelimitsthe operatingpressureof thefan motorto a pre-defined maximum valueof e.g.210bar. Nole: solenoidvalve(bypass set if the proportional Themaximumfan speedis automatically valve)(-Y8)fails.

Liebhen-wekEhingen GmbH- Technlcal lraining


- 1 1-

UETITRR

Componentdescription UW05 - Coolingsystem/ Fandrive fanpump 2.3Coolingsystemwithvariable >2.3.1Purpose: ihespeedof thefanmotorand witha variable fanpumpregulate Cooling systems of the hydraulicoil, chargeair and enginecoolant. impelleraccordingto the temperature

>2.3.2Design

-Y50CYBold)

Proportionalvalve,fan dnve Fig.14:FanpumpLT|V1100-4.1

Fig.15:Excerpifromelectrical circuitdiagramUW LTM1100-4.1 Liebher-WerkEhingenGmbH- Techni€l lralning


ITIBIITRR

Gomponentdescription UW05 - Coolingsystem/ Fandrive Prcducdbyj$pid/Edi'oni3M07/veBon:1

-::.l f. .-

E T

r I 1 . ,

:*,jix;'*'**, I

l}"''+;----l

I t

r--;;;----

I

Fig.16:Cooler LTN,4 1100{.1 schematic

l-E ::l^",:/

Pump

1...x..s;.i::....ifi i...'..: 'lrl-'Hi /:\

:

t

t I-liF..l

-

-

Fanmotor

- Coolingsystemwilhvadablefan pump Fig.17:Overview

Li6bh6n-Werk Ehing€n GmbH- T€chni€lvainins

personn€ OnlyforLIEBHERR service

- ' t 3-

UEHINR

Gomponent description UW05 - Goolingsystem/ Fandrive

>2.3.3Function sensorsto monitorthe engineoil temThe ECU(enginecontrolunit)usestemperature perature,coolanttemperature andchargeair temperature. Depending on the coolingrequirements, the FCUcontrolsthe fan coolingsystemby applyinga PWI\4outputsignalto the fan pump. Applyingcurrentto the proportional valve"fandrive"-Y50will reducethe fan speed. Note: set if the proportional solenoidvalvefor thefan The maximumfan speedis automatically driveCY50)fails.

Liebh6ir-W€* Ehingen GmbH-Technical training

personnel OnlylorLIEBHERR service

-14-

UTBlIINR

Component description

UW06- Transmission

Onlyfor LIEBHERR servicepersonne

Glossary: CAN

Controller areanetwork

ECU:

Electronic controlunit(enginecontrolunit)

EDC;

Electronic dieselcontrol(injectionsystemfor dieselengines)

TCU

controlunitfor controlunit= Electronic Transmission gearchangeson actuatingthe electro-hydraulic systems. 6WGtransmission

EST

Electronic controlunit

TC

Torqueconverter

lT

Intarder

cV

Splittergroupor splitterdrive

GP

sectiongroup Downstream

WSK(WK)

bypassclutch) Converter clutchunit(converter

WSV

Clutchsafetyvalve

WGV

Clutchbackpressurevalve

WT

Heatexchanger

NFS

stopvalve Downstream

Slip

in rotationalspeedbetween Slipis usedto describethe difference two elements.

Kick-down

the accelerator describesthe actionoffullydepressing "Kick-down" and overriding anyspeedsettings (onlyavailableon 6WG-transmission systems).

Dropbox

ofthe transmission. Thedropboxis situateddownstream

Countershafts

fromonedriveshaftto an intermediate shaft lf thepoweris transferred shaftis referred to as a andthenbackto a driveshaft,thisintermediate countershaft.

Component description UW06 - Transmission lndex Contentspage1

Li€bhetr-werkEhing€nGmbH- Techni€l trainrg


-3-

ITTBHIRR


UW06 - Transmission

Liebher-WerkEhingenGmbH- Technl@llraining


-4-

ITBITIRR

Componentdescription Transmission Prcdudby:|waFlo/Edito:20M07/Ve6on]2

general 1.Transmission, Purpose: . . . . .

of the engine Thetransmission formspartof the powertrainand is downstream to the tractiveeffortdelts taskis to convertthe enginespeedandtorqueaccording vehicle mandedby the ratio Startingandselectingthe geartransmission opeEtion* Gearchangesandclutch Neutralandreversingthe rotationwhendrivingin reverse

Design:

Fig.4:Overview of powertrain

Function: on the Thetransmission systemmayhaveseveralforwardand reversegearsdepending mooet. Thetransmission ratioi is givenby the ratioofthe numberof teethon the drivengear the speedandtorque.Variousgearwheel wheelanddrivinggearwheel;thisdetermines sets(As-Tronic) or planetwheelsets(6WG)are usedto providedifferenttransmission ratiosi.

* = option uebhefi-we EhlngonGmbH- Technic€lttaining


-3-

IIIBHIRR

Gomponent description UW06 - Transmission 2. Transmission overview >2.1Automatic : transmission Automatictransmission systemsconsistof a hydro-dynamic torqueconverteranda powershifttransmission downstream withmultiplegearsandan integrated or flangedon transfergearbox. A clutchis not requiredto changethe transmission ratio. Thegearchangeis performed withoutthe interruption of powertransfer. .

ERGOPOWER ZF 6WG310. without retarder

___rT Fio.5: Overview ERGOPOWER ZF 6WG310

.

Allison CLBT755- with retarder CLBT755DB

rI Fig.6: Overview AilisonCLBT755 wilhretarder

Ll€bhen-We* Ehingen GmbH - Techniel tEining


-6-

lTIBTIIRR

Gomponent deseription UW06 - Transmission P'lnuedby:repi/Ediddn:200107/Vedon:2

>2.2Gearbox: ratios. Gearboxes consistof severalgearwheelsetsto allowdifferenttransmission ratio.Thisinterrupts the powertransfer A clutchis requiredto changethe transmission duringgearchanges. 2.2.1Automaticgearbox; .

- with clutch ZF '12A'52302

nax inNt ba!6 n NMGe bnadz = NW (ryrbk*fi

r 100) pd*ide)

Fig.7: Ove.view ZF 12452302- withclutch

2.2.2Automaticgearboxwith upstreamconverter: .

- with upstreamconverterand reiarder ZF 12AS3002-TC 12AS3002-TC n*

hpd brque in NM(btu x 100)

vaianr2= Nw (pd€rbk{tPosdb.l

rc2

12AS3002

- wilhlpstreamconverter andretarder Fig.8: Overview 2F 12AS3002-TC

' = option Liebher-WerkEhingenGmbH- Techni€l taining


UIBlIINR


UW06 - Transmission

.

ZF 12TC3040SO- with upstreamconverlerand intarder 12TC30405

__TTT

TC HD

12AS3040TC/IT

12TC3040SO converter andintarder Fig.9: Overview ZF 12TC3040SO- withupstream

)2.3 Semi-automatic transmission: systemsare a specialtype of gearbox. Semi-automatic transmissions Operating the clutchwill engagethe gearwhichwas previouslymanuallyselected. .

ZF ECOSPLIT165/15'l- with clutch 16S/151 Engine

Numbdge,G+

Cad6n

Ca.ddn

shaft

shan

TTT |

Fig.10:Ovorview ZF ECOSPLIT 163/151-with clutch

Liebher-Wek Ehing€. GmbH- Techni€l tbining


-8-

ITBIIIRR

Componentdescription Transmission 3. Automatictransmission 3.1General do nothavea gearstickor clutchpedal. Automatictransmissions Theclutchis replacedby a torqueconverterwithconverterbypassclutch(Fig11).This providesa positivemechanical to allowsmoothgearchanges. connection are planetarygears.Theyconsistof severaldrivingstagesand Automatictransmissions of planetarygears. differentnumbers/combinations The by the manufacturer. and basedon a logicdetermined Gearselectionis automatic performed gear disc clutch. The by activating the corresponding transmission changeis the converterclutchunitis closed, controlled.Unless transmission is electro-hydraulically as frictionheatin the oil. someof the poweroutputby the engineis dissipated converterbypassin firstgearto alreadyincludea mechanical Automatictransmissions power provideuninterrupted transfer. to the transferspowerfromthe transmission transmission Thismeansthatthe automatic provide gear fast change. Automatic transmissions outputdrivesystemevenduringthe gearchangetimesandoptimisedgearchangepoints.

>3.1.1Converterwith converterclutch unit Purpose: . . .

theenginetorque converts andtransfers the clutch allowssoftstartingwithoutoperating vibrationin the engine dampensany rotational

Design:

Bypassclutchwithdiscset

Piston Converter clutchunit bypassclutch) {converter

Drive T.ansmission inputshaft

Turbinewheel (seconoary wheel)

Guidewheel (deflectionwheel)

C!p springs

Pumpwheel iprimarywheel)

discbypassclutch Fig.11:Converierwith Liebhed-We* EhingenGmbH - Technl€l kaining


-9-

ITBHIRR

Componentdescription UW06 - Transmission

Torsiondamper (primary wheel) Converter clutchunit (converter bypassclutch)

Guidewheel idefleclion

Turbinewheel (secondary wheel)

viewofthe converter Fig-12:Cut-away

Turbinewheel (secondary wheel) Torsiondamper (primary wheel) Guidewheel (deflectionwheel)

Converter cluichunil (converler bypass clulch)withtrictionpad

of converter withfrictionpadbypassclutch Fig. 13:Overview

Function: Pump,turbineandguidewheelarelocated insidea sealedhousing whichis completely filledwithoressurised oil. The movementandforceis transferred by the meltpressureof the flowingoil.Thedriving gearwheel(pumpwheel)and drivenwheel(turbinewheel)are thereforenot in directmechanical contact.Thisexplainsthewear-freecharacteristic of the torqueconverter Liebh6r-Werk Ehing€n GnbH- T6chni€ltraining


-10-

lIIBHIRR

Gomponentdescription - Transmission

Fig.14:Starl-up

- thepumpis drivenby engine (fi914) Whenstarting - theturbineinitiallydoesnot move.Theoil flow is forcedto adjustto the bladeand is divertedaccordingly.Maximumtorquetransferis achievedin thisflow Theeffectof the oil pressurecausesthe condition. the vehicle.Diverting turbineto turnand accelerate optimum flow theoilwithintheguidewheelprovides guide pump. the lf thereis no diversionby intothe wheel,theoilfeedsintothepumpto opposethedirectionof rotationwhichcausesan unwantedbraking effectedby the guidewheel effect.Theswirl-change the turbine torque to exceedthe pumptorque. causes

theflowcharAs the speedof theturbineincreases, acteristic stretchesdueto the flowof fluidpushingthe turbinebladesbackwards andforwards(fig15).The Thetorquetransflowdirectiontendsto straighten. missionratioreduces.Howeverit is notyet necessaryto diverithe oil withinthe guidewheelin orderto pumpflowangle. obtaintheoptimum

Fig. '15:Intermedialeposition

Oncethespeedsof thepumpandturbineareviTtuthrough allyidentical, theoilwillflowalmoststraight the blades(fig16). Duringthisphase,theflowis guide the wheel bladesfromthe rear/suction against side.Theguidewheelnowturnsin thesamedirecthe blocking tionas thepumpandturbinebecause effectof the one-wayfree-wheelhas beenlifted.The Thetorqueis conversion rangehasnowfinished. not boosted,insteadit is onlytransferredat a ratioof 1:1. pointof the Oncethispointis reached(coupling converter),the converteracts as a fluidcoupling with a higherefficiencythan duringnormalconverter oDeration. Whenreachingthe couplingpoint,the converter clutchunit- WSK(alsoknownas converterbypass beclutch)is closed.Thiscreatesa tixedconnection pump wheels. This disables the tweenthe andturbine to rise. converterandthe efficiency continues

point) Fig.16:Aligned(coupling Liebher-WeftEhingenGmbH- Technic€ltrainin9

personn€ service OnlyforLIEBHERR

- 1 1-

ITIBHTRR

Gomponent description UW 06 - Transmission

Turbinewheel Tp=

Pumpwheel Oilflow

=.-l-

torque of pumpwheel torque ofiurbinewheel T R = torque ofguidewheel

frornengine t TP

Casea: Tractiveload ounng skrt-up

I

Ti Guide wheel

Nr=0 Vehicleis stationary

Case b: Tractive load ' n ) intermediatestate

Casec: Tractiveloadat . couplingpoint t Fig-17:Conve.ter torque

TheWsK-solenoid valvewillswitchat a specificspeedandcreatea fixedconnection betweenthe oumoandturbinewheelvia the converterclutchunit. Thiseliminates lossin thetransducer. anyslipandhydraulic

Hydro-dynamic WSKopen operation

Glutchoperation WSKclosed

Fig.18: Cut-away drawingconverter clutchunit in openandclosedstale

Liebher:We*Ehing€n GmbH- T€cnni6ll€ining


lTIBITIRR

Componentdescription Transmission

pointWSK Measuring

WSK-solenoid valve

WSK Connection

frofr controlunit Systempressure

Venlinghole

clutchunii Fio. 19:Solenoid valvewSK - converter

The pressurised oil for closingthe converterclutchunitis fed throughtheWSK-solenoid valveto the pistonwhichcompresses the discset.

Convertersafetyvalve 8.5bar

WSK-solenoid valve

Converter

Converter clutch unit- WSK

Convertersafety valve8.5bar

clutchunii Fig.20: ExcerptlromcircuitdiagramWSK- converter

Liebher-WerkEhingenGrbH - Technic€ltralning

servicepersonne OnlyforLIEBHERR

- 13 -

ITBHIRR


>3.1.2Planetarygear(planetaryset) Purpose: ratiounderload,i.e.withoutinterThe planetarygearis usedto changethe transmission gear power allowsa verycompactartransfer.The innerteethon the ring ruptingthe rangement of thegearwheels. Design:

gear Fig.21:llluslration showingprinciple of planetary

Function: Thesimplestformof planeiarygears(fig21) consistsof a sungearwheel,planetcarrier withplanetwheels, anda ringgearwheel. connected In this basicplanetarygearset,the sungearwheelin the m'ddleis positively gear planet wheel with inner teeth. throughseveral wheelsto a ring Thesungearwheel,planetwheelcarrieror ringgearwheelcaneitherbe driving,driven or permanently braked. By permanently brakingthe planetwheelcarrier,it is possibleto select gear gearwheel.In this casethe enginemust a reverse withoutthe needfor an additional be connected to the sungearwheelandthe axledriveto the ringgearwheel.

L!6bher-WerkEhingenGmbH Techni€l tfainng

personnei OnlyforLIEBHERR service

- ' 1 4-

UIBIIIRR


Function: gearsare advantageous systemsfor whencomparedto othertransmission Planetary ratiounderload,i,e. as theyallowa changeof transmission speedandtorqueconversion transmiswithoutinterrupting the powertransfer,andare morecompactfor comparable planets. Changesin direcoverseveral sionratios.Thisis dueto loadbeingdistributed tionare alsopossible. Largetransmission ratioto slowersp€ad

Fig.22i locked,outputvia planetcarrier Notransmission ratio(= directiransmission)

Fig.23:(3.gear)sungearwheelandring geararedriven,directconn€ction uebher-werk EhingenGmbH- T€chnlcallraining


ratioto slowerspeed Smallhansmission

Fig.24:(2.gear)dnggeardriven, sungearwheel locked,outputvia planetcanier ratioto slow€rspeed Largelransmission

Fig.25:(R€ear)sungearwheeldriven,planetset locked,ouiputvia dngg€ar

-15-

UIBHRN

Component description Transmission

>3.1.3Discclutches Purpose: Discclutchesare usedto selectpre-setgears. gearwheelsandthe is established betweenthe individual A friction-locked connection planetset on the intermediate (ZF-Ergopower differential transmissions) or betweenindiplanet (Allison vidual sets transmission). Thisestablishes a connection betweenthe inputand outputshafts. Design: of several Theirdistinctive featurewhencomparedto otherclutches,is the arrangement frictionpadsin a row Thediscclutchesare cooledwithoil to providea higherpowerand energyraung,

Discclutches

Fig.26: Disc clutchesbasedon the exampleofthe 6WG310

Function: Depending on the selectedgear,discclutchesactivatethe relevantgearwheelsetsor planetsets. controlThisresultsin differentspeedsandtorque.Discclutchesareelectro-hydraulically ledandmaybe switched underload.

Liebher-W6k EhingenGmbH- TechnicaltEining


- 16 -

lIIBHTRN

description Gomponent Transmission 3.2ZF Ergopower6WGtransmission 3.2.1General >Electro-hydrauliccontrol unit Purpose: Thepurposeof the hydrauliccontrolunit(fig27) is to switchthe discclutchesin the autocontrolunit. matictransmission basedon the signalsfromthe electronic Design: thefollowingmaincomponents: Theelectro-hydraulic controlunitcomprises . 6 proportional (Y1-Y6) valveswithpressureregulators . l\4ainpressureregulation valve . Convertersafetyvalve .

Tamâr.t"ra

ean<^r

Fig.27i Electro-hydraulic conirolunitHSG94- 6wc-transmission

Temperature sensor ovedemperatureoil sump/ coldstart Fig.28:Temperature sensor

Function: valves(Y1-Y6),the corresponding Depending on the actuationof the proportional switchedandthe pre-setgearis discclutches(K1-K4,KV and KR)are hydraulically engaged.Themainpressurevalvelimitsthe maximumswitchingpressureandreleases the mainflowto the converterand greasingcircuit.Thefeedto the converterincludesa convertersafetyvalvewhichprotectsthe converteragainstexcessiveinternalpressures. aaining Uebher-Werk Ehingen GmbH- Tschnical

OnlyforLIEBHERR servicepersonn€

UIBHTNR

Component description Transmission

>Electronicconlrol unit Puroose: Themainfunctionsof the electronic controlunit(Ug29) are: . Controlling controlunitto automatically the pressureregulatorfor the electro-hydraulic gears change . Modification of the optimumgearchangepoints . Controlling the kick-down function . Storageofall operatingerrorsand overloadconditions . Converter control* . Gearrestriction

Design:

controlunitTCUEST-37- 6wctransmissions Fig.29i Eleclronic

Function; Thefollowingcriteriaaretakenintoconsideration whenchanginggear: . Speedof engine, turbine, centrewheelchainandoutput . Transmissiontemperature . Gearchangetype(up,down,reverseandselectinga gearfromneutral) . Loadcondition(fulland partialload,traction,thrustwhilstalsotakingintoaccount) . Loadchanges duringthegearchange

Liebhetr-Werk EhingenGmbH- Techni€l lra ning


-18-

lIIBIIIRR


>Function,general: fortheERGOPOWER series210,251,260,310conThezF-WGtransmission systems powershifttransmulti-gear torqueconverteranda downstream sistof a hydro-dynamic gearbox. transfer missionwith integrated Thetorqueconverteris a wear-freestart-updevicewhichfullyadaptsto the conditions (requiredtorque). on rollerelementbearings. meshedand supported All gearwheelsare permanently gear are oil-cooled and greased. wheels, bearings and disc clutches The modeusingthe EST-37elecThetransmission is switchedmanuallyor in fully-automatic discclutches tronicunit(seepage18 fig 29) and hydrautically-operated valvesare controlledby a pre-setlogiccontrol. Whenchanginggear,the proportional Thiscausesa pistonto applypressureoil to the relevantdiscsetsandcompressthem.A gearwheelsand betweenthe individual friction-locked connection is therebyestablished differential. A pressurespringforcesbackthe piston the planetset on the intermediate valvehasbeencancelled. and releasesthe discset afterthe actuationof the proportional gear) builtintothe outputsection(planetary Thepurposeof the intermediate differential compensais to transferdifferenttorouesto thevehicleaxlesandactsas an intermediate lockmay directionof the vehicle).The difierential tionin the drivingdirection(lengthwise betweenthe axles. be usedto disablebothfunctionsandestablisha riqidconnection

Liebher-WerkEhingenGnbH - Techni@ltEining


-19-

lIIBilENR

Gomponent description UW06 - Transmission

>3.2.2ERGOPOWER 6WG2r0 Valvefor converter clutch{WK-valve) Pressure oilpipefrom Pressure oil oiDeftomcontrol unitto WK-valve

VentpipeWK Connection to heatexchangor Connection to excnanger OiltempeGture regulator (thermal switc+ring valve)

Electrohydlauliccontrol unit Connection to heat excnanger

Greasingpipefor powertak€-off

Oil fller pipewith oil dipstick

Output flangeto rear axle Fig.30:6WG210ERGOPOWER

Liebher-WerkEhingenGmbH- Techniel lEining


-20 -

UIBIIINR

description Component UW06 - Transmission

Valvefor converter clutch (WK-valve) couplingbell Converter

flangeto engine

Outputflangeto fronlaxle of thefront Pneumatic activation/deactivation axledrive differential lock) {longitudinal Fio.31:6WG2'10 ERGOPOWER

training liebher-we&Ehingen GmbH- T€chnlcal

personne, OnlyforLIEBHERR service

-21 -

ITIBTIIRR

Component description UW06 - Transmission P6ddby:|kepld/fuifon:20'04'077v.Eion:2

Pressure oil pipefrom conirolunit10

Changefilter

(blueZF-finefilter)

Fio.32:6WG210ERGOPOWER

Discclutches Driveflangeto engine

Electro-hydraulic conlrolunit Gearwheels

Intermediate differential gear) (planetary Outputflangeto frontaxle

Outputflangeto rearaxle

Fig.33:6WG2'10 ERGOPOWER Liebheii-We* Ehinsen GmbH- Technlc€l oainins


_ ZZ -

1TEHTRR

Gomponentdescription

Transmission

for electro-hydraulic conholunit Connector Electro-hydraulic controlunit (withtransmission sensor) sumptemperature Changefiller (blueZF-finefilter)

lnductive sensor

ourpur

Fio.34:6WG210ERGOPOWER Fig.35:6WG210ERGOPOWER

Inductive lnductive sensor sensor intemalmiddlespeed pumpspeed

Conveder clutchunit

Fig.36:6WG210ERGOPOWER lnductive sensor turbinesp6ed

Ll€bh6n-W€d. Ehhg€nGmbH' Techni€l trainins

personnel OnlyforLIEBHERR seryice

-23 -

Cranehydraulics On

ITIBTIERR

ComponentdescriPtion

UW06 - Transmission

Transmission PumP

Drive Disc clutches

Discclutches lntermediate differential (planetarygear)

6WG210 viewERGOPOWER Fig.37:Cut-away

lEining GmbH- T€chni@l Ehingen Lrebher-werk

personnel service Onlyfor LIEBHERR

-24 -

lIIBHTNR


measuring oftheproportional valvesto eachofthegearsandtheirassociated Theallocation page (see pointsis shownin theswitching 26 fig40) . table(Fig39)andtheoilschematic Forexample,if Y1 andYOare active(markedred),discclutchesK4 and K2 have switched. Thisselectsthe4th forwardgear. valvesY1 andY6 can be checkedat measuring Thecorrectfunctionof proportional points60 and57 respectively.

points6WG210 of measuring Fig.38:Overview

Fig.39: Switchchart6WG210

valves areactuatedusingthe 6 proportional Thesix discclutchesfor the transmission Yl to Y6.The proportional valve(pressurecontrollerunit)consistsof a pressureregulastopvalveandvibrationdamper.The controlpressurefor actuatingthe tor,downstream valve.Thepressureoil is downstream stopvalveis generatedby the pressurereduction stopvalveto the relevantclutch. fedthroughthedownstream The pressures to the clutchesinvolvedin makingthe gearchangearecontrolledby for eachclutch. meansof directproportional driveswithseparatepressuremodulation Thisallowshydraulicoverlapping of the clutchesbeingswitchedon andoff.Thisresults gearchangeswithoutanyinterruption in tractiveeffort. in immediate Liebher-WerkEhingenGmbH- Tochni€ltra ning


-25-

ITEHIRR


Oil schematic- Forwardslst gear il Kr s: -f!44-

i1Kl

I

I i

, I lut.,.l

(electrc-hyd€ulic coitrolunt)

convedflollpdpresde

rl!?!!r!!4q!L

Fig.40:Oilsche.natic 6WG210- FoMards1slgear

actuationis providedby the Theoil supplyto the converterandtransmission pump.Thispumpsucksthe oil fromthe sumpthroughthe coarsefilterand transmission pumpsit throughtheZF-finefilterto the mainpressurevalve.lf it is not possibleto maintaintheflowto the ZF-fineflltecthe lubrication oil is directlyfed throughthe fllterdifferpressure on theZF-display. ence valve(bypass valve)andan erroris indicated Note: Older6wc{ransmissionsystemsare equippedwitha blackchangefilter(ZF-finefilter). valve(internalbypass). Theseincludean internalfllterpressuredifference with filter)withNew6wc-transmission systemsareequipped a bluechangefilter(ZF-fine pressure outan internalfilter difference valve(withoutan internalbypass),see(fig40). withthe Forthisreason, blackandbluechangechangefilte€shouldonlybe replaced sametype. Liebher-WeREhingenGmbH- TechnicaltEining


UEBHINR

Componentdescription UW06 - Transmission Wheelschematicforwarddriving direction:

o) 0) .

(!

;,

.5 N

z5x

g

b

I

€ :

.e

.e

I b .9 E t ; _9

(')

cLO

V E

€5 BB6 Ece g cs 5 !; !Ei i i!i !o !o ! : + ?g!E9C€€

" P { 2

I

c '6

E F

=-1=

^,J[-^

2 fo arddriving direction Fig.41:Wheelschemalic Ergopower 6WG210 Liebher-We* Ehnqen GmbH- Iechni€l l€hing


_27

-

ITIBHTRR

Gomponentdescription UW06 - Transmission Wheelschematicreversedrivingdirection: 3

E

e >

6

o oi €

3

o

!

o o) N

E 5

E .9 f I

o)

,9 E = .9

E o

€stbnt

E* Y g g :

!!E!!EP4

+

'6 .9.

E F

a Fig.42:Wh€etschomatic Ergopower 6WG210reversearivi_ng Oireaion Liebheii-WekEhingenGfrbH - Techni@ltEining


-28 -

UIBHINR

Componentdescription Transmission Pdu€dby:€pd/Edilon:200.07/venioi]2

6WG310 >3.2.3ERGOPOWER .B27 sensor Temperature converter output

-A69 Electro-hydraulic controlunit,HSG94

-Y72 Solenoid valve, Converter clutch

.824 lnductivesens

(engine/pump speed) -825 lnductive sensor Turbinespeed

-s70 Cranehydraulics OFF/ON

826

lnductive sensorintemal N,4iddle speed

.s31.

Driveaxle'1, 1=ON,0=OFF

ON/OFF

Fig.43rErgopower6WG3'10

Liebher-We* EhingenGmbH- T€chnlcallraining


-29 -

TTIBIIIRR


UW06 - Transmission

.B2A lmpu|sesensor, Tachograph

Outputf,angeto rearax'o

-B29 Inductive sensor Powertake-offsp6ed

Changeover Off-roadgear/ to€rclgear €65 Off-roadgear 1=ON

Fig.44: Ergopow€r 6WG310

Uebh3r-welk EhlngenGmbH- Tschni€t taining

Onlyfor LIEBHERR seryicepersonne

-30-

UEHINR


Electro-hydraulic controlunit

Converter clutch!nit Driveflange 2. Powertake-off

pump Transmission

Itr

:-tl

axle Coupling ,,KV/K1'

Retarder Converler

KR

K2 Coupling axle "KFYK2'

Coupling axle "K4lK3'

Countershaft

Outputflange Frontaxles

Outputflange Rearaxles

I -

Axleactivation (longitudinal differential lock)

Fig.45: Cut-away viewErgopower 6WG310 Liebheii-WerkEhingenGmbH- Techni@ilraining


- 3 1-

lntermediatedifferential (planelarygear)

lIBHINR

ComponentdescriPtion UW06 - Transmission

valvesto eachof the gearsand theirassociated The allocationof the proportional (see table(Fig47) andtheoil schematic pointsis shownin ihe switching measuring page33 - fig48). andK2 have F"i".r.pfJ if i2 andY6 are active(markedred),discclutchesK4 valvesY2 tnis setectsthe4th fonrvarigear.The correctfunctionof proportional switcneO. andY6 can be checkedat measuringpoints60 and 57 respectively'

poinls6WC310 of measur;ng Fig.46:Overvlew

---Trcponionat

vatveactlre

!ed. no, of measudns pohll

Fig.47: Switchchari6WG310

Liebheir"weaEhinggnGmbH- Techni€l training


-52-

lTTBIITRR


Oil schematic- Forwards'lst gear

il

*' P6

a'

ir+-!!

(elecrb-hydEuliccontrolunit)

",u co^veddulpdp€$rc

i**'-cei ' i i

: i

I t

PoFdonarva€dGcclld|(3

Fig.48:Oil schematic 1stgear 6WG310- Forwards

Liebher-WerkEhingenGmbH- Techni€l tEining


-33-

lTIBHIRR

Component description UW06 - Transmission 3.3ALLISONtransmission CLBT755 DB >3.3.1ALLTSON Design:

-R28 Temperature sensor, transmission oil

Dropbox (downstream dropbox)

Fig.49:Allison transmission CLBT755withdropbox

=l*iJL

--

Electro-hydraulic conkolunilwith valvesfor conlrolling the solenoid discclutches. Temperature sensor forwardand reversepressure

Fig.50:Allisontransmission CLBT755withdropbox Liebher-Werk Ehinsen GmbH- Techni€llralning


- 34 -

UIBlIINR


Transm:ssion AllisonECU

Fig. 51: Transm;ssionECU

Discclutch4th gear

DiscclutchfoMard gear

Discclutchsih gear Turbinewheel

Discclutch3rd gear

Discclutch1stgear

Discclutch2nd gear

Output

Guidewheel

clutchunit Conveder (conveder bypassclutch)

Planetsets controlunitwiihsolenoid hydraulic thediscclutches valvesfor controlling

Torqueconverter

Frg.52. Ove/viewAlson lransmissionwithoJtreralder

Liebher-WerkEhing€nGmbH

personnel OnlyforLIEBHERR s ervrce

-35-

lTIBIIIRR


withoutretarder Fig-53:Cut-away viewAllison lransmission

Function: Thetransmission ratiosfor 5 forwardgearsandone reversegearare achievedusingfour planetsets.Theseplanetsetsareactuated controlled discclutchusingsixhydraulically meshed. es.Allgearwheelsarepermanently characteristic. Thetorqueconverterensuresa smoothandjerk-freedriving-off ln contrast withZF 6WG-transmissions, theAllisontransmission CLBT755DBis retarder. Thisservesto providehydraulicbrakingassistequippedwitha hydro-dynamic which are controlled via the retarderactuator.Theretarder anceand has2 brakingstages is onlyactivewhenthe converterclutchunii is switchedon. Maximumbrakingassistance is providedat highspeeds. Thedownstream transfergearboxis a dropbox. to Theaccelerator sensor,speedregulatorand gearrangeselectortransmitinformation valves.These the ECU.The ECUanalysesthis information andcontrolsthetransmission pipes usehydraulic to controlihe shiftup/downand bypassfunctions. For The ECUcontrolunitalsomonitorsthe systemfor abnormaloperatingconditions. pressureswitchesto monitorwhetherihe forexample,the ECUusestheforward/reverse gearhasbeenhydraulically selected ward/reverse switchedafterthe ECUhaselectrically thisgear. oilsump.lf a TheECUalsousesan oilsensorto checktheoil levelin thetransmission transmission faultoccurs,an errorcodewill indicateihe typeof error.

Llebhen-WerkEhingenGmbH-Techni@ lfainng


-36-

IIBHIRR


UW06 - Transmission Prcdudby:|wapid/fu[oi20M07,vadon:2

4. Automaticshift transmissions 4.'l Automaticshift transmissionAS-TRONIC General >4.1.1

AnautomaticshifttransmissionisatransmissionSystemwherethedriverdoesnotop controlunit by an electronic insteadthis is performed atea clutchor thetransmission; valves. (gearingactuator)andelectro-pneumatic and manualmodes' Iiis possibleto selectbetweenfully-automatic of a clutchby the driver cylindersperformthegearchangefunctionOperation Pneumatic controlis coupledto lwhetnerautomaticor manual)is no longerrequiredTransmission separates' ine gDC and bringsthe engineto the precisespeedwhenthetransmission loadsare also Clutchwearandhightransmission iniJermits jert-ireeg"", "h"ng"". minimised.

training GmbH- Technical Ehingen Liebhsn-Werk


-37 -

rIIBHRR

Gomponentdescription UW06 - Transmission >4.1.2Transmission Design: systemis a combination of an electro-pneumatically TheZF-ASTRONIC transmission on the cranemodel, shiftedclawtransmission andan automaticdry clutch.Depending includesan integratedhydraulicintarder transmission theZF-ASTRONIC

Plugto clutchactuator

Transmission actuator Pl!9, vehicle

Solenoid valve (openaccumulator chargevalve)

Heatexchanger Oilfillingnozle

Oilinspection plug RPMsensordrive shaft

Output

lntarder Prop.solenoidvalve (intarderactivation)

temperaCoolant (heat turesensor output) exchanger

Plugto intarderECU

Clutch actuator with 4 solenoidvalves+ bavel sensors

Fig.54:Automatic shifttransmissionAS-TRONIC UebheF-Werk Ehingen GmbH- Techni€llralning


-38-

ITEIIIRR

Gomponentdescription UW06 - Transmission

Function: The useof an automaticclutch(no clutchpedal)meansthatthe driverdoesnotneedto by thetransmission control. operatethe clutch.Theactualgearchangeis performed (the16-gear section modelhasa TheZFAS-TRONIC comprises a maintransmission has a 3-gear transmission), as well as a splitter 4-geartransmission; the12-gear model group(GP)basedon a planetary group(GV)anda downstream design. section

Constant

K1

Transmissionoil pump

Sectiongroup gear) iplanetary

Reversegeaf

Transmission brake Splittergroup

wheel IVaintransmission sectionwithreversing (3-or 4- geariransmission)

gear-AS-TRONC Fig.55:Cut-away viewshowingsplittergroup,maintransmission sectionandplanetary

Splittergroup ReversegearReversingwheel

Transmission b€ke

Outputflange Ivlaintransmission section withrevers'ng wheel(3-or 4- gearhansmission)

Secliongroup gear) (planetary

gear-AS-TRONIC Fig.56:Ivlainviewshowingspliilergroup,maintransmission sectionandplanetary L ebher-WerkEhingenGmbH- Techni@llralnlng


-39-

ITIBHIRR


The maintransmission usesa claw-shift, the splitterand planetgroupsare synchronised is notsynchronised. whereasthe maintransmission performed actuatorandtransmission brake. Synchronisation is by the transmission Swiichingmodule

Swiiching cylinderfor tiongroup(range)

Selectorcylinderfor maintransm;ssion secton (select)

Switching cylinderfor section(shift lransmission

Switching claws

Switchingcylinderfor spliltergroup (split)

iv

$4,

It,

Fig.57i Overviewshowingswilchingclaws and swilchingcylinder

Switchingcylinderfor splittergroup

Switching cylinder formain transmission section Switchingcylinderfor

':. ,:.

sectlongroup

Selectorcylinderfor maintransmission sectton

Switchingclaws

viewclawtransmission AS-TRONIC Fig.58:Cut-away Liebher-Werk Ehinsen GmbH- Technical tEinins


- 40 -

lIIBIIIRR

Componentdescription UW06 - Transmission Pdu€dby:wprc/Editon:20&077ve8ioi]2

of a Thetransmission actuatorandclutchactuatorare the mostimportantcomponents Thetransmission actuatorperformsall the switchingactions fully-automatic transmission. andfullycontrolsthe clutch. to bothcountershafts. Constants K1 and K2 are usedto determinethe powerdishibution gearis via the maintransmission section.The Thereturnto the mainshaftin a particular group provides the output drive. section to the driver(e.9.gear displayindicatesall relevantsysteminformation Thedashboard ratio,errorsetc).

>4.1.3Transmissionactuator Purpose: Thetransmission actuator(fig60)fulfilsthefollowingtasks: . Shiftoointcontrol . Controlling valvesusedto changegear the electro-pneumatic . Controlling the clutchactuator . Self-testwitherroroutput . Sendgearindicatorsignalto the displayunit . Processing thefollowing: of sensorsignalsto determine - the currentpositionof all switchingcylinders - thetransmission inputspeed - thetransmission oil temoerature - the amountof availableair pressure . Communication withthe enginecontrolunitandABs-controlunitvia the CAN-bus . Controlling the transmission brake

WABCOidentification plateon transmission actuarcr

- WABCO plate identificaton Fig.59:Transmission acluatorAs-Tronic Note: of the previoustmnsmissionactuator transmission actuator(GS3.3)is a furtherdevelopment (GS3.0)-Theyare not compatible.The transmission actuatortype(GS3.3)is identitiedby the plateaffixedto the transmission actuator. lastdigit"...007"on the WABCOidentification Llebher-WelkEhingenGmbH- T6chnicaltraining


-41-

UE]ITRR


Design: electronics, switching Thetransmission actuator(fig60) consistsof thetransmission valves,pneumatically-operated switchingcylindersand sensors. actuatorwithtravelsensors.lts compactdeTheclutchactuatoris an electro-pneumatic in transmission housing. signallowsit to be integratedthe Selectorcylinderfor maintransmissionsection(select) Switchingcylinderfor spliltefgroup (split)

Switching cylindertor main transmission section(shift) Switching cylinderfor seciiongroupGange)

-A6.1

ECUtransmission actuator with inlegratedelec-

tronictransmission control and . vaversensors, . temperature sensoc . air pressure sensor, . Speedsensor (transmission input)

Shiftrod

actuatorAs-Tronic, loc€tion Fig.60rTransmission

F i g . 6 1Excerpt E: x c fromschematic for compressed airsystem/ transmission aciuator: Legend: -Y1 -Y2 and -Y3 -Y4 and -Y5 -Y6 and -Y7 -YBand -Yg -Y10

Transmission brake Switching cylinderfor splittergroup(split) section(select) Selector cylinderformaintransmission section(shifl) Switching cylinderfor mainiransmission group (range) for Switching cylinder seclion Releasing ihe cyl;nders withcompressed ah

Li€bheii-We(Ehlng€n GnbH- Tschni€ltraining


-42-

UIB|ilNR

descriPtion ComPonent UW06 - Transmission

iio,",r *

".4",

eo"*' ' ooo'' u'"'" '

>4.1.4Clutch(dry'clutch)

iilffi .

shaft input too",*1li:'i'l**P:HIll"€J:i9,i::lil*, *etransmission "

to transferthe enginetorquero

iE::"*""'"" :fl!:#"J11;:",U*:gr""J"il"::::iffi overroad asainst : : $,i#:fifi:*l;'$1'$'"-t"r components

clutches andmulti-disc (e g 12AS23O2) clutches single-disc oetween 3i"Jlkr"n,,"r"" (e.g.16A52602).

Plate clutchPressurc sPrings Membrane

TorsiondamPer

beadng Throw-out dive shaft Transmission

Releaseiork Actuating Pisbn Clutchactuator

clutchpads (frictionpads)

Servicelid nsmissions) tErnrng Liebh€r-WeftEhingenGmbH Technl€l


-M-

UEHRN


UW06 - Transmission

plate Clutchpressure lVembrane springs Clutchpads (fdctionpads)

Throw-out beadng

Transmissiondriveshalt Releasefoft

piston Actuating

Clutchactuator Servicelid

in 16-gear transmissions) Fig.64:Overview ofa dual-disc clutch(incorporaied

Throw-out beadng

Releasefork

Acluatingpiston

Fig.65:Throw-oul bearingwithr€leaseiork Liebhen-Werk Ehinsen GmbH- Techni@l tEinins


_ 45 -

lIIBHIRR

description Component Transmission Pfududby:iwep]d/Editon:20'0.'07lveB6n:2

Clutchpressureplate Ciutchpad (frictionpad) Hubprofile Torsiondamper

- rearview Fig.67:Clutch element

Fig. 66: Clutchdisc

Circlipand releasewirefor beadngsnap-in mechantsm

plate Clutchpressure

spring Membrane

Tangential leafsprings {prevenldragtorque}

Fig.68: Cluichelement- frontview

Function: Theclutchdisc(fig66) hasrivetedfrictionpadson bothsidesand is fixedto the tEnsmissiondriveshaftusinga hub profileto preventrotation.Whenthe clutchis closed,the drive torqueis transfenedfromtheflywheeland clutchpressureplateto the transmission shatt. A membranespringprovidesthe requireddampingforce.Thethrow-outbearing(fiq65) andactsas a leverto springvia a "snap-inmechanism" is connected to the membrane releasethe clutch. vibrationbetweenthe engine Thetorsiondamperon the clutchdiscdampensrotational Thisincreases the servicelifeof the powertrainand reducesnoise andtransmission. emissions. Liebher-WerkEhingenGnbH - Techni@ll€ining

personne Onlyfor LIEBHERR service

-46-

IIEIIIRR

ComponentdescriPtion UW06 - Transmission

Openingand closingthe clutch: Situation Neutral

Brake+ D Startingup (pressaccelerator) Driving

Gearchange

Comment

CIutch

{l{F{F {F {F-

Li€bher-wek EhingenGmbH- T€chnl@llEining


Engagingthe starting gear:3rdgear onlY Fullload-release whenclutchhasfullyclosed

- 4 7-

lTUIIRR

Gomponentdescription UW06 - Transmission >4.1.5Clutchactuator Purpose: The clutchactuator(fig 69) seryesto open or closethe clutchwhichinterruots the oowgearchanges. er transferfrom the engineto the drive wheelsand allowautomatic

Design: '' Travelsensor @

Switchingvalves Clutchaciuator

ng prslc

Controller Fig.69:Clutchactlator |

- !i15

-.TiJ

-ril6

Switchingvalvesclutch actuator-A69; . -Y14- Quickly closeclutch . -Y15- Slowlycloseclutch . -Y16- Quickly openclutch . -Y17-Slowlyopenclutch

Function;

Fig.70: Excerptfromschematic forcompressed valvesclutchactuator: airsystem/ switching

Theclutchactuatorand its pneumatic actuatingpistonsare controlledby the electronics in the transmission actuatorThisusesthe releaseforkto ooeratethe throw-outmechanismwhichinterrupts the powertransferbetweenthe engineandthe shifttransmission duringgearchanges. pistonsis determined The positionof the two pneumatic usinga travelsensor.Twopairs of redundant, switchedvalvesare usedto openand closethe clutch.Slightdepression of the clutchis possiblewhenperforming delicatedrivingoff and manoeuvring work.The pointduringeverystart-upandforclutchactuatorzerosthe currentclutchapplication wardsthis information to the transmission electronics. A LICCON-special screendisplays theclutchwearas a numeric value.

Llebh€r-WerkEhingenGmbH- Techni@llra ning

personrel OnlyforLIEBHERR service

-48-

lIIBHTNR

Componentdescription Transmission >4.1.6Intarder(secondaryretarder) Generalfunctionsand overview Puroose: hydraulicbrakewithmultiple retarder)is a wear-freepermanent Theintarder(secondary Thisrelievesthe loadon the service in thetransmission. brakingstagesthat is integrated prevents overheating. (foot brake and brake brake)andengine

Design: Heatexchanger Accumulator chargevalve

Oiltank

Coolanttemperature sensor(heatexchange. output)

Oilfilter andoildrain plugAS-Tronic Prop.solenoid valve (intarder activation )

Plugto intarderECU

Fio.71:ZF 16A52602 withintarder

driveshaft. Theintarderis coupledvia a boosterslageto thetransmission The heatexchangeris directlyflangedontothe intarder. Note: blockbehindthe Thesecondaryretarderis notfittedas a separateandindependent henceits name"intarder". transmission; insteadit hasbeenintegrated, Llebh€ii-WerkEhingenGmbH- Techni€l training


-49-

UBIIRR


UW06 - Transmission

;d,*d

b,.""pd/E","" re

d,v.^""

2

chargevalve Accumulaior Heatexchanger

Oiltankintader

valve Prop.solenoid activaiion) (intarder oil pump

Stator(firmlY to ihe housing) attached withintarder Fig.72:ZF 16A52602

Oil pump

Oiltankintarder

Heatetchanger viewintarder Fig.73:Cut_away Li€bhe -w€& EhlngenGmbH' Tochnicalirainrng


-50-

lIEIIERR


UW06 - Transmission

Function: cooling is continuously cooledbythecoolantin thevehicle Theintarder heatexchanger circuit. Accurn ulatorchargevalve

Stator(firmlyattrached to the housingi

Fig. 74: Intarderswitchedoff

chargevalve.Thisis done Actuationof the intarder(braking)activatesthe accumulator andcanbe performed in several by pullingthe steeringcolumnswitch(right)backwards stages.Compressed air thenforcesthe oil fromthe oil tankintothe workingcavitybetweenthe rotorandstator(rapidbrakingaction). forcedisperses the oil intothe stator Theshapeof the rotorbladesandthe centrifugal whichis fixedto the housing.Thisoil dispersion effectbrakesthe rotorand hencethe veusinga heat hicle.Frictionconvertsthe kineticenergyintoheatwhichmustbe dissipated exchanger. Accumulaior chargevalve (-

"ot0,""""0 "n

Oiltank

Stator(firmlyaitached Heatexchanger

to thehousing)

- . . - . . . .

Fig.75:lntarderactuated(braking) Liebheii-WerkEhnsen GmbH- Techni€l trai.ing


- 51 _

UIBIITRN

Gomponent description UW06 - Transmission Pduedbykfid/Edllm]20@07lvadon:2

Intardercomponents . IntarderECU lnstallation location:centerconsole participant (120ohm End on CAN-BUS resistor) termination

Fig.76: IntarderECU

Theaccumulator chargevalveis actuated by the intarder-Ecuwhenthe intarderis switchedon.Pneumatic actuationof the oil piston (drainthe contentof theoil tank) tank

Fig.77:Accumulator chargevalve

.

Heat exchanger

The heatexchangeris a watercoolerwhich is connected to the vehiclecoolingcircuit.lt ensuresthatthe intarderandtransmission cooled. are sufficiently

Fig.78: Heatexchangef

tfainins Lr€bh€n-W€lk Ehlno€n GmbH- Tgchnical


_ 52 _

UIBIIERN


Transmission

Oil tank Reducesthe intarderresponsetimeby drainingthe contentof the oil tank('1.4l) into the intarderoil circuit.

Fig.79:Oiltank

.

Coolanttemperaturesensor-A68 81 Protectsthe coolingsystemagainstoverheatingduringintarderoperationthrough reductionof the temDerature-dependent brakingtorque.

Fig.80:Coolanttemperature

.

Prop.solenoidvalve - Intarderactivation-Y68_Yl Activation of the hydraulicunitinsidethe intardet Actuationvia the intarder-EcUusing a PWM-signal.

activation Fig.81:Prop.solenoidvalve- Intardor

.

lntarderswitch ' Switchon the centerconsoleto switchoff the intarder

Fig.82:Intarderswitch"ON"/ "OFF Liebhen-W€rk Ehing€n GmbH- Techni€llEinins


-53-

ITEIIRR

Componentdescription UW06 - Transmission / systemdesign >4.1.7Components linearCAN-BUS witha startandend participant

WheelRPMECU . Optimising the gearchanges whentuminganddrivingon differenttypesof terrain.

TransmissionECU . Transmission control

Keyboardunit Selectfrom: R,N,D Gearup/down Drivingprograms; 1 = Automatic 2 = Manual l\4anoeuvring mode or off-roadgear

Displayunit Displays: ' automaticmode . manoeuvnng mode . gearcunentlyselected . neutralposition . errorcode

EngineECU . Reduction oftheengine powerpriorto a gear cnange . Increasing the torquein manoeuvring mode

IntarderECU . Influence of gear changepointsto increasethe braking effect

Steeringcolumnswitch . Activatingthe intarderin switchposition1 . Changegearup/down in manual operation

. clutchooen/ closed

Fig.83:Components / systemdesign Liebher-WerkEhingenGmbH- Techni€l aaining


-54-

UEBHINR


UW06 - Transmission 4.2Automaticgearboxwith upstreamconverter >4.2.1TC-Tronicwith r€tarderZF12AS3002TC Design: thefollowingcomponents; essentially comprises TheTC-Tronic transmission . 12As-Tronictransmission . Converter withconverterclutchunit . Retarder . Hydraulic convertercontrol . Electrical retarderandconvertercontrol . Clutch Returnfrom heal exchanger

-A61 Transmission ECU,transmission actuator electronic transmission wit\ integrated actualion andlravelsensors, temperature sensor,airpressure sensorandRPM input) sensor(transmission

Retarderregulation valve,

Toheat exchanger

-B27 Temperature sensor WSK,oiltempe€tLrre = 40140OHIVI 20' 130' = 751OHM

Fillingnozzle

converter Compressed air connectionretarder regulation

plug1 Oilfiller Gearbox

-Y72 valve Prcportional (S/lVcontrolled) 1=WSK closed Clutch Primaryretarder

TofqueconverterTC withconverter clutch unitWSK,

Converter reseryoir

Oilfilier Fig.84:To-Tronic- ZF12AS3002TC Liebh€ii-W€* Ehin96nGmbH- Techni€l lEining


-55-

ITEHIRR


UW06 - Transmission

Oilfillefplug Firsttimenlling Converter

Oilfillerplug2 gearbox

-A69 Clulchacluatorwith4 magnetic swilching valvesandtravelsensorc Fig.85:To-Tronic- ZF 12AS3002TC

Discset

Turbinewheel (secondary v'heel)

Clutch(dryclutch) Transmission Splittergroup orlpump Reversegear

cup springs

Converter clutch unil Retarder

I\,4ain transmission section wjlhreversing wheel(3-gear transmission)

Secliongroup (planetary gear)

Guidewheel (defleciion Pumpwheel Transmission brake (primary wheel) w-heel)

12AS3002 - ZF12AS3002TC F;9.86:Cut-away drawingTC-Tronic Liebheii-W€rkEh n96n GmbH- Techni€l tEining


-56-

UIBHIRR


Clulch (dry clutch)

Tufuinewheel (secondary wheel)

Cupspdngs

Guidewheel (defleclion wheel)

Pumpwheel (primary wheel)

Fig.87: Cutaway modelof TC2

Liebhen-W€rkEhing€nGmbH- Techniel tkining


- 5 7-

lIIBHTRR


UW06 - Transmission

>Retarder Puroose: Theretarder(primaryretarder)is a wear-freepermanenthydraulicbrakewith multiple unitbetweenthe engineand brakingstages.The retarderis an independent goodbrakingperformance transmission and providesparticularly at highenginespeeds. Theretarderrelievesthe loadon the servicebrake(footbrake)and enginebrakeand preventsoverheating. Design: Retaderregulation valve Prop.solenoidvalve (retarde.activaijon)

Staior(firmlyattached to the housing)

Heatoxchanger

Fig.88: Retarder/ZF 12AS3002TC

Ljebher-Werk Ehlng€n GmbH- Tgchrical tralnlng


-58-

lIIBHIRR


Transmission

>R€tarder Purpose; Theretader (primaryretarder)is a wear-freepermanenthydraulicbrakewithmultiple brakingstages.Theretarderis an independent unitbetweenthe engineano transmission andprovidesparticularly goodbrakingperformance at highenginespeeds. Theretarderrelievesthe loadon the servicebrake(footbrake)and e;gine brakeand preventsoverheating. Design: Retarderregulaljonvalve

Prop.solenoidvalve (retarder activation )

Stator(firmlyattached to ihe housing)

Heatexchanger

Fig.88: RetatdetI ZF 12AS3002 TC

Liebher-WelkEhingenGmbH- TechnicattEining

Onlyfor LIEBHERR personne service

-58-

UIBIIIRR


Function: valve. comprises a stator,rotorand retarderregulation Theretarderessentially pulling backwards and can steering column switch the right Brakingitselfis actuatedby air appliedto the retarderregulation in severalstages.Thecompressed be performed valvereleasestheflowof oil intothe retardercircuit. the oil intothe statorwhich The rotationas wellas the shapeof the rotorbladesdisperses the cycle recommences. is fixedto the housing.lt thenreturnsto the rotorwhere movementofthe rotorand hencethevehicle Thediversionof the oil delaysthe rotational pressure by andfrictionintoheatwhichis transspeed.The kineticenergyis converted ferredto the coolingwatervia a heatexchanger.

valve Retaderregulation

Outletspiral

aircon Compressed Pressurcoilfrom heatexchanger Pressure oilto heat exchanger

Connection coolingwater Heatexchanger Fig.89; OveNiewof retarder

Liebhen-WerkEhingenGmbH- Techni€l tfainng


-59-

UTBIIIRR

Gomponent description UW06 - Transmission

>Hydraulicconvertercontrol

Valveblockconverter control

clutchun;t converier wsK (-Y176)

converter clutchunit WSK

Converter back pressuae valve

Fig.90: Hydraulic converter control

aciuation Retader requationvalve

\fiffirf

-----i'iLi'fi'illl3*' x X .

- converter - ZF12AS3002TC Fig.91rExcerptfromschematic controlTC-Tronic

Liebher-WerkEhingenGmbH- Technl€l lEining

personnel OnlyfprLIEBHERR service

-60-

lTIBHIRR

Gomponentdescription UW06 - Transmission

>Electricalconverterand retardercontrol Electrical converterand retardercontrolis performedby the ECU- EST41

retardefcontrolunitEST41 Fig.92:Converterand

>Clutch plate Pressure

; . ; : "

Ceranclutch Fig.93:Clutchwithremovedp.essureplate Membrane sping

Pressure beaiing Fig.94: Clulchassembled Llebhetr-Werk EhingenGmbH- Technlcallbining


- 6'l -

ITIBHINR

omponentdescriPtion UW06 - Transmission

"fl* "

."'" r*',"". *'' *" "'

clutch: the converterclutch unit and >Openingand closing

qit||ztion

Neutral

Brake+ D StartinguP (pressaccelerator)

Driving

Gearchange Brake+ D + Manoeuvnng button

Converter I

Ctutcn

-l F- {F{F- {F-l l-' {l.{l-- {l.*l F{F '{ l-' {l.-

trarnng GmbH- Technical Ehing€n Li€bhen-Werk


Comment -------'--------

converterclutchunll vvr^ opensat < n =.9501/mln (turbine speeo). Engagingthe startinggear: 3rdor 2ndgear Full load-release uruY

whenclutchhasfullycloseo Converterclutcnunll vvor\ closesat n > 10501/mln (turbine speeo). lighton thedisihe control after playunitextinguishes ca. l secono. . . WSKis closedto obtaln. precisespeedratiosdunng gearchanges. -----'-:---:-

=

in" ;i;;i.:i:#,'# "i;;;: wllr highconvertertorque causethe craneto move whenthe brakeis releaseo' usingcon(manoeuvring verter)

lIIBHENR


Transmission >4.2.2TC-Tronicwith intarderZF 12TC3040SO Puroose: Conversion of enginetorqueandspeedaccordingto the tractiveeffortdemandedby the ratioselection. vehicle.Automaticstartingandtransmission gearchange,a converterclutchunit,a with an automatic Thetransmission is equipped cluichand an intarder. Design:

converteroitchamber Plug,vehicle Plugto clutch acluarcr

Transmission actuator Oilfillingnozle Gearbox

Pressure reducing valve/ compressed airconnection . TorqueconverterTC with converterclutch unitWSK, . Dryclutch

Solenoid valve (openaccumulator chargevalve) Heat exchangef Oiltank intarder

Coolanttemperature sensor (heatexchanger output)

Oilfillerplug Gearbox

RPMsensor driveshafr

Oilfilter and oil drain plugAS-Tronic

Gearbox 12453040

Prop.solenoidvalve (intarderactivation)

Plug10intarderECU - ZF12TC3040SO Fig.95:TC-Tronic

Liebher-We* EhingenGmbH- Techni@ll€ining

personnel Onlyfor LIEBHERR seryice

-63-

UIBHINR

Component description UW06 - Transmission

Oilfillernozzle converter oilwith oildipstick

-Y72 Proportional valve (S/vvcontrolled) '1= WSKclosed

Temperature sensorconverter output,oiltemperature = 40140OHM 20" '130" = 751OHM

Oil drain plug WSK

Liftingpointsduring lransportalion and installation Changefilter (pressure filter);must be replaced during everyoilchangel

.469

Oildrainplug

Clutchactuatorwith4 magnetic on-offvalvesandtravelsensors

Changefilter (suction filter);mustbe replacod duringeveryoilchang€l Fig.96rTo-Tronic- ZF 12TC3040SO Li6bher-W€rk Ehing€n GnbH- T€chnical llalnhg

personnel OnlytorLIEBHERR service

-64-


- Transmission

Discset

Turbinewheel (secondary wheel)

(pfimarywheel)

-/

._.

t.-:-

._ _.:

___

!

!-

i__

L

t:

.'F ; i ! :-'-,'I

] r' )/

1i

Cupspdngs

Converter clutchunil

Torqueconvede

wilhconverter clutchunitforTC3040SO Fig.97:Cut-away drawingtorqueconverter Llsbher-WgrkEhingenGmbH- Techni@ltEining


-65-

ITBHIRR


>Electricalintardercontrol Electrical intardercontrolis oerformedbv intardercontrolunitEST42 whichis locatedin the centerconsole.

Fio. 98: lntardercontrolunil - EST42

>Convertercontrol Converter clutchunit

Converlerback pressurevalve 6 bar

Switching valveWSK

Convertersafety valveI bar

Pressure filter Converterflling and pump switching

Pressure valveWSK13.5baf

Suctionfilter - converlerconlrolTo-Tronic- ZF 'l2TC3040SO Fig.99: Excerptfromschematic

Llebhon-w€rk Ehingen GmbH- Techni€ltcinino


_ 66 _

UIBTIIRR


UW06 - Transmission

>Differencesto ZF 12AS3002TC is equippedwithan intarderinsteadof a primaryretarder' TheZF 12TC3O4OSO Intardercontrolis performedby an additionalintardercontrolunitEST42. fillingandswitchingpumpis largerthanthaton previousTC-TRONIC Theconverter time' the manoeuvring modelsand improvesheattransfer.Thisincreases valvelimitsthe pressurerequiredto closethe converterclutchunit TheDressure (converter bypassclutch)to 13.5bar (to reducethe sizeof the spring'a converter backpressureof 6 bar is used). for the converter Theconvertersafetyvalveprovidesmaximumpressureprotection whentheoil is is utilised (max.8 bar),The3rd positionof the convertersafetyvalve extremelycold(theoil directlyflowsintothe sump).

Liebher-Wei( EhingenGnbH - TechnicaltrainFg


lIIBIIIRR

Componentdescription UW 06 - Transmission Pduedb'kfiro]Edio20e07/ve6m:2

5. Semi-automatic shift transmissions (synchronous >5.1ZFECOSPLIT 16S/151 transmission withEasyshifr2. gearchangesysiem) Design: .830 position Tmvelsensor downstream group(section groupswitched)

Switching cylinder Reversegear Switching arm

Valveblock

Speedsensorfor tachograph

Maincompressed aarconnection for emergency switching

Switching cylinderfor gears3/4and7/8

Switching valvefor group oownstream

Switching cylinderfor gears1/2and5/6

Displaygearindicator

Switching cylinder group downstream (sectiongroup)

Hydro-pneumatic clutch lhrow-outcylinder

-r-.i

.,:..,]r, Fig.100rECOSPLIT 16S151

Liebheir-Werk EhingenGmbH, T6chni@ttEining


-68-

UIBHIRR

Component description Transmission Fftdu.edby:*pd/fuiddn:2ded7lveBifr:2

Design: Transmission control unitEST28

-s394 Switch"SplittergroupON"

-s396 Switch"Transmission neutral"for antigasand startinginhibitor

-829 Travelsensor"Gearengaged" and neutral-pos."

Fig.101:ECOSPLIT 16S151

Function: Thegearstagesof the Easyshift2-changesystemsare selectedon the steeringcolumn switchby the driver. requiredfor A displayshowingthe gearsis alsoinstalled. Thisshowsall the information drivingoperation(e.9.howmanygearsto changeup/downas wellas the selectedgear). Thisdisplayis controlledby the electronic controlunit.

LiebheE-Werk Ehingen GmbH - Techni€l tlaining


-69-

UBIITRR

Gomponentdescription UW 06 - Transmission

Thecontrolunitprocesses all incomingsignalssuchas the gearpositionof the transmisgear sion,transmission speedetc.,andforwardsthe electricalsignalfor the pre-selected to the valveblock.Thesolenoidvalvesrequiredto actuatethe switchingcylindersare integrated in thisvalveblock. Theclutchpedalmustbe fullydepressed to performthe gearchange.Depending on the pre-selected gear,the corresponding pneumatically switchingcylinderis switchedby a tripswitch.A signaltransducer sendsa pulseto the clutchpedaloncethe gearchange hasbeenperformed by the transmission. Thispulsecan be felt at the pedaland prompts the driverto engagethe clutch.ln orderto protectthe engineandtransmission, the elecgear permitted tronicsonlyallows changeswhichliewithinthe speedrangesdefinedby thevehicleandtransmission manufacturers.

Swtchinscylin;error

Legend: -Yl to -Ys -Y6 -Y8 -Y13

Actuating lhe switching cylinder Sectiongroup Neuiral Splittergroup

Fig.102:Exceptfiom schematic Easyshift Liebhetr-Werk Ehln96nGmbH- Techni@ltGining


-70 -

ITIBHIRR

description Component

UW07- Transfergearbox/ Driveshafts

service OnlvforLIEBHERR Dersonnel

Componentdescription UW 07 - Transfergearbox/ Drive shafts Prcddby:|*epid/Ed!m:]3o07/veEon:1

Ehingen GmbH-Techni€ltralning uebhen-werk


-3-

ITIBHINR

Componentdescription UW07 - Transfergearbox/ Driveshafts Transfergearbox )'1.Transfergearbox,general 1.1Purpose Vehiclesare equippedwitha transfergearboxif severalaxleshaveto be ddvenat the sametime.Thisis locatedbetweenthe transmission andthe axleandcomDensation gearson the driveaxles. Thetransfergearboxperformsthe followingtasks: . Torquedistribution to multipleaxlegears . Extendsthegeartransmission range(roadgear/ off-roadgear) . Drivespumps(e.9.emergency steeringpump)via powertake-off ' Blocksspeedcompensation (differential lock)in caseof excessiveslipdifferences betweenthe drivewheels

'1.2Layout Drivewheel roadgear

Drivowheel off-roadgear

Drive Switching cylinder off-roadgear/ neulral /roaogear

Shiftclaw Powertake-off

Outputto roar axles Outputto frontaxles Longitudinal differential based gear on a planetary

Longitudinaldiffer€ntiallock

Fig.1: Cut-away viewof thetranstergearbox

Liebher-Weik Ehlng€n GmbH - Techniel training


-4-

UEIIIRR

Gomponentdescription UW 07 - Transfergearbox/ Driveshafts

1.3Longitudinaldifferentiallock for transfergearbox Purpose: betvveen thefront compensation differential lockblocksthe differential Thelongitudinal and rearaxlesduringoff-roaddriving. Design: Air connection lock Longiiudinal differential transfergearbox Controlswitch lock Longitudinal differential

fork Switching

Switchingsleeve

lock differential Fig.2: Culawayviewofthe longitudinal

Function: lock(e.9.clawcouanda mechanical lockconsistsof a standarddifferential A differential (off-road, iceetc.). pling),whichis manuallyswitchedin duringdifficultdrivingconditions function. Thisdisablesthedifferential and its compensation

Manualbutton, pressfor 2-hand operation lock Fig.3: Switching in the longitudinaldifferential

Note: lockandsafetynotesaregivenin the differential The switchingorderfor the longitudinal model. for the specificcrane operatinginstructions lraining LlebheF-Werk Ehinsen GmbH- Technlcal


- S _

ITBHIRR


UW07 - Transfergearbox/ Driveshafts Frcdudby rep.t/editun:13.04.077v8Eion:r

2, Single-stagetransfer gearbox >2.1 KesslerW 3750 D€sign

Non-return valve, Pipefromoil cooler

Drive Non-retum valvo, Pipeto oil cooler

Emergency steering pump Wheeldriven axialpistonpump for centering cjrcuit AHL

-B2A Pulsogenorator fortransfergearbox tachograph

Oillevelcheck / oilfill plug Outputto frontaxles

differentiallock

€30 Contactswitch Longitudinal transfer differential gearbox,acknowledgement

Fig.4: Transfergearbox- KesslerW3750

Li€bher-WerkEhingenGmbH- Techni€l iEining


-6-

ITIBIIIRR


UW07 - Transfergearbox/ Driveshafts >2.2SteyrPuch3800 Design

Pulsegenerator for hansfer gearbox tachograph valve, Non-retum Pipeto oil cooler

Emergency steeringpump

Outputto rearaxles

Outputto frontaxles

.s122 Contactswitch Longitudinal differential transfergearbox, acknowledgement

for ak connection Compressed lock difierential longitudinal Oildrainplug

/ oilfill Oillevelcheck

plug - SteyrPuch3800 Fig.5: Transfergeadox

Liebhetr-W€rk EhingenGmbH- Techni€l lraining

personne service Onlyfor LIEBHERR

UBHRN

Gomponentdescription UW07 - Transfergearbox/ Driveshafts

Design

Outputto frontaxles Outputlo rearaxles

Longitudinal differential based gear on a planetary Fig.6: Cut-away viewofiransfergearbox- SteyrPuch3800

Liebheii-WerkEhing€nGnbH - Techni€l lraining


-8-

UBITIRR

Componentdescription UW07 - Transfergearbox/ Driveshafts 3. Two-stagetransfer gearbox >3.1 Changeoverroad gear/ neutral/ off-roadgear Purpose: mechanism betweenroad transfergearboxesare equippedwitha changeover Two-stage gearandoff-roadgear(thereis alsoa neutralpositionfor the transfergearbox). gearreduction whichincreases vehicletractionon Theoff-roadgearis an additional off-roadterrain. Design: Controlswitch geafon Off-road

Air conneclion NeutElposition Emergencyswitchio Neutral

Air connection gearOn Off-road Air @nnection Roadgear on

Adjustment screw Switchrod

Fig. 7: Cut-awayview - Changeove.betweenroad gear/ off-roadgear

Function: betweenroadgear,off-roadgearand Compressed air is usedto controlthe changeover neutralposition.Theoff-roadgearis switchedin andout usingthe "Off-roadgear"button (tortoise) on the keyboardunit.

Buttonoff-roadgear gear) (crawling

Fig.8: Changeover betweenroadgear/ off-roadgear

Note: for switchingin off-roadgearandtowingmode. Referto the operatinginstructions Liebheir-Werk EhingenGmbH- Techni€l t€ining


-9-

UTBHINN

Gomponentdescription UW 07 - Transfergearbox/ Drive shafts >3.2Kessl€rVG1600 Design

.s.fi0 Controlswitchoffroadgear(On)

Compressed airconnection for longitudinal differental lock

Emergenry steeringpump

€'l,lS Contact switch

Oulputlo frontaxles

Longitudinal differentialtransfergearbox, acknowledgement Oil coolertransfer gearbox Air connection off-road gearON

Non-retum valve, Pipeto oil cooler

Air connection neutralON Switching cylinderoff-roadgear/ neutral/roadgear Air connection road gearON Pulsegenerator Ior transfergearboxtachograph

Non-return valve, Pipefromoilcooler Oillevelcheck / oilfill plug Outputto rearaxle Oildrainplug gearboxKesslerVG 1600 Fig.9: Transfer llsbher-WerkEhingon GmbH- Techni€ttrahlng


-10-

UIBHTNR

Componentdescription UW 07 - Transfergearbox/ Drive shafts

Switchingsleev€

Drivewheel roadgear

Longitudinaldifferentiallock

Outputto rearaxles Output{ofrontaxles

Longiiudinaldifferentialbased

gear ona planetary Fig.10:Cut-away viewtransfergearboxKesslerVG 1600

Uebher-WerkEhingenGmbH- Techni@liEining


- '11-

ITIBHIRR

Gomponent description UW 07 - Transfergearbox/ Drive shafts >3.3SteyrPuchVG2100 Design

Switchingcylinderoff-roadgear / neutral/roadgear

Air connection off-road gearON

Emergency sreenngpump

Airconnection neutralON Air connection roadgoarON

Non-return valve, Pipeto oil cooler

.G4 PulsegeneGtorfor tansfergearbox tachograph

oitntl plug

Output to rearaxle

Oil levelcheck plug

.S161Contact versaldifforential On=1

Outplt to front axle Oil drainpl Fig.11:TransfergearboxSteyrPuchVG 2100

Liebhen-W€rk Ehlngen GmbH- Techni€lhainlng


-12-

UIBHIRR

Gomponentdescription UW 07 - Transfergearbox/ Drive shafts >3.4KesslerVG2600 Design Switchcylinderoff roadgear/ neutral/ roadgear

valve, Non-retum Pipefron oil cooler

Emergency steeringpump

.828 for Pulsegenerator Iransfergearbox tachograph

Contactswilch Longitudinal tialtransfer acknowledgement Outputto rearaxles

Outputto ftont axles

Compressed air@nnection for longitudinal difierential lock

Airconneclion roadgearON Airconnection neutralON

Contactswitch, acknowledgement Ofi roadgearON

off-road Air connection gearON

.s64 Contactswitch, acknowjgdgement Road gear ON

Fig.12: TransfergearboxKessler2600 Ehingen GmbH- Tschni€iEining Llsbher-WeR


- 13 -

UEHINR


UW07 - Transfergearbox/ Driveshafts

Switching cylinderoff-road gear/ neutral/roadgear

Powertake-off

Outputto rearaxles

Outputto front

Longitudinaldifferentialbased on a ptane€rygear

Fig.13:Cut-away viewtransfergearboxKesslef2600

Liebher.-Werk Ehlng€n GmbH- T€chnical tralning

Onlyfor LIEBHERR personnel service

-14-

IIBIITRR

Componentdescription UW 07 - Transfergearbox/ Drive shafts >3.5KesslervG 3750 Design

Air connection

Air conngction off-roadgearON

neutral ON A'r connection roadgearON -s65 Contactswitch off-roadgear"ON"

.s64 Contactswitch roadgear"ON" -828 for Pulsegenerator transfer tachograph geatbox

axialpistonpump for centering circuitAHL / oil Oillevelcheck plug Outputlo front axles

for compressed ak conneclion lock longitudinal differential

-s30 Contactswitch transfer Longitudinal differential gearbox,acknowledgement

gearboxKessler3750 Fig.14:Transfer

U6bh6n-W€rk Ehlng€n GmbH- Techni€llraining


- 15 -

UBIIRR

Gomponentdescription UW07 - Transfergearbox/ Driveshafts

Drivewheel ofJ-roadgear Switchingcylinderoff-roadgear /

neuhal/roadgear Switching sleeve

Oulpulto rearaxles Outputto frontaxles

Longjtudinal difierential lock

Longitudinal differential based on a planeErygear

Fig.15rCut-away viewtransfergoarboxKessler3750

Uebheii-WerkEhing€nGmbH- Techni€l training


-16-

UIBIIERR


UW07 - Transfergearbox/ Driveshafts >3.6 KesslerVG 1600combinedwith axle Design for Pulsegenerator transfergearbox tachograph

Drive

Pipet9 oil cooler

Pipefromoilcooler

€42 Contactswitdl transversal difierential axle2 Compressed air connection for switching in axle1

Compaessed airconnection for off-roadgear

Outputto frontaxles Contactswitch swtchin axle1

for Compressed airconnection roadgear

-s64 switch, Contact roadgearON

Contactswitch, off-roadgearON

Outputto rearaxles

for ak connection Compressed switching in axle2 / longitudinal differential lock

Contaciswitch Switchin axle2 / longitudinal dlfferential lockfortransfergearbox

withaxle Fig. 16:TransfergearboxKesslerVG 1600combined Liebher-Werk Ehin€en GmbH- T€chnlcal lraininq


_fl

-

llIBHIRR

Gomponentdescription UW 07 - Transfergearbox/ Drive shafts

Swltchingsleevo

.s64 Contact switch, roadgearON

Contactswitch, off-roadgearON

Outputto frontaxles

€31 Contactswitch switchin axle1 Longitudinaldifferenlial

contactswitch Switchin axle2 / longitudinal differcntial lockfor transfer geadcox

Fig. 17:Cut-away viewtransfergearboxKesslerVG '1600combined withaxle

Liebher-WerkEhlng€nGmbH- techni€l tEining


- 1 8-

ITIBIIRR

Gomponentdescription UW 07 - Transfergearbox/ Drive shafts Driveshafts >1.Driveshafts,general 1.1PurDose Driveshafts(cardanshafts)are usedto evenlytransferthe torquefromthe transmission to thetransfergearboxandfromthe transfergearboxto the axledrive. anyangularmotion. Cardanjointsat eachendof the driveshaftcompensate provides within the driveshaft. compensation longitudinal A slidersection

Cardanjoint

Slidersection

Cardanjoint

(cross-toothed ) Fig.18:Driveshaft(cardanshaft)

1.2Layout

LTNI1400-7.'1 Fig. 19:Driveshaftinstallation Liebhen-werkEhinsgnGmbH- T€chni€l tEinins


_ 1g -

rIBHINR

Gomponentdescription UW 07 - Transfergearbox/ Drive shafts

Type"A" withgreasenippleon slidersectionand cardanjoint

Fig.20:Ddveshafttype"A"

Typ€"8" greasenippleonlyon cardanjoint(lowmaintenance)

Fig.21:Driveshafttype"8"

Type"C" withoutgreasenipple"maintenance-free"

@I-,rm D Fig.22:Ddveshafttypo"C"

U€bher-Werk Ehingen GmbH- Techni€liEining


-20-

ITIBIIIRR

description Gomponent

UW08- Axleswith attachments


Componentdescription UW08 - Axles with attachments

seryiceTraining Liebhefi-We* Ehlng€n GmbH- Cuslomer


lIIBIITRR


UW08 - Axleswith attachments 1. Kessleraxles 1.1Axles,general >1.1Puroose Theaxlecombinesdrive,steering,axlesuspension and brakingcomponents whichfullil purpose: thefollowing . Transferring the drivetorque . Supporting the maximumaxleloads(12tand 14ton roads)and maximumaxlepressures(off-roaddriving). Switchingin the differential locksduringoff-roaddrivingor in caseof difficultcondittons. >1.2 Layout

Steeringarm Axle struts (transverse controlarm)

Steeringcylinder

Tracking rod Trackinglevef

Trailingarm Brak6cylinder Fig. 1:Axle, general

Liebheii-WekEhingenGmbH- Custon€rSorulc€Tralnlng


-4-

ITBIITRR


Tralning Liebher-WeR Ehingen GhbH- Customer S€rvice


-3-

UIBIIRR

Componentdescription UW08 - Axles with attachments Poduc€!by:kpidTEdroi: i3.04.07/vecron 2

1.2Axle types axl€s >1,2.1Non-driven Fixedaxle (axlecannotbe steeredor driven)

fromschematic forfixedaxle Fig.2: Excerpt - 3rdaxle LTM1100-5.1

Fig.4: Fixedaxle

Steering axle (axle can be steered but is not driven)

Fig.5: Steeringaxle

Fig.3: Excerplfromschematic - 3rdaxle LT[.41220-5.1

Liebher-wei< Ehlng€n GmbB- clslomerserviceTrahing


- C -

rIIBHINR


>1.2,2Permanentlydriven axles Driveaxle (axlecannotbe steeredand is permanentlydriven)

- 2ndaxle Fig.6: ExcerptfromschematiclTl\4 1100-5.1

Steeringdrive axle (axlecan be steeredand is pormanentlydriven)

Fig.7: Excerptfromschema{c - 4thaxle LTM1070-4.1

Liebher-We*Ehingen GmbH, Customgr S6rvic6 T€ining


Fig.8: Steeringdrivea(lo

-6-

rIIBHINR

Gomponentdescription UW08 - Axleswith attachments fudu.edbywepd/fulonrsed/VeEon

>1.2.3Drive-throughaxles(axleswitchedin) Axle with intermediatedifferential (switchingin/outthe wheel-drivedrivenvia the intermediatedifferential)

Fig.9; Excerpllrom schematicLTM 1120-5.1- 4lh axle

11:Axlewiihintermediate differenlal

Fiq. 10:Axle with intermedialedifferential

Fig. 12: Overviewshowingaxle wilh intermedialedifferential Training Ehingen GmbH- Customer Seruice Liebhsr-wsrk


- 7 _

TTIBHINR

Gomponent description UW08 - Axleswith attachments

Axle with drive-throughdeactivation (switchingin/outthe wheel-drive)

Fig.13:Exceptfromschematic LTM11004.1with8x8drive- 2ndaxle

Fig. '14:Axle with drive-throughdeactivation

Fig.16:Axlewithdrive-through deactivation

ilF-<.F;

fr4*,tr 'FII' -€r-'

Fig.15:Oveaview showingaxlewithdrive-through deactivalion Liebher-w€* EhingonGmbH- CustomerSeNiceTEining


-8-

UIBIIIRR

Componentdescription UW08 - Axleswith attachments ProdGdby:wepd/Edi[on:13807/veEon:2

Axle with axle deactivation (switching in/out the wheel-drive for a downstream axle )

Fig.17:Excerptfromschematc withdrive- 3rdaxle LTI\,'| 1100-4.1

Fig. 18:Axle deaclivation

Frg.19: Overviewshowingaxle with axle deaclivalion Liebher-We* EhingsnGmbH- CuslomerSeryiceTbining

personnel service onlyfor LIEBHERR

-9-

UIBIIIRR

Componentdescription UW08 - Axles with attachments 1.3Axle drive >1.3.1Drive

Switchingsleeve Transversaldiiferentiallock Compensationbevelgear

Axleshaftwheel

Difierentialhousing

Axlehousi

Cam switch

Drivebevelgear

Connection Compressedair

Housing Axledrive

Spring Crownwheel

Driveflange

Fig.20:Cut-away viewof axledrive Liebher-WerkEhingenGhbH - CuslomerSeryiceTraining


- 10 -

lTTBTITRR

Componentdescription UW08 - Axleswith attachments

>1.3.2Wheelside Aciuationcylinder Ringgear Suspension bracket Wheelhub

Planetary wheel

Trackinglever

viewof axledrivewheel-side Fig.21:Cut-away

Training Liebher-WeR Ehinqen GmbH- qrstomorSeryice

personne OnlyforLIEBHERR service

_f

_

UTBIIRR

Component description UW08 - Axles with attachments

Brake€ctuation cylinder

Wh€el hub

\ryheelbolts Sungear Ringgear

Planetary wheel

Wheelhubcover Fig.22: Planetary drive/ brakedrum/ wheelhubcover Liebher-WerkEhingenGmbH- CuslomsrServic€Training


_n

-

rIEHRR

Componentdescription UW08 - Axles with attachments gear 1.4Differential / Compensation general >1.4.1Differential, Purpose: Whenmakingturns,thewheelson an axletraveldifferentdistancesandshouldtherefore notbe coupledtogetherin a fixedmanner. gearis to compensate the speed Thepurposeof the differential or compensation to the torque the drivewheels. differences betweenthe drivewheelsandevenlydistribute

Design: Drivebevelgear

Axleshaftwheels

Compensation bevel gears

leftaxleshaft

righl axle shaft

Crown

Compensation housing

Fig. 23: Overviewof differentialgears

Lebhen-Werk Ehinsen GnbH- ClstomersetoceTEinins


- 13 _

IIIBHINR

Gomponent description UW 08 - Axles with attachments

>'1.4.2Transversedifferentiallock Puroose: gearhasa detrimental effectif a drivewheelspinson an Forexample,the compensation lockdisablesspeedcompensation differential icy or softroadsurface.Thetransversal axle. lt is used to connect bothdrivewheelstogether betweenbothwheelson a drive the appliedtorque. whenthe speeddifferences aretoo Iargeandevenlyd;stribute Design:

Fig.28: Exampleof transve6aldifbrentiallock

lock Fig.27: Exampleof transversal differential

Fig.29: LTN41100-4.1Exampleof transversaldifferentiallocks Function: lock. Atransversedifferential lockconsistsof a standarddifferential and a mechanical Thisis locatedbetweenbothwheelson an axleand is usedas an axledifferentialtoprovidecompensation betweentwowheels. Forexample,whenmakinga turn,the outerdrivewheelwillturnfasterby the sameproportionthatthe innerwheelis turningslower. Theamountoftorquetransferis determined by the drivewheelwiththe pooradhesionto the roadsurface. (offThe lock(e.9.a clawconnection) is manuallyswitchedin duringdifficultconditions perso that the differential no longer roaddriving,iceetc.)to disable/lock the differential formsthe describedcompensation function. Liebh€r-W6k Ehlng€nGmbH- CustomerSedice TEininS

Onlvfor LIEBHERRseryiceoersonnel

- i5

_

UBIITRR


differential lock >1.4.3Longitudinal Purpose: The longitudinal differential lockblocksthe differential compensation betweenthe front and rearaxlesduringoff-roaddriving. Design:

-s30 Contact switch, Longitudinal differential lockON = 1

Fig.30:Exampleof longitudinal lock differential

Compressed air connectron Longitudinal differential

- Longitudinal Fig.31:ExcerptfromcircuitdiagramLTIV1100-4.1 lock differential

Function: A differential lockconsistsof a standarddifferential and a mechanical lock(e.9.clawcoupling),whichis manuallyswitchedin duringdifficultdrivingconditions (off-road,iceetc.). Thisdisablesthe differential and its compensation function. Liebher-wsrk Ehinqen GmbH- CustomerSeruiceTEinins _ 16 _


ITEIITRR

Componentdescription UW08 - Axleswith attachments

>1.4.4Switchingin differentiallocks Engagethe fronttransversa,differentiallock

Engagethefrontandreartm locks* versaldifferenlial Longitudinal differential lockor allwheeldrive

Engagethe reartransversaldifferential lock Man!albutton, Pressfor 2-hand operation

shouldbe engaged

Fig. 32: Switchingin lhe differentiallocks

Caution: of e.g.40 km/his aciivatedwhenthe differential a speedrestriction On someequipment (see instructions). in respective operating locksare switched Thedifferential locksshouldonlybe $witchedin whenthe vehicleis stationaryandin the followingorder(seeoperatinginstructions). Switchingsequence lock(s) 1. Longitudinal differential lock(s)rear 2. Transversal differential differential lock(s)front 3. Transversal

* = option Lisbhotr-WelkEhingenGmbH- CuBtomerSetui@Training


- 1 7-

lTIBIIIRN

Componentdescription UW 08 - Axles with attachments 2. Retarder 2.1Telmaeddycurrentbrake >2.1.1Purpose Assiststhe normalservicebrake.The powertrainis brakedby the generatedelectromagneticfields(eddycurrents). >2.1.2Design Ex. TelmaFocalF2200: (fittedto last axle) - electro-magnetic Telmaretarder - friction-free, wear-free - silentrunning, maintenance friendl, - shortresponsetimes(350ms) - braking powerdependent on enginespeed Fig.33:Eddycurrentbrake

Electrical connect'on (4-stage)

Airgap

Coolingblade

Rotor (softirondisc)

Rotor (softirondisc)

Driveshaftflange Fig. 34: llluslrationshowingprincipleof eddy cuffentbrake Liebher-Werk Ehingen GmbB- Customer SeruiceT€ining


- 18 -

ITIBHIRR

Componentdescription UW 08 - Axleswith attachments fudmedby:|wepid/Edfoi13'@07/VaEon:

>2.1.3Function Rotors

The rotorsare firmlyattachedto the dfiveshaft.

The statorbehveenthe two 2 rotorsis iirmlyaf tachedto the axle.

to the Thecoilsareattached polarity: statorwithalternating plus- minus,minus- plusetc.

ThestagesontheTelmaareusedto excitetheopDositecoils.Thiscausesmorcor lesscunentto flow Amagneticfieldis createdwhich throughthecoi19. penetratesbothrotors.

Sincethisbrakeconvertskineiicenergytoheat, Themagnetic fieldinducesoddycunentswhich brakethe rotors,driveshaftanddriveaxlewheels the rotorsarefittedwithcoolingribsandfan blades. Tlaining Liebher-werk Ehingen GFbH- Customer S€ryice


-19-

IIIBITTRN


>2.1.4Actuation lf an eddy currentbrake is fitted,it can be switchedon by pullingback the "steering columnswitchright"and increasing the brakinglevelin severalstages (seefig.2).

- 9 0

; <

Fig.36: Rightsteeringcolumnswilch

r

Fig. 35: Switchingin the retarderbased on lhe exampleof LTI\,I1100-4.1

data >2.1.5Technical TelmaFocalF2200; Voltage Max.braking torque gap Nominal air Current levelStage1 Stage2 esak) Stage3 Stage4 per currentcircuit Resistance (20'c r 5%) per coil Resisiance (i5%) Weight Dimensions

24V 2200Nm 1 . 4m m 274 54A 8'1A 107A 0,732A 0,364c) 174kg 5 1 0x 5 1 0x 2 4 0m m

L ebher-WerkEhingenGhbH - CuslomerSeryiceTfainng


- 20 _

ITIBHIRR


UW10-Partl-Steering

personnel OnlyforLIEBHERR Service

Componentdescription UWl0-Part1-Steering

Llgbhor-WerkEhingonGmbH- T€chni€l Laining


-2-

lIBHRR

Componentdescription UW10-Partl - Steering

!l€bh€r-W€( EhlngenGmbH- Techni€l haining

Onlyfor LIEBHERR Servicepersonnel

-3-

TTEHINR

Componentdescription UW10-Part1-Steering

Liebhen-Werk Ehing€nGmbH- T6chnlc6ltralning

Onlyfor LIEBHERRServicepersonnel

-4-

UBHTRR


Frontaxle steering

UWl0-Part1-Steering 1. Steering >1.1General steering,mobilecranesare alsoequippedwithhydraulic Apartfromtheirmechanical power-assisted steering. of dual-circuit steeringsystemswith3 pumps(steeringcircuitl, steering Theinstallation vehicleswith on commercial steeringpump)is mandatory circuitll andemergency severalsteeredaxlesin orderto complywithstatutorysafetycriteriawhilstalsoimproving independent by two completely highlevelof safetyis underlined steeringcomfort.This eachotherduringnormaloperation. steeringcircuitswhichcomplement

Ddveshaft

Steeringrod

Steedngarm

Remolesteeringmotor

Steeringgear

fle rod

Steering cylinder Steeringarm steering Fig. 1:lllustration showingpdncipleof tront-axle Liebhen-werkEhingenGmbH- T€cbni€l lEining

personnel Service OnlyforLIEBHERR

- 5 i

lIEHINR

Gomponentdescription UW10-Part1-Steering

>1.2SteeringcircuitpumpsI and ll Purpose: Thesteeringcircuitpumpssupplypressureto the hydraulicpower-assisted steering for thefrontaxlesteeringcylinders. Design: pumpHaldexBamsGmbH e.g-double-gear WPl5A2B330330-Anti-clockwise rotalion pumpsteeringcircuit1 and2 Hydraulic

Fig.'1:SteeringpumpsLTt41400-7.1

Fig.2:Principle ofa gearpump Fig 3l.ut-awaymodelofagearpump Function:

SteeringcircuitpumpsI and ll aredirectlyattachedto the engine.Theyare drive-independentandsupplythe requiredpumppressureto the steeringcylindersvia the steering gear.Thishydraulically assiststhe steeringmotion.

Liebheir-W€rk Ehing€nGmbH- Techni€l tEining

personnel Onlyfor LIEBHERR Service

-6-

ITIBHIRR


Front axle steering

UWl0-Part1-Steering

steeringpump >1.3Emergency Purpose: ofthe steeringpumpis to ensurethe steeringcapability The purposeof the emergency pump 2 has failed. engine or steering craneevenwhenthe Design:

steedng Emergency pump,radialpiston pump

steedng Emergency pump, Gearpump sauei DanfosssNP 3/44DSC07

steeringpump Bild2: Emergency LTMl100-4.1

Fig.1: Emergency steeringpump LTM1400-7.1

Function: of the Theemergency sleeringpumpis fittedto the transfergearboxor the drive-side transmission. steeringpumpwillcontinueto The pumpis wheeldriven.Thismeansthatthe emergency pumpoil evenwhenthe engineis turnedoff,providing the craneis movingforwards. on the speedofthe crane. The pumpoutputis thereforedependent pump oil from the emergency steeringpumpis directlydiverted lf steering ll is driven,the to the tank. Steeringpumpll will notoutputanyoil whenthe engineis turnedoff.Theemergency pumpsupplies circuitll. steering oiltosteering Highspeed

+

Lowspeed

+

highp'.rmp speed lowpumpspeed

+

steering highlevelof power-assisted

+

lowlevelof poweFassisied steeing

\J/

Liebhetr-Werk EhingenGmbH- Technicallrainhg


TIEIIIRR


Front axle steering

UW10-Part1-Steering

>1.4 Flow rate indicator Purpose: Flowrateindicator(-S118)is installedin steeringcircuitI and monitorsthefunctionof steeringcircuitI andsteeringpumpl. In caseof a fault,the cabwarninglightfor steering circuitI willbe lit. Design:

-Si18 Fig. 1:Flowindic€tor

Fig-2: Excerptfromhydraulic schematic for chassi6:

Fig.3: Excerptfromelectrical schematic for chassis:

Function: Theflow rateindicatorincludesa contactswitch(normally-closed). lf the oil flowdropsbelowa certainrate,the contactswitchwilltrip andthe cabwarning lightfor steeringcircuitI is lit. Waminglight SteeringcircuitI pump) (Steering

m ug4 EI

Let

Etr

n4 HI

Fig.4:WarninglightsieeringcirculiI LiebheB-Werk Ehing€nGmbH- Techni€l lrain ng

OnlyforLIEBHERR Servicepersonnel

-8-

I.TTEIIRR

Componentdescription UW10-Partl - Steering

/ supporting >1.5Multiwayvalveoil supplyaxlesuspension PurDose: The multiwayvalve-Y5 setsthe dil flowof the steeringcircuitpumpll freeto the axle suspension / supporting.

valve 4/2 '1= Mulliway / supporling axlesuspension 0 = Steeringboosterofthe frontaxle

Design:

-MP2O point, measuring pressure of thepump steeringcircuit2

valvesteeringboosterLTl,l1100-4.1 fig. 1: I\rulliway

flowcontroller 20 l/min

fig 2: Exceapt fiomelectrical 6chematic N,lultiway valve- LTIV1100-4.1

Function: the hydraulicoil of the steeringcircuitpumpll is lf the4/2 multivalve-YSis notactivated, whois integratetd in releasedto supportthesteeringof the frontaxle.Theflowcontroller, theMultiway valve,limitsthedilflowto 20 l/min. the hydraulicoil of the steeringcircuitpumpll is lf the4/2 multivalve-Y5 is activated, / supporting. releasedto the axlesuspension Liebhed-Wei
personne, OnlyforLIEBHERR Service

_g _

ITIBIITRR


Frontaxle steering

UWl0-Partl - Steering

>1.6 ZF-valveblock 7760with flow rate indicator,sequencevalve and DBV Purpose: Flowrateindicator(-S119)is installedin steeringcircuitll and monitorsthefunctionof steeringcircuitpumpll or the emergency steeringpump. lf a faultoccursin steeringcircuitll (auxiliarysteeringpump),the warninglighton the cab displayunitfor steeringcircuitll will be lit. Design: (P2) Connection Emergency steeringpump

Contactswilch-S119

(T)to Connection IANK

Nozzle (Pl) Connection Pumpsteering circuitll Non-return valve (blocksthe oil return fow)

Pressure limitingvalve (150bar)

'1:ZF valve block

Connection(A) to steennggear

Pl

Pumpconneclion for steering circuitll P2 Emergency steeringpump connecaon A Sleeringgearconnection T Oil boxconnection 1 Sequence valve 2 Flowrateindicalor limitingvalve 3 Pressure (150bar) 4 Non-retum valve Fig.2: Cut-away modelZF valveblock7760 Liebhetr-Work Ehlngen GmbH- Techni€ltraining

personner OnlyforLIEBHERR Service

- 10-

TTEHIRR


Front axlesleering

UW10-Part1-Steering

5 C H L, jT rE l t e a

-:Ll9

Fig.4i Excerptfrom hydraulic schematicfor LTIM1100-4.1

Fig.3: Exceptfromelectrjcal schematic for LTM1100-4.1

Function:

,.8)

Warninglight Steeringcircuitll steeringpump) {auxiliary

q@GEE@ trdF;Jt tffit ffil steeringpump) Fig.5: Warninglightsteerjngcircuiill (auxiliary

pumpll to steering Thevalveblockhousing contains a control slidevalvewhichconnects correctly. steeringcircuitll providingit is functioning steeringpumpto the oil boxvia the returnchannel. Theoil flowsfromthe emergency lf the mainoil flowrateof steeringpumpll dropsbelowa certainlevel,the controlslide pumpto steering circuit... steering valveclosesandconnects theemergency steering Theelectricalcircuitof theflowrateindicatorwill be closedif the emergency pump pumpfailsor thereis reduced lightfor steering ll.Thewarning oilflowthrough pump pump)willbe litto signalthefailureof steering steering circuiill (auxiliary steering pump. ll or theemergency steering Liebheir-Werk EhingenGmbH- fechnicallEining


_f

-

UIBIITRR


Frontaxle steering

UW10-Part1-Steering

>1.7ZF half-blocksteeringgear7421 Purpose: The purposeof the half-block steeringgearis as follows: . Hydraulicpower-assisled steeringfor mechanical steeringmovements . Steeringstop(pressurereductionin hydrauliccircuitbeforewheellockis reached)

Note; The half-block steeringgearis fittedin craneswith3 or moresteerablefrontaxles.

ZF half-block Steeringgear 7421

Fig.1: Dual-circuit designwithmechanic€l steedngstop

Advantage:

Highoil flowmakingit suitablefor "largemachines"

Disadvantage:

Expensive as it is manufactured in lowquantities.

Liebheii-WerkEhingenGmbH- Techni€l Laining


UEIIRR

description Component UW10- Part1 - Steering

Design: steeringgearhousingincludesthe steeringvalvesas wellas the entire TheZF-half-block steeringgeat Twohydrauliccontrolvalvesbeforeand afterthe steeringnut mechanical are centrallyalignedwiththe steeringspindleand attachedto the steeringgear.Poweris ballthreadontothe steering fromthe steeringspindlethrougha recirculating transferred mechanism. nutwhichin turntransfersit to the segmentshaftvia a cog systemsis onlypossiblevia the hydro-steering steeringfor half-block Power-assisted externalsteeringcylinder

screw(wo|m)

sleerlngnut

Stee ngspindle

Segmentshaft (sectorshaft)

Fig.2: Cul-awayview ofa duaFcircuitdesignwith mechanicalsteeringstop

Fig.3: Excerptfrom schematic:hydrauliccontrol Pressurisedair systemFig. LT[,41400-1

Li6bhen-We*EhingenGmbH-Techni€ lra ning


- 13 -

ITIBHIRR


Front axlesteering

UW10-Part1-Steering

Dual-circuitsteoringsystemwith 3 pumps:

Steeringcircuitll

SteeringcircuitI

10 5 2 10

Sleeringspindle tumsin clockwisedirection

Fig.4:Steeringcircuitpumpsrunning

1 Steering circuitpumpll (Worm) 2 Screw 3 Valveblock7760 a b c d

(S119) FIN mteindicaror Sequene varve Noni€lumlalve Non-eiumvalve

7 Steeringspindle 8 Oilbox 9 Steering circuitpumpI 10 Pressure limitingvalve 11 Flowrateindicalor(S'118) 12Wo*ing cylinder '13Segmentshafl

4 Replenishing valve 5 Steeringnut 6 Emergoncy steeringpump

Liebher-W€rkEhingenGmbH- T€chnlcaltralning


ITEIIRR

Component description UW10-Part1-Steering

Steeringcircuitll

Steedng

1'l

10

5 2

10

Steering spindlotumsin clockwise direction

Fig.5: Emergency sleeringpumprunning(enginehasstopped) 1 Steering circuitpumpll 2 Screw 3 Valveblock7760 a b c d

Fl@ Ete indic€ior(S119) Sequencevalve NoMetun €lve Non-ellln valve

7 Steedngspindle I Oilbox I SteeringcircuitpumpI '10Pressure limitingvalve (S118) 1'1Flowrateindicator 12Workingcylinder 13Segment shaft

4 Replenishing valve 5 Steeringnut 6 Emorgency steeringpump

lraining Liebher-W€rk Ehlng€n GmbH- Tschnic€l


- 15 -

UEIIRR


Frontaxle steering

UW10- Part'l - Steering

Workingpipe Wheellockright steeringckcuilI

WorkingpipeWheellock pipe leftsteering circuitll (connection 3) Working wheellock righlsteering circuit Workingpipe (connection4) Drive mechanical 11 (connection 4) (steering Wheellocklefl ourpur steedngcircuitI (segment shaft) t-..1,,:) (connection 3)

X

l a n Kr e l u r n - ' Sleeringcircuit

| (connection 2)

.

Tank retun = Steeringorcu

. ,/

/

|

2) {connection

-MPl -MP2 DBV Pumpinlet Pumpinlei pEssureWod{ng pressure Steeringcircuitll Steeing circu t I Steering circuit Working point fconnection1) measurement | (connection 1) measuEmentpoirt sleering circuitL steennq circuitll

Fig.6: Component (clockwise overview- half-block steeringgear- clockwise screw)

Caution: On anti-clockwise steeringgears,the rightand Ieftwheellockconnections are swappedover. Workingpipe Wod(ingpipe wheellock leftsteeringcircuit ll (connectjon 3)

righisteering circuit ll (connection 4) p inlet

i'i"ilXff[T'lr] mechanical

output (segment shaft) Tankreturn Steering circu+r (COnnecton

DBV Steeringcircujtll - half-block Fig.7: Componenl overview (clockwise steeringgear- clockwise screw) Ll6bher-WerkEhingenGmbH- Technic€llraining


- lO -

UTBIIIRR

description Component

Frontaxle steering

UW10-Partl - Steering

Note: Thereare clockwise and anti-clockwise steeringgears.The typeuseddependson position the insiallation of the steeringgearand the arrangement of the steeringlinkage.

Fig.8: Examploof steednggear- clockwise, exce@tfromcircuitdiagramLT[,11400-7.1:

g6ar- anti-clockwise, excerptfromcircuitdiagramLTI\41'l00-4.1: Fig.9: Exampleof st66ring Liebher-W€* EhlngenGmbH- Technicaltaining


- 1 7-

UBHINR


Front axle steering

UW10-Part1-Steering

Function: In orderto maintain hydraulic assistance duringthesteering movement, the screwand boihits connected valvebushingsmustbe movedfromtheirneutralposition. Thescrewis heldin the neutralpositionby cupsprings.A forcemustthereforebe applied to overcome thepre-tension of ihe spring. Thesteeringnuttogetherwiththe segmentshaftandsteeredwheelscounteracts any rotationalmovement. Whensteering,poweris transferred fromthe steeringspindleihrougha recirculating ballthreadontothe steeringnutwhichin turntransfersit to the segmentshaftvia a cogmechanism. Thesteeringnut is movedbackandforthby this rotationalmovement causing thesegment shaftto turn. Thecontrolvalveis locatedinsidethe valvehousingandcentrallywith respectto the steering spindle.The rotational motionof thescrewspindle willcauseaxialmovement (backandforth)of the controlvalve.Thissetsthe controledgesin sucha way thatthe pressurised oil entersthe workingcylinderchamberfromthesteeringpump. Releasing thesteeingwheelwillcausethevalveto springbackto itsnormalposition; the returnflowis thereforemaintained. Themechanical steerjngstoppreventssteeringintothe wheellockpositionsat full pressure. hydraulic Thisprotectsthe kinematicsteeringcomponents frombeing stressed.The mechanical steering stopis adjusted usingihe collarson thesteering gear. spindle of thesteering

Liebheii-WerkEhlngenGmbH- Technicalt€ining

persornel OnlyforLIEBHERR Service

- 18 -

ITIBHIRR


Frontaxle steering

UW10-Part1-Steering

Checking and adjusting the mechanical steering stop: (anti-clockwise steering gear) Tesl procedure: Slightlyrelievethe loadon the steeringaxles(liftusinghydr'support)- Tyresmuststill be touchingthe ground. Turnthe steeringwheelin the'right"directionwiththe enginerunninguntilyoureachthe wheellockposition. expectedvalue= I - 3 mm. Checkthegap(play)on thewheellockcomponents. The"left"steeringdirectionis checkedin the samemanner'

. . . .

Adiustmentprocedure: 't. 2. 3. 4. 5.

Slightlyrelievethe loadon the steeringaxles(seetestprocedure). Withthe enginerunning,turnthe steeringwheelto the .ightandjust beforethe pointof usea spacerto maintaina gapof2 - 3 mm). wheellock(if necessary willreturnby approx.'l14 Turnoffthe engineandreleasethe steeringwheel(steering steeringwheetturntowardsthe neutralposition). Removeshoulderscrew(A)whenthe engineis tutned off . Note:Collectanyescapingoil. ring('1) Pointa spikethroughthethreadedholefor shoulderscrew(A)to turnadjustment againstthe directionof steeringwheelrotationuntilthe lipson all the rings (2 and3) arealigned.

design Fig. 10:Steednggear-antitlockwise,

d€wing cut-away Fig.11:Steeringgear- anti-clockwise,

Liebher-Werk Ehingen GmbH - Technical fiaining

-19-


ITIBHIRR

Gomponent description

Frontaxle st€ering

UW10- Part 1 - Steering

Adjustmentring1

Adjustment ring4

Fig.12:Half-block gear-Adjustment steering

Adjustingthe right end-position:

Adjustingthe left end-position:

smallersteering Hexsocket headspike

I HexsocketI headspikeI I V

l#;

7.

for largersteering

Up for largersteering angle Downforsmaller steering angle

In thispositionturnbackthe steeringwheeluntilshoulderscrew(A)canbe screwedintothe nextholeon the adjustment ring(1). Screwin the shoulderscrew(A)andnewseal. The leftwheellockis adjustedin thesamemanner,aftershoulderscrew(B)and adjustment ring(4)havebeenunscrewed. The lipson rings5 and6 mustbe aligneo.

Note: lfthe mechanical steeringstopcatcheswhenthe maximumsteeringangleis reached,the hydraulicpower-assisted jresJrre). steeringwillfa to ca. i0 bar(circulation

TechnicalinformationZF half-block hydro-steeringtyp€ 7421 see manual8905090 08 Li€bher-W€(Ehingen cmbH- Techni€ttraining

OnlyforLIEBHERR personnel Service

-20 -

UEIITRR


Front axle steering

UW10-Part1-Steering

>1.8ZF Servocomsteeringgeartype 8099 Puroose: The puposeof the Servocomsteeringgearis as follows: . Hydraulic power-assisted steeringmovements steeringfor mechanical . Steeringstop(pressurereductionin hydrauliccircuitbeforewheellockis reached)

Note: The Servocomsteeringgearis fittedin craneswithlessthan3 steerablefrontaxles.

Design:

in compactdesign) Fig.1: Cut-away viewZF Servocom steeringgear80gg(ballnuthydro-steering

Advantage:

production. dueto high-volume inexpensive

Disadvantage:

lowoil flowmakesit onlysuitablefor "smallmachines".

Liebheir-Werk EhingenGmbH- Techni@ltGining


-21 -

UBITIRR


Frontaxle steering

UW10-Part1-Steering

TheZF-Servocom dual-circuit housingincludessteeringvalves,a working cylinderandthe completemechanical steeringgearmechanism. Bothsteeringvalvesconsistof the rotaryvalvesinsidethe screwwith6 controlgrooves and2 controlsocketseach. Atorcionbar,whichis drilledand bracedto the rotaryvalveandscrew,keepsthe steering valvesin the neutralpositionprovidingno counter-force is appliedto the steeringwheel.

Steeringspindle

Hydraulic steeringstopvalves steeringcircuitI

Hydraulic steeringstop valves steeringcircuitI Hydraulic ste€ringstopvalves steeringcircuitll

Fig.2: Cut-away modelof Servocom steoringgear

i

r

Fig.3: Excerptftomschemstic: Controlhydra!lic pressurised airsystemMK 100(anti-clockwise) Liebher-W€rkEhlng€nGmbH- Techniel irainlng


-22 -

rIBHRR


Fronl axle steering

UWl0-Part1-Steering

Workingpresu re measuremeni

Workingpiperightwheellock Workingpressu- output circuit| (connection 2) re measurement(s€gment shafr) Thesegment shaftcanalsobe insertedfromthe otherside.

pointsleedng

pipecircuitll

Tankreturn Circuit ll

Workingpiperight wheellockcircuitll (connection 22)

Replenishing Oil replenishment

screw): Fig.4: Overview- steeringgear - anli-clockwise(anti-clockwise

Gaution:f gears,the rightand left wheellock connections a re swapped steering On clockwise over. hydraulic sleeringstopckcuitli (rightsteering direction)

WorkingpipeleftwheeltocK 1) circuit| (connection

Replenishing

Oil repleni menlsteering circuitll

/

Tankreturn Circuitll

Drive (steering wheel)

Fig. LTM1080-1

hydraulic steering slopcircuitI (rightst€eringdirection) .MP4 hydraulic steerjngslop Workingpres- circuilll (leftsteering suremeasure- direclion) mentpoint

Workingpipe leftwheellock ckcuitll steeringPump (connection z1) hydraulic stopcircuitI (left pressure steeringdirection)pipe circuitI - steeringgear-anti-clockwise (anti-clockwise screw): Fig.5: Overview L ebhen-WelkEhingenGmbH Techni€l iEining


-23-

IIIBIIIRR


Front axle steering

UWl0-Part1-Steering

Dual-circuitsteeringsystemwith 3 pumps(clockwise):

Fig.6: Steedngcircuitpumpsrunning: '1 Steering circuitpumpll 2 Sequenca valve 3 Valveblock7760 4 Conbolvalvo1 5 Wo*ing cylinder pump 6 Emergency st€€ring (S119) 7 Flowrateindicator 8 Oil box I SteeringcircuitpumpI 10Oil box 11 Flowrateindicator (S118) U€bher-WerkEhingenGmbH- T€chnlc€tl€ining


12 Controlvalve2 '13Workingcylinder l4 Steedngstopvalve 15 Ringgrcove 16 Ringgroove 17 Pistonpos;tion indjcator 18Segmentshaft 19 Hydraulic steeringstop 21 Piston 22 Steeringspindle

-24-

IIIBHINN

Componentdescription UW10-Part1-Steering

pumprunning(enginehasstopped) Fig.7: Emergency sLeering 1 Steedngchcuitpumpll 2 Sequence valve 3 Valveblock7760 4 Controlvalve 1 5 Workingcylinder 6 Emergency steeringpump (S119) 7 Flowrateindicator 8 Oilbox I Steering circuitplmp I 10Oilbox (S118) 11 Flowrateindicator

Ll6bh6tr-W6rk Ehlng€nGmbH' Techni€l tEining


12 Controlvalve2 13Workingcylinder 14Sleeringstopvalve 15 Ringgroove 16 Ringgroove '17Pistonpositionindicator 18 Segment shaft 19 Hydraulic steeringstop 20 Screw 21 Piston 22 Steeringspindle

-25-

UBHINR

Gomponent description

Front axle steerino

UW10-Part1-Steering

Funclion: Theforceis transferred fromthe steeringwheelviathe steeringspindleand screwonto the steeringnut.Thisin turntransferstheforcethroughthe segmentshaftandsteering gearsandontothewheels. Turningthe steeringwheeldeformsthe torsionbarwithinits elasticrangecausinga twistingactionbetweenthe rotaryvalveandthe controlsockets. Thiscauses thepressurised grooves oiltoflowintothering-shaped on thecontrolsockets. Threesymmetrically arrangedradialopeningsallowthe oil to reachthe circularcontrol groovesfor the innerrotaryvalve.Whenthe valveis in the neutralposition,it flows throughthe entryslitsand intothe axialgrooveson the controlsocket. Fromiheretheoil reacheseachsideof ihe workingcylinder. Bothsteeringvalveswill regulatea predeJlned oil flowto the steeringcylindersdepending on the requiredsteeringforce.Thisis fullyindependent in twoseparatepipecircuits. piston Thesteeringassisiance is controlledby oneof the twosteeringvalves. Theothersteeringvalveopensthe pathfor the oil to provideexternalassistance using oneor moresteedng cylinders. Theactuatedsteeringcylindertherebyassiststhe mechanical sieeringmovementand reducesthe amountof effortexertedby the cranedriverduringsteering. Steeringcircuitll is usedto supplythe Servocomas wellas a separatesteeringcylinder andassumes thesteering function duringnormaldriving operation. SteeringcircuitI suppliesone or moresteeringcylindeIsand is completely shutoff by fullyclosing thereturnslitswhensteering at standstill. Oncethe desiredwheelpositionshavebeenreached,the controlvalvesare returnedto theirnormalpositionby the torsionbar and blocktheflowof oil to the steeringcylinders. Bothsteeringcircuitsare fittedwitha hydraulically adjustable steeringstopto protectthe gear,wheellocksandsteering pumpsagainstexcessive steering loadat themaximum steering angle. Theadjustable steeringstopvalvesin the housingallowa reducedapproachto the steeringend position. The steeringstopvalvesin steeringcircuitI are actuatedby the pistonmotionbeforethe adjustment screwreaches thepistonendposition. In contrast,the steeringstopvalvesin steeringcircuitll are openedby a camon the segmentshaft. As soonas the sieedngstopvalvehasopened,the steeringcan be turnedin furtherwith increasedeffortandsignificantly reducedhydraulicsupporito the wheellockor steering position. stoD

Liebh€r-WerkEhingenGmbH- Technl€l training


-26 -

lTIBTITRR


Frontaxle steering

UW10-Part1-Steering Checkingand adjustingthe hydraulicsteeringslop: (steeringgear- anti-clockwise) Testprocedure: presskeysE + E) andlockthe (simultaneously to "NIVEAU" 1. Movethevehicle presskeysfc j + ffi). (simultaneously axlesuspension (keyW ) to automatically liftthecraneand 2. Usetheoperating unitforthesupport alignit horizontally. pointsl\,44 (steering circuitl) andM5 (steering a manometer to measuring 3. Connect gear(pressure up to 250bar). circuitll) on thesteering without applying anymajoreffortto the turnthesteering 4. Withtheengineidling, is reached, Oncethewheellockposition rightor leftwheellockposition. brieflycontinueturningthe steeringwheelto overcomethe returnforceof the steeringvalveuntilthefixedsteeringwheellockpositionis reached.Thesteering wheelshouldbe heldin thisposition. mustnowbe lf the steeringstophasbeencorrectlyadjusted,the manometer permitted). pressure (approx. 40 to 90 bar are of ca.50 bar indicating an oil lf the measuredpressureis too highor low,the pressuremustbe corrected screws1 to 4 (see steering stopvalvesor adjustment usingthecorresponding nextpage)as describedbelow Note: SteeringcircuitI mustbe adjustedbeforesteeringcircuitll on all cranesJlttedwith Servocomsteerino.

Adjustmentprocedure: 1. 2. 3. 4. 5.

6. 7.

turnthesteering fullyto right. As described in point4. (seetestprocedure), screw screw1 andscrewin/outadjustment Removetheflxingnutfromadjustment directions andanti-clockwise 1 if the pressureis too high/low(clockwise respectively). turnthesteering in step4. (seetestprocedure), Thenproceed as described fullyto the left. screw2 andseta pressure of 50 barusing Remove theixing nutfromadjustment screw2, as describedin step2. adjustment whenfully againin a righvleft direction andcheckthepressure Turnthesteering screws1 turnedin. lf necessaryre-adjustthe pressureto 50 bar using adjustment or 2. Repeatthis processseveraltimesuntilthe pressureremainsconstantat ca. 50 bar. There-tighten screws1 and2. thefixingnuton adjustment to thosefor circuitll aremadein a similarmanner Theadjustments forsteering screws3 (rightsteeringdirection) steeringcircuitI by screwingin/outadjustment and4 (leftsteering direction).

Liebheff-Werk Ehngen GmbF -Techni€ lraning


-27.

UIBHIRR


Front axle steering

UW10-Part1-Steering

Adjustmentof left wheel lock steedngcircuit1;

Adjustmentof right wheel lock steeringcircuit1: out (more € pressure)

tn (tess pressure)

tn

(less

<-+

pressure)

Iool: Size14 open-ended

I (hydraulic steeringstopcircuitl, rjghtsteeringdirection)

out (more pressure)

Ppanner Specialtool Size 5 Allen key

2 (hydraulic steedngstop circuitl, leftsteeringdirection)

Fig.8: Servocom adjustment 4 (hydraulic steering stopcircuitll, leftsleeringdireciion)

Adlustmentof left wheel lock steeringcircuit 2: tn Ilaee nra.e,,.6\

A I

3 (hydraulic steeringstopcircuitll, nghtsteeringdirection)

Adjustmentof right wheel lock steeringcircuit 2: in

Tobla Size19open-ended spanner Size10open-ended spanner

pressure)

TechnicallnformationZF Servocomtype 8096and 8099 seemanual890510508

*

A

II

Y out (morepressure)

Liebhstr-Werk Ehingen cmbH- T€chni€tlraining


-28-

out (morepressure)

ITBIITRR


UW10- Partll - active rearaxlesteering

Onlvfor LIEBHERR Serviceoersonnel

Componentdescription UWl0 - Part ll - active rear axle steering b':|repid/fuhon120207/V3cion2

Li€ihsr-W€d( Ehingen GmbH- T€chnlcal lalnlng


-2-

UEHINN

Componentdescription UW10- Partll - activerearaxlesteering

Liebheii-Werk Ehingen GmbH - T€chni€l lrainlnq


_3 -

rIuftnR

Componentdescription UW10- Part ll - active rear axle steering )1. 1. General In orderto improvethe turningcharacteristics and minimisetyrewear,all newcranes do notmechanically lock(pin)the steeringfor the rearaxles.The rearaxleson mobile craneswith rearaxlesteeringare steeredelectro-hydraulically and speed-dependentj this is lockedto straight-ahead at speedsaboveapprox.25 km/h(dependson particular model). Variouscomponents are builtintothe activerearaxlesteeringto providethe highestdegreeof safety. Theseensurethatthe steeredrearaxlesare automatically posiresetto a straight-ahead tionwhena faultoccurs. Activerearaxlesteeringwasfirstfittedon LTNI1090-3(LTM1'100-4.1) mobilecranesin summer2003-

Advantagesof activerear axlesteering: . Smallturningradiusfor roaddriving . Lowtyrewear . Perfectlyadjuststo the drivingsituation . Highestdegreeof safety . Simoleooeration

Lrebher-Werk Ehingen GmbH-Tschnic€l training


-4-

UIBHINR

Gomponent description UWl0 - Part ll - active rear axle steering

X.l Layout St€srlngaxles:

1staxle 2hd axle

3rd axle 4th axle

;"::,"::",}

Axleswith BoschCAN proportional valves

Fig.'1:Rearaxlesbasedon exampleof LTM1100-4.'l

uebheF-we* Ehing€nGmbH- Technlcaliraining


-5-

rlEHINR

Component description UW10- Partll - activerearaxlesteering

>1.2Steeringprograms(onlyon craneswith 4 axles) P1 Roadsteering Axles1 and2 are mechanically steered usingthesteering wheel(hydraulically assisted).Axles3 and4 are "activelv"steered at speedsup to 30 km/h(speed-dependent) anddepending on thesteering angleofthe frontaxles.At speedsabove30 km/hthey poare set and lockedin the straight-ahead sition. Altering thesteering angleas a functionof the speedprovidespreciseandstable drivingbehaviour at highspeeds, tyrewear is reduced andmanoeuvrability is significantly improved. P2All-wheelsteering Axles3 and4 are steeredin proportion to the steeringangleof the 1staxleto provide possible thesmallest turningradius,max. driving speed20 km/h. P3 Crabsteering Axles3 and4 are steeredin the samefashionas axles1 and2 viathesteering wheel, max.drivingspeed20 km/h.

P5

P4 Steeringwithoul swing.out Axles3 and4 aresteeredin proportion to program Fig.2:Sleering fora 4-axle vehicle thesteering angleof the 1staxleso thatthe rearof ihevehicledoesnotswingout,max. drivingspeed20 km/h. Note; . lf a faultoccurswiththerearaxlesteer P5 Independent rearaxlesteering ing,it is disabled andlherearaxlesareeiAxles3 and4 are steeredusingkeysinde- therblockedto preventfurihersteeringor pendentlyof the steeringanglefor axles1 set straightusingthe centeringcylinders and2 anddepending on whethercrabsteer- . Twoindependent hydraulic circuits with ingor turningis required, max.drivingspeed wheel-driven andengine-driven hydraulic 20 km/h. pumpto provide ihe highest degreeof safety P6 Rearaxle steeringlocked* Axles3 and4 cannotbe steered.

* = device-dependent (onmobilecraneswithup to 4 axles) Lr"bh"r-Weh Ll'i19enCmol . scl-n,(dl.cinng


-6-

lTIBIIERR


>1.3Summaryof speedswith LTM1100-4.1

EI = (

* [

sle€ringangl€oi st€€ring ane LA2to kegrees.

hydEUli€llyclampedo.

Permiltedspeedin travelprogramPi Roaddrivlrg

E (E Y

Pemitled speed for travel

6

50

g0vin Km/h

Note: on thetypeof mobilecrane. Themaximum speedsaredependent

Liebhetr-Werk EhingenGmbH- Technicaltraining


UBHIRR

Componentdescription UW10- Partll - activerearaxlesteering 2. Steeringcircuit >2,1 Componentoverview- Steeringcircuit

Conkolling"lndependenlsteeing P5"

Pl - Pq fSteeringprograms

Controllight,rearaxlesteering-On

f f i @ t r @ @ @ @lrllrl q@@tr8@@ E E

F-dF,{I rEr ffir Steering progGms fo. active rear axle st€€ring ?1= R o a dd i v i n g (dependenton WG!B50 and drivinsspeed) P2= Alwhee steeing {dependenlon WG|B5o, speedlimlted) P3 = Crab stee.ing(asfor BA2) P4= RedLrced swing oul rat€ (as for BA2) P5 = Independentsteering (speedlirnlled) PO= Sieerinolockedin centrcoosition

I LrccoN rssr'(ow)

EAM2 Addr.3

EAM5 Addr.6

EAM1 Addr.2

Var displ.pump

HA-steering

Steedng cylinder

'tAtl, a *Addt "

,ffi

-850/ anglesensorlst axle (inputfor actjverearaxlesteering) Liebher-WerkEhingenGmbH- TechnicaltEining


-8-

-B52 Anglesensor 4th axle

Angle sensor 3rd axle

UTBIITRR

Componentdescription UW10- Part ll - active rear axle steering

>2.2 Pumpactive rear axle steering Purpose: pumpsupplies hydraulic oilto the the steerinqcircuitfor the active Therearaxlesteering rearaxlesteering. Design: as a pumpwithswashplatefor usein opencircuits. Theaxialpistonpumpis designed Therotation angleis fullyadjustable.

-D22 Axialpistonpumpfor rear axle steering\ A1OVO28.DFR1

N,4odel 3 1(incl.loadsensing function)

-MP7 point, lVeasuring P1'lPump rearaxlesteering

Nozzle/ filter combination, Nozzle0.6 (coldweather

Theso-calledcoldweathernozzleis usedto artifipressure by 10 bar This ciallyincrease thestand-by allowsthe pumpto operatequickerat coldoutdoor temperatures. Fig.4: Excerpt fromcircuitdiagrarn LTlt41100-4.1 Liebher-we* EhingenGmbH- Techn€llbining


-9-

lIIBHTNR

Component description UW10- Part ll - activerearaxlesteering

DFRl Al OVODFR1 Baureihe 31

DFR/DFR1

-a:r-], [::pressure Leakage HighpressureLowpressure Suction oilpressure Set pressure Fig.5: Cufawayview- Pumpactiverearaxlesteering AloVO / DFRl

Function: Thepumpis equipped witha flowregulator thatallowsload-dependent regulation of the pressure pump operating (loadsensing function). The flowrateregulates itselfaccording to theload. Theflowrateregulator is adjusted to ensurethatthepumppressure is alwayshigherthan pressure. themaximum operating lf thereareseveral loads(steering axles),shuttle valvesareusedto determine theprespressure. pump sureof theaxlewiththehighest load Thisis indicated to the flowrate regulator viatheloadsignalIineX. Therotation angleis thenregulated so thattheflowrateis adjusted to the axlerequirement. Theflowrateregulator thencontrols thepumpto opposethe pressure pressure flowto occur. causing Theflowrateincreases untilthedifferential set on thepumpregulator is reached. Thismeansthatthe systemalwayshasa certainpowerreserveoverthe loads. Thediflerencebetweenthe loadpressureand pumppressureis alsoreferredto as the stand-bv Dressure.

L ebheii-WerkEhingenGmbH Techn@l lra ni.g

Orly tor LIEBHERRServicepersonre

- 10 -

1IIBHTNR

GomponentdescriPtion UW10- Partll - activerearaxlesteering

>2.3 Bosch CAN proportionalvalves(steeringvalves) Purpose: valvessupplya precisequantityof oil and controlthe steerThe BoschCANproportional on thevehiclespeedand selecteddrjvingprogram' ingcylinders.Controlis dependent Design: Note: The Boschcontrolblock is availablein 2- or 3-foldmodelsdependingon the vehicletype pointreturnpressure measuring Pressure

pointpumppressure measuring Pressure

pointLS-pressure measudng Pressure

Fig. 6: Boschcontrolblock- 2-foldmodel

pointreturnpressure measudng Pressure

pointpumppressure Pressure measuring pointLs_pressure measudng Pressure

Fig.7: Boschcontrolblock-3-foldmodel Liobheii-WerkEhing€nGmbH- TochnicaltEining

personnel Service Onlyfor LIEBHERR

rIIBHINR

Gomponentdescription UW10- Part ll - active rear axle steering

Pre-controlvalve Controlpiston

Slop valve

Pressure balance

Controlboad (Processo4

Resei spring

Controlchannels Fig.8: Cut-away view- Boschconllolblock

visualdisplay diagnostics

Pre-control valve Controlpiston Stopvalve

Errorsignal diagnostics

Resetspring Nominal -CAN -P0i

Pressure

Setpiston

oatance

induclive

displacement Conlrclchannels rransoucer - Boschcontrolblock Fig.9: Overview

Liebheii-W€kEhlng€nGnbH - Techni@ltEining


-12-

IIBHINN


-Y231 Prop.valveaxle4 CANBoschvalve

-MP8

pointloadsignal Measuring prcssure pump rearaxlesteering

-Y232 Prcp.valveaxle3 CAN Bosch valve

Nozzle/ non-retum valvecombination (nozzle0.8)

Highpressure filter steeringcircuit

plateI Fig.10:Steering

-A67 Pressure limiting valve,165bar

Liebhetr-Werk EhingenGftbH - Techni€l Laining


- 13 -

UTBIIIRR

Componentdescription UWl0 - Part ll - active rear axle steering

Shuttlevalves

'

Pressureredlcing valve

I ls:

Note: The BoschCANproportional valvesshouldnot be swappedoveras theyhavea factorylD and are confioured withan address.

BoschCANproportional valve Supplypressurebalance BoschCANp.oporlional valve

iii:'

I

Supplyp.essurebalance

Fig.11:ExceptfromcircuitdiagramLTM1100-4.1:

Function: The proportional valvesare controlledby the l/O modulesviathe CAN-busdependingon the nominalvalueoutputby the controlsystem.Thegatevalveis onlyactuatedhydraulically(by meansof controlpressure). An integrated displacement sensor(inductive) internallymonitorsthe positionof the gatevalve.Thisis why the CAN-valveis alsoreferredto gatevalve. as an intelligent An upstreamsupplypressurebalanceallowsload-dependent regulation of the operating pressure(loadsensingfunction).Thepumpflowvolumeis distribuleddependingon the loads.

Liebheii-WerkEhingenGmbH- T6chni@ltGining


-14-

IIIBIIIRR

Componentdescription UWl0 - Partll - activerearaxlesteering

>2.4 Steeringcylind€r Purpose: for adjustingthe positionof the axlepivotandwheelsThesteeringcylinderis responsible Design:

-tz4 Sleeringcylinder axle4

-LZ3 Steeringcylinder axle3

-LZ2

-u1 Steeringcylinder axle1

Steeringcylinder axle2

Fig.12:SteeringcylinderLTI\41100-4.1:

Liebher-W€ft EhingenGmbH- T€chni€l lEining

personnel Onlylor LIEBHERR Service

- 15 -

UBHINR

Component description UW10- Part ll - active rear axle steering

Function: Thesteeringanglefor the rearaxlesis dependent on the steeringangleof the leading axle(VA= axle1) andsteefedusingthe steeringcylinders. Thesteeringangleof the leadingaxle(VA= axle'l) is measuredby an anglesensor (nominalvalue anglesensor),an electricalcontrolsystemis usedto controltheproportionalvalves(steeringvalves)andapplyhydraulicfluidto the steeringcylindersforthe rearaxres.

Fig.13: Excerptfromhydraulic schematic LTM1100-4.1:

Uebher-W..k EhlngenGmbH- Techniel haining


-16-

ilIBHMN

Component description UW10- Part ll - active rear axle steering PdHb,rM€'|d/Edl'hl2m07/v.E]m:?

Functlon: Both| / O modulesmonitoreachothervia the CAN-BUS. A2-channelcontrolsystemis usedto fulfilthe highsafetyrequirements. lt is monitored whetherthe specifiedsteeringanglenominalvalueis reached. A continuous nominal/actual valuecomDarison checkswhetherthe steeredrearaxles followthe nominalvaluewithina giventolerance. Appropriate safetymeasuresare takenifthereis a largediscrepancy betweenthe signals

Fig. 16:Excerptfiomcirc.uit diagramLTIVI100-4.1:

Ll€bh€r-w€fi Ehingen GdbH - Techni@l tEining


- 1 8-

UIBHINR


>2.6Anglesensor Purpos€: anglesof theleadingaxle (VA= axle1) thewheeldeflection Theanglesensors measure 3 to | / O modules aswellasthesteering axlesandfoMardthisdataovertwochannels and4. Design: Theanglesensoris composesof thefollowing primarycomponents: . Permanent magnetwithmagneticholder . Housingwith2 anglesensorsand integrated LED(green/yellow) . Adjustment button \-/

systems. intemalmeasuring Eachsensoris equippedwithtwo independent the ln thedrivingdirection, Eachsensorthereforeconsislsof two angletransducers. = anglesensorsareon the rightin the axlepivotof the leadingaxle(VA axle1) andthe steeringaxles. Anglesenso. Adjustment button

Drillhole

Fig.17:Anglesensorremoved

Fig.18:Alignth€ magnet

The magnetis flrmlyattachedto the axlepivotboltby the magnetholderTheangle sensoris screwedto the steeringarm.Thereis an air gap betweenthe sensorandthe magnet. Whenthewheelis deflectedthe sensorturnswhereasthe magnetis stationary Ll€bh€n-W€rk EhingenGmbH- Techni@ltrainhg


- t 9-

UBIIIRR


Sensor Screwcover

Fig.19:Anglesensorwithoutcover

Fig.20:Anglesensorcomplete

Funclion: Thesteeringangleof the leadingaxle(VA= axle 1) is measuredby anglesensor-B50 (nominalvalueanglesensor).An electricalcontrolsystemis usedto controlthe proportionalvalves(steeringvalves)and applyhydraulicfluidto the steeringcylindersfor the rearaxles.The rearaxlesare thereforeelectro-hydraulically steeredaccordingto the vehiclespeedand pre-selected operatingmode. The steeredrearaxlesarefittedwithanglesensor-B51,-852...Thesemeasurethe actualvaluesof the steeringaxles. Theanglesensors aredual-channel: - Channel A outputs a signalin therange0....20mA - Channel B outputs a signalin therange20....omA Anglemeasurement range(usable mech.range): -45"............0"....-.......+45' 1 . 2 1m 1 A....................18.789mA An erroris outputwhen:l<1mAandl>1gmA. Sincethesesignalsactin an opposite sense,theycanonlyoutputan identicalvalueof lomAwhenthewheelsare setto the 0.-position. lf an anglesensoris replacedit mustbe zeroed. Whenreplacing l/O-Module 3 or 4, all anglesensorsmustbe zeroed(seetestprogram32). Liebheii-w€.kEhingenGmbH- Techni€l training


-20 -

ITIBITIRR


-

!

l

-

i1, i

t ;1 l l

ii>

:l

- anglesensor: 1100-4.1 Fig.21: ExcerptiromcircuitdiagramLT[r1

SpEZIA!-BILD S Y S T E M - F U N K T I O N : => ?, 3: analose werte ceber ginterachslenk@g

wxRT - Beschreibung

GR.ZE OPERAND 0.0> o,o> 0.0> 0.0> 5 : 0.0> 0.o> 0.0> 0.0> 0_0> 0_0> o_0> 1-2, 0 . 0 > L 3 : 0.0 > 0.0> 0.0>

E A t l - v 3 -2 0 0 : EA.M,V4.200: EAfi.v3.201: E4M.V4.201: E A MV . 3.2 02: EAl4.V4.202: E - A l "Vl .3 , 2 0 3 : E 4 1 4 . v 4 . 2 0 3: EAM_\r3.204: EA}4_V4_204: E4.M.\r3.213: EAr.v4.213: EA'll,v3,214: E A J "V I ,4 , 2 1 4 : E4M,V4,215:

rTM 1090/3

1

va kF!

v}' KaEl b lcrad/lo] !A1 Kanal a [G€d/10]

: : : : : : : : : : : :

2 3 1 0 0

o 1 0 0 0 0

a

Lsrao/ f ut

: wrMerqeFr

: i,lintelgeber : winLelgeber

winkelgeber LA1 Kanal b wiDkelgebet LAz Kanal a c.adl101 LA2 Kanal b G r a d / x o l fiiDkelgeber LA3 Kdal a Grad/101 Winkelgeber b G€d/101 winkelgebet LA3 (da1 LA4 Kaal a winketgebe! Winl
EEEEEEEM 14000203 D

Fig.22: Excerptfromspecialpicture LT[/ 1100-4.1 - anglesensor: Liebheir-Werk Ehingen GmbH - T€chnicallrahing


-21 -

UEBIIIRR

Componentdescription UW10- Partll - activerearaxlesteering 3 Genteringcircuit >3.1 Componentoverview- Centeringcircuit

t

F

.x

f -li"-+",_r

\

.,,T.' @

o

\" 6l

o o

g (\

o-

I t

o-

E Llebh€r-WerkEhingenGmbH- Techni@ltEining

personnel Onlyfor LIEBHERR Servlce

UIBIIERR

Gomponentdescription UW10- Partll - active rear axle steering

>3.2 Centeringpump Puroose: Thecenteringpumpsuppliesoil to the centeringpumpso that valvesin thecentering cylinderareunblocked a) Duringnormaloperation: thenon-retum b) Durjngfaultconditions: centeringof the activerearaxlesteeringis assured

Design: The centeringpumpis ffangedontothe transfergearbox. for switchingbeA crossplateis mountedon the centeringpump.Thisis responsible pump (oil when driving forwards and backwards. right left rotation supply tween and non-return valves: Theflanged-on crossplateincludesintegrated = (vertical) . 0.1 bar Non-retum valveon suctionside . 0.5 bar Non-retum valveon pressureside(horizontal)=

Crossplatefor leftand right rotation

.D25 wheelddven axialpistonpump 41OVO45 DFR Rexfothcompany (flowrate regulation blocked)

Fig.23:LTM1100-4.1

LiebheF-WeftEhingenGmbH-Techni@ltslnhg


-23 -

UBHTNR


Flow€te (blocked) Pressure culoff 210bar

pumpLTM1100-4.1 Fig.24:Exce.ptfiom circuitdiagramfor centering

Function: The pumpis set to the max.rotationangleusinga spring. lf oil is pumpedby the pumpwhenno loadsare active,pressurewill buildup in the system.In thiscasethe pressureis limitedto 210 bar by a pressurelimitingvalve. Usuallythe pumpis mntrolledby the pumpregulation valve(flowratecontroller). The pressurecut-offis onlya basicsafetymeasure.In thiscasethe pumppressureis maintainedat a constantvalueof 210 bar by the pressurecut-off.Thepumpregulation valve (flowrateregulator) is not operational

Ll€bh€r-Werk Ehingen GmbH- T€chnica, lralnlng


-24 -

UBHTM

description Component UW10- Part ll - active rear axle steering

>3.3valve block active rear axle steering(AHL Block) Purposei components: TheAHL-block consistsof thefollowingindividual . . . . . .

Centering valve Blockingvalve release Solenoidvalve,hydraulicaccumulator Pressureswitchcenteringcircuitmonitoring Pressurelimitingvalve Highpressurefilter

Design: -Y222 5/2-wavvalve centeringvalve 0 = centre

-Y226

-Y220

3i2a ay valve valve,blocking

Solenoidvalve release Pressure accumulator (preventscenteringwhenengineis switched off) Seea@umulator chargevalve

Highpressure circuit filterhydraulic centenng

Pressure switc+r, centering prossure monitoring SeepressureswitchAHL Fig.25:AHLBlockLTC1055J.1

U€bhsn-WerkEhingenGmbH- Techni€l lrslnlng


-25 -

UEHRR

Gomponentdescription UW10- Partll - activerearaxlesteering

SPEICHER G A S F U E L L D RRU C

190BAR

Fig.26rExcerptfromckcuildiagram AHLBlockLTC1055-3.1

>3.3.1Blockingvalve GY226): Purpose: Valveto openthe non-return valveson the centeringcylinder. Design: See Fig25 and Fig26. Function: Duringnormalconditions the blockingvalveis activatedandthe non-return valveson the centeringcylinderare open.Thisis deactivated abovecertainspeedsdependingon the drivingprogram.In thiscaseit is not possibleto furthersteerthe axles.

Liebhen-WeREhin96nGmbH- T€chnic€llraining


-26-

ITBITTRR

Componentdescription UW10- Part ll - active rear axle steering Pfuducdby:wepid/Ediboi12'02'07/v.Es:2

-Y222,...\l >3.3.2Centeringval]'e(-Y22'1, Purpose: the steeringcylinder. Change-over valvefor releasing Design: SeeFig25 andFig26. Function; lf a faultoccurs,the centering Thecenteringvalveis activatedduringnormalconditions. valvedropsout causingthewheelsto be centred.

)3.3.3 Solenoidvalve- releasevalvehydro accumulatorGY220) Purpose: servesto maintainthe oil supplyto the centeringcircuitevenwhenthe Theaccumulator craneis notmoving.Thisallowssteeringat standstill. Design: SeeFig25 andFig26. Function: The hydraulicaccumulator is flled at regularintervalsby -Y225(switchin steeringcircuit filledby the centeringpump ll) whenv < approx.skm/hand is continuously whenv > skm/h. to releasethe hydraulicacAs soonas the engineis running,valve-Y220is energised willfall if steeringmovecumulator for filling.The pressurein the hydraulicaccumulator mentsare performed whenthe engineis runningandthe vehicleis not moving.This maintains the releaseof the centeringcylindersat standstill. The centeringandblockingvalvesdropoutwhenthe engineis switchedoff.At the same dropsout andblocksthe pressureto the hydraulic time,accumulator chargevalve-Y22o accumutatot cylinder fromthehydraulic accumulator. supplyto thecentering Thisinterrupts thepressure prevents is switched ofi. centering when the engine This

Llebheii-WerkEhingenGmbH- Te9hni@ltraining


IIIBIIIRR

Gomponentdescription UW10- Part ll - active rear axle steering

>3.3.4Pressureswitch - monitoringcenteringcircuit (€89) Purpose; PressureswitchGS89)is usedto monitorthe centeringcircuit(erroranalysis). Design: Alsoseefig 25.

Fig.27:Pressure switch, pressuremonitoring centering

Fig.28:Exlracifromhydraulic schematic pressure Pressure switchcentering monitoring

Fig.29:Exiractfromcircuitdiagram Pressure swiichcenleringpressuremonitoring

Function: > 180bar.lf the pressurefallsbelow180bar Theswitchis closedat centeringpressures > at speedsv 10 Km/h,an errormessage is output.

Liebh6r-WsrkEhlngenGmbH- Techni€l i€ining


-28-

UTEIITRR


> 3.4 Flow monitorAHL (€90) Purpose: FlowmonitorGS90)servesio detecta brokepipeor leaks(erroranalysis).

Design;

Fig.30:FlowmonitorAHL

-

r-- = I

;i r. i-

L -.----.-t Fig.32: ExcerptfromcircuitdiagramAHL flowmonitor

Fig.31:Excerptfromhydraulic schematic AHL6owmonitor

Function: pipe(1obar)exceeds Blockingactionis takenifthe flowratethroughthe pre-tension movement. l/min without any steering approx.2

uebher-w€ftEhlng€n GmbH- Techni€liraining

Servicepersonnel Onlyfor LIEBHERR

-29 -

rIIBIIINR

Componentdescription UW10- Part ll - active rear axle steering by:]repd/Ediion:120207/Venion:2

>3.5 Directionalvalveemergencysupply centering Puroose: The4/2-wayvalveis energised at regularintervalsto fill the hydraulicaccumulator withoil whentheengineis running.

Design: -Y225 centering by steeringcircuilll

Fig.33:Directional valveemergency supplycentering LTM1100-4.1

rSiT0Tiu G

0

1

I

0

Fig_34:Excerptfromcircuitdiagramdireclional valveemergency supplycentering LTM1100-4.1

Funclion: Duringa "centering" faultconditionthe 4/2-wayvalve-Y225is energised for approx20 sec.Thisutilisesthe pressureof steeringpumpll to assistthe centeringcircuit.Thisensuresthatthe centeringactioncanbe performed. Li€bh€r-Weft EhingenGmbH-Technicaltrainlng


-30-

UEHINR

description Component UW10- Partll - active rear axlesteering

>3.6 Pre-tensionvalve Purpose: the ringandpisin the fan returnline.lt pre-tensions valveis integrated The pre-tension ton surfaceof the centeringcylinderto 10bar. Thisensuresthatthe pistonrunsalonginsidethe centeringcylinder. Thispermitsfastercente ng. Design:

1 0 BAR

-MP6 point Measuring Pre-tension 10 bar, Returnfan

Fig.35:Exceptfromcircuit diagrampretensionvalve LTt\,l1100-4.1

valveLTI\4 11004.1 Fig.36:Pre-tension

>3.7FaultdisplayAHL greenlil rapidflashing => slowflashing =>

everything o.k. Faullin steeringsystemwitherrcrcode Faultin lhe LSB-busconnection Cont\ollight,rearaxlesteer:ng

i@b:rE@@@@

g@Gtrtr@@

trtrtr8tr Fig.37: FaultdisplayAHL

Note: Thesteeringprogramkeyswillstartto flashin the event of a faulton the activerearaxle steering. Llebher-we*Ehingen GmbH-Techni€ lralning

personnel OrlyforLIEBHERR Service

-31

ITIBHERR

Componentdescription UW10- Part ll - active rear axle steering by:|*epid/futroi:12'02'07/VeFioi:2

)3.8 Centeringcylinder Purpose: The centeringcylinderperformsvarioustasks.Theseare dependent on the procedure step(steering, blockingandcentering).

Fig.38:Centering cylinder Pistonsurface

Ringsurface

Tappet Fig.39:Cut€wayviewcentering cylinder

Fig.40: Excerptfrom ckcuit diagramcentedngcylinder

Llebh€r-Werk Ehinge.GmbH- T€chnlcat tralning

personnel OnlytorLIEBHERR Service

-32 -

rIIBHIRR

Component description UW10- Partll - activerearaxlesteering

>3.8.1Centeringcylinderduringsleeringaction: themovement to thecentering cylinder whichfollows of 10 baris applied Herea pressure steering cylinders. axles which are controlled by the of the (flowthrough valve-Y226CY227)) valves-Y221| -Y222andblocking centering T= Tankreturnviatankpipe "L4" X=

plate "A71"are released vaveson mounting Thenon-retum by crealingflowihroughblocklngvalve-Y226CY227) pr+tensioning pressure totheringandpistonsudaces ofthe A= Applylng -Y221(-Y222) nngvalves cylinder bycreating flowthrough thecente centenng

Fig.41: Cut-awayview cent€ring cylinderduringsteeringacton --.--

[

r:

rl

TF--\

il-Illl

Blockingvalve Centeringva ve

,

Fig.42: Overview- slee ng actionaxle 3 Liebher-werkEhingenGmbH- Technicaltrainng


-JJ

lIIBHIRR


>3.8.2Centeringcylinderduring blocking action: Initiated whena pre-defined speedis exceededand duringfaultconditions. ln this case it is not possibleto furthersteerthe axles.The rear axles can only be steeredin the 0" direction. (flowthroughcenteringvalves-Y221| -Y220;!9 flow throughblockingvalve-Y226\-Y227))

T=

Tankreturnvia tankpipe"L4" X= Blocking the non-reilrnvalvesby relevlngthe pressurein the X-pipe (conneclion to lank)by dropping out blocking valves-Y226(-Y227) A= Applying h ghpressure totheringandpiston surfaces ofthecenterjng cylinder by creaiingflow lhroughthe centeringvalves-Y221CY220)

F g. 43: Cut-awayview centerng cylinderduringblockingaction

ntering cylinder hasbeendesigned so thatthesteering anglecanonlybe reduced s thecenireposition whenhydraulic clamping is active(straight-ahead driving).

Blockingvalve

Centering valve

Fig.44: Overvlew- blocklngacuonaxle 3 Liebher-WerkEh ngen GmbH-Technicaltrainng


-34-

ITIBIIIRR

Gomponent description UW10- Part ll - activerearaxlesteering

>3.8.3Centeringcylinderduringcenteringaction: duringfauliconditions. Centeingis performed Highpressureis appliedto bothouterchambersof the centeringcylinderto forcethe rapidreturnof therearaxlesto 0'steering. Thecontrolsystemwill not initiatecenteringat speedsbelow3 Km/h. (Ig flow throLrghcenteringvalves-Y221/ -Y222and blockingvalve -Y226(-Y227)) T = Tankrelum vla tank oioe "L4" X=

Â.71"

Blockingthe non-reiumvalvesby relievingthe pressurein the X-plpe (connectionto lank) by droppingoul blockingvalves-Y226 (-Y227) Applying hgh pressure tothe ringandpistonsurfac€s of thecenlering cylinder by dfoppingout centeringvaves-Y221(-Y220). Al the sametime both steeringcylindersare released-

Fig.45:Cufawayviewcenteang cyllnderdurlngcentering action

Blockng valve

Centerng valve

E g. 46 Overview - cenlering arreg ".t:on

Liebher-WefkEhingenGmbH- Techn@lt€ining


ITIBHIRR

Gomponentdescription UWl0 - Partll - activerearaxlesteering

>3.9 Safetymeasuresduring fault conditions Thereare4 safetymeasures(l\,41 to [,44)whichcanbe initiatedfor activerearaxlesteeringwhena faultoccursin the activerearaxlesteeringsystem. Almostall the safetymeasuresimmediately blockthe rearaxlesteeringlt is thendeterminedwhether or notthevehicleis currently turning(angleof frontaxle>150). However thisdoesnotapplywhenthereis a faultin thefrontaxleanglesensor, theangle sensorof steeringaxle2 or the BoschCANproportional valvefor steeringaxle2.

M1;Cenlrethe steering Conditions: Measure l\r1is takenin eitherof thesecases: . Case1: Thevehiclespeedis below3 km/hand no CAN-datais sentfromthe other lO-module. . Case2: Thevehiclespeedis above3 km/hand no curvedrivingis detected.In this casethe pressurein the centeringcircuit(-S89)mustbe at its normallevel. Valveactuation: - flow is appliedto Y 225 (emergency supplycentering) for approx.20 sec - thereis no flowthroughY 226 (blockingvalve). - thereis no flowthrough Y 221(centering valveLA 1). - thereis no flowthroughY 222 (centering valveLA 2). -Y231 and-Y232(CAN-valves LA 1 and LA2) are setto a targetsteeringangle= 0o Effects: - Thecurrentspeedbecomes themaximum speed(upto 40 km/h). - Thefaultnumberis displayed. - Thecontrollightfor activerearaxlesteeringflashes. - The buttonson the steeringprogramsflash. - Thecenteringcylindersandaxlesareactivelymovedto ihe centreposition.

Liebher-WerkEhingenGmbH-Techni€ lranng


-36-

ITIBIITRR

description Component UW10- Partll - activerearaxlesteering

M2:Specialcase,blocksteering Conditions: Measure Ml is takenin eitherofthesecases: . Case1:Thevehiclespeedis below3 km/h,noturning; in thecentering thepressure circuitis notO.K. . Case2: Thevehiclespeedis above3 km/handflowmonitorCS90)is faulty Valveactuation: - thereis no flowthrough valve). Y 226(blocking - flowcontinues valveLA 1). through Y 221(centering - flowcontinues valveLA2). ihrough Y 222(centering 'Y231 and-Y232(CAN-valves LA 1 and LA2) are set to a targetsteeringangle= 0o (providing anglevalueis O.K.). Effects: - Thecurrent speed(upio 40 km/h). speedbecomes themaximum - Thefaultnumberis displayed. - Thecontrollightfor activerearaxlesteeringflashes. - Thebuttons programs flash on thesteering M3:Specialcase,blocksteering Conditions: Thevehiclespeedis above3 km/handthemobilecraneis turning. Valveactuation: - thereis no flowthroughY 226 (blockingvalve). - flowcontinues through Y 221(centering valveLA 1). - flowcontinues valveLA2). throughY222 (centering -Y231and-Y232sleerthewheelsin the 0odirection,providing the anglevaluesare still position untilthe"turning O.K.lf theanglevaluesarenotO.K.,thewheelsareleftin this criterion". is no longerfulfilled. Effects: - Thecurrent speedbecomes themaximum speed(upto 40 km/h). - Thefaultnumberis displayed. - Thecontrollightfor activerearaxlesteeringflashes. - Thebuttons programs on thesteering flash,

t = The "turningcriterion" the angleof the frontaxle hasreducedby 3o is completed-once sincethe faultoccurred. Liebher-We* Eh ngen GmbH- Techni€ltEining


- 3 7-

ITIBHIRR

Gomponentdescription UWl0 - Part ll - active rear axle steering

M4: Spocialcase,centrestee ng (duringpoweroutage) Conditions: Centeringis electrically triggered,no voltagepresent. Valveactuation; - Thereis no flowthroughY 226 (blockingvalve)(automatic). - Thereis no flowthroughY22'l (centering valveLA 1) (automatic). - Thereis no flowthroughY 222 (centering valveLA2) (automatic). Effects: - Thecurent speedbecomesthe maximumspeed(upto 40 km/h). - Thefaultnumberis displayed. - Thecontrollightfor activerearaxlesteeringflashes. - The buttonson the steeringprogramsUash. - Thecenteringcylindersandaxlesare activelymovedto the centreposition.

Liebher-Werk Ehlng€n GmbH- Techniellraining


-38-

UIBIIERR

Gomponentdescription UW10- Partll - activerearaxlesteering

)4 Summary AHL Electro-hydraulic steering: in the BoschCANproporiional valves. Thesteeringis actuatedby the processors therearaxlesareelectro-hydraulically Thesteering angleon theleading axleis reduced; operating mode. on thevehiclespeedandthepre-selected steered depending intoa hydraulicactionby the proportional valveson the Thecalculated angleis converted pump. pressure is supplied hydraulic by an engine-driven A closedaxles.Therequired loopcontrolcircuitis createdusingthe actualvaluesobtainedfromthe displacement valvesandthe anglesensorson eachof the measurement systemon the proportional rearaxles. Thefollowing modesaresupported: operating . . . . . .

Roaddriving All-wheelsteering Crabsteering raie Reducedswing-out Independent steering Rearaxlesteeringlockedin centreposition

The centering valveis onlydeactivated whena faultoccurs(no power);eachaxleis then independently steeredto 0'. The blockingvalveis activated duringfaultconditions and whenthe maximumpermitted Above V n..,i"s..*the axles speedfor the activerear axle steeringis reached(V ",*,"n."*).(no power)and the are controlleddown to 0", the blockingvalve is also activated clamped.ln the blockedstatethe axlescan onlybe corresponding axlesare hydraulically steeredtowards0' (themaximumangleis thenthe currentangle).

Centering valve: valve: Blocking

valveforreleasing thesteering cylinder Change-over Valveto openthenon-return valveson thecentering cylinder

(exception is the blockingvalve Thesevalvesare onlyactivatedduringfaultconditions The aboveV .,""n"".",). lt mustbe ensured thatthesevalvesalsoswitch"mechanically". centeringvalveshouldnotbe activatedwhendrivingfor testpurposesas it affectsthe drivingcharacteristics. Eventhoughthe blockingvalveis activatedwhendriving,no tests shouldbe carried out. insteadthereis a cyclictestafter Thesevalvesarethereforenottestedwhentravelling, therelevant testprogram. lt is verified whether ENGINE ONor by callingup thefunctional valve"dropsout"andswitchesto a safesiate.

Liebheir-Werk EhingenGmbH- TechnicaltGining


-39-

ITTBHIRR

Gomponent description UW10- Part ll - activerearaxlesteering

HA - steering: Hydraulic fluidis appliedto theproportional pump-D22(via valvesby rearaxlesteering highpressurefilter"steeringcircuii"). Theflowrateof the LS-controlled rearaxlesteeringpumpis controlleddepending on pressure, thedifferential thevolumeflowis dependent on theloads. Themaximumpressureof the steeringcircuitis limitedby a pressureregulatorandan pressure additional limiting valve. On thesecondary sidethesteering cylinders areprotected by pressure limiting valves. Switching theblocking valvesunblocks thecentering non-return valves,releases the hydraulic clamping of theHA-steering and allowsHA-steering. Thecentering valvesarealsoswitched, theconnection to thepistonand pistonrodsideofthesteering is cylinder blockedandthecentering cylinder is released intothetank. Thesteering anglefortherearaxlesis nowdependent on thesteering angleof the frontaxles. Thesteering angleof theleading axleis measured by an anglesensor(nominal valueanglesensor),an electricalcontrolsystemis usedto controlthe proportional valves (steering valves)andapplyhydraulic fluidto thesteering cylinders fortherearaxles. Thesteeredrearaxlesare equippedwithanglesensorsthat monitorthe specifiedsteeringangle- nominalvalue. A continuous nominal/actual valuecomparison checkswhether thesteeredrearaxles followthe nominalvaluewithina giventolerance, appropriate measuresaretakenif thereis a discrepancy between thesesignals.

Liebhetr-Wefk Eh ngen GmbH-Technicaltraining


-40-

lTIBHIRR

Gomponent description UW10- Partll - activerearaxlesteering

Centering: pumpD25supplies circuit via hydraulic fluidto thecentering centering Thewheel-driven circuitcentering". filter"Hydraulic thehighpressure The highpressurein the centeringcircuitis protectedby a pressureregulatorand a pressurelimitingvalve.Thecenteringcylindersare alsofittedwithpressurelimitingvalves. pressure swiichat v >10km/h. is monitored by a pressure Thecentering is 0. angle- nominalvalue is activated thesteering Whencentering valvesare releasedandthe relevant Theblockingvalvesare poweredoff,the non-return Steering is no longerpossible. clamped. axlesarehydraulically anglecanonlybe reduced designed so thatthesteering cylinder has been Thecentering driving). clamping is active(straight-ahead whenhydraulic towards thecentreposition piston piston powered rod sides of the steering off, the and valves are also Thecentering valveanddischarged intothetank. areconnected by thecentering cylinder Thepressuregeneratedby axialpistonpump(D25)centresthe HA. withcentering on 3 of the 1400-7.1 is onlyequipped fortheLTN/I Therearaxlesteering valvewhen 4 steeredrearaxles(HA),theothersteeredaxleis releasedby a directional centenng occurs. Moniloringof the centeringpipe: valve.Duringsteering angle limiting by a pressure Thefancircuitreturnis prelensioned pistons and pressure cylinder viatheflowmonitor is applied to thecentering reduction, applied in the centre. causing them to be switched centering valves, with no steeringmoveIf theflow raterequiredto applythe centeringpistonsat standstill mentis > 2 l/min,a pipehasburstor a leakhasoccurred. measuresare thentaken. Appropriate Theflowmonitoroutputsan errormessage.

Liebhen-WerkEhingenGmbH- TechnlcaltrainLng


UIBHTRR


Ll€bh€r-Wqk EhingenGmbH- T€chni@ttainins


-42-

r|EIIINR


UW12- Axle suspension

Onlvfor LIEBHERR service oersonnel

Componentdescription suspension

Liebheri-Werk EhingenGmbH- Techni€l tEining


-3-

lIIBIIIRR

Component description UW12-Axle suspension

U€bh€r-We* Ehlng€nGmbH- T€chnic€ltralnlng

Onlvfor LIEBHERR serviceoersonne

-4-

UBHINR

UW12 -Axle suspension 1 Axle suspension,general >1.1PurDose wearon thecrane cushions thevehicleandreduces TheNiveaumatik axlesuspension androads. It can be lowered,raisedor drivenat a specillclevel(springstrutcentrepositionor terrain application. compensation) to suita particular applications: Thevehicleis raisedor lowered in thefollowing . Automatic (suspension in drivingmode)forallaxles andmanualleveladjustment . Loweringthe cranestructureto reducethe headroom . Raisingthe cranestructureto improvethewadingcapability . Raisingthefrontend (or rearof thevehicle)to increasethe gradient . Lateraltiltingof the cranestructureto facilitatedrivingon slopes

>1.2Layout Thesuspension andaxlecompensation are hydro-pneumatic. Cylindersarefitted canbe adjusted betweenthe axleandthevehicleframe.Thesuspension characteristics pressureon the hydro-pneumatic tank.The usingthe oil leveland gaspre-tensioning viathekeyboard Niveaumatik suspension is operated unitin thecab. cylinder Axlesuspension

Axle blockjngvalves

'/ Nitrogen bladderacclmulator (suspension component)

Fig. 1: F gure showingprincipleof axle suspension- layout Liebheri-We*Ehnqen GmbH- Iechni€l lralnins


_5 -

1TIBITIRR

Gomponentdescription UW12 -Axle suspension Prcdmedby:iEpi0/Ediddni29'0306/\hreion:4

5

,H5

i E

16

17

18

19

Fig.2:Hydraulic axlesuspension LTN4 1050-3.1:

Uebheir-Werk Ehingen cnbH - Technicat tainirg

Onlyfor LIEBHERR personnel service

-6-

lIBHTNR

Gomponent description UW12 - Axlesuspension Function fifstaxleon therighl Fillingihe axlesuspension cylinderforthe (raisethevehicle) -Y13, Draining theoilfromthefirstaxleonthe right(lowervehicle) 2. Solenoidvalve Pressure compensation fof thecrosswise axlesuspension cylinders. The 3. Diaphragmreservoir pistonsudaceforiherightaxlesuspension cylinder(1staxle)is connected on theleftaxlesuspension cylinder(axles2 and3). to theringsurfaces Blocking theaxlesuspension for axle1 righi 4. Axle blockingvalve -Y9, posjuon Valve in rest axle blocking valvesin lockingposition 5. 5/2 Way-solenoid CYga) (axlesuspension valve blocked) - ValveswitchedCYgb)axleblocking valvesopen (axlesuspension sptung) axle1 right(canbe blocked) 6. Axlesuspension cylinder Suspension -561,Levelswitch Acknowledgement axlesuspension axle'1right(41 = fill;A2= drain) 7. -Y18, Solenoidvalve 8. Fillingihe axlesuspension cylinderforthe 2nd and3rdaxlesonthe dght (ralsethevehicle) -Y19, Solenoidvalve 9. Dfainingtheoilfromthe2ndand3rdaxleon the right(lowervehicle) foraxles2 and3 right 10. Axle blockingvalve Blocking lhe axlesuspension forthecmsswise axlesuspension cylinders when 11. Diaphragmreservoir Pressure compensalion piston axlesuspension is sprung.The suriacefortheleitaxlesuspension to lhe ringsurfaces on therightaxlesuscylinder('1staxle)ls connected pensioncylinder(axles2 and3)whenthe axlesuspension is "sprung". -Axlesuspension for axles2 and3 blocked 12. -S50,Contactswitch Acknowledgemeni axle2 right(canbe blocked) 13. Axlesuspension cylinderSuspension 14. Axlesuspension cytinderSuspension axle3 right(canbe blocked) ; axlesuspension axle3 right(A1= fill;A2 = drain) 15. -563,Levelswitch Acknowledgement flrstaxleontheleft(raisevehicle) 16. -Y10,Solenoid valve Fillingtheaxlesuspension cylinderforihe -Y11, 17. Solenoid va,ve Draining the oilfromthefirstaxleonthe left(lowervehicle) for axle1 left 18. Axleblocking valve Blocking the axlesuspension 19. -S51,Contactswiich Acknowledgement axlesuspension axle1 sptung forlhe crosswise axlesuspension cylinders. The 20. Diaphragm reservoir Pressure compensation pistonsurfaceforthe leit axlesuspension cylinder(1staxle)is connected on therightaxlesuspension cylinder(axles2 and3). to the ringsurfaces (can 21. Axlesuspension cylinderSuspension axle1 left be blocked) 22. -560,Levelswilch Acknowledgement axlesuspension axle1 left(Al = fill;A2= drain) 23. -Y16,Solenoid valve Fillingthe axlesuspension cylinderforthe2ndand3rdaxleonthe left (raisevehicle) 24. -Y17,Solenoid valve Draining lhe oilfromlhe 2ndand3rdaxleonthe eft (lowervehicle) the axlesuspension for axles2 and3 left 25. Axleblocking valve Blocking compensation forthecrosswise axlesuspension cylinders when 26. Diaphragm rcseNoir Pressure axlesuspension is sprung.Thepistonsurfaceforthe dghtaxlesuspension to theringsufaceson theleftaxlesuscylinder(1staxle)is connected pensioncylinder(axles2 and3)whentheaxlesuspension is "sprung". (can 27. Axlesuspension axle2 left be blocked) cylinderSuspension 28. Axlesuspensioncylinder Suspension axle3 left(canbe blocked) axlesuspension axle3 left(A1= fill;42 = drain) 29. -562,Levelswitch Acknowledgement Pos. Designation -Y12,Solenoidvalve 1.

Fig.3: Explanationof the positionnumbers/ hydraulicaxle suspenslonLTM 1050-3.1 Liebheii-W€* Ehingen GmbH -Technicaltrain ng

Onlyfor LIEBHERRservicepersonnel

-7

-

UIBHIRR

Componentdescription UW12 - Axlesuspension 2 Nitrogentank >2.1Purpose Thegeneralpurposeof the nitrogentankis to absorba volumeof fluidunderpressure andreleaseit as required.Nitrogentanksarethereforeusedin combination withaxle suspension cylinderson axlesuspension systems. >2.2 Layout Bladderaccumulators anddiaphragm reservoirs havea storagebladder andmembrane respectively to separatethegas (nitrogen) fromthe hydraulicoil. pressure Gasfill P0 (pre-tension

Sioragecapaciiyin litres Gas fill pressureP0 c€n be changedusinga fillingand iestingdevice

ldentificalion plate

Gasvalve(nitrogen fill

Nitrogenfilling tanK

pressure Operating PS InDar

Storage bladder Hydrauljcoil

Oil valve(mushroom Ventingscrew Connection to the hydraulic system

charge discharge

Bladderaccumulator Bladderaccumulatof empty

Bladderaccumulator cnarge0

Fig.4:BladderaccumulalorFirmaRexroth Liebher-WerkEhingenGmbH- Techni€l tralning


-8-

IIBHIRR

Gomponentdescription suspension Sioragecapacityin lilres

Gas fill pressureP0 c€n be changedusinga fillingand testingdevice

u r.i. 330 BARrs-3./so"c "l"ifl'1"*Xi:"--l---'--ps "rooc PT472 BAR sBo330-2,8E1/663U-3304K050 Plugscrew plate ldentific€iion (stampedin)

Nitrogen filling Tank I\,4embrane (rubber) Hydraulic oil Closinghead

to the Connection hydraulic sysiem cl-1arge discharge Diaphragm rcseNoir empiy Fio. 5: Bladdefaccumulator-FirmaHYDAG

reseNoir Diaphragm discharged

Diaphragm reservoi cnargeo

Fillingand testingdevice for diaphragmreservoirs

Fillingand testingdevice ior bladderaccumulators

Fillinghose Fig.6: F:llingand testingdevice u8bh€r-wedEhlngsn GmbH- Techni€lt€ining


UIBHTNR

Gomponent description UW 12 - Axle suspension

Fillingand teslingdevice

Fillinghose Membrane

HydraLr'ic accumu,ator

Fig. 7: Schematicofthe fillingand testingdevice

2.3Function Bladderaccumulator: Duringnormalconditions the storagebladderis pre{ensioned with nitrogenvia the gas valve(gasfill pressureP0)and completely fillsthe steeltanktherebyclosingthe mushroomvalve.Oncethe oil pressurein the hydraulicsystemreachesthe gaspre{ension level,hydraulicoil flowsthroughthe mushroom valveintothe accumulator to compress the nitrogenin the bladder.Thevolumeof nitrogenwillthereforereduceby the amountof absorbed hydraulic oilvolume. Dropping theoil pressure causesthenitrogen to expand andforcethestoredhydraulic oil backintothehydraulic system. Diaphragm reservoir: Diaphragm reservoirs are equippedwitha diaphragminsteadof a bladderto separatethe gaslillpressure fromthehydraulic oil, Thememblaneexpandsvia the screwplugandoperatesthe closinghead Theyare usedfor lowstoragevolumesand usuallyhavebetterdynamiccharacteristics whencomoared to bladder accumulators.

Llebher-WerkEhingenGmbH- Techn€l lralning


-10-

ITBHIRR


UW12 - Axlesuspension 3 Axle suspensioncylinderwith proximityswitch )3.1 Purpose Suspension andequalisation component betweenthe axleandthe vehicleframe,Raising lateral and loweringthe cranestructureand tilting. Theaxlesuspension cylindersarefittedwithproximityswitchesfor automaticheight regulation. >3.2 Layout Actuatingthe appropriate solenoidvalvespumpshydraulicoil ontothe pistonsurfaceof theaxlesuspension the vehicleis loweredby cylinderand raisesthe vehicle;conversely pressure pision valves release the oil from the actuatingsolenoid to surface. Thehydraulicoil whichis forcedoutor flowsontothe ringsurfaceof the axlesuspension cylinderservesto dampenany movement.

K R

K = piston surfaceR = ring surface Fig.8: Axlesuspension cylinder Uebher-WeREhingenGmbH-Techniel Laining


- 1 1-

ITIBHIRR

Component description UW 12 - Axle suspension

l\,4obile craneswithup to 4 axlesarefittedwithlevelswitcheson the 1stand lastaxle; mobilecraneswithmorethan5 axlesusuallyhavethemfittedon the1standpenultimate axle. Levelswitch-S6xcomprises two proximityswitches(A1and42). heightregulation. Thelevelswitchis usedforautomatic Theset positionof thevehiclefor drivingmode (vehicleat correctheight)is detected. Theoutputsignalsof bothproximityswitchesare dependent on the boomstatusof the (seetable). axlesuspension cylinder Gondilion Vehicleraised/ lowerlevel Vehicleat correctlevel

A1 0 0 1 1

Vehiclelowered/ raise level

A2 0 'I

Proximltyswitch (inductivesensor)

0 1

K R

Levelswitch

Axlesuspension cylinder

pos ossLl lble po ions 00s osilii Ithe rh witcl

Exceetfromschematic: ProximityswjlchA1

Proximity switch Proximity switch,q1 __z t€l_,., t-;=L Pr;ximityswitch42

K = oiston surfaceR = ring surface -

ffi L ebheii-werkEhing6nGmbH -Techni€ t6inng


-12-

ITIBIIIRR

Gomponentdescription UW 12 - Axle suspension 4 Axlesuspension sprung/ blocked >4.1 Purpose Theaxlesuspension is blockedwhenthe craneis supported(craneoperation) andin (free-standing craneoperation)drivingmodewithequipment Theaxlesuspension is setto sprungfor roaddriving(drivingmode).

X.2 Layout

Compressed airconkol lineAxlesuspension blocked/ sprung

€50. Contactswitch, Axlesblocked

Fig. 10:Axle blockingvalve LTIV1030-2.1

Pistonforvenljngvalve; Axlesuspension blocked Fig.11:AxleblockingvalveLTM1030-2.1

Li.bhotr-W€rkEhlng€nGmbH- Techniel tEining


- 13 -

UBHIRR

;:::

Component description UW 12 - Axlesuspension

-Yga -YSb Axlesuspension

Fig.1215/2Waysolenold va ve, pneumatjcchangeoveraxle suspensionblocked/ sprung- LTll 1045-3.1

>4.3 Function Axle suspension lowered level rarse0 Drivingwithloads Supportvehicle Manually raisethe vehicle [,,lanually lowerthevehicle Roaddrivingmode

Axle suspensioncylinder blocked sprung X X X' X-

X

X X

prnciple Fig.l3: Figure showing ofsprurgaxlesuspenson

* = On y on mob le craneswlth 5 or more axlesor on all newlydeve oped crane modelsfrom 2007

(withoutpiperupt!reprotection). L ebher-WerkEhin9enGmbH- Technlcaltrairing


-14-

IITBHIRN

Componentdescription UW12 - Axlesuspension

Solenoidvalve Ralse(flll)

Solenoidvalve Ralse(fili)

Solenoidvalve Lower(drain)

Solenoidvalve Lower(drain)

Contaciswitch, Axles blocked

Contactswitch,

Nitrogen bladderaccumuLator (suspension component) Axlesuspension cylinderleft

Nitrogen bladderaccumulator (suspension component)

Solenoidvalve, pneumaticchangeoveraxle suspension blocked/ sprung

cylinderdght

Fig.,l: Schera.;col sprLngaxlFsuspersior

L ebhen-WerkEhingenGmbH-Techni€ltfain ng


ITBHIRR

Componentdescription UW 12 - Axle suspension

Crosswiseswitching: On mobilecraneswith up to 4 axles(appliesto revisedor newlydevelopedmachines from2005),vehicleroll is preventedby crosswiseswitchingof the axlesuspension cylin(e.9.whenbrakingthe vehicle) ders.Thisimprovestrackingstability.Pitchingmovements are exaggerated, howevertheyare negligible dueto the improveddrivingcharacteristics. . .

The pistonsurfacesofthe axlesuspension cylinderson the frontaxlesare connected cylinderson the diagonally to the ringsurfacesof the axlesuspension oppositerear axles. The ringsurfacesofthe axlesuspension cylinderson the frontaxlesare connected 1o the pistonsurfacesof the axlesuspension cylinderson the diagonally oppositerear axles.

Fig. 15: Schemaiicof the axle suspensionswilchedin crosswiseconfiguration

Liebher-WerkEhingenGmbH- Techniel tGining


- lO -

UBHINR

Gomponentdescription UW12 - Axlesuspension

Parallelswitching: machines to revised or newlydeveloped On mobilecraneswith5 or moreaxles(applies not cylindersis used. from2005)crosswise switchingof the axlesuspension cylindersare connectedin parallel. In thiscasethe axlesuspension switchingcanbe Thetrackingstabilityof thesemachinesis so goodthatcostlycrosswise omitted. . .

to the ringsurcylinderis connected The pistonsurfacefor the leftaxlesuspension cylinder of thesameaxle. faceon therightaxlesuspension to the pistonsurcylinderis connected The ringsurfacefor the leftaxlesuspension cylinder of thesameaxle. faceon therightaxlesuspension

in parallelconfiguration switched Fig.16rSchematic ofthe axlesuspension

Liebhetr-Wed( EhingenGmbH- Techni@llraining


- 1 7-

lTIBIITRR

Gomponent description UW12 - Axlesuspension

-

Highpressure Cl6mpedpressurc Controlpressure Lowpressufe

- Crosswise Fig.17:Axlessuspension LTl,./1050-3.1 configuration / axleslspensionsprung

Liebheri-Werk EhingenGmbH- Techni€l lEining


- t8-

IIIBHIRR

GomponentdescriPtion

UW12- AxlesusPension

p.ma

lll ?

b, repLot ra;i"", zg.ososi v.a-'

I

-' '^"

J €

I l.j !

-

Highpressurc p€ssuf€ Clamped controlprcssure LowPressure

lmpactto leftwheel,axle1 e.g causedby unevenroadsurface

sprung_ / axlesuspension configuration LTI\,1050-3'1- Crosswise Fig.18:Axlessuspension lmpacitolefiwheel,axle1

_ Uebher-WelkEhingsnGmbH T€chnic€llEinrng


- 19 -

UEHINN

Gomponentdescription UW 12 - Axle suspension

In this example: . ihe vehiclehas been set to a horizontallevel axles 1 and 2+3 are blocked axle compensationis switched the cranehas laleralstability

- Drivingwithequipment Fig.19:Figureshowingprinciple of blockedaxlesuspension Note: In thisexample: . all axlesareblocked . the craneis supported without tyres

- Suppoded Fig.20: Figureshowingprinciple of blockedaxlesuspension tfalning Liebh€rr-weft Ehing€n GnbH-Technical


-20 -

UEITIRR

Componentdescription UW12 - Axlesuspension

!!

-

-

i,i'o-I rn

"l';" 1- l

1**-I- - -

I

Highpr€ssure ctamp€dpr€ssure Controlpressure

1050-3.1 Fig.21:Excerptfiomaxlesuspenson LTI\,4 / AIle suspelsionblocked

Liebher-we*Ehingon GmbH- Techn€l lraining


-21 -

TTIBHIRR

Component description UW 12 - Axlesuspension

>5.3 Function

Buttonfoa "automatic level

Axle blocking "ON"

Button "Manuallevel

Fig.22:

Note: The"2-hand mustbe operated duringmanualandautomatic levelcontrol(when button" controlling the vehicleheight). The mobilecranecanbe manuallysetto the correctlevelwhenin a sprungor blocked* state.Thefunctionindicators on the "manuallevelcontrol"buttonswillflashwhenthe appropriatesuspension cylindershavereachedthe requiredlevelforroaddriving. Forsafetyreasons(riskof toppling)the mobilecranecanonlybe automatically setto the correctlevelwhenin a sprungstate. Thefunctionindicatoron the "automatic levelcontrol"buttonwill be lit whenautomatic levelcontrolis activeandflashwhenthellnal oositionis reached. Thefunctionindicators on the "manuallevelcontrol"buttonswillflashwhenthe relevani suspension cylindershavereachedthe requiredlevelforroaddriving.

* = Only on mobilecraneswith 5 or moreaxlesor on all newlydevelopedcrane modelstrom

2007(withoutpiperuptureprotection) Liebheii-WerkEhingenGnbH -Technicaltraining


-22 -

UIBIITRR

Component description UW12 - Axlesuspension 5 Axle blockingvalve/raise- lowervehicle >5.1 Purpose Actuatingthe solenoidvalveson the axleblockingvalvewillloweror raisethe vehicle. )5.2 Layout -Y19 Sol€noidvalvs Lowerrighl rear

-Yt 8 Solenoid valve Raiserightrear

P Pressuresupply

Nozzle (forspeed regulation)

Note: A nozle";nside fittingcontrolsthesteady raisingactionforthe vehicle.

Tankreturnpipe SP Diaphragm reservoh

valveLTM'1030-2.1 Fig.23:Axleblocking

M Meas!renent point

Workingpipe Raisevehicle

l I

Workingpipe Lowervehicle Fig.24:Axleblocking valveLTM1030-2.1


i1,,

J i4+

E

-,1'.-.''

Fig.25:Excerptfromschematic LTN,I 1030-2.'1 valve /Axle blocking

* = not fittedon all lnobilecranes. Liebher-W€rk Ehingen GmbH- T€chnic€l l€ining

;

-23 -

lIBHINR

Gomponent description UW 12 - Axlesuspension

_

Highpressure pressure Clamped contro pressure

Fig.26:Excerptfromaxlesuspension LTM1055-3.1 / ALrtomatically raisevehicleto req!kedlevelinsprungslate

Nole: lf thevehicleis automatically raisedto the requiredlevelin the sprungstate,highpressureis appliedto the pistonand ringsurfacesof the axlesuspension cylinder. Theaxlesuspension cylinderextendsdueto the difference in surfaceareabetweenthe pistonsurfaceand ringsurface.

Liebherr-Werk Ehin96nGmbH- Techni€l trainlng

OnlyforLIEBHERR servicepersonner

-24-

IIBIIIRR

Gomponent description UW 12 - Axle suspension 6 Axle compensation valves >6.1Purpose switched on mustbemanually Onmachines with5 or moreaxles,axlecompensation is activated, it is sub-divided intotwo lf axlecompensation whendrivingwithequipment. groups. front well as the rear axles. will occur between the axles as Axlecompensation

>6.2Layout

-S55Camswitch compensatron

Fig.27: Axle compensationvalveLTM 1200-5.1

>6.3Function Automatic level comrol

Axle blocking "ON"

2-handbutton

Note: . Axlecompensation is automatically activatedwhenraisingor loweringthe axle suspension. . lvlanual is axlepressurecompensation is onlypossible whentheaxlesuspension blocked. Fig.28:Cabkeyboard unit Liebheii-WerkEhingenGmbH- Technicallralning


-25-

UIBHINR

Gomponentdescription suspension

.Y6a Solenoid valveaxlecompensation 1 = no compensalion (compensation axles1-2/ 3 / 4-5) .Y6b Solenoid valveaxlecompensation 1 = withcompensation (compensation axles'1-2/ 3-5)

,il;

.s53

.s55

Camswilch Camswitch AxlecompensationAxlecompensation hydraulic LTM1200-5.'1 Fig.29:Excerptfromschemalicfor axlesuspension /Axle compensation LiebheF-Werk EhingenGmbH-Techni€l Lainlng

personne. OnlyforLIEBHERR service

-26 -

IIEITTRR

Componentdescription UW 12 - Axle suspension Froducedby:|wepid/Edidd:29,03'06/6don:4

-

Hlghpr€ssure C ampedpressure Controlpressufe Lowpressurc

LTM1200-5.1 / fig. SO,fr""rpt fror fo|.hyd|.uuli" axlesuspension ""h"r"ti" blocked / Drivingwithequipment Axlesusponsion L ebher-Werk Ehinqen GmbH- Techni€llraining


_27 _

l llrBll IRR

GomponentdescriPtion UW 12 - AxlesusPension 7 Raise/ lower axles (largemachineswithout active rear axle steering) >7.1Purpose oneor rearaX|esteering, andindependent rearaxlesteering active Without on machines moreaxlesmustberaised. >7.2Layout -Y30 Raiseaxles3+4 (iill ringsurface)

-Y31 Loweraxles3+4 (emptyringsurface)

-s80 Pressureswitch, >120bar= Acknowledgement Axles3+4up

-Y32 Raiseaxles3+4

(emptypistonsurface)

I

F g'31 HydtdLlcblock- Raiseax'esL fl\,l1250/1

>7.3Function Automaiiclevel conlrol

--1 l -

.

J

:

\,r*

lEl

-.- -"1-,;;,-i,;-'

i

'oN" Axre brockjns

__l|

-

axtes ,/Ra$e

f

lqf aalft=/flr-1-- tw

/

' f rodslo thi sleering Release

blockHydraulic Fig.32:Excerptfromschemaiic RdrseaxresLTI\,I1250/1

i ;.

L

:..i ti-5 i i r,, ::..,=----...\,.= I

.,t-i.. ... , '

'

'

.

'

.

'

, . : . t

'.

eE.

.

I

-

L

t

Fig.33:Cabkeyboardunite.g.LTM1250/1

EhingenGmbH _Techni@varnng Liebheir-Werk


-28 -

UTTHINR

Componentdescription UW 12 - Axle suspension 8 Piperuptureprotection* >8.1Purpose protection is to increase thepayload fortheoperating mode ofthepiperupture Thepurpose prevents protection also thesuspension cylinderfrom to read'.Thepiperupture "free-standing whichwouldotheMisecausethemobilecraneto tipovet emptying whena hoseruptures >8.2Layout

Piperuptureprotection

Fig.34:Piperuptureproleclion

>8.3Function cylinders,the pistonsideof lf piperuptureprotection* is fittedto the lastaxlesuspension pylinder This is blocked. is dampedwhentheaxlesuspension therearaxlesuspension point arm and increases displacesthetilting of the mobilecrane.Thisextendsthe lever to reat"by ca.20yo. the maximumpayloadfor operatingmode"free-standing posllevelling pipe protection. is not with a blocked axlesuspension lf rupture is fitted, possible.Forthisreason,piperuptureprotection* is no longerJittedon all mobilecrane modelsfrom2007. Note: level Whendrivingwithequipment, the mobilecranemustthereforebe set to a horizontal prevents ground. the cranefrom This andthe supportcylindersextendedca. scmoff the tipping whena hoseruptures. Actuation via -Ygbaxle suspensron sprung

Piperupture proteclion Fig.35:Excerptfromschematic for pipeaupture '= notfittedon all mobilecranes. Liebhen-WeAEhingenGmbH- T€chni€l tEininq


-29 -

lTIBIIIRR

descriPtion Component UW12 - AxlesusPension fud,dbykald/Edb-400€]v*.-a

9 Axle oscillation >9.1Purpose item

is an optional is usedfor off-roaddrivingwith loads.Axleoscillation Axleoscillation* on2- and3-axlemobilecranes.

>9.2Layout 3/2Waysolenoidvalve(open)for valve theair switching

-

PiperuptureP

Fig.36: Except from circuitdiagramaxle oscillationLTIVI1045-31

t = Option Liebher-WerkEhingenGnbH - T€chni€l tEining


-30-

lTIBIIIRN

Gomponentdescription UW12 - Axlesuspension

5'ENEDRUC(LUFTAILAOE

LTIV1045-3.1 Fig-37:Excerpifromcircuitdiag€maxleoscillation Axlesusoension block€d- axleoscillation aclive

Liebher-WerkEhingenGmbH- Technicallralning

Onlyfor LIEBHERR servicepersonn€

- 3 1-

lIBHIRR


UW13 - Electricalcircuit diagram

L T M1 0 9 0 - 4 . 1 LTM1100-4.1

Onlyfor LIEBHERR Servicapersonnel

Gomponent description UW 13 - Electricalcircuitdiagram

Li€bhor-WerkEhingenGmbH- T6chnicaltEining


-3-

UEBHTRR

Gomponentdescription UW13 - Electricalcircuitdiagram 1. UsingLiebherrcircuitdiagrams 1.1Schematic structure >1,1.1Divisionchassis/ superstructur€ (2). Apartfroma fewexceptions, chassis(1)andEuperstructure

L T M1 1 0 0 - 4: 0ltsaLrloT0n

( S T U F E' I I

/ IIER 3 )

L T M1 0 9 0 - 4 . 1 LTt41100-4.1

Li€nh€tr-WeftEhing€nGmbH- Techni€l lEining


-4-

UEIMR

Component description UW {3 - Electricalcircuitdiagram

>1.1.2Footer The footer(l) includes various data.

Uebh€r-w€lk Ehing€nGmbH- Tecbnlcall€inlng


- 5 -

Gomponentdescription UW 13 - Electricalcircuitdiagram

>1.1.3Coverpage Thecoverpagestatesthe versionof the electronic circuitdiagram. (uW)or relates to thechassis Pagetitle (1)indicates whether thecircuitdiagram (OW). superstructure and"Circuit diagram turntable LTIV'1100-4.1" are "Circuit diagram EL.systemvehicle" respectively. staiedfor the chassisand superstructure (e.9.LTM11004.1) thetypedesignation Distinctivefeatures(2)arelisteddirectlybeneath -40" KATll). to identifythe specificmodel(e.9. Otherdistinctivefeatures: Chassis versions: Superstructure versions:

-40' (CATI andll),dieselengine(stagelll) Dolly,USA,Japan,-40' (CATI andIl) Radioremotecontrolanddetachable boom

1 1 0 -04 - 4 0 ' K A TI I OIESELlIOTOR (STU FEIII / TiER

L ebhen-WerkEhingenGmbH-Techni€llra ning

personne, OnlyforLIEBHERR Service

lEBHERR

Gomponent description UW13 - Electricalcircuitdiagram

>1.1.4Indexof pages/ Tabl€of contents The Indexof pag€s(1) is an alphabetically sortedlistof all pagetitleswith page corresponding circuitdiagram numberreferences.

LiebheF-W6d

-8-

tBtffiR

ComponentdescriPtion UW13 - Electricalcircuitdiagram

>1.1.5Pagelayout andF) Eachpageof thecircuitdiagramis dividedinto8 columns(1-8)and5 rows(A,B,C,E page a includes reference into40lleldsEach Thisme;ns thateverypageis sub-divided maybe foundinthe3rdcolumn thatthecomponent implies columnlD e.g. 124,3.This are not usedhere. on page124.Rowidentifiers

Li6bher Werk EhingsnGmbH- Techni€l lEining


-9-

UEBTftRR

Component description UW13 - Electricalcircuitdiagram

>1.1.6Overviews Overviewdiagramsare usedto illustratee.g.the installationlocationof componentsor on mobilecraneswith databustechnoloqv the connections betweenunits.ForexamDle, the LSB/ CANoverviewis listed.

Liebheii-WerkEhingenGmbH Techni€l trainn9


- . t 0-

UEBItrRR

Gomponentdescription 13 - Electricalcircuit diagram Pbduced bv: weoiro/ Ed t on: 13.02.07/ VeEion: 1

Installationlocation The chassisand superstructure are each sub-dividedinto installationlocationgroups(1) Chassis: . H C a b . F Vehicle . S Controlcabinet Superstructure: . K C a b . D Turntable . A Boom . S Controlcabinet Example:

=g+!-K53:30

Liebherr-WerkEhingenGmbH - Technicalt|aining


-z',t-

lEBHINR

Componentdescription UW 13 - Electricalcircuitdiagram Produ€d by: lw.piro / Edition:13,02.07 /Ve6lon:1

Resourcetype All resources aredividedintogroups: Excerptfromlist: . . . . . . .

A F K M R S X

Modules/ sub-modules Safety devices Relaysi contactors Engine Resistors Switch Plug Valves

Example:

=U+H-K53:30

3t€ tl-

t R r o a R! t r r , r a 8 a r i t r T t L 1

3 c

F l.' a

H

3El:alEL;

=U+ri-Kt3:30

T

tJ

:30

It

I

Liebherr-WerkEhingenGmbH - Technicalt€ining


-22 -

IIIBTtrRR

Componentdescription UW 13 - Electricalcireuitdiagram Producedbv: lweoio / Edilion:13,02.07/ Ve6ion: 1

Terminal/ signal

withDIN72552: a numberin accordance Everysignalis assigned Excerpt: . 1 5 . 3 0 . 30b . 5 0 . D +

(+) Batteryswitchedafterignitionstartswitch (+) Battery (+) Batteryswitchedaftermasterbatteryswitch Starter Alternator

Example:

15 F44L

3 ! s C I I P E IB J H G Atr: Jlil 7?ii,:

30

;

ll

3lb

a:

BEI:P:EL:

3Et:p

!,1111

B+. B

Liebhen-WerkEhingenGmbH -Technicaltraining


-23 -

UEBI#RR

Componentdescription UW 13 - Electricalcircuitdiagram Prcducedbv: weoiro/ Edition:13.02.07/ VeBion: 1

Resource index list This table(resourceindex)may be usedto quicklylocatea resourceusino the reference givenon the circuitdiagram. Example: -Al

may be foundon page26.1

-A

-t Type of resource (Modules/ sub-modules)

1

-> Counter

t0.. 1 r 1 :3.1

\

-A1

- t l

1

+H

2

3i.1

l

t'].'.1 t3.;,:

l!:,! ll:.1

Liebherr-WerkEhingenGmbH -Technicaltraining


-24 -

T.EBHENR

Gomponentdescription UW 13 - Electricalcircuitdiagram P.oduc€dbv: lweoid/ Edilid: 13.02.07; v6id:

1

>1.1.14Revisionlist The revisionlist detailschangesto circuitdiagramstogetherwith commentsand pagereferences. Note: Any rewiringwork on the cranemust be notedon the list by the personcarryingout these modifications.

t

t ,

] \

l

\ \

["------,*, t l BLATT

BEt4ERKUNG

5 5 , 5 6 , 5 7 sPs-TExrE GEAND ERT 59

1 0 71 1 3

BLATTEESCHRE] 8UNG ERNEITERT

I

Liebherr-WerkEhingenGmbH - Technicaltraining


-25 -

UIBHTRR

Componentdescription UW13 - Electricalcircuitdiagram Prcducedbv: lweoirc/ Edition:13.02.07/ V66ion: 1

>1.1.14Revisionlist The revisionlist detailschangesto circuitdiagramstogetherwith commentsand pagereferences. Note: Any rewiringwork on the cranemustbe notedon the list by the personcarryingout these modifications.

\ \ \

["-*---toot BL A T T

59

1 0 71 1 3

t

I

BEI.4ERKUNG

SPS.TEXl6 EE I N D E R T

R ATTEFS'I

A F TR I I N l ]

ERIIElTERT

J

Ljebherr-WerkEhingenGmbH - Technicaltraining


-25 -

UTBHIRR

Componentdescription UW 13 - Electricalcircuitdiagram PFduced bv: lwelilo / Ediiion:13,02.07/ V€rsion:1

1.2 Generalpoints on schematics )1.2.1 Cross-references/ continuation of cables Source references(1) (sBL i 87.6)and Destinationreferences(2) (58LF1L/ 89.3 and 5BLF1L2 | 120.51 are usedto followthe circuitdiagramacrossseveralpages.



-26 -

UEBHENR

Gomponentdescription UW13 - Electricalcircuitdiagram Poduced by: iwepiro/ Editjon:13.02.07/ V€Bioni 1

)1.2.2 Cablecross-section An identifiersuch as 2.5Q may appeardirectlynextto a cable. This indicatesihe cablecross-section. In this casethe cable cross-section(1) is 2.Smm'?.

' t ' t

it t t

1 . "F-r { I

II l

I lt i

I

i

1i' '.'-1 r

r

l

l

I

l

_ _.r,.i._ 'l' _ _ _.r..i,_ '--

:',"



-27 -

T.EBHIRR

Componentdescription UW 13 - Electricalcircuitdiagram Prodo@dbv: weDiro/ Edition:13.02.07/ Version:1

)1.2.3 Cable identification/ core labels The core label (1) providessourceand destinationreferencesfor a particularcore. In this casethe sourceand destinationare -X50:2.3and -S17:30.2respectivelv. Gore label: =U+H-X50:2.3=u+H:g3[! Explanation: This core connectsconnectorblock-X50terminal2.3 to switch-S17 terminal30.2.both of whichare in the chassiscab.



-28 -

UfBHTRR

Componentdescription UW 13 - Electricalcircuitdiagram Prcducedbv: lreoilo / Ediiion:i 3,02.07/ VeEioni 1

Locating the source: Referto the resourceindextableto locatethe sourceof the core labelon the circuit diagram. Use the BMK (-X50)previouslydeterminedfrom the core labelto locatethe corresponding circuitdiagrampage(134.1)in the table. Core label: =U+H-X50:2.3=U+H-S1 7:30.2

_t -:::9

i39.1

:33.: -:1t9

:3e.1

:/

:11 r -x50 ;; I

-tl

l

+H

I 1 9 .t

134.1

:39,5

Liebherr-WeftEhingenGmbH - Technicaltraining


-29 -

UEBIIERR

Gomponentdescription UW 13 - Electricalcircuitdiagram PDducedby: lwepio / Edilionr13.02.07/ Version:1

Locating the source: Gonnectorblock -X50(1) may be foundon page 133 column1. The core labelindicatesthat it is Terminal2.3. (2) Cross-reference(3) referencesthe 5th columnon page37. Core label: =U+H-X50:2.3=U+H-S1 7:30.2

Liebherr-WerkEhingenGmbH - Technicalt|aining


-30-

UEBHERR

Componentdescription UW 13 - Electricalcircuit diagram Prcdlc€d bv: lreoi.o / Ediuon:13.02.07 / V€6ion:1

Locating the source: The 5th columnon page37 alsocontainsconnectorblock -X50(1) withterminal2.3.(21. Note: Terminal2.3 also referencesthe destinationon page38.2. Core label: =U+H-X50:2.3=U+H-S1 7:30.2

Liebhen-WerkEhingenGmbH - Technicaltraining


- 3 1-

lEBDTERR

Componentdescription UW 13 - Electricalcircuitdiagram Prcducedbv: l@oilo/ Edilion:13,02.07/ V€rsioniI

Locating the destination: In orderto locatethe destinationof the core labelon the circuitdiagram,referbackto the resourceindextable. Use the BMK (€17) previouslydeterminedfrom the core labelto locatethe corresponding circuitdiagrampage (38.2)in the table. Gore label: =U+H-X50:2.3=U+HjW:30.2

i l:.1

H5P16

:ll=.1

=[J

+H

8.2

=; L

t6r t ii P a l

135,5

l1:

t:,3

8l 113



3iIJ

-32 -

UTBHTRR

Componentdescription UW13 - Electricalcircuitdiagram Producedbv: l@oiro / Edition:13.02.07/VeFioni 1

Locating the destination: Switch (1) -S17may be foundon page38 column2. The core labelindicatesthat it is terminal (2130.2. Gore label: =U+H-X50'2.3=U+Hff :392

l ' i



-33-

T.EBTTERR

Componentdescription UW 13 - Electricalcircuit diagram PFdued bv: lweoiro/ Ediiion:13.02-07/Ve6ion: 1

)1.2.4 Symbols for connectors Connectors (1) are labellede.g.with -X8 17 and includea cross-reference(2) e.g. { 39.1to indicatethe pin assignment.

Liebherr-WerkEhingenGmbH- Technicaltraining


-34-

T.EBHINR

Gomponentdescription UW 13 - Electricalcircuitdiagram Producedbv: lreoiro / Edilion:13.02.07/ Ve6ion: 1

)1.2.5 Symbols for mech, switches Mechanicalswitchesare eithermanually operated(1) e.g. -S23/ "Transfergearbox neutral"or actuatedby meansof a pure mechanicalactuator (2) e.g. -564 / "Roadgear ON" (camswitch).

2

+F

.ln

s-

lco

STRASSENGANG EIN



-35-

IEBHIRR

Componentdescription UW 13 - Electricalcircuitdiagram Producedbv:lweoiro/ Edilion:13.02.07/ Ve6ion: 1

)1.2.6 Symbols for pressure switches Pressureswitchesoperatewhen the air pressurerisesaboveor falls belowa specific value.The switchtype can eitherbe Normallyopen (1) or Normally-closed(2). Example: Switch-S114opensat pressuresin excessof 5 bar.

-srt+[f



-36-

UEHTRR

Componentdescription UW 13 - Electricalcircuitdiagram Pbdlced be: lweDiro/ Edition:13.02.07/ VeBion: 1

)1.2.7 Symbols for inductive switches The alternatingelectro-magnetic fieldof Proximity switch (1) will changewhen it approachesmetal. This in turn changesthe drawncurrent. A pre-definedswitchingthresholddeterminesthe distanceat whichthe switchcloses.



- 3 7-

TEHINR

Gomponentdescription UW 13 - Electricalcircuit diagram Produed bv:lweDiro/Edition:13.02.07/V66ion: 1

)1.2.8 Symbols for valves Valves(1) are actuatedvia EAMsor CPUs.For example,theyopenor closethe oil circuit. The free-wheeling diodeservesto reduceinductivevoltageswhichoccurwhen the valve is switchedoff.

Liebher-WerkEhingenGmbH - Technicaltraining


-38-

UETtrRR

Gomponent description UW 13 - Electricaleircuit diagram Prcdlced bv: lreoiro / Edition: 13.02.07 / VeBion: 1

)1.2.9 Symbolsfor proportionalvalves Proportionalvalves(1)aresymbolised usingan additional horizontal line. just two states.The magnitudeof the currentdeterProportional valveshavemorethan minesthe flowrate. Forexample,valve-Y66closesat a currentof 0.7[A].At currentsabove0.7[A]the proporto the riseof current. tionalvalvewill openin proportion

\.,,1 ,

::l

:Rtr.lRr . :Alli,lR< !Rt:lirrrl:

Liebhen-WerkEhingenGmbH - Technicalkaining


-39-

,

T.EBHIRR

Gomponentdescription UW l3 - Electricalcircuit diagram Prodo@dbv:lreoiro / Edition:13.02.07/ Ve6ion: 1

>1.2.10Design and function of relays / relay contacts Relaysgeneral; A relayis composedof a coil with a magnetic core (1),an armature(2) whichactuates at leastone change-overcontactand a free-wheelingdiode (3). Note: The free-wheeling diodeservesto reduceinductivevoltageswhichoccurwhen the relay is switchedoff.

2

Liebher-WerkEhingenGmbH- Technicaltraining


-40-

UEBHTNR

Component description UW l3 - Electricalcircuit diagram Produc€d by: lwgpilo / Edilion: 13.02.07 / V€€ion; 1

Relaysgeneral: Relayshavetwo separatecircuits,a control circuit (1) anda working circuit (2), Controlcircuit (1) consistsof a switchand a relaycoil. Workingcircuit (2) consistsof a relaycontactand load.

24V

'

9

L-= Liebhen-WerkEhlngenGmbH- Technicaltraining


-41 -

Componentdescription UW 13 - Electricalcircuit diagram Poduced by. w€pno/ Ed I on. 13.02.07/Ve6ion: 1

Relays general: labelled. Relay contacts (1) are individually Test circuit (2) is fittedto the side of the housingcover. The contactlabelscan also be foundon circuit diagram (3).

ilcl Liebher-WerkEhingenGmbH - Technicalt.aining


-42-

UEBHTRR

Gomponentdescription UW 13 - Electricalcircuit diagram Produ.edbv: l@oiro / Edition:13.02.07/Ve6ion: 1

>1.2.'|1Symbols for relays Symbols for relays: lf 24Y andgroundare appliedacrossa relay coil (1) e.g. -K18,the relayclosesand switchesits contacts. The voltageappliedto the relaycan be tracedbackto indicatewhetherthe relayhas beenactivated. E.g.if -K18 is actuatedusingbutton (2) -S3 on masterswitch1 (left). Relay-Kl B includesone relay contact (3). Thereis a cross-reference to page 141.7. -K1B may be foundon this page. Relaycontact

r' lt t

'

-

j

- - l

ll

1

I

"-l

-

3

-J.- |



-43 -

UEBHENR

Gomponentdescription UW 13 - Electrical circuit diagram Poduc€d bv: lwgoio / Editiod:13.02.07/VeFion: 1

Relay contact (1) switchesthe loads"ON" and "OFF". Relaycontactsmay be used in normally-closed, normally-open or change-overconfigurations. Note: Relaycontact-K18is normally-open. The relaycontacthas a cross-reference to page98.7. Relaycoil -K18 may be foundon this page.

-k18

J30

J

t99,7 t'

I

83

t r t r .-^!:,rlr;tt_r A_::)r, ;1!ii'iii1li1!E+-Ei,



-4-

T.EBHIRR

Componentdescription UW 13 - Electricalcircuit diagram Produced bv: lreoiro / Edition: 13.02.07 / VeFion: 1

A relaye.g. -K51can alsoconsistof severalrelay contacts (1). ln this case each of the relav contactshas its own cross-reference.

"" '= l+ r-----------------r I ii;x

r

.. I

;l '*' '-1.:.-','



-45-

UEBHERR

Gomponentdescription UW 13 - Electricalcircuit diagram Producedbv: lwgoilo/ Edilion:13,02,07/ Ve.sion:1

30,50 startswitch/ C1.15, >1.2.12lgnition I

:

l

i a* .-;

4



-46-

UIBHTNR

Componentdescription UW 13 - Electricalcircuitdiagram PFdled bv: lreoiro / Editon:13.02.07/VeBion:1

Summaryof the most importantterminalsignals: . . . .

D 3 o( 1 ) 30 (2) 15(3) 50 (4)

\ (+) Baftery iiliro,,roi-ie

(+) Batteryswitchedaftermainbatteryswitch(blue) (+) Batteryswitchedafterignitionstartswitch(red) (+)Starter(green)

4

:11f .

::+-

I

:1A

, _ . , L _ _ . - _ _ . L . _, . _

€

€ T



- 4 7-

T

lftBHTRR

Gomponentdescription UW 13 - Electricalcircuit diagram P.oduc€dby: ls€drc / Edition:13.02.07/ V€lsion:1

>1.2.'13Gircuit diagram in PDF format Acrobat Reader: The Acrobat Readermay be used to view circuitdiagramson the PC.

Liebher.-Werk Ehingen GmbH - Tecinical training


-48-

Gomponentdescription UW 13 - Electricalcircuit diagram Producedbv: l@oiro / Edilion:13-02.07/ Ve6ion: 1

>1.2.14Usingthe BMK-list General: The BMKlist is usedto locateand searchfor all electricalcranecomponentssuch as switches,valves,relays.... (OW). The BMKlist is sub-dividedintothe chassis(UW)and superstructure Thereare two methodsfor locatingresourcesin the BMK-list: o Via the tableof contents . Via the index

Technische Information LTM 11OO-4-1 ab Krannr. 063 449 Ubersichtder Bauteilemit BetriebsmittelKennzeichnung(BMK) TECHNISCHE DATEN: . max.Traglastbei2,5 m Aushdung: 100t . max. Hubh6he mlt Ooppelklappspitze: 84 m . max. Alsladunq mil DoppelklappspiEe: 58 m . Teleskopauslegeruinge: 11.5- 52m . Ballastvarianten: 0.81bls max.22 t KOMPONENTEN: . Aktive HinlerachslenkunS: 3. und 4. Achse eleklrohydfaulischgelenkt . Fahrmotor:LiebherrD 846Tl A7 CommonRail .Automalisi€rtes Schaltsetriebe:ZF 12AS 2302 . Kranantrleb:LlebherrD934Tr-E46 PLD . Datenbus-Technik mit 2 CAN-Buss€nund 3 Ls-Bussen

b E

Liebhen-WerkEhingenGmbH- Technicaltraining


-49-

l|IAHERR

Gomponentdescription UW 13 - Electricalcircuitdiagram Producedbv: lweoiro/ Edluon:13.02.07 /Ve6ion:1

Table of contents: The tableof contentsfor the UW and OW is sub-dividedinto severalsubiects pagenumber. and referencesthe corresponding

ir- ffi

-{'.u,r,, *"" -\

Anschtvdvdn€,

A€Emhhg

Aisich /d

oruckbesrenzunssvatil im Krofinofi5ysls Hohls.hr€uben zu DrrknaMerungim Kr.frstoffst5rem....,... ..,.

.., . Zg

hihlen, BeleLEhtrn€

Abslutabedien€inheic Seitsma*irunqs|eudnen.e.hs ...........................5 Ab,lt$cdi"rFir heil Seie nr+iaunqsl-udnFrlink. a Wasgg€kuhhe tua€re AL'gasmkn-hrurE Inrenb€leuc|nug,Tur€n Lufrug

33

......... Kihlffi

und W:lfrela6cher

d-NiMU

Motdeu€rgsat,

Miftelkssole - H.uptsh.ltei g.netun SictErungen,Spannungswandler. l0 1t Minelkonsole E/A lvloduleod Oaqnoredecker 12 Mirelkdde - Beeuckun$modul, Inbder ECll

t3 Mift€lkonele

- SLcheuge.

Drkseber urd \bnlile der Bretudaqe KmpressorundTrockner VefrilblGk lilGrerbrawhq 4 KaEl

16

Kr.heofi

hd -Tspebntr Luldhedruck

Vorfher und T.nk

Adodasi€i.sSchahg.uiebe

ZF 12 AS 230? hn Inbtder: .......-.-.......... 37

K u p p l u n g su- n d G e r i e b e s r e l l € r

Pumpen, Lunsanrbb

od

......-.-....37

KuHndage

ABV AnsteErlerlte

Veneilergerieb€ VG 2600- KontakEchah* !nd Taclb!€bd.,.....,.. ... ... ,,..41 - UmsctEltdgSvossertce&indeg.ng Veneilergeriebe ,,,,.,,,,,,,....,,..,...,,,,., 42 Kontakrs.tElter an Ache I und 2 43 Motdansicttr

Kontahsch.lter

SclwungEdseite

. . . . ..... . . . . . . . 2 2

Krafreoff-s€ryice-Ceder

an Ache

3 und .l

Radd€hahl-S€n5i)6.,.,.,....

Wi.belsoodb€meTelh. Fo6l F 2200'

45

KSC

LTM1100-4.1 - Unterwagenab Krannr.063 449. BMK- Baureiteubersichr



-50-

UEBHERR

Componentdescription UW13 - Electricalcircuitdiagram Poduced bv: lweoio / Edition:13.02.07/ Ve6ion: 1

lndex: in the BMK-list The indexis an alphabeticlistingof all resources togetherwith pagereferences.

LTM 110o-4.1 - Unterwagen ab Krannr. 063 449 . BMK- Baureiteobersichr

M

M12...1 M1e...5:l M20.,.€ Mzt..g M?m .20

MP0,.,52

MP1S20...4S N N1..56 P

R RS.3l

Rr6..61 R25..12 S s t . .t 0 5,1..9 s5...0 s12...7 s13,.,7 514...7 515...7 s16..7 s17.9 518.9 519..9 522...11,3a 523...r3 S30.,,ll s31.,.13 s33.,.41 s.|l.,,,t3 s,r2...13 543...13 s44,.13 s50...60 5 5 r. 5 S s60..5e s61..5e s62...58 s63...58

564...,12 s65...,r2 s89...53 sq0...52 5114...15 5r18..,47 5119...!€ 5159',,,e s191...5 U ul..t0

Y42...19 Y43...10

X x2,o...3s x4!..37 x45...37 x56...61 x64,,.9 x65..,9 x90...fl x91...11,35 x92,..n,37 x93,..11,38 Y5...,rS

Y10...59 Y1r,.,59



Y1l..60 Y16..59 Y17..59 Yl8,.60 Y19..@ Y20,,17 Y24,.11 Y25 1t

- 5 1-

Yi0...3s v5t'.17 v53...33 Y55...17 Y66...17 YS0!,..55 YSob...55 YS1a...55 Y01b,.,55 Y82a...55 YS2b...55 Y81a..,55 Y83b...55

Y8.lb..5,1 Y35b...5,1 Y86b..,5,1

Y102a.,.15 Y102b.,.15 Y107...8 Y10S...8 Y109...8 Y220..53 Y221...54 Y222..53 Y225...14 Y2?6..53 Y231...52 Y232...52 Y102.,32 r7O3..,24 y 1 1 1. 2 ? v712...22 f113...22 v114...22 Y715,.,22 y116..22

UEBHERR

Componentdescription UW 13 - Electricalcircuitdiagram Pdduc6d bv: lweono/ Ediiion:13.02.07/ VeBionr1

Mainsection: The mainsectionof the BMKlist illustratesand labelsall electricalresources. The followingresourcedata is providedby the BMK: o Installationlocation . (BMK)e.g. -S41 Resourceidentification o (if relevant)the LSB address o Additionalinformation

AnEiebstrang: Koniaktschalteran Achse 3 und 4

Antriebstrang: Koitaktschalter an Achse 1 und 2

s41

s42 Aclre I aeealDh€r

2 alerdifi.'SPercAchse

LTM 1100-4.1 - Unterwagen ab Krannr. 063 449 . BMK- Bauteileribe.sicht

Liebherr-WerkEhingenGmbH - Technicalkaining


-52-

1IEBHIRR

Gomponentdescription UW 13 - Electricalcircuit diagram Poduced by: lwepiro/ Edluon:13.02.07/ Ve6ion: 1

PDF (Acrobat Reader): The BMKlist can also be viewedusingthe AcrobatReader.

Tech nische I nformation LTM 11OO-4-l ab Krannr- O63449 Ubersicht der Bauteile mit Betriebsmittel Kennzeichnung (BMK) T€CHNtSCHE DATENI . n4. rrrgr.3r b.l r.t marsr.dlnE: . mar. subhdh€mir tlpp.rxrappspiE€ .narAushdung mlt Ooppolkhpp6plts€: !€ m . Lr€sk.p.usr.g€rklng6: r1,5- 52i

KOiTIPONEtITEN: . Ak v6 tirnlcr.cnsrcnkung: a unda Ach$ .|okronydburb.n q.r.nkr . A!rom$|s|.n* sch.ngot.rob.:zF12As2102 . K..nanl ,ob:Ll€bher D034TrEA6 PID . Dabnbustrchnll mll2 cAN-Bus
Liebherr-WerkEhingenGmbH- Technicalt|aining


-53-

UEBHIRR

Component description UW 13 - Electricalcircuit diagram PrDdu@d bv: lweoiro / Edition: 13.02.07 / Ve6id:

Liebhen-WerkEhingenGmbH - Technipaltrair ng


-il-

1


UW14- Heating/ Auxiliaryheater

Onlvfor LIEBHERRServiceoersonnel

Gomponentdescription UW 14 - Heating/Auxiliary heater Pmducedbv: lweoio / Ediiion:18 12.06/ VeFion: 2

lndex ...............4

1. Heating

................................10

2. Auxiliaryheater 2.1Category1.................

2.2Categoryll (40'C version).......



-3-

UEHTNR

Componentdescription UW 14 - Heating/Auxiliary heater Pbduced by: lwepi.o/ Edition:18.12.06/ Ve6ion:2

1. Heating 1.1General )Purpose The"standardheater"heatingsystemis usedto heatthe cranecab anddefrostthe windshields whentheengineis running. )Design Valves Watercircuit - heating Actuators

Displayunitwith controllight Auxiliaryheater"ON " / Faultdisplay

Waterheater pump Circulation

Controlpanelwithbuttonsfor heatingcontrol

Heaterunit Thermo90ST.

Fig.1: Overviewshowinglocatonof installedheatingcomponentsincluding heaterThermo90ST auxiliary * = Option (on mobile cranes with up to 5 axles) Liebherr-WerkEhingenGmbH - Technic€ltraining


_4 -

lTIBITIRR

Gomponentdescription UW 14 - Heating/Auxiliary heater P@ducedby: lwepilo/ Edilion:18.12 06 / Ve6ion:2

-M2'l Controldrive Air footwell/ Windshield

-A145 Drive Fan Heatexchanger

.M20 Controldrive

Recircul air/freshair

viewx y'

Fig.2: WaterheaterunitchassisLTM1220-5.1

Fig.3: Heatexchanger waterheaterunit

Outlet heatedair Windshield

Fan Heatexchanger

Ventilationflap Footwell/ window

Heatexchanger Water- heating Outletheatedair Footwell

View X Ventilationflap Recirculatedairlfreshair

Intakerecirculatedair

Intakefresh atl Fig.4: Waterheaterunitchassis- Internallayout



-5-

lTTBHIRR

Gomponentdescription UW 14 - Heating/Auxiliary heater P'oducedby: lwepno/ Edition:18.12.06/Ve6ion:2

Pre-heatcab lncreaseblower speeo

Engine-dependent AuxiliaryheatingON*

Reduceblower speeo

Fig. 5: Controlpanelior heatingcontrol

Recirculatedair Freshair

Windshield Footwell ventilate ventilate

-Y107 Valvewatercircuitheating Enginerunning: Valveopen Engineat standstill: Valveclosed

-Y108 Valvewatercircuitheating(switched) / Coldcabandenginepre-heating

Fig. 6: LTM 1220-5.1- Valveswater circuit

-Y109 Valvewatercircuitheating(switched) / pre-heatcab

. = Option Liebherr-WerkEhingenGmbH - Technicaltraining


-6-

llElltRR

Componentdescription UW14'Heating/Auxiliaryheater Prcdued by: lwopiro / Editon: 18.12.06 / ve^ton: 2

Coolantpump

Fig. 7: Coolantpump - D846-A7

Returncab/ from heater

Liebhe.r-WerkEhingenGmbH - Technicaltraining


-7-

UEHTNR

Componentdescription UW 14 - Heating/Auxiliary heater Prodlced bv: lsedlo / Edition:18.12.06/veclon:2

)Function

(Coolantgircuit) 1 2 3 4 5

Heat exchangervehicleheating(waterheater unit) Dieselengine Waterpump(coolantpump) Cooler Regulationvalve

Fig.8: Overviewof heatingsystemwithout auxiliaryheater

The water-cooled dieselenginewarmsup duringoperationand the heat is transferredto the watercircuit. The pushbutton"Pre-heatcab"/ "Pre-heatengine"on the controlpanelis usedto modify the switchingratioof the watercircuitvalves(-Y108and -Y109). When the pre-heatedcoolantflowsthroughthe heat exchangerin the cab water heater unit,the air is heatedand distributedby a blowerintothe cab. Threepossiblesituationscan arise: The engineonly heatsitselfup The engineonly heatsthe cab The engineheatsthe cab as well as itself(seefigure2). Normalposition: . The cab is pre-heatedusing1/3 of the heatingpower(stage1 - heatedwindshield - SFlbrecirculated air withfreshair content) . The engineis heatedwith 213of the heatingpower Liebherr-WerkEhingenGmbH - Technicaltraining


-8-

UBITERR

Gomponentdescription UW 14 - Heating/Auxiliary heater Producedbv: lEoilo / Edilion:18.12.06/ Ve6ion: 2

-Y108 Watercircuitvalve Heating(switched) / Coldcabandenginepre-heating

tr

-Y107

Engine pre-heat

/ preValvewalercircuitheating(switched) heatcab Fig. 9: Overviewof heatingsystemwith auxiliaryheater/ engineas sourceof heat

i



-9-

lIIBIIIRR

Gomponentdescription UW 14 - Heating/Auxiliary heater Prcducedby: lwepid / Edition:18.12-06/ VeEion:2

2.Auxiliaryheater 2.1Category| 2.1.1Waterheater- Thermo90S/90ST )Purpose is usedto pre-heat water-cooled enginesandactsas Auxiliary heaterThermo90S/90ST thevehiclewindshields. heaterfor heatingthethecabanddefrosting an independent )Design

4

S"-=--'

5

Auxiliarvheater: lfnermo SOSISOST; 1 Combustion air blower 2 Fuelconnection 3 Temperature sensor 4 Temperature limiter 5 lnlet- coolant pump 6 Circulation 7 Outlet- coolant 8 Outlet- exhaustgas 9 lnlet- combustion air 10 Control unit 11 Buttonfor switchingon after limiterhasbeen temperature activated

Fig. 10:Auxiliaryheater*

-A130 Controlunit Auxiliarv heater

-A131 Heaterunit Thermo90ST

Fig.11:AuxiliaryheaterThermo90ST. Liebherr-WerkEhingenGmbH- Technicaltraining


-10-

UIBHINR

Gomponentdescription UW 14 - Heating/ Auxiliaryheater Prcd@d by: lwepio / Edition:18.12.06/VeBion:2

Controllight heater"ON" / Auxiliary Faultdisplay

-M19 pump Metering heater auxiliary

Fig.13: Displayunit

Fig.12:Meteringpumpauxiliaryheater

Fig. 14: Buttonenginepreheating

Fig.15:Timerauxiliaryheater" Uebherr-W€rkEhingonGmbH - Technicaltraining


- f

-

lIEHINR

Componentdescription UW 14 - Heating/Auxiliary heater Producedbyr lwepid / Edition:18 12 06/ Version:2

)Function

tilil o

Controllines Fuelpipe Exhaustpipe Watercircuit

t

1 2 3 4

Heatexchanger vehicleheaiing fimer* Dieselengine Heaterunit

E

^:.^, ,r^1i^- ^..-^

c 6 7

urlcurauon PumP Walerpump(coolantpump) Cooler

11 I

8 9 10 11

13

Regulation valve Exhaustsilencer pump Metering Fuelsuctionoroe

12 Controlunit 13 Fueltank

Fig.16: Overviewof heatingsystemwith Thermo90S/STauxiliaryheater

The auxiliaryheateris switchedon usingthe "AuxiliaryheaterON" buttonor via the timer*. The waterheaterunitfunctionsindependently of the vehicleengineand is connected to the coolingsystem,fuel systemand electricalsystemson the vehicle. Fuelis fed in externallyusingthe meteringpump.The heaterunittransfersthe heatgeneratedby the combustionof the dieselfuel intothe watercircuit.The circulationpumpensuresthat the coolantflowsthroughthe vehiclecircuit.The circulationpumpis switched on by the controlunit.lt runsthe wholetime that the heaterunit is in operation. The pushbutton"Pre-heatcab"/ "Pre-heatengine"on the controlpanelis usedto modify the switchingratioof the watercircuitvalves(-Y108and -Y109)(Fig.2 and Fig.3). . = Option Liebherr-WerkEhingenGmbH - Technicaltraining


-12-

IIIBHINR

Componentdescription UW 14 - Heating/Auxiliary heater Poduced bv: weono/ Ediuon:18.12.06/ VeEion:2

The sourceof heatcan be the engine,auxiliaryheateror both.Thereare threepossible CASES:

. . .

Case 7; The engineis running(warm)and the auxiliaryheateris switchedoff (seefig. 2). Case2: The engineis turnedoff (cold)and the auxiliaryheateris switchedon (seefig. 3). Case3: The engineis running(warm)and the auxiliaryheateris switchedon (no fig.)

The timer*is usedto selectthe time at whichheatingcommencesin a time windowof up to 7 davs.

-Y107 Valvewater circuitheating Enginerunning:Valveopen Valveclosed Engineat standstill:

-Y108 Watercircuitvalve / Heating(switched) Coldcabandenginepre-heating

E

Heat cab Freshair / Windshield/ recirculatedair footwell

Engine pre-heat

-Y109 Valvewater circuitheating(switched)/ preheatcab Fig. 17: Overviewof heatingsystem with auxiliaryheatet - Engine is heating/ Auxiliary heater "OFF" Liebherr-WerkEhingenGmbH - Technicaltraining


-13-

UIBIIIRR

Gomponentdescription UW 14 - Heating/Auxiliary heater P.oducedby: lwepio / Edilion:18.12.06/VeBion: 2

-Y107 Valvewatercircuitheating Enginerunning: Valveopen Engineat standstill: Valveclosed

-Y108 Watercircuitvalve Heating(switched) / Coldcabandenginepre-heating

E

/ Freshair/ Windshield recirculatedair footwell

+t

i+

-Y109 Valvewater circuitheating(switched)/ preheat cab

Fig.18:Overview of heatingsystemwith auxiliaryheatet- Auxiliary heater is heating / engine turned off



-14-

llEHINR

Componentdescription UW 14 - Heating/ Auxiliaryheater P r o d u c e d b y : l w e p i l o / E d i l i1o8n1: 2 0 6 / v e 6 o n : 2

9

1 2 3 4

10 11

:

13

14 --

Fueloioe Combustion air inlet Combustion air outlet Water outlet

6 7 I 9

Combustion air blower Fuel connection Glowplug Bumer Water outlet nozzle Temperaturesensor Flamemonitor Pluggedconnection Heat transfermedium

10 11 12 13 14 15 16 17

Combustionpipe Temperature limiter Timel Water fillingnozzle pump Circulation Exhaustoutletnozzle Meteringpump Combustion air fillingnozzle

heater 90S/,ST auxiliary Fig.19:Overview ofThermo )Fault diagnostics The heaiingfaultdiagnosticsseryeto rapidlyidentifyany faults.SFlbThetype of fault is indicatedby the flashingsignalson the Operationalindicatorlights -H628 on the display unit.Afterfive shortsignals,countthe numberof longflashingsignals. The numberof flashingsignalsallowsthe faulttype to be determinedusing the codingbelow.

. . . . . . . . . . .

1x 2 x 3 x 4 x 4 x 6 x 7 x 8 x 9x 10x 11x

No start(after2 startattempts) Abortedflame Under-or overvoltage flamerecognition Premature or short-circuit Flamemonitorooen-circuit or short-circuit Temperature sensoropen-circuit pumpopen-circuit or short-circuit Metering short-circuit or Blowermotoropen-circuit, incorrect soeed Glowplugopen-circuit or short-circuit Overheating pumpopen-circuit or short-circuit* Circulation

. = Option Liebherr-WerkEhingenGmbH - Technic€ltraining


-15-

UIBNIIRR

Gomponentdescription UW 14 - Heating/Auxiliary heater Prcducedbv: lweoio / Edilion:18.12.06/ ve6ion: 2

)Fault rectification Cancellingthe fault interlock: A simplefaultinterlockmay be cancelledby switchingthe auxiliaryheateroff and then backon. Gancellingthe heating interlock: In some casesa heatinginterlockmay occur.This is cancelledby interrupting the operating voltagewhen the auxiliaryheateris switchedon . lt is recommended that the supplyfuse for the auxiliaryheateris takenout.

Liebh€n-WerkEhingenGmbH - Technicaltraining


-16-

UIBIIIRR

Componentdescription UW 14 - Heating/Auxiliary heater Produeedby: lwepio / Editio.:18.12.06/ve6ion:2

2.2 Categoryll (-.40'Cversion) 2.2.1WaterheaterDBW2020 Purpose enginesandactsas an indewater-cooled is usedto pre-heat Auxiliary heaterDBW2020 pendentheaterfor heatingthethecabanddefrosting thevehiclewindshields. bythe of -40",it is pre-heated lf thedieselengineis startedat outdoortemperatures DBW2020andAirtop5000untilit is ableto start. withtheThermo90STwaterheater. TheDBW2020 is notusedin combination

lDesign

1 Burnerhead 2 lgnition unit 3 Coolant,outlet (injection tubeheating) 4 Thermostat 5 Heattransfermedium i 6 Exhaustoutlet 2 7 Control unit1553/ 24V

. 5

1

Fig. 20: Overviewof auxiliaryheater DBW2020.56.

. = Option Liebhen-WerkEhingenGmbH - Technicaltraining


- 1 7-

UIBlfiNR

Gomponentdescription UW 14 - Heating/Auxiliary heater Prcducedbv: lweoid / Edilion:18.12.06/veFion:2

Thermostatvalve 59'C

-A133 Heaterunit D8W2020.32 -4132 Controlunit1555 Auxiliary heater t24V,90W, 23.3KW

Circulationpump auxiliarvheater Fig. 21: Auxiliaryheater D8W2020. in tool box - LTMl055-3.1

Cab circulation

pump Fig.22:Cabcirculation

* = Option Liebherr-WerkEhingenGmbH - Technicaltraining


-18-

UTBIIIR

Gomponentdescription UW 14 - Heating/Auxiliary heater Producedbv: lseono / Edition:18.12.06/ ve6ion:2

) Function 1

3

hi

o 7 8 9 10 11 12 13

--1

Non-return valve pump cab circulation Cabheatexchanger (waterheaterunit) Valvewatercircuit-Y109 Valvewatercircuit-Y108 Valvewatercircuit-Y107 Cooler tank Coolant expansion Dieselengine Themostatvalve59' Non-return valve AuxiliaryheaterDW2020 pumpauxiliaryheater Circulation

I

___:a __J

D 846A7 / enginepre-heating Fig.23:CoolingwatercircuitwithauxiliaryheaterD8W2020.65"

The auxiliaryheater(12) is switchedon usingthe "AuxiliaryheaterON" buttonor via the of the dieselengine timef. The auxiliaryheater(waterheaterunit)runs independently and is connectedto the coolingsystem,fuel systemand electricalsystemson the vehicle. Fuelis fed in usingthe internalmeteringpump.The waterheaterunittransfersthe heat generatedby the combustionof the dieselfuel intothe SFlbwatercircuit. The pushbutton"Pre-heatcab"/ "Pre-heatengine"on the controlpanelis usedto modify the switchingratioof the watercircuitvalves(-Yl 08 and -Y109).The sourceof heatcan be the engine,auxiliaryheateror both. The auxiliaryheatercirculationpump(13) ensuresthat the coolantflowsthrough the enginecircuiton the vehicle. The coolantis pre-heatedin the shortenginecircuit.Whena temperatureof 59'C is reachedin the shortcircuit,the thermostatswitchesthe coolantintothe maincircuitand hencethe engine(Fig 1). The cab circulationpump(2) ensuresthat the coolantflowsthroughthe cab circuiton the vehicle. The timer*is usedto selectthe time at whichheatingcommencesIn a time windowof up to 7 davs.

* = option Liebherr-WerkEhingenGmbH - Technicaltraining


-19-

IIIBHERR

Componentdescription UW 14 - Heating/Auxiliary heater Prcdu@dbv: lwe.ilo / Editionr1a 12 06 /Vecio.:2

1

2

3

4

5

21

20

Controlunii 2 Engine 3 lgnition unit Clutch c Combustion air blower 6 Solenoid valve 7 Plugconnector o Waternozzles 9 lgnition electrode 1 0 Diffusernozzle 1 1 Thermalfuse 1

6

7

19

18

17

16

'12 Temperaturelimiter 13 Wateroutletnozzle 14 Heattransfer medium 15 Combustion chamber 16 Torsion body 17 Exhaust outlet 18 Flamemonitor pump) 19 Fuelpump(internal metering 20 Fuelpipes 21 Fuelinletwithregulation

15

't4 Fuelpipe Combustion air inlel Combustion airoutlet Wateroutlet

Fig. 24: Overviewof auxiliaryheater D8W2020.65-

* = Option Liebhen-WerkEhingenGmbH - Technicaltraining


-20 -

UIBIIIRR

Componentdescription UW 14 - Heating/Auxiliary heater P.oducedby: leepio / Edition:14.12.06/VeBion:2

2.2.2 Cab air heater AirTop2000S )Purpose TheAirTop 20005 air heateris installedon -40'C models(Cat ll) in additionto the auxiliary heater(D8W2020waterheater). It is usedas a rapidindependentheater,whichis usedto heatthe cranecab and defrost the vehiclewindows. )Design

-A-134 Controlunit Auxiliary heater

-A135 Heaterunit AirTop2000S

Fig.25:Auxiliaryheater/ air heater- AirTop20005-

-s25 Rotaryswitchair heater . Switching onioff . Settingtheheateroutput . Faultindicator (blinkercode) . Release afterfault Weekday

'llmer Fig.26: auxiliary heater* / rotaryswitch

Alarmdisplay Storagespace Time

display Operational

Standard clock withalarm

ProgramselectionlmmediateRetumflow Supply heating

* = Option Liebhen-WerkEhingenGmbH- Technicaltraining


-21 -

UTBHTNN

Component description UW 14 - Heating/Auxiliary heater PEducedby: lwepiro/ Edition:18.12.06/VeBion:2

)Function

1 Rotaryswitch 2 Heaterunit 3 Heatlransfermedium 4 Heaterblower pump 5 Metering 6 Fueltank

Controllines Fuelpipe Exhauslpipe lntakeair Fig. 27: Overviewof heatingsystemwith AirTop2000S*

The rotaryswitchon the centerconsoleis usedto switchthe air heateron andoff and determine the heateroutout. to TheAirTop2000S air heaterrunsindependently of thevehicleengineandis connected thefueltankandelectrical systemson thevehicle. pump. Fuelis fed in usingtheexternalmetering gasesresulting fromthecomTheheattransfermediumis heatedby thecombustion bustionof thedieselfuel.Theheatedair is directedbv thehotair blowerintothevehicle compartment. NOTE: Changesin settingson the operatorcontrolsare executedby the controluniVheater unitwitha timedelav. * = Ootion Liebher-WerkEhingenGmbH - Technicaltraining


-22 -

UEHTNR

ttrHH8n

- 9Z-

ecrrues louuosred uu3Hsf 11roJ^luo 6ulu!e4lecluqoel- Hqug ue6uq3 VeM-xsqq€n

6u[Paqard auroua uoung:62'6rl

NOreleeqfierlrxneuopng

- 0009oolrlvrolPsr4 rv :82 orl l'e-990|,y!1"1 6u|}eoq-oJduorssrursueJl-SV roJasoq 6u4eoH

0009dolrlV lrunroleoH i LgtVreleeqfuerlrxny ]!un 9StV-

eu!6ueleselp uo duJnduorpalul roj esoq6urleeH

u6;sag{

'dulnduolcefureurOue leserpeq1leeq-erd puesu:e}s,{s uorsslursueJl oruorf-sv}eaq-ordo1pesnosles! Jaleoqt;e ggggdolt;yeq1 '(releeqrole^ ozozMgcl)ralpoqruerll -xneqllsorllol uonrppe ul (ll le3) slopourO .0t- uo pellelsur srroleoqre ggggdogryaq1 esodrn6l ggggdo1.r;y 6ugleaq-ard augEue raleeq4V tZ'Z

z :uoEa^ / go-z t g I :uon!p3 / 0Lro.4 :^q p.snpord

rolBaqfte;;;xny/ FulleaH- tt Mn uolldu3sopluouoduoS

uliltgn

'cz-

ocrruosuu3HEf ll roj Iluo leuuosrad 6urure.4 leetuqcol- Hqurg us6utqf

ouqeaqleô Jo lrncJrc-Uorls lrncrc-uedo6n;dmolg paooslsoJocur 'lrnorc-uado i ro llncrc-]Jor.ls JoloruJolv\olE Jolrnclrc-uedo dund 6uueleyy lrncrc-Uor.ls ro rosues olnleledulof lrncJrc-Uoqs lrncro-uedo yncrrc-uedo ro lol!uott.tautpll ]rncJ!c-Uoqs uorlru6ocer oueU olnleuieJd ebel;oruano ro -lepul eluBupauoqv (slduape UelsZ laye) lels oN

oM-ltoqqol.l

x0L x6

xB xL x9

xv xv xt

xz xL

'(moleqees) burpoceq1 6ursnpeurulegopeq ol edfi llnpJeql s^ ollp sleuOtsOurqseg JoJequlnuor1f 'sleu6ls6urqseg 6uo;1orequnu oql lunoo'sleu6rsUoLls€Ûr€UVqllS uoleoqrre ggggTdo;gyqlls €r.ll eq1Iq pelecrputst llneJJoed^l aqf lo 9ZS-qclrAsfueloJuo OJ1eq1uo s;eubrsOurqseg 'sllneJIue Ilnuapr,{lprdelol eruasscnsou6etp buneeqeq1 1;ne1

scglsou6elp 11ne3{

z :uors.A / 90 z f8l :lonrpl / 0jd.4 i^q pa.npqd

roleaqfte;!;xny/ oulleaH- tt Mn

uolldussopluouodruoc

Componentdescription UW 14 - Heating/Auxiliary heater Prcducedbl. lwepno/ Edition:18.12.06/ VeBion:2

ProgramselectionlmmediateReturnflow Supply Fig.30:Tlmer

) Function lf the temperatureselectionis switchedto "Coldcab" and the auxiliaryheateris switched transmission on by the bufton"AuxiliaryheaterON" or via the timer,the SFIbAS-Tronic pumpare pre-heated. systemand dieselengine-injection of the vehicleengineand is connectedto TheAir Top 5000air heatbrruns independently the fuel tank and electricalsystemson the vehicle. Fuelis fed in usingthe externalmeteringpump. The heattransfermediumis heatedby the combustiongasesresultingfrom the combustion of the dieselfuel.The heatedair is directedby the hot air bloweronto the transmissionand the dieselengineinjectionpump. Note: and plug-inpumpsare heatedrespectively. On CR and PLD enginesthe high-pressure



-25 -

UIBITTR

Gomponentdescription UW 14 - Heating/Auxiliary heater Producedbv: lweDno/ Edition:18.12.06/ Veeion:2

fuel tank - Auxiliaryheatingsupply(40' version) 2.2.4Supplementary )Purpose heateron -40' the auxiliary fuelfor supplying fueltankholdsseparate Thesupplementary models.

)Design -M36 pump Metering heater Auxiliary AirTop5000 SFlb(AirheaterAS-Tronic / fuelpump transmission pre-heating) -M35 pump Metering AirTop2000S heater auxiliary (airheaterin cab) fueltankfor Cat. ll- - LTM1055-3.1 Fig.31: Supplementary

)Function fueltankto theair pumpsfeedtheseparate fuelfromthesupplementary Themetering amountof fuelis supplied. Onlytherequired heaters(Airtop2000s/5000). provides fuelflow. a constant fuelpumpon the DBW2020 Theinternal musthavea supplyandreturnline. fuelpumptherefore Theinternal



-26 -

UEHIRR

Componentdescription UW 14 - Heating/Auxiliary heater Produed qr h€plto / Ediltbn: 1a-12,06 / VeFion: 2

Liebhen-Werk Ehingen GmbH - Technical training


-28 -


UW18- Others/Accessories

Projectnumber: 9996008


Componentdescription UW 18 - Others/Accessories Prcdu@dby: l@pid / Edilion:11.06.07/VeBion:2

lndex Trailing axles 1. LWE Trailing axle

Liebherr-WerkEhingenGmbH - CustomerServiceTraining


-3-

UEBIIIRR

Gomponentdescription UW 18 - Others/Accessories P@d!@d b!. lwepilo / Edition: 11.06.07 / Ve6ion: 2

Trailingaxles 1. LWETrailingaxle )1.1 Purpose The trailingaxle is an optionalaxlewhichcan be attachedto specificvehiclemodels. Attachingthe trailingaxle increasesthe maximumpayloadof the crane,for exampleto allow extra ballastto be carried. The maximumpermittedoverallloadis determinedby the numberof axlesmultipliedby The penaltiesfor any the permittedaxle load.The maximumaxle load is country-specific. on the country. excessloadwill also be handleddifferentlydepending For example,if a craneoperatorwantsto carrythe full additionalballastfor a particular craneoperation,it couldoccurthat the mobilecranewithouta trailingaxlewill exceedthe maximumpermittedaxle loadfor roaddriving. The hailingaxle is attachedto the rearof the mobilecrane.The total load is therefore distributedbetweenthe axlesof the mobilecraneand the trailingaxle. Mobilecranesfitted with trailingaxles thereforeallow the crane operatorto carry additionalballast.

)1.2 Layout

Fig. 1: LTM 1200-5.1withtrailingaxle Liebhe.r-WerkEhingenGmbH - CustomerServiceTraining


-4-

UEHTNN

Componentdescription Others/ Accessories Produ@d by: lwepid / Editjon: 11.06.07 / Ve6ion:2

with the exceptionof the The activerearaxlesteeringfor the trailingaxle is independent powersupply.The trailingaxle can thereforealso be fittedto mobilecraneswithout active rearaxle steering. The mobilecranemustbe preparedaccordinglyfor operationwith the optionaltrailing axle: . Additionalanglesensorson the first and last axlesof the mobilecrane . Electricalpreparations . Hydraulicpreparations . Cab controlinstruments(controllights and buzzer) . Mechanicalpreparations

12t Counterweight

Contentin box 0.61

Support plates6.641

Fig.2: LTM 1200-5.1withtrallingaxleand counterweights

101 Counterweight

Counterweight supports0.37t

framewith Counterweight toolkit0.75t



- 5 -

T.IEIITRR

Componentdescription UW 18 - Others/ Accessories PmdEed by lrep|lo / Editon: ri 06.tt / veBid:

Therearetwo typesof trailingaxleswithactiverearaxlesteering: . Trailingaxlewithdrumbrakes(Fig3) . Trailingaxlewithdiscbrakes(Fig4)

Fig. 3: Trailingaxle wilh drum brake

Note: Trailingaxleswithdrumbrak6sshouldonlybe fittedandoperatedon craneswithdrum brakes,otherwisean errormessageis outputandthe trailingaxleis allowedto coast.

newaxlesuspension cylinder

Fig.4: Trailingaxlewithdiscbrakes

Trailingaxleswithdiscbrakesshouldonlybe fiftedandoperatedon craneswithdisc brakes,otherwisean errormessageis outputandthe trailingaxleis allowedto coast. Liebhen-Werk Ehingen GmbH - Customsr Sewice Training


_6 _

UEIIRR

2

Gomponentdescription - Others/ Accessories P@ducedbv: lweoio / Edilion:11.00.07/ VeEion:2

Type identificationfor vehicle and trailing axle: The I / O modulesdetectthe connectedvehicletype by queryingthe pin assignmentof both Harding-connectors. (discbrakeswith drum brakes)to be For example,this allowsprohibitedcombinations detected. Oncethe vehicletype is known,the lengthof the vehicleis also known.The steeringangle calculations can then be made.

At presentone differentiatesbetween 12 differentvehicletypes:

Drumbrakes: Typel: fype2: Type3: Type4: Type5: Type6: TypeT:

LTM1055-3.1 LTM1045-3.1, LTM1045-3.1, LTM1055-3.1(CR,PLDengine) LTM11004.1 LTM1090-4.1, 1220-5.1 11 00-5.1 LTM LTM , LTM1100-5.2 LTM1095-5.1, LTM 1070-4.1 LTM ''|070-4.1(CR, PLD engine)

Disc brakes,first availablewith these engine interfaces:

TypeS: Type9: Type10: Type'l1: fype12:

(mechanical) LTM1045-3.1, LTM1055-3.1 1 (mechanical/elechical) 1, LTM1055-3. LTM'1 045-3. LTM11004.1 LTM1090-4-1, LTM1150-5.2, LTM1200-5.1, LTM1130-5.1 LTM1095-5.1,LTM1100-5.2, LTM1220-5.2 LTM1070-4.1

Liebhen-WerkEhingenGmbH - CustomerServiceTraining


_7 _

lIEIIRR

GomponentdescriPtion UW 18 - Others/Accessories PDdued by: l@pilo / Edition: ll .06.07 / veBion: 2

Mountingpointstrailingaxle

holestrailing Pinning axle

Fig. 5: Mechanicalpreparationstrailingaxle

Four-foldliftingchains

Fig. 6: Trailingaxle conectlyattached



-8-

UEHINR

Gomponentdescription UW 18 - Others/ Accessories P f o d u c e bd y r l w e pO / E d t i o n : 1 1 0 60 7 / v e E o n : 2

Leverto releasethe salety plate (allowsthe lrailingaxle to be unpinned) Boltwith linchpin

rl i'!

Directional controlvalvewilh hand Supportfor trailingaxle Ieverto controlthe pinningmecha- whenuncoupled nism.

Liebherr-WerkEhingenGmbH - CustornerServiceTraining


_g _

Dualreleasevalve (parkingbrakeand retarder)

UIBHIRR

GomponentdescriPtion UW 18 - Others/ Accessories Produ@dby:lwepio / Edilion:1106.07/ve6onl2

Bowdenwire cable

Spring Safety plateto protectthe bolts againstthe unintentionalrelease of the pinning mechanlsm Pinningcylinder

Boltsfor mechanicallY pinningthe trailingaxleto the vehicleframe

Mountingpoints

Supportfor trailingaxle whenuncoupled

Fig.8: Pinningand mountingthe trailingaxle Liebherr-WerkEhingenGmbH - CustomerServiceTraining


-10-

lIIBIIIRR

Componentdescription UW 18 - Others/Accessories Prcducedbv: ls€oill) / Edition:11.06.07/ V*id:

Fig.9: Installed anglesensorshownon LTM1095-5.1

An additionalanglesensormustbe fiftedto the vehicleaxles(alwaysthe frontand rear vehicleaxles)on the leftside of the vehicle. Liebhen-werkEhingenGmbH - CustomerServiceTraining


_ fl

_

UEITRR

2

Gomponentdescription UW 18 - Others/Accessories PEdled bv: lweDilo/ Edltion:IL06.07/VeBlon:2

-Y239 valve Proportional (BoschCANvalve)

-A181* Brake pad monitorright

-s57 Camswitchaxle compensation right -A13 l/Omodule3 Supportcontrolun:tfor activating the testprograms"activerearaxlesteering forthetrailing axle". -414 l/Omodule4 -s56 Camswitch Axlecompensation left -A180Brakepadmonitor left Fig.10: Installedsensors,modulesand valveson trailingaxle

-A13 l/Omodule3

-A14 l/Omodule4

rr'4 I

Supportcontrolunitfor activating the testprograms"activerearaxlesteeringforthetrailing axle".

Fig.11: Controlcabinetfor the trailingaxle * = Onlyon trailingaxleswithdiscbrakes Liebherr-WerkEhingenGmbH - CustomerServiceTraining


-12-

ITIBHINN

Componentdescription UW 18 - Others/ Accessories Pbdu@d bv:lweDiro/ Edilon: 1106 07 / vecion:2

1.3 Function )1.3.1 Trailing axle, general The trailingaxlesteeringfollowsthat of the vehicledependingon the vehicleoperating mode. betweenthe operating On vehicleswithout"activerearaxlesteering"one differentiates vehicles with activerear axlesteermodes"rearaxlesteeringlocked"and "released",on betweenthe operatingmodes"roaddriving"and "off-road ing (AHL)one differentiates driving". In orderto indicatethe operatingmode,vehicleswithAHL are equippedwith an interface to the keyboardunit in the cab whereasvehicleswithoutAHL have an interfaceto mesteering chanicallyoperatedcam switcheson the rearvehicleaxle.The electro-hydraulic pre-selecf processors. the Depending on by two steering axle is controlled for the trailing ed operatingmode,the steeringangleis takenfrom the firstor last vehicleaxleand then adjustedaccordingto the vehiclespeed. The foffowing steering paftern has been defined for vehicles with AHL: . "Roaddriving":Steeringangleinputfrom steeringanglesensoron leadingaxle (front axle)and oppositesteeringof NLAto permita narrowturningradius. . "Off-roaddriving":Steeringangleinputfrom steeringanglesensoron last steered site use (crab of steeringprogramsfor construction vehicleaxleand imple;nentation driver etc.) steering,manualsteeringby the The folfowing steering pattern has been defined for vehicles without AEL: . "Locked":Steeringangleinputfrom steeringanglesensoron leadingaxle (frontaxle) and oppositesteeringof NLAto permita narrowturningradius. . "Released":Steeringangleinputfrom steeringanglesensoron laststeeredvehicle site use (crabsteering, of steeringprogramsfor construction axleand implementation manualsteeringby the driveretc.)

Liebhefr-WerkEhingenGmbH - CustomerServiceTraining


_ i3

_

rlIBHERR

Componentdescription UW 18 - Others/Accessories Producsd by: lwepid / Edilid: 11_06.07/ Ve6ion: 2

)1,3.2 Pinningand unpinningthe trailingaxle Movethe leverdownto pinthe trailing axte.

Fig.12:Down= pintrallingaxle

Move the lever up and at the same time pull the bolt pullingdeviceto unpinthe trailingaxle.

Fig.13:Moveup andpullboltretainer= unoin trailingaxle

Note: The levercan no longerbe movedup if the dooron thetrailingaxleis locked.Thisis preventedby a studin the doorof the trailingaxle. Thisprevents thetrailingaxlebeingunpinnedby an unauthorised person.

Fig. 14: Mechanicalprotectionagainst the trailingaxle beingunpinned Liebher-Work Ehingen GrnbH- Custom€r Servic€Training


- ,14 _

UEHTNR

Componentdescription UW 18 - Others/Accessories PEdued br lweono/ Editon:11.06.07/VeFion:2

ryl f:r

i . T J ] TL T] ]

i

Highpressure(suppliedby gearpumpfor steeringclrcuitll) Controlpressureafterpressurereducingvalve24bar pressurelbar) Retumsteeringcircuitll (pre-tension Loadindication Dressure

- Pintrailingaxle LTM1200-5.1 Fig.15:Excerptfromhydrauliccontrolschematic



- 15 _

UEHRN

Componentdescription UW 18 - Others/Accessories P@dued by: lwepio / Edilion:11.0607 / Ve6ion: 2

)1.3.3 Openingand closingthe parkingbrakefor the trailingaxle .

To closethe parkingbrakeon the trailingaxle,pull out the red pushbufton.

.

To releasethe parkingbrake,push in the red pushbufton.

Note: The parkingbrakecan be closedwhen uncoupledor attached. Fig.16: Releasingand closing the parkingbrake

)1.3.4 Opening and closing the service brake for the trailing axle

Toclosetheservicebrakeon thetrailingaxle,pulloutthe blackpushbutton. pushin the black pushTo releasethe service_brake, / button. Note: The servicebrakecan only be closedwhen uncoupled. Fig.17:Releasing andclosingthe servicebrake red pushbutton pulledout= parkingbrake closed

blackpushbutton pulledout= servicebrakeclosed

red pushbutton pushedin = parkingbrake open

black pushbutton Dushedin = servicebrakeoDened

Fig. 18: Releasingand closingthe service brake

Note: The dual releasevalveis a boughfin part.This makesthe black pushbutton moreor less redundant! Liebher-WerkEhingenGmbH - CustomerServiceTraining


_ 16 _

llBHTNR

UUITIgN

ecrruas lauuosred uu3H83ll roJ^luo -

8t

-

6ururerr e.ln,esreurolsnc- Hqurgueourqa rre,1,1-rJoqqor-r

arnssordcuaqdsourlv(:repessaldLuoc) aJnssord aNesarJlV 'uadoolerq 6urryed'(uedo)paleredo e)erq lou ualsls Jtepsssalduoculol] ldl$x3 :!z 6ll aclrues- uor]rsod 6unupeqi uraFe 6ullle4roj sBeuraq9s

uoDnq uollnq -qsnd por -qsnd Icelq

outlloJluos

'6rues lll lrncJlc -ol atnssaJoiv

'pesolcsr alerq ourlredaql esr^Jei.llo'uoDnqqsnd por €ql ur ourqsnd,t1lnl uadoaq lsnura)erq butlled eq1 Iq penerqcesl slql' uorlrsoddurnupeql ur (pasunssaJd) 'olxe 6urlle4aLllJoJruolsls olerq aql ol rre pesserduocser;ddnsstql 'uortrsod6urnr.rp o)erq ocrruoseql JoJ(uoDnqqsnd eq1ol Iceq sbuuds,{llecr1eu.ro1ne palceuuoc eql ol sl elxe outlterleql se uoossv Icelq) e^le^ aseeleJeql'auerc olrqou-r polProdolou alerq oelruos- olxe oulllPrl sr.llJo uolllsod 6u;npg g'g'11

z:uoroe /,t090 t|:uoflp: / 0Jda4:Iq panpord

solJossaccv/sror.llo- 8|, ,\ n uolldllcsop luouoduog

louuosodacrruos uuf H83ll roj ^luo

tnHltgll

-

Ll

-

ou!u!e{e3!^rosJouropnc- Hqureuaourq!,1,aM-!aqqa!'r

'pssunsseJd sr ropull^c-dolsulaql uaq^ pesolcs! olerq ool^Jsseql 'posunsseJd sr ropurlfic-dolsulaql ustlivlpousdosl elelq buryed eq1 :oloN dolsurlo uorpunr:020u rapurc ourrerq

6ursnpauado JrPpasseJduro3 (uo[cas 6uuds)alaq 6uqre6

re passordLuoo 6ursnpasolc aueJqLuaur) oIBJqac!ruas

elaq 6ur4e6 elpjq ocNas

aFe ourle4eql rol urals^sre pesse:duo3:61 0t3 (elErqunrp ro] ^tuo)nEO

(JepreleJ pueo)erq0uqred) e4e^ aseolorleno o

J

L

7

'eru3s lllllncJ|3 -ar olnssalo Jtv

olxE 6u!l!pJloql uo sluouodruocuralsfs Jle passaJduoCI't't<

z :uors€A/ l0 !o ll :uoop3 / 0oo4t :^q p@npod

souossocev/sroqlo- g|,Mn uolld!rcsopluauodruoS

Gomponentdescription UW 18 - Others/ Accessories P@dued by: lwepid / Edition:11.06.07/ Ve6ion:2

)1.3.7 Driving position of the trailing axle - service brake operated Operatingthe servicebrakeon the mobilecranewill pressurisethe controlline.The compressedair appliedto connection1 on the trailerbrakevalveis fed to the Tristopcylinder for the servicebrake;servicebrakingthen occurs.

Air pressurereserve,circuitlll

*#l+r IiH Hf blackpush- red Pushbutton button

Fig. 22: Excerptfrom compressedair system schematicfor trailingaxle in the drivingposition- service

brakeoperated(closed),parkingbrakeopen. air) Air reservepressure(compressed pressure Atmospheric \Jur ruur Pr voJ\rr e

Note: Connection1 on the trailerbrakevalveventsafteruncouplingor if the air reservepressure pipeio the trailingaxleruptures.The full tank pressureappliedto connection1-2 is fed to the brakecylindersfor the servicebrakevia connection2. The trailingaxle is then automaticallv braked.



-19-

UEHTRR

Gomponentdescription UW 18 - Others/Accessories P.oducedbv: weoio / Editon: 11.06.07/ VeGion:2

)1 .3.8 Uncoupledstate of the trailing axle - park position The black pushbutton is stillin the drivingposition(fullyextended).The air reservepressure is thereforeonlyappliedto connection1-2of the trailerbrakevalve. lf no compressedair is appliedto connection1 of the trailerbrakevalve,the trailerbrake switchesover.Connection1-2 is connectedto connection2 insidethe valveautomatically trailerbrakevalve.This causesthe servicebraketo close(pressurise). Howeverthe brakingactionof the servicebrakewill reduceover time due to the effects of leakage.The parkingbrakeshouldthereforebe closed(vented)afterthe trailingaxle is detachedfrom the vehicle.This is achievedby pullingout the red pushbutton. Oncethe air reservepressuredrops,the servicebrakereleasesand the parkingbrakeis appliedto the samedegree.The trailingaxle is thereforealwaysbraked.

Air pressurereserve,circuitlll

I-l +El

r

l : t F t' i{ V:; -ar -l

black push- red pushbutton button

Fig. 23: Excerptfrom compressedair systemschematicfor trailingaxle when uncoupled servicebrake closed,parkingbrake open.

air) Air reservepressure(compressed pressure Atmospheric Liebherr-WorkEhingenGmbH - CustomerServiceTraining


_ 20 _

UIBIIIRR

Gomponentdescription UW 18 - Others/Accessories Prcdled by: lwepno/ Edilion:11.06.07/ ve6ion: 2

Note: The red pushbutton mustbe pulledout when the trailingaxle is detached.This causes the parkingbraketo close(vents).Otherwisethe trailingaxleis not braked. To immediately closethe parkingbrake,pressthe black pushbutton afterdetachingthe trailingaxle.Connection1 on the trailerbrakevalveis pressurisedand connection2 is vented.This causesthe servicebraketo open (vented).

Air pressurereserve,circuitlll I

+ U

t l -h-i cJ

I

t.

U Y I --black push- red pushbutton button

- servicebrake for trailingaxlewhenuncoupled Fig.24:Excerptfromcompressed air systemschematic open- parkingbrakeclosed. air) Air reservepressure(compressed Atmosoheric oressure

Liebherr-WerkEhingenGmbH - CustomerServic€Training


_ 21

IIIB|IINR

GomponentdescriPtion UW 18 - Others/ Accessories Prcdued by: lwepilo/ Edition:11.0607 / veBion:2

)1.3.9 Active rear axle steering components for the trailing axle Pressurereducingvalve24bal pressure forhydr.adiust (minimum ingthe CAN-valves)

Coastingvalve

DBV (limitsthemax. steeringpressure for externalwheel impact) t-

DBV (limitsthe max. internal steering pressure)

--

,-

CAN Boschvalve

2-waypressurebalance 3-waypressurebalance

IIACHLAUfACHSE

Pinning for trailingaxle Thermalexpansion tank

DBV when Loadindication (determines themaximum the pressure andpinning unpinning forpinningandunaxle trailing pinning thetrailingaxle) Fig.25: Excerptfrom hydrauliccontrolschematicLTM 1200-5'1:

Couplingthe hydraulichoses: pressure. hosesat increased io couplethe steering difficult or extremely It is notpiossible to allowthermalequalisation' A tankhasbeenintegrated (dueto a risein temperapressure to increased maybe subjected TheaxleSuspension letdownwhen be completely thevehiclemust ture).In orderto dealwitfithissituation, pressure to drop.Any Thiscausestheaxlesuspension theirailingaxleis uncoupled can be coupledup. axle trailing willnothavea seriousimpact;the in pressure increase



_ 22 -

UEHTRR

Componentdescription UW 18 - Others/Accessories Prcducedby: lwepim/ Edition:11.06.07lVe6ion:2

>1.3.10Steeringoperationfor the trailingaxle

a

It

l i

i

=

Tankto allowthermal equalisation (supplied circuitI or ll) by gearpumpforsteering Highpressure Controlpressureafterpressurereducingvalve24bar pressurel bar) Returnsteeringcircuitll (pre-tension pressure Loadindication Fig.26: Excerptfrom hydrauliccontrolschematicLTI/ 1200-5.'l- Steeringoperationfor trailingaxle

Note: lf the engineis runningand thereis no faultcondition,the hydraulicoil will continuallyflow lf no hydraulicoil flowsthroughthe flow monitor, throughthe flow monitor(transducer). it indicatesa faultin the hydraulicsystemand an errormessageis output.This provides monitoringof the hydraulicconnectionsand any potentialleaks.



_ 29 -

UBHTRR

ComponentdescriPtion - Others/ Accessorles

Podu@d by: lwepio / Editon:1106 07 / Ve6ion:2

fault conditions )l .3.11Releasingthe trailing axle during CoastingGY229notactive) i f-:t i

I

II

E

I .FN

Highpressure(supplledby gearpumpfor steeringcircuitll) Controlpressureafterpressurereducingvalve24bar pressurelbar) Returnsteeringcircuitll (pre-tension position) betweenthe ringandpistonsurface(coastingor floating Pressurecompensation Loadindication Pressure @ematicLTM1200.5.1.Re|eaSingthetrai|ingax|eduringfau|t conditions



-24 -

IIEIITRR

Componentdescription UW 18 - Others/Accessories Prcdued by: lwepim/ Edilion:11.06.07/ Ve6ion: 2

>1.3.12Faultdisplayand fault handling Onlyoperatethe cranewiththe trailingaxle oncecontrollight-H21 "Trailingaxlecondition"has extinguished. lf controllight-H21 "Trailingaxle condition"flasheswhen driving,thereis a fault in the steeringsystem. Buzzer-H19 "Trailingaxlefault"soundsat the sametime to audiblynotifythe driverof the faultin the trailingaxle. switchesto "Coasting" The trailingaxle is no longeractivelysteeredand automatically (floatingposition). of the vehicle. This changesthe drivingcharacteristics

-H21 Controllight"Trailingaxlecondition"

-H22 Warninglight"Brakepadson trailing axleworn"

axle Fig.28:Control lightstrailing

-H19 Buzzer axle Faulton trailing

Fig- 29: Buzzet fault on trailingaxle Liebherr-WerkEhingenGmbH - CustomefServiceTraining


_ ZS _

UIBHTNR

Component description UW 18 - Others/Accessories Produed by lwepi.O/ Edilion:11.06.07 /VeBion:2

1.3.13 Hydraulicvehicle components Mobilecranespreparedfor use with trailingaxleshaveseveraladditionalhydrauliccomponents,i.e.theydifferfrom machinerywhichhas not beenpreparedfor use with trailing axles(see excerptfrom hydraulicschematicwith trailingaxle Fig Fig 31 and Fig 32).

largersteeringpump

Flowdivider

I .

imij,Tr-"1 ,l lil

Fig.30: HydraulicschematicLTM1200-5.1 withtrailingaxle

Liebhen-WerkEhingenGmbH - CustomerServiceTraining


_ 26 _

ITIBIIIRR

Gomponentdescription UW 18 - Others/Accessories Produed btx l@pto / Editd: 11.06.071Ve6ion:2

-Y197 Changeover oil supply

o

mG

l'*d

l u E u H E R R w r {|

l*

Bs,3

I

I

Fig. 31: HydraulicschematicLTM1200-5.'lwith trailingaxle

Hydraulic coupling: Whenthetrailingaxleis not attached,conneclpipesPNandTN.

Liebhen-WerkEhingenGmbH- CustomerSewiceTraining


_ 27 -

IIIBITIRR

Componentdescription UW 18 - Others/Accessories Prcducedby: lwepiro/ Edilion:11.06.07 /VeBion:2

1,3.14Testsystemfor the trailingaxle as wellas to starustop thetest Thesupportcontrolunitis onlyusedfor displaypurposes programs for thetrailingaxle.

ilIEHINN TctlDaoqtafi|nc ( Unterwaoenl

@s!ss

Note: The currentdescriptionfor the test systemcan be queriedvia Lissy usingprojectnumber9996008.

Fig-32: Descriptionof test systemfor the lrailingaxle

Fig. 33: Supportcontrolunit for the trailingaxle

Liebherr-WerkEhingenGmbH - CustomerSe ice Training


_ 2g _

UEHTNR

Functionaldescription UW 19 - Emergencyoperatingmodes Produ@dbv: lweoio / Edilion:06-06-07/VeFion:3

UW19- Emergency operationfor the chassis



-1-

lIEHTNR

Functionaldescription UW 19 - Emergencyoperatingmodes Produed by: lwepid / Edilion:06.06.07/ Vecion: 3

Note: purposes is for information onlyandservesto improvethe Thisdescription understanding of thereader. Gaution: Theoperatinginstructions andtest programsfor a particularcranemustbe readbefore givenin theoperating lf in doubt,followthe instructions attempting emergency operation. program. instructions andtest

Liebher.-WerkEhingenGmbH - Technicaltraining

-2-

llBHTNR

Functionaldescription UW 19 - Emergencyoperatingmodes Prcduced by: lwepio / Edilion: 00.06.07 / Version: 3

Index 1. Emergency operation - chassis

- support.. .............................5 1.1Emergency operation '1.2Emergency - blower conlro|...................... ........................-...7 operalion '1.2.1Emergency - modelusing"blowercontrolwiththermalpressurevalves"..7 operation - modelusing"blowercontrolwithhydrostatic blowerdrive"...8 operation 1.2.1Emergency ..........................10 1.3Transmission emergency operalion....................... forowc{ransmission systems.........................10 1.3.1Emergency transmission operation forAllison transmission systems......-.-.-............11 transmission operation 1.3.1Emergency

Liebherr-WerkEhing€nGmbH - Technicaltraining

-3-

UEIIRR

Functionaldescription UW 19 - Emergencyoperatingmodes PEdued br lrep|lo / Edition 06 06 07 / Vecim: 3

Liebherr-Werk Ehingen GmbH - Technical training

-4-

UEHINN

Functionaldescription UW 19 - Emergencyoperatingmodes Produed by: lwepno / Edilion: 06.06.07 / Version: 3

1. Emergencyoperation- chassis )1.1 Emergencyoperation - support In case of an electricalcontrolfailureon the directionalvalvesfor the support,it is possibleto manuallyretracUextend them on some cranesby pressingthe magnetic pistonon the affectedvalve.The pressurestage must also be pre-selected. As soon as the pressureon the magneticpiston is released,the actuatedmovement is halted.To ensure emergencyoperationof the slidingbeams and support, valve -Y5 "Oil supplysupport/ axle suspension"(-Y24 = old designation)must be manuallyactuated.This requiresa special"valvecap" (Fig. 2) which is screwedonto the magneticcoil of -Y5. The slidingbeams and supportscan be extendedor retracted by manuallyoperatingthe appropriatevalves.

Procedure: - the engineis running - the hydraulicsystemis operational - the pressurestageis pre-selected

LTM1100-4.1 / axlesuspension Fig.1: Pressure supplysupport

Note: On cranemodelsLTM 1030-2.1 and LTM 1040-2.1valve caps must be screwedonto two directionalvalves(rotationvalves).

.Y5 Oilsupplysupport/ axlesuspensron

Fig.2: Pressufesupplywith varvecap Liebherr-WerkEhingenGmbH - Technicaltraining

-5-

UEBHENR

FunctionaldescriPtion oPeratingmodes UW 19 - EmergencY Produ@dby: lwepilo/ Edilion:06.0607 /Version:3

for Ex.pushbufton of manualoperation the support

block1TM11004.1 Fig.3: Support

ScrewfittingEmergencY operation- (new)RotationvalveslD. No.476670108

ScrewfittingE#"tg"n"Y operation(old)Rota1100tionvalves(LTM 4.1/1TM1090-4.1)lD. No.790533908

Screwfitting valvessuPPort Directional lD.No.790065608 Fig. 4: Emergencyoperationscrew fittingtypes

Liebherr-WerkEhing€nGmbH - Technicaltraining

-6-

lIUIERR

Functionaldescription UW 19 - Emergencyoperatingmodes Prcdued bv:lweDio/ Edidon:06.06.07 / VeEion:3

)1.2.1 Emergencyoperation - model using "blower control with hydrostatic blower drive" Emergencyoperationusingthe test programsfor the hydrostaticblowerdrive- Test43 (manual)and Test44 (automatic): Purpose: Thesetest routinesserueto checkthe functionof the hydrostaticblowerdrive. Testprogram43 setsthe selectedspeedin 10%-stepsbetween0..100%,test program between 44 is executedautomatically and increasesthe speedevery5s in 1O%-steps 0..100%. Function: The following4 keys (Fig.'l) on the keyboardunit must be operatedsimultaneously to activatethe test program:

Fig. 2: Test programactive

Fig. 1: Activatetest program

lf the "testprogramis active",the 7-segmentdisplaysH162..H165(Fig.2) (faultdisplay)will indicatea runninglight. Keys Pl and P2 on the keyboardunit are used to select each test.

The@ - key is usedto startthe selectedtest. The [J - keyis usedto stopthe selectedtest.


-8-

1IEIIIRR

Functionaldescription UW 19 - Emergencyoperatingmodes Produ@dbv: lweoid / Edilion:06.06.07/ VeBion:3

displayson the controlunit. uses boththe dual-7-segment Visualisation Upper display: The selectedtest is indicatedusingboth 7-segmentdisplays(top left and top right)on the keyboardunit.Duringthe automatictest sequence(test44) both 7-segmentdisplayswill flashat approx.1 Hz (1/sec.)afterthe test has finished.

Lowerdisplay: Blowersoeed"dr"is shownhereas a percentage (0..99(100).

Fig.3: Displayblowertest

Test43 remainsactiveuntilit is quit by pressingthe i-key.Onlythen is temperature-dependentcontrolre-activated. The blowerspeedis increasedusingkeys P1 or P2. CAUTIONTest 43! Sincethe blowerregulationis switchedoff whenthe test programis active,ihe engineor transmission can overheat.Any warningis signalledby a continuousbeepingsoundfrom the keyboardunit. '100%untilthe i-keyon the Test44 will finishautomatically howeverthe blowerremainsat controlis then re-activated. chassisis pressed.Temperature-dependent Error code: No errorcodesare outputduringthe courseof thesetests.

Caution: It is essentialto readthe test programfor the particularcranemodel.


-9-

UBHIRR

Functionaldescription UW 19 - Emergencyoperatingmodes Producedbv: weoio/ Edilion:06.06.07/Verson: 3

1.3 Transmission- emergencyoperation )1.3.1 Emergencytransmission operation for GWG-transmissionsystems Purpose: (emergency Emergency transmission operation drivingprogram) servesto assistthecraneoperator in drivingthecraneoutof thedangerareawhenthereis a faultinthevehicle's electrical system. Function: lf the electricalsystemon the vehicledetectsa fault (flashingLEDson all drivingkeys) it automatically switchesto the emergencydrivingprogram.An errorcode is shownon the lower7-segmentdisplay(faultdisplay)of the displayunit.The transmissionis set to automaticooeration. Caution: The emergencydrivingprogramdoes not includean enginestartmonitoringfunction. The drivingrangecan also be selectedwithoutoperatingthe servicebrake.This fault mustbe immediatelyrectifiedby servicepersonnel. EMERGENCY-driving rangeswitch(transmission emergency operationswitch)to switchlhe transmissioninto forwardgear,reversegear or neutral.

LSB-connector

Fig.1:Transmission emergency operation switch / centre console LTM1070-4.1 Note: Emergencytransmission operationis only possiblewhen the vehicle'selectricalsystemhas detecteda fault.lf no fault is present,the drivingrangeselectedusingthe emergencydrivingswitchis rejec! ed. Demonstration operation(e.9.during of emergencytransmission cranehandover)requiresLSB-connectors on l/O modules1 and 2 to be unpluggedwhen the systemis not undervoltage.This disconnectsthe transmission from the BUS-SYSTEMcausingthe vehicle's electricalsvstemto detecta failure. Fig.2: lo-module Gaution: It is essentialto readthe operatinginstructions for the particularcranemodel. Liebherr-WerkEhingenGmbH - Technicaltraining

-10-

lIIBHIRR

Functionaldescription UW 19 - Emergencyoperatingmodes Produ@dbv: lweoid / Edition:0606 07 /VeEion:3

)1.3.1 Emergencytransmission operation for Allison transmission systems Purpose: operation(emergencydrivingprogram)servesto assistthe Emergencytransmission craneoperatorin drivingthe craneout of the dangerareawhen thereis a fault in the vehicle'selectricalsystem. Function: lf it is not possibleto set a drivingrangeusingthe drivingrangeswitch, performthe followingactionsin the orderdescribed: . Turnoff the engine . Removeplug connection-X653.1 . Attachconnector-X653.1to -X653.2 . Startthe engine . Selectthe desireddrivingrangeusingthe emergencydrivingswitch Caution: The emergencydrivingprogramdoes not includean enginestartmonitoringfunction. The drivingrangecan also be selectedwithoutoperatingthe servicebrake. Thisfaultmustbe immediaielyrectifiedby servicepersonnel.

, Faultdisday pushbuttons "Diagnostics all test"for displaying currenttransmissionfaults on the displayunit range switch EMERGENCY-driving (transmissionemergencyoperationswitch) to switchthe transmissioninto forwardgear,reversegear or neutral.

Fig.1:Transmission emergency operation LTM10704.1 switch/ centreconsole

-x653.1 l/Omodule 5/ Connector Transmission Allison ECU -x653.2 Emergency operation Allisonconnector operation Allisonconnector Fig.2: Emergency

Caution: for the oarticularcranemodel. It is essentialto readthe operatinginstructions Liebherr-WerkEhingenGmbH - Technicaltraining

_ ,11 -

ITTBHIRR

Functionaldescription UW 19 - Emergencyoperatingmodes ftoduced by: lwepio / Edilton: 06.06.07 / \r'eFion: 3

Liebherr-W€rkEhing€nGmbH - Technicaltraining

-12-

UBIIRR


OW04- Slewingring connection

Onlvfor LIEBHERRServicepersonnel

Gomponentdescription OW 04 - Slewingring connection Prcduced br lweDiro/ Edidon. 21 -02 07 I VeBian: 1

Index 1. Slewingring connectiongeneral

2 Toothedgep|ay............

7

3 Tilt p|ay..................

7

4 Greasingof slewing ring ..............-...............

..............8 ..,...................8

6 Earthingduring welding work..................

Liebhen-WerkEhingenGmbH - Iechnica!training


-3-

IIEBHINR

Componentdescription OW 04 - Slewingring connection Prcduced bv: lreono / EdiUon:21.02.07 / VeEion: 1

1. Slewingring connectiongeneral )1.1 Purpose (tumtable) (slewingring)supports thesuperstructure on the Theslewingringconnection (rotating chassis bearing). )1.2 Layout of at leasttworings.Theseare is a circularbearingconsisting A slewingringconnection (roller rollers or elements). using ball bearings rotationally connected

Greasenipple

Outerring \ 1..?a-

i\-,r -

. t l

at, t-

lntermediateoieces

a-

rDo

-

Fig.1: Ballbearingsupported slewingring

o -

Outergearteeth Rollerelement

Fig.2: Ballbearingsupportedslewingring Liebher.-WerkEhingenGmbH - Technic€ltraining


-4-

UEHINR

Componentdescription OW 04 - Slewingring connection Poduced bv: lweoio / Edition:2102.07/ VeBion: 1

lnnerring

Fig.3: Rollerslewingring

--

Outergearteeth Ring-shaped rollerelementbearing

-)I

ring Fig.4: Rollerslewing



-5-

IITDHTNR

Componentdescription OW 04 - Slewingring connection PEducedbv:lweDio / Edition:21.02.07 / VeEion: 1

)1.3 Function The innerand outerringsare connectedby meansof ball bearings(on smallercranes)or a ring-shapedrollerelementbearing(on largercranes). The outerring is connectedto the chassisusingexpansionscrewsand has outergear usingexteeth.The innerring is connectedto the turntableframeon the superstructure pansionbolts.Theslewinggear transmission is permanently fixedto the turntableframe. The slewinggear pinionlocksintothe outergear teethon the outer ringof the slewing ring connection.Driving the slewinggear motorthereforedrivesthe innerringand hence the wholeturntable.The turntablecan thereforeturn through360".

Slewinggear motor

geartransmission Slewing

Fig.5: Slewingringconnection

Outerring

Innerring

Turntable trame



-6-

1IEIIRR

Gomponentdescription OW 04 - Slewingring connection Podlced br |repno / Edilton: 21.02-07 / Veîon: 1

)2 Toothedge play

Fig.6:Toothedgemeasurement Toothedge play (torsionalplay) is used to describethe play betweenthe outer gear teeth on the slewingring and the drivecog wheelon the slewinggear transmission. On toothedslewingring connections,the tooth edge play must be adjustedat the narrowest pointon the toothgear duringassemblyor when replacingthe slewingring (thewidest radiusof the slewingring is at this point). The nanowest point on the tooth gear is markedby a punched-inplus-symbolbetween the two teeth with red magkings.

)3 Tilt play The tilt play increaseswith the track wear.

the innerandouterringon theslewthe radialplaybetween Tiltplayis usedto describe Ing nng connecuon.

MK= Tiltingtorque

Fig.7: Tilt play Liebhen-WerkEhingenGmbH- Technicalkaining


-7-

UEHTNR

Componentdescription OW 04 - Slewingring connection PDducedby: laepiro/ Edition:21.02.07/ vecion: I

)4 Greasingof slewingring Greaseis injectedintothe slewingringfrom the centrallubricationsystemusingthe progressivedistributorand greasenipple.The progressivedistributoris fiftedwith a proximity switchto monitorthe strokeand determinethe amountof requiredgrease.

Fig. 8: Progressivedistributor

)5 Expansionbolts Expansionboltsare usedto attachthe outerslewingringgear teethto the chassisand the innerslewingringgedrteethto the turntable.Tighteningthe expansionboltsto the requiredtorquewill expandand wedgethe boltscausingthemto grip.

Fig.10: Expansionbolt

)6 Earthingduringweldingwork The earthingpointmustbe as closeas possiblewhen performingany weldingwork' Neverweld on the turntableif onlythe chassisis earthed.Otherwisethe slewingring components(rolleror ball bearingsas well as the ring contactsurface)couldbecome permanently damagedwhen arcingoccurs. Liebherr-WerkEhingenGmbH - Technicaltraining


-8-

UTTHERR


OW09- Luffinggear/ ballasting


Componentdescription OW 09 - Luffing gear / ballasting PEdu@d by: lwepilo/ Editon:30.01.07/ VeBion:1

Inhaltsverzeichnis 1. Luffing gear............. 1.1 Luffing gear general.......

..........................4

10

1.2 Luffing gear components...... 1.2.1Loweringbrakevalveluffing9ear...........

.........................12

1 . 2 . 2P r e s s u rsee n s o lru f f i n gc y l i n d e r

13

...... 2. Ballasting

......................13

2.1 Ballastinggeneral...

18

2.2Ballastingcomponents....



............10

-3-

lIIBHINR

Component description OW 09 - Luffinggear lballasting Prcdled

by: l*epilo / Edilion: 30-01.07 / VeEion: 1

1. Luffinggear 1.1Luffinggeargeneral )1.'1.1Purpose or Theluffinggearis usedto settheangleof the boom.lt is adjustedby extending retractingone or bothof the luffingcylinders. (radius). Theluffingfunctionis usedto raiseor lowerthe loadandchangethe projection ;1.1.2 Design

Fig.1: Excerptfromluffinggearschemalicgeneral

Note: Theluffinggearalwaysusesan openhydraulic circuit. Liebherr-WerkEhingenGmbH - Technicalkaining


-4-

UBIIIRR

Gomponentdescription OW 09 - Luffinggear/ ballasting Prcdu@dby: lwepid / Edilion:30.0107 / Ve6ion: 1

)1.1.3 Function Luffing up: lf the masterswitchis movedin the luffingup direction,the directionalconirolvalve opens.The loadopposesthe hydraulicpressure.The oil pumpedby the hydraulicpump is then initiallyblockedby the non-returnvalveon the loweringbrake. The pressurewill then increaseuntilit is sufiicientto openthe non-returnvalve.The hydraulicoil flowsthroughthe non-returnvalveon the loweringbrakeand the luffingcylinder is extendedcausingthe boomto be luffedup. The luffingcylindercouldbe destroyedif it is fully retracted(to the block)or extended withoutbraking,on LTM 1095-5.1(or later)this is preventedby reducingthe luffingup actionbeforethe loadtorquerestriction(LMB)switchoff pointand reducingthe luffing downactionbeforethe supportblockis reached.lfthe masterswitchis movedbackto 0', the directionalcontrolvalvealso returnsto the centreposition,The directionalcontrol followthe masterswitchsignal,insteadit closesaftera time valvedoes not immediately pressure in the "luffing"pipedropsand the non-returnvalvefor The delay(integrated). the loweringbrakeis closed.The boomis held in positionby the hydraulicoil whichis trappedin the luffingcylinder. Luffing down: lf the masterswitchis movedin the "luffingdown"direction,the directionalcontrolvalve loweringbrakevalve,"luffingdown"valveand controlpipecause opens.The proportional hydraulicoil to be appliedto the controlpistonof the loweringbrakeand opensit proportionallyfrom a presetvalue. a connectionbetweenthe luffingcylinderpistonsurfaceand the tank; This establishes the weightof the luffingcylinderresultsin a controlledluffingdown action' tank pipe. This causesthe ring surfaceto suck hydraulicoil throughthe pre-tensioned lf the boombecomesflatterduringluffingdown,the loadpressureincreasesin the piston surfaceof the luffingcylinder.The initialflow of the luffingcylindermustalso be adjusted if the loweringbrakeis actuatedand ihe pressurein the pistonsurfaceof the luffingcylinder increases. Eachluffingcylinderis thereforefittedwith a pressuresensorfor measuringthe hydraulic pressureat the luffingcylinderpistonsurface. is usedto preventthe luffingdownactionfrom speeding Pressurecompensation up as the boombecomesflafter. This is a hydraulicfunctionand can alsobe controlledon the LTM 1090/3or LTM 1100-4.1 by reducingthe masterswitchsignal. lf the masterswitchis movedbackto 0" duringluffingdown,the directionalcontrolvalve also returnsto its centreposition. followthe masterswitchsignal,inThe directionalcontrolvalvedoes not immediately steadit closesaftera time delay(integrated). loweringbrakevalveis regulatedbackdown to lowerthe controlpipe The proportional pressurefor the loweringbrake.This will startto close,whichcausesthe luffingdown actionto be slowlybraked. Liebherr-WerkEhingenGmbH - Technicalt.aining


-5-

UIBTilIRR

Componentdescription OW 09 - Luffinggearlballasting Podued bv: lweoid / Edilion:30.01.07/ Ve6ion: 1

Shuttlevalve H6

MI

q q

Proportional valve Actuationdirectional controlvalve

DBVBlock retainer

Directionalcontrolvalve

2-waypressure oatance Pressuresensor lufflngcylinder !iIPPZYLINDER

Cartridgevalve

pressure

loweringbrake

t r-----;irPiitr --_-----t

Q)

/

I

I

Lt

L

4f2 way magnetic VAIVE

Lufflngdown

1 . 5' . I

Fig. 2: Excerptfrom luffinggear schematicgeneral Liebher.-WerkEhingenGmbH - Technicaltraining


-6-

lIFilINN

Gomponentdescription OW 09 - Luffinggear lballasting Produed bv: lweoid / Edition: 30.01.07 / VeBion: 1

I.JI PPZYLII'IOER

--

High-pressure Tank Lowpressure Controlpressure Loadpressure

Fig. 3: Luffingcylinderpistonsurfacetensioned Liebherr-WerkEhingenGmbH-

-fecinical training


-7-

uElltiR

Gomponentdescription OW 09 - Luffing gear / ballasting P@du@dbr lwepiro/ Edibon:3001 07 / ve6ion: 1

IIIPPZYLIiIDER

--

High-pressure Tank Lowpressure Controlpressure Loadpressure

Fig.4: Lufflngup Liebher-WerkEhingenGmbH - Technicaltraining


-8-

UEHTNR

Componentdescription OW 09 - Luffinggear/ ballasting Prcduced by: lwepio / Edition: 30.01.07 / ve6ion: 1

Pr

-:t=

-t

---I{lPPZYLINDER

-Ys ii

_Yl0

rTlF ! | 'fl rrl

High-pressure Tank LOwpressure Controlpressure Load pressure Fig. 5: Lufiingdown Liebherr-WerkEhingenGmbH - Technicaltraining


-9-

UETTEiR

Gomponentdescription OW 09 - Luffinggear/ ballasting Prcdued by: lwepilo/ Edihon:30o1.07/ Ve6lon: 1

)1.2 Luffinggear components 1.2.1Lowering brake valve luffing gear The loweringbrakevalveluffingtrapsthe hydraulicoil in the pistonsurfaceof the luffing cylinderto whichthe wholeweightof the boomis applied.The loweringbrakesupportscontrolled liftingand loweringof the boom.Luffing down loweringbrake usingpressure-compensated valvesis alwaysat the samespeedregardlessof the boomangle,boomlengthor boomload. On hydraulically-controlledequipment Fig. 6: Loweringbrakevalvewithouthydraulic without hydraulic overpressure (e.9.LTI\,4 1030-2.1 overpressure compensation ) compensation:The speedof the luffinggear is not adjusted. Luffingdownwill speedup as the boombecomes longerand flatter.

craneswith On hydraulically-controHed for overpressurecompensation(e.gLTM1040-2.1):Fig.7: Excerptfromschematic lowering brake valve withoul overpressure Overpressure compensation andluffinggear (e.9.LTM1030-2.1) compensation arehydraulically controlled. speedadjustment

Fig.8: Loweringbrakevalvewith hydraulic (e.9.LTM1040-2.1 overpressure compensation ) Liebherr-WerkEhingenGmbH - Technicaltraining


-10-

UEilINR

Componentdescription OW 09 - Luffinggear/ ballasting Prcdu@dby: lwepio / Editon:30.0107 /ve6ion: 1

Fig. 9: Excerptfrom schematicfor loweringbrake valve with hydraulicoverpressurecompensation (e.9. LTM 1040-2.1) Safetypressure-reliefvalve 430 bar is factory-

On cranes with electricalcrane control systems (exceptions from LTM 15008.1 and LTM1300-6.1): usesfinal Overpressure compensation flow and initialflow adjustment. For example,if the pressurein the ring surfaceof the luffingcylinderincreases, the finalflow is limitedwh'ereasthe initial flow is increased. The additionalhydraulicpressure is only activatedduring compensation emergencyoperation.

car /.1^ n^r ..lilct\

-MP Measuring Control pressure Loweringbrake

Fig.10:Loweringbrakevalveluffing on craneswithelectricalcranecontrol (e.9.LTM1400-7.1) systems

a ---f

-:-

Fig. 11: Excerptfrom schematic- lowering brake on craneswith electricalcrane control systems(e.9.LTM1400-7.1) Liebher-WerkEhingenGmbH - Technicaltraining


- 1 1-

1IEIIIRR

Gomponentdescription OW 09 - Luffinggear/ ballasting PEdued by: lwepi.o/ Edilion:30-01.07/ ve6ion: 1

1.2.2Pressuresensorluffingcylinder sensormeasures Theluffingcylinderpressure pressure in the luffingcylinderpithe hydraulic stonsurfaceandis usedforthefollowing: . Calculation of the loadtorquelimiter . Pressure-dependent initialflowadjustment forthe lufiingdownfunction . Pressurecompensation* . Loadstorage*

-B2 sensor, Pressure luffingcylinder pistonsurface Fig.12: Pressuresensorluffingcylinder

* = OPtion Liebherr-WerkEhingenGmbH - Technicaltraining


-12-

IIIBHINR

Componentdescription OW 09 - Luffinggear Iballasting Pmdu@d br lwetiro / Edilion: 30.01-07 / VeBion: I

2. Ballasting 2.1Ballastinggeneral )2.1.1 Purpose The ballastand the weightof the vehicleboth serveto counteractthe load.The term ballastingis used to describethe raisingand loweringof the ballastby the ballastingcylinder and the associatedelectricaland hydrauliccomponents.

)2.1.2Design

cylinder Ballasting

Ballast

Fig.13: BallastLTM1100-4.1

Fig.14: BallastLTM 11004.1/ Planview Liebherr-WerkEhingenGmbH - Technicalkaining


Ballasting cylinder

-13-

UBIIRR

Componentdescription OW 09 - Luffinggear/ ballasting Prcdued by: lwepno / Edilion: 30.01.07 / Ve6ion: 1

)2.1.3 Function

BALLASTIERUI{G

'^,1

i*

.,,i)*l- -'

Releasablel['26="--?ffi'

schematic Fig.'15:Excerptfromgeneralballasting



-14-

-'T*T;

nonReleasable returnvalve

UBHTNR

Gomponentdescription OW 09 - Luffinggear/ ballasting PEdued by: lwelno / Edilion: 30 01 07 / Version: 1

Ballast clamped: The hydraulicoil in the ringsurfaceof the ballastingcylinderis clampedby the releasable load holdingvalve.This holdsthe ballastin the requiredposition.The bladderaccumulator providesthermalpressurecompensation.

BAL

ERUI||G

___J11 lr-l

rl

r

.._^--ll__..

rl

I

i| ?^rlilFi I

fr -,,r1

I

TI r -

.ll

I'

r49

Ji,

t t T r{l

rtr I

xr-I

-

I ! !

380_.I

^l ft_

iI

*-

High-pressure Tank LOWpressure Controlpressure

Fig.16: Ballastclamped

Liebhen-WerkEhingenGmbH - Technjcaltraining


-15-

lTIBIIIRR

Componentdescription OW 09 - Luffinggear/ ballasting P@dued by: lwepno/ Editon:30.0107 / ve6ion: 1

Ballastup: lf pushbutton-5602 "Ballastup i down"is movedupwards,4/3directionalvalve-Y'l9a is suppliedwhichreleaseshigh pressurevia the flow dividerand the loadholdingvalves onto the ringsurfaceof the ballastingcylinder.The ballastingcylindersretractand raise the load untilthe pushbuttonis released.A buzzerwill soundonce the ballastingcylinder has beenfullvretracted.

B A L L A S TEI R U N G

----

High-pressure Tank LOWpressure Controlpressure

Fig.'l7: Ballastup



-16-

IIIBHINR

Gomponentdescription OW 09 - Luffinggear/ ballasting PEdued b][ lwel'lo / Edition: 30.01.07 / VeBion: 1

Ballast down: lf pushbutton-5602 "Ballastup / down"is moveddown,4i3 directionalvalve-Y19bis suppliedwhichreleaseshigh pressurevia the releasablenon-returnvalveonto the piston surfaceof the ballastingcylinder.The ballastingcylindersextendand lower the ballast untilthe pushbuttonis released.A buzzerwillsoundoncethe ballastingcylinderhas been fullvextended.

BALLASTI ERUNG

-

High-pressure Tank LowPressure Controlpressure

Fig.18: Ballastdown



- 1 7-

llEHINR

Gomponentdescription OW 09 - Luffinggear/ ballasting Podu@d bv:lweDio / Ediuon:30.01.07 / veGion: 1

2.2Ballastingcomponents 2.2.1Ballasting cylinder The ballastingcylindersare usedto raiseand lowerthe ballast. lf the ballastis e.g. restingon the chassis,it can be pickedup by the ballastingcylinder.

T(\ Fig. 19: Ballasting cylinder

Pistdnsurface

\ \ \\ :

Ringsurface

2.2.2Pressureswitch ballasting cylinder up Everyballastingcylinderhas a supplypressure switchfor measuringthq pressurein the ring surface.The supplypressureswitch(normallyopen)switchesif a hydraulicpressuregreater than 230 bar is applied. Bothswitchesare in series. LICCONinput"Ballastingcylinderup / down" is onlyactivatedonce both cam switchesare actuated. Fig.20: Supplypressureswilch

2.2.3Cam switch ballasting cylinder down actuatedon each A cam switchis mechanically ballastingcylinder(normally-closed) as soonas the ballastingcylinderis down (extended). LICCONinput"Ballastingcylinderup / down" is only activatedonce both cam switchesare actuated. LICCONinput"Ballastingcylindernot down" is activatedif one of the cam switchesis not actuated. Liebherr-WefkEhingenGmbH - Technicaltraining


-18-

Fig.21: Cam switch

HEHINR

Gomponentdescription OW 09 - Luffinggear lballasting PDdo@d bv: lweoio / Ediiion:30.01.07/ Ve6ion: I

2.2.4Pushbutton ballasting cylinder up / down This pushbuttonhas a centrepositionfor movingthe ballastup/downusingihe ballasting cvlinders.

Fig.22: Switchballastup / down

ffi

€602 Pushbutton in roof ballast console, up/down

2.2.5Buzzer ballasting cylinder up / down cylinder Fig.23: Buzzerballasting

The buzzeris eitherin ihe roof consoleof the cab or in the controlcabinet. superstructure It will soundin both states,namelyballasting cylinderup/down. On oldercranesihis is indicatedby the lampon the "Ballastingcylinderup / down"switch

r f -- - - r

**o l[{sl_ - vuzzel lFt4-rf | rL\| Ell

Ballastup/down

2.2.6Hydraulicallyreleasedload holding valve The hydraulically releasableloadvalvetrapsthe hydraulicoil at the ring surfaceto holdthe ballast ln posrt|on. lf ballastdown is actuated,the pressurein the controlpipeslowlyopensthe load holdingvalve-



-19-

Fig. 24: Load holdingvalve

IIIBIITRR

Gomponentdescription OW 09 - Luffinggear Iballasting Prcdued bv: lweoid / Edilion:30.01.07/ Ve6ion: 1

2,2.7Releasablenon-returnvalve piston surface The releasablenon-retumvalveis opened when ballastup is actuated;this allowsthe oil to escapefrom the ring surfaceintothe tank.

r-

1

z 1 -J a

Fig.25: Releasable non-returnvalve

2.2.8Hydraulicallyreleaseddual load holding valve* On somecranesthe hydraulically releasable performs dual load holdingvalvealso the functionof a basicload holdingand releasable non-returnvalvefor the pistonsurface.

Fig.26: Dualloadholdingvalve

2.2.9Bladder accumulator The bladderaccumulatoris connectedto the ring surfaceof the ballastingcylinders. It storeshydraulicoil up to a pressureapproxca. 150 bar and preventsthe ballastfrom moving downwhen the craneis shut down. Fig. 27'.Bladdetaccumulator

* = option Liebherr-WerkEhingonGmbH - Technic€ltraining


-20 -

UEHENN

Component description OW 09 - Luffinggear/ ballasting Podled

by:lwepi.o/ Edition:30.01.07/ VeEion:1

2.2.10Flow divider The flow dividerensureseoualretractionof the ballasiingcylindersand constantliftingof the ballast. It dividesthe incomingflow intotwo specific partialflowsusingthe throftleprinciple. Sincethe controlpistonof the valve(Fig 30) actsas a pressurebalance,this generally alsoappliesif thereare differentpressures in the oartialflows. Fig.28: Flowdivider

Fig. 29: Flow dividerexcerpt from circuitdiagram

InputC Fig.30: Flowdividercut-awayview



-21 -

UBHINR

ComponentdescriPtion OW 09 - Luffinggear lballasting P'!du@d by: lwepid / Editon: 30 01 07 / VeEion:1

2.2.1'lPointer ballast Pick'uP Pick up ballast: . Turncranesuperstructure, untilpointer"Turntableca.2'" is alignedwith the marked screw"Referencepoint",the ballastingcylinderswill now be nextto the openingsfor the ballastPick-uP. . Lockthe turntable. . Presspushbutton-s602 "Ballastup / down"down untilthe ballastingcylindersare fullyextendedand the buzzersoundsor indicatorlamp is lit' . Releasethe turntable. . carefullyturnthe cranesuperstructure to the right,untilpointer"Turntableca' 0"" is alignedwith the markedscrew"Referencepo:nt",the ballastingcylinderswill now extendintothe openingson the ballastplates. . Lockthe turntableagain. . Pressoushbutton-s602 "Ballastup / down"up untilthe ballastingcylindersare fully retractedand the buzzersoundsor indicatorlamp is lit' . Releasethe turntableagain' Pufting down the ballast: . rum cranesuperstructure, untilpointer"Turntableca. 0'" is alignedwith the marked screw"Referencepoint",the ballastcan now be lowered' . Lockthe turntable. . Presspushbutton-s602 "Ballastup / down"down untilthe ballastingcylindersare fullyextendedand the buzzersoundsor indicatorlampis lit' . Releasethe turntable. . carefullyturn the cranesuperstructure to the left,untilpointer"Turntableca' 2'" is alignedwith the markedscrew"Referencepoint",the ballastingcylinderswill now be nextto the openingson the ballastpick-up. . Lockthe turntableagain. . Presspushbutton-s602 "Ballastup / down"up untilthe ballastingcylindersare fully retractedand the buzzersoundsor indicatorlamp is lit' . Releasethe turntableagain. Pointer "Turntable ca.2SDgr"

Pointer "Turntable0"" markedscrew "Reference Point" Fig-32: Pointerballastpick-upvariant2

Fig.31: Pointerballastpick-upvariant1 Liebhen-WerkEhingenGmbH -'fechnicaltraining


-22 -

IIEIIERR

Gomponentdescription \-

OW14- Telescopicboom / Telematics


Componentdescription OW 14 - Telescopicboom / Telematics Prcdu@dby: lwepio / Ediion: 13.11.06/ ve6ion:01

Contents '1.Telescopicboom 9enera1..,.,..........

................5

.....14

16

.....................24

7. Operatingmodes............

...........................32

9. Boom systems



-3-

1lBTTTRR

Gomponentdescription OW 14 - Telescopicboom / Telematics Prcdued bI lB€prro / Edition: | 3 11.06 / VeBin:o1

Liebhen-We* EhingenGmbH - Technicaltraining


-4-

lIEITIRR

Gomponentdescription OW 14 - Telescopicboom / Telematics Prcdued by: lwepiro / Edilion: 13.11.06 / veEion:o1

1. Telescopicboom general )1.1 Purpose manuallyor automatically. Thetelescopicboommaybe extended/retracted Thisprovides cranewithvariableradiusandlift.Theboommustbe thetelescopic application. loadin theintended designed to lifttheattached p'|.2 Layout Fig.1 : Diagramshowingprincipleof telecylinder electrical/electronic sensors

piece Articulated (mainbody)

Telepinning Telelll

gipperpinhydraulic nrng telescooic dual-action cylinder

yoke Connecting Telepinning (Telepinpulling mechanism)

a,r

Telepinning

il

comprisesthe followingcompon"ftl'l?v" The boomessentially

Boom head

il

Articulatedpiece(mainbody) Telescopiccomponentswith pinningholesat 0%, 46To,92Toand 100%. Rollerset

Boomheadwith hoistlimitswitch cylinder Dual-action telescopic gripperpinningat thefootof thehydraulic cylinder Hydraulically actuated to lockthe telescopicsectionstogether Hydraulically actuatedtele-pinning moduleof the LICCONcrane Electrical/electronic controlsensors.an additional controlsystem. Uebhen-WerkEhingenGmbH - Technicaltraining


-5-

IIBHR

Componentdescription OW 14 - Telescopicboom/ Telematics Producedby: lwepid / Edilion:13.11.06/ VeBion:o1

(pistonsurface) K1 t<2 K3

(ringsurface) R1 R2

Fig.2:1TM1400-7.1 Boom

Loweringbrake valvecontroltele cylinder X

Rotatingunion ring surface,loweringbrake control,tele- /gripper pinning

Tele-/ gripper pinning A Rotatingunion pistonsurface telecylinder

Cabledrum suppry

Lengthsensor

Fig.3 : LTC1055-3.1.1 Boomhead

-8929 Anglesensor telepulley head

.s917 Terminal box pulleyhead

€930

Hoistlimitswitchright pulleyhead

€931*

2. Hoist limitswitch pulleyhead left

* = option Liebherr-WerkEhingonGmbH - Technicaltraining


-6-

UEHENR

Componentdescription OW 14 - Telescopicboom/ Telematics Pbdued bv:lweolo / Edilion:13 1106 /ve6ionrol

piece head/ articulated F i g .4 : L T C1 0 5 5 - 3 . 1 .Boom 1

-s917 Terminalbox

-N2 Cabledrum Articulatedpiece

-8909 Anglesensor Telemainbody

-Mg0g*

'

-8921

Windsensor

Actuator worKrng lightsarticulated piece L S B6 . 1 , Address19

-E907* WorkinglightsarticuIrta.l

îaâ

Fig.5:Boomprofile

- = option Liebherf-WerkEhingenGmbH - Technicaltraining


UIBHTRR

Componentdescription OW 14 - Telescopicboom/ Telematics Prodlced bv: lweoid / Edilion:13.11.06/Ve6ion:01

Fig.6 : Telescopic boomfromrear Polyamidebearingplate(slideshoes)

Polyamideslideblocks for the tele cylinder

flexiblymounted

Polyamide slideblocks

Polyamide slideblocksr

Fig.7 : Telescopic boomfromfront

Polyamide bearingplates (slideshoes) Liebherr-WerkEhingenGmbH - Technicaltraining


-8-

IIIBTItRR

description Component OW 14 - Telescopicboom / Telematics Producedbv: lweoio/Edilion: 13 1106/Ve6ion:o1

Fig.8 : Diagramshowingprincipleof telecylinderextensionmechanism

Lengthsensor Telecylinder

yoke Connecting Telepinning (Telepin pulling mechanism)

.(

supplyto pinning device

t t

i,-d.j4

Controlvalvet ele-/ gripper unpinning

Controlhead Gripperpinning

Cylinderguide

comprises: telescopicsystem"Telematics" The automaticrapid-stroke . a dual-actiontelescopiccylinder . hydraulically actuatedgripperpinningto selectthe activetele-component . hydraulically actuatedtele pin to lockthe telescopicsectionstogether . electrical/ electroniccontrolsensors

Note: The hydraulicoil for the tele-/ and gripperunpinningflowsthroughthe hydrauliccylinder

Liebher-WerkEhingenGmbH - Technicaltraining


-9-

UIBHTNR

Componentdescription OW 14 - Telescopicboom/ Telematics Prod!@d by: lwepio / Edidonr13-11.06/VeBion:o1

The oval-shapedboom cross-sectionprovidesutmoststabilityduring bendingand torsionAutomatedtelescopiccontrolis basedon the LICCONcranecontrolsystemto provide provided severalextensionlevelsfor the telescopicboom.The highlevelof functionality gained from automatic by the time by this new boomtechnologyis characterised telescopingand the resultingusefulvarietyof combinations.

460/o, 92o/oand 100oh. Eachtefescopicsectionhas pinningholesat 0o/o,

principle of telecylinder Fig.9: Diagram showing lnductive sensortele-/ gripperpinning

yoke Connecting Telepinning (Telepinpulling mechanism)

Telepinning

Lengthsensorlele cylinder andpowersupplyto pinning device

Controlhead

Cylinderguide

pinning Gripper Induclive sensorfor monitoring the gripperpositions Liebherr-WerkEhingenGmbH - Technicaltraining


-10-

lTIBIIIRR

Gomponentdescription OW 14 - Telescopicboom/ Telematics Prcdo@dbv: lweDio/ EdlUon:13.11.06/ ve6ion:o1

2. Gripperpinning/ telepinning )2.1 Purpose The gripperpinningservesto connectthe telescopiccylinderto a telescopicsection.Tele pinningis usedto lockthe telescopicsectionstogether ;2.2 Layout interlocked. Gripperand tele pinningare mechanically with the aid of the This meansthat the telescopicsectioncan only be pinned/unpinned yoke gripper with the telescopicsectionat the sametime.This if the is interlocked upper preventsa mechanicalmalfunctionof the telescopicsystem. Fig.1 : Gripperpinning/ tele pinning

-Y40(-Y17) Changeover valve Telepinning/ Gripperpinning

Connectingyoke Telepinning (Telepin pulling mechanism)

i

-s918 Inductivesensoras proximityswitch ; Telepinned CPU1,LSB2 Address16

".r

3

c

-s919 lnduclive sensoras proximityswitch Teleunpinned CPU1,LSB2 Address17 pinning Gripper

€912

-s913

-s914

-s915

lnductive sensor as proximity switch rightpinned Gripper CPU1,LSB2 Address20

lnductivesensoras proximityswitch Gripperleftpinned CPU1 , L S B2 Address18

lnductivesensor as proximityswitch Gripperrightunpinned C P U 1 ,L S B2 Address21

lnductivesensor as proximityswitch Gripperleft unpinned C P U 1L, S B2 Address19



-'t1 -

IIIBHTNR

ComponentdescriPtion OW 14 - Telescopicboom/ Telematics P r o d u c ebdy r w e p r l o / E dr o n 1 3 1 1 0 6 / v e E r o n 0 1

Fig.3:Telepinning

Fig.2 : Telepinning

openingfor meInstallation Hex socket head screwfor screwing in the tele pin (disassembly) chanicallyunpinningthe griPper pinningmechanism whenhydraulicsystemis faulty

holegripper Pinning pinning right

Fig.4:Telepin

Connectingyoke Telepinning (Telepin pulling mechanism)

Spring

Pull musnroom

)2.3 Function the telescopicsections.A tele pin can The springpushesup the tele pin to interconnect usingthe connectingyoke if the gripperpinningis fullypinnedin only be pinned/unpinned tele.converselythe grippercan only be unpinnedfrom the telescope the corresponding if the connectingyoke (telepin pullingmechanism)has beenfullyextendedupwards andthete|epinhasbeencomp|etelypinned.The|iponthete|epinpreventsunintended unpinning,e.g.due to the tele pin snappingbackwhen the springbreaks.lf the gripperis unpinned,the tele cylindercan be freelymovedand anothertele component hydraulically may be selected.lt is only possibleto pullthe tele pin if the gripperpinningwas previously pinnedto the tele cylinder.lnautomaticmodethe telescopiccylinderis retractedafter ensuresthereis frictional everypinningoperation.This so-called"tensioning" lockingbetweeneachof the elements.Furthermoreit is guaranteedthat the pinning systemis relievedby the extensionof the cylinderduringthe unpinningprocess(gripper or telescope)therebycausingthe gripperor telescopeto be unpinned' Liebherr-WerkEhingenGmbH - Technicaltraining


-12 -

lIETITRR

Component description OW 14 - Telescopic boom/ Telematics P'.ducei by wep r01 EditLonl3 lr oti i V.rs:.n:ol

2.3 Function F r g .6 : T e l ep r n n e dg. r i p p eur n p i n n e d : T e l ep i n n e d

l:ri^^^r

,,nî^^6r{

F i g .7 : T e l ep i n n e dg, r i p p epr i n n e d :

Tele pinned

'

G r i p p epr i n n e d

F g . 8 : T e l eu n p r - ' r e dg.r o p e rp i n n e d :

L e b h e r r - W e r kE h i n g e n G m b H - T e c h n i c a l r a i n j n g

,

- .t:::i\./i3e . , ae.:t-

-13-

lTIBHIRR

Gomponentdescription OW 14 - Telescopicboom/ Telematics Produed by: lwepi.O/ Edition:13.1106 / Ve6ionrol

3. Trackingswitch 3.1Trackingswitch )3.1.1Purpose

The trackingswitchesindicatewhetherthe gripperpinning mechanismis in a pinnedpositionandwhich tele has been selected.

23.1.2 Layout €908

€901

Induclivesensor a.s.proximity switch bripperposttron ounng.emergency operalton No LSB sensor

Inductivesensoras proximityswitch Tele 1 C P U 1 ,L S B2 Address10

-x456b Plug, Gripper{elepinning

_s902 Inductive sensoras proximityswitch feh- 2 CPU1,LSB2 Address'11

-s904 Inductive sensoras proximitv swilch l e l e4

-s903 Inductive sensoras proximityswitch tete 3

CPU1,LSB2 Address13

CPU1,LSB2 Address'12

;3.1.3Function Thediffering heightsof thesignalarmsallow theLICCONto usetrackingswitches (induc_ tivesensors) to detectwhetherthegripper pinningmechanism is in a pinnedposition andwhichtelehasbeenselected. Liebherr-WerkEhingenGmbH - Technicaltraining


-14-

Signalarms

UIBHTRR

Componentdescription OW 14 - Telescopicboom/ Telematics Produed bv: lweoto / Edilion:13.11.06/ Ve6ron:01

3.2 Dual tracking switch )3.2.1 Purpose The trackingswitchesindicatewhetherthe gripperpinningmechanismis in a pinnedpositionandwhich tele has been selecled.

)3.2.2Layoul

-s902

-s901

Dualinductivesensoras proximityswitch Trackingsensor,left LSB 5.2,Address11

Dualinductivesensoras proximityswitch Trackingsensor,right LSB 5.2,Address10

Dual indicativesensor

:

,1:. - r l I . :

I

:c-

. r -

! Jt.KT:l'l

1

I r l r - l : :

.::

11. r;E :rl:tiiLll; S i 1 ! i - l n: x ! a F r : t s i l i L : t T !.t

s!'lyrtr I

?,t

::1{::! i s:aRllrll t ! 1 1 5 i ,? 1 i l . : : ; i s . : ! n L - [ j ii:

iLit-i:

t - -

- - -

i:i

siilslR : ;li,l'inl:ti si'ti"rn 2 s llinr'rii

ll i ir l I r

: c:=

t-----

i '

f I

:

L____!1]lil

AnalogueoutputTele emergencyoperation

I

ri'1,.,1 : i:{ Yi

l 1 : r - Hsr i ; a f ^ i : i

ili

G i S t ; t / , Ir ,

r:

:rl it

;i!ailii:;: i::iriLr:-

:-:

-':

)3.2.3 Function The differingassignmentsof dummypanelsto plasticpanelsallowthe LICCONto use dual trackingswitches(dualinductivesensors)to detectwhetherthe gripperpinning mechanismis in a pinnedpositionand whichtele has beenselected. Liebherr-WerkEhingenGmbH- Technicaltraining


-15-

UIBHTRR

Gomponentdescription OW 14 - Telescopicboom / Telematics Producedby: lwepro / Edihon:13.11.06/ Ve6ion:o1

4. Loweringbrake )4.1 Purpose The hydraulicoil for the telescopiccylinderringsurfaceis drainedintothe tank in a controlledmannerwith the aid of the loweringbrakes.This causesthe retractionof the telescopiccylinderwith eithernone,one or severaltelescopicsections.

)4.2Layout Fig. 1 : Loweringbraketelescoping

Pressurelimitingvalve is tactory-set(do not adjust)

Lowering brake valve V2

)4.3 Function The "loweringbraketelescoping"consistsof two loweringbrakesS1 and 32. Lowering brakeS1 is directlyactuatedby controlpressureX and opens the path for the regulatedflow of hydraulicoil from the ring surfaceinto the tank.At the same time control pressurex is presentat the pressurelimitingvalve.Loweringbrake52 will only open once the factory-setpressureis reached.Thisallowsfiner controlof inwardtelescoping when underload. Fig.2 : Extractfromcircuitdiagram- Loweringbraketelescoping ::ia:(C?

Liebherr-WerkEhingenGmbH -Technicaltraining


- ' t 6-

TTBHINR

Gomponentdescription OW 14 - Telescopicboom / Telematics Prcdued by: lrepilo / Edilionr13.11.06/VeBion:o1

5. Telescopingcontrol: 5.1 Modelwithout hoist gear ll - Masterswitch left - wilhouthoistgearll Fig. I : LTM1095-5.1

fit t

t-/

t

I

M52

fiI

5.2Modelwith hoist gearll - Masterswitchright - withhoistgearll Fig.2 : LTM1095-5.1

t@1

1"" , .l flt-Z ' -.r-I f,li t t@L

M51

5,3 Foot pedal telescoping Footpedaltelescoping Fig.3 : LTM1400-7.1

l1l

I -s501

I

Pedalsensor,footpedal telescoping

Liebhen-WerkEhing6nGmbH - Technicaltraining


Er ftt

- 1 7-

IIBIIIRR

Componentdescription OW 14 - Telescopicboom/ Telematics Produed bv: lweDi.o/ Edi6on:13.1106/ve6ion:o1

6. Systems )6.1 Telescopicboom in an open hydraulic circuit Magneticvalvesare usedto controlthe variousfunctionsof telescopicboomsin open hydrauliccircuits. Pressurestagesare switchedin/outto achievethe requiredlevelsof functionalpressure (seetableExtractfrom circuitdiagram).Theselevelsdifferdue to the varyingratioof pistonsurfaceto ring surfaceand dependingon whetherthe tele cylinderis movedindechange-overbetweengripper pendentlyor togetherwith othertelescopicsections.The pinning/ tele pinningis performedusinga 2/3 way magneticvalve.The tele cylinderis pinning). equippedwith (see chapter:Gripper/tele Fig. 1 : DualpumpA20VLO190EP

Pressure cut-off valve

-Y35

Dual-pumppumpS/6 Variabledispl.pump Telescoping,luffing A20VLO190EP

Lufflngup / cylinder (Pump6)

Pressure Iimiting valve 100bar

-Y34 Luffingup / cylinder (Pump5)

Non-returnvalve Fig.2 : ControlblockLTM1400-7.1 P3/ l DBV 320bar

Pressurestage P5/V DBV 12bar

P 1/ t DBV170bar

P4/tV DBV235bar

P2/ DBV220bar

-Y15

-Y11b

Lufflngup

Pressure

-Y'l2a

-Y11a

Pressurestage

Pressurestage

-Y10 Telescoping in

-Y14 Telescoping out



-Y13 Pressure

-Y',l2b Pressurestage

IIIBIIIRR

Componentdescription OW 14 - Telescopicboom / Telematics 13.11.06/ VeEion:ol Prcducedby: lwepio / Eda$on:

- Telescopicboom not actuated Excerptfrom circuit diagramLTM1400-7.1 .E ::

,*f"t; HG HIH

HIH

\ 1 1 5\

\

= ala = \ \ \ \ 1\ l

\9

o)o

t

;t:) O E J.'F

:a= o) Y',=c ; h o -o-

frRRR

+" l g .

" q)

o o) 99) >.9

; 3

.- *-f--t" r r T -

2 o

o 2 o

T - t -

3 d N

o >

.=z

c) ct o

'6-

E

3 N N

o > ! F \ ( 5 O ) f'6.c-

_9 o

o g b

n 9 N g

o

o-9 > =

- . 4

Y ;

i 3

C F \

or x' >.E

-

> 9

co6 $o-

q)

o-9

q)

-Qn

=>

O d r

!c!

o<

'== ! c

>\t

( 6 f (r)

(l)

+o-

o 6

o 6 o,) G o ) >,*

3 ; c.t 9

(D

() (, ot o o o -:a

E o =

o

> - - c EHE E 9

6n9

N N

p c o-d

Liebher.-Werj< EhingenGmbH - Technicaltraining


-19-

9)(D _*6 au>

E * x= F- d, d 9

UIBITIRR

Gomponent description OW14- Telescopic boom/ Telematics Produed by: lwepio / Edition:13.11.06 / Ve6ion:01

- Telescopingout GripperpinnedTeleunpinnedp2 Excerptfrom circuit diagramLTM1400-7.1 _ntn

\l

: ( a

r+H+ H+4

Hlf; \

\9

\

R Rn RRR

. . 6 i ._ -

r----j] i*

o =

o tro o o = o

iE

9 o -

0)

F

. = c Lo - =

gedE l :

fE iXf. >i s. E€

=^;3€ ='-9.;-9



-20 -

UTBHTNR

Componentdescription OW 14 - Telescopicboom/ Telematics Producedby: wepio / Edibon:I 3 1106 / Ve6ion:01

)6.2 Telescopicboom in an open load-sensinghydraulic circuit hydrauliccircuitsare controlThe varioustelescopicboomfunctionsin open load-sensing led by meansof magneticvalves.Pressurestagesare switchedin/outto achievethe requiredlevelsof functionalpressure(seetableExtractfrom circuitdiagram).The changeover betweengripperpinning/ tele pinningis performedusinga 2/3 way magneticvalve fittedon the tele cylinderloadpressureXL is appliedto a pressuresensorvia shuttle valves.Magnetic valve-Y49actuatesa cartridgevalveto establisha connectionbetween the cylinderringsurfaceand the tank returnwhen telescopingout.

DBV Tele off DB 140 BAR Pressure stage P3 Fjg.1 : MaincontrolblockLTM1100-4.1

-Y12 Pressurestagep3

Fig.2 : MaincontrolblockLTM11004.1

DA 150BAR,PressurestageP2

DB 80BAR,Pressure stageP1

-YOa Prop. valve,TeleON

Controlblock protection 385BAR

DBV Teleon, DA 270 BAR

Stroke limitation telescoping in P4 270 BAR

-Y11 Pressurestage P4

?!9E!l?_{?gg,P4 Liebherr-WerkEhingenGmbH - Technicaltraining


-21 -

ITIBHIRR

Componentdescription OW 14 - Telescopicboom/ Telematics Pbd!@d by: lwepro / Edilion:13.11.06 / Version:o]

Excerpt from circuit diagram LTM11004.1- Telescopicboom not actuated

o _

r

u

i ;

1

s * 9,4\> a / '

=

9

t

!. 9i fi a

l/T\l v l

dl

rAr l\21 o

3 = N

o >

0)o .E2 o > ''.... .:.. = ;

!.

d9 16l

s

9

o .o

-

qt

2(E

.9 (D

o)

zo

o(D Ctr O

o o

E c

5E c . \

N P

N d

" l

o

= x

l I I I L-

(D

'--:

.o € o

() xi2

C

No-

q) o o(g o o

(') '- -oO ^ o 3 _9 6 - otr

q)5 2 o

gE'

.9a (l)X

:q? x: .::

o

=e

=r o-

-

B

E

H+ f+# H+ 9 :.ti

o -

E

9 P

o

q

-

\ t2

\

€

=P

o o 2 o o

Liebherr-WerkEh;ngenGmbH- Technicaltraining


-22 -

i.= P E ?\a

: o

Rt ai

->

\

a Rft

.9 6c i

\

d9

lTTBtffNR

Gomponentdescription OW 14 - Telescopicboom/ Telematics

- Telescoping out GripperpinnedTeleunpinnedp3 Excerptfrom circuitdiagramLTMI'1004.1

g CIr q l H 'A

d t

E ! u

;

d t 2

m n <

9

- t E 4

Lfi-U

I

I I

tF

o = crt

CC.)

-

a

##

ulL |-t I

\

K -

-?

:

J;

|i !

"+ \ \ 4^

\

RK

s

f; :

g

i c = O

9 p qrt a .n 6 Ya 9 . 9 CLE

E 9 >r -= oa . C : i

at=

= i

Uebherr-WefkEhingenGmbH - Technicaltraining


-23 -

o t D - t t i = o

'9 or ; o

6

E e = o O J

lTIBHIRR

Gomponentdescription OW 14 - Telescopicboom/ Telematics Produed by: lwepid / Edilion:13.1106 / Ve6ion:o1

7. Operatingmodes )7.1 Automatic telescoping operation interfacewhichindicatesto The LlccoN telescopingscreenis a dynamicfull-graphics the cranedriverthe pinningstateof the telescopicboom,the relativepositionof each telescopeand the extensionstateof the telescopiccylinder.The automatictelescoping procedureallowseasytelescopingoperationof the telescopicboom by the cranedriver, the telescopiccylinderor telescope. sincehe is not responsibleor pinning/unpinning

simplifiesany telescoping The LlccoN telescopiccontrolsystemthereforesignificantly work;onlyihe requiredtelescopingtargetmustbe entered.The LICCONtelescopiccontrol systemdeterminesthe orderin whicheachtelescopeis movedto reachthe required end oosition.

executedonce actionsare automatically All telescopicmovementsand locking/release the requiredtelescopingtargethas beenspecified.The individualtelescopesare essentiallycontrolledto specificpinningstates,i.e.the movementsare alwaysto the telescoppositionsare not possible. pinned.Intermediate I92o/o| 100o/o ic states oo/oI 460/o

The followingmovementsand actionsare executedby the system: . Locking/releasing the tdlescopiecylinder. . Locking/releasing the telescope. . Orderof the telescopesbeingtelescopedto reachthe requiredend position.

This automaticprocedureis only executedas longas the masterswitchis beingoperated.The mainswitchis usedto determinethe directionand speedof the telescopic movement.This allowsthe cranedriverto maintaincontrolof the crane.The directionof cylindermovementis specifiedby the LlccoN computersystem. lf the telescopicboom is extended,whereby it is necessaryto move currentlyunreachabletelescopes,first telescopein untilthe last telescopebeingmovedis reached.In this case,firsttelescope out). in beforeextendingthe telescopicboom (telescoping The automaticsymbolis displayedduringautomatictelescopingoPeration:

ae I

qn0.l

Note: by enteringa shortcodeor mustbe setandconfirmed Thecurrentsetupconfiguration pressing thefunctionkeys. Liebherr-WerkEhingenGmbH - Technicaltraining


-24 -

IIIBIITRR

Componentdescription OW 14 - Telescopicboom/ Telematics Prcdued bv lmoil() / Edition:13.11.06/ Ve6ion:01

Fig. 1 : Telescopingscreen

currentextensionlevel [%] of telescopes1 - 5

U-:Lai = LUt 6 1 G Lt==

L'E t . f

tr

LI

rc E a@ g

K] L.r!l@t

00 ,'10u/100/i00 /lffi

ffiM

Targetselectionfor telescopes1 - 5

=mrctrrcm

ti--.

I

Functionkeys: "F1": "F3": "F4": "F5": "F6": "F7": "F8":

Change-overbetweenautomaticmodeand manualtelescoping Targetselectiontelescope1 Targetselectiontefescope2 Targetselectiontelescope3 Targetselectiontelescope4 Targetselectiontelescope5 press1x - Switchoff acousticsignal press2x - Faultsvisuallydisplayedin symbolelement"Horn"will be screen. automatically displayedon the errordetermination

Note: screenor telescoping Thetelescoping targetcaneitherbe seton theconfiguration screen.



-25 -

UTBHTNR

Componentdescription OW 14 - Telescopicboom/ Telematics Produed by: lwepr0 / Edilion:13 1106 / vers on:01

Selectionof the telescopingtarget on the Fig. 2 : Configurationscreen configurationscreen: Use arrowkeys (4) to moveslidingmarker(1) leftor rightto the column corresponding to the requiredtelescopicboomlength. Note: This selectionis storedwhen chanoinqto the craneoperatrngscreen s}|FI ,

Fr

F2l ;F3 :Fa

:F5: :t8

Selectionof the telescopingtarget using Fig.3: Telescoping screen the telescoping screen: Functionkeys F3 to F8 are assignedto each telescope(e.9."F3" = Tele1). The telescopingtargetis selectedby pressing the functionkeysseveraltimes. Eachtime the key is pressedthe targeted extensionstateof the corresponding telescope is changedto the next percentagestep (0%, 46%,92%or 100%).Eacf of thesepositions has pinningholefor telepinning.

a/: : . F 6 : : E N T € f t

;irr!:-

lr-:!, re...'i., :{::L'r::l{.;:

ri=+ =:>-ai :gI.:

.=-

Note: lf a flashingsymbolelementwith a crossed-outtelescopicboomappearson the first line of the telescopingscreen,it is not possibleto unpinthe telescopicsections,the unpinned load liftvaluehas beenexceededor no load lift chartis available.



-26 -

IIIBIIIRR

Componentdescription OW 14 - Telescopicboom / Telematics Prcdu@dbv: l@oio / Ediiion:13.11.00 / VeBion:o1

the nexttelescoping direction on the TheLICCONcomputer systemalwaysindicates screen. telescoping screenor craneoperating Themasterswitchor footpedalmustbe operatedto followthe specifieddirection.

:'lll i

- preselected telescopic targetreached

qno:

Targetdireciionof masierswitch:

t?l l

-^*l I

V - Demand:telescopein

RJfri

. - Demand:telescopeout

f,JIB ]

Note: telescoping actionhasbeen Thedirectional arrowwillextinguish whenthepreselected completed. is alsovisuallydisplayed on theoperating screen. Thisstate"Telescoping targetreached" Afterca. 3 to 5 secondsthis changesto the telescoping screenif the masterswitchcontinuesto be operated.

Uebhen-WerkEhingenGmbH- Technicaltraining


-27 -

UETTRR

Componentdescription OW 14 - Telescopicboom/ Telematics Produ@dby: lwepio / Ediijon:13.11.06/VeEion:o1

)7.2 Manualtelescopingoperation Telepinning screen Fig.1 : Telescoping

fIEIHETE

trEE > !,4r ) 33r

8trtr

BN@

tr@@

4la/ 4E/ 4tr/ 4li / 4E- 4E

@@@

t--- /--- /--- /---

-\

trtrtr trtrtr

Btr@

?-

F--,

llrell llezllllrellIIENTER ll

Gripperpinning

Automaticmode

Two lines

Key Fl is usedfor the change-overbetweenmanualand automatictelescopingoperation. Note: from auiomaticto manualoperationis not possible,moveselector lf the change-over switch5618 to the centreposition.



-28 -

IITBIIERR

Componentdescription OW 14 - Telescopicboom/ Telematics Produed by: lwepi.O/ Edilion:13.11.06/ Vecion:o1

Significanceof switch symbol €618 Unpinningthe telescopeby usinganothertelescope. -Thetelescopeis only connectedto the tele cylinder. -Thetele cylindercan be movedusinga telescope. A connectionis establishedbetweenthe tele cylinderand the telescooe. -Thetele cylinderis connectedto the telescope. -Thetelescopeis pinnedto anothertelescope. -Thetele cylindercannotbe moved. betweenthetele cylinderandthe telescope. Loosenthe connection -Thetele cylinderis free. -Thetele cvlindercan be moved.

1. Lock the tele cylinder to the telescope (close gripper pinning) Firstpush-5618down. -H613 Continuemovingthe tele cylinderuntilthe two linesare displayednext to the requiredtelescopeand -H613is lit. =' -'9. , TIP: again, Continuethe movementuntilthe two lineshaveextinguished then very slowlymovebackuntilthe two linesreappear. Moveswitch-5618 to the centrepositionto engagethe gripperpins. 2. Unpin the telescope (open tele pinning) The nextstep is to switch-5618 upwards. Unpinningis now performed.The telescopeshouldbe slightlyextendedto supportthis action.The unpinningactionwill also be noticeable. Moving the telescope 3. The telescopecan be retractedby movingthe masterswitch. if the telescopehas reachedthe end position,move-5618 to the centre positionto pin the telescope. Press5618 downto releasethe tele cylinder. The tele cylindercan now be freelymovedif any othertelescopeshaveto be retracted. The two lineson the telescopingscreenextinguish-H613now goes off again.Proceedas describedin steo 1.

Liebhen-WerkEhingenGmbH - Technica!training


- 29 _

UIBHTNR

Componentdescription OW 14 - Telescopicboom / Telematics Prcdued by: lreFrc / Ediiion: 13-11.06 / VeFid:ol

8. Hydro-mechanicaltelescoping systemwith pulleyblock )8.1 Purpose Thetelescopicboommaybe hydraulically extended/retracted. Thisprovidesthe telescopiccranewithvariableradiusand lift.The boommustbe designedto liftthe attachedloadin the intendedapplication.

)8.2 Layout

Fig. 1 : 3-stagehydro-mechanical telescopingsystemwith 2level pulleyblock Articulatedpiece

Flatrope

Flatrope2

Telecylinder



Retum cable 2

-30-

UBHINR

Componentdescription OW 14 - Telescopicboom/ Telematics Arduced by: l*epiro / Fdition:13.11.06/ Ve6ion:01

Flat rope 1

Flatrope2

Returncable 1

Telecylinder Retum cable 2

)8.3 Function 2 and3 are exTelescope1 is extended/retracted usinghydrauliccylinders.Telescopes tended/retracted usinghydraulic cylinders together withropesanda 2-levelpulleyblock 1,2 and3 are alwaysextended/retracted synchronously. system.Telescopes



- 3 1-

UBHINR

Gomponentdescription OW 14 - Telescopicboom / Telematics Prcdued br lrepiro / Edilion: 13.11.06 / VeEion:o1

9. Boomsystems )9.1 Abbreviations

T

Telescopicboom Extendedtelescopicboom

K/NZK

Foldingjib / hydraulicallyadjustable

F

Fixed latticejib

N

Luffinglafticejib

ry

Telescopicboom relaxed

D

Spacer

D

Denickboom

It

Suspended ballast

I

T

/

SOWF)



-32 -

UEHENR

Gomponentdescription OW 14 - Telescopic boom / Telematics Prcducedby: lwepid / Edilion:13.11.06/ Ve6ion:01

10.Reversalwindow )10.1 Gripperpinningreversalwindow (signalarms)areusedto applythegripperpinning. Speedreduction is Thetrackswitches controlledby the lengthsensor. Figl: Reversalwindowgripperpinning Telescoping out

Telescoping in -----

O t u ( m d i m u ns p 6 e d )

<-

r I I

Q= 76 Unin (rcduced sp€ld l€v.l firhout pins

I i---T-

O= 3l Umin (rcduced

I

)10.2 Telepinningreversalwindow of telepinningandthespeedreduction. Thelengthsensorcontrol's theapplication Figl: Reversalwindowtele pinninghole in Telescoping

Telescoping out

a*

<-

{ dimale Geschwindigkeit)

rerescope in I

---t- I -1--it-t

l

l

l

O = 76 Uftin keduced sp€.d l.v.l wlthout pirs q= 3t Umin {.educed

I

ben.ooli€d

!(.-_'

I

Note: On cranemodelsLTM 1160-5.1and LTM 1200-5j the reversalwindowis pressure-controlledinsteadof time-controlled. Liebhen-WerkEhingenGmbH- Technicaltraining


-33-

UEHENR

Component description OW 14 - Telescopicboom / Telematics Prodled by: lwed|{) / Edi[on: 13.11-06/ V4ion:01

Liebhen-Wsrk Ehing€n GmbH - Technical training


-34 -

UEIIRR


OW16- LICCONTestsystem

:II*Irngu:

f,'flrrrrrr ,s'rrlEEtrtrtrElAlEl

NurfUrLlEBHERR-Servicepersonal

Note: test programs. Thisdocumentexplainsthe procedurefor superstructure program wasselected' engine active" 39 ,,VentDiesel As an example,test test programs.In Thisdocumentcanalsobe usedas a samplefor othersuperstructure procedure will deviateslightly. this case,the conesponding for "Testprograms(chassisand superstructure) Seealsothe description to thecranenumber.

Componentdescription OW 16 - LICCONTestsystem Prcduc€d by lwdpilo / Edilion: 18.10.06 / V€€ion: !

Contents 1. TestprogramsSuperstruc{ure

t.---'

Liebhen-We* Ehingen GmbH - Technical training


UIBHRN

Gomponentdescription OW 16 - LICCONTestsystem Pmd€ed by: lw€pid / Edition: 14.10.06 / V€lsiod 1

Liebhen-werk Ehingen GmbH - Technical training


uErmn

Componentdescription OW 16 - LICCONTestsystem Producedbv: lweoirn/ Edition:18-10.06/ Ve6ion: 1

1. TestprogramsSuperstructure 1.1 Test program 39 - Vent Dieselengine active (for PLD engines) Fig.2 : Configuration screen 1.1.1Releaseof i-key

I.E't, Task: The engineventingis usedto vent the fuel linesbetweenpumpand nozzleon a PLD engine.

=.=i-e =!:=

*._-

G'.e .'GjQ-

Basicprerequisite: The enginesin the chassisand the superstructure mustbe turnedoff.

ito

1 . Switchthechangeoverswitch to UWOW(chassis / superstructure) position. ,,Superstructure" z.

-!!

:tl :;;i i

ir:, ri.. rnri6)

Fig.3 : Operatingscreen

Turnon thesuperstructure battery masterswitch.

, 7 a:

1::9

,-?:is-: iEli

i 0 ::--==

3. Turntheignitionswitchsuperstructure engineto position1 (15) (fig.1).

.J

LXJ

t2'9 Fig.1 : lgnitionswitchsuperstructure engrne position| (15)

Til i-

: < >_o:

l9

o - r 1rs) tr /t\r(so)

grcFr 1

?

F3

IFE- .r

F{

it- \ = /rt

ENIER

Fig.4 : Operalingscreen

v

'l::8 : s-

*|

4 . Inthe configuration screen(fig.2)

'

4

5

6

pressthebutton@ .

^ .T,

5 . lf errorsarepresent, confirmerrorwith

theFl,,Horn"key(fig.3).

F +F r

press@ll 6 . In theoperating ""t""n, + ll@ll at thesametime(fig.4),to open n w' PROGRAM' . the,,SUPERVISOR

@a

t : = . : : :



- 5 -

-'!'

F1

F2

Fr

i1

!

::_

,

!/, .1 lEq

, 1.' .

- /4,

;)ql oo:o

trtr
Fs 11

!q

E:r,nEF.

TTTBilINR

Gomponentdescription OW 16 - LICCONTestsystem Prcducedbv: lweoiro/ Edition:18.10.06/VeFio.i 1

7. Enterthe dailycoOe[-[-[-[ numberkeys (fig.4). Note: The dailycode is calculatedwith the Daily codecalculator.In the LICCONPROthe dateandthe GRAMSUPERVISOR, cranenumberrequiredfor calculationis snown.

- modify Fig.5 : LICCONPROGRAI\4 SUPERVISOR

key(fig.5). B. Press@,,rrrrOolfv"

- i-key Flg.6 : LICCONPROGRAMSUPERVISOR

9. Presskeyl, j ,,Test system"(fig.6).



- 6 -

IITBHTNR

Gomponentdescription OW 16 - LICCONTestsystem Prcdu.edbv: lweoilo/ Edition:18.10.06/ VeE on: 1

- access Fig.7 : LICCONPROGRAMSUPERVISOR

10.Presskey@ for,,ACCESS".

11. Enter access number E - El . El via numberkeys.

Note: The releaseof the i-keyis eliminatedagain at ignition'OFF".

- End Fig.8 : LICCONPROGMM SUPERVISOR

12.Press @,,rruo'key(fig.B).

'13.Press "f ruO'keyagain(fig.9). @

- End Fiq.9 : LICCONPROGMM SUPERVISOR



-7

-

UIBHINR

Componentdescription OW 16 - LICCONTestsystem Pdduced by: lwepio / Ediiion:18.10.06/Ve6ion: 1

- accept Fig.10 : LICCONPROGRAMSUPERVISOR

14.Press@l (fig.10).

t"v to acceptthechange


Onlyfor LIEBHERR-Servicepersonnel

- I -

lITBHTNR

Componentdescription OW 16 - LICCONTestsystem P o d u c e db v : l w e o n o/ E d t o n : 1 8 . 1 0 . 0 6 / V e 6 i o o : l

1.1.2Note source word description (operand)

Fig.1 : StarttheMulti-CPU testsystem

'1. Press keyto startthe I MultiCPUTest system(fig.1).

key 2. Press @,,svsrrv sPECIAL" to see the specialviews(fig.2).

3. Press@ "pug"down"key(fig.3) Fig.3 : Indexspecialviews untilthemenuentry,,Engine superstructure: Testprograms, errormemory" appears in thespecialviewoverview. Note: Thespecialviewoverview canlookdifferentlyfor eachcranetype.



- 9 -

lIIBIIIRR

Gomponentdescription OW 16 - LICCONTestsystem Pmduced by: hrspilo / Edition; 18.10.06 / VeBion: 1

Testpr. super Fig.4 : Selectionspecialview:Enginesuperstr.: 4. Selectthemenuentry,,Engine programs, errormemo structure:Test , Daucre68/ - sllitr r 0) r ' pressing down" the ry"by @ ,,Cursor key(fig.4).

.!

r.elflt,..rre

r.!l-,,D

tI]n@rMtr@

r?6 ,3€rrl

Fig.5 : Specialview- Enginesuperstructure...

5 . Confirmthe selectionwithFE] openthespecialview(fig.5).

to

6 . Notethe sourceworddescription

(theoperand)of test program39: ,,VentDieselengineacti,ve" (forexampleQW2.39).'

EEENtfEE@

keytwice 7. PresstheEl ,,BACK' tn a row.

training Liebhen-Werk Ehingen GmbH-Technical

- 10 -


UEHRN

description Component OW 16 - LICCONTestsystem Producedby: lwepO / Edition:I8.I 0.06/ Vercion:1

Fig.1 : Selection/ Test+ Error

1.1.3Changesourceword

+ enor key(fig.1). 1. PresslrsI ,,Test

F i g . 2 : S e l e c t i o/nA W L D I S - l N T

2. PresslEl_ll key(fis.2). ,,AWLDIS-lNT" 3. WiththekeysE,o |E, setthecursor to QW

4. Enterthe previouslynotedsourceword description via the numberkeys. Note: The sourceworddescdption 2.39mustbe enteredwith 2039.

key(fig.3). 5. PresstheIEI ,,CHANGE"

training Liebherr-Werk EhingenGmbH- Technical


Fig.3 : Selectionchangesourceword

- 11

UIBHINR

Gomponentdescription OW 16 - LICCONTestsystem P'oduc€dby: lwspno/ Edilion;18,10.06/ Ve6ion: I

Fig. 4 : Changeand accept sourceword

6. Viathenumberkeys,enterthevalue 039 (forTestprogram39) andconfirm with[erTE (fig.4).


- 12 -


lIIBTIIRR

Gomponentdescription OW 16 - LICCONTestsystem Poduced bv: weoiro/ Edition:i8.10.06/ Ve6 on: 1

Fig. 1 : Start SystemSpecial

1.1.4Checksourceword change Note: Afterchangingthe sourceword,it must be ensuredthat the changewas accepted.

1. PresstheE ,,BACK" keytwice.

key 2. Press@,,svsrev sPEC|AL" (fis.1) re../ PressE ,,page down"keyuntilthe Fig.2 : Specialview- Enginesuperstructu menuentry"Enginesuperstructure: Testprograms, appears errormemory" in thesoecialviewoverview.

4 . Selectthemenuentry,,Engine

Testprograms, error superstructure: memory" by pressing the]Fl ,,Cursor down"kev.

5. Confirmtheselection with@] opentheSpecialview.

to

6. Checkentry(fig.2). Note: Thepreviously changedsourcewordmust nowhavethechanged value (39forTest rogram39)


- 13 -


lIIBHINR

Gomponentdescription OW 16 - LICCONTestsystem PEducedbv: lweoim/ Edition:14.10.06/ Ve6ion: 1

engine- position 1.1.5StartTestprogram39 - ,,VentDie- Fig.1 : lgnitionswitchsuperstructure (50) r sel engineactive"

1. Turnthe ignitionswitchof the superstructure engineto positionll (50) untilthesuperstructure enginestarts (fis.1). Note: To start Test program39 -,,VentDiesel engine active", a secondpersonis required. with startingthe superSimultaneously structureengine,the manualfuel pump (fig. 2) must be actuated.The fuel system is vented.Due to the increasedinjection of fuel, the exhaustfumesare increased significantly. The ventingprocesscontinues only as long as the ignitionswitchis engagedor untilthe engineis running.As soonas the engineis running,the process is stoppedby the enginecontrol.The QW settingsare deletedagainvia ignition

Manualfuelpump

..oFF".

Liebher.-WerkEhingenGmbH - Technicaltraining

- 14 -


IIIBIIRR

Functionaldescription OW 20 - Emergencyoperatingmode Pbduced bv:lweoio/ Edilion:0606 07 / veBion:3

OW20- Emergencyoperationfor the superstructure



-1-

1IBIIIRR

Functionaldescription OW 20 - Emergencyoperatingmode PDducedby: lrepno / Editon:06.06.07/ Ve6ion:3

Note: purposes Thisdescription is for information onlyandservesto improvethe understanding of thereader. Caution: Theoperating instructions for a particular cranemustbe readbefore andtestprograms givenin theoperating attempting lf in doubt,followtheinstructions emergency operation. instructions andtestprogram.



-2-

UISIENR

Functionaldescription OW 20 - Emergencyoperatingmode PEdu@d by: lwepi.O/ Edition:06.06.07/ VeEion:3



-3-

1lIBHINR

Functionaldescription OW 20 - Emergencyoperatingmode ftldu@d by lwedo / Edirion: 06.06.07 / vellion: 3



-4-

UEHINN

Functionaldescription OW 20 - Emergencyoperatingmode Prcducedbyr lwepiro/ Edition:06.0607/ Ve6lon:3

1. Emergencyoperationfor superstructure 1.1 Emergencyoperationwithout LICCON(via X-Not) )1.1.1 General Emergencyoperationvia the -XNOTconnectorsis usedwhen the LICCONcomputer svstemfails.

Speed adjusiment: A potentiometer is usedto regulatethe speedfor the cranefunctionsThe speedregulationfunctionfor "Model1" only controlsthe slewinggear,whereas "Model2" also includesthe hoistgear and luffinggear.

potentiometer Speedregulation

potentiometer Fig.1: Speedregulation

fir Fig.3: Model2

Fig. 2: lvlodel1 Liebherr-WerkEhingenGmbH - Technicaltraining


-5-

UTBHINR

Functionaldescription OW 20 - Emergencyoperatingmode PDdu@d bv: lweDio / Edalion: 06.06.07/ Ve6ion: 3

1.1.2Slewinggear -Removeconnector-X55from the relaypanel. -Removeconnector-XNOTfrom the relaypaneland pluginto socket-X55.

i ij ii ij ii i'r :i, ' r I r ' : ' r | | : - , I I r r i : I | | |

F::i:i :.i:.jH i ;

i i I i i i i i l:l

i riiiiliill n (:>fL,J

C

'

.I

a

;

:

"-- h

:

E

E

; E

ili

r: :turnleft

fir

r : turnright -S622"Function Pushbutton driving switch"(turnleftor right)

Caution: Afterthe cranefunctionhasbeencompleted,removeconnector-XNOT and plug connector-X55 intosocket-X55.

Liebhen-WerkEhingonGmbH - Technicaltraining


-6-

UIBHINR

Functionaldescription OW 20 - Emergencyoperatingmode Prcdlced bv: lweoio / Edition:06.06.07/Ve6ion:3

1.1.3Hoist gear I -Removeconnector-X51on the relaypanel. -Removeconnector-XNOTfrom the relaypaneland pluginto socket-X51. F ii i"; i; i; f; l:: : _

' I r r

' | | |

' r r r

' I I t

I I

F 1; J;:i l; fi

i i i i i l l l l l l i i i i i r i l l l

ts

Lr.r +

Lc- Lcr+

q- j ,,

F

ir_+!' { - ,..

E

F;-,r-r ,1;lll

fii

rr : raisehoistgear I

fir

I : lowerhoistgear I Pushbufton-5622 "Functiondriving switch"(raiseor lowerhoistgear l)

to ,,raisehoistgear ll" the To disable"hoistgear I unwound"operatesynchronously pushbutton-5626 (-5620) "Pressurestage" *

I '-' l.

|t_il 1 I ilt_Eltl+l \ : /

Caution: removeconnector-XNOT andplug Afterthecranefunctionhasbeencompleted, intosocket-X51. connector-X51

* = Activating pressure onlywithappliances with of the,,Manual boost"is necessary pressure-sreps Liebherr-WerkEhingenGmbH - Technicaltraining


-7-

1lEHENR

Functionaldescription OW 20 - Emergencyoperatingmode Poduce! bv: lweDiiO / Edition:06.06.07/ Ve6 on: 3

1.1.4Hoist gear ll -Removeconnector-X52 on the relaypanel. -Removeconnector-XNOTfrom the relaypaneland plug intosocket-X52. 3 i; i; i': ii i'; i l ; l ' L | r r r t -

: i r |

' I | |

r l r I

FI : r I, I= ri > i i ; F i

i '

I - l

i i i i t l i i i l = l . i i r ll : , | J L -'

{---l------l

IL_d--:-l.: :tr

c------H

l

f,i

r; : raisehoistgear ll

fir

I : lowerhoistgear ll Pushbutton-S622"Functiondriving swit6h"(raiseor lowerhoistgear ll)

to ,,raisehoistgear ll" the To disable"hoistgear ll unwound"operatesynchronously pushbufton-S626(-S620)"Pressurestage"* / r-r

\.

iEL+ Gaution: and plug Afterthe cranefunctionhas beencompleted,removeconnector-XNOT connector-X52into socket -X52.

* = Activating pressure boost"is necessary with of the,,Manual onlywithappliances pressure-steps Liebherr-WerkEhingenGmbH - Technicaltraining


-8-

lIIBHINN

Functionaldescription OW 20 - Emergencyoperatingmode Podlced bv: lweDiro/ Edilion: 06.06.07 / Ve6ion: 3

1.'1.5Luffinggear -Removeconnector-X53 from the relay panel. -Removeconnector-XNOTfrom the relaypaneland pluginto socket-X53. P'*itl: i:ft 1:: r r , r , I r I r I l - lI ' r | , I r r r l

u:"1 :"i, :"i :.1I | i ' i r i , t

l

i i l i i r I i i lEl i ill i iiiil.l .e--!.-o....-o..!' n

!

-

D

.-4*=_-u L

o

-

-:: E

-'

!

fit

rr :luffingup

fir

: : luffingdown Pushbutton-5622 "Functiondriving swititr" 1tuffup/down)

.

-3626(-5620)"Pressure stage"* operatesynchronously to ,,luffing up"the pushbutton

/ '-. I.

|t-il 1 | iltd{Fl I I|:II

t -

I

/

Caution: After the crane functionhas been completed,removeconnector-XNOTand plug connector-X53into socket -X53.

* = Activatingof the

pressure-sreps

,,Manualpressureboost"is necessaryonlywith applianceswith

Liebhen-WerkEhingenGrhbH- Technicaltraining


-9-

IIIBHINN

Functionaldescription OW 20 - Emergencyoperatingmode Podu@d bv: rweoio / Edition:06.0607 / Veclonr 3

1.1.6Telescoping -Removeconnector-X54from the relaypanel. -Removeconnector-XNOTfrom the relaypaneland plug intosocket-X54.

lilrli";lii

.- .Li

+)-

+ i i i i i ,i i i i r i r l r r i l . i

'f

,", - il ;r

i'ii','.";i+ f r-q

-q

. .

l-l

lr -.1

F'

E

D

T

F

:l :1 rE:( |

fI I

:: :telescoping in

Fr

I

il|

:telescoping out Pushbutton-S628(-5622) "Functiondrivingswitch"(telescopein/out)

Controllight-H619(-H613)"Gripperin position"

ffi

:

unpintele

0

:

pintele,

|

:

unpingripper

i

l

pingripper

Selectorswitch-5624(-5618)"Gripper / tele,unpinandpin"

-5620"Manualpressure boost" Pushbutton

Afterthecranefunctionhasbeencompleted, removeconnector-XNOT andplug -X54connector-X54 intosocket Emergency is not possible withouttheLICCON. telescoping operation ontheLTM1400-7.1 Liebherr-WerkEhingenGmbH - Technicaltraining


-10-

IIIBHINR

Functionaldescription OW 20 - Emergencyoperatingmode Producedby: lwepid / Editionr06 06 07 / Ve6ion: 3

Unpintele: . Selector switch-5624(-561B)0 -> ll

"Unpintele"

lt- l 4 tl

ltuilt=tl -5628GS622) "Telescope Pushbutton 0 -> | out"untiltheteleis unpinned. -S626 pushbutton (-5620)"Pressure operatesynchronously siage"* T

I

nl,m l n l m I n,lEllE$r*tllgFl \ /

Telescopein and unpin the tele: . Pushbutton-5628 (-5622)0 -> ll

"Telescopein"

-5626(-S620)"Pressurestage"* pushbutton operatesynchronously

.

n,lmll=+

n,l$llll

/-

\

llt.l I

lllqti*l \/

.Switch-5624 GS618)Il -> 0 -

Select"Pintele"and

t4 tl

ft-tLtEtl =

.

L_.I

I _ i . - I

.Pushbutton-5628 (-5622)0 -> ll

"Telescooein" and

.Operatepushbutton -5626(-5620)"Pressure stage"untilthetele-pinaudiblylatches. l

l

i', lliriillf

lll-ll I

rl thdillJj

lil@l{f,| I t-t I

-

| \r^lll-1,

I

ll-ll

\-

I

/

* = Activatingof the ,,Manualpressureboost"is necessaryonlywith applianceswith pressure-sreps Liebherr-WerkEhingenGmbH - Technicaltraining


-'t1-

UTBTTTRR

Functionaldescription OW 20 - Emergencyoperatingmode Prcducedbv: lweDio/ Edition:06.06.07/ VeFion: 3

Releasethe cylinder: .Pushbutton-5628 CS622)0 -> |

"Telescoping out" operateuntilthe lockingpin on the telescopingcylinderis relaxed

f,r fll

.Selectorswitch -5624 CS61B)0 -> |

Select"Gripperreleased"

Extendingand locking the cylinder: .Pushbutton-5628 GS622)0 -> | Operate"Extendcylinder"until-H619 (-H613)"Gripperin position"is lit t-t

n,IffilFil,

llEll .6

n,lLsllEF LEI

-S624CS618)| -> 0

.Pushbutton-S628 (-5622)0 -> |

n,lffiTFl

"Lockgripper"

"Telescope out"untilthe pin latches audiblv

n'l&llEli* Liebhen-WerkEhingenGmbH - Technicaltraining


-12-

UTBHINR

Functionaldescription OW 20 - Emergencyoperatingmode Producedbv: lweoiro/ Edilion:06.06.07/VeEion:3

)1.2 Emergencylowering (emergencycrank) Emergencyoperationis optionaland variesdependingon the cranemodel.A transformer or externalhydraulicpowerunit assiststhe operatorin selectingand performing(using the handlever)all cranefunctionsevenwhen the hydraulicshavefailed.Furtherdetails are givenin the operatinginstructions for the specificcranemodel- thesemust be and is observed.The followingdescriptiononlyappliesto cranemodelLTM1100-4.1 providedto improvethe understanding of the reader.

Connectthe hydraulichoses Set the ball valveon the chassisto emergencyoperation

Ballvalvechassis

Fig.2: Hydraulictransformer Hydraulictransformer and ballvalveon Fig.1: Transformer chassisLTM1100-4.1

Note: The operatinginstructions and emergencyoperationsignon the cranesuperstructure both includea table(Fig.3) depictingall the possiblecranefunctions. Onlyone movementcan be performedat any one time.

C 1

/4 \ s d 6{ "9 r( i . \ 4d d6 { 6" }9 i

1\ A 9, 9- \ C {

O

"r "y

U

* '

{ \ { 1

J

2

7

a/ U

powerunit(Hatz) operation Fig.3: Example ot emergency operation signon LTN,'I11004.'1 Fig.4: Emergency Liebher-werk EhingenGmbH - Technicaltraining


-13-

lIEHINR

Functionaldescription OW 20 - Emergencyoperatingmode Poduced bv:lweDi'O/ Edition:06.06.07/ VeEion:3

Set the ball valvesfor a particularcranefunction(referto the tablein the operating instructions or the emergencyoperationsignon the cranesuperstructure Valve1

Valve2

Valve3

Valve4

Valve5

Valve6 Valve7 Valve8

Fig.3: Exampleshowingballvalves1-8/ LTM1100-4.1

Note: The ballvalvesmustalwaysbe fullyswitchedto the desiredswitchingposition.

- Carefullyoperatethe handleverto drivethe cranefunctionpreviouslyselectedusing the ballvalves

Handlever

Fig.4: Ballvalve9 and handlever/ LTM11004.1

Note: All ballvalvesmustbe switcheddownfor normal"craneoperation"



-14-

UIBHTNR

Functionaldescription OW 20 - Emergencyoperatingmode Prcducedbv: lweoio / Ediiion:06.06.07/VeEion: 3

)1.3 Manualemergencytelescoping operation using LICCONand key switch "-S81" When performingmanualtelescoping(e.9.telescopingunderload),unpin/pinthe telescopingcylinderand performthe telescopingactionby hand. The markingon the telescopingscreenindicatesin whichtelescopethe pinningdeviceof the telescopingcylinderis located. The distanceto the telescopepinninghole can be read off on the telescoping screento an accuracyof 1%. Manualtelescopingis only used in exceptional circumstances as automaticoperationpermitsthe rapidattainmentof any telescopingstate. Note: The "Emergencytelescopingoperation"key switchshouldonly be turnedon by authorisedpersonsinstructedin the use of the "Emergencytelescopingoperation" feature. C A U T I O N: Overloadprotection(LMB)and hoistlimitswitchare bypassed. D A N G E R : Craneoperationwith key switch-SB1turnedon is prohibited. Thereis a severeaccidentrisk! Emergencytelescoping operation after the failure of an inductive sensor using key switch "-S81": Set key switch-SB1in the qontrolcabinetto emergencyoperation.

fT-'ii

*FHI l}t ,tt'] Key switch telescoping

The emergencyoperationsymbolis shownon the operatingscreen. Emergencyoperation

Liebhen-WerkEhingenGmbH - Technicaltrainlng


-15-

IIIBHINR

Functionaldescription OW 20 - Emergencyoperatingmode Poduced bv: lweDio/ Ed tion:06.06.07lVe6ioa:3

switchedoff when the engineis turnedoff. Key switch-S81 is automatically program,press In the "telescoping" "F1" key to switchto manual telescoping. The "Automatic telescoping" indicatorand the set values for eachtelescopicsectionextinguish on the LICCONmonitor.

The telescopiccylinderand its telescopicsectionare locked and releasedusingpushbutton-5618.

Functionkey F1 on the monitor Press"Manualtelescoping"

"Automatictelescoping"

Unpintele

ilH

Pin tele, pin gripper

t

:

unprngnpper

Function of switch positions -5618: Positionfrom 0 -> ll

Telescopicsectionis unpinned,telescopiccylinderstays lockedin telescopicsection(teleunpinning).

Positionfrom ll -> 0

Telescopicsectionis pinned(telepinningestablished).

Position0

Telescopiccylinderis lockedto telescopicsection;telescopic sectionsare pinned(telepinningand gripperpinningactive).

Positionfrom 0 -> |

Telescopiccylinderis releasedfrom telescopicsection, telescopicsectionsremainpinned(gripperunpinning).

Positionfrom I -> 0

Telescopiccylinderis lockedto telescopicsection, Telescopicsectionsare pinned(gripperpinningestablished).

Controllight-H613is litto showthatthe telescopiccylinderis in the lockedposition.

Liebherr-WerkEhingenGmbH - Technic€ltraining


-16-

.s.

m.

Controllight-H619CH613) "Gripperin position"

IIIBHIRR

Functional description OW 20 - Emergencyoperatingmode Poduced bv: lweoid / Edition:06.06.07/Ve6ion:3

HWI operation: - Telescopeis telescopedin usingleft master switch (or foot pedal)for craneswith t hoist gear,startingwith the innermosttelescope. HWll operation: - Rotaryswitch for master switchfunction mustbe set to telescopingoperation(left position). - Telescopeis telescopedin usingrightmaster switch(or foot pedal)for craneswith 2 hoist gears,startingwith the innermosttelescope.

f,r l'.,-

f\

-";:

/-\

Ms2 I

fir HWI - operation/ left masterswitch:

Note: requires the Theexecution of emergency operation systemon engineto be runningandthe hydraulic Telescoping thesuperstructure to be operational. speedis reducedduringemergency operation,

Rotaryswitchfor masler switch functionin HWll operalon

t@L

t*'" X f i r ) . . o _L I tt ---J_ ";:r I I l@r

>fit X

___l_ | I ' _l_

ti:1

HWll- operation / rightmasterswitch:

Telescopingusing telescopingfoot pedal:



- 1 7-

UTBHINR

Functionaldescription OW 20 - Emergencyoperatingmode Prcducedbvrlweol.o/Ediuon:06.06.07/VeEion:3

Procedure: Prereouisites: - The telescopicsectionsare pinned(telepinningactive) - The telescopiccylinderis pinned(gripperpinningactive) 1. Moveswitch-S118from position0 to position2 to unpin. out" directionto releasethe 2. Movemasterswitch(or foot pedal)in the "telescoping jumps pin tele whichthen backdue to the springtension. 3. Oncethe tele pin is released,movethe masterswitch(or foot pedal)in the "telescoping in" direction. 4. Beforereachingthe tele pinningholeat 0%, moveswitch-S118from position2 to position0 to applythe tele pin. 5. Movethe masterswitchon the telescopingin directionuntilthe lockingpin on the tele pin audiblylatches. 6. Movethe masterswitch(or foot pedal)in the "telescoping out" directionto releasethe pinning. pin gripper locking on the 7. Moveswitch-S118from position0 to position1 to releasethe gripperpinning. 8. Movethe masterswitch(or foot pedal)in the "telescoping out" directionuntil control light-H613"Gripperin position" is lit. 9. Moveswitch-S118from position1 to position0 to applythe tele pin. 10. Movemasterswitch(or foot pedal)in the "telescoping out" directionuntilthe tele pin pinned. is

Liebherf-WerkEhingenGmbH - Technicaltraining


-18-

IIEBHIRR

Functionaldescription OW 20 - Emergencyoperatingmode P'oducedby: lwepio / Edition:06.06.07

)1.4 Hydraulicemergencytelescopingoperation

hosefor Hydraulic hosefor Hydraulic (blue)/ cylinder lock(red) telepinning / connect2 to 4 connect 'l to3

Ball valve pinning tele (blue)

rodfor Auxiliary coupling quick-release connections on teleunpinning mechanism

Couplingpoint turntable emergencyoperationgripperpinning(1) Ball valvepinninggripper (red)B

-MP point Measuring Telepinning

Ball valve Pressureboost emergencyoper€ttion telescoping(A)

-MP Measuring pointA2

Quick-reIeasecoupling (3) Emerpncyoperation girye r ngUnpinning telescopi (red)

Membranevessel

Quick-rele asecoupling (4) Emergencyoperation telescopingunpinningtele (btue)

Controlblockunpinning

Changeover valve Telepinning/ Gripperpinning Liebher.-WerkEhingenGmbH - Technicaltraining


\.-,'

-19-

;t

UEHINR

Functionaldescription OW 20 - Emergencyoperatingmode Producedby: lwepid / Edilion:06 06.07/ VeBion:3

Pre-requisites for emergencyoperationwith ball valves: - Craneengineis operational - Operationalhydraulicplant - Telescopepinningand gripperpinningmechanismsare operational - Telescopiccylindercan be telescopedin/outusingmasterswitchor -XNot

- Priorto emergencyoperationwith ballvalves,the valvefor changingover the gripperpinning/ tele pinning-Y40 GY17)mustbe electrically disconnected. - Set the telescopicboomas steepas possible. The enginemust be turnedoff beforeconnectingor disconnecting any hydraulic lines. Hydraulichosescan only be connectedat a maximumdistanceof 2 m. If necessary,use an auxiliarycouplingrod to couplethe hydraulichoses. - Coupleup the hydraulichosesfor pinningthe telescopicsections(blue): Connectcoupling1 to coupling3. - Coupleup the hydraulichosefor gripperpinning(red): Connectcoupling3 to coupling4. - Turnon switch-SB1(emergencytelescopingoperation)in the controlcabinetif telescopingwill be performedusingthe masterswitch. - Switchto manualtelescopingin the "telescoping" program,"F1".

The emergencyoperationsymbolappears.

- Set ballvalveA to emergencyoperation. Moveball valveA from normalto emergencyoperation: -BallvalveA in line -> Normaloperation -BallvalveA at rightangles-> Emergencyoperation



-20 -

UIBHIM

Functionaldescription OW 20 - Emergencyoperatingmode PEducedbv:lweDl0 / Edilion:06.06.07/ veE onr 3

Pinningand unpinningof the telescopicsections(telepinning)and telescopiccylinder (gripperpinning)is performedusingballvalvesB and C. Telescoping in/outis performedusingeitherthe masterswitchor pushbutton-5622 "Functiondrivingswitch"in X-Notoperation.

Lock/release the telescopiccylinderusingballvalveB: -BallvalveB pointingup -> telescopiccylinder(gripper)released -BallvalveB pointingdown-> telescopiccylinder(gripper)locked the telescopeusingballvalveC: Lock/release -BallvalveC pointingup ->telescope(telepinning)unpinned -BallvalveC pointingdown-> telescope(telepinning)pinned

Gripperpinned Telepinned

unpinned Gripper Telepinned

Gripperpinned Teleunpinned

non-permissible state

the hylf the telescopicboomhas beenfullytelescopedin, it it necessaryto uncouple draulichosesfor emergencyoperation. The enginemustfirst be switchedoff. - Disconnectthe hydraulichoses. - Set ballvalveA to "craneoperation". - BallvalvesB and C must be set to pointdown. - Afteremergencyoperation,removethe test adapterand allowthe fluidto flow throughthe operationalvalve-Y40 (-Y17).



-21 -

UEIIIRR

Functional description OW 20 - Emergencyoperatingmode Produced by: lwep r0 / Editon:06

06 07 / Ve6ion: 3

1.5Re-establish tele status tele status,general: )1.5.1 Re-establish rlRfft 0 E O

LI[[!]r,1 rElttE:l]}fl1]G ;,1

5

6

:i z r' 1r.=1,

fT}{ffi

Ff5/_tfflFtfti

li Zt 0: Llts 1 L&nlenribrdereLlzumVE.bol:a,lprll, lelelamsehquelli!

''r-l\,o..

=l:+,a}

,91Fi,

Ff :

i?:

:F3

:F.: :F5 56: :F7: .I!:

Fig.1:Telestatus tipped:

Fig.2: Error Fig. Errormessage message

The tele statusis tippedwhenthe commonmemorycard is replacedorthe LICCON receivesa "tele-pinpinned"signal,eventhoughthe lengthsensoris in a positionwhere thereis no pinninghole. lf the tele statushas tipped,neitherautomaticnor manualtelescopingis possible. . All numericvalueson the tqlescopingscreenare displayedas flashing"???". . Symbolelement"Suppresstelescopingaction"and "STOP"are flashing. . A systemerrormessage(telescoping in) is shownon the operatingscreen. CAUTION: The flashingvaluesin the symbolelementswarn that the indicatednumericvaluesfor "Currentload","Pulleyheadheight"and "Projection" are not precise.

The tele statuscan be re-established either manuallyor usingthe LICCONcontrol system. )1.5.2 Manuallyestablishtele status: Manuallytelescopein by operatingkey button(D) "Assembly": . Retractall telescopicsectionsup to the last tele. . The cylindermustbe pinnedin the last telescope(telewith pulleyhead)and telescoped in to a tele lengthlessthan 50%.

Liebherr-WefkEhingenGmbH - Technicaltraining


-22 -

lIIBHTNR

Functionaldescription OW 20 - Emergencyoperatingmode Produced by: lwepid / Edilion: 06 06 07 / Vecion: 3

)1.5.3 Establishingthe telestatusvia the LIGGONcontrolsystem: Fig. 3: Multi-CPUtest system

Gaution: The dailycodeis requiredto set the tele statususingthe LICCONcontrolsystemI

LICC0N llfTl-zE-lEsTsYsrfi - VAsm $.m

L I l l 1 1 t r 0 /P2r o l o N. ollml

1. PresstneE} "SystemSpecial" key on themulti-CPu testsvstem.

I ^ . o

> U:A

c) LItltXR-ltR( ENll6El1S ;ISIEfIIII:

tffirFE; S r 13

ffiflitrIRlB

;YSIBll{lFIeXnTI0l:

ITn:

lE

fiDffi .twffi tr-rF(rl1

RfFf 0l0r? I |

ol.m-B 0374- 094168 m.rc-(E.s m.04

:l

-_II-INI F1

F2

F3

\\F4 .::z -rq.4: :'pecralscreens ffi llLD-latei 0

/ F5

F6

F7

LI}l 1$0/2

tIHXSIfff

2. In the Systemspecial,selectspecial screen"LMBSCREEN4 (manuallvset tele

status)". Caution: Thespecialscreennumberwillvary ingon thecranemodel.

F8

$ ite 3/ 4

> 0,33rfl.6ft]-ESltrffigi,trIl[IfRt[I]i 0,34rEINfi1-fltrImB{,trIltrIfRt{Ili 0,35:n]sllltstrftftli, trIfzlfRlfili, KmKItr!{XII 0,36:EINIIIEI(PIffTI{,ft}'I!F.I€l, KMKLEIXTT 0.T/r IE-CKPItXtli,SIHEt, KffilltFtXIE gREt, 0,38:F-)ftL Kffil{IlStRTE 0,3r SftUnm / fEfi 16 EllsIELi{nIE 0.40:flttl fi$tXS}[Im ,/ KltFf, l{l{:l{I, m-tr(Elm trz 0.41rtutoTele,fhuptbild 0,42: turoTele,mo}{tl,l 0,43: tuioTele,mOFHIei 0,44rSbeitsbere ichsbeeen,uns 0,45rLIB-I 0,46rLfiH r].i rnl *4;i-:a+trtr1tffi!Fe-q1jr' - )6- ) ! , a E : L i l B B l l l l 4 " " . r d . . w . F l l s er ? n r

r-l

F2

F3 F4

F5

F6 F7

F8

5: LMB SCREEN4 SYsTtI-FUNkTMI SFUItr-BIII =>0.48:LnBBILo4 (Telestatus rEnlellsetzen)

3. Notedownthe datawordsand CPU. Caution: The datawordswill vary dependingon the cranemodel.

L T I1 r S 0h/ 2o t o

Dl1.1?0

4. Changing thedatawordsaccording to the extension stateof thetelescopic sections. 5. Entera number1-6in DW1.126to indicate in whichtelescopic sectionthetele

0.0>D l 1 . 1 ? 1 3 : 0.0>Dr1.1Z 0.0>Dr1.12: 5 : 0.0>Dr1,1?4 6 : 0.0>Dr1,1. 7 l 0.0>IIl1,126 0.0)ul,ln

tzl Lx,l ttl t2,1

0(25al

0,D rl€5C3 0.D 0€5C4 0,D &C5t5 0,D 0@6 0,D 0.€Sl

: : : : :

lm lm 0 0 Tn

I : : : :

Zulinderin Teieflrmr 1:tlebern.0:tX 1 6,11 16,20,30:Error tzl Telel aktuelleLaense T€le tzl 2 aktuelleLaense tzl Tele3 akiuelleLaense

: : : :

tzl Tele4 alluelle Laense tzl Tele5 aliuelle Laene tzl Tele 6 akluelle Laense tcnl Arsfaf.laense Zul inder

cylinderis located. Liebhen-WerkEhingenGmbH - Technicaltraining


-23 -

IIIBHINR

Functionaldescription OW 20 - Emergencyoperatingmode Poduced bv: lweoio / Fdiuon:06.06.07 /Ve6ion:3

LICC0N - lT}5rr 6.m |r.LTI-ZE-1tsTnSrt1

L T I1 m 0 /n2' o i o m. (|lllm > 1411]

ts

ITM : 01.m- € f1 0?4 - u4sl FIffl,|If 03.18 6.3l mTnPfill 03.04 fRt!$Ft

6. SelectthecorrectCPUand presskey

0 1 2

"AWLDIS.INT".

F2

F3

F4

F5

F6

F7

F8

Fig.6: Multi-CPUtest system

L. L. tL. L . L. c-._. rL._.

A

At_ I],I tt.

L [. t1{._ oL._

.

6T F T

L D.

1

F[ lr'T[ : L FL L

l

P__ F-, F.. Y Y. TtT

ru

IIL t_tL r$L

7. Nowenterin turnallthepfeviously noted words with tele data together the actual lengths.

Illl.120.

F1

F2

0: lm

: Telelaense 1

F3

F4

F5

F6

F7

F8

Fig.7: AWL operandspecification 5 Y 5 T E }1- F U N |( T I 0 N : SFgltrllll) .) 0,,18rt!l BIL! 4 (Teles!.tusrBnuellse{rei)

ln.tr ryry

B. Checkthe valueson the soecialscreen. 9. Enterthe value-1 in DW 1.127to apply the modifiedDW-values.

l: ?l 3: 4l 5: 6l

0.qiu1.120 0/,,j) Dl1. 121 r'/.o>Lw.Ia 0.D fl.t1.121 0.D II,l1.124 0.D Itll,1[\0) Itll.128 E : l]NDII,IL.TA ! : 0.0)

0.0> 1 : U.U> 0(ac .. 2 . 8.0>0cT4 . 3 , 0,D 016t5 0.D 0c5cE .5: 0.D &e$: : 6 10.0>0c66f

TI I Fl

F2

|I.r

lm ..\.

l$ \r l m f

t l 3r,t/ 0 0 0

7ru I

III F3

Proto LTfl 108122

ffixft{D

lfRT tuschreibuns

Telelaenqe1 I:/.) Telelaenqee V.l Telelaens€3 Izl Telelaenae4 lzl Telelaenq€5 lzl Telelaense6 l'/.1 lulinder in Tele flmr -1rLjebetr,0r0(1S. ll-1E,a0,:0:trror tzl r.le 1akluelle Laens€ l7l ]ele 2 aktuell€ Laens€ lrl i.le 3 aktuelle Laens lzl Tele,4 altu-aLieLaense lrl Tele 5 aliueLle Laense trl Tele 6 altuelle Laense lcml tusfahrlaenseZqlinde. I n l l u l i n d e r i n T e l el h .

IIIE F4

F5

F6

F7

F8

Fig-8: LMB SCREEN4 (manuallyset tele status) Liebhefr-WerkEhingenGmbH- Technicaltraining


-24 -

IIIBHINR

Functionaldescription OW 20 - Emergencyoperatingmode Pbduced bv: lweDio/ Edition:06.06.07/ Vedon: 3

)1.6 EmergencyoperationTY-guying- Failureof monitor function keys - LTM1400-7.1 EmergencyoperationwithTY-stayropesis usede.g.when a functionkey on the monitorhas failed.This is operatedusingthe controlpanelpushbuttons for diagnostic operationTY-guyropes.Momentary-contact functionkeysare used.This requiresa secondpersonunlessa controlpanelis pluggedin. Emergencyoperationis not possible in the eventof a totalmonitorfailuresincethe TY programcannotbe activatedusingthe F-key. Caution: The TY-diagnostic systemand henceemergencyoperationwithTY-guyropesshouldonly be activatedby authorisedspecialists(LIEBHERRcustomerservice).

paneldiagnostic Fig.1: Control operation TY-guyropes

-s129

-s120

Switchoff TYtest sysrem

SwitchonTYdiagnostics sYStem

-s121

-s122 Function keyF2On,Secure TYframeswithguyropes

Functionkey Fl On, RelaxTY-frames

-s124

-s123

Function keyF4 On, Foldout TY frames

Functionkey F3 On, Fold in TY frames

-s125

€126 Function keyFGOn, PutdownTY frames

Functionkey F5 On, ErectTY frames



-25 -

lIIBIIIRR

Functional description OW 20 - Emergencyoperatingmode Pmduced bv: lw€oilo / Ednion: 06.06.07 / velllon: 3

i,_

'

i-''

\-.,1!''

li

Liebhen-We..k EhingenGmbH - Technicaltraining


-26 -

UBHRN

Liebherr Lehr Buch

Recommend Documents