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description

Gomponent

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

',

U
R

unir A=+

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

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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).

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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

-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

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TIEIIIRR

Gomponentdescription
UW01 - Fundamentals
of electricity

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

il

Conventional

-__>

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
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UIBHIRR

Componentdescription
of electricity
UW01 - Fundamentals

>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

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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

in an eleclrical
Fig.8: Vadables
circuil

theequation:
The followingaid can be usedto remember

Note:
Simplyuseyourfingerto coverthe desiredsymbol!
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IIIBilTNR

Componentdescriplion
UW01 - Fundamentals
of electricity

Measurement
examples:

Resistance

UinV

R , = 2 Q Irin A

R z =1 Q Irin A

Shortcircuit

z,a

i0

10

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

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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

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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.

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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.

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ITBHTRR

Gomponentdescription
UW01 - Fundamentals
of electricity

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

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lTIBIITRR

Gomponentdescription
UW01 - Fundamentals
of electricity

>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

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.
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UEBilENR

Componentdescription
of electricity
UW01 - Fundamentals
Pdudby'*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.
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I.TIBHINN

Componentdescription
of electricity
UW01 - Fundamentals

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

measurement
/ voltageerrorcircuit
Fig.22:Indirectresjstance

Fig.23: Indirectresislance
measurement/
curentenorcircuit

Caution:
The redand blackleadsmustbe connected
to R andCOI\4respectively
whenmaking
resistance
measurements.
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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
betweentwotestvalus
UT

Bottomdeadcenter

ZMEi

Unilto bs measured

Componentdescription
UW04 - Driveunit / dieselengine

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ITIBIIRR

Component
description
UW04 - Driveunit / dieselengine

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UIBHNR

Componentdescription

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

>1.2Motordesignation

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
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UIBIIIRN

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

Pushrod

Dipstick

Oilfilter
Piston
lnjection
pump
Connecting
roo
Crankshaft

Oilpan

Plunger

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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

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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

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Flameglowplug

Genetor

lTIBHIRR

Component
description
UW04 - Driveunit / dieselengine

D924- A4 / 4 CylinderDieselInlineEngine(ow engine);


EnginemntroluniiECU1

Fuelpreliminary
filterunit
Fuelllnefilter

D926- A5 / 6 CylinderDieselInlineEngine:

EnginecontrolunitECU4

Heatingflange

FLrel
finefilter
Oilfilter

Fuelpreliminary
filterunit

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UIBHTNR

Componentdescription
UW04 - Driveunit / dieselengine

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

Fulpreliminary
filtorunit
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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!
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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

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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
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IIIBHRR

Componentdescription
UW04 - Driveunit / dieselengine

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

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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.

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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.

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Exhaust

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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

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Fig.3: D846-A5withpistonvalvepump

ITEHIRR

Component
description
UW04 - Driveunit / dieselengine

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).

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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

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UIBIIERR

Componentdescription
UW04 - Driveunit / dieselengine

Fig.2:Overview
PLDengine

1 Nozle holder(claw)
2 Cylinderhead
3 lnjectionIine
Nozzle
5 Solenoidvalve
6 Fulfeed
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

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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

e # \ ' * , t i= u

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

RailPressure
5 barfeedpressLlre
1.5bar- Flamestarting -

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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

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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

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lTIBIIIRR

Gomponent
description
UW04 - Driveunit / dieselengine

Schematicdiagram,inductive
RPMsensor

HallRPMsensor:

HallRPMsensor
Fig.4rWingdiagrcm
excerpt

Fig.3: Originalilluslration,HallRP[/ sensor

Hall
RPI\4sensor

Teeth

Flywheel

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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
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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)

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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

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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
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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
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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.

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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

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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)

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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).

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-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

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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

Prefilter

3
4
5
6
7
I
I
10

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

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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
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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

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lTIBITIRR

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

1
2
3
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

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lIIBHINR

Componentdescription
UW04 - Driveunit / dieselengine

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

(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.
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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
= closddmper)

lntakemanifold

Exhaustmanifold
AGRhealxchangr
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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.

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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

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ITETIBR

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

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
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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

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UIBHINR

Componentdescription
UW04 - Driveunit / dieselengine

Fig.1: Functional
schematic
cylinderheadin brakeoperation

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

lntakecycle

Compression
cycle

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Workingcycle

Exhaustcycle

1IIBHRN

descriPtion
Gomponent

UW05- Goolingsystem/
Fandrive

servicepersonne
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Gomponent
description
UW05 - Coolingsystem/ Fandrive

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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
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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.

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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

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lTIBHIRR

Componentdescription
UW05 - Coolingsystem/ Fandrive

Chargeair pipe

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

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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.

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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
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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

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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.

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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
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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--;;;----

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

l-E ::l^",:/

Pump

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

t I-liF..l

Fanmotor

- Coolingsystemwilhvadablefan pump
Fig.17:Overview

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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.

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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

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ITTBHIRR

Componentdescription

UW06 - Transmission

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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.

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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

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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 (pdrbk{tPosdb.l

rc2

12AS3002

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

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UIBlIINR

Componentdescription

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

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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
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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
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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
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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

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

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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

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ITBHIRR

Componentdescription
UW06 - Transmission

>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.

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UIBIIIRR

Componentdescription
Transmission

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 slowerspad

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

Fig.23:(3.gear)sungearwheelandring
geararedriven,directconnction
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ratioto slowerspeed
Smallhansmission

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

Fig.25:(Rear)sungearwheeldriven,planetset
locked,ouiputvia dnggar

-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.

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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
.

Tam^ar.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
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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

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lIIBIIIRR

Componentdescription
Transmission

>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

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-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

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-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
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-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
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_ 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

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Cranehydraulics
On

ITIBTIERR

ComponentdescriPtion

UW06 - Transmission

Transmission
PumP

Drive
Disc
clutches

Discclutches
lntermediate differential
(planetarygear)

6WG210
viewERGOPOWER
Fig.37:Cut-away

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-24 -

lIIBHTNR

Componentdescription
Transmission

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
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-25-

ITEHIRR

Componentdescription
UW06 - Transmission

Oil schematic- Forwardslst gear


il Kr
s:
-f!44-

i1Kl

I
i

, I lut.,.l

(electrc-hydulic
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,
blackandbluechangechangefilteshouldonlybe replaced
sametype.
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UEBHINR

Componentdescription
UW06 - Transmission
Wheelschematicforwarddriving direction:

o)
0)
.

(!

;,

.5
N

z5x

.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

c
'6

E
F

=-1=

^,J[-^

2
fo arddriving
direction
Fig.41:Wheelschemalic
Ergopower
6WG210
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_27

ITIBHTRR

Gomponentdescription
UW06 - Transmission
Wheelschematicreversedrivingdirection:
3

e
>

o
oi

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:Whetschomatic
Ergopower
6WG210reversearivi_ng
Oireaion
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-28 -

UIBHINR

Componentdescription
Transmission
Pdudby: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

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-29 -

TTIBIIIRR

Componentdescription

UW06 - Transmission

.B2A
lmpu|sesensor,
Tachograph

Outputf,angeto rearax'o

-B29
Inductive
sensor
Powertake-offsp6ed

Changeover
Off-roadgear/
torclgear
65
Off-roadgear
1=ON

Fig.44: Ergopowr
6WG310

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-30-

UEHINR

Componentdescription
Transmission

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
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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

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lTTBIITRR

Componentdescription
UW06 - Transmission

Oil schematic- Forwards'lst gear

il

*'
P6

a'

ir+-!!

(elecrb-hydEuliccontrolunit)

",u
co^veddulpdp$rc

i**'-cei
' i
i

:
i

I t

PoFdonarvadGcclld|(3

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

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-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
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- 34 -

UIBlIINR

Componentdescription
Transmission

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

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-35-

lTIBIIIRR

Componentdescription
UW06 - Transmission

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.

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-36-

IIBHIRR

ComponentdescriPtion

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

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-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
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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
bke

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

Secliongroup
gear)
(planetary

gear-AS-TRONIC
Fig.56:Ivlainviewshowingspliilergroup,maintransmission
sectionandplanetary
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-39-

ITIBHIRR

Componentdescription
Transmission

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
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tEinins

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- 40 -

lIIBIIIRR

Componentdescription
UW06 - Transmission
Pdudby: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
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-41-

UE]ITRR

Componentdescription
UW06 - Transmission

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,
loction
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

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-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
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-M-

UEHRN

Gomponentdescription

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
bearingwithrleaseiork
Liebhen-Werk
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tEinins

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_ 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.
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-46-

IIEIIIRR

ComponentdescriPtion
UW06 - Transmission

Openingand closingthe clutch:


Situation
Neutral

Brake+ D
Startingup
(pressaccelerator)
Driving

Gearchange

Comment

CIutch

{l{F{F
{F
{F-

Libher-wek EhingenGmbH- Tchnl@llEining

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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.

Llebhr-WerkEhingenGmbH- Techni@llra ning

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-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,
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service

-49-

UBIIRR

ComponentdescriPtion

UW06 - Transmission

;d,*d

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

d,v.^""

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
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-50-

lIEIIERR

Componentdescription

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- Technil trai.ing

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- 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
Lrbhn-Wlk
Ehlnon
GmbH- Tgchnical

Onlyfor LIEBHERR
servicepersonnel

_ 52 _

UIBIIERN

Componentdescription

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
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-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- Technil aaining

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-54-

UEBHINR

Componentdescription

UW06 - Transmission
4.2Automaticgearboxwith upstreamconverter
>4.2.1TC-Tronicwith rtarderZF12AS3002TC
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,oiltempetLrre
= 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
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-55-

ITEHIRR

Gomponentdescription

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
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-56-

UIBHIRR

Componentdescription
UW06 - Transmission

Clulch (dry clutch)

Tufuinewheel
(secondary
wheel)

Cupspdngs

Guidewheel
(defleclion
wheel)

Pumpwheel
(primary
wheel)

Fig.87: Cutaway modelof TC2

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- 5 7-

lIIBHTRR

Componentdescription

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

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Ehlngn
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tralnlng

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-58-

lIIBHIRR

Gomponentdescription

Transmission

>Rtarder
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

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-58-

UIBIIIRR

Componentdescription
UW06 - Transmission

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

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-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

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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
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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
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Ehingn
Libhen-Werk

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service
OnlyforLIEBHERR

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

Gomponentdescription

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

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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
duringeveryoilchangl
Fig.96rTo-Tronic- ZF 12TC3040SO
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Componentdescription

- Transmission

Discset

Turbinewheel
(secondary
wheel)

(pfimarywheel)

-/

._.

t.-:-

._ _.:

___

!-

i__

t:

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

] r'
)/

1i

Cupspdngs

Converter
clutchunil

Torqueconvede

wilhconverter
clutchunitforTC3040SO
Fig.97:Cut-away
drawingtorqueconverter
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ITBHIRR

Componentdescription
UW06 - Transmission

>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

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_ 66 _

UIBTIIRR

ComponentdescriPtion

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).

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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

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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.

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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
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ITIBHIRR

description
Component

UW07- Transfergearbox/
Driveshafts

service
OnlvforLIEBHERR
Dersonnel

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

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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

Longitudinaldifferntiallock

Fig.1: Cut-away
viewof thetranstergearbox

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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
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ITBHIRR

Componentdescription

UW07 - Transfergearbox/ Driveshafts


Frcdudby rep.t/editun:13.04.077v8Eion:r

2, Single-stagetransfer gearbox
>2.1 KesslerW 3750
Dsign

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

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ITIBIIIRR

ComponentdescriPtion

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

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UBHRN

Gomponentdescription
UW07 - Transfergearbox/ Driveshafts

Design

Outputto frontaxles
Outputlo rearaxles

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

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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
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-9-

UTBHINN

Gomponentdescription
UW 07 - Transfergearbox/ Drive shafts
>3.2KesslrVG1600
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
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-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

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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

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-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
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UEHINR

Componentdescription

UW07 - Transfergearbox/ Driveshafts

Switching
cylinderoff-road
gear/ neutral/roadgear

Powertake-off

Outputto rearaxles

Outputto front

Longitudinaldifferentialbased
on a ptanerygear

Fig.13:Cut-away
viewtransfergearboxKesslef2600

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-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

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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

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UIBIIERR

Componentdescription

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
Ehinen
GmbH- Tchnlcal
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_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

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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- Tchnil tEinins

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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"

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-20-

ITIBIIIRR

description
Gomponent

UW08- Axleswith attachments

servicepersonne
Onlyfor LIEBHERR

Componentdescription
UW08 - Axles with attachments

seryiceTraining
Liebhefi-We*
Ehlngn
GmbH- Cuslomer

servicepersonne
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lIIBIITRR

Componentdescription

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

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ITBIITRR

Componentdescription
UW08 - Axles with attachments

Tralning
Liebher-WeR
Ehingen
GhbH- Customer
Srvice

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-3-

UIBIIRR

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

1.2Axle types
axls
>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

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rIIBHINR

Componentdescription
UW08 - Axles with attachments

>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
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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


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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
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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


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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
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lTTBTITRR

Componentdescription
UW08 - Axleswith attachments

>1.3.2Wheelside
Aciuationcylinder
Ringgear
Suspension
bracket
Wheelhub

Planetary
wheel

Trackinglever

viewof axledrivewheel-side
Fig.21:Cut-away

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UTBIIRR

Component
description
UW08 - Axles with attachments

Brakectuation
cylinder

Whel hub

\ryheelbolts
Sungear
Ringgear

Planetary
wheel

Wheelhubcover
Fig.22: Planetary
drive/ brakedrum/ wheelhubcover
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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

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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.
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UBIITRR

Componentdescription
UW08 - Axles with attachments

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.
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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
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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
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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
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IIIBITTRN

Componentdescription
UW08 - Axles with attachments

>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

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

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ITIBHIRR

Gomponentdescription

UW10-Partl-Steering

personnel
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Service

Componentdescription
UWl0-Part1-Steering

Llgbhor-WerkEhingonGmbH- Tchnil Laining

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lIBHRR

Componentdescription
UW10-Partl - Steering

!lbhr-W( EhlngenGmbH- Technil haining

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TTEHINR

Componentdescription
UW10-Part1-Steering

Liebhen-Werk
EhingnGmbH- T6chnlc6ltralning

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-4-

UBHTRR

Componentdescription

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
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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.

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ITIBHIRR

Componentdescription

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/

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TIEIIIRR

Componentdescription

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:Flowindictor

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
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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
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ITIBIITRR

Componentdescription

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
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TTEHIRR

Gomponentdescription

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
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UIBIITRR

Componentdescription

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
designwithmechanicl
steedngstop

Advantage:

Highoil flowmakingit suitablefor "largemachines"

Disadvantage:

Expensive
as it is manufactured
in lowquantities.

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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

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ITIBHIRR

Componentdescription

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
Nonilumlalve
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

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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 indicior(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
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UEIIRR

Componentdescription

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)

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)
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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
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UBHINR

Componentdescription

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

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ITIBHIRR

Componentdescription

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,

dwing
cut-away
Fig.11:Steeringgear- anti-clockwise,

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ITIBHIRR

Gomponent
description

Frontaxle stering

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
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UEIITRR

Componentdescription

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".

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UBITIRR

Componentdescription

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
steringstopvalves
steeringcircuitll

Fig.2: Cut-away
modelof Servocom
steoringgear

Fig.3: Excerptftomschemstic:
Controlhydra!lic
pressurised
airsystemMK 100(anti-clockwise)
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rIBHRR

Componentdescription

Fronl axle steering

UWl0-Part1-Steering

Workingpresu
re measuremeni

Workingpiperightwheellock
Workingpressu- output
circuit| (connection
2)
re measurement(sgment
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
(rightsteringdirection)
.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
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IIIBIIIRR

Gomponentdescription

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
string
(S119)
7 Flowrateindicator
8 Oil box
I SteeringcircuitpumpI
10Oil box
11 Flowrateindicator
(S118)
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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

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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

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lTIBTITRR

Componentdescription

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).

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UIBHIRR

Componentdescription

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

II

Y
out
(morepressure)

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out
(morepressure)

ITBIITRR

Componentdescription

UW10- Partll - active


rearaxlesteering

Onlvfor LIEBHERR
Serviceoersonnel

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

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UEHINN

Componentdescription
UW10- Partll - activerearaxlesteering

Liebheii-Werk Ehingen GmbH - Tchnil lrainlnq

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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

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UIBHINR

Gomponent
description
UWl0 - Part ll - active rear axle steering

X.l Layout
Stsrlngaxles:

1staxle
2hd axle

3rd axle
4th axle

;"::,"::",}

Axleswith
BoschCAN
proportional
valves

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

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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

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lTIBIIERR

Componentdescription
UW10- Partll - activerearaxlesteering

>1.3Summaryof speedswith LTM1100-4.1

EI
= (

* [

sleringangloi string
ane LA2to kegrees.

hydEUlillyclampedo.

Permiltedspeedin travelprogramPi Roaddrivlrg

E
(E
Y

Pemitled speed for travel

50

g0vin
Km/h

Note:
on thetypeof mobilecrane.
Themaximum
speedsaredependent

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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 string
?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)
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-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
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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.

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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
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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

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IIBHINN

Componentdescription
UW10- Part ll - active rear axle steering

-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

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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:'

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.

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Componentdescription
UWl0 - Partll - activerearaxlesteering

>2.4 Steeringcylindr
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:

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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:

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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:

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UIBHINR

Componentdescription
UWl0 - Part ll - active rear axle steering

>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
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UBIIIRR

Componentdescription
UWl0 - Part ll - active rear axle steering

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).
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ITIBITIRR

Componentdescription
UW10- Part ll - active rear axle steering

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

va kF!

v}' KaEl b lcrad/lo]


!A1 Kanal a [Gd/10]

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

2
3
1
0
0

o
1
0
0
0
0

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 Gd/101
winkelgebet
LA3 (da1
LA4 Kaal
a
winketgebe!
Winl<e1geber LA4 Kanal b
z.nElielkleis
E, E3, ?: Druckschalte!
E. E4.4: DruckscfElte!
ZenErrcrkleis
Zentrielkleis
E. E3.0: DurchflusEEch.
'-enkpunpe
E. E4. O: DrrchflusssclElEer
Hi1fslsklrmp
E, E4,3:
Durchflusch.

EEEEEEEM
14000203 D

Fig.22: Excerptfromspecialpicture LT[/ 1100-4.1 - anglesensor:


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UEBIIIRR

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

.x

f
-li"-+",_r

.,,T.'
@

\"
6l

o
o

g
(\

o-

I
t

o-

E
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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

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UBHTNR

Componentdescription
UW10- Part ll - active rear axle steering

Flowte
(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

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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

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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.

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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

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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.

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UTEIITRR

Componentdescription
UW10- Part ll - active rear axle steering

> 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

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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

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.
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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.
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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:Cutwayviewcentering
cylinder

Fig.40: Excerptfrom ckcuit


diagramcentedngcylinder

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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 centring cylinderduringsteeringacton


--.--

r:

rl

TF--\

il-Illl

Blockingvalve
Centeringva ve

Fig.42: Overview- slee ng actionaxle 3


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lIIBHIRR

Componentdescription
UW10- Partll - activerearaxlesteering

>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


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-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=

^A.71"

Blockingthe non-reiumvalvesby relievingthe pressurein the X-plpe


(connectionto lank) by droppingoul blockingvalves-Y226 (-Y227)
Applying
hgh pressure
tothe ringandpistonsurfacs
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

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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.

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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.
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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.

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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.

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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.

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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.

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UIBHTRR

Componentdescription
UWl0 - Part ll - active rear axle steering

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r|EIIINR

Component
description

UW12- Axle suspension

Onlvfor LIEBHERR
service
oersonnel

Componentdescription
suspension

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lIIBIIIRR

Component
description
UW12-Axle suspension

Ubhr-We* EhlngnGmbH- Tchnicltralnlng

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-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


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1TIBITIRR

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

,H5

i E

16

17

18

19

Fig.2:Hydraulic
axlesuspension
LTN4
1050-3.1:

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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


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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 cn 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
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IIBHIRR

Gomponentdescription
suspension
Sioragecapacityin lilres

Gas fill pressureP0 cn 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
ldentificiion
(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
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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.

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ITBHIRR

Gomponentdescription

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
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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
tl_,.,
t-;=L
Pr;ximityswitch42

K = oiston surfaceR = ring surface -

ffi
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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

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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

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

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-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

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service
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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

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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

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lTIBIITRR

Gomponent
description
UW12 - Axlesuspension

Highpressure
Cl6mpedpressurc
Controlpressure
Lowpressufe

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

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IIIBHIRR

GomponentdescriPtion

UW12- AxlesusPension

p.ma

lll
?

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

-' '^"

I l.j !

Highpressurc
pssuf
Clamped
controlprcssure
LowPressure

lmpactto leftwheel,axle1 e.g causedby


unevenroadsurface

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

_
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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
Liebhrr-weft
Ehingn
GnbH-Technical

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UEITIRR

Componentdescription
UW12 - Axlesuspension

!!

i,i'o-I rn

"l';" 1- l

1**-I- - -

Highprssure
ctampdprssure
Controlpressure

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

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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)
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UIBIITRR

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

Onlyfor LIEBHERR
servicepersonnel

i1,,

J i4+

-,1'.-.''

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

* = not fittedon all lnobilecranes.


Liebher-Wrk
Ehingen
GmbH- Tchnicl
lining

-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.

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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
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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
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IIEITTRR

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

Hlghprssure
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- Technillraining

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_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)

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

>7.3Function
Automaiiclevel
conlrol

--1
l
-

\,r*

lEl

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

'oN"
Axre
brockjns

__l|

axtes
,/Ra$e

lqf aalft=/flr-1-- tw

'
f
rodslo thi
sleering
Release

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

i
;.

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

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

'

'

'

'

, . : .
t

'.

eE.

Fig.33:Cabkeyboardunite.g.LTM1250/1

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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.
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service

-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
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lTIBIIIRN

Gomponentdescription
UW12 - Axlesuspension

5'ENEDRUC(LUFTAILAOE

LTIV1045-3.1
Fig-37:Excerpifromcircuitdiagmaxleoscillation
Axlesusoension
blockd- axleoscillation
aclive

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lIBHIRR

Component
description

UW13 - Electricalcircuit
diagram

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

Onlyfor LIEBHERR
Servicapersonnel

Gomponent
description
UW 13 - Electricalcircuitdiagram

Libhor-WerkEhingenGmbH- T6chnicaltEining

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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

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UEIMR

Component
description
UW {3 - Electricalcircuitdiagram

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

Uebhr-wlk EhingnGmbH- Tecbnlcallinlng

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Servicepersonnel

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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

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Service

lEBHERR

Gomponent
description
UW13 - Electricalcircuitdiagram

>1.1.4Indexof pages/ Tablof contents


The Indexof pags(1) is an alphabetically
sortedlistof all pagetitleswith
page
corresponding
circuitdiagram
numberreferences.

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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

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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.

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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

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-z',t-

lEBHINR

Componentdescription
UW 13 - Electricalcircuitdiagram
Produd 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

3El:alEL;

=U+ri-Kt3:30

tJ

:30

It

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-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

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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)

-> Counter

t0..
1 r 1
:3.1

-A1

- t l

+H

3i.1

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

l!:,!
ll:.1

Liebherr-WerkEhingenGmbH -Technicaltraining

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-24 -

T.EBHENR

Gomponentdescription
UW 13 - Electricalcircuitdiagram
P.oducdbv: lweoid/ Edilid: 13.02.07; v6id:

>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
BLATT

BEt4ERKUNG

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

1 0 71 1 3

BLATTEESCHRE] 8UNG
ERNEITERT

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-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

BEI.4ERKUNG

SPS.TEXl6
EE I N D E R T

R ATTEFS'I

A F TR I I N l ]

ERIIElTERT

Ljebherr-WerkEhingenGmbH - Technicaltraining

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UTBHIRR

Componentdescription
UW 13 - Electricalcircuitdiagram
PFduced bv: lwelilo / Ediiion:13,02.07/ Vrsion: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.

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UEBHENR

Gomponentdescription
UW13 - Electricalcircuitdiagram
Poduced by: iwepiro/ Editjon:13.02.07/ VBioni 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

1i' '.'-1
r

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

:',"

Liebherr-WerkEhingenGmbH - Technicaltraining

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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<ns>=u+H:g3[!
Explanation:
This core connectsconnectorblock-X50terminal2.3 to switch-S17 terminal30.2.both
of whichare in the chassiscab.

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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<ne>=U+H-S1
7:30.2

_t
-:::9

i39.1

:33.:
-:1t9

:3e.1

:/

:11
r -x50
;; I

-tl

+H

I 1 9 .t

134.1

:39,5

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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<ne>=U+H-S1
7:30.2

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UEBHERR

Componentdescription
UW 13 - Electricalcircuit diagram
Prcdlcd bv: lreoi.o / Ediuon:13.02.07
/ V6ion: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<ne>=U+H-S1
7:30.2

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lEBDTERR

Componentdescription
UW 13 - Electricalcircuitdiagram
Prcducedbv: l@oilo/ Edilion:13,02.07/ VrsioniI

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<ne>=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

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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<ne>=U+Hff :392

l ' i

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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.

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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).

+F

.ln

s-

lco

STRASSENGANG
EIN

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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

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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.

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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.

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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:

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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.

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UEBHTNR

Component
description
UW l3 - Electricalcircuit diagram
Producd by: lwgpilo / Edilion: 13.02.07 / Vion; 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

'

L-=
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Componentdescription
UW 13 - Electricalcircuit diagram
Poduced by. wpno/ 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
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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

'

- - l

ll

"-l

-J.- |

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UEBHENR

Gomponentdescription
UW 13 - Electrical circuit diagram
Poducd 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

t99,7 t'

83

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

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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

.. I

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

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UEBHERR

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

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

i a*
.-;

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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)

:11f .

::+-

:1A

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

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lftBHTRR

Gomponentdescription
UW 13 - Electricalcircuit diagram
P.oducdby: lsdrc / Edition:13.02.07/ Vlsion:1

>1.2.'13Gircuit diagram in PDF format


Acrobat Reader:
The Acrobat Readermay be used to view circuitdiagramson the PC.

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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
.Automalisirtes Schaltsetriebe:ZF 12AS 2302
. Kranantrleb:LlebherrD934Tr-E46 PLD
. Datenbus-Technik
mit 2 CAN-Bussnund 3 Ls-Bussen

b E

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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,

AEmhhg

Aisich /d

oruckbesrenzunssvatil im Krofinofi5ysls
Hohls.hruben
zu DrrknaMerungim Kr.frstoffst5rem....,...
..,.

.., . Zg

hihlen, BeleLEhtrn

Abslutabedieninheic
Seitsma*irunqs|eudnen.e.hs ...........................5
Ab,lt$cdi"rFir heil Seie nr+iaunqsl-udnFrlink.
a
Wasggkuhhe tuare AL'gasmkn-hrurE
Inrenbleuc|nug,Turn
Lufrug

33

.........
Kihlffi

und W:lfrela6cher

d-NiMU

Motdeurgsat,

Miftelkssole - H.uptsh.ltei g.netun SictErungen,Spannungswandler. l0


1t
Minelkonsole E/A lvloduleod Oaqnoredecker
12
Mirelkdde - Beeuckun$modul,
Inbder ECll

t3
Miftlkonele

- SLcheuge.

Drkseber urd \bnlile der Bretudaqe


KmpressorundTrockner
VefrilblGk lilGrerbrawhq
4 KaEl

16

Kr.heofi

hd -Tspebntr
Luldhedruck

Vorfher und T.nk

Adodasii.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-sryice-Ceder

an Ache

3 und .l

Raddhahl-Sn5i)6.,.,.,....

Wi.belsoodbmeTelh. Fo6l F 2200'

45

KSC

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

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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

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

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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 aeealDhr

2
alerdifi.'SPercAchse

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

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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)
TCHNtSCHE DATENI
. n4. rrrgr.3r b.l r.t marsr.dlnE:
. mar. subhdhmir tlpp.rxrappspiE
.narAushdung mlt Ooppolkhpp6plts:
! m
. Lrsk.p.usr.grklng6:
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:Llbher D034TrEA6 PID
. Dabnbustrchnll mll2 cAN-Bus<en
und, Ls-Buss.n

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

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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).......

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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)
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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

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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
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llElltRR

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

Coolantpump

Fig. 7: Coolantpump - D846-A7

Returncab/ from
heater

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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
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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

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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

S"-=--'

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.
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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"
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lIEHINR

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

)Function

tilil
o

Controllines
Fuelpipe
Exhaustpipe
Watercircuit

1
2
3
4

Heatexchanger
vehicleheaiing
fimer*
Dieselengine
Heaterunit

^:.^, ,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
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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

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"
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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

/
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

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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

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
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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.

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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

Fig. 20: Overviewof auxiliaryheater DBW2020.56.

. = Option
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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
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UTBIIIR

Gomponentdescription
UW 14 - Heating/Auxiliary heater
Producedbv: lseono / Edition:18.12.06/ ve6ion:2

) Function
1

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

___: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
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IIIBHERR

Componentdescription
UW 14 - Heating/Auxiliary heater
Prcdu@dbv: lwe.ilo / Editionr1a 12 06 /Vecio.:2

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

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
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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
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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
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UEHTNR

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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

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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

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UEHIRR

Componentdescription
UW 14 - Heating/Auxiliary heater
Produed qr hplto / Ediltbn: 1a-12,06 / VeFion: 2

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Gomponentdescription

UW18- Others/Accessories

Projectnumber:
9996008

servicepersonnel
Onlyfor LIEBHERR

Componentdescription
UW 18 - Others/Accessories
Prcdu@dby: l@pid / Edilion:11.06.07/VeBion:2

lndex
Trailing axles
1. LWE Trailing axle

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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


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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

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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.
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UEIIRR

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

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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

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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.

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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


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Componentdescription
UW 18 - Others/Accessories
Prcducedbv: lsoill) / 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.
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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
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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.)

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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
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Componentdescription
UW 18 - Others/Accessories
PEdued br lweono/ Editon:11.06.07/VeFion:2

ryl
f:r

i
. T J ] TL T] ]

Highpressure(suppliedby gearpumpfor steeringclrcuitll)


Controlpressureafterpressurereducingvalve24bar
pressurelbar)
Retumsteeringcircuitll (pre-tension
Loadindication
Dressure

- Pintrailingaxle
LTM1200-5.1
Fig.15:Excerptfromhydrauliccontrolschematic

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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!
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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
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6unupeqi uraFe 6ullle4roj sBeuraq9s

uoDnq
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outlloJluos

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lll lrncJlc
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'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
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z:uoroe /,t090 t|:uoflp: / 0Jda4:Iq panpord

solJossaccv/sror.llo- 8|, ,\ n
uolldllcsop luouoduog

louuosodacrruos
uuf H83ll roj ^luo

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aueJqLuaur)
oIBJqac!ruas

elaq 6ur4e6
elpjq ocNas

aFe ourle4eql rol urals^sre pesse:duo3:61 0t3


(elErqunrp ro] ^tuo)nEO

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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.

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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

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
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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

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

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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

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Componentdescription
UW 18 - Others/Accessories
Prcducedby: lwepim/ Edition:11.06.07lVe6ion:2

>1.3.10Steeringoperationfor the trailingaxle

It

l 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.

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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

II

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

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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


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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

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Gomponentdescription
UW 18 - Others/Accessories
Produed btx l@pto / Editd: 11.06.071Ve6ion:2

-Y197
Changeover
oil
supply

mG

l'*d

l u E u H E R R w r {|

l*

Bs,3

Fig. 31: HydraulicschematicLTM1200-5.'lwith trailingaxle

Hydraulic
coupling:
Whenthetrailingaxleis not
attached,conneclpipesPNandTN.

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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

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Functionaldescription
UW 19 - Emergencyoperatingmodes
Produ@dbv: lweoio / Edilion:06-06-07/VeFion:3

UW19- Emergency
operationfor the chassis

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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

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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

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Functionaldescription
UW 19 - Emergencyoperatingmodes
PEdued br lrep|lo / Edition 06 06 07 / Vecim: 3

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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
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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

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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.

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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.

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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.
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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
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_ ,11 -

ITTBHIRR

Functionaldescription
UW 19 - Emergencyoperatingmodes
ftoduced by: lwepio / Edilton: 06.06.07 / \r'eFion: 3

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UBIIRR

Componentdescription

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............

3 Tilt p|ay..................

4 Greasingof slewing ring ..............-...............

..............8
..,...................8

6 Earthingduring welding work..................

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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 -

<D

Outergearteeth
Rollerelement

Fig.2: Ballbearingsupportedslewingring
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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

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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

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1IEIIRR

Gomponentdescription
OW 04 - Slewingring connection
Podlced br |repno / Edilton: 21.02-07 / Ve^ion: 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


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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.
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UTTHERR

Componentdescription

OW09- Luffinggear/
ballasting

Servicepersonnel
Onlyfor LIEBHERR

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....

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

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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.
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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.
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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)

Lt

4f2 way magnetic


VAIVE

Lufflngdown

1 . 5' .
I

Fig. 2: Excerptfrom luffinggear schematicgeneral


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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
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training

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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
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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
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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
)
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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)
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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
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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


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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

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-'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

.._^--ll__..

rl

i| ?^rlilFi I

fr -,,r1

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

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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

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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

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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.
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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-

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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-

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
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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

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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
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IIEIIERR

Gomponentdescription
\-

OW14- Telescopicboom
/ Telematics

Onlyfor LIEBHERRServicepersonnel

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

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1lBTTTRR

Gomponentdescription
OW 14 - Telescopicboom / Telematics
Prcdued bI lBprro / Edition: | 3 11.06 / VeBin:o1

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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.
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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
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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

^ia^a

Fig.5:Boomprofile

- = option
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Servicepersonnel

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)
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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

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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
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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)

-s918
Inductivesensoras
proximityswitch ;
Telepinned
CPU1,LSB2 Address16

".r

-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

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-'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'
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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

,,n^i^^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.
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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 . :

:c-

. r -

! Jt.KT:l'l

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

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.
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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?

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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-/

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

Pedalsensor,footpedal
telescoping

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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

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-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:)
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-

3
N
N

o >
! F
\ ( 5 O )
f'6.c-

_9
o

o g b

n 9
N g

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
=

> - - c
EHE E 9

6n9

N
N

p c
o-d

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EhingenGmbH - Technicaltraining

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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)

. = c Lo - =

gedE
l :

fE iXf. >i s. E

=^;3
='-9.;-9

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-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
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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
_

i
;

s
*
9,4\>
a
/
'

!.
9i
fi
a

l/T\l
v l

dl

rAr
l\21
o

3
= N

o >

0)o
.E2
o >
''....
.:..
= ;

!.

d9 16l

o
.o

qt

2(E

.9
(D

o)

zo

o(D
Ctr O

o o

E
c

5E
c . \

N P

N d

" l

= x

l
I
I
I
L-

(D

'--:

.o

() xi2

No-

q) o
o(g
o o

(')
'- -oO ^
o
3
_9
6
- otr

q)5
2 o

gE'

.9a
(l)X

:q?
x: .::

=e

=r o-

H+
f+# H+
9
:.ti

o -

9 P

\
t2

=P

o
o 2
o o

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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
<

- t E
4

Lfi-U

I
I

tF

o
=
crt

CC.)

##

ulL
|-t
I

K
-

-?

J;

|i !

"+
\ \
4^

RK

f;
:

i c
= O

9 p qrt
a .n
6
Ya 9 . 9
CLE

E 9 >r -=
oa
. C : i

at=

= i

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Onlyfor LIEBHERR

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o t D
- t t
i = o

'9 or
; o

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.
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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--.

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.

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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.

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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.

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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.

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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.

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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

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Retum cable 2

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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

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UBHINR

Gomponentdescription
OW 14 - Telescopicboom / Telematics
Prcdued br lrepiro / Edilion: 13.11.06 / VeEion:o1

9. Boomsystems
)9.1 Abbreviations

Telescopicboom
Extendedtelescopicboom

K/NZK

Foldingjib / hydraulicallyadjustable

Fixed latticejib

Luffinglafticejib

ry

Telescopicboom relaxed

Spacer

Denickboom

It

Suspended
ballast

SOWF)

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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
spld lv.l firhout pins

I
i---T-

O= 3l Umin (rcduced

)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

O = 76 Uftin keduced
sp.d l.v.l wlthout pirs
q= 3t Umin {.educed

ben.oolid

!(.-_'

Note:
On cranemodelsLTM 1160-5.1and LTM 1200-5j the reversalwindowis pressure-controlledinsteadof time-controlled.
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UEHENR

Component
description
OW 14 - Telescopicboom / Telematics
Prodled by: lwed|{) / Edi[on: 13.11-06/ V4ion:01

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UEIIRR

Componentdescription

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
Prcducd by lwdpilo / Edilion: 18.10.06 / Vion: !

Contents
1. TestprogramsSuperstruc{ure

t.---'

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UIBHRN

Gomponentdescription
OW 16 - LICCONTestsystem
Pmded by: lwpid / Edition: 14.10.06 / Vlsiod 1

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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

'l::8 : s-

*|

4 . Inthe configuration
screen(fig.2)

'

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 : = . : : :

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-'!'

F1

F2

Fr

i1

::_

!/,
.1
lEq

, 1.' .

- /4,

;)ql
oo:o

trtr <it:o-:

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).

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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

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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

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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.

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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 ,3rrl

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.

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GmbH-Technical

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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"

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Fig.3 : Selectionchangesourceword

- 11

UIBHINR

Gomponentdescription
OW 16 - LICCONTestsystem
P'oducdby: lwspno/ Edilion;18,10.06/ Ve6ion: I

Fig. 4 : Changeand accept sourceword

6. Viathenumberkeys,enterthevalue
039 (forTestprogram39) andconfirm
with[erTE (fig.4).

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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)

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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".

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IIIBIIRR

Functionaldescription
OW 20 - Emergencyoperatingmode
Pbduced bv:lweoio/ Edilion:0606 07 / veBion:3

OW20- Emergencyoperationfor
the superstructure

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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.

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UISIENR

Functionaldescription
OW 20 - Emergencyoperatingmode
PEdu@d by: lwepi.O/ Edition:06.06.07/ VeEion:3

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1lIBHINR

Functionaldescription
OW 20 - Emergencyoperatingmode
ftldu@d by lwedo / Edirion: 06.06.07 / vellion: 3

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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
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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

'

.I

"-- h

; 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.

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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 ,,

ir_+!' { - ,..

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
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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

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
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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

i i l i i r I i i lEl
i ill i iiiil.l
.e--!.-o....-o..!'
n

.-4*=_-u
L

-:: 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 -

Caution:
After the crane functionhas been completed,removeconnector-XNOTand plug
connector-X53into socket -X53.

* = Activatingof the

pressure-sreps

,,Manualpressureboost"is necessaryonlywith applianceswith

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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'

:l :1 rE:( |

fI I

:: :telescoping
in

Fr

il|

:telescoping
out
Pushbutton-S628(-5622)
"Functiondrivingswitch"(telescopein/out)

Controllight-H619(-H613)"Gripperin position"

ffi

unpintele

pintele,

unpingripper

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
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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

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

i', lliriillf

lll-ll I

rl thdillJj

lil@l{f,|
I t-t
I

| \r^lll-1,

ll-ll

\-

* = Activatingof the
,,Manualpressureboost"is necessaryonlywith applianceswith
pressure-sreps
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-'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*
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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 {

"r
"y

* '

{ \ {
1

a/
U

powerunit(Hatz)
operation
Fig.3: Example
ot emergency
operation
signon LTN,'I11004.'1 Fig.4: Emergency
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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"

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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

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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

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.

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.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:

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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

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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
emergencyoperttion 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
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-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

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-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).

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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

: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%.

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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.Il,
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 rl5C3
0.D 05C4
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
Tle
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.
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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._.

At_
I],I
tt.

L
[.
t1{._
oL._

6T
F
T

L
D.

F[
lr'T[
:
L
FL
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
Telelaens3
Izl
Telelaenae4
lzl
Telelaenq5
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)


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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

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lIIBIIIRR

Functional
description
OW 20 - Emergencyoperatingmode
Pmduced bv: lwoilo / Ednion: 06.06.07 / velllon: 3

i,_

'

i-''

\-.,1!''

li

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UBHRN