AC100_Training_manual_Ver.2.0.pdf
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Technical Training
8331.7 Technische Schulung J.Christmann
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Demag AC 100
• Der kürzeste 5-Achser mit nur 10,9 m Unterwagenlänge • 14,3 t Gegengewicht verfahrbar bei nur 12 t Achslast • Stärkster 100-Tonner im Markt • Hoher Fahrkomfort durch modernste Antriebstechnologie
• The shortest 5-axle crane with a carrier length of just 10.9 m • 14.3 t counterweight carried on the crane giving just 12 t axle load
3995
• Most powerful 100-tonne crane in the market
14050
3860
10995
• State-of-the-art transmission ensures high travel comfort
• La 5-essieux la plus compacte avec une longueur du châssis de 10,9 m seulement 7000
AC 100
• 14,3 t de contrepoids transporté sur la grue sans dépasser 12 t de poids à l’essieu • La 100-tonnes la plus puissante du marché • Transmission à la pointe de la technologie garantissant un grand confort de conduite
www. dematic.com
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Inhalt Contents Contenu Seite · Page: Technische Daten · Specifications · Caractéristiques Abmessungen · Dimensions · Encombrement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technische Daten · Specifications · Caractéristiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 6
Übersicht Standard-Traglasttabellen Overview of standard duty charts · Tableau synoptique des abaques standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
Hauptausleger · Main boom · Flèche principale Arbeitsbereiche · Working ranges · Portées . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tragfähigkeiten · Lifting capacities · Capacités de levage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 9
Hauptauslegerverlängerung · Main boom extension · Rallonge de flèche Arbeitsbereiche · Working ranges · Portées . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Tragfähigkeiten · Lifting capacities · Capacités de levage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Technische Beschreibung · Technical description · Descriptif technique Unterwagen · Oberwagen · Zusatzausrüstung . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Carrier · Superstructure · Optional equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Châssis · Partie supérieure · Equipements optionnels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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Abmessungen Dimensions Encombrement
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Technische Daten Specifications Caractéristiques
Achslasten · Axle loads · Poids d’essieux Grundgerät mit Unterflasche, Bereifung 14.00 R 25 · Basic machine with hook block, tyres 14.00 R 25 · Machine de base avec crochetmoufle, pneumatiques 14.00 R 25 Achsen · Axles · Essieux Gesamt · Total · Total
5 x < 10 000 kg < 48 000 kg
Grundgerät mit Hauptauslegerverlängerung 17 m, Unterflasche 14,3 t Gegengewicht, Bereifung 14.00 R 25 · Basic machine with 17 m main boom extension, hook block, 14.3 t counterweight, tyres 14.00 R 25 · Machine de base avec rallonge de flèche 17 m, crochetmoufle, 14,3 t de contrepoids, pneumatiques 14.00 R 25 Achsen · Axles · Essieux Gesamt · Total · Total
5 x 12 000 kg 60 000 kg
Arbeitsgeschwindigkeiten (stufenlos regelbar) · Working speeds (infinitely variable) Vitesses de travail (réglables sans paliers) Antriebe Mechanisms Mécanismes
Normalgang Normal speed Marche normale
Schnellgang High speed Marche rapide
Max. zulässiger Seilzug 1) Max. permissible line pull 1) Effort max. admis sur brin 1)
Seil ø / Seillänge Rope diameter / Rope length Diamètre du câble / Longueur du câble
Hubwerk I Hoist I Treuil I
60 m /min
110 m /min
72 kN
21 mm / 240 m
Hubwerk II Hoist II Treuil II
60 m /min
110 m /min
72 kN
21 mm / 240 m
Drehwerk · Slewing Orientation
max. 1,7 1/min · max. 1.7 1/min max. 1,7 1/min
Ausleger-Teleskopieren · Telescoping speed · Vitesse de télescopage
12,5 – 50 m: 300 s
Ausleger-Winkelverstellung · Boom elevation · Relevage de flèche
–1,5° – +82°: 55 s
Fahrleistungen · Carrier performance · Performance du porteur Fahrgeschwindigkeit · Travel speed · Vitesse sur route Vorwärts · Forward · Avant Rückwärts · Reverse · Arrière Steigfähigkeit bei Transportgewicht · Gradeability in travel order · Capacité sur rampes en état de transport sur route Bodenfreiheit · Ground clearance · Dégagement au sol (14.00 R 25 / 16.00 R 25)
80 km/h 0 . . 6 km/h max. 40 % 335/ 370 mm 3)
Unterflasche/Hakengehänge · Hook block/Single line hook · Crochet moufle/Boulet Typ Type Type
mögliche Traglast 1) Possible load 1) Charge possible 1)
125 180 163 132 118
100,0 t 179,2 t 150,0 t 121,6 t 117,2 t
Anzahl der Rollen Number of sheaves Nombre de poulies
Gewicht Weight Poids
„D“
7 5 3 1 Hakengehänge/ Single line hook/ Boulet
1100 kg 1930 kg 1700 kg 1550 kg 1250 kg
2,00 m 1,90 m 1,90 m 1,80 m 1,70 m
max. Einscherung max. reeving mouflage maxi 14 11 17 13 11
Schwerlasteinrichtung Heavy-lift attachment Equipement levage lourd 1 Zusatzrolle/add. sheave/poulie suppl.
Bemerkungen · Remarks · Remarques 1)
variiert je nach Ländervorschrift · varies depending on national regulations · varie en fonction des normes nationales
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Übersicht Standard-Traglasttabellen Overview of standard duty charts Tableau synoptique des abaques standard
7,10 x 7,00 m
7,10 x 4,50 m
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Arbeitsbereiche Hauptausleger Working ranges main boom Portées flèche principale
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Tragfähigkeiten Hauptausleger Lifting capacities main boom Capacités de levage flèche principale 7,10 m x 7,00 m
25 t Ausladung Radius Portée 1m 13 13 13,5 14 14,5 15 16 17 18 19 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46
Hauptauslegerlänge · Length of main boom · Longueur de flèche m
12,5 t,0 100,0* 84,5 78,1 72,6 67,8 63,5 56,0 48,7 41,9 35,3 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0
16,8 t,0 -,0 -,0 76,1 70,8 66,1 62,1 55,3 48,8 42,0 35,4 29,7 22,1 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0
21,0 t,0 -,0 -,0 73,0 68,3 63,7 59,7 53,0 47,7 41,5 34,7 29,1 22,7 17,8 14,5 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0
25,2 t,0 -,0 -,0 -,0 53,0 50,4 47,9 43,5 39,7 36,5 33,7 29,2 23,1 18,2 14,8 12,3 10,4 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0
29,5 t,0 -,0 -,0 -,0 -,0 -,0 41,7 39,5 36,6 34,1 31,9 29,8 22,5 17,7 15,1 12,8 10,9 9,4 8,2 7,2 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0
33,7 t,0 -,0 -,0 -,0 -,0 -,0 -,0 33,9 30,9 28,4 26,2 24,2 20,9 17,3 13,9 11,9 11,0 9,4 8,2 7,2 6,4 5,7 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0
7,10 m x 7,00 m
14,3 t Ausladung Radius Portée 1m 13 13,5 14 14,5 15 16 17 18 19 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40
DIN/ISO
360° 38,0 t,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 27,5 25,5 23,6 22,0 19,2 16,9 14,0 11,5 10,5 9,6 8,3 7,3 6,5 5,8 5,1 4,5 -,0 -,0 -,0 -,0 -,0 -,0
42,2 t,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 21,0 20,5 19,8 18,1 16,2 14,4 12,3 10,7 9,2 8,1 *** 7,4 *** 6,5 *** 5,8 *** 5,1 *** 4,6 *** 4,1 *** 3,2 -,0 -,0 -,0 -,0
46,4 t,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 15,4 15,1 14,5 13,9 13,2 12,1 10,4 8,9 8,0 ** 7,1 ** 6,2 ** 5,5 ** 4,8 ** 4,2 ** 3,7 ** 3,3 ** 2,9 ** 2,1 -,0 -,0
50,2 t,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 13,0 12,5 12,0 11,5 11,0 10,5 10,0 9,0 7,7 6,7 5,8 5,1 4,4 3,8 3,3 2,9 2,5 2,1 1,8 1,5
DIN/ISO
360°
Hauptauslegerlänge · Length of main boom · Longueur de flèche m
12,5 t,0 84,5 78,1 72,6 67,8 63,3 52,6 42,4 33,0 26,8 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0
16,8 t,0 -,0 76,1 70,8 66,1 62,1 52,7 42,6 33,1 26,8 22,4 16,4 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0
21,0 t,0 -,0 73,0 68,3 63,7 59,7 49,0 39,4 33,9 27,6 23,0 17,0 13,1 10,4 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0
25,2 t,0 -,0 -,0 53,0 50,4 47,9 43,5 37,1 32,3 28,0 23,5 17,4 13,4 10,7 8,7 7,2 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0
29,5 t,0 -,0 -,0 -,0 -,0 41,7 39,5 36,1 30,4 26,2 22,8 18,0 14,0 11,2 9,2 7,6 6,5 5,5 4,7 -,0 -,0 -,0 -,0 -,0 -,0 -,0
33,7 t,0 -,0 -,0 -,0 -,0 -,0 33,9 30,9 28,4 24,5 21,4 16,4 14,1 11,3 9,3 7,7 6,5 5,5 4,7 4,0 3,4 -,0 -,0 -,0 -,0 -,0
38,0 t,0 -,0 -,0 -,0 -,0 -,0 -,0 27,5 25,5 23,4 20,5 16,0 14,3 11,5 9,4 7,9 6,7 5,7 4,8 4,1 3,5 3,0 2,6 -,0 -,0 -,0
42,2 t,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 21,0 20,5 19,8 16,2 13,8 11,5 *** 9,5 *** 7,9 *** 6,7 *** 5,7 *** 4,9 *** 4,1 *** 3,5 *** 3,0 *** 2,6 *** 2,2 *** 1,4 -,0
46,4 t,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 15,4 15,1 14,5 13,0 11,2 ** 9,1 ** 7,6 ** 6,4 ** 5,4 ** 4,5 ** 3,8 ** 3,2 ** 2,7 ** 2,2 ** 1,8 ** 1,5 ** 1,2 **
50,2 t,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 13,0 12,5 12,0 11,5 10,5 8,7 7,2 6,0 5,0 4,1 3,4 2,8 2,3 1,8 1,4 1,1 0,8
Bemerkungen · Remarks · Remarques * nach hinten * over rear * sur l’arrière
** Hauptauslegerlänge 45,0 m ** Length of main boom 45.0 m ** Longueur de flèche principale 45,0 m
Ausladung Radius Portée m 3 3 3,5 4 4,5 5 6 7 8 9 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46
*** Hauptauslegerlänge 40,8 m *** Length of main boom 40.8 m *** Longueur de flèche principale 40,8 m
Ausladung Radius Portée m 3 3,5 4 4,5 5 6 7 8 9 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40
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Anmerkungen zu den Tragfähigkeiten Notes to lifting capacity Conditions d’utilisation
Tragfähigkeiten entsprechen ISO 4305 und DIN 15019.2 (Prüflast = 1,25 x Hublast + 0,1 x Auslegereigengewicht, auf die Auslegerspitze reduziert). Das Gewicht der Unterflaschen, sowie die Lastaufnahmemittel, sind Bestandteile der Last und sind von den Tragfähigkeitsangaben abzuziehen. Kranbetrieb zulässig bis: Staudruck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60 N/m2
Windgeschwindigkeit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9,8 m/s
Weitere Angaben in der Bedienungsanleitung des Kranes. Anmerkung: Die Daten dieser Broschüre dienen nur zur allgemeinen Information; für ihre Richtigkeit übernehmen wir keine Haftung. Der Betrieb des Kranes ist nur mit den Original-Tragfähigkeitstabellen und mit der Bedienungsanleitung zulässig, die mit dem Kran mitgeliefert werden.
Ratings are in compliance with ISO 4305 and DIN 15019.2 (test load = 1.25 x suspended load + 0.1 x dead weight of boom reduced to boom point). Weight of hook blocks and slings is part of the load, and is to be deducted from the capacity ratings. Crane operation is permissible up to a wind pressure of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60 N/m2
wind speed of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.8 m/s
Consult operation manual for further details. Note: Data published herein is intended as a guide only and shall not be construed to warrant applicability for lifting purposes. Crane operation is subject to the computer charts and operation manual both supplied with the crane.
Le tableau de charges est conforme à la norme ISO 4305 et DIN 15019.2 (charge d’essai = 1,25 x charge suspendue + 0,1 x poids de la flèche réduit à la pointe de flèche). Les poids du crochet-moufle et de tous les accessoires d’élingage font partie de la charge et sont à déduire des charges indiquées. La grue peut travailler jusqu’à une pression du vent de . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60 N/m2
vitesse du vent de . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9,8 m/s
Pour plus de détails consulter la notice d’utilisation de la grue. Nota: Les renseignements ci-inclus sont donnés à titre indicatif et ne représentent aucune garantie d’utilisation pour les opérations de levage. La mise en service de la grue n’est autorisée qu’à condition que les tableaux de charges ainsi que le manuel de service, tels que fournis avec la grue, soient observés.
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Arbeitsbereiche Hauptauslegerverlängerung Working ranges main boom extension Portées rallonge de flèche
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Tragfähigkeiten Hauptauslegerverlängerung Lifting capacities main boom extension Capacités de levage rallonge de flèche 7,10 m x 7,00 m
25 t 38,0 m
Hauptausleger · Main boom · Flèche principale
Ausladung Radius Portée 1m 17 18 19 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 46,4 m
0° t,0 14,4 14,2 13,7 13,1 12,2 11,3 10,4 9,7 9,0 8,3 7,4 6,4 5,5 4,7 4,4 4,2 3,9 3,6 3,2 2,9 -,0 -,0 -,0 -,0 -,0 -,0 -,0
Verlängerung · Extension · Rallonge 17,0 m 9,2 m 0° 20° 20° 40° t,0 t,0 t,0 t,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 7,4 -,0 -,0 -,0 7,1 -,0 9,3 -,0 6,9 -,0 8,9 -,0 7,0 7,1 8,6 4,8 6,5 7,0 8,3 4,6 6,0 6,8 8,0 5,6 4,3 6,6 7,7 5,3 4,1 6,5 7,5 5,0 3,9 6,4 7,1 3,7 4,7 6,3 6,8 3,6 4,4 6,1 5,8 3,4 4,2 5,3 5,0 4,0 3,3 4,5 4,3 3,2 3,8 3,9 3,9 3,1 3,6 3,8 3,7 3,1 3,3 -,0 3,6 3,0 2,8 -,0 3,3 2,6 2,8 -,0 2,9 2,4 2,4 -,0 -,0 2,2 2,3 -,0 -,0 2,1 2,2 -,0 -,0 2,1 2,1 -,0 -,0 2,0 1,9 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0
42,2 m
Verlängerung · Extension · Rallonge 17,0 m 9,2 m 0° 20° 0° 20° 40° t,0 t,0 t,0 t,0 t,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 10,0 ** -,0 -,0 -,0 6,4 ** -,0 10,3 -,0 -,0 6,2 9,4 -,0 -,0 -,0 5,8 8,7 7,1 -,0 -,0 5,5 8,1 6,8 4,3 ** 6,1 5,2 7,5 6,5 4,1 5,8 4,9 7,0 6,2 4,0 5,5 4,7 6,5 5,8 3,8 5,2 4,4 6,1 5,5 3,6 5,0 4,2 5,7 5,2 3,5 4,8 4,0 5,4 5,0 3,3 4,6 3,8 5,1 4,7 3,2 4,4 3,6 4,4 4,5 3,0 4,2 3,5 4,2 ** 4,1 2,9 4,1 3,3 3,7 ** 3,8 ** 3,7 2,8 3,0 3,2 ** 3,4 ** 3,5 ** 2,7 2,7 ** 2,6 2,8 ** 3,0 ** 3,1 ** 2,6 ** 2,6 2,4 ** 2,6 ** 2,7 ** 2,3 ** 2,3 2,1 ** 2,2 ** 2,0 2,0 ** 2,2 ** 1,8 ** 1,9 ** -,0 1,7 ** 1,9 ** 1,6 ** 1,6 ** -,0 1,4 ** 1,7 ** 1,0 1,4 ** -,0 1,2 ** 1,4 ** -,0 -,0 -,0 1,0 ** 1,2 ** -,0 -,0 -,0 -,0 0,9 ** 0,9 ** -,0 -,0
Hauptausleger · Main boom · Flèche principale
40° t,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 3,6 3,5 3,4 3,3 3,2 3,1 3,0 3,0 2,9 2,9 2,9 2,9 2,6 2,3 -,0 -,0 -,0 -,0 -,0 -,0
Ausladung Radius Portée 1m 18 19 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58
40° t,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 3,2 3,1 3,1 3,0 3,0 2,9 2,9 2,8 2,7 2,6 2,5 2,5 2,1 2,1 ** 1,8 ** 1,2 -,0 -,0
Ausladung Radius Portée 1m 18 19 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58
Hauptausleger · Main boom · Flèche principale
Ausladung Radius Portée 1m 17 18 19 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56
50,2 m
DIN/ISO
360°
Verlängerung · Extension · Rallonge 17,0 m 9,2 m 0° 20° 40° 0° 20° 40° t,0 t,0 t,0 t,0 t,0 t,0 -,0 10,8 *** -,0 -,0 -,0 -,0 -,0 -,0 11,7 -,0 -,0 7,2 -,0 -,0 11,3 -,0 -,0 7,0 -,0 8,8 10,7 -,0 -,0 6,5 7,1 8,4 10,0 -,0 -,0 6,1 6,9 8,1 9,3 4,5 -,0 5,7 6,7 7,8 -,0 8,7 5,3 4,3 6,5 7,5 3,4 8,1 4,1 5,0 6,4 7,2 3,3 7,5 4,7 3,9 6,2 6,9 3,2 7,0 3,7 4,5 6,0 6,6 3,1 6,5 4,2 3,6 5,9 6,1 3,1 5,7 4,0 3,4 5,5 5,3 3,0 4,9 3,8 3,3 4,8 4,5 2,9 4,6 3,2 3,7 4,1 4,1 2,9 4,2 3,1 3,5 3,9 2,8 3,8 *** 3,9 3,1 3,4 3,5 2,8 3,6 *** 3,4 2,9 3,1 2,8 3,2 *** 3,3 *** 3,0 2,8 2,9 2,8 2,8 *** 2,9 *** -,0 2,6 2,6 2,4 2,5 *** 2,6 *** -,0 2,5 2,3 2,3 *** -,0 2,4 1,8 2,2 *** 2,2 -,0 -,0 -,0 2,1 *** 2,1*** 2,0 -,0 -,0 -,0 1,8 *** 2,0*** -,0 -,0 -,0 -,0 1,6 *** 1,7 *** -,0 -,0 -,0 -,0 -,0 1,2 1,1 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0
Hauptausleger · Main boom · Flèche principale
0° t,0 -,0 -,0 -,0 8,4 7,9 7,5 7,1 6,7 6,3 6,0 5,7 5,4 5,0 4,4 3,8 3,2 2,8 2,4 2,0 1,7 1,4 1,2 0,9 0,7 -,0 -,0 -,0
Verlängerung · Extension · Rallonge 17,0 m 9,2 m 0° 20° 20° 40° t,0 t,0 t,0 t,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 5,6 -,0 6,9 -,0 5,4 -,0 6,4 -,0 5,2 5,5 6,1 4,1 5,0 5,2 5,7 4,8 3,9 5,0 5,4 3,8 4,6 5,2 4,8 4,4 3,6 4,9 4,6 4,2 3,4 4,4 4,7 4,0 3,3 4,2 4,5 3,8 3,1 4,1 4,3 3,0 3,6 4,1 4,0 2,9 3,4 3,7 3,5 3,2 2,8 3,2 3,0 2,9 2,7 2,7 2,6 2,6 2,5 2,2 2,3 2,5 2,2 1,9 2,0 1,8 2,2 1,6 1,6 1,6 1,9 1,3 1,3 1,3 1,6 -,0 1,0 1,3 1,0 0,8 -,0 0,8 1,1 -,0 -,0 0,6 0,8 -,0 -,0 0,6 -,0 -,0 -,0 -,0 -,0
Bemerkungen · Remarks · Remarques * nach hinten * over rear * sur l’arrière
** Hauptauslegerlänge 45,0 m ** Length of main boom 45.0 m ** Longueur de flèche principale 45,0 m
*** Hauptauslegerlänge 40,8 m *** Length of main boom 40.8 m *** Longueur de flèche principale 40,8 m
40° t,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 3,2 3,1 3,0 2,9 2,9 2,8 2,7 2,7 2,6 2,5 2,5 2,4 2,1 1,8 1,5 1,2 0,9 -,0 -,0
AC 100
10/99
07.10.1999 10:43 Uhr
Seite 13
Tragfähigkeiten Hauptauslegerverlängerung Lifting capacities main boom extension Capacités de levage rallonge de flèche 7,10 m x 7,00 m
14,3 t 38,0 m
Hauptausleger · Main boom · Flèche principale
Ausladung Radius Portée 1m 17 18 19 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 64 56 46,4 m
0° t,0 14,4 14,2 13,7 13,1 12,2 11,3 10,3 8,5 6,9 5,9 5,6 5,0 4,3 3,6 3,1 2,6 2,2 1,9 1,6 1,3 -,0 -,0 -,0 -,0 -,0 -,0 -,0
Verlängerung · Extension · Rallonge 17,0 m 9,2 m 0° 20° 20° 40° t,0 t,0 t,0 t,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 8,1 -,0 -,0 -,0 7,8 -,0 9,3 -,0 7,5 -,0 8,9 -,0 7,0 7,1 8,6 4,8 6,5 7,0 8,3 4,6 6,0 6,8 8,0 5,6 4,3 6,6 7,5 5,3 4,1 6,5 6,2 5,0 3,9 5,5 5,1 3,7 4,7 4,6 4,7 3,6 4,2 4,4 4,4 3,4 3,7 4,1 3,9 3,4 3,3 3,5 3,3 2,9 3,2 2,9 2,8 2,8 2,8 2,5 2,4 2,7 2,4 -,0 2,0 2,4 2,1 -,0 1,7 1,7 2,0 -,0 1,4 1,5 1,7 -,0 -,0 1,4 1,2 -,0 -,0 1,2 1,0 -,0 -,0 0,9 0,8 -,0 -,0 0,7 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0
42,2 m
Verlängerung · Extension · Rallonge 17,0 m 9,2 m 0° 20° 0° 20° 40° t,0 t,0 t,0 t,0 t,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 10,0 ** -,0 -,0 -,0 -,0 -,0 10,3 6,4 ** -,0 -,0 -,0 9,4 -,0 6,2 -,0 7,1 8,7 -,0 5,8 6,1 6,8 8,1 4,3 ** 5,5 5,8 6,5 7,5 5,2 4,1 5,5 6,2 7,0 4,0 4,9 5,8 5,2 6,0 4,7 3,8 5,0 5,4 ** 5,5 4,4 3,6 4,8 4,6 ** 4,6 4,2 3,5 3,8 ** 4,2 ** 4,3 ** 3,8 ** 3,3 3,2 ** 3,5 ** 3,8 ** 3,4 ** 3,2 2,7 ** 3,0 ** 3,2 ** 2,9 ** 3,0 2,2 ** 2,5 ** 2,6 ** 2,4 ** 2,8 ** 1,8 ** 2,0 ** 2,2 ** 2,0 ** 2,5 ** 1,4 ** 1,6 ** 1,8 ** 1,6 ** 2,0 ** 1,1 ** 1,3 ** 1,4 ** 1,3 ** 1,7 ** 0,8 ** 1,0 ** 1,1 ** 1,0 ** 1,4 ** 0,6 ** 0,7 ** -,0 0,7 ** 1,1 ** -,0 -,0 -,0 -,0 0,8 ** -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0
Hauptausleger · Main boom · Flèche principale
40° t,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 3,6 3,5 3,4 3,3 3,2 3,1 3,0 3,0 2,8 2,7 2,6 2,2 1,9 1,5 -,0 -,0 -,0 -,0 -,0 -,0
Ausladung Radius Portée 1m 18 19 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58
40° t,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 3,2 3,1 3,1 3,0 3,0 2,9 2,9 2,6 2,4 ** 2,0 ** 1,6 ** 1,3 ** 1,0 ** 0,7 ** -,0 -,0 -,0 -,0
Ausladung Radius Portée 1m 18 19 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58
Hauptausleger · Main boom · Flèche principale
Ausladung Radius Portée 1m 17 18 19 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56
50,2 m
DIN/ISO
360°
Verlängerung · Extension · Rallonge 17,0 m 9,2 m 0° 20° 40° 0° 20° 40° t,0 t,0 t,0 t,0 t,0 t,0 -,0 10,8 *** -,0 -,0 -,0 -,0 -,0 -,0 -,0 11,7 -,0 7,2 -,0 -,0 -,0 -,0 11,3 7,0 -,0 -,0 -,0 8,8 10,7 6,5 7,1 -,0 -,0 8,4 10,0 6,1 6,9 8,1 4,5 -,0 9,3 5,7 6,7 7,8 -,0 4,3 5,3 8,6 6,5 7,5 3,4 4,1 5,0 7,1 6,4 6,4 3,3 3,9 4,7 6,2 5,7 5,4 3,2 3,7 4,5 5,4 4,8 3,1 3,6 4,2 5,0 *** 5,0 3,1 3,4 3,9 4,2 *** 4,4 *** 4,5 3,0 3,3 3,4 3,6 *** 3,9 *** 4,1 *** 2,9 3,2 *** 3,1 3,1 *** 3,3 *** 3,5 *** 2,9 2,8 *** 2,9 2,6 *** 2,8 *** 3,0 *** 2,4 *** 2,6 *** 2,8 2,2 *** 2,4 *** 2,5 *** 2,0 *** 2,4 *** 2,4 1,8 *** 2,0 *** 2,1 *** 1,7 *** 2,0 *** 2,2 *** 1,5 *** 1,7 *** 1,4 1,4 *** 1,7 *** 1,9 *** 1,2 *** 1,4 *** -,0 1,1 *** 1,4 *** 1,5 *** 1,0 *** 1,1 *** -,0 0,8 *** -,0 0,9 *** 1,1 *** 1,2 *** -,0 -,0 -,0 0,7 *** 0,9 *** 0,7 -,0 -,0 -,0 0,7 *** -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0
Hauptausleger · Main boom · Flèche principale
0° t,0 -,0 -,0 -,0 8,4 7,9 7,5 7,1 6,7 5,7 4,8 4,0 3,3 2,7 2,2 1,8 1,4 1,0 0,7 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0
Verlängerung · Extension · Rallonge 17,0 m 9,2 m 0° 20° 20° 40° t,0 t,0 t,0 t,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 5,6 -,0 6,9 -,0 5,4 -,0 6,4 -,0 5,2 5,5 6,1 5,0 4,1 5,2 5,7 4,8 3,9 5,0 5,4 4,6 3,8 5,2 4,8 4,4 3,6 4,4 4,6 4,0 3,4 4,0 3,7 3,3 3,3 3,4 3,1 2,8 3,1 2,8 2,6 2,3 2,9 2,1 2,3 1,9 2,4 1,9 1,7 1,5 2,0 1,4 1,3 1,2 1,6 1,1 0,9 0,9 1,3 0,6 0,8 -,0 1,0 -,0 -,0 0,7 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0
Bemerkungen · Remarks · Remarques * nach hinten * over rear * sur l’arrière
** Hauptauslegerlänge 45,0 m ** Length of main boom 45.0 m ** Longueur de flèche principale 45,0 m
*** Hauptauslegerlänge 40,8 m *** Length of main boom 40.8 m *** Longueur de flèche principale 40,8 m
40° t,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 -,0 3,2 3,1 3,0 2,9 2,9 2,8 2,7 2,4 2,0 1,7 1,3 1,0 0,7 -,0 -,0 -,0 -,0 -,0 -,0
AC 100
10/99
07.10.1999 10:43 Uhr
Seite 15
Technical description
Carrier Drive/Steering Frame Outriggers Engine Transmission Axles
Suspension Wheels and tyres Steering Brakes Electrical equipment Driver’s cab
10 x 6 x 8 Monobox main frame with outrigger boxes integral, of high-strength fine grain structural steel. Four hydraulically telescoping outrigger beams with hydraulic jack legs. Mercedes Benz OM 502 LA water-cooled 8-cylinder engine (Euromot), output to DIN: 350 kW (476 hp) at 1800 1/min, max. torque 2300 Nm at 1080 1/min. Fuel tank capacity: 500 l. Automatic transmission (16 ranges), transfer case with longitudinal differential lockout control. Axle 1: steering; axle 2: with planetary hubs, steering, transverse differential lockout control; axle 3: rigid axle, non-steer; axle 4: with planetary hubs, steering in crab steer mode, longitudinal and transverse differential lockout control; axle 5: with planetary hubs, transverse differential lockout control. Hydropneumatic suspension, all axles hydraulically blockable. 10 wheels fitted with 14.00 R 25 tyres, single wheels on all axles. ZF dual-circuit semiblock mechanical steering with hydraulic booster. Service brake: dual-line air system with anti locking system. Parking brake: spring-loaded type, on 2nd, 4th and 5th axles. Sustained action brake: constant decompression with butterfly valve, exhaust brake, hydraulic retarder. 24 V system. Rubber-mounted all steel driver’s cab with safety glazing, electr. window winders, controls and instrumentation, air-suspended and heated driver’s seat, unsprung passenger’s seat, vertically adjustable steering wheel, heated outside mirrors, rotaflare warning light.
Superstructure Engine Hydraulic system Hoist Slew unit Boom elevation Crane cab
Main boom Counterweight Safety devices Hydraulic servo control
Mercedes Benz OM 904 LA water-cooled 4-cylinder in-line engine (Euromot), output 125 kW (171 hp) at 2300 1/min, max. torque 630 Nm at 1200 1/min, fuel tank capacity: 200 l. 1 variable displacement axial piston pump to provide 4 simultaneous, independent working movements and separate pump for slew unit. Fixed displacement axial piston hydraulic motor, hoist drum with integral planetary gear reducer and spring-applied multi-disk. Drum rotation indicator. Hydraulic motor with planetary gear reducer, change-over from brake to free swing by control lever, spring-applied holding brake. 1 differential cylinder with automatic lowering brake valve. Spacious all-steel comfortable cab with sliding door and large hinged windscreen, tiltable 20°, roof window with armoured glass, full instrumentation and crane controls, working light. Hot water heater operated either self-contained or engine-dependent, with engine preheating and timer, thermostat-controlled. Windscreen washer and intermittent control type windscreen wiper. Boom base and 4 telescopic sections, fabricated from fine grain structural steel, telescoping ability with partial load, buckling-resistant Demag ovaloid design. 14.3 t. Electronic safe load indicator with digital readout for hook load, rated load, boom length, boom angle, load radius, analog display to indicate the capacity utilization, limit switches on hoist and lowering motions, pressure-relief and safety holding valves. Hydro-electric pilot control through self-centering control levers.
Optional equipment Drive/steering Wheels and tyres Tow coupling Hoist II Main boom extension Hydraulic fly jib Additional counterweight
10 x 8 x 8 16.00 R 25 on 11.25-25 rims. D-value 12 t or 19 t, air-brake connection. Fixed displacement axial piston hydraulic motor, hoist drum with integral planetary gear reducer and spring-applied multi-disk brake. The use of hoist II avoids re-reeving the hoist line when using the optional jib. Side-folding 1 or 2-part jib, 9.2 m or 17.0 m. 0°, 20° and 40° offset. On request. 10.7 t, integrates into standard counterweight, installed hydraulically by the crane itself.
Subject to change without notice!
10/ 99
AC 100
10/99
07.10.1999 10:43 Uhr
Seite 17
Zeichenerklärung Key Légende
Gegengewicht · counterweight · contrepoids Tragfähigkeiten, abgestützt · Lifting capacities on outriggers · Capacités de levage sur stabilisateurs · 360°
„D“
D
engineering
mannesmann dematic Mobile Cranes Division 19.02.99
Profile of Product All-terrain crane DEMAG AC 100
Max. lifting capacity:
100 t at 3 m radius
Max. load moment:
333 tm
Main boom length:
50.2 m, telescoping hydraulically
Main boom extension:
9.2 m / 17.0 m (two-part folding jib)
Max. boom lengths:
59.4 m / 67.2 m incl. boom extension
Travel speed:
80 km/h - tyres 14.00 R 25
Gradeability:
approx. 40 %
Weight in travel order:
60 t, basic counterweight 14 t, hook block type 32, 14.00 R 25 tyres, drive 10 x 8 x 8, 17.0 m boom extension 48 t, as above, but with 3 t counterweight 45 t, as above, but without counterweight
Axle loading:
5 x 12 t
Drive:
10 x 6
Steering:
10 x 8
Overall length:
14.1 m
Overall width:
2.75 m
Overall height:
3,99 m
Safety devices:
standard
AC 100
engineering
mannesmann dematic
1.0.
CRANE CARRIER:
Profile of Product
2
Mannesmann Demag 5-axle carrier Length: Width: Turning radius: Drive/steering:
11.00 m 2.75 m 11.55 m 10 x 6 x 8
1.1.
Steel structure:
1.1.1.
Frame
Torsion-resistant monobox main frame with outrigger boxes integral, made from high strength fine grain structural steel.
1.1.2.
Outriggers
Outrigger base longitudinal: transverse:
7.10 m 7.00 m
SLI-programme for second outrigger base: longitudinal: 7.10 m transverse: 4.50 m
4 hydraulically extending outrigger beams with jacking cylinders. Controlled from each side of the chassis, or from the cabin, monitored by 90° bubble levelling indicator. Jacking cylinder stroke approx. 600 mm. Outrigger pads remain fitted to jack legs during transit, without exceeding the 2.75 m overall vehicle width. 4 outrigger pads 542 mm x 542 mm.
1.2.
Drive and transmission:
1.2.1.
Engine
Type: Emission: Output: Torque: Cylinders: Cooling: Fuel tank capacity:
1.2.2.
Transmission
Daimler-Benz OM 502 LA EUROMOT 350 kW 1 at 1800 /min 1 2300 Nm at 1080 /min 8 water circulation type 450 l
Automatic transmission, 16 forward speeds and 1 reverse.
AC 100
engineering
mannesmann dematic
Profile of Product
1.2.3.
Transfer case
between axles 2 and 4 with longitudinal differential lockout control.
1.2.4.
Drive
10 x 6 Axles 2, 4 and 5 permanently driven.
3
1: Steer ing, non-driving 2: With planetary hubs, transverse differential lockout control 3: Rigid bogie axle, non-driving 4: With planetary hubs, longitudinal and transverse differential lockout control 5: With planetary hubs, transverse differential lockout control
1.2.5.
Suspension
Hydropneumatic suspension giving +/- 110 mm height adjustment, all axles blockable hydraulically.
1.2.6.
Wheels
10
1.2.7.
Tyre size
14.00 R 25
1.3.
Steering:
10 x 6 on-highway Fully independent hydrostatic on both rear axles offhighway (3rd axle raised).
1.4.
Brakes:
conforming to EC-directives
1.4.1.
Service brake
Dual-line air-operated braking system.
1.4.2.
Parking brake
Spring-loaded brake on axles 2, 4 and 5.
1.4.3.
Sustained action brake
Exhaust brake, constant decompression and butterfly valve, and hydraulic retarder.
1.5.
Electrical system:
24 V 3-phase alternator 55 A 2 batteries 12 V / 180 Ah Lighting in compliance with EC-directives
AC 100
engineering
mannesmann dematic
Profile of Product
4
1.6.
Driver's cab:
Rubber-mounted steel cab, 2.42 m wide. New design full vision cab, comfortable equipment incl. heated and air-suspended driver’s seat, head and arm rests, three-point seat belts, adjustable steering wheel, safety glass used throughout, slide-by side windows, windscreen defroster fans. 10 kW engine-dependent hot water heater, electric windscreen washer and wiper, sun visors, dashboard with clearly arranged instrumentation, ample stowage space for small articles, heated outside mirrors, rotaflare warning light.
1.7.
Tools:
Set of spanners, grease gun, tyre inflation kit, air gauge, oil can, emergency triangle, first-aid kit, emergency flasher, wet weather gear, safety helmet.
2.0.
SUPERSTRUCTURE:
2.1.
Steel structure:
2.1.1.
Frame
DEMAG fabricated fine-grain structural steel, allwelded. Torsion-resistant weight saving longitudinal beam construction.
2.2.
Slew ring:
Triple-row roller bearing slew ring with external ring gear for ease of service and maintenance.
2.3.
Crane drive:
2.3.1.
Crane engine
Type: Daimler-Benz OM 904 LA Emission: EUROMOT Output: 125 kW 1 Torque: 630 Nm at 1200 /min Fuel tank capacity: 200 l
2.3.2.
Hydraulic system
1 variable displacement axial piston pump for main crane movements (load sensing / hydro-electric pilot control), separate pump for slew system, hydraulic oil cooler. This enables the operator to engage 4 independent motions at the same time. Reservoir capacity: 1400 l.
AC 100
engineering
mannesmann dematic 2.3.3.
Hoist
Profile of Product
Fixed displacement axial piston motor, hoist drum with integral planetary gear reducer and spring-applied multi-disk brake. Hydraulic braking, drum rotation indicator. Drum diameter: Rope diameter: Rope length: max. line pull: max. line speed:
2.3.4.
Slew system
5
455 mm 21 mm 240 m 72 kN 110 m/min
Hydraulic motor with planetary gear reducer, free swing engaged by joystick lever, springapplied holding brake. 1
Slewing speed infinitely variable 0 - 1.7 /min.
2.3.5.
Boom elevation
1 differential cylinder with automatic lowering brake valve. Elevation: Elevation time:
- 1.5° to 82° - 55 sec
2.3.6.
Controls
The crane is controlled by 2 self-centering servo levers, ergonomically positioned next to the operator’s seat (cross-type control levers for 2 working motions each). The working speed is controlled by both the engine revs and the lever position. Hydro-electric pilot-control.
2.4.
Operator’s cab:
Comfortable all-steel cab with sliding door and hinged windscreen, tilts back 20°, safety glass used throughout, roof window with armoured glass, washer and intermittent control wiper for front and roof window. Full instrumentation and crane controls. Working light, rotaflare warning light on upper frame. Steps on both front and side to facilitate access, roller blind, holder for beverage cans. 5 kW hot water heater operated either self-contained or engine-dependent, used for engine preheating, thermostat-controlled with timer, high-speed fan, defroster vents for all windows.
2.5.
Counterweight:
25 t total. In conformity with 12 t axle loading regulations when in travel order with 14 t counterweight.
AC 100
engineering
mannesmann dematic
Profile of Product
6
25 t counterweight can be carried on the crane though axle loadings then increase to 14.5 t. All counterweights are stowed hydraulically and installed by the crane itself.
2.6.
Electrical system:
24 V
2.7.
Safety devices:
Electronic safe load indicator with sealed touch-type keyboard is standard, digital read-out for hook load, nominal load, boom length and angle, radius, integrated display to indicate the capacity utilization in %, limit switches on hoist and lowering motions, pressure relief and safety holding valves. Large display.
2.8.
Telescopic boom:
Boom base and 4 inner sections fabricated from fine grain structural steel. The boom extends by one hydraulic cylinder. UNIMEC system. Boom head with 6 sheaves and parts to mount the boom extension. Total length: 50.2 m Telescoping time from 10.1-50.2 m: 300 sec
2.9.
Other equipment:
3.0.
OPTIONAL EQUIPMENT:
3.1.
Drive 10 x 8:
Anemometer, fire extinguisher, outrigger spotlights, 2 working lights.
Axle 1 driven additionally, steering, with planetary hubs, connectable, transverse differential lockout control. Axle 2 additionally with longitudinal lockout control.
3.2.
Wheels and Tyres:
3.2.1.
16.00 R 25 vehicle width 2.75 m / vehicle height 3.95 m
3.2.2.
20.5 R 25 vehicle width 3.00 m / vehicle height 3.95 m
3.2.3.
Spare wheel, loose
AC 100
engineering
mannesmann dematic
Profile of Product
3.2.4.
Spare wheel with mount
3.2.5.
Spare wheel with mount and hoist
3.3.
Trailer tow coupling:
3.3.1.
D-value = 12 t, pin ∅ 40 mm
3.3.2.
D-value = 19 t, pin ∅ 50 mm Incompatible with mounted spare wheel.
3.4.
Air-conditioning:
3.5.
Tropicalisation (up to 45°C)
3.6.
Exhaust with spark arrestor
3.7.
Main boom extension, folding, 9.2 m-17.0 m:
for carrier and upper cab, integrated into heating and ventilation system.
Fixed 1- or 2-part extension. 0°, 20° and 40° offset. 1-part extension: 9.2 m 2-part extension: 9.2 m or 17.0 m Folding to right side of boom base for transportation. The scope of supply includes a ladder.
3.8.
Hoist 2:
Avoids re-reeving of hoist line when using the boom extension. Technical data same as hoist 1. Tail swing with hoist 2: 4900 mm.
3.9.
Centralized lubrication:
Carrier
3.10.
Hook blocks with safety hooks:
With fold-away rope guard to facilitate reeving, with handles integral, and hooks with safety latches.
Type 125 (100 t)
7-sheave with ramshorn hook, max. 14 lines, (1100 kg)
Type 80 (79.2 t)
5-sheave with ramshorn hook, max. 11 lines, ( 930 kg)
Type 63 (50.0 t)
3-sheave with ramshorn hook, max. 7 lines,
7
AC 100
engineering
mannesmann dematic
Profile of Product
8
(700 kg)
3.11.
Type 63 (50.0 t)
3-sheave with single hook, max. 7 lines, (700 kg)
Type 32 (31.9 t)
1-sheave with single hook, max. 3 lines, (550 kg)
Type 8 (7.2 t)
single-line hook, (250 kg)
Stowage facilities:
-
for 1 or 3 sheave hook block for single line hook for mats for slings
3.12.
rooster sheave
3.13.
additional working light on boom base
3.14.
Self-contained heater:
9 kW heater for carrier cab, with timer, used for engine preheating.
3.15.
Rotaflare warning light:
1 x additional rotating beacon for carrier cab.
3.16.
Top steer facility
4.0.
MISCELLANEOUS:
4.1.
National regulations:
Different national regulations for crane acceptance and roadability can require alterations to serial cranes ensuing technical and price modifications.
4.2.
Standard painting:
Superstructure: RAL 9003 - signal white Carrier: RAL 7037 - dusty grey
4.3.
Special painting and signwriting:
Special customer signwriting (decal) and all RAL colours.
Subject to change without notice.
Technical Training
AC 100 Steering
Adjusting the proximity switches: Important!!! Crab steering must be locked. Screw in B358.1 till H344 (crab steering not locked) goes out. Unlock crab steering. Screw in B358.2 till H345 (crab steering unlocked) goes on. Danger of accident!!! Axle 3 can automatically raise!!!!
B 358.1
Normally closed
B 358.2
Normally opened Hydraulic connection
Crab steering unlocked: B358.1 not switched: LED on/closed. H344 on B358.2 switched: LED on/closed. H345 on
Crab steering locked: B358.1 switched: LED off/open. H344 off. B358.2 not switched: LED off/open. H345 off.
AC100 Lenkstange e
Steering not locked: B358.1 not switched: LED on/closed. H344 on B358.2 not switched: LED off/open. H345 off
Technische Schulung
Technical Training Carrier
AC 100
Pin crabsteering axle 4
S355.2 switch normally open
Pin completely down switch S355.2 open pin lifted or completely up switch S355.2 closed
Technische Schulung
S355.1 switch normally closed
Pin completely down switch S355.1 open pin completely up switch S355.1 closed
AC100 Bolzen Hundegang e
Technical Training Carrier
AC 100 Suspension
Suspension cylinder with 2 proximity switches
cylinder too high
hydraulic connection cylinder
level too low
too high
bronze
level position steel hydraulic connection too high
proximity switch
proximity switch
Technische Schulung
AC100 Federungszyl e
Technical Training
AC 100 Hydraulic
Panel carrier right hand side
B360 100 bar
4 circuit safety valve
R325
Y355.1
Y314 Y313
Technische Schulung
Y305D Y305C Y364.8 Y364.4
Y363
Y365
Y364.2
Y361 Y362
AC100 Panel carrier right
Technical Training
AC 100 Carrier
Panel carrier left hand side Y364.1
Y365B
Y365A
Y356.2
Y343 MP2
Technische Schulung
Y367 Y310A
Y356.1
Y344 MP1
Y366A Flow divider
Y357
Y310B
Y305A Y305B Y346.7 Y346.3
B359
Y366B
AC100 Panel carrier left
Technical Training
Pressure switch parking brake (within the frame)
Technische Schulung
AC 100 Pneumatic B310.3 2 bar
B310.2 5 bar
AC100 Druckschalter Handbremse e
Technical Training Carrier
AC 100 SPS
CPU module LED MK2
Binary card 1
LED MK1 Status: off
Binary card 2
LED E2.5 LED E2.1
LED E1.1 Input 1.1 (Green when 24V input)
DIAG LED status: green 5V LED status: green
Technische Schulung
LED E6.6
LED E5.4 (ground input not AC100)
LED A7.4 Output7.4 (Red when 24V output)
AC100 Digsy UW e.doc
Technical Training
AC 100 SPS
CPU-Module Function - Computer with interfaces for data communication -
Engine RPM signal is adapted for the programming interface
- Two nine pin connectors are used for both serial interfaces (PI and CI) - 2 LED’s
DIAG(Diagnostic-LED)
green orange
red out blinking - 5V LED green red out blinking red/green blinking red/oran. - Switch S1=0: - Switch S2=3: - Jumper in position R:
Technische Schulung
Program running Internal housing temperature too high Internal battery charge too low Programming mode SPC in waitstate 24V CPU < 14V EEPROM not installed EEPROM or RAM error Program stopped, no program, LED defective Received information on the PI or CI correct CPU power supply functioning correctly CPU stopped, power supply < 4,65V CPU stopped, Power supply voltage missing, LED defective cyclical restarts/ Watchdog working constant reset, defective internal component Subscriber receives address 0 Data transmission rate 19200 Baud Communications interface (CI) is RS485
AC100 SPS UW e
Technical Training
AC 100 SPS
Binary Input/Output (I/O-Module) Function Reception of 24V switched signals Output of 24V control signals 16 input channels for 24V switched signals 16 output channels 8 for a current of up to 2A 8 for a current of up to 400 mA (These outputs can also be configured as input channels) The switch condition of the in- and output channels are shown through LED’s green for input channels red for output channels The Binary modules are addressed, therefore there is no need to set dipswitches or jumpers. 2 LED’s are used as short circuit indicators, one LED for each output channel. In case of a short circuit, the afflicted output channel is automatically turned off. These LED’s can be found on the front plate and are marked MK1-MK8. The output channel short circuit indicators can show the following situations: - Return current from an unswitched output channel - Power supply < 17V - Output current > 2.5A (Short circuit) The short circuit indicators are only useful when the output channels are connected to relays that have a low resistance protection diode built in. This means that only relays with a low resistance protection diode may be used to replace existing relays in an output channel of a binary I/O card, otherwise the complete output channel will be turned off and proper function can not be achieved.
Technische Schulung
AC100 SPS UW e
Technische Schulung
AC 100 Elektrik
Meldeleuchtenmodul A
Nr. 1 2 3 4 5 6 7 8 9 10
Funktion
Function
Geländegang Getriebetemperatur Wandlerschaltkupplung Getriebeölfilter Fehlercode Getriebe Straßengang Notkupplungspedal ausklappen Kupplungsübertemperatur Getriebeölniveau Fernlicht
Off road Temperature transmission Tourque converter Oilfilter transmission Transmission error On road Unfold emergency clutch pedal
Technische Schulung
Temperature clutch Oil level transmission High beam
Farbe / Color Gelb / yellow Rot / red Gelb / yellow Gelb / yellow Rot / red Grün / green Rot / red Rot / red Rot / red Blau / blue
AC100 Meldeleuchtenmodul A.doc
Technische Schulung
AC 100 Elektrik
Meldeleuchtenmodul B
Nr. 1 2 3 4 5 6 7 8 9 10
Funktion
Function
Niveau hinten links Niveau vorne links Hydrauliktemperatur Hydraulikölfilter Dolly Niveau hinten rechts Niveau vorne rechts Lenkkreis 3 Lenkkreis 2 Lenkkreis 1
Level rear left Level front left Hydraulic temperature Oilfilter hydraulic Dolly Level rear right Level front right Steering circuit 3 Steering circuit 2 Steering circuit 1
Technische Schulung
Farbe / Color Gelb / yellow Gelb / yellow Gelb / yellow Gelb / yellow Rot / red Gelb / yellow Gelb / yellow Rot / red Rot / red Rot / red
AC100 Meldeleuchtenmodul B.doc
Technische Schulung
AC 100 Elektrik
Meldeleuchtenmodul C
Nr. 1 2 3 4 5 6 7 8 9 10
Funktion
Function
Vorglühen Ladekontrolle Motorölstand Motoröldruck Störung Motor Motorstop Luftfilter Kühlwasserstand Kühlmitteltemperatur Fahrtrichtungsanzeiger
Glow plug Batterie light Engine oil level Engine oil pressure Engine error Engine stop Air filter Water level Water temperature Indicator
Technische Schulung
Farbe / Color Gelb / yellow Rot / red Rot / red Rot / red Rot / red Rot / red Gelb / yellow Gelb / yellow Rot / red Grün / green
AC100 Meldeleuchtenmodul C.doc
Technische Schulung
AC 100 Elektrik
Meldeleuchtenmodul D
Nr. 1 2 3 4 5 6 7 8 9 10
Funktion
Function
ABS Info ABS Anhänger ABS Bremsdruck Blinkeranzeige für Anhänger Bremsdruckreduzierung Retarder Wirbelstrombremse Handbremse Betriebsbremse betätigen
ABS Info ABS trailer ABS Break pressure Indication for trailer
Gelb / yellow Rot / red Rot / red Rot / red Grün / green
Reduction of brakepressure Retarder Telma Parking brake Activate brake
Gelb / yellow Gelb / yellow Gelb / yellow Rot / red Gelb / yellow
Technische Schulung
Farbe / Color
AC100 Meldeleuchtenmodul D.doc
Technische Schulung
AC 100 Elektrik
Meldeleuchtenmodul E
Nr. 1 2 3 4 5 6 7 8 9 10
Funktion
Function
Differenzialsperre längs Differenzialsperre quer Kranbetrieb Hundegang 1 Hundegang 2 Umschaltung auf 3Punktsystem Federung gesperrt Achsen halten Hundegang Achsen heben
Differential lock longitudinal Differential lock transvers Crane operation Crab steering 1 Crab steering 2 Suspension 3 point setting
Gelb / yellow Gelb / yellow Gelb / yellow Gelb / yellow Gelb / yellow Gelb / yellow
Suspension lock Hold axles Crab steering Raise axles
Gelb / yellow Gelb / yellow Gelb / yellow Gelb / yellow
Technische Schulung
Farbe / Color
AC100 Meldeleuchtenmodul E.doc
Technical Training Chassis
AC100 Electrics
Equipment list - chassis A170 A300 A301 A302 A308 A310 A312 A320 A326L A326R A345 A360 A361 A386 A387 A390 A391 A392 A400 A401 A402 A403 A404 A410 A903 A904 A907 B2 B3 B57 B60 B61 B62 B63 B65 B66 B170 B171 B172 B301 B310.1 B310.2 B310.3 B310.4 B310.5 B310.6 B310.7 B322.1 B322.2 B323 B324.1 B324.2 B358.1 B358.2
Air conditioning Engine control MR Vehicle control FR Adaption module ADM Flasher relay Star point CAN Wiper impulse transducer Electric accelerator (FFG) Mirror adjustment left Mirror adjustment right Central lubricating system (control unit) 16-slot binary board 1 16-slot binary board 2 ABS electronics ABS information module Parking heater chassis timer Parking heater chassis control unit Parking heater chassis heater EPS Driving switch chassis Clutch control KS Automatic gear selection AG Retarder electronics RS ECU transmission Voltage converter 24/12 V Radio Radio telephone
Retarder coolant temperature sensor Retarder oil temperature sensor Pressure switch air conditioning Air conditioning Air conditioning Fuel level sensor Pressure switch brake light Pressure switch parking brake (5bar) Pressure switch parking brake (2bar) Pressure switch parking brake up (2bar) Pressure switch parking brake down (2bar) Pressure switch parking brake circuit 1 (5bar) Brake pressure display Pressure switch steering pump 1 Pressure switch steering pump 2 Pressure switch air filter 1 Sensor return filter 1 Sensor return filter 2 Proximity switch steering rod not locked Proximity switch steering rod unlocked
AC100 Betriebsmittelliste UW e.doc
Cab Engine Under passenger seat Under passenger seat Cab electrics Cab electrics Cab electrics Cab Cab Cab Rear cab Under passenger seat Under passenger seat Under passenger seat Cab electrics Cab Cab Cab Under passenger seat Cab Under passenger seat Under passenger seat Under passenger seat Under passenger seat Cab electrics Cab Cab
Cab Tank Beneath cab
Left panelling Left panelling Air filter Hydr. oil tank Hydr. oil tank Steering rod Steering rod Technical Training
Technical Training Chassis B359 B360 B370.1 B370.2 B370.3 B370.4 B370.5 B370.6 B401 E300 E301 E302 E304.1 E305.1 E305.2 E306.1 E306.2 E332.1 E336 F100.1 F100.2 F101 F102 F103 F104 F105 F106 F107 F108 F109 F110 F111 F112 F113 F114
F115 F116 F117 F118 F119 F120 F121 F122 F123 F124
Proximity switch 100 bar on axle 3 Proximity switch 100 bar on axle 3 Proximity switch level front top Proximity switch level rear right top Proximity switch level rear left top Proximity switch level front bottom Proximity switch level rear right bottom Proximity switch level rear left bottom Pulse generator tachograph Rotation chassis-superstructure Outrigger lighting Outrigger lighting Rear fog light Left headlight Right headlight Left dipped headlight Right dipped headlight Reverse light Cab lighting Main fuse chassis (50A) Main fuse chassis (100A) Ignition lock, voltage supply EPS, MKR, AGE, RET, back-up fuse for F102, F112, F119, F123, F124, F126, F127, F203, F207 (25A) Engine/transmission, charge monitor, load relay, neutral transmission display (10A) Socket (5A) Left headlamp, headlamp display (10A) Right headlamp (10A) Left dimmed headlamp (10A) Right dimmed headlamp (10A) Back-up fuse for F104, F105, F116, F117, (25A) Cigarette lighter (10A) Rear fog light, lighting (10A) Outrigger lighting (10A) Rotaflare light, reverse light, horn, brake light indicator display, handbrake (10A) Outriggers Operating hours, overspeed cutout, Scandinavian light, differential lock, axle locking, axle differential, crabwalk steering, steering of superstructure (15A) Back-up fuse F113, F114, F120, F125, load (25A) Parking light, instrument panel lighting Parking light, sign lighting, lighting outrigger operating box right Tachograph, MFD 10, (5A) Tachograph, MFD 10, indicator lights, (5A) Air conditioning, central lubricating system Air conditioning (25A) Air drier, horn, windscreen washer/wiper, mirror heating/adjustment, seat heating, timer for parking heater, fan (15A) CPU board (5A) Binary board, button – raise level/axles, unlock/lock crabwalk (10A)
AC100 Betriebsmittelliste UW e.doc
AC100 Electrics
Suspension cyl. Suspension cyl. Suspension cyl. Suspension cyl. Suspension cyl. Suspension cyl. Transmission Middle of slew rim Outrigger operating box Outrigger operating box Rear bumper Front bumper Front bumper Front bumper Front bumper Front bumper Cab Battery compartment Battery compartment Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics
Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Technical Training
Technical Training Chassis
AC100 Electrics
F125
Proximity switch level/crabwalk unlocked/locked, pressure switch axle 3 100 bar, switch axle 3 unlocked / locked (5A) Cab electrics F126 CPU board (5A) Cab electrics F127 Binary board, crabwalk (10A) Cab electrics F128 Rotaflare lights, indicator display, voltage converter CU interior lighting, cab lighting, superstructure operation (15A) Cab electrics F202 Terminal 15 engine control (10A) Cab electrics F203 Fault diagnosis engine (10A) Cab electrics F204 Fault diagnosis engine (10A) Cab electrics F205 Terminal 30 vehicle control FR (10A) Cab electrics F206 Terminal 30 ADM (10A) Cab electrics F207 Emergency control transmission, digital input MKR (15A) Cab electrics F208 Parking heater (15A) F209 Parking heater timer (5A) Cab electrics F210 Parking heater fan (10A) Cab electrics F211 ABS (5A) Cab electrics F212 ABS (10A) Cab electrics F213 ABS (10A) Cab electrics F214 ABS trailer (25A) Cab electrics G301 Three-phase generator Engine G302 Batteries 2 x 12V Rear cab H305 Indicator light fault transmission Cab H307 Indicator light fold out coupling Cab H308 Indicator light coupling applied Cab H308.1 Indicator left front Front bumper H308.2 Indicator left side H308.3 Indicator left rear Rear bumper H308.4 Indicator right front Front bumper H308.5 Indicator right side H308.6 Indicator right rear Rear bumper H309.1 Parking light left front Front bumper H309.2 Parking light right front top Cab H309.3 Parking light right side H309.4 Parking light left rear Rear bumper H309.5 Parking light left front H309.6 Parking light right front Front bumper H309.7 Parking light left front top Cab H309.8 Parking light left side H309.9 Marking lighting Rear bumper H309.10 Marking lighting Rear bumper H309.11 Parking light right rear Rear bumper H309.12 Parking light right front H309.13 Parking light right rear H309.14 Parking light left rear H310 Headlight display Cab H310.1 Brake light left Rear bumper H310.2 Brake light right Rear bumper H311 Indicator light level rear left Cab H312 Indicator light level front left Cab H314 Indicator light air filter Cab H316 Indicator light level rear right Cab H317 Indicator light level front right Cab H319 Indicator light steering pump 2 Cab H320 Indicator light steering pump 1 Cab AC100 Betriebsmittelliste UW e.doc
Technical Training
Technical Training Chassis H322 H323 H324 H325 H326 H327 H329 H330 H331 H332 H333 H334 H335 H337 H339 H340 H341 H342 H343 H344 H345 H347 H348 H349 H350 K101 K102 K103 K104 K105 K106 K107 K108 K109 K110 K111 K112 K113 K114 K115 K116 K117 K118 K119 K120 K201 K202 K203 K204 K205 K206 K301 L386.1 L386.2 L386.3 L386.4
Indicator light charge display Indicator light oil level engine Indicator light oil pressure engine Indicator light fault ADM/MR Indicator light overspeed Indicator light air filter Indicator light engine temperature Indicator light indicator vehicle Indicator light ABS info Indicator light ABS Indicator light ABS Indicator light brake pressure Indicator light indicator trailer Indicator light retarder Indicator light handbrake Indicator light activate brake Indicator light longitudinal differential lock Indicator light transverse differential lock Indicator light superstructure operation Indicator light crabwalk not locked Indicator light crabwalk unlocked Indicator light axle lock Indicator light hold axle Indicator light crabwalk selected Indicator light axle 3 top Relay overspeed Relay release operating hours Relay light Scandinavia Relay light Scandinavia Relay rotaflare light Relay handbrake Relay horn Relay steering of superstructure Relay crabwalk steering Relay ABS Relay ignition engine/transmission Relay condenser air conditioning Relay compressor air conditioning Relay ignition of superstructure Relay reverse signal Relay transmission neutral Relay crabwalk unlock/lock Relay ignition of superstructure Relay brake light Relay engine running Relay lock axles Relay switch to superstructure Relay switch to superstructure Relay handbrake Relay handbrake Relay transmission neutral Load voltage relay ABS sensor axle 1 left ABS sensor axle 1 right ABS sensor axle 2 left ABS sensor axle 2 right
AC100 Betriebsmittelliste UW e.doc
AC100 Electrics Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics ABS distributor box ABS distributor box ABS distributor box ABS distributor box Technical Training
Technical Training Chassis M301 M302 M303 M404 P100 P301 P400 R170 R301 R302 R303 R310.7 R325 R328 S300 S301 S302 S303 S305 S306 S307 S308 S309 S312 S313 S314 S315.1 S315.2 S316 S319.1 S319.2 S320 S321.1 S321.2 S321.3 S321.4 S326 S327 S328 S331 S332 S334 S335 S350 S355.1 S355.2 S360.1 S360.2 S370 S400 S404 S500 S501 S502 S503 S504
Starter Pump windscreen washing system Windscreen wiper motor Electric coupling Multi-function display MFA10 Tachograph Display transmission Air conditioning 150 Ohm 1.6 KOhm 3.3 KOhm Display brake pressure MFD10 Air drier Seat heater Ignition start switch Independent gas adjustment Crabwalk steering left Crabwalk steering right Button level front Button level rear right Button level rear left Button level automatic Central lubricating system Outrigger lighting Switch rotaflare light Switch rear foglight Door contact switch left Door contact switch right Switch warning indicator Plunger switch longitudinal lock actuated Plunger switch longitudinal lock actuated Plunger switch axle 1 connected Plunger switch transverse lock actuated Plunger switch transverse lock actuated Plunger switch transverse lock actuated Plunger switch transverse lock actuated Switch axle locking Switch - hold axles Switch crabwalk Switch longitudinal differential lock Switch transverse differential lock Switch seat heating Switch mirror heating Switch electr. mirror adjustment Crabwalk unlocked (axle 4) Crabwalk not locked (axle 4) Button raise axles Button raise axles Switch air conditioning Steering column switch Steering column switch cruise control/retarder Button outrigger front right vertical extend/retract Button outrigger front right vertical extend/retract Button outrigger front left vertical extend/retract Button outrigger front left vertical extend/retract Button outrigger rear right horizontal extend/retract
AC100 Betriebsmittelliste UW e.doc
AC100 Electrics Engine Cab Cab Rear cab Cab Cab Cab Cab Cab electrics Cab electrics Cab electrics Pedal Right of air tank Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Axle 4 Axle 2 Axle 1 Axle 2 Axle 4 Axle 1 Axle 5 Cab Cab Cab Cab Cab Cab Cab Cab Axle 4 Axle 4 Outrigger operating box L. Outrigger operating box R. Cab Cab Cab Outrigger operat. box (right) Outrigger operating box (left) Outrigger operat. box (right) Outrigger operating box (left) Outrigger operat. box (right) Technical Training
Technical Training Chassis S505 Button outrigger rear right horizontal extend/retract S506 Button outrigger rear left horizontal extend/retract S507 Button outrigger rear left horizontal extend/retract S508 Button outrigger rear left vertical extend/retract S509 Button outrigger rear left vertical extend/retract S510 Button outrigger rear right vertical extend/retract S511 Button outrigger rear right vertical extend/retract Y29 Solenoid valve Y30 Solenoid valve Y31 Solenoid valve Y32 Solenoid valve Y33 Solenoid valve Y34 Solenoid valve Y35 Solenoid valve Y36 Solenoid valve Y37 Solenoid valve Y38 Solenoid valve Y39 Solenoid valve Y44 Solenoid valve retarder Y94 Overspeed cutout Y304A-F Solenoid valve steering drive superstr. Y305A Crabwalk turn of wheels Y305B Crabwalk turn of wheels Y305C Crabwalk turn of wheels Y305D Crabwalk turn of wheels Y306A Outrigger front right vertical Y306B Outrigger front right horizontal Y307A Outrigger rear right vertical Y307B Outrigger rear right horizontal Y308A Outrigger front left vertical Y308B Outrigger front left horizontal Y309A Outrigger rear left vertical Y309B Outrigger rear left horizontal Y310A Outrigger retract Y310B Outrigger extend/suspension Y313 Longitudinal differential lock Y314 Transverse differential lock Y331 Switchover handbrake in superstructure Y343 Switchover steering circuit 1 Y344 Switchover steering circuit 2 Y355.1 Crabwalk unlock / lock axle 4 Y356.1 Crabwalk rear axle steering left Y356.2 Crabwalk rear axle steering right Y357 Hold axle 3 Y358A Steering rod unlock crabwalk Y358B Steering rod unlock/lock crabwalk Y361 Level front Y362 Level axles 3/4/5 left Y363 Level axles 3/4/5 right Y364.1 Limit switch spring-loaded cylinder Y364.2 Limit switch spring-loaded cylinder Y364.3 Limit switch spring-loaded cylinder Y364.4 Limit switch spring-loaded cylinder Y364.7 Axle differential axle 3/4 Y364.8 Axle differential axle 3/4 Y365 Disconnect suspension circuit front AC100 Betriebsmittelliste UW e.doc
AC100 Electrics Outrigger operating box (left) Outrigger operat. box (right) Outrigger operating box (left) Outrigger operat. box (right) Outrigger operating box (left) Outrigger operat. box (right) Outrigger operating box (left)
Engine compartment Hydraulic block
Outrigger cyl. Outrigger cyl. Outrigger cyl. Outrigger cyl. Outrigger cyl. Outrigger cyl. Outrigger cyl. Outrigger cyl.
Hydraulic block F.L. Hydraulic block F.L.
Technical Training
Technical Training Chassis Y366A Y366B Y367 Y386.1 Y386.2 Y386.3 Y386.4 Y386.5 Y386.6 Y386.7 Y386.8 Y420 Y422
Raise axles Release level Hold axles ABS system axle 1 left ABS system axle 1 left ABS system axle 1 right ABS system axle 1 right ABS system axle 2 left ABS system axle 2 left ABS system axle 2 right ABS system axle 2 right Pneumatic valve engine brake Pneumatic valve constant throttle
AC100 Betriebsmittelliste UW e.doc
AC100 Electrics
ABS distributor box ABS distributor box ABS distributor box ABS distributor box ABS distributor box ABS distributor box ABS distributor box ABS distributor box Engine compartment Engine compartment
Technical Training
Initial set-up for AC100 transmission 1
Requirements : - Set the tachograph in accordance with the tyre size, (code switch) - Bridge the neutral relay. - Set the parameters for FMR, ADM, ABS (according to tyre size) with HHT / Minidiag 2. - ABS – sensors / valves: check allocation in accordance with instructions with HHT / Minidiag 2. - Teach in accelerator pedal in ADM and FMR with HHT / Minidiag 2. - Teach in CAN – environment with HHT / Minidiag 2.
!! The ventilation procedure must be carried out very carefully, as the system must be properly vented to ensure correct operation of the clutch. The compressed air system must be completely filled!! !! Hydraulic lines must be correctly laid.
Ventilation circuit: emergency pedal – separator 2
Connect the ventilation unit to the fluid tank ( Fig. 1 ).
3
Connect the ventilation hose to the slave cylinder of the clutch separator (Fig. 2)
4
Fold out the emergency clutch pedal (Fig. 3). Switch on the ventilation unit.
5 6
7
8 9
Open the vent valve on the slave cylinder of the clutch separator (Fig. 2) and allow brake fluid to flow through for approx. 3 mins. Actuate the emergency clutch pedal quickly 3 times, holding it down for approx. 3 seconds on the last time. Then leave the brake fluid to flow for approx. 15 s without actuating the emergency clutch pedal. Step 7 must be repeated 12 times. Close the ventilation valve.
!! Secure the ventilation hose on the vent valve with a hose clamp. Collecting container must hold at least 5 litres. The ventilation unit must be completely full!! !! Turn the release knob in the clockwise direction (Fig. 4) !! The pressure in the ventilation unit should not fall below 1.5 bar!! !! Open the vent valve 90°.
Ventilation circuit: Separator – safety valve – clutch booster 10
11
12
13
14
15 16
Connect the ventilation hose to the clutch booster gear (Fig. 5).
!! Secure the ventilation hose on the vent valve with a hose clamp. Collecting container must hold at least 5 litres. The ventilation unit must be completely full!! Switch on the ignition and depress the !! During this procedure solenoid emergency pedal once valve M1 is placed under current and solenoid valve M3 on the safety valve ( Fig. 6 ) must not be placed under current. The system is switched over to the pedal circuit. Switch on the ventilation unit !! The pressure in the ventilation unit should not fall below 1.5 bar. The ventilation unit remains switched on during the ventilation process!! Open the ventilation valve on the !! Open the ventilation valve 90°. clutch booster ( Fig. 5 ) and allow brake fluid to flow through for approx. 3 mins. Actuate the emergency clutch pedal quickly 3 times and on the last time keep pressed down for approx. 3 seconds. Then allow brake fluid to flow through for approx. 15 secs. without actuating the emergency clutch pedal. Step 14 must be repeated 12 times. Switch off the ignition for at least 7 s.
17
Ventilation circuit: El. clutch – safety valve – clutch booster Fold in the emergency clutch pedal.
18
Switch on the ignition.
19
Leave the brake fluid to flow through for approx. 3 mins.
20
Close the ventilation valve.
21
Switch off the ventilation unit.
22
Check the foot clutch values via HHT / Minidiag 2.
23
If the differential value < 480 repeat the ventilation procedure from point 17 otherwise continue with point 25. Switch off the ignition for at least 7 secs.
24
!! During this procedure the solenoid valve M3 on the safety valve ( Fig. 6 ) is placed under current and the system is switched over to the automatic circuit!!
HHT – EPS(GS) – ACTUAL VALUE – VALUE 15 - Clutch pedal not pressed down, value should be between 900 and 990. - Press down the clutch. - Differential values for when the clutch is pressed and when it is not pressed should equal Min 480. - Write down the difference in values.
25 26 27 28 29 30
Teaching in control unit EPS(GS) Fill the compressed air system to the maximum. Apply the parking brake / switch off the ignition. Press down and hold the emergency clutch pedal. Press down and hold the function button and the neutral button. Switch on the ignition. Arrow flashing up / down. Teaching procedure is started When the display flashes ”N “ start the engine When the buzzer sounds release the emergency clutch pedal. When the buzzer sounds press down the emergency clutch pedal. When the buzzer sounds release the emergency clutch pedal. When the buzzer sounds press down the emergency clutch Teaching procedure ended. pedal. When “N “ is displayed release the emergency clutch pedal.
31
32
Release the function button and neutral button. Switch off the ignition for at least 30 secs. Fold in the pedal and then switch off the ignition Check the automatic circuit values via HHT – EPS(GS) – ACTUAL VALUE HHT / Minidiag 2. – VALUE 15 - Gear in neutral – value should be between 900 and 990. - Place in gear. - Differential values between neutral and in gear should equal Min 480. - Write down the value.
33
If the value < 480 or the difference between point 22 and 31 > 40 counts, repeat the ventilation procedure, commencing at point 34, otherwise continue with point 45
34 35
36 37
38 39 40 41 42 43
44
Continuing the ventilation procedure Switch on the ignition. Switch on the ventilation unit. !! The pressure in the ventilation unit should not fall below 1.5 bar. The ventilation unit remains switched on during the ventilation procedure!! Open the ventilation valve on the !! Open the ventilation valve 90°!! clutch booster ( Fig. 5 ). Actuate the semi-gear switch on the shift lever, then leave the brake fluid to flow through again for approx. 15 secs. without actuation. Step 37 must be repeated 12 times. Close the ventilation valve. Remove the ventilation unit. Adjust the fluid level in the compensator tanks. Check the ventilation valves to make sure that they are properly sealed Check the automatic circuit levels via HHT – EPS(GS) – ACTUAL VALUE HHT / Minidiag 2. – VALUE 15 - Gear in neutral – value should be between 900 and 990. - Place in gear. - Differential values between neutral and in gear should be Min 480. - Write down the value. If the value < 480 and the difference between point 22 and 43 > 40 counts, repeat point 34, otherwise continue with point 45.
45 46 46 47 48 49
50 51 52 53 54 55
Continue set up In the CU relay remove K152 / remove the neutral relay bridge. If possible delete fault MKR(KR). Carry out a clutch adjustment via HHT HHT – MKR(KS) – ACTIVATION – / Minidiag. CLUTCH ADJUSTMENT Instructions given by HHT / Minidiag Following successful adjustment of the clutch, replace relay K152. Teach in terminal W with HHT / HHT – FMR(FR) – TEACHING IN – Minidiag 2. TERMINAL W Instructions given by HHT / Minidiag Switch off ignition for at least 30 secs. Teaching in control unit EPS(GS) with automatic circuit Fill up compressed air system to the maximum Apply the parking brake / ignition off Emergency clutch pedal should be folded in. Press and hold in function key and neutral key. Switch on the ignition Arrows flashing up / down Teaching in procedure is started Display “N“ flashing Start engine Buzzer sounds 4x
56 57
“N“ is displayed Release the function key and neutral key. Switch off the ignition for at least 30 secs. Then switch on. Delete all faults in electronics system (if possible).
Teaching in procedure ended
Set up completed
Technical Training
AC 100 Counterweight
Couterweight cylinder old
B52 (53) slew enable
B50 (51) cylinder up
Lock valve
Technische Schulung
AC100 Gegengewichtszyl neu.doc
! FB155 V 3.0 NAME *GGW STEU ! : : : : : : :U E 25.1 :U E 23.5 := A 19.2 : :U E 25.1 :U E 23.4 := A 19.1 : : :U E 25.1 :UN E 23.3 :U E 23.6 := A 19.3 : :UN E 23.1 :U E 23.0 := A 19.4 : :U E 23.1 :U E 23.0 :UN E 23.3 :O( :U E 23.3 :U E 23.2 :U E 23.1 :) := A 19.6 : :UN E 23.3 := A 19.5 : :BE
08.02.2000
17:11
GGW Steuerung Verfahren, Auf-und Abr sten des GGW **********************
OW nach hinten Taste GGW ab Ventil GGW ab
ss over rear switch ccw down valve ccw down
OW nach hinten Taste GGW auf Ventil GGW auf
ss over rear switch ccw up valve ccw up
OW nach hinten GGW liegt nicht auf Taste Klaue zu Ventil Klaue zu
ss over rear ccw not on claw switch close claw valve close claw
Drehen nicht freigegeben GGW oben/unten GGW unten
slew not allowed ccw up/down ccw down
Drehen nicht freigegeben Zylinder oben GGW liegt auf
slew not allowed cyl. up ccw lays on claw
1 GGW liegt auf 1 Klaue auf 1 Drehen frei 1 Drehwerk frei GGW liegt nicht auf GGW entbolzt
ccw lays on claw claw open slew enabled slew enabled ccw lays not on claw ccw unpinned
Technical Training
AC 100 Counterweight
Counterweight cylinder
Cable track Position indicator bar
B 52 ( 53 ) slew - enable B 50 ( 51 ) Cylinder up Lock valve B54 ( 55 ) Clamp open B56 ( 57 ) Clamp closed ca. 60mm
B 58 ( 59 ) CWT in Position
Technische Schulung
AC100 Gegengewichtszyl neu e.doc
! FB155 V 3.0 NAME *GGW STEU ! : : : : : : :U E 25.1 :U E 23.5 := A 19.2 : :U E 25.1 :U E 23.4 :U E 23.7 :U E 23.2 :O( :U E 25.1 :U E 23.4 :U E 23.3 :) := A 19.1 : : :U E 25.1 :UN E 23.7 :U E 23.5 :O( :U E 25.1 :U E 23.6 :) := A 19.3 : :U E 23.0 :O( :U E 23.7 :U E 23.2 :UN E 23.1 :) := A 19.6 : :U E 23.3 :O( :U E 23.2 :UN E 23.7 :) := A 19.5 : :U E 23.2 :U E 23.7 := A 19.4 : : : :BE
29.06.2000
15:51
ZYL Steuerung GGW Verfahren, Auf-und Abrüsten des GGW **********************
OW nach hinten Taste ZYL ab Ventil ZYL ab
SS over rear switch cyl. down valve cyl. down
OW nach hinten Taste ZYL auf Klaue in Position Klauen auf
ss over rear switch cyl. up claw in position claw open
1 OW nach hinten 1 Taste ZYL auf 1 Klauen geschlossen 1 Ventil ZYL auf
OW nach hinten Klaue in Position Taste ZYL ab 1 OW nach hinten 1 Taste Klaue zu 1 Ventil Klaue zu ZYL oben 1 Zyl in Position 1 Klaue auf 1 Drehen frei 1 Drehwerk frei Klaue zu 1 Klaue auf 1 Zyl in Position 1 GGW entbolzt Klaue auf Zyl in Position GGW verbolzt A19.4 war GGW unten wird GGW verbolzt
ss over rear switch cyl. up claw closed valve cyl. up
ss over rear claw in position switch cyl. down ss over rear switch claw closed valve close claw cyl. up cyl. In position claw open slew enabled slew enabled claw closed claw opened cyl. In position ccw unpinned claw opened cyl. In position ccw pinned A19.4 was ccw down ccw will be pinned
Technical Training
AC 100 Axle loads
Counter weight - Axle loads 4 variations are possible 1. 0 t CW, approx. 9 t axle load (no hook block, no MBE) 2. 2 t CW approx. 9,6 t axle load ( with single sheave hook block) 2 x 1 t CW permanently mounted to the SS frame 3. 12/13,3 t CW approx. 12 t axle load (with hook block, 17m MBE) 2 x 1 t CW permanently mounted to the SS frame 10/11,3 t lifted with cylinders and pinned to the SS frame 1 x 6,7/8 t, 1 x 3,3 t while driving, the 6,7/8 t CW stays on the carrier, the 3,3 t plate is pinned to the SS frame 4. 25 t CW approx. 14 t axle load 2 x 1 t CW permanently mounted to the SS frame 23 t lifted with cylinders and pinned to the SS frame 1 x 8 t, 1 x 8,6 t, 1 x 3,3 t, 1 x 3,1 t while driving, the 8 t and 8,6 t CW stay on the carrier, the 3,3 t and the 3,1 t plates are pinned to the SS frame Is the crane equipped with 14‘‘ tires, you have to add the 1,3 t piece in the lower counter weight plate (6,7/8t).
Technische Schulung
AC100 Achslasten e
DEMAG
AC100
Axle loads and Counterweights
Counterweights at 60 t total weight 1.0 t fixed on either side of superstructure + 3.3 t fixed at superstructure + 5.3 t fixed at superstructure + 6.7/8 t basic to be laid upon carrier = 12 resp. 13.3 t total
05.07.00
8329
1
DEMAG
AC100
Axle loads and Counterweights 13.3 t counterweight (total weight: 60 t) Drive 10 x 8 x 8, tyres 16.00 R 25 8.0 t basic plate laid upon carrier (front) 5.3 t fixed at superstructure Central lubrication, rope box, tow coupling Hook block, 1 sheave at main boom
05.07.00
8329
2
DEMAG
AC100
Axle loads and Counterweights 12 t counterweight (total weight: 60 t) Drive 10 x 8 x 8, tyres 14.00 R 25 6.7 t basic plate, mounted at carrier front 5.3 t fixed at superstructure Central lubrication, rope box, tow coupling Hook block, 1 sheave 17 m jib
05.07.00
8329
3
DEMAG
AC100
Axle loads and Counterweights 12 t counterweight (total weight: 60 t) Drive 10 x 8 x 8, tyres 16.00 R 25 6.7 t basic plate, mounted at carrier front 5.3 t fixed at superstructure Central lubrication, rope box, tow coupling Hook block, 1 sheave 9 m jib
05.07.00
8329
4
DEMAG
AC100
Axle loads and Counterweights
Counterweights with 48 t total weight 1.0 t fixed on either side of superstructure = 2.0 to total counterweight
05.07.00
8329
5
DEMAG
AC100
Axle loads and Counterweights 2 t counterweight (total weight: 48 t) Drive 10 x 8 x 8, tyres 14.00 R 25 2 t fixed at superstructure Hook block, 1 sheave at main boom
05.07.00
8329
6
DEMAG
AC100
Axle loads and Counterweights 2 t counterweight (total weight: 48 t) Drive 10 x 8 x 8, tyres 16.00 R 25 2 t fixed at superstructure without hook block
05.07.00
8329
7
DEMAG
AC100
Axle loads and Counterweights
Maximum counterweight 5.3 t fixed at superstructure + 8.0 t basic plate, laid upon carrier + 3.1 t + 8.6 t = 25 t maximum counterweight
05.07.00
8329
8
DEMAG
AC100
Axle loads and Counterweights
Specialty: 8.6 t counterweight to be separated into:
2 units 2.7 t each and 1 unit 3.2 t
Advantage: Counterweight may be lifted with a standard truck loader
05.07.00
8329
9
Technical Training
AC 100 Telescope Telecylinder AC100
C-C D-D
Technische Schulung
E-E
AC100 Telezylinder e.doc
Telescope control AC100
Date: 08.09.99 Original: C. Quien
Page:1 of 11
1.0 Allocation of the Initiators in the LPU Fig. 1:
B1: “in front of” position Section locking tele 1 and 3 B2: “behind” position Section locking tele 1 and 3 B3: “in front of” position Section locking tele 2 and 4 B4: “behind” position Section locking tele 2 and 4 B5,B7,B9,B11: “in front of” position section pinning (1-4 sections), connected via sliding contact PP (see above) B6,B8,B10,B12: “behind” position section pinning, connected via sliding contact FOP (see above) B13: LPU locked B14: Scan pinning right B15: Scan pinning left B16: Scan locking right B17: Scan locking left
AC100 SVE II e neu.doc,
Page 1 of 11
Page 2
1.1 Definitions: „in front of“ position:LPU in telescoping-out direction with first initiator in switch position (locking/pinning) „behind“ position: LPU in telescoping-out direction with second initiator in switch position (locking/pinning) Fine position : LPU in telescoping-out direction with both initiators in switch position (locking/pinning) 1.2.1 Description of Locking and Pinning Unit Function Two times two inductive proximity switches are fitted on the top of the locking and pinning unit (B1-B4). These recognise the locking condition of the LPU and, in conjunction with the length transducer of the telescopic section, identify the individual tele sections. To prevent an incorrect identification of the sections as a result of length tolerances, 2 initiators record the switching line of the boom sections 1 and 3 (right side of the LPU), while two record the switching line of sections 2 and 4 ( left side of the LPU). The „in front of“ position of tele 1 and 3 is scanned by initiator B1, the „behind“ position by B2. The „in front of“ position of tele 2 and 4 is indicated by activation of initiator B3, the „behind“ position by initiator B4. The current tele section can therefore be clearly identified from the length signal and switch condition of the proximity switches. The initiators, which reach the switch line first when telescoping out, mark the „in front of“ position. When the second initiator („behind“ position) reaches the switch line, the "fine position" is reached, i.e. the lock pins are "shot" or "drawn". The locking valves must be activated until the LPU sensors have registered a safe limit condition. These limit conditions are: LPU unlocked and pinned LPU locked and unpinned LPU locked and pinned Control of the LPU functions is assumed by a C-task ( C -programming ), which is performed in a shorter time interval. Because of the mechanical design of the LPU, the situation is prevented in which a section is unpinned without first being locked. The pinned status is queried via a switch gate, which moves with the pinning mechanism. The combination of the switch signals of a total of five initiators allows a precise allocation of the current pinning or locking status of the LPU. The allocation of the initiator conditions, as shown in the logic chart in diagram 2, shows the possible pinning and locking conditions of the LPU.
AC100 SVE II e neu.doc,
Seite 2 von 11
Page 3
Logic chart/locking and pinning conditions Fig. 2.: B13 B14 B15 B16 B17
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1
0 0 0 0 1 1 1 1 0 0 0 0 1 1 1 1
0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1
0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1
1 1 1 1
0 0 0 0
0 0 0 0
0 0 1 1
0 1 0 1
1 1 1 1 1 1 1 1 1 1 1 1
0 0 0 0 1 1 1 1 1 1 1 1
1 1 1 1 0 0 0 0 1 1 1 1
0 0 1 1 0 0 1 1 0 0 1 1
0 1 0 1 0 1 0 1 0 1 0 1
Status LPU
switched not switched
ERROR ERROR ERROR ERROR ERROR ERROR ERROR ERROR ERROR ERROR ERROR ERROR LPU moving LPU moving LPU moving Unlocked & pinned LPU moving ERROR ERROR Locked and unpinned LPU moving ERROR ERROR ERROR LPU moving ERROR ERROR ERROR Locked & pinned ERROR ERROR ERROR
Pinned & unlocked
switched not switched
locked & unpinned
switched not switched
locked & pinned Fig. 3: Activated solenoid valves: Speed Max 100mm/s 40 mm/s 10 mm/s
Telescope in Y16.2,Y16.3,Y16.4 Y16.2,Y16.3,Y16.4 Y16.2,Y16.3,Y16.4 Y16.2,Y16.3,Y16.4, Y16.5
Telescope out Y16.1 Y16.1 Y16.1 Y16.1
Fig. 4: Default values prop. valve flow - telescope: Speed Max 100mm/s 40 mm/s 10 mm/s
Telescope in Y16.2, Y16.2, Y16.2, Y16.2,
AC100 SVE II e neu.doc,
mA mA mA mA
Telescope out Y16.1, Y16.1 Y16.1 Y16.1
mA mA mA mA
Seite 3 von 11
Page 4
1.2.2 Semi-automatic function process Semi-automatic tele preselection: The crane operator selects a boom configuration using the input menu and, as a result, specifies a telescoping process and a prescribed sequence. The telescoping sequences are coordinated by the tele control system. As the balance of the head weight is changed within the boom during telescoping, the LPU has to be returned to its end position once the telescoping sequence has been completed . The new load may only be enabled once the LPU has returned to the area of the boom foot section. This also prevents the oil volume in the hydraulic tank from reaching excessively high temperatures. The crane operator specifies the desired telescoping direction and speed via the pilot control sensor. The LPU moves out of its basic position towards the rear bearing of the selected section at the preset speed. Once the control system detects a "need for action", the system reacts after a specified time; this strategy remains the same for all LPU actions, and is explained in more detail below:
Speeds during telescoping
200 mm before PP
PP locking reached
Position locking reached
Section locked or unlocked
Position pinning reached
Section pinned or unpinned
Vmax
80-100 mm/s
40mm/s 10mm/s
AC100 SVE II e neu.doc,
Seite 4 von 11
Page 5
1.2.3 Locking and unpinning boom sections Input requirement: LPU unlocked, all sections pinned. Locking: The LPU travels to the locking position at the speed specified with the pilot control lever. Independent of the movement of the pilot control sensor, the telescoping movement is reduced to approx. 80-100 mm/s (Fig. 3) approx. 200 mm before the desired locking position is reached. When the LPU reaches the „in front of“ locking position of the section prescribed by the control system during the telescoping procedure, (proximity switch B1 or B3 activated), the telescoping speed is limited to approx. 40mm/s (Fig. 3). At the same time a C-routine monitors when the exact position is reached from the moment that the „in front of“ position is reached (proximity switch B1 or B3 activated). As soon as the corresponding proximity switch „behind“ position is reached (B2 or B4), the locking bolt is "shot" and the telescoping speed reduced to 10 mm/s (Fig. 3), whereby the SPS must continue to actuate the safety valve Y26 until the "locking" procedure is completed (B13 activated). Switching over: Once the PDC receives the message "locked and pinned" (B13 ,B14 and B15 activated), the direction arrows in the display are switched over from "lock" to "unpin" in the following program cycle and the telescoping speed is increased back to 40mm/s. The arrows of the „in front of“ and „behind“ position for the section locking in the display must be different to those for section pinning (eg inverse/normal). Unpinning: The crane operator telescopes in the displayed direction until the pinning sensors of the selected rear bearing report back the fine position, with whose help the selected section can be unpinned by the locking and pinning unit once the load has been transferred (Y27). Here, too, the control ensures that self-activation of the valve control "unpin section" (Y27) is deactivated again when the end position "unpinned and locked" is reached. Depending on the position of the boom section once the sensors have switched from "lock" to "unpin" the control must react as follows: „in front of“ position section unpin: Sensors register "in front of position" of the section unpinning reached (e.g. „in front of“ position for the 2nd boom section corresponds to B7 and B8 being activated). The control enables movements for telescoping in and out, but specifies a corresponding direction, if the target position has been exceeded by ∆L= ± 200 mm.
AC100 SVE II e neu.doc,
Seite 5 von 11
Page 6
„Behind“ position section unpin: Sensors register "behind position" for section unpinning reached. The control enables movements for telescoping in and out, but specifies a corresponding direction, if the target position has been exceeded by ∆L= ± 200 mm. The display provides information on the necessity of a change in direction and the operator must reverse the telescoping movement of the boom using the pilot control lever. Fine position section unpin: Sensors register "fine position" for section pinning reached. The C-task releases the solenoid valve for the unpinning (Y27) and continues to activate it until the section is unpinned and locked (initiators B13,B16 and B17 activated) and the requirements for stopping the unpinning procedure are met.
1.2.4 Procedure for transporting, pinning and unlocking boom sections Input requirement: section locked and unpinned Pinning: Independent of the movement of the pilot control sensor, the telescoping movement is reduced to approx. 80-100 mm/s approx. 200 mm before the desired pinning position is reached (proportional valve Y16.1). When the section reaches the „in front of“ pinning position prescribed by the control system during the telescoping procedure, (proximity switch B5,B7,B9 or B11 activated), the telescoping speed is limited to approx. 40mm/s. At the same time, from the moment the „in front of“ position is reached (proximity switch B5,B7,B9 or B11 activated), a C-routine monitors when the exact position of the pinning position prescribed by the control system is reached. As soon as the corresponding proximity switch „behind“ position (B6,B8,B10 or B12) is reached, the section pin is "shot" and the telescoping procedure is reduced down to 10 mm/s (Fig. 3, Fig. 4), whereby the SPS must make sure that the pinning valve Y28 remains activated until the entire "pinning" sequence is completed. Switching over: Once the PDC receives the message "locked and pinned" (B13 ,B14 and B15 activated), the direction arrows in the display are switched over from "pin" to "unlock" in the following program cycle and the telescoping speed is increased back to 40mm/s. The arrows of the „in front of“ and „behind“ position for the section locking in the display must be different to those for section pinning (eg inverse/normal). Unlocking: The crane operator continues to telescope until the sensors of the LPU report the exact unlocking position of the LPU (B1&B2 or B3&B4 activated). With this signal the locking pin is drawn (Y25). Here, too, the control ensures that self-activation of the valve control "unlock section" (Y25) is deactivated again when the limit position "pinned & unlocked" is reached. Depending on the position of the boom section once the sensors have switched from "pin" to "unlock" the control must react as follows:
AC100 SVE II e neu.doc,
Seite 6 von 11
Page 7
„in front of“ position lock / unlock: Sensors register "„in front of“ position" for section locking reached. The control enables both telescoping in and out, but specifies a corresponding direction if the target position has been exceeded by ∆L= ± 200 mm.
„behind“ position lock / unlock Sensors register "„behind“ position" for section locking reached. The display provides information on the necessity of a change in direction and the operator must reverse the telescoping movement of the boom using the pilot control lever. The control enables movements for telescoping in and out, but specifies a corresponding direction, if the target position has been exceeded by ∆L= ± 200 mm.
Exact position lock / unlock Sensors register "exact position" for section locking reached. The C-task releases the solenoid valve for unlocking (Y25) and continues to activate it until the section is pinned and unlocked and the requirements for stopping the unlocking procedure are met.
AC100 SVE II e neu.doc,
Seite 7 von 11
Page 8
2.0 Manual Control: The manual control is not located on the tele control system, and enables the operator to carry out a manual selection of possible locking/pinning positions, depending on enabled sensor conditions. If the manual control program option is selected, the maximum possible telescoping speed is limited to 150mm/s. Starting from this level, there is a further reduction of the speed to 80mm/s if manual selection of an LPU function is made and finally a reduction to 40mm/s when the „in front of“ or „behind“ position is reached. It is to be assumed that, during crane operation, operating conditions may occur, either as a result of maloperation or sensor failure, which can no longer be covered by the tele control system. It is therefore necessary to enable the crane operator to intervene manually in the telescoping and pinning sequences. In order to make a decision on which movement can be authorised, however, it must be possible to determine whether a) maloperation or b) sensor failure has caused the "exit" from the tele control system. The type and extent of the error determines the reaction that is required. In case a) it is relatively easy to reaccess the control system by configuring the equipment to the requirements for the next programme step in the telescoping sequence. 2.1
Block overview – telescoping sequence Start
Read in Data Travel to section
Lock and unpin section
Telescope section to target position
Pin and unlock section
All sections processed?
Once the "circular structure" of the telescoping sequence has been interrupted as the result of a fault, the entry conditions for the next step in the programming sequence must be selected manually and passed on to the tele control system for further processing. All steps necessary for this are indicated to the operator on the display. All sensor information as well as the actual length value are output via the display.
no
yes Move LPU to basic position
End
AC100 SVE II e neu.doc,
Seite 8 von 11
Page 9
2.2 Troubleshooting If the control system does not receive all information as the result of system faults or sensor component failures, specified procedures can be authorised. In any case, a fault evaluation has to be carried out, the result of which determines what further action is required.
2.2.1 Initiator failure – position scanning (B1-B12): Telescoping out: Fault in „in front of“ position: If, when telescoping out, the initiator for the „behind“ (secondary) position (B2,B4,B6,B8,B10,B12) is activated without the „in front of“ position signal (B1,B3,B5,B7,B9,B11) being present, there is a fault in the logic for the „in front of“ position. Action: If the initiator for the „behind“ position is triggered first, the equipment must be telescoped in until the initiator switches off, and then telescoped out again until the initiator is activated again. A fault message with specification of the initiator designation is output. Fault in „behind“ position: If, when telescoping out, the initiator for the „in front of“ position is activated and then deactivated again without any signal from the „behind“ position being given, there is a fault in the logic for the „behind“ position. Action: The system is telescoped out until the signal for the „in front of“ position switches off. Telescope in again until the initiator is activated again. A fault message with specification of the initiator designation is output. Telescoping in: The switch positions for the „in front of“ and „behind“ position are designed for the telescoping out procedure, in order to have a precise allocation to the sensor at all times. Accordingly, the above-mentioned logic is reversed when telescoping in. Fault in „in front of“ position: If, when telescoping in, the initiator for the „in front of“ position (B1,B3,B5,B7,B9,B11) is activated without the „behind“ position signal being given first (B2,B4,B6,B8,B10), there is a fault in the logic for the „behind“ position. Action: If the initiator for the „in front of“ position is activated first, the system must be telescoped out until the initiator switches off, and then telescoped in again until the initiator switches back on again. A fault message with specification of the initiator designation is output. Fault in „behind“ position: If, when telescoping in, the initiator for the „behind“ position is activated first and is then switched off again, without the „in front of“ position signal being given, there is a fault in the „in front of“ position logic.
AC100 SVE II e neu.doc,
Seite 9 von 11
Page 10
Action: The system is telescoped in until the signal for the „behind“ position switches off. It must then be telescoped out again until the initiator is reactivated. A fault message with specification of the initiator designation is output. For the above-mentioned cases, the target section is probably exactly in position. For diagnosis purposes, a length transducer signal can be additionally evaluated, if it is ensured that a length is stored when the first position signal is reached, the exact (fine) position must be located within a distance of max 100mm from this position. A length query must be carried out in order to ensure that the sensors do not evaluate a "wrong" section. The required locking and pinning procedures are authorised via sensors B13, B14 and B15. The authorised functions are selected using the soft keys. 2.2.2 Initiator failure LPU status analysis (B13,B14,B15): Fault observation: Taking the truth table Fig. 1 as the basis for the function of the LPU status sensors, only certain initiator errors can be covered by the system program. If, as a result of a failure, a bit combination results which corresponds to that of a fault, it is not possible to determine the locking and pinning condition of the LPU. For reasons of safety, the fault of the status sensors of the LPU can therefore only be dealt with if a valid bit combination in line with Fig. 1 is caused. Fig. 4: LPU fault sequence
Pinning and locking sequences of the LPU Emergency control sequence 4
START LPU manual
LPU position OK ?
no
Enable manual locking
yes
LPU pinned
no
yes Enable manual locking and unlocking
LPU unlocked & pinned
yes Enable manual locking
no
LPU locked
yes Enable manual pinning and unpinning
no
LPU locked & pinned
yes Enable manual unlocking and unpinning
no
LPU locked & unpinned
no
Fatal error! Direct operation only possible using code!
yes Enable manual pinning
ENDE
AC100 SVE II e neu.doc,
Seite 10 von 11
Page 11
2.2.3 Failure of the length transducer Using the length transducer information, the system decides when the maximum telescoping speed has to be reduced. Under operating conditions, maximum telescoping speeds of 300 mm/s can be reached, which corresponds to a current change of approx. 500 µA /s. If this limit value is exceeded, there is a fault in the length transducer. If no or only incorrect length information can be evaluated, all locking/pinning procedures of the manual control authorised by the LPU sensors can be selected. The fault is indicated on the display and dealt with as follows: a) b) c) d) e)
The control switches to "manual operation" Telescoping in and out is authorised Manual LPU functions are authorised Maximum telescoping speed is reduced to 150 mm/s Fault output on the display
AC100 SVE II e neu.doc,
Seite 11 von 11
Technical Training
AC 100 PDC
Manual telescope control The following errors of the LPD sensors can be eliminated by an uncoded handcontrol: 1. 2. 3. 4. 5. 6.
B13=0, B14=1, B15=1, B16=0, B17=0 B13=0, B14=1, B15=1, B16=0, B17=1 B13=0, B14=1, B15=1, B16=1, B17=0 B13=1, B14=0, B15=0, B16=0, B17=0 B13=1, B14=0, B15=0, B16=0, B17=1 B13=1, B14=0, B15=0, B16=1, B17=0
Those configurations of the sensors can also occur when the LPD is on its way to pin or unpin. Therefore the error message in the PDC screen will only appear after 5 seconds of the above mentioned LPD positions. The following screen will appear:
This screen tells you to press the
Technische Schulung
button.
AC100 Handsteuerung Telekop e.doc
Technical Training
AC 100 PDC
In this screen you can activate the manual uncoded control with the button. The next screen will appear. The system will propose something to eliminate the fault, here „unlock“.
If the system proposes „unlock“, but the button „pin“ is pressed, then the system displays that „action“ on the screen, but nothing will happen. The signal will not be sent to the solenoid valve. (see next screen).
Technische Schulung
AC100 Handsteuerung Telekop e.doc
Technical Training
AC 100 PDC
When the proposed button is pressed, the screen shows it on the left side of the icons and the system activates the solenoid valve which is displayed on the right side of the icons( here Y25). The telescope speed will be reduced (Y16.5).
If this action has solved the problem than the proper proximity switches are activated again and the screen will automatically change back to normal and then the automatic telescope control will be activated again.
Technische Schulung
AC100 Handsteuerung Telekop e.doc
Technical Training
AC 100 PDC
In the SVE (LPD) screen the coded manual control can be activated with the button and a code. If the button is pressed without being displayed on the PDC screen, the manual control screen appears, but the buttons are not active.
Technische Schulung
AC100 Handsteuerung Telekop e.doc
Technical Training
AC 100 SVE
B3 in front of locking position Tele 2/4
B2 behind locking position Tele 1/3 B1 in front of locking position Tele 1/3
B4 behind locking position Tele 2/4
+24V slider for proximity switch pinning Tele 1-4
Ground slider for proximity switch pinning Tele 1-4
Slider for signal „in front of pinning position Tele 1-4“
Slider for signal „behind pinning position Tele 1-4“
Technische Schulung
AC100 SVE Neu e
Technical Training
AC 100 Telescope
Length and angle indicator
Angle indicator
Length indicator main boom Length adjustment
Length indicator telescope cylinder
Technische Schulung
AC100 Längengeber e.doc
Technical Training Superstructure
AC 100 Telescope
Sliders locking and pinning
Slider „+ 24V“
Position locking
Slider „ground“
Slider „in front of pinning position“
Slider „behind pinning position“
Technische Schulung
AC100 Schleifkontakte Verbolzung e.doc
Technial Training Superstructure
AC 100 Telescope
Main boom rear view
Locking position tele 2 Locking position tele 1 Locking position tele 4 Locking position tele 3
Pinning position tele 1,2,3,4 pins tele 1,2,3,4
Technische Schulung
pins tele 1,2,3,4
AC100 Ausleger Innenansicht e.doc
Technical Training
AC 100 Telescope
Slider for locking position
Sensor „behind“ pinning position B6,B8,B10,B12
Pin for „boom pinning“
Sensor „in front of“ pinning position B5,B7,B9,B11
Roller for LPU centering
Hole for pinning
Hole for boom locking
Pin for „boom pinning“
Roller for LPU centering
Technische Schulung
AC100 Hauptausleger von hinten e.doc
Technical Training
AC 100 Telescope
Sensors „in front of“ and „behind“ pinning position
Proximity switches
Signal
Technische Schulung
+ Signal
AC100 Näherungsschalter Verbolzen e.doc
Technical Training
AC 100 Telescope
unlocking
unpinning
locking
pinning
Technische Schulung
AC100 hyd. Notsteuerung Tele e.doc
Technical Training Superstructure
AC 100 Telescope
Cross section main boom
Technische Schulung
AC100 Hauptausleger Schnitt quer e.doc
Technische Schulung
AC 100 Main boom
Cut through main boom
Technische Schulung
AC100 Auslegerschnitt e.doc
Notice of modification No. : 58-75
Type of crane: Telescopic crane
Model: AC 100
Date:
Established by:
01.02.2001
Dept. 8331.5 Michael Weber
Phone: +49 6332/ 83-1744
Fax No.: +49 6332/ 91011594
e-mail: michael.weber @dematic.de
Solving telescopic problems under unsupervised manual operation
Remarks:
Modification has been carried out on : Modification has been carried out by: Order ref. no.: Model:
AC 100
Serial number: Country / Place / Date Signature: Please complete the sections above and return this page and page 4 to Product support department (Mr. Weber Fax no. see above)!
-------------------------
--------------------------
Peter Benien
Michael Weber Page 1 of 13
Notice of modification No. : 58-75
Table of Contents
Page 3
1. General 1.1. Diagnosing faults and determining the condition of the LPU (Locking and Pinning Unit)
Page 4 Page 5 and 6
1.2. Rectifying faults
Page 7
1.3. Possible causes of faults
Page 8 and 9
2. Menu guidance and code input 2.1.
Menu guidance and monitor displays up to code input - Overview of signals / proximity switches
Page 10
2.2. Entry of generic code
Page 11
3. Checking the length transducer signals 4. Activating "RESET"
Page 12
5. Activating "RESET LK"
Page 13
6. Determining the generic code
Page 2 of 13
Notice of modification No. : 58-75
1. General: The reason for this documentation is to provide support to service personnel or colleagues on call in their work of rectifying faults (using "unsecured manual operation"). It is not intended to extensively explain the design and function of the LPU and other elements of the telescopic boom. We strongly recommend that you obtain more detailed information with the help of relevant training materials or queries if questions or uncertainties remain. This text can only deal with occurring faults and their rectification in a very general way. Simply put, it can be said that a majority of faults occur in the following manner: 1. 2. 3. 4.
A pinning / unpinning procedure has not been fully carried out (e.g. a pin is stuck). A locking / unlocking procedure has not been fully carried out (e.g. a locking bolt is stuck). The LPU has carried out pinning / locking procedures in the wrong section. The crane operator accidentally activates a reset of the tele control system.
To keep matters simple, we recommend that when the above mentioned faults occur, you retract all boom sections to their rear end position, pin lock them in that position, then retract the LPU and carry out a "RESET". This procedure is described in more detail under point 1.2. Required tools: Item
Description
Description, instructions
1
Laptop
Program PATKey V 2.00 is required (can be obtained by enquiring at Dept. 8315)
1.1. Diagnosing faults and determining the condition of the LPU : Before you actually begin to rectify any faults please clarify the following points (please use page 4 for this and then send it back to us): 1. Which fault has occurred and during which activity did it arise? 2. Which proximity switch signals and other signals are there? (it would be best to call up illustration 3 for this) 3. Is a fault message (e.g. E 87) displayed? If so, which one? 4. Which suggestion is the PDC offering? 5. Does the schematic illustration of the boom shown on the display correspond to the actual condition? (see point 2.1.) 6. Can the LPU move freely or is it stuck? This can be ascertained by extending / retracting the LPU and checking if a section moves or the length transducer signal "-B703" changes at the same time. 7. Does the length transducer "-B703" (length transducer of the LPU) display an extension length and is it possible to assume that this value is correct? (if necessary, check with the display of "-B702" [exterior length transducer, total length of main boom]) After clarifying these questions, the occurring fault can be analysed and the procedure for rectifying it can be decided upon.
Page 3 of 13
Notice of modification No. : 58-75
Fault report Serial number.: 77 ............. Date: ........................ Time: .....................
Temp.: ................°C
Crane operator / Service personnel: ............................................ Phone: .................................................. Immediately after a fault has occurred, please fill in the following illustrated LPU diagram. Complete all areas marked with "...." (e.g. the areas for fault code, length code, etc.) and mark the pending signals (e.g. "-B1", "-Y16.3", etc.) with a tick. Please note the "DESIRED" and the "ACTUAL" values of the length code. Other comments (fault origin, possibly feeder valve pressure, the time between the two last telescopic procedures, rectifying attempts of the crane operator, etc.): .............................................................................................................................................................................................................
.............................................................................................................................................................................................................
Fault occurred during (please tick):
W telescoping in
W telescoping out
W with case W without case
Page 4 of 13
Notice of modification No. : 58-75
1.2. Rectifying faults : The following combinations of LPU proximity switches are required for safe LPU operation. We strongly recommend that you only carry out a forwards / reverse movement when one of the following conditions is in place:
B13
B14
B15
B16
B17
Condition of the LPU
0
1
1
1
1
Unlocked & Pinned
1
0
0
1
1
Locked & Unpinned
1
1
1
0
0
Locked & Pinned
In almost every case, the simplest way of rectifying faults is by following a procedure during which all extended telescopes are individually retracted and a reset is then actuated. For this procedure, please carry out the necessary steps in the following order: §
Can the LPU move freely and to which length is it extended? If the LPU cannot move freely, it is necessary to find out during which procedure it became stuck. This procedure must then be reversed (it might be necessary to move the LPU slightly forwards or backwards). Then you must clarify the direction in which the LPU must be moved in order for it to achieve "fine position locking" of the boom section that is extended to the greatest length. Please take the following into consideration: - The "empty" LPU must be "unlocked & pinned". - While extending the LPU, each of the proximity switch signals "B5, B7, B9, B11" and "B6, B8, B10, B12" are shown on the monitor in black.
§
The length of the extension distance from the LPU to the 45% hole is 4.5m +/- 0.5m, to the 90% hole it is 9.0m +/- 0.5m and to the 100% hole it is 10m +/- 0.5m.
§
The boom section can be locked when "fine position locking" has been reached. This position is indicated when the proximity switch signals "B1" and "B2" (in BS 1 and BS 3) and / or "B3" and "B4" (in BS 2 and BS 4) are displayed at the same time. If, for example, only "B1" (= preposition) is displayed, the LPU must be extended some more. In contrast, if only "B2" (= postposition) is displayed, it must be slightly retracted. After the generic code has been entered, the boom section can be locked by pressing the key marked
.
Page 5 of 13
Notice of modification No. : 58-75
§
If the system is extended a little further following the locking procedure, "fine position pinning" is reached immediately afterwards. This position is indicated when the proximity switch signals "B5, B7, B9, B11" and "B6, B8, B10, B12" are displayed at the same time. If only one proximity switch signal is displayed, it is necessary to move the system forwards or backwards, depending on the displayed signal. Then the section can be unpinned by pressing the key marked
.
§
After unpinning, the key must be pressed again in order to cancel the speed reduction of the tele cylinder (the "-Y16.5" signal indicates that the speed reduction is activated).
§
The section can now be moved to its rear end position. In the area of the rear end position, "fine position pinning" is indicated when the proximity switch signals "B5, B7, B9, B11" (= preposition) and "B6, B8, B10, B12" (= postposition) are displayed at the same time. In this case, the section can be pinned by pressing the key marked
§
After pinning, "fine position locking" can be reached in most cases by extending a little bit further. When the proximity switch signals "B1" and "B2" and / or "B3" and "B4" are displayed, the key marked
§
.
can be pressed for unlocking.
After the completed unlocking procedure, the LPU is released again and the key marked must be pressed again in order to cancel the speed reduction of the tele cylinder (the "-Y16.5" signal indicates that the speed reduction is activated).
§ §
After this, the next extended section can be tackled. After completed locking / unpinning procedures, it can be retracted, etc.
Page 6 of 13
Notice of modification No. : 58-75
1.3. Possible causes of faults: The pins in the LPU or in the boom sections can become stuck if the speeds are too high during the locking and pinning procedures. Speeds can become too high if speed reduction is not functioning correctly. The reason for this can be contaminated or bridged contacts caused by material wear. In such a case, please check the following areas: § check the grinding contacts in the rear bearing of the relevant section for contamination and wear (see following picture), § check the plug-in connections, via which LPU signals are transmitted, for damp and other contamination.
Check these areas
Page 7 of 13
Notice of modification No. : 58-75
2. Menu guidance and code input: 2.1. Menu guidance and monitor displays up to code input:
Figure 1 (LLD picture)
By pressing the button marked vated.
on the LLD screen the following LPU picture is acti-
Figure 2 (LPU picture) The following display will be shown when the key marked 3).
is pressed (Figure Page 8 of 13
Notice of modification No. : 58-75
Figure 3 Lock
Unpin
Pin
Unlock
LPU
section
section
LPU
The RESET button is omitted in this picture in the software version 1.34 (data).
Overview of the signals / proximity switches: "-B1" = Preposition locking tele 1 / tele 3
"-B6, -B8, -B10, -B12" = Follow-up pos. pinning
"-B2" = Postposition locking tele 1 / tele 3 "-B3" = Preposition locking tele 2 / tele 4 "-B4" = Postposition locking tele 2 / tele 4 "-B13" = LPU locked
"-B16" = Enquiry locking right
"-B14" = Enquiry pinning right
"-B17" = Enquiry locking left
"-B15" = Enquiry pinning left "-B5, -B7, -B9, -B11" = Prelim. position pinning "-Y16.5" = Valve speed reduction 10 mm/s (telescopic cylinder) "-B703" = Length transducer interior "
" = System suggestion (
means: PDC has no suggestion)
if box is black: valve is switched if box is black: valve is preselected Page 9 of 13
Notice of modification No. : 58-75
2.2. Entry of generic code:
When the key marked is pressed again when figure 3 is displayed, the following display will be shown (figure 4). The generic code must be entered at this point. You will obtain it by calling up the program "PATKey" on the laptop (see point 6 of this documentation).
Figure 4 You will come to the following figure 5 after confirming your entry. It is now possible to switch the indicated valves unsecured by the PDC.
Figure 5 Lock
Unpin
Pin
Unlock
LPU
section
section
LPU Page 10 of 13
Notice of modification No. : 58-75
3. Checking the length transducer signals :
The following display will be shown on the monitor by pressing the LPU picture (see figure 2) is indicated.
key when the
Picture 6 You can check here if both length transducer values are approximately identical. This is indicated by displaying "Length 1 MB". The top value (here: 33.6 m) is the one measured by the length transducer, the bottom value (here: 33.7 m) represents the calculated value. If the difference between these two values is > 0.4, the fault message "E 87" will appear. A larger difference between the values indicates e.g. the following fault: § Exterior length transducer is damaged or the rope has been reeled in unevenly 4. Activating "RESET" : By the pressing the key marked , the graphic ACTUAL values of all telescopes (see picture 6: 90%, 45%, 90% and 0%) are set to "0". This is why this key may only be activated when all telescopes actually are set to "0%" and the LPU is fully retracted. Note: from software version 1.34 (data), a reset can be activated by pressing the key only after the generic code has been entered. Reset can also be activated with "Ignition Off / On" when the following requirements are fulfilled: § all sections are retracted to 0% and are pinned, § the LPU has been retracted completely and is locked and unpinned.
Page 11 of 13
Notice of modification No. : 58-75
5. Activating "RESET LK" :
The following display is shown on the monitor by pressing (see figure 2) is indicated.
when the LPU picture
Figure 7
Operation mode can be selected by pressing the key. The selected operation mode is shown inversely in the space "TYP ..." (here "TYP HA"). Now "RESET LK" can be selected using the curser keys (↑) or (↓). Another important note on this: "RESET LK" resets the PDC to a defined length code. Accordingly, this can only be switched when an extension procedure has been completely carried out. Example: "LK 17" was selected (4x 90%), however, there was a fault after the second BS was moved to the 90% position. Now, the 2nd BS can be manually pinned and unlocked in the corresponding position with the help of the generic code. The correct position is most quickly found by first driving the LPU back to approx. 8m and then by driving it forward, taking the length transducer signal "-B703" and the proximity switch signals into consideration. At 9.0m +/0.5m, the signals "B5, B7, B9, B11" and "B6, B8, B10, B12" should appear and shortly afterwards, the signals "-B3" and "-B4". When "B5, B7, B9, B11" = 1 and "B6, B8, B10, B12" = 1 you can pin, after further extension (when "-B3" = 1 and "-B4" = 1) you can unlock. Then the LPU is driven back, the first BS is manually locked and unpinned and brought into the 90% position. After a pinning and unlocking procedure is manually carried out, the LPU is once again driven completely back. Now the actual length code (LK) must be entered into the HA program; only once this is done can a "RESET LK" be actuated. After "RESET LK", the matching operation mode must be selected in picture 7 (e.g. here: "TYP HA", "Counterweight 25.0", "Outrigger support area 7.0" und "Reeving number of the hoist rope: 10" After these measures have been taken, the PDC is ready for operation again. By following this procedure, you will save time as you are not required to bring back all pinned boom sections. Page 12 of 13
Notice of modification No. : 58-75
6. Determining the generic code The allocation of the generic code can be started on the WINDOWS user interface with the commands "Start", "Programs", "PATKey" and "PATKey". To do so, a number combination such as the one shown in figure 8 must be entered in "Maschinencode" (= "Machine code:", here 1135, in figure 4 : 3452, however, other combinations are also possible) and a time period must be determined in "Gültigkeitsdauer"(= "Validity duration:", e.g. "60" for 60 minutes). By pressing the "Return" key or clicking on "Zugangscode ermitteln" (= "Determine access code"), the Patkey program calculates an 8-figure generic access code (here, for example 36869394). As shown in figure 4, this must be entered with the number field of the PDC system (as shown in figure 4, little stars [ * ] will appear). After confirming with the "C" key, it is possible to switch the valves shown in figure 5 (-Y25 to -Y28) in an unsecured manner.
Figure 8
Page 13 of 13
Technical Training
AC 100 Hydraulics Main hydraulic block 25 bar pilot controled pressure relief 0,7 l permanent leak
pressure relief valves set according to drawing
Primary pressure relief 380 bar LS pressure relief 320 bar Proportional valves
Technische Schulung
AC120 Hydraulik Hauptblock e.doc
Technical Training Superstructure
AC 100 Hydraulic
Position of the balancing valve with one movement engaged
If only one movement is engaged the balancing valve is completely opened. The LS-Signal is send to all other balancing valves and the pump.
Technische Schulung
Druckwaage e.doc
Technical Training Superstructure
AC 100 Hydraulic
Position of the balancing valve with two movements engaged
With two movements engaged the balancing valve of the movement with the higher pressure opens completely, the balancing valve of the movement with the lower pressure close.
Technische Schulung
Druckwaage e.doc
Technical Training
AC 100 Hydraulics
Mainpump A11VLO 190 LR3DS (rear view)
MP
LR DR S
Working pressure from slew pump on LR (Z)
MLS
LS-Signal from function (X)
This pump delivers oil for: -telescope cylinder -hoist 1 and 2 -luffing cylinder -counter weight cylinders -pilot pressure
Technische Schulung
AC100 Hauptpumpe e
Technical Training
AC 100 Hydraulics
Slewing pump A10VG 45 EP21
Control pressure ports
Control pressure ports
Y14.1 air bleed
Pressure switch 2,5 bar
Y14.2
Pump 3 for SLV* and tilting cabin
boost pressure port 15-20 bar
Filter boost pump
shuttle valve to LR of the main pump
test point slew right
Test point slew left
*SLV = Speicherladeventil
Technische Schulung
AC100 Drehwerkspumpe e
Technical Training
AC 100 Hydraulics
Feeder valve The task of the feeder valve is to hold the pressure level in an accumulator circuit between certain limit values (shut-off pressure, activation pressure). The switch pressure difference equals approx. 18% of the shut-off pressure. Note: If downstream consumers produce a higher pressure than the shut-off pressure of the feeder valve, the feed circuit is raised to this pressure level. The valve consists primarily of a pilot control with a pressure adjustment element (1), pressure sensor (2) and return valve (3). Switchover of the pump supply volume from accumulation pressure to neutral circulation: During the charging process, the pump supplies the accumulator circuit (SP) via the return valve (3). The pressure is fed via the control line and pilot control to the load signal side (4) of the pressure sensor (2). This throttles the pump flow until the pressure, which builds up in the accumulator circuit, overcomes the spring force of the pressure adjustment element (1). The force pilot control element switches the load signal line (4) of the pressure sensor (2) to T. The pressure sensor (2) then switches the pump supply current P to N and the return valve (3) closes. The charging process is completed and the pump supply current flows at reduced ∆P through the charge valve.
N SP
T
Picture
1
3 4
2
Technische Schulung
P
AC100 Speicherladeventil e
Technical Training
AC 100 Hydraulics
Feeder valve
Measuring point for accumulation pressure
Adjustment of accumulation pressure Technische Schulung
AC100 Bild Speicherladeventil e.doc
Technical Training
AC 100 Electric
Indications on the dashboard SS Glow plug
Air filter Counterweight pinned
Slewing allowed
Counterweigh t cylinders up
Generator not charging
Filter hydraulicoil Counterweight unpinned
Slewing not allowed
Counterweight cylinders down
Multiple warning
Switched top SS
No function
Slew brake
Engine malfunction
Technische Schulung
Oil level engine
AC100 Meldeleuchtenmodule OW e
Service Bulletin No. : 60 - 11 Mobile Cranes Model:
Type:
Replacement for:
Telescopic AC 25, 40-1, crane 50E, 80, 120
-
Date:
Produced by:
Tel No.: Fax No.:
06. 98
Dept. 8333 Mr. Sieger
06332 06332 83 2575 83 2579
Information regarding the MFA 10 multifunction display in the cab of the superstructure and/or chassis and its operation On the strength of our receiving a number of enquiries on the matter, the following pages will hopefully provide a clarification as to how the ‘’MFA 10’’ multifunction display is operated and help clear up the problems you seem to be having with the ‘’display of actual values’’. Location:
MFA 10 Spare Part No.
Crane cabin AC 120 (395)
000 096 12
Driver’s cabin AC 25, 40-1, 50E (150),120 (395)
654 149 40
----------------------(Benien)
-------------------------(Rübel) 1
Service Bulletin No. : 60 - 11 Mobile Cranes 1) Operating the MFA 10 multifunction display:
4 3 1
2
8 7 6 5
While the ignition remains switched off and provided you have not yet called up any information on it, this display will show the correct time and the number of operating hours elapsed (all LEDs are off). A self-test will be carried out when the ignition is switched on As soon as the ignition is switched on, the MFA 10 will carry out its own self-test. All the different segments of the display will be activated and the LEDs will light up. All the various sensors will then be checked. Any defective sensors will be shown up as sensor error messages (SEnS 12 to SEnS 18) and this information will be stored. The MFA will then be ready for operation.
Functions of buttons 1 to 8 1 - Fuel level 2 - Engine oil pressure 3 - Coolant temperature in the engine 4 - Transmission oil temperature in the chassis, hydraulic oil temperature in the superstructure 5 - Engine speed 6 - Daily operating hours 7 - Line voltage of generator 8 - not assigned in the chassis, wind speed in km/h in the superstructure (optional) As soon as one of the above buttons is pressed, its LED will light up. The relevant value and unit symbol will be shown on the display. 2
Service Bulletin No. : 60 - 11 Mobile Cranes
4 3 1
2
8 7 6 5
Displaying sensor error messages during the self-test Sensor errors are displayed during the self-test as follows: • The relevant LED on button 1 to 8 lights up. • The unit symbol for the sensor found to be defective is shown on the display. • The number of the connector pin for static input is shown in the top line of the display, the static input (SEnS 12 to SEnS 18) of the defective sensor in the line at the bottom of the display. • Sensor errors are shown as ‘’ -- -- -- ‘’ on the display once the self-test has been completed.
Setting the clock Proceed as follows to set the time: • Press buttons 6 and 7 at the same time for five seconds. The time will flash on the display. • Press button 5, 6, 7 or 8 until the correct time is shown. • To store the time you have set, press buttons 6 and 7 at the same time until the time displayed no longer flashes.
3
Service Bulletin No. : 60 - 11 Mobile Cranes
4 3 1
2
8 7 6 5
Confirming the warning limits (buzzer active) A warning buzzer is triggered when a value which has been programmed into the system has either not been reached or has been exceeded. The value concerned will be shown on the display and the relevant LED on the button will start to flash. The warning limit will be automatically reset as soon as the value concerned returns to normal. To confirm this, press the relevant button for approx. three seconds until the buzzer switches off. The display will then return to its original display mode. You must always find out what caused the warning in the first place! The warning limit ‘’Engine speed exceeded’’ cannot be confirmed (switch off the buzzer). When driving downhill, the speed of the vehicle must be reduced by braking until the buzzer switches off.
Resetting the daily number of operating hours Press button 6 for approx. three seconds. The display will be reset to 0.
4
Service Bulletin No. : 60 - 11 Mobile Cranes
4 3 1
2
8 7 6 5
Reading information on limit values being exceeded and reading sensor errors from the memory store The number of times limit values have not been reached or have been exceeded and various sensor errors are stored as messages. This memory store can be read. Proceed as follows: • Switch off the ignition. • Press buttons 5 and 6 at the same time for at least three seconds. First, the display shows the limit values from SEnS 0 to SEnS 11 which have been stored and then any sensor errors from SEnS 11 to SEnS 18 which have also been stored. Displaying limit values: The top line of the display shows the number of times (how often) the relevant warning limit has not been reached or has been exceeded. The line at the bottom of the display shows the assignment of dynamic input in the comparator (SEnS 0 to SEnS 4) and the assignment of static input in the comparator (SEnS 5 to SEnS 11). Displaying sensor errors: The top line of the display shows the number of the connector pin which is used for static input. The line at the bottom of the display shows the assignment of static input in the various sensors (SEnS 11 to SEnS 18). This memory store can only be reset using the software! The table overleaf shows how the various comparators and sensors are assigned to each dynamic and static input. 5
Service Bulletin No. : 60 - 11 Mobile Cranes
Limit values : (programmed limit values either not reached or exceeded) Display top line
Assignment
bottom line
Number of
messages
SEnS 0
Engine speed
SEnS 1
n/a in the chassis, wind speed in the superstructure
SEnS 2
n/a, bridge between pin 7 + 8
SEnS 3
n/a, bridge between pin 5 + 6
SEnS 4
n/a
SEnS 5
transmission oil temperature in the chassis, hydraulic oil temperature in the superstructure
SEnS 6
n/a
SEnS 7
coolant temperature in the engine
SEnS 8
n/a
SEnS 9
engine oil pressure
SEnS 10
n/a
SEnS 11
n/a
Sensor errors : (defective sensors, short-circuits, broken cables) Display
Assignment of sensors
top line
bottom line
Pin No. 12
SEnS 12
transmission oil temperature
SEnS 13
n/a
SEnS 14
coolant temperature in the engine
SEnS 15
n/a
SEnS 16
engine oil pressure
SEnS 17
n/a
SEnS 18
fuel level
Pin No. 11 Pin No. 10 Pin No. 9
6
Service Bulletin No. : 60 - 11 Mobile Cranes
4 3 1
2
8 7 6 5
Resetting the service interval display The MFA 10 triggers a service interval display (SIA) to be shown every 250 operating hours. This display is intended purely to remind the crane driver to carry out the tasks specified in the lubrication and maintenance instructions for the crane concerned at the correct time. The service interval display (SIA) can only be reset when the vehicle is stationary. The service interval display is reset as follows: • • • • • • •
Switch off the ignition. Press buttons 7 and 8 at the same time and hold them down. Switch on the ignition. Wait a moment to allow the self-test to run its course. Switch off the ignition. Release buttons 7 and 8. The display will show ‘’SIA 0’’.
The service interval display (SIA) will now be reset.
7
Service Bulletin No. : 60 - 11 Mobile Cranes 2) Display of actual values:
4 3 1
2
8 7 6 5
All the information shown on the multifunction display in the cab of the superstructure and/or chassis is given in the form of numerical values. These numerical values are based on the signal values (voltage, current) issued by the relevant pressure and temperature transmitters. In assessing the information shown, remember to take into account the accuracy of each of the individual transmitters. The transmitters have a tolerance of approx. ±10%. Ambient temperatures of below 0° C are not shown with a minus sign. For example: A coolant temperature of - 5° C will be shown as 0° C on the display. In some cases, minimum values can be programmed into the system. This means that these minimum values will be displayed until they are exceeded, regardless of the actual situation. Take, for example, the display of hydraulic oil temperature on the AC 120 superstructure (AC 395-1):
→
Display of minimum value of approx. 40° C ←
The minimum value programmed into the system (approx. 40°) will be shown on the multifunction display up until it is exceeded, regardless of the actual temperature of the hydraulic oil.
8
Service Bulletin No. : 60 - 11 Mobile Cranes
The level of tolerance shown by the transmitters will however also affect the warning limits already programmed. Variations may therefore be seen between models from the same range. As soon as the warning limit programmed into the system is reached, a buzzer will be activated and the display will automatically switch over to the relevant value. The value shown will be represented on the display and the relevant LED in the selector button will start to flash. If the warning threshold is exceeded, this can be confirmed (acknowledged) by pressing the relevant button (for three seconds). If you cannot determine the reason for the fault, e.g. defective transmitter or cable, this might be because an error has occurred in the master instrument of the MFA 10. In this case, the master instrument must be replaced. If the customer expresses concern about the warning limit for the temperature of the hydraulic oil (hydraulic oil temperature 85°C Hyd. tank Pressure switch return filter 2.5 bar Hyd. tank Pressure sensor luffing cyl. bottom end Luffing cylinder Length angle sensor LWG 321 Main boom Length sensor tele cylinder Main boom (interior) Speed signal converter (frequency/mA) Cab Rotary joint H1 Hoist drum Rotary joint H2 Hoist drum Outer lighting front Cab Outer lighting rear Cab Outer lighting boom Main boom Rotary joint Slewing rim centre Ignition switch S 101 (25A) Cab electrics Em. stop eng. superstr., chassis op., eng. start chassis (10A)Cab electrics Continuous current (terminal 30) ADM (10A) Cab electrics Cigarette lighter, socket, horn, all-round lighting (10a) Cab electrics Outer lighting, instrument lighting, anemometer (10A) Cab electrics A/C (10A) Cab electrics Voltage converter, radio (10A) Cab electrics A/C (25A) Cab electrics Current supply PAT, (10A) Cab electrics Windscreen wiper roof/front, MFA10, indicator lights fault, timer parking heater, fan Cab electrics Joystick left/right, length transducer tele cyl., pressure transducer, speed signal converter, length angle transducer (10A) Cab electrics MFA10 Cab electrics Cab adjustment, dead man's switch, slew gear free-running, telescoping loads, speed slew gear/hoist 2/luffing gear/hoist 1, high speed Cab electrics Oil cooler motor (15A) Cab electrics Siren overload, slew gear siren, oil cooler relay, support front superstructure, (10A) Cab electrics Aircraft warning light (10A) Cab electrics Initiators superstructure to the rear/lower limit switch, tilt shut-off (10A) Cab electrics Parking heater timer (10A) Cab electrics Fan (10A) Cab electrics Parking heater control unit Cab electrics CWT cyl. up or down, claw open (10A) Cab electrics Terminal 15 engine control MR (10A) Cab electrics Diagnosis engine (10A) Cab electrics
AC100 Betriebsmittelliste OW e
Technical Training
Technical Training Electrics F126 F127 F600 G601 G602 H18 H19 H106.1 H106.2 H110 H111.1 H111.2 H111.3 H114 H114.1 H115 H700 H700.1 H701 H705 K1 K2 K3 K101 K102 K103 K104 K105 K110 K221 K224 K225 K226 K227 K228 K229 K230 K231 K232 K233 K234 K238 K600 K605 M104 M105 M118 M130 M131 M132 M171 M190 M191 M601
AC 100 Superstructure
Diagnosis engine (10A) Switchover pilot control, switchover speed of hoists, slew gear brake proximity switch CWT, proximity switch LBU, (10A) Main fuse superstructure (50A) Rotation current generator Battery superstructure Rotation indicator H1 Rotation indicator H2 Clearance light CWT left Clearance light CWT right Horn superstructure Main boom head lighting 1 Main boom head lighting 2 Main boom head lighting 3 Rotaflare light superstructure Rotaflare light superstructure Aircraft warning light Indicator light LLD bridging Siren LLD shut-off Indicator light HLS bridging Indicator light luffing gear raise Time relay for A705 Relay tilt indication (optional) Relay tilt indication (optional) Relay oil cooler Emergency stop engine Relay A/C condenser fan Relay A/C compressor Rotaflare light Release relay fan Release relay raise luffing gear Relay LLD shut-off Relay LLD shut-off Relay LLD shut-off Relay hoist limit switch Relay hoist limit switch Relay buzzer for overload (only GB) Relay outriggers left rear/front vertical Relay outriggers right rear/front vertical Relay outriggers (enable only one horizontal cyl.) Relay outriggers (enable only one horizontal cyl.) Relay enable slew gear Load relay superstructure Load relay superstructure Time relay slew gear siren Fan motor
Cab Cab Counterweight Counterweight Lower cab Main boom head Main boom head Main boom head Main boom head Main boom head Main boom head Cab Outside cab Cab Cab Cab electrics Tilt indicator Tilt indicator Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab electrics Cab
Motor oil cooler Wiper motor front screen Wiper motor roof window Windscreen washer pump Motor condensator fan Water pump parking heater Fuel dosing pump Starter superstructure engine
Rear cab Cab Cab Cab Rear cab Rear cab Rear cab Engine
AC100 Betriebsmittelliste OW e
Cab electrics Cab electrics Battery Engine
Technical Training
Technical Training Electrics N700 P100 P200_1 P200_2 P200_3 P200_4 P200_6 P200_7 P200_8 P200_9 P200_10 P201_2 P201_3 P201_5 P201_9 P201_10 P700 R170 R171 R172 S2 S6 S7 S8 S9 S10 S11 S14 S14.1 S14.2 S15.1 S15.2 S16.1 S16.2 S18.1 S18.2 S23 S61 S62 S100 S101 S103 S110 S112 S114 S115 S116 S119 S120 S130 S131 S132 S170 S191
Power supply PAT Multifunction display MFA10 Indicator light CWT cyl. up Indicator light enable slew gear Indicator light CWT lying on claw Indicator light air filter Indicator light CWT down Indicator light slew gear not released Indicator light CWT cyl. claw closed Indicator light high-pressure filter Charge control light Indicator light oil level Indicator light fault engine Indicator light fault chassis Indicator light slew gear brake Indicator light crane operation Display console PAT Temperature control A/C Air temperature sensor Icing protection A/C Hoist limit switch Button enable slew gear (pilot control lever left) Button speed change Slew gear/hoist 2 (pilot control lever left) Button speed change Lower luffing gear/hoist 1 (pilot control lever right) Button – high speed (pilot control lever right) Dead man's button (pilot control lever left) Dead man's button (pilot control lever right) Switch – slew gear brake Direction key slew gear left (pilot control lever left) Direction key slew gear right (pilot control lever left) Direction key raise luffing gear (pilot control lever right) Direction key lower luffing gear (pilot control lever right) Direction key – telescope out (pilot control lever left) Direction key – telescope in (pilot control lever left) Direction key – raise hoist 1 (pilot control lever right) Direction key – lower hoist 1 (pilot control lever right) Switch – switchover pilot control (optional) Button – move CWT Button – CWT claw up Emergency stop - engine Ignition switch – superstructure Engine start - chassis Horn button Switch outside lighting Switch rotaflare light Switch – aircraft warning light Switch lighting Switch inside lighting Switch – raise speed:superstructure Switch – windscreen wiper front Switch – windscreen wiper roof Button – washer pump Switch – A/C Switch - fan
AC100 Betriebsmittelliste OW e
AC 100 Superstructure Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Rear cab Rear cab Main boom Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Technical Training
Technical Training Electrics S210 S220 S600 S700 S701 S705 S707 S708 S801 S802 S803 S804 S805 X550.7 Y1 Y10 Y14 Y14.1 Y14.2 Y15.1 Y15.2 Y16.1 Y16.2 Y16.3 Y16.4 Y16.5 Y18 Y18.1 Y18.2 Y19 Y19.1 Y19.2 Y25 Y26 Y27 Y28 Y45 Y46 Y61A Y61B Y170 Y200
Zero point button (pilot control lever - left) Zero point button (pilot control lever right) Main battery switch Bridging switch LLD HLS bridging Bridging switch – raise luffing gear Switch – switchover speed: hoists Switch – telescoping loads Button - vertical outriggers in/out Enable button outriggers vertical/horizontal left Enable button outriggers vertical/horizontal right Enable button outriggers vertical overall Button outriggers horizontal in/out 13 pin bridging plug HLS (825 Ω) Solenoid valve – enable pilot control pressure Solenoid valve – enable slew gear Solenoid valve - slew gear brake Solenoid valve - slew gear left Solenoid valve - slew gear right Solenoid valve – raise luffing gear Solenoid valve – lower luffing gear Solenoid valve – extend tele cyl. 1 Solenoid valve - retract tele cyl. 1 Solenoid valve - bypass tele cyl. bottom end Solenoid valve - bypass tele cyl. rod end Solenoid valve – speed tele cyl. Solenoid valve – disc brake H1 Solenoid valve – raise hoist 1 Solenoid valve – lower hoist 1 Solenoid valve – disc brake H2 Solenoid valve – raise hoist 2 Solenoid valve – lower hoist 2 Solenoid valve – unlock LBU Solenoid valve – lock LBU Solenoid valve – unbolt boom section Solenoid valve – bolt boom section Solenoid valve – tilt cab Solenoid valve – tilt cab Solenoid valve – CWT up Solenoid valve – CWT down Compressor coupling A/C Solenoid valve CWT claw closed
AC100 Betriebsmittelliste OW e
AC 100 Superstructure Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab X550 Rear cab Rear cab Rear cab Slew gear pump Slew gear pump Control block Control block Control block Control block Tele cyl. Tele cyl. Tele cyl. Lower brake valve Control block Control block Lower brake valve Control block Control block LBU LBU LBU LBU Rear cab Rear cab Rear cab Rear cab Rear cab Rear cab
Technical Training
Eberspächer ®
Troubleshooting and repair instructions
J. Eberspächer GmbH & Co. Eberspächerstr. 24 D-73730 Esslingen Phone (central) (07 11) 939-00 Fax (07 11) 939-0500 http://www. eberspaecher.de
These Troubleshooting and Repair Instructions apply to the following heater versions:
HYDRONIC B
Cat. No.
HYDRONIC
Cat. No.
B 5 W S — 12 Volts
20 1777 05 00 00
D 5 W S — 12 Volts
25 2031 05 00 00
D 5 W S — 12 Volts / fully equipped
25 2032 05 00 00
D 5 W S — 24 Volts
25 2009 05 00 00
B 5 W S — 12 Volts / fully equipped 20 1778 05 00 00
Page
Contents
Functional description ................................................. 2 Sectional diagram ....................................................... 3 Functional diagram B 5 W S ........................................ 4 Functional diagram D 5 W S ........................................ 5 Specifications ............................................................. 6 First check the following if faults occur ........................ 7 Fault diagnosis with the timer module ......................... 8 Fault diagnosis with the diagnostic unit ....................... 9 Fault code, fault description, remarks, remedial action .................................. 10 — 14 Faults which the diagnostic system does not indicate ................................................................ 14 Repair instructions ........................................... 15 — 23 • Assembly drawing B 5 W S .................................... 16 • Assembly drawing D 5 W S .................................... 17 Wiring diagram ..................................................... 24, 25 Fuel quantity measurement ........................................ 26
20 1777 95 11 54
05.1998
Subject to alterations
Printed in Germany
1
© J. Eberspächer
C 47 / 48
Functional description Safety devices The flame is monitored by the flame sensor and the max. permissible temperature by the overheat sensor. Both influence the control unit, which shuts down the HYDRONIC in the event of faults. • If the HYDRONIC does not ignite within 90 seconds after the start of fuel feed, start-up is repeated. If the HYDRONIC does not ignite repeatedly within 90 seconds after the start of fuel feed, a fault shutdown takes place. • If the flame goes out by itself while the heater is in operation, a restart is initially carried out. If the HYDRONIC does not ignite within 90 seconds after the start of fuel feed, or if it ignites but goes out again, a fault shutdown takes place. The fault shutdown can be cancelled by briefly switching the heater off and on again. • In the event of an overheat (e.g. shortage of water, poorly ventilated coolant circulation system), the overheat sensor is tripped, fuel feed is shut off, then a fault shutdown is activated. Once the cause of the overheat has been eliminated, the HYDRONIC can be restarted by switching it off and on again (prerequisite: the HYDRONIC has cooled down sufficiently). • If the voltage drops below approx. 10 Volts or 20 Volts or rises above 15 Volts or 30 Volts, a (delayed) fault shutdown is activated. • If the glow plug is defective or an electrical lead running to the metering unit is broken, the HYDRONIC does not start. • The blower motor speed is monitored continuously. If the blower motor does not start or becomes blocked, a fault shutdown is activated.
The HYDRONIC can be wired up to operate as an auxiliary heater only or as a combination of auxiliary heater and add-heater — the latter serving to compensate for a lack of heat dissipation from the vehicle engine. Auxiliary heater operation Switching on The pilot lamp in the operating element (timer module, switch, etc.) comes on when the HYDRONIC is switched on. The water pump starts up, and after a defined pre-rinsing and preglow program has been completed the combustion air blower, glow plug and metering pump come on. Once a flame has been detected and the combustion process has stabilised, a time control switches the glow plug off. Heating mode Depending on heat demand, the HYDRONIC alternates between “HIGH” and “LOW” settings. The temperature thresholds are permanently programmed in the electronic control unit. If the heat demand in the “LOW” setting is so low that the cooling water reaches a temperature of 85°C, the heater switches to the “OFF” setting, then continues to run for about 130 seconds. The pilot lamp is also lit while the heater is in the “OFF” setting, and the water pump continues to run until the heater is restarted. Switching off When the heater is switched off, the pilot light goes out and fuel feed is shut off. Also in the case of HYDRONIC D 5 W S, the glow plug is switched on for 20 seconds. The combustion air blower and the water pump run on after the heater is switched off (for 50 sec in the case of B 5 W S and for 120 sec in the case of D 5 W S) and are then switched off automatically.
Please note! • The HYDRONIC must always be switched off when refuelling. • The HYDRONIC must not be operated in garages. • The coolant should contain at least 10% antifreeze all year round as protection against corrosion. • When performing electric welding work on the vehicle, disconnect the plus terminal of the battery and connect to GND in order to protect the control unit. • Also switch on the HYDRONIC briefly (for approx. 10 sec.) once a month outside the heating period in order to prevent the water pump and burner motor seizing up. • Before switching on or pre-programming the heating mode, move the heating lever of the vehicle to the “WARM” (maximum) setting and the blower to the “slow setting” (low power consumption). • Operating instructions for timers and switches are supplied with the operating elements. • If it is necessary to use other switches as per usual in automotive engineering, they must have a minimum rating of 1 ampere.
Stationary ventilation Stationary ventilation means that it is possible to activate the vehicle blower directly via the timer module or via radio wave remote control T4 bypassing heater operation in order to ventilate the vehicle interior — which often becomes extremely hot in the summer — before setting off (separate wiring, see Wiring diagram, pp. 24 and 25). Diagnosis If the control unit detects a fault at start-up of the HYDRONIC or while the HYDRONIC is in operation, it is indicated on the timer module display within 15 seconds in the form of a fault code (F + 2-digit number). If the heater is operated in conjunction with the “Mini” timer, the fault code can be read out of the control unit by connecting a diagnostic unit (Cat. No. 22 1512 89 00 00). An adapter cable (Cat. No. 22 1000 30 71 00) is required in order to connect the diagnostic unit.
2
Sectional diagram (heater shown: HYDRONIC B 5 W S)
1 2 3 4 5 6 7 8 9
Combustion air blower Electric motor Heat exchanger Combustion chamber Glow plug Flame sensor Temperature sensor Overheat sensor Control unit
10 11 12 13 14 15 16 17 18
Combustion air hose Exhaust pipe with silencer Metering pump Strainer built into metering pump Main fuse Interface / 8-pin plug Water pump Relay, vehicle blower Timer module
3
A
= Exhaust gas
B
= Fuel
V
= Combustion air
WA = Water outlet WE = Water inlet
Functional diagram — HYDRONIC B 5 W S
Switching temperatures High — Low 80 °C Off — On 75 °C Low — Off 85 °C Low — High 75 °C
Vehicle blower On 30 °C / Off 20 °C
4
Functional diagram — HYDRONIC D 5 W S — 12 Volts / 24 Volts
Switching temperatures High — Low 80 °C Off — On 75 °C Low — Off 85 °C Low — High 75 °C
Vehicle blower On 30 °C / Off 20 °C
5
Specifications
Test code
HYDRONIC B
HYDRONIC
S 288
S 274
Heating medium
Water, coolant
Heating capacity control Fuel
High / Low Gasoline (commercially available)
Rated voltage Heating capacity
Fuel consumption Electric power consumption (excl. wp) • at start-up • in High setting • in Low setting
Diesel (commercially available)
12 Volts
12 Volts or 24 Volts
High
Low
High
Low
5000
1500
5000
2200
Watts
0,69
0,21
0,62
0,27
l/h
at 12 Volts
at 24 Volts
< 100 37 10
< 100 37 12
< 100 37 12
Watts Watts Watts
10
10
20
Volts
15
15
28
Volts
Operating range • Lower voltage limit An undervoltage safety device built into the control unit switches the heater off at approx. 15 Volts or 28 Volts
• Upper voltage limit An overvoltage safety device built into the control unit switches the heater off at approx. 15 Volts or 28 Volts
Permissible operating pressure
up to 2.5 bar overpressure
Minimum water flow rate
300 l /h + 1 % by vol. 2,5 % by vol.
CO2 value
10,5 % by vol. -
CO in exhaust gas
<
Smoke spot number acc. to Bacharach
15 Volts or > 28 Volts, check the alternator controller or the battery.
011
Undervoltage cut-out
Undervoltage is continuously applied to control unit for at least 20 seconds ——>HYDRONIC is not operational • Disconnect connector B1/S1, switch off the vehicle engine, and measure the voltage applied to plug B1 between terminal jack 1 (red (rt) 2.5 mm² wire) and terminal jack 2 (brown (br) 2.5 mm² wire). If the voltage is < 10 Volts or < 20 Volts, check the fuses, the supply leads, the GND connections and the positive terminal on the battery for voltage drop (corrosion). • Is sufficient voltage present during the engine start-up procedure?
012
Overheat (software threshold value)
Temperature at overheat sensor >125°C • Check water circulation system: - check all hose connections for leaks - is a restrictor fitted in the water circulation system? - was attention paid to the correct direction of flow during installation of thermostat and check valve? - has the water circulation system been bled carefully? - check water pump for function • Check temperature sensor and overheat sensor and replace if necessary. See page 22 for reference values.
014
Possible overheat detected (difference evaluation)
Difference between temperature values of overheat sensor and temperature sensor > 25K. The prerequisite for this fault code being indicated is that the HYDRONIC is in operation and that the water temperature at the overheat sensor is at least 80°C. • Check water circulation system: - check all hose connections for leaks - is a restrictor fitted in the water circulation system? - was attention paid to the correct direction of flow during installation of thermostat and check valve? - has the water circulation system been bled carefully? - check water pump for function • Check temperature sensor and overheat sensor and replace if necessary. See page 22 for reference values.
Please note! The HYDRONIC with date of manufacture up to 12.97 has the following values: Difference between temperature values of overheat sensor and temperature sensor > 15K. Water temperature at overheat sensor min. 70°C
015
Equipment disabled — max. permissible number of 10 possible overheats exceeded
The control unit is interlocked. • Release the control unit interlock by erasing the fault memory with the timer module or the diagnostic unit (see pages 8 and 9). • Check the water circulation system: - check all hose connections for leaks - is a restrictor fitted in the water circulation system? - was attention paid to the correct direction of flow during installation of thermostat and check valve? - has the water circulation system been bled carefully? - check water pump for function
10
Fault code Fault description
Remarks • Remedial action
017
Overheat detected — EMERGENCY STOP (hardware threshold value)
Temperature at overheat sensor >130°C • Check water circulation system: - check all hose connections for leaks - is a restrictor fitted in the water circulation system? - was attention paid to the correct direction of flow during installation of thermostat and check valve? - has the water circulation system been bled carefully? - check water pump for function • Check temperature sensor and overheat sensor and replace if necessary. See page 22 for reference values.
020
Glow plug interruption
021
Short-circuit, overload or ground fault at glow plug output
• Carry out a functional check on the glow plug as fitted. For this purpose, unclip the 1.5² white (ws) wire from terminal jack 9 and the 1.5² brown (br) wire out of terminal jack 12 of the 14-pin plug. Apply a voltage of 8 Volts or 18 Volts ±0.1 Volts to the glow plug and measure the current intensity after 25 seconds. The glow plug is OK if the following values are measured. If this is not the case, replace the glow plug. +1 A 8 Volt glow plug — current intensity = 8.5A -1,5 A 18 Volt glow plug — current intensity = 4.5A ± 1.5A • If the glow plug is OK, check the cable harness from the glow plug for damage and continuity. • If fault code 021 is displayed, also check glow plug for assembly of the connection piece and the corrugated washer. Check cable harness for short circuit.
Important! In the case of the HYDRONIC — 12 Volts, carry out functional check using max. 8 Volts. In the case of the HYDRONIC — 24 Volts, carry out functional check using max. 18 Volts. Exceeding the prescribed voltages will result in irreparable damage to the glow plug. Pay attention to the short-circuit-proofing of the power supply unit.
030
Speed of combustion air blower motor outside permissible range
Blower wheel or combustion air blower motor blocked (frozen up, soiled, sluggish, cable harness rubbing against end of shaft, etc.) • Clear blockage • Measure speed of combustion air blower motor using max. 8.2 Volts + 0.2 Volts or 15 Volts + 0.2 Volts. For this purpose, unclip the 0.75² brown (br) wire from terminal jack 14 and the 0.75² black (bk) wire out of terminal jack 13 of the 14-pin plug. Attach a marking on the end of the combustion air blower motor shaft and measure the speed with a contactless tachometer (see page 21). If measured speed < 10,000 rpm, replace the combustion air blower. If measured speed > 10,000 rpm, replace the control unit.
Important! In the case of the HYDRONIC — 12 Volts, carry out functional check using max. 8.2 Volts + 0.2 Volts. In the case of the HYDRONIC — 24 Volts, carry out functional check using max. 15 Volts + 0.2 Volts. Check the positive/negative lines for proper connection. Pay attention to the short-circuit-proofing of the power supply unit.
031
• Check to see if the combustion air blower motor wiring is laid properly or damaged. • Measure speed of combustion air blower motor using max. 8.2 Volts + 0.2 Volts or 15 Volts + 0.2 Volts. For this purpose, unclip the 0.75² brown (br) wire from terminal jack 14 and the 0.75² black (bk) wire out of terminal jack 13 of the 14-pin plug. Attach a marking on the end of the combustion air blower motor shaft and measure the speed with a contactless tachometer (see page 21). If measured speed < 10,000 rpm, replace the combustion air blower. If measured speed > 10,000 rpm, replace the control unit.
Open circuit in combustion air blower motor Important! In the case of the HYDRONIC — 12 Volts, carry out functional check using max. 8.2 Volts + 0.2 Volts. In the case of the HYDRONIC — 24 Volts, carry out functional check using max. 15 Volts + 0.2 Volts. Check the positive/negative lines for proper connection. Pay attention to the short-circuit-proofing of the power supply unit.
11
Fault code Fault description
Remarks • Remedial action
032
Blower wheel or combustion air blower motor blocked (frozen up, soiled, sluggish, cable harness rubbing against end of shaft, etc.) • Clear blockage • Before proceeding with the functional check on the combustion air blower motor, perform a resistance measurement. If measured resistance is < 2 kΩ, then a ground fault has occurred — replace the combustion air blower. If measured resistance is > 2 kΩ, then a ground fault can be ruled out — measure the speed of the combustion air blower. • Measure speed of combustion air blower motor using max. 8.2 Volts + 0.2 Volts or 15 Volts + 0.2 Volts. For this purpose, unclip the 0.75² brown (br) wire from terminal jack 14 and the 0.75² black (bk) wire out of terminal jack 13 of the 14-pin plug. Attach a marking on the end of the combustion air blower motor shaft and measure the speed with a contactless tachometer (see page 21). If measured speed < 10,000 rpm, replace the combustion air blower. If measured speed > 10,000 rpm, replace the control unit.
Short circuit, overload or ground fault of combustion air blower motor Important! In the case of the HYDRONIC — 12 Volts, carry out functional check using max. 8.2 Volts + 0.2 Volts. In the case of the HYDRONIC — 24 Volts, carry out functional check using max. 15 Volts + 0.2 Volts. Check the positive/negative lines for proper connection. Pay attention to the short-circuit-proofing of the power supply unit.
038
Open circuit in vehicle blower relay control
• Check electrical lead routed to relay Rectify open circuit. Replace relay if necessary.
039
Short circuit, overload or ground fault in vehicle blower relay control
• Disconnect relay. If fault code 038 is displayed, then the relay is defective — replace relay.
041
Open circuit in water pump
• Check supply lead to water pump for continuity. For this purpose, unclip the 0.5² brown (br) wire from terminal jack 10 and the 0.5² violet (vi) wire out of terminal jack 11 of the 14-pin plug. Rectify open circuit. Replace relay if necessary.
042
Short circuit, overload or ground fault in water pump
• Disconnect connector in the “water pump” line. If fault code 041 is displayed, then the water pump is defective — replace water pump.
047
Short circuit, overload or ground fault in metering pump
• Disconnect connector in the “metering pump” line. If fault code 048 is displayed, then the metering pump is defective — replace metering pump.
048
Open circuit in metering pump
• Check cable harness of metering pump for continuity. Clear open circuit. Replace metering pump if necessary.
050
Equipment has been disabled due to too many failed starts (10 start attempts plus repeat start-up for each start attempt)
Max. permissible number of safety time counters exceeded; the control unit is interlocked. • Release the control unit interlock by erasing the fault memory with the timer module or diagnostic unit. • Check fuel quantity and fuel supply (see page 26).
051
Time overshoot — cold air blowing
At start-up, the flame sensor indicates a temperature of >70°C for longer than 240 sec. • Check exhaust gas and combustion air piping. • Check flame sensor — see page 20 for reference values.
12
Fault code Fault description
Remarks • Remedial action
052
Safety time exceeded
The max. permissible number of start attempts has been used up. • Check exhaust gas and combustion air piping. • Check the fuel quantity and fuel supply (see page 26). • In the case of the HYDRONIC B 5 W S, clean, and if necessary replace, the strainer in the connection.
053
Flame loss in “High” setting
056
Flame loss in “LOW” setting
Attention! In the event of flame loss in the “High” or “Low” settings and if start attempts are still permitted, the HYDRONIC performs a restart followed by repeat start-up if necessary. If the restart of repeat start-up was successful, the indicated fault code is cleared. Fault (because a new start attempt is no longer permissible) • Check exhaust gas and combustion air piping. • Check the fuel quantity and fuel supply (see page 26). • Check flame sensor — see fault codes 064 and 065.
060
Open circuit in temperature sensor
• Remove the control unit and check the connecting cable of the temperature sensor from damage. If the cable harness is OK, then short the temperature sensor — route wire in 14-pin plug from terminal jack 3 to terminal jack 4. Switch on the HYDRONIC. - if fault code 061 is displayed, remove and check the temperature sensor (see page 22). - if fault code 060 is displayed, check the control unit and replace if necessary.
Please note! The test can only be performed with a jumper strap fitted in the 14-pin plug if the HYDRONIC is still installed in the vehicle or if a test bench is available.
061
Short circuit, overload or ground fault in temperature sensor
• Remove the control unit and check the connecting cable of the temperature sensor from damage. If the cable harness is OK, then disconnect the 14-pin plug from the control unit and unclip the 0.5 mm² blue (bl) wire from terminal jack 3 and the 0.5 mm² blue (bl) wire from terminal jack 4. Plug the 14-pin plug into the control unit and switch on the HYDRONIC - if fault code 060 is displayed, remove and check the temperature sensor (see page 22). - if fault code 061 is displayed, check the control unit and replace if necessary.
Please note! The test can only be performed with a jumper strap fitted in the 14-pin plug if the HYDRONIC is still installed in the vehicle or if a test bench is available.
064
Open circuit in flame sensor
• Remove the control unit and check the connecting cable of the flame sensor from damage. If the cable harness is OK, then short the flame sensor — route wire in 14-pin plug from terminal jack 1 to terminal jack 2. Switch on the HYDRONIC - if fault code 065 is displayed, remove and check the flame sensor (see page 20). - if fault code 064 is displayed, check the control unit and replace if necessary.
Please note! The test can only be performed with a jumper strap fitted in the 14-pin plug if the HYDRONIC is still installed in the vehicle or if a test bench is available.
13
Fault code Fault description
Remarks • Remedial action
065
• Remove the control unit and check the connecting cable of the flame sensor from damage. If the cable harness is OK, then disconnect the 14-pin plug from the control unit and unclip the 0.5 mm² blue (bl) wire from terminal jack 1 and the 0.5 mm² brown (br) wire from terminal jack 2. Plug the 14-pin plug into the control unit and switch on the HYDRONIC - if fault code 064 is displayed, remove and check the flame sensor (see page 20). - if fault code 065 is displayed, check the control unit and replace if necessary.
Short circuit, overload or ground fault in flame sensor Please note! The test can only be performed if the HYDRONIC is still installed in the vehicle or if a test bench is available.
071
Open circuit in overheat sensor
• Remove the control unit and check the connecting cable of the overheat sensor from damage. If the cable harness is OK, then short the overheat sensor — route wire in 14-pin plug from terminal jack 5 to terminal jack 6. Switch on the HYDRONIC. - if fault code 072 is displayed, remove and check the overheat sensor (see page 22). - if fault code 071 is displayed, check the control unit and replace if necessary.
Please note! The test can only be performed if the HYDRONIC is still installed in the vehicle or if a test bench is available.
072
Short circuit, overload or ground fault in overheat sensor
• Remove the control unit and check the connecting cable of the overheat sensor from damage. If the cable harness is OK, then disconnect the 14-pin plug from the control unit and unclip the 0.5 mm² red (rt) wire from terminal jack 5 and the 0.5 mm² red (rt) wire from terminal jack 6. Plug the 14-pin plug into the control unit and switch on the HYDRONIC - if fault code 071 is displayed, remove and check the overheat sensor (see page 22). - if fault code 072 is displayed, check the control unit and replace if necessary.
Please note! The test can only be performed if the HYDRONIC is still installed in the vehicle or if a test bench is available.
090 / 092 — 103 091
Control unit defective
Replace control unit
External interference voltage
Fault in control unit caused by interference voltages radiating from vehicle electrical system. Possible causes: Poor-quality battery, chargers, other sources of interference —> Eliminate interference voltages.
Faults which the diagnostic system does not indicate Fault description
Remarks • Remedial action
HYDRONIC does not start
The water pump and the vehicle blower start as soon as the HYDRONIC is switched on. • Remove temperature sensor and check (see page 22). The vehicle blower starts after the HYDRONIC is switched on — “stationary ventilation” function is activated. • Set “stationary ventilation” switch to “OFF” position.
14
Repair Instructions
Page
Page
Assembly drawing B 5 W S ...................................... 16
Removing and checking flame sensor ....................... 20
Assembly drawing D 5 W S ...................................... 17
Measuring speed of combustion air blower motor .... 21
Removing control unit Checking control unit ................................................ 18
Removing combustion air blower ............................. 21 Removing combustion chamber ............................... 21
Removing glow plug of HYDRONIC D 5 W S Removing cable harness of glow plug ....................... 18
Removing and checking overheat sensor and temperature sensor .................................................. 22
Removing glow plug of HYDRONIC B 5 W S Removing cable harness of glow plug ....................... 19
Removing / installing heat exchanger ........................ 23
Removing strainer and connection of HYDRONIC B 5 W S ................................................. 19
Please note the following during installation! Carefully check all seals and O-rings. Renew if necessary. All parts must be cleaned and checked for damage prior to assembly. Renew if necessary. Note: The Repair Instructions describe how to repair the HYDRONIC in the dismantled state.
15
Repair instructions for B 5 W S — 12 Volts
Sketch 1
1 2 3 4
Cover — jacket Cover — combustion air blower Control unit Combustion air blower
5 6 7 8
16
Water cooling jacket Glow plug Flame sensor Connection
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
O-ring Strainer Bush Overheat sensor Temperature sensor Compression spring O-ring Cable harness Seal Seal Heat exchanger Combustion chamber O-ring Engine cover Cable harness — glow plug Support
Repair instructions for D 5 W S — 12 Volts / 24 Volts
Sketch 2
1 2 3 4
Cover — jacket Cover — combustion air blower Control unit Combustion air blower
5 6 7 8
17
Water cooling jacket Glow plug Flame sensor Overheat sensor
9 10 11 12 13 14 15 16 17 18 19
Temperature sensor Compression spring O-ring Cable harness Seal Seal Heat exchanger Combustion chamber O-ring Engine cover Adapter piece (for 24 Volts version only) 20 Cable harness — glow plug
Removing control unit (see Fig. 1) Detach the 4 fastening screws from the blower cover and then remove the 4 fastening screws from the control unit. Lift up the control unit and detach the engine cover, taking care to avoid damaging the lining. Remove the control unit and disconnect the 14-pin plug.
c
For assembly, first of all connect the 14-pin plug to the control unit. Attach the engine cover to the combustion air blower, taking care to avoid damaging the lining. Insert the bush of the “water pump” cable harness into the cut-out in the combustion air blower. Lay all electrical leads between the electric motor and housing and then insert the control unit into the guide slot of the combustion air blower. Insert and tighten the fastening bolts of the blower cover and control unit.
a
b Fig. 1
a Control unit b Engine cover with lining c 14-pin plug
Checking control unit The basic tester is connected to the PC, and the control unit can be tested by means of an installed test program.
A basic tester and a control unit adapter are required for checking the control unit. The control unit adapter makes the electrical connection between the control unit and the basic tester.
Cat. No. — Basic tester 22 1508 89 00 00 Cat. No. — Control unit adapter 22 1521 89 00 00
Removing the glow plug from the HYDRONIC D 5 W S (see Fig. 2)
3
• Remove control unit Unscrew the M4 nut from the glow plug and remove the cable harness. Unscrew the glow plug from the housing. Please note! In the case of the HYDRONIC D 5 W S — 24 Volts, unscrew the adapter piece from the glow plug and fit onto the new glow plug. Removing cable harness of glow plug Using a release tool made by AMP (Cat. No. 726519), unclip the 1.5² white (ws) wire from terminal jack 9 and the 1.5² brown (br) wire from terminal jack 12 of the 14-pin plug. For installation, lay the cable harness between the electric motor and housing.
b
a Glow plug b Adapter piece for glow plug (for HYDRONIC D 5 W S — 24 Volts only) c Glow plug — insert here
a Fig. 2
18
Removing glow plug of HYDRONIC B 5 W S (see Fig. 3) • Remove control unit Unscrew the M4 nut from the glow plug and remove the cable harness. Unscrew the glow plug from the connection.
b c
Removing cable harness of glow plug Using a release tool made by AMP (Cat. No. 726519), unclip the 1.5² white (ws) wire from terminal jack 9 and the 1.5² brown (br) wire from terminal jack 12 of the 14-pin plug. For installation, lay the cable harness between the electric motor and housing.
a Glow plug b Glow plug — insert here c Flame sensor -with support
a
Removing strainer and connection from HYDRONIC B 5 W S (see Fig. 4 and sketch 3)
Fig. 3
Removing strainer • Remove control unit • Take out combustion air blower • Remove glow plug Remove O-ring and pull the strainer out of the connection using round nose pliers. Check strainer and O-ring. Renew if necessary. Removing connection • Remove flame sensor together with the support. Press the connection out of the housing and then swivel the fuel pipe outwards. Clean the connection and check the O-ring. Renew if necessary. b
Fitting connection and strainer Insert connection into locating hole. Swivel the fuel pipe into the initial position and then press the connection into the locating hole. Insert the support into the slot, and then feed the flame sensor through the hole in the support and insert it into the tapped hole in the housing and screw securely. Press the strainer into the connection until fully home. Fit the O-ring on the strainer and insert it into the housing.
a c Fig. 4
Please note! The welding spots of the strainer must face downwards. Carefully check the O-rings prior to installation. Renew if necessary.
a Glow plug b Connection c Support d Strainer e O-ring f Flame sensor Sketch 3
19
e
d
e
Removing flame sensor (see Fig. 5) • Remove control unit Using a release tool made by AMP (Cat. No. 726534-1), unclip the 1.5² blue (bl) wire from terminal jack 1 and the 0.5² brown (br) wire from terminal jack 2 of the 14-pin plug. Unscrew flame sensor from housing. Check flame sensor. Replace if necessary. For installation, lay the cable harness of the flame sensor between the electric motor and housing.
2
a
a Flame sensor b Flame sensor — insert here Fig. 5
Checking the flame sensor (see sketch 4) Check the flame sensor using the Digital Multimeter. If the resistance value of the flame sensor lies outside the table of values or the diagram, then replace the flame sensor.
Sketch 4
Table of values [
Temp. [°C
-50
0
[
803
1000 1022 1062 1097 1194 1309 1347 1385 1498 1573 1758 1941 2120 2297 2470
[
R [Ω
Vref [V
10
20
30
50
80
90
100
130
150
200
250
300
350
400
1,407 1,639 1,661 1,719 1,738 1,840 1,948 1,983 2,016 2,111 2,171 2,308 2,432 2,542 2,642 2,732
20
Measuring speed of combustion air blower motor (see sketch 5) Measure speed of combustion air blower motor using max. 8.2 Volts + 0.2 Volts or 15 Volts + 0.2 Volts. For this purpose, unclip the 0.75² brown (br) wire from terminal jack 14 and the 0.75² black (bk) wire out of terminal jack 13 of the 14-pin plug. Attach a marking on the end of the combustion air blower motor shaft (for instance a black-and-white disk) and measure the speed with a contactless tachometer. If measured speed < 10,000 rpm, replace the combustion air blower. If measured speed > 10,000 rpm, replace the control unit.
a
b Sketch 5
a Electric motor b Black-and-white plastic disk Removing the combustion air blower (see Fig. 6) • Remove control unit • Remove flame sensor • Remove glow plug Using a release tool made by AMP (Cat. No. 726534-1), unclip the 0.75² brown (br) wire from terminal jack 14 and the 0.75² black (bk) wire from terminal jack 13 of the 14-pin plug. Slacken the 4 fastening bolts in the blower cover and detach the blower cover. Unscrew the 3 fastening bolts and detach the combustion air blower.
a
b c
Please note! Before proceeding with assembly work, carefully check the seal between the combustion air blower and the combustion chamber. Renew if necessary.
d Fig. 6
a Combustion air blower b Electric motor
c 14-pin plug d Seal
Removing the combustion chamber (see Fig. 7) c
• Remove control unit Slacken the 3 fastening bolts in the combustion air blower. Lay the combustion air blower aside (the cable harness of overheat sensor and temperature sensor must not be removed). Remove the combustion chamber from the heat exchanger. Please note! Before proceeding with assembly work, carefully check the seals. Renew if necessary.
a b c d d
b
Combustion chamber Jacket with heat exchanger Combustion air blower Seal — combustion air blower / combustion chamber Seal — combustion chamber / heat exchanger
d a e Fig. 7
21
Removing the overheat sensor and temperature sensor (see Fig. 8) Remove control unit, blower cover and heat exchanger cover. Slacken the compression spring fastening bolt and detach the compression spring. Remove the overheat sensor and temperature sensor from the locating hole in the heat exchanger with flat nose pliers. Using a release tool made by AMP (Cat. No. 726534-1), unclip the two wires of the temperature sensor (terminal jack 3 0.5² blue (bl) and terminal jack 4 0.5² blue (bl)) and the two cables of the overheat sensor (terminal jack 5 0.5² red (rt) and terminal jack 6 0.5² red (rt)) from the 14-pin plug.
c b
a Overheat sensor b Temperature sensor c Compression spring
Fig. 8
Checking overheat sensor and temperature sensor (see page 6)
Please note! The overheat sensor, temperature sensor and cable harness form a module, which means that they are not available as component parts. Before installation, coat the O-rings of the overheat sensor and temperature sensor with special-purpose grease, e.g. “Hellerine”.
Resistance (kOhms)
Check the overheat sensor or temperature sensor using the Digital Multimeter. If the resistance value of the overheat sensor or the temperature sensor lies outside the table of values or the diagram, then replace the overheat sensor or temperature sensor.
Temperature (°C)
Sketch 6
Table of values [
Temp. [°C
0
10
20
30
40
50
60
70
80
90
100
110
120
5,33
3,60
2,48
1,75
1,25
0,91
0,67
0,50
0,38
[
32,54 19,87 12,48 8,06
[
R [kΩ
4,275 3,960 3,561 3,100 2,611 2,135 1,705 1,339 1,041 0,805 0,622 0,483 0,376
Vref [V
a
22
Removing the heat exchanger (see Fig. 9) d • Remove control unit • Remove combustion air blower • Remove combustion chamber
a
Pull the overheat sensor and temperature sensor out of the locating hole in the heat exchanger with flat nose pliers. Press the heat exchanger through the water connection (water inlet) and out of the jacket using a screwdriver. Perform a visual inspection of the heat exchanger. Clean or renew the heat exchanger if necessary. a b c d
b
Heat exchanger Jacket O-ring Water connection (water inlet)
c Fig. 9
Installing the heat exchanger (see Fig. 10) Insert the heat exchanger into the jacket. The heat exchanger must be installed so that the slot in the heat exchanger base catches the detent of the jacket base. As a point of reference, the overheat sensor connection must match up with the locating hole in the jacket.
e
b
Please note! Before proceeding with assembly work, carefully check the seals and the O-ring. Renew if necessary. Check that the heat exchanger is properly seated in the jacket (the heat exchanger must be pressed firmly into the jacket). Before installation, coat the O-rings with special-purpose grease, e.g. “Hellerine”. a b c d e
c
Heat exchanger Jacket Detent Slot in base of heat exchanger Base of overheat sensor
Fig. 10
23
d
a
Wiring diagram HYDRONIC B — 12 Volts and HYDRONIC — 12 Volts / 24 Volts
not available to HYDRONIC D 5 W S — 24 Volts
24
Parts list 1.1 1.2 1.5 1.12 1.13
Burner motor Glow plug Overheat sensor Flame sensor Temperature sensor
2.1 2.2 2.5.7 2.7 2.7.1 2.7.5 2.12 2.15.9
Control unit Metering pump Relay, vehicle blower Main fuse 20 A /12 V-15 A/24 V Fuse, actuating element 5 A Fuse, vehicle blower 25 A Water pump Sensor, outside temperature
3.1.9 Switch, stationary ventilation 3.2.6 Timer, “Mini” version 3.2.9 Timer, rectangular (modular timer) 5.1 5.1.2 5.9.1 5.10
Battery Fuse holder in vehicle Switch, vehicle blower Vehicle blower
a) b) c) d) e) f) i) k)
Connect to D+ for add-heat criterion (optional) connect to +15 Lighting terminal “58” Stationary ventilation (optional, see page 15) External ON/OFF key (optional) Cut open cable Radio module connection Switch (additional heating, e.g. cross-section 4 mm² from 5.5 m to 8.0 m ——> cross-section 6 mm²
Insulate unused cable ends. The plug and socket housing are shown from the conductor entry side.
Rt bl ws sw gn gr ge vi
20 1777 00 96 01 a
= = = = = = = =
red blue white black green grey yellow violet
Please note! In the case of vehicles equipped with heating or air conditioning system, please observe our vehicle-related Workshop Information on the blower control. If the Workshop Information is unavailable, pay attention to the vehicle manufacturer’s instructions regarding connection or interface for blower control.
25
Fuel quantity measurement Preparations for measurement (see sketch 7) Detach the fuel line from the HYDRONIC and place it in a measuring glass (10 cc. capacity). Switch on the HYDRONIC. After about 45 seconds, the metering pump starts to pump fuel. When the fuel is coming out smoothly and free of bubbles, the fuel line is filled and bled. Switch off the heater and empty out the measuring glass.
Please note! Only perform fuel quantity measurement if the battery is charged sufficiently! During measurement, the voltage applied to the control unit must be at least 11 Volts/23 Volts and must not exceed 13 Volts/25 Volts.
Measurement Switch on the heater. After about 45 seconds, the metering pump starts to pump fuel. Keep the measuring glass at the level of the HYDRONIC during measurement. After about 90 seconds, fuel pumping is switched off automatically. Switch off the heater, as otherwise start-up is repeated. Measure the fuel quantity in the measuring glass.
Sketch 7
Evaluation Compare the measured fuel quantity with the values specified in the following table. If the measured fuel quantity is above the max. permissible value or below the min. permissible value, the fuel metering pump must be replaced.
Fuel quantity
HYDRONIC B 5 W S
HYDRONIC D 5 W S
Nominal fuel quantity
11.5 cm3/90 sec.
8.0 cm3/90 sec.
Max. fuel quantity
12.1 cm3/90 sec.
8.5 cm3/90 sec.
Min. fuel quantity
10.9 cm3/90 sec.
7.5 cm3/90 sec.
26
27
Page 1 of 16
Requirement profile for pilot control and LLD functions on the AC100
Christian Quien, Dept. 8315 File: AC100 Anforderungsprofil e
1 Layout of the PDC unit A701
A702
Design. A701 A702 A703 A704 A705 A706 A707 A708 A709 A710 A711 A712 A713 A714 A715 N 700
A703
A705
A706
A704
A707
A708
Function CPU module LLD module for DS 350C Video controller board, driver for TFT16-slot digital input basic board 16-slot digital output extension 16-slot digital input extension 16-slot digital input basic board 16-slot digital output extension RESERVE 11-slot analog input 8-slot analog output 2-slot analog output 2-slot analog output 2-slot analog output Reserve DC / DC converter
A709
A712
A713
PAT designation 22 020 10 0100 22 020 10 0009 22 020 30 0070 22 020 30 0052 22 020 30 0066 22 020 30 0058 22 020 30 0052 22 020 30 0066 --------------22 020 30 0030 22 020 30 0022 22 020 30 0025 22 020 30 0025 22 020 30 0025 --------------450 17 1006
1
A714
A715
A716
Dematic ID no. 000 281 12 000 282 12 000 286 12 000 287 12 000 289 12 000 288 12 000 287 12 000 289 12 --------------000 290 12 000 291 12 000 292 12 000 292 12 000 292 12 --------------000 283 12
N700
Page 2 of 16
Requirement profile for pilot control and LLD functions on the AC100
Christian Quien, Dept. 8315 File: AC100 Anforderungsprofil e
2 Pilot control sensor Manufacturer Remote control units Berlin Kurt Oelsch GmbH Type ST 2000i - X/Y/1/2/3/Ol/Or/W1A/St8/St10/01 w/o dust protection cap Characteristic line and connection plan in accordance with TL ident. no.: 00125912 Art. no.: 3495Z01-024.016 ldentical pilot control sensors are used on the left- and right-hand side 2.1 General signals of the pilot control sensor - Current output: 4-20mA (connection in accordance with circuit diagram) - Zero point switches: All 4 zero point switches of a pilot control switch are connected in parallel. With this signal the amplifier final stages of the analog output board are limit switched with a time delay. - Direction switches: Authorisation of the outputs, emergency control. - Switch S6 left Slew gear free running - Rotation indicator left for hoist 2 (fed past the control to H18) - Rotation indicator right for hoist 1 (fed past the control to H19) - Switch S9 right High-speed switch for "raise luffing gear" and hoists switches S10 (le), S11 (ri) Dead man's switch pilot control lever right and left 2.2 Assignment of the pilot control levers: The pilot control sensor layout is aligned with the connections a4, a6 and a8 of the 16-slot digital input extension module A706. For a crane without hoist 2, a6 is without current. If a machine is to be fitted with hoist 2, DEMAG installs a permanent bridge to a8. The switch S23 is also only optional for hoist 2 operation. Without hoist 2, the wiring for the pilot control is installed by DEMAG in accordance with the customer's wishes. The pilot control levers assign the following current levels to the movement directions: Lever moved fully forward (Y-direction): I= 20mA Lever moved fully backwards (Y-direction: I= 4mA Lever moved fully to the right (X-direction): I= 20mA Lever moved fully to the left (X-direction): I= 4mA Lever in middle position (): I = 12mA
2
Page 3 of 16
Requirement profile for pilot control and LLD functions on the AC100
Christian Quien, Dept. 8315 File: AC100 Anforderungsprofil e
2.2.1 Standard setting without hoist 2 a4=0 a6=0 a8=0 Pilot control lever left
Pilot control lever right
Telescope extend
Hoist1 lower
Slew right
Slew left
Boom lower
Boom raise
Telescope retract
Hoist1 raise
Signals of the pilot control sensor left - Luffing switch S7: (S707 not actuated): slew gear slower faster (S707 actuated): hoist 1 slower faster Signals of the pilot control sensor right - Luffing switch S8 Lower luffing gear slower faster 2.2.2 Option 1 without hoist 2 a4=0 a6=1 a8=0 Pilot control lever left
Pilot control lever right
Hoist1 lower
Boom lower
Telescope extend
Telescope retract
Slew right
Slew left
Boom raise
Hoist1 raise
Signals of the pilot control sensor left- luffing switch S7
Hoist 1 slower faster
Signals of the pilot control sensor right - Luffing switch S8: (S707 not actuated): Slew gear slower faster (S707 actuated): Lower luffing gear slower faster 3
Page 4 of 16
Requirement profile for pilot control and LLD functions on the AC100
Christian Quien, Dept. 8315 File: AC100 Anforderungsprofil e
2.2.3 Option 3 without hoist 2 a4=0 a6=0 a8=1 Pilot control lever left
Pilot control lever right
Boom lower
Hoist1 lower
Slew right
Slew left
Telescope retract
Boom raise
Telescope extend
Hoist1 raise
Signals of the pilot control sensor left - Luffing switch S7: (S707 not actuated): Slew gear slower faster (S707 actuated): Lower luffing gear slower faster Signals of the pilot control sensor right - Luffing switch S8 Hoist 1 slower faster
2.2.4 Standard setting with hoist 2 a4=1 a6=0 a8=0 Control setting as for 2.2.1
4
Page 5 of 16
Requirement profile for pilot control and LLD functions on the AC100
Christian Quien, Dept. 8315 File: AC100 Anforderungsprofil e
2.2.5 Setting 1 with hoist 2 a4=1 a6=1 a8=0 Pilot control lever left
Pilot control lever right
Hoist2 lower
Hoist1 lower
Slew right
Slew left
Boom lower
Boom raise
Hoist2 raise
Hoist1 raise
Signals of the pilot control sensor left - Luffing switch S7: (S707 not actuated): Slew gear slower faster (S707 actuated): hoist 1 and hoist 2 slower faster Signals of the pilot control sensor right - Luffing switch S8 Lower luffing gear slower faster 2.2.6 Setting 2 with hoist 2 a4=1 a6=0 a8=1 Pilot control lever left
Pilot control lever right
Telescope extend
Hoist1 lower
Slew right
Slew left
Hoist2 raise
Telescope retract
Hoist2 lower
Hoist1 raise
Signals of the pilot control sensor left - Luffing switch S7: (S707 not actuated): slew gear slower faster (S707 actuated): hoist 1 and 2 slower faster Signals of the pilot control sensor right - Luffing switch S8 Lower luffing gear slower faster
5
Page 6 of 16
Requirement profile for pilot control and LLD functions on the AC100
Christian Quien, Dept. 8315 File: AC100 Anforderungsprofil e
3. Digital inputs on 16 slot basic module A 704 Plug assignment scheme: Input DE0 DE1 DE2 DE3 DE4 DE5 DE6 DE7 DE8 DE9 DE10 DE11 DE12 DE13 DE14 DE15
PIN 02 04 06 08 10 12 14 16 18 20 22 24 26 28 30 32
a + + + + + + + + + + + + + + + +
e -
Signal designation Direction switch +X pilot control lever left Direction switch -X pilot control lever left Direction switch +Y pilot control lever left Direction switch -Y pilot control sensor left Zero point switch pilot control sensor left Preselect switch S 708 telescope loads / erection loads Luffing switch S7 left pilot control sensor pressed left Luffing switch S7 left pilot control sensor right pressed Direction switch +X pilot control lever right Direction switch -X pilot control lever right Direction switch +Y pilot control lever right Direction switch -Y pilot control sensor right Zero point switch of the left pilot control sensor right Switch – high speed S9 Luffing switch right pilot control sensor pressed left Luffing switch right pilot control sensor pressed right
4. Digital outputs on 16 slot extension A 705 Plug assignment scheme: Output DA0 DA1 DA2 DA3 DA4 DA5 DA6 DA7 DA8 DA9 DA10 DA11 DA12 DA13 DA14 DA15
PIN a02 a04 a06 a08 a10 a12 a14 a16 a18 a20 a22 a24 a26 a28 a30 a32
Signal designation Activation Y1, enable pilot control pressure Activation Y14, slew gear parking brake Activation Y16.3, bypass bottom end Activation Y16.4, bypass rod end RESERVE RESERVE RESERVE RESERVE RESERVE Activation Y61a, CWT cylinder up Activation Y61b, CWT cylinder down Activation Y200, claw closed CWT down and claw closed CWT claw closed Slew gear locked RESERVE
6
Page 7 of 16
Requirement profile for pilot control and LLD functions on the AC100
Christian Quien, Dept. 8315 File: AC100 Anforderungsprofil e
5. Digital inputs on 16-slot extension module A 706 Plug assignment scheme: Input DE0 DE1 DE2 DE3 DE4 DE5 DE6 DE7 DE8 DE9 DE10 DE11 DE12 DE13 DE14 DE15
PIN 02 04 06 08 10 12 14 16 18 20 22 24 26 28 30 32
a + + + + + + + + + + + + + + + +
e -
Signal designation Emergency operation active, switch outputs Coding jumper H II Switchover pilot control options Switchover pilot control options Switchover hoist speed adjustment H1/2 Static slew gear brake (S14) RESERV E RESERV E CWT cylinder up B50, B51 Slew gear released, B52,B53 CWT claw up, B54,B55 CWT in position, B56,B57 RESERV E RESERV E RESERV E RESERV E
6. Digital inputs on 16-slot basic module A 707 Plug assignment scheme: Input DE0 DE1 DE2 DE3 DE4 DE5 DE6 DE7 DE8 DE9 DE10 DE11 DE12 DE13 DE14 DE15
PIN 02 04 06 08 10 12 14 16 18 20 22 24 26 28 30 32
a + + + + + + + + + + + + + + + +
e -
Signal designation Preliminary position locking tele 1 and 3 (B1) Follow-on position locking tele 1 and 3 (B2) Preliminary position locking tele 2 and 4 (B3) Follow-on position locking tele 2 and 4 (B4) LBU bolted (B13) LBU limit position (B14) LBU locked (B15) Preliminary position section bolting tele1-4 (B5,B7,B9,B11) Follow-on position section bolting tele 1-4(B6,B8,B10,B12) Superstructure locked to the rear (B43) Lower limit switch H1(B18) Lower limit switch H2(B19) RESERVE RESERVE RESERVE RESERVE
7
Page 8 of 16
Requirement profile for pilot control and LLD functions on the AC100
Christian Quien, Dept. 8315 File: AC100 Anforderungsprofil e
7. Digital outputs on 16-slot extension module A 708 Plug assignment scheme: Output DA0 DA1 DA2 DA3 DA4 DA5 DA6 DA7 DA8 DA9 DA10 DA11 DA12 DA13 DA14 DA15
PIN a02 a04 a06 a08 a10 a12 a14 a16 a18 a20 a22 a24 a26 a28 a30 a32
Signal designation Lock LBU (Y2) Unlock LBU (Y3) Bolt sections (Y4) Unbolt sections (Y5) RESERVE RESERVE RESERVE RESERVE RESERVE RESERVE RESERVE RESERVE RESERVE RESERVE RESERVE RESERVE
8. Reserve slot A 709 9. Analog inputs on 11-slot module A 710 Plug assignment scheme: Input AE0 AE1 AE2 AE3 AE4 AE5 AE6 AE7 AE8 AE9 AE10
PIN Signal designation a14 Pilot control lever left X-direction right stop = 20 mA, left stop = 4 mA a16 Pilot control lever left Y-direction rear stop = 4 mA, front stop = 20 mA a18 Pilot control lever right X-direction right stop = 20 mA, left stop = 4 mA a20 Pilot control lever right Y-direction rear stop = 4 mA, front stop = 20 mA a22 Length telescope (B703) min= 4mA, max =20mA a24 RESERVE a26 RESERVE e14 Total length main boom B702 min=4mA, max=20mA e16 Angle main boom B702 min=4mA, max=20mA e18 Motor speed B707 F/I converter PAT e20 Pressure sensor luffing cylinder
8
Page 9 of 16
Requirement profile for pilot control and LLD functions on the AC100
Christian Quien, Dept. 8315 File: AC100 Anforderungsprofil e
10. Analog outputs on 8-slot basic module A 711 Plug assignment scheme: Input AA0 AA1 AA2 AA3 AA4 AA5 AA6 AA7
PIN e2 e6 e10 e14 e18 e22 e26 e30
Signal designation RESERVE RESERVE Luffing gear up/down (A714) Hoist 1 raise/lower Hoist 2 raise/lower Slew gear left/right Telescope tele cylinder in/out RESERVE
Terminal Piggy X4 X4 X5 X5 X6 X6 X7 X7
11. Analog outputs on 4-slot piggy module A 712 max. current = 1A Plug assignment scheme: Input AA0 AA0 AA0 AA0 AA1 AA1 AA1 AA1
PIN a2/a4 e2/e4 a6/a8 e6/e8 a10/a12 e10/12 a16/a18 e16/e18
Signal designation/piggy connection Extend telescope / X7 Current output Retract telescope / X7 Current output RESERVE Current output RESERVE Current output -
Signal 0-1 A 0-1 A 0-1 A 0-1 A 0-1 A 0-1 A 0-1 A 0-1 A
12. Analog outputs on 4-slot piggy module A 713 max. current = 1A Plug assignment scheme: Input AA0 AA0 AA0 AA0 AA1 AA1 AA1 AA1
PIN a2/a4 e2/e4 a6/a8 e6/e8 a10/a12 e10/12 a16/a18 e16/e18
Signal designation/piggy connection Raise hoist II Current output Lower hoist II Current output Slew gear left Current output Slew gear right Current output -
9
Signal 0-1 A 0-1 A 0-1 A 0-1 A 0-1 A 0-1 A 0-1 A 0-1 A
Page 10 of 16
Requirement profile for pilot control and LLD functions on the AC100
Christian Quien, Dept. 8315 File: AC100 Anforderungsprofil e
13. Analog outputs on 4-slot piggy module A 714 max. current = 1A Plug assignment scheme: Input AA0 AA0 AA0 AA0 AA1 AA1 AA1 AA1
PIN a2/a4 e2/e4 a6/a8 e6/e8 a10/a12 e10/12 a16/a18 e16/e18
Signal designation/piggy connection Luffing gear down Current output Luffing gear up Current output Raise hoist 1 Current output Lower hoist 1 Current output -
Signal 0-1 A 0-1 A 0-1 A 0-1 A 0-1 A 0-1 A 0-1 A 0-1 A
14 Digital output module A705 Assignment of the relays Relay 1
a2
Function: enable valve for pilot control pressure Y1 The relay is always picked up in crane operation (e2). It drops out (a2) when the LLD shut-off is activated. If "lower hoist" (1 or 2), "retract telescope" or slew gear are activated, the relay has to be picked up again. If these movements are no longer activated, the relay must drop out again, provided that the LLD shut-off is still active. If, for example, "lower luffing fly jib" and "lower hoist" are driven into the shut-off range at the same time, the relay should also drop out initially. The relay only picks up when the control levers are returned to the zero position and then one of the loadmoment-reducing movements are carried out. If a movement is then carried out which increases the load moment, the relay drops out. The hoist limit switch shut-off is treated exactly as the LLD shut-off. When the lower limit switch is shut off, the relay can always remain picked up. When the LLD is bridged, the relay must pick up. The same applies when the hoist limit switch is bridged. Relay 2
a4
Function of static slew gear brake The relay triggers the slew gear brake valve Y14. For the recognition of switch conditions, two additional digital inputs are required. On the input board A706 the switch S14 is connected to input a12 and the pilot control sensor switch S6 to input a14. Y14 = 1 when
S14 ∧ S6 10
Page 11 of 16
Requirement profile for pilot control and LLD functions on the AC100
v
Christian Quien, Dept. 8315 File: AC100 Anforderungsprofil e
S14 ∧ slew gear under current (enable slew gear)
In addition the output should remain activated for 2 seconds once the movement is completed. This prevents the static slew gear brake falling closed when the superstructure is still turning.
15 Analog outputs 15.1 Solenoid valve data: The following table shows the default values of the solenoid valve data which are set on the machine: Function/solenoid valve Slew gear right / Y14.1 Slew gear left / Y14.2 Extend tele / Y16.1 Retract tele / Y16.2 Luffing gear up / Y15.1 Luffing gear down / Y15.2 Raise hoist 1 / Y18.1 Lower hoist 1 / Y18.2 Raise hoist 2 / Y19.1 Lower hoist 2 / Y19.2
Entry current 200 mA 200 mA 200 mA 200 mA 150 mA 200 mA 200 mA 200 mA 200 mA 200 mA
Start-up current 230 mA 240 mA 460 mA 480 mA 450 mA 400 mA 440 mA 440 mA 440 mA 440 mA
Normal speed current 560 mA 560 mA 800 mA 800 mA 600 mA 600 mA 560 mA 610 mA 610 mA610 mA
High-speed current 660 mA 680 mA 680 mA 680 mA 680 mA
15.2 Speed dependency For the movements "raise luffing gear" and "lower hoist" the current is also controlled in relation to the diesel speed. The purpose is to avoid an insufficient supply to the valves at low speeds. At low speeds the maximum current is lower than at full speed when the lever is fully deflected. Minimum motor speed 800/min Maximum motor speed 2200/min
15.3 Desired value changes Via the luffing switches S8 and S9 in the pilot control sensors, the current to the proportional valves can be changed directly by the driver. This is possible for the movements - hoist, slew gear and lower luffing gear. Example: slew gear Starting current Normal speed current
240 mA 560 mA at 100% 11
Page 12 of 16
Requirement profile for pilot control and LLD functions on the AC100
Christian Quien, Dept. 8315 File: AC100 Anforderungsprofil e
Proportional valve current 368 mA at 40% (240 mA + 4•(560 mA - 240 mA)) The changes in the desired values may only have a dampened effect, the current must be changed via a ramp. 15.4 Regulation of the ramps The function of the ramp is to limit changes in the solenoid valve current when the pilot control lever is moved quickly. This causes start-up movements to be more gentle. If the movement is started or stopped slowly, the ramp is not used. Subsequent changes to the ramp times should be possible without much difficulty. 15.4.1 Ramp time at start of movement The ramps are activated by the direction switch. Slew gear Raise hoist Lower hoist Telescope Luffing gear
3s 3s 1.5 s 1s 3s
15.4.2 Ramp time at end of movements All movements with the exception of the tele control 1s. The telescopes are switched off once the preselected boom length is reached without stop ramps. When the LLD is shut off, the solenoid valve currents for the movements "raise hoist" and "raise and lower luffing gear" are driven directly to zero without ramps. When the LLD prewarning is given (90% of the permissible load moment) the solenoid valve currents are reduced to a maximum 50%. This applies to the movements "raise hoist", "lower luffing gear" and "extend telescopic section". The reduction is made using a time ramp. This ramp is determined empirically. When the hoist limit switch is triggered, the solenoid valve current for "raise hoist" and "extend telescope" are set to zero without a ramp. When the lower limit switch is activated, the solenoid valve current for "lower hoist" is set to zero without a ramp. The speeds which can be changed using luffing switches S8 and S7 should initially be set to an average value of 50% of the maximum current of the corresponding movement with the "ignition on". The speed change should be continual. At a set reduced speed, the full lever movement should remain available for activation. The high speed should also be activated and deactivated using a ramp. This ramp should also be determined empirically. 12
Page 13 of 16
Requirement profile for pilot control and LLD functions on the AC100
Christian Quien, Dept. 8315 File: AC100 Anforderungsprofil e
16 Slew gear control Hydromatic displacement pump A10VG 45 EP21 The slew gear works in a closed circuit. In these types of system, the speed depends on the lever position and the diesel engine speed. We want to look at two different cases. 16.1 Slew gear without further movements In this case the displacement angle of the pump depends on the lever path. The slew gear speed is therefore proportional to the diesel speed. 16.2 Slew gear with other movements If further movements are activated during slewing, it is important that the slew gear speed is kept constant (with the same lever displacement), even if the diesel speed changes. The displacement angle of the pump depends on the speed in this case.
13
Page 14 of 16
Requirement profile for pilot control and LLD functions on the AC100
Christian Quien, Dept. 8315 File: AC100 Anforderungsprofil e
16.3 Other movements with hoist When movements are carried out and subsequently the slew gear is activated, the slew speed is exclusively dependent on the oil flow which is currently available. In this case the slew gear speed is therefore not kept constant. Engine speed Current
[mA]
800
1000 1200 1400 1600 1800 2000 2200
200 240 280 320 360 400 440 480 520 560 600
0 3.6 7.2 10.8 14.4 18 21.6 25.2 28.8 32.4 36
0 4.5 9 13.5 18 22.5 27 31.5 36 40.5 45
0 5.4 10.8 16.2 21.6 27 32.4 37.8 43.2 48.6 54
0 0 0 0 6.3 7.2 8.1 9 12.6 14.4 16.2 18 18.9 21.6 24.3 27 25.2 28.8 32.4 36 31.5 36 40.5 45 37.8 43.2 48.6 54 44.1 50.4 56.7 63 50.4 57.6 64.8 72 56.7 64.8 72.9 81 63 72 81 90 nmax = 2200 U/min
0 10 20 30 40 50 60 70 80 90 100
Slew gear quantity in % in relation to speed and starting current
14
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Requirement profile for pilot control and LLD functions on the AC100
Christian Quien, Dept. 8315 File: AC100 Anforderungsprofil e
The following diagram is designed to explain the slew gear control. From a fixed operating point 0, the pump quantity is changed via the displacement angle when the slew gear is activated and at a constant engine speed (characteristic line 1). If the speed is changed and the lever position kept constant, the volume also changes accordingly (characteristic line 2). If a second movement is activated and the speed is changed, the slew gear speed should remain constant (characteristic line 3).
100
90
80
70
60
50
40
30
20
10
0
Ansteuerstrom (%) 800
1000
1200
1400
1600
1800
2000
2200
15
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Requirement profile for pilot control and LLD functions on the AC100
Christian Quien, Dept. 8315 File: AC100 Anforderungsprofil e
9 LLD programming: - LLD shut-off:
Proportional valves set to zero In addition the control lines to the proportional valves are interrupted via relay contacts
In the LLD program different operating modes should be possible: • •
Erection program -> Boom can be telescoped out quickly to any length; however only erection loads will be enabled. Telescoping loads: -> Boom can be telescoped out under load in accordance with specified telescoping sequences.
- HLS shut-off:
Proportional valves are set to zero The movements luffing fly jib down, hoist up and extend tele are shut down.
.
16
Service Manual Modular PDC Version 1.2
Status 26.03.1999
H.-P. Huwer, Dpt. 8315
Service Manual
Pdc_e.doc
Modular PDC Version 1.2
1.
Status: 26.03.99 Page 2 of 26 Printed: 24.08.00
General instructions on working with computer components In the following chapters the basic components of the modular "Pat Dynamics Control - PDC" are described. The PDC is responsible (or will be responsible in the near future) for various control, monitoring and visualisation tasks on the machines AC 100, AC 120, AC 300, AC 500-1, AC 650, CC 2800 and CC 2500. Certain basic rules, which apply to work with electronic instruments, must be followed when carrying out maintenance and repair work on this system. In the following pages, these rules will be outlined as they apply to the individual components and the definitions used will be explained.
General rule Printed circuit boards (pcbs) or modules may only be inserted and removed off circuit! Changes to the wiring, the coding switches/coding jumpers and fuses may only be made off circuit!
EPROM
electric programmable read-only memory
A memory module which can be programmed electrically using suitable programming appliances, and which can only be read in normal mode. In order to be able to re-program the module it must first be deleted by extended UV irradiation. To enable the UV light to reach the actual chip, the EPROM has a window. Following programming, this window is sealed off to the light using a sticker, in order to avoid unintentional erasing, e.g. as a result of irradiation from the sun. This sticker may therefore only be removed to erase the EPROM. EPROMs can be destroyed by electrostatic charges. Before touching an EPROM, you must always make sure that you are not carrying an electrostatic charge. Ideally, special earthing armbands, electrostatic mats and tools etc. should be used for this purpose. If these accessories are not available, at the very least equipotential bonding should be created between the PDC and operator by touching a metal part of the PDC before touching the EPROM. An EPROM is removed from its socket by pulling the EPROM evenly from both sides using an IC extraction pincer. As an additional aid, a small screwdriver can be used to lever the EPROM out of its socket alternately from both sides. This is the only way to prevent the EPROM pins from becoming bent. A dismantled EPROM can be used again and should be returned to Dept. 8315.1. In addition, Dept. 8315.1 must always be informed when an EPROM is replaced. An EPROM is inserted in its socket by first placing all pins in the holders. Any pins which may have been bent must be straightened carefully (!). When all pins are located in their holders, the EPROM is pressed into the socket evenly and without any slant. Subsequently, you must check that all pins are correctly located in the socket, or whether pins are bent outwards or inwards (difficult to see !).
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Ribbon cable In order to link up contact series, ribbon cable with up to 68 cores is often used in computers. These ribbon cables are either soldered directly into a pcb or are connected by means of plugs/couplings. These plugs/couplings are usually fitted with insulation contacts. The ribbon cable is inserted in the contact element and pressed into the insulation contacts with a plastic strip. The plastic strip is then locked into the contact element. This type of assembly can support relatively high mechanical loads, however a plug connection must never be released by pulling on a ribbon cable. When releasing a plug connection, pull only on the plastic body. If a plug connection is stuck, you can loosen it by carefully (!) levering with a screwdriver. To avoid switching of the poles of the ribbon cable, at least the core / contact is marked with the number "1" on the connection points of a ribbon cable (i.e. on the pcb). The ribbon cable itself comprises different-coloured cores or a marking for the core with the number "1". It is normal, for example, that grey ribbon cable has a red core marked as number "1". In addition the plugs/couplings are mechanically coded with lugs and grooves and can only be inserted easily in the correct direction.
Coding switches To make one-off settings on a pcb, so-called coding switches are used. These are small rotary switches with, for example, 10 or 16 positions. The coding switch is adjusted carefully (!) using a small screwdriver. The position of the coding switch is indicated, for example, by a small arrow. The different settings of the coding switch may only click into position lightly, i.e. the operator is responsible for setting the precise switch position.
Coding jumpers An additional option for making settings on a pcb is the use of coding jumpers. This involves conductively linking two contact pins by means of small connectors. The connectors must be inserted carefully and only in the specified direction. Extra connectors may not be inserted on free contact pins.
Trimming potentiometers In order to enable stepless adjustments, some pcbs are fitted with small trimming potentiometers. These trimming potentiometers must be carefully turned with a suitable screwdriver. Overtightening of the mechanical stop must be avoided, as the entire pcb has to be replaced if the potentiometer is defective. The current position of the potentiometer is generally indicated with a small marking (arrow tip, dash). If this is not the case, the correct position must be set by rotating the potentiometer to both end stops to determine its range and then turning to the desired setting.
2.
Layout of the plug-in pcbs in the computer The plug-in pcbs described in the following chapters can be found in various positions and in different quantities, depending on the appliance type and the technical features. It is possible to
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Modular PDC
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Version 1.2
view the current configuration of the PDC, i.e. the type and position of the plug-in pcbs, on the control console. The following image shows this screen display as an example for a CC crane.
PROWAY interface board LLD board
Basic digital input boards
Analog input boards
Basic analog output board
Video board
CPUboard
Status fields
Info menus
Piggy digital input boards PROWAY users
Piggy digital output boards
Piggy analog output boards
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The following image shows the corresponding screen display as an example for an AC crane. The principle layout of the plug-in pcbs remains the same, but the number and designations change.
Basic digital input boards Analog input boards
PROWAY interface board
Basic analog output board
Videoboard LLD board CPUboard
Status fields
Info menus
Piggy digital input boards PROWAY with PROWAY users
Piggy digital output boards
Piggy analog output boards
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The boards CPU, LLD (load limit device), PROWAY and video always occupy the first four positions (as shown here). On the following plug-in slots are the digital in- and output boards, whereby the basic board is always inserted first, followed by the piggy boards. After this come the analog in-and output boards. Again, the basic board is inserted first, followed by the piggy boards. The extreme right position is always occupied by the plug-in pcb with the voltage supply for the entire computer ) provide information on the status of the plug-in boards. The status fields (in this example: The displayed symbols are explained via the info menus.
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3.1
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Layout of the CPU board The CPU board is the actual nerve centre of the PDC unit. This houses the processor, the memory modules and all I/O modules required for operation. For a change in the software, only the EPROM modules are of interest. These are arranged as follows. Data EPROM 22 System EPROM 12 RAM modules
System EPROM 11 Data EPROM 21 The bottom number on each EPROM describes the plug-in position on the pcb. The EPROMs on plug-in slots -11- and -12- contain the operating system software. The EPROMs on slots -21- and -22- contain all control programs (SPS), data blocks, graphics, applications and configurations. The EEPROM is located on the lower layer and cannot be replaced without dismantling the CPU. A replacement of the EEPROM is not normally required.
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Modular PDC Version 1.2
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The EPROMs have various markings which have the following meanings. ECIS TFT1
General marking for the operating system EPROMs
M2
Not appliance-related, system EPROM
03.35
Running index, updated with each new program version
2CF3
4-digit HEX number, check sum
-11-
Module slot number
39
Machine code, e.g. here AC 300
01.08
B1 System EPROM no. -11B2 System EPROM no. -12-
C1 User software, EPROM no. -21Running index, updated with each C2 User software, new program version EPROM no. -22-
AC 300
Machine designation in plain text
46DD
4-digit HEX number, check sum
-21-
Module slot number
The 4-digit HEX number represents the last 4 digits of the check sum on the complete binary content of the EPROM. When a new EPROM is created or duplicated, it is essential that the correct check sum is specified!
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Modular PDC Version 1.2
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The following connections and display elements are located on the front panel of the CPU board. Switch and LED "Reset":
System reset, cold start
Switch and LED "Abort":
Warm start
Switch and LED "F1":
Service button "F1" and display "F1"
7-segment display:
Status and fault display
Switch and LED "F2":
Service button "F2" and display "F2"
Port "1", RS 232:
Download port for Etool
Port "2", RS 232:
Debug and modem port
Port "3", RS 422:
Reserved for console control
Service Manual Modular PDC Version 1.2
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Layout of the LLD board The LLD board is to be seen as an independent processor board. It assumes all necessary tasks and calculations for the load limit devices. For a change of software, once again only the EPROM modules are of interest. These are arranged as follows. Loads EPROM TLK Data EPROM DAT System EPROM 0
The bottom number on each EPROM describes the slot on the pcb. The system EPROM -0contains the operating system software with all calculations. The data EPROM DAT contains the data and parameters specific to the crane. The load EPROM TLK contains the actual carrying loads. For the check sums, the same applies as outlined for the CPU.
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Modular PDC Version 1.2
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The following connections and display elements are located on the front panel of the LLD board. LEDs "RES", "INT", "1", "2", "3", "4": LED "Load": LED "A2B":
Service lamps for PAT
Display for overload HES display
Port "RS 232":
Programming and parameter port for LLD
"Digital I/O X2":
I/O plug X2, see circuit diagram
"Keyswitch X3":
I/O plug X3, see circuit diagram
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Layout of the analog input board The analog input boards read the measurement values of various sensors, with each board having 7 inputs. The unit comprises several boards with an identical layout, but which have to be differentiated for the computer. For this reason, each board receives a clear address, which is set using the address coding switch, see image. The addresses are counted, starting from "0" up to the maximum "F", i.e. there are 16 possible addresses. Each address may only occur once in the system for this board type! When replacing a defective board, the same address must be set on the replacement board as was set on the defective board. If two boards are replaced (e.g. for test purposes), the addresses of the boards must also be replaced. The address coding switch is to be turned carefully (!) using a suitable screwdriver. If the correct address is not known for a board, the information on the address and module slot can be obtained from the documentation of the company PAT.
Address coding switch 0-F
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Layout of the analog basic output board The analog basic board produces variable electric control signals which are output via so-called piggy boards. To this end, a maximum of eight signals are produced which are output via a maximum of four piggy boards, i.e. each piggy board possesses two channels. The analog signals are transferred via four connector plugs and ribbon cable to the piggy boards. As with the analog input board, each analog basic output board possesses an address coding switch which is used to assign each board an address which can only be allocated once in the system. In this case too, when replacing a defective board the same address must be allocated to the replacement board as was given to the defective board. If two boards are replaced (e.g. for test purposes), the addresses of the boards must also be replaced. The address coding switch is to be turned carefully (!) using a suitable screwdriver. If the correct address is not known for a board, the information on the address and module slot can be obtained from the documentation of the company PAT. As a rule the address is "0", as there is only one analog basic output board in the system. Furthermore, the analog basic output board possesses a coding jumper which can be inserted in six different positions. This jumper sets the ripple frequency which is superimposed on the control signal of the proportional hydraulic valves. The six positions correspond with the following frequencies from the left to the right: 160 Hz, 80 HZ, 40 HZ, 20 Hz, 10 Hz, 5 Hz. In the following image the ripple frequency is set to 80 Hz.
4 × connector plugs for piggy boards
Coding jumper, 6 different positions Address coding switch 0-F
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Modular PDC Version 1.2
4.3
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Layout of the analog piggy output board The analog piggy board receives two input signals from the basic board via a ribbon cable, which it then amplifies and transfers to two consumers (e.g. proportional valves). The ribbon cable is connected to a corresponding connector plug. The maximum output current is 1 amp for each channel. There are no address coding switches on the analog piggy output board. The address is determined by the fact that each board receives its signals from the analog basis output board via its own output or its own ribbon cable. This means that when the ribbon cable of the piggy boards is replaced for test purposes, all connector cables must also be replaced ! The board also houses a fuse, with which the output steps are protected against short circuiting, and a trimming potentiometer, which is used to set the ripple amplitude of the output board. This potentiometer always remains in the middle position, unless specified otherwise.
Connector plug for the cable of the basic board Trimming
Fuse
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4.4
H.-P. Huwer, Dpt. 8315
Layout of the digital basic input board The digital basic input board reads the measurement values of 16 binary sensors, i.e. "0"- or "1"values. In addition up to four digital piggy boards are operated via this board, which can either be input or output boards. These boards are connected via a ribbon cable, with a cable being fed from the first piggy board with a connector coupling to the basic board where it is inserted in the connector plug. On the piggy board there is an additional connector plug, to which the ribbon cable of the next piggy board can be connected etc. In this way, a maximum of four piggy boards can be connected in succession. The board is fitted with a fuse, which safeguards all connected piggy boards. If this fuse is defective, none of the piggy boards will work, even if the control display states otherwise. This board also has a unique address, which is set using the address coding switch (see image). The addresses are allocated in ascending order from "0" up to the maximum "F", i.e. there are 16 possible addresses. Each address for this type of board can only be allocated once for each system. When replacing a defective board the same address should be set on the replacement board as on the defective board. If two boards are replaced (e.g. for test purposes), the addresses of the boards should be replaced. The address coding switch should be turned carefully (!) using a suitable screwdriver. If the correct address is not known for a board, information on the address and module slot can be taken from the documents of the company PAT. Up to three digital basic input boards can be found in the system.
Connector plug for ribbon cable Address coding switch 0-F Fuse
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Layout of the digital piggy input boards The digital piggy input boards also read the measurement values of 16 binary sensors. The boards are, however, not independent, but are operated via the digital basic input boards. The board is connected to the basic input board as already described via a ribbon cable with a connector coupling. The connector coupling at the end of the ribbon cable is not shown here. Next to the ribbon cable is the connector plug for the next piggy board. The digital piggy boards are addressed by them being inserted at a certain point behind the basic input board, they do not possess a coding switch. For example, if a maximum of four piggy boards follow behind the basic input board, they are automatically awarded the addresses "0" to "3". This means that the function of the digital piggy input boards depends on their slot position. If, for example, two boards are replaced for test purposes, the connections on their front panels must also be replaced. If this is not done, the digital input signals are connected to the wrong channels.
Connector plugs for ribbon cable Ribbon cable with plug
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Layout of the digital piggy output board The digital piggy output boards possess 16 floating relay outputs with make contacts. These boards are also not independent and are operated via the digital basic input board. The board is connected to the basic input board as described for the digital piggy input boards via a ribbon cable with a connector coupling. These boards are also addressed by their allocation to a specific slot behind the basic input board, they also do not possess a coding switch. For this reason the function of the digital piggy output boards also depends on their slot position. Consequently, if two boards are replaced for test purposes, the connections on their front panels must also be replaced. If this is not done, the digital output signals will be connected to the wrong consumers. Each relay output is safeguarded with a miniature slow-blowing fuse of 2 A. The fuses are plugged in and are mechanically fixed in place using two plastic strips which are screwed in. To replace a fuse, the corresponding strip must be removed and then reattached once the new fuse has been fitted. There are 2 spare fuses on the board for emergencies. 16 × fuse for output relay 16 × output relay
Connector plug for ribbon cable Ribbon cable with plug
2 × spare fuse
PAT GmbH ⋅ Postfach 652 ⋅ D-76260 Ettlingen
Produktbereich Baumaschinenelektronik
Error Code Table (PDC-LMI) DEMAG AC 100, AC 300, AC 500 and AC 650 Date: Apr. 13, 2000 System programs: LEDC V1.012 (18.02.2000) LEDC V1.1G (05.04.2000) LEDW V1.0E (07.03.2000) Error Code O P H E01
E02
E04
Error Overload prewarning A2B switch Fallen below radius range or angle range exceeded
Part No.: 71 400 84 0268 Part No.: 71 400 84 0275 Part No.: 71 400 84 0271
Cause
Remedy
• cutoff due to overload
• reduce load moment
• the A2B switch is activated • fallen below the minimum radius or gone past the maximum angle specified in the respective load chart due to luffing up the boom too far • gone past the maximum Radius range radius or fallen below the exceeded or fallen minimum angle specified in below angle range the respective load chart due to luffing up the boom too far Operating mode not • A non existing operating mode has been selected acknowledged or
not existing
E05
Forbidden length range of the main boom
• lower the hook block • luff up the boom to a radius or angle specified in the load chart • luff down the boom to a radius or angle specified in the load chart • Correctly enter the operating mode according to the attribution of the operating state • Check programming of the data EPROM
• The selected operating mode is not available in the data EPROM or blocked. • Boom has been extended • Extend/retract boom to too far or not far enough, correct length e.g. if it is prohibited to go beyond a certain maximum boom length or with load curves for jibs where the main boom has to be extended to a certain length.
© 2000 PAT GmbH · D-76275 Ettlingen · Hertzstr. 32 - 34 · ++49 (0) 7243 709-0 · FAX ++49 (0) 7243 709-141 AC100 PDC Errorcodes.doc / 13.04.2000
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PAT GmbH ⋅ Postfach 652 ⋅ D-76260 Ettlingen
Produktbereich Baumaschinenelektronik
• Length sensor adjustment has changed, e.g. the cable slid off the length sensor reel.
• Clutch between length sensor pot and drive is defective
E06
E07
• Length potentiometer defective • Cable between the central unit to the length sensor is either defective or disconnected. • Electronic component in the measuring channel is defective • Gone past the maximum radius or fallen below the minimum specified in the respective load chart due to luffing down the jib too far.
Radius range exceeded or fallen below angle range during luffing jib operation. • Overload relay defective Faulty acknowledgment by • LMI board defective the overload relay of the connection board.
• Retract boom. Check the prestress of the cable reel (cable must be taut). Open the length sensors and carefully turn the length sensor pot counterclockwise until the detent by use of a screwdriver. • Replace complete clutch including drive wheel and adjust length sensor pot as described above. • Replace length potentiometer • Check cable and plug, replace, if need be • Replace analog board • Luff up the luffing jib to a radius or angle indicated in the load chart.
• Replace LMI board
Relay should be energized but 2nd contact is indicated off, or the 2nd contact is indicated on while the relay should be deenergized.
© 2000 PAT GmbH · D-76275 Ettlingen · Hertzstr. 32 - 34 · ++49 (0) 7243 709-0 · FAX ++49 (0) 7243 709-141 AC100 PDC Errorcodes.doc / 13.04.2000
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PAT GmbH ⋅ Postfach 652 ⋅ D-76260 Ettlingen
E08
E21
E22
E23
E24
Produktbereich Baumaschinenelektronik
• refer to E07 • refer to E07 No acknowledgment from the anti-twoblock relay • Check bus cable and plug Upper limit value for • Bus error measuring channel • length sensor is not correctly • Correctly connect length "length telescopic connected. sensor boom" exceeded.
Upper limit value in measuring channel "pressure piston side " exceeded
Upper limit value in measuring channel "pressure rod side" exceeded Upper limit value in measuring channel "force luffing jib" exceeded
• Electronic component in the measuring channel is defective
• Replace analog board
• Length sensor is defective.
• Exchange length sensor • Check bus cable as well as plug
• Bus error • Pressure transducer not correctly connected
• Correctly connect sensor.
• Electronic component in the measuring channel is defective
• Replace analog board
• Replace pressure transducer. • as E22
• Replace pressure transducer • as E22
• Bus error
• Check bus cable as well as plug
• Force transducer not correctly connected
• Correctly connect sensor
• Electronic component in the measuring channel is defective
• Replace analog board
• Force transducer defective
• Replace force transducer
© 2000 PAT GmbH · D-76275 Ettlingen · Hertzstr. 32 - 34 · ++49 (0) 7243 709-0 · FAX ++49 (0) 7243 709-141 AC100 PDC Errorcodes.doc / 13.04.2000
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PAT GmbH ⋅ Postfach 652 ⋅ D-76260 Ettlingen
E25
E26
E27
E2B
E31 E37
Upper limit value in measuring channel "angle main boom" exceeded
Lower limit value in measuring channel "angle luffing jib" exceeded Lower limit value in measuring channel "length tele I + II" exceeded Upper limit value in measuring channel "angle boom head" exceeded Error in the system program Error in the logic program course
Produktbereich Baumaschinenelektronik
• Bus error
• Check bus cable as well as plug
• Angle sensor not correctly connected
• Correctly connect sensor
• Electronic component in the measuring channel is defective
• Replace analog board
• Angle sensor defective • as E25
• Replace angle sensor • as E25
• as E21
• as E21
• as E25
• as E25
• The system program PROM is defective.
• Replace system program PROM (PROM No. 0)
• The system program PROM is defective.
• Replace system program PROM (PROM No. 0)
• Computer module 80C537 defective.
• Replace computer module 80C537.
• LMI board defective • The system program in the LMI does not match to the programming in the data EPROM. • The system program in the LMI does not match to the programming in the RLC EPROM. • Computer module 80C537 is defective.
• Replace LMI board • Replace system program PROM or data EPROM (PROM No. 1).
E38
System program and data EPROM do not match.
E39
System program and RLC EPROM do not match.
E41
• Replace computer module Error in the internal 80C537. write/read memory (RAM) of computer • LMI board defective • Replace LMI board module 80C537 Error in the external • Write/read memory (CMOS- • Exchange LMI board. RAM) or LMI board defective write/read memory 1st. part (RAM)
E42
© 2000 PAT GmbH · D-76275 Ettlingen · Hertzstr. 32 - 34 · ++49 (0) 7243 709-0 · FAX ++49 (0) 7243 709-141 AC100 PDC Errorcodes.doc / 13.04.2000
• Replace system program PROM or data EPROM (PROM No. 2).
4 von 8
PAT GmbH ⋅ Postfach 652 ⋅ D-76260 Ettlingen
E43
E48
E49
E51
E52
E56
E57
E58
Produktbereich Baumaschinenelektronik
Error in the external • During on-line programming • Replace external working an error has been detected RAM. write/read memory when writing on the external • Replace LMI board. (RAM) of the main working RAM board during on-line programming • Plausibility check: more than 24 sub operating modes number of load points per length step > 30.
• The programming or number of sub-operating modes and load points.
• Computer module 80C537 defective.
• Replace computer module 80C537.
• LMI board defective
• Replace LMI board
• No valid data in the write/read memory of the memory extension upon data loading during on-line programming • No valid data in the crane data EEPROM.
• Exchange LMI board.
• Memory module wrongly bridged.
• Bridge memory module acc. to memory type • Replace crane data EPROM
Error in load chart PROM.
• Crane data EPROM defective • Memory module wrongly bridged.
• Replace load chart EPROM
Error in crane data EEPROM.
• Load chart EPROM defective. • Memory module wrongly bridged.
Cyclic RAM test. Error in the internal write/read memory (RAM) of the computer module 80C537 Faulty data in online operation
Error in the crane data EPROM or EEPROM.
• Crane data EEPROM defective Error in serial crane • Serial crane data EEPROM does not contain valid data. data EEPROM.
Error in the serial analog data EEPROM.
• Memory module defective • No valid data in the serial analog data EEPROM.
• LMI main board defective. © 2000 PAT GmbH · D-76275 Ettlingen · Hertzstr. 32 - 34 · ++49 (0) 7243 709-0 · FAX ++49 (0) 7243 709-141 AC100 PDC Errorcodes.doc / 13.04.2000
• Load crane data EEPROM containing valid data.
• Bridge memory module acc. to memory type.
• Bridge memory module acc. to memory type • Replace crane data EEPROM • Write data on the serial crane data EEPROM (by means of test program or on-line function), then restart the LMI • Replace memory module. • Write data on the serial analog data EEPROM by means of the test program, then, restart the LMI • Replace LMI main board.
5 von 8
PAT GmbH ⋅ Postfach 652 ⋅ D-76260 Ettlingen
E60
The number of the selected EPROM base and the programmed value are not identical
Produktbereich Baumaschinenelektronik
• Load chart EPROM defective
• Replace load chart EPROM
• Base number not programmed
E81
• Program the correct base number (1 for base 1, 2 for base 2) • Load chart EPROM wrongly • Check base programming in programmed the load chart EPROM. • Check angle sensor on the Too large difference • The angle as to the horizontal on the boom head boom head. of the boom angles exceeds the main boom • Check angle sensor on the at tip and base angle by more than 5 base boom. boom. degrees.
E82
More than 1 telescope is unbolted (exception: 3rd. and 4th telescope)
E84
Wrong rigging condition.
• Only unbolt one telescope at a time
• The selected rigging condition is not contained in the data EPROM.
• Select another rigging condition • Check the programming in the data EPROM. • Check the programming in the data EPROM.
E85
Error in the radius determination
• The computed radius is too small (negative deflection)
E86
Faulty percentage for at least one telescope
E87
Faulty length measurement.
• Telescope has a percentage • Read out the percentages < - 2% or > 106 %. on the console. If a telescope has to be extended too far: retract tele and bolt • Length measurement Tele I • Check length measurement + II defective Tele I (see E17) • Measurement of overall • Check length measurement length defective (see E11) • Error in the length memory. • If wrong percentages are displayed: retract and bolt all telescopes. The error is reset if the measured telelength corresponds to the base boom length.
The determined tele-combination does not correspond to the length measurement.
• Length measurement Tele I + II defective
• Check length measurement Tele I (see E27)
• Overall length measurement • Check measurement of defective. overall length (see E21)
© 2000 PAT GmbH · D-76275 Ettlingen · Hertzstr. 32 - 34 · ++49 (0) 7243 709-0 · FAX ++49 (0) 7243 709-141 AC100 PDC Errorcodes.doc / 13.04.2000
6 von 8
PAT GmbH ⋅ Postfach 652 ⋅ D-76260 Ettlingen
E88
E91
Faulty main boom position during luffing jib operation
Produktbereich Baumaschinenelektronik
• During luffing jib operation the main boom is not in the prescribed angle range
Luff boom to the permitted range
• Check angle measurement of the main boom. • Angle measurement of main boom defective. • LMI board defective • Replace LMI board
No data transmission from the ECIS console to • Dual Port RAM defective ECIS-LMI
• Backplane board defective
© 2000 PAT GmbH · D-76275 Ettlingen · Hertzstr. 32 - 34 · ++49 (0) 7243 709-0 · FAX ++49 (0) 7243 709-141 AC100 PDC Errorcodes.doc / 13.04.2000
• Replace Dual Port RAM • Replace Backplane board.
7 von 8
PAT GmbH ⋅ Postfach 652 ⋅ D-76260 Ettlingen
E92
E93
E94
E97
E98
Produktbereich Baumaschinenelektronik
• LMI board defective Error in the data transmission from the ECIS console to • ECIS console defective the ECIS-LMI
Error in the data transmission from the ECIS - LMI to the ECIS console No data transmission from the ECIS LMI to the ECIS console Semaphore in the dual-port RAM cannot be read. After several readings the content is not twice identical. Semaphore in the dual port RAM cannot be written. After several writings and readings the content is not identical.
• Replace LMI board • Replace ECIS board
• Backplane board defective • as E92
• Replace Backplane board • as E92
• as E91
• as E91
• as E91
• as E91
• as E92
• as E92
Remark If an error message is displayed that does not figure in this list, please immediately contact the competent PAT service department.
© 2000 PAT GmbH · D-76275 Ettlingen · Hertzstr. 32 - 34 · ++49 (0) 7243 709-0 · FAX ++49 (0) 7243 709-141 AC100 PDC Errorcodes.doc / 13.04.2000
8 von 8
ECIS - Software documentation
page 1
1.0 System errors
1.1
S 00nn
Control error codes
S 0001
list of inputs not available
S 0002
definition error in list of inputs
S 0003
no space available for input chart
S 0004
variable in list of inputs doesn´t exist in PDB
S 0009
undefined error in list of inputs
S 0011
list of outputs not available
S 0012
definition error in list of outputs
S 0013
no space available for output chart
S 0014
variable in list of outputs doesn´t exist in PDB
S 0019
undefined error in list of outputs
S 0020
no control program available
S 0021
no space available for control blocks (coldstart)
S 0022
checksum error (coldstart)
S 0023
no data blocs in the EEPROM
S 0030
checksum error, control aborted
S 0090
input invalid (when application doesnt´t indicate 4 digit error codes)
S 0093
timeout in communication ECIS - LMI
S 0094
WatchCopyLMBData: CopyLMBData started again (modular ECIS only)
S 0095
WatchIO: I/O started again (modular ECIS only)
S 0096
WatchControl: control aborted
S 0097
WatchProfibus: polling started again
S 0098
CRC error in EPROM
S 0099
fatal error, control aborted
SFehler_E.doc
Rev.: 01
17.09.99
ECIS - Software documentation
1.2
nn
S 01nn
page 2
Input invalid (control)
number of the last invalid input in the list of inputs (hexadecimal)
1.3
S 02nn
Read data bloc: bloc doesn´t exist
1.4
S 03nn
Read data bloc: wrong length
1.5
S 04nn
Read data bloc: wrong checksum
1.6
S 05nn
Write data bloc: bloc doesn´t exist
1.7
S 06nn
Write data bloc: wrong length
1.8
S 07nn
Write data bloc: error while writing EEPROM
nn
number of data bloc (hexadecimal)
SFehler_E.doc
Rev.: 01
17.09.99
ECIS - Software documentation
1.9
S0Enn
page 3
Error codes application program
S 0E0D
No application task found.
S 0E0E
Fatal ERROR by searching application task !!
S 0E0F
No PEARL-application-interface found.
S 0E10
Wrong PEARL-coded-application-interface found. Please use newer system-EPROM !! Expected system-EPROM >= (Versionsnummer)
S 0E11
PAT-ME2: Wrong PEARL-coded-application-interface found. Please use data-EPROM linked for Modular ECIS. Data-EPROM was linked for Console ECIS. Konsole2: Wrong PEARL-coded-application-interface found. Please use data-EPROM linked for Console ECIS. Data-EPROM was linked for Modular ECIS.
S 0E12
No C-application-interface found.
S 0E13
Wrong C-coded-application-interface found. Please use newer system-EPROM !! Expected system-EPROM >= (Versionsnummer)
S 0E14
PAT-ME2: Wrong C-coded-application-interface found. Please use data-EPROM linked for Modular ECIS. Data-EPROM was linked for Console ECIS. Konsole2: Wrong C-coded-application-interface found. Please use data-EPROM linked for Console ECIS. Data-EPROM was linked for Modular ECIS.
SFehler_E.doc
Rev.: 01
17.09.99
•
SVE-Errors
Error_T 00 01 02 03 04 05 06 07 08 09 10 11 21 22 23 25 26 27 29 30 31
B13 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 1
B14 0 0 0 0 0 0 0 0 1 1 1 1 0 0 0 1 1 1 1 1 1
B15 0 0 0 0 1 1 1 1 0 0 0 0 1 1 1 0 0 0 1 1 1
B16 0 0 1 1 0 0 1 1 0 0 1 1 0 1 1 0 1 1 0 1 1
B17 0 1 0 1 0 1 0 1 0 1 0 1 1 0 1 1 0 1 1 0 1
Technical Training
PDC Seven Segment Display
General With normal operating conditions the six outer segments will be lit one after the other in anticlockwise direction. In case of a malfunction error messages from the local I/O ( PPBus) and the display and keyboard driver only are displayed. ‘E’ ‘=‘ with 6 digits following is the sequence of the display for error messages. ‘A’ ‘=‘ with 6 digits following is the sequence of the display for non-error messages. The 6 digits are devided logically into 3 groups. The following tables are explaining the code of these groups. Example ‘E = 06 01 02‘ is on display Decoding Group 1 Group 2 Group 3
E 06 01 02
is an error message something with a Local IO Digital output card is wrong device malfunction or device is missing card number 2
That means that card number 2 in the configuration - a digital output card - doesn't work or is missing. Group 1 source or creator of the message decoding of possible display: 00 Control (S5) in general 01 Control (S5) Input invalid 02 CPU- Card 03 Operating system RTOS-UH 04 Profibus 05 Local IO in general 06 Local IO Digital output card 07 Local IO Digital input card 08 Local IO Analogue output card 09 Local IO Analogue input card 0A Local IO Winch counter card 0C LMI 0D Keyboard/Display 0E Systemstart after booting of operating system RTOS-UH 0F Software interface LMI/LMI-Display FF Unknown Message source
PDC\7SEGMENTE DISPLAY E.DOC
TECHNICAL TRAINING
• 1 •
Technical Training
PDC Seven Segment Display
Group 2 message group General 01 device malfunction or device missing 02 error in configuration 03 CRC-error 04 memory corrupted 05 not enough or too many interrupts 06 device missing to the configurated port 07 port double configurated 08 wrong portnumber 09 calibration failed 0A EEPROM defective or wrong data in EEPROM 0B parameter error in program 0C error in general PPBUS-parameters in configuration 0D no application found 0E error while loading an application 0F no PEARL-interface found (= error in DATA-EPROM's) 10 wrong versionnumber of the PEARL-interface 11 wrong identifier for hardware-version of the PEARL-interface 12 no C-interface found 13 wrong version number of the C-interface 14 wrong identifier for hardware version of the C-interface 15 operating mode table found of the wrong type 16 error in DPRAM 17 wrong version 18 device reports an error 19 corrupted report from a device FF
unknown message group
PDC\7SEGMENTE DISPLAY E.DOC
TECHNICAL TRAINING
• 2 •
Technical Training
PDC Seven Segment Display
Group 3 Message number The meaning of the message number depends on the codes of group 1 and 2 and gives only further information about the message. So the main information is kept in the codes of group 1 and 2. If a code for group 3 is not given here, it usually does not have any important meaning. For group 1 codes 05 to 0A (local I/O) message number has the following meaning: Group 2 Codes 01, 02, 05-07, 09, 0A: message number is the number of the local I/O card. Attention, counting starts with 0 (an not with 1) . . Group 2 code 08: message number is the number of the invalid port or invalid number of ports in the configuration. Group 2 code 0C: message number specifies what's wrong in the general parameters for the PPBus 16: Address specification in configuration doesn't fit to the A16-mode 24: Address specification in configuration doesn't fit to the A24-mode FE: Invalid interrupt vector in configuration FF: access mode in configuration is wrong (not A16 and not A24) For group 1 code 0D and group 2 code 01, group 3 code is the number of the defective device, where 7 is the display and 1 is the separated keyboard.
PDC\7SEGMENTE DISPLAY E.DOC
TECHNICAL TRAINING
• 3 •
3
Description of buttons Startbild: Bildmodul 000
Buttons:
LOGO.BMP
1: not used 2: not used 3: not used 4: not used 5: not used 6: Buzzer off 7: not used 8: not used
Sprachauswahl: Bildmodul 002 SPRACH.BMP
no buttons available
4
Hauptmenü: Bildmodul 010 LMB_T.BMP
LMB_G.BMP
LMB_R.BMP
5
Tastenebene 1 - Bildmodul 010 EBENE_1.BMP
Funktionstasten:
1: Switching from level 1 to level S 2: Switching to next level 3: not used 4: Switching to length selection 5: Switching to load chart 6: Buzzer off 7: Tara button 8: Change operating mode/reeving Tastenebene 2 - Bildmodul 010 EBENE_2.BMP
Funktionstasten:
1: Switching to next lower level 2: Switching to next higher level 3: Telescope display 4: not used 5: Speed swing/hoist/derricking 6: Buzzer off 7: Small display of relative radius 8: Zoom of current display
Tastenebene S - Bildmodul 010 EBENE_S.BMP
Funktionstasten: 1: not used 2: Switching to level1 3: Parameter adjustment 4: Switching to bus overview 5: Switching to service screen 6: Switching to language adjustment 7: Set time 8: Invert screen
6
Geschwindigkeiten: Bildmodul 024
Funktionstasten:
GESCHW.BMP
1: not used 2: not used 3: not used 4: not used 5: not used 6: Buzzer off 7: not used 8: Back to main screen
Betriebsartanwahl: Bildmodul 040
Funktionstasten:
BAVORW.BMP
1: Enter operating mode 2: Menu prompt operating mode 3: not used 4: Change reeving 5: not used 6: Buzzer off 7: not used 8: Back to main screen
7
Traglasttabelle: Bildmodul 042
Funktionstasten:
TLT.BMP
1: not used 2: not used 3: not used 4: not used 5: not used 6: Buzzer off 7: not used 8: Back to main screen
Längencodeanwahl: Bildmodul 044
Funktionstasten:
LKANW.BMP
1: Selection- previous length code 2: Selection- next length code 3: Changelength code 4: not used 5: not used 6: Buzzer off 7: not used 8: Back to main screen
8
Teleskopiergeschwindigkeit: Bildmodul 046
Funktionstasten:
TELE_GE.BMP
1: not used 2: not used 3: not used 4: not used 5: not used 6: Buzzer off 7: not used 8: Back to main screen
Bussystemübersicht: Bildmodul 050
Funktionstasten:
BUS.BMP
1: Switching to information local I/O-module 2: not used 3: not used 4: not used 5: not used 6: Buzzer off 7: not used 8: Back to main screen
9
Businformationen: Bildmodul 052
Funktionstasten:
MBUSINF.BMP
1: not used 2: not used 3: not used 4: not used 5: not used 6: Buzzer off 7: not used 8: Back to previous screen
Übersicht Digitaleingänge SVE: Bildmodul 058 Funktionstasten: SVE.BMP
1: not used 2: not used 3: not used 4: not used 5: not used 6: Buzzer off 7: not used 8: Back to service screen
10
Digitaleingänge: Bildmodul 060
Funktionstasten:
A704.BMP
1: Overview analog inputs 2: not used 3: Overview digital outputs 4: not used 5: Overview digital inputs module A706 6: Buzzer off 7: Overview digital inputs module A707 8: Back to service screen
Digitaleingänge: Bildmodul 062
Funktionstasten:
A706.BMP
1: Übersicht Analogeingänge 2: frei 3: Übersicht Digitalausgänge 4: Übersicht Digitaleingänge Karte A704 5: frei 6: Hupe aus 7: Übersicht Digitaleingänge Karte A707 8: Zurück zur Service Menüauswahl
11
Digitaleingänge: Bildmodul 064
Funktionstasten:
A707.BMP
1: Overview analog inputs 2: not used 3: Overview digital outputs 4: Overview digital inputs module A704 5: Overview digital inputs module A706 6: Buzzer off 7: not used 8: Back to service screen
Digitalausgänge: Bildmodul 066
Funktionstasten:
A705.BMP
1: Overview analog inputs 2: Overview digital inputs 3: not used 4: not used 5: Overview digital outputs module A708 6: Buzzer off 7: not used 8: Back to service screen
12
Digitalausgänge: Bildmodul 068
Funktionstasten:
A708.BMP
1: Overview analog inputs 2: Übersicht digital inputs 3: not used 4: Overview digital outputs Module A705 5: not used 6: Buzzer off 7: not used 8: Back to service screen
Analogeingänge: Bildmodul 070
Funktionstasten:
A710.BMP
1: not used 2: Overview Digital inputs 3: Overview Digital outputs 4: not used 5: not used 6: Buzzer off 7: not used 8: Back to service screen
13
Analogausgänge: Bildmodul 072
Funktionstasten:
A711.BMP
1: Overview analog inputs 2: Overview digital inputs 3: Overview digital outputs 4: Overview SVE 5: Overview Joysticks 6: Buzzer off 7: Overview of values calculated from the SLI 8: Back to service screen
Übersicht: Bildmodul 074
Funktionstasten:
M_A711.BMP
1: not used 2: not used 3: not used 4: not used 5: not used 6: Buzzer off 7: not used 8: Back to main screen
14
SVE Übersicht: Bildmodul 076
Funktionstasten:
SVE_UEBERS.BMP
1: Manually unlock SVE 2: Manual operation of SVE 3: Overview analog inputs 4: Overview SVE 5: Manually unpin SVE 6: Buzzer off 7: Overview of values calculated from the SLI 8: Back to main screen
15
Nullpunkt Ausladung setzen: Bildmodul 080
Funktionstasten:
SETNULLP.BMP
1: not used 2: not used 3: not used 4: Set zero point 5: not used 6: Buzzer off 7: not used 8: Back to main screen
Nach Datengruppe A: Bildmodul 100
Funktionstasten:
DATA_A.BMP
1: not used 2: not used 3: not used 4: not used 5: not used 6: Buzzer off 7: not used 8: Back to previous screen
16
Analogeingänge SVE: Bildmodul 110
Funktionstasten:
AIN_SVE.BMP
1: not used 2: not used 3: Switching to SVE overview 4: not used 5: not used 6: Buzzer off 7: Overview of values calculated from the SLI 8: Back to main screen
17
Description of symbols Bus error - more information in screen Error SLI Time Operating mode Actual reeving Actual length code Error in control system
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