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Contents
Übersicht Standard-Traglasttabellen
Overview of standard duty charts · Tableau synoptique des abaques standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
AC 80-1 04/99 29.06.1999 10:31 Uhr Seite 4
Dimensions
AC 80-1 04/99 29.06.1999 10:32 Uhr Seite 5
AC 80-1 04/99 29.06.1999 10:32 Uhr Seite 6
Specifications
* nach hinten
* over rear
* sur l’arrière
AC 80-1 04/99 29.06.1999 10:32 Uhr Seite 9
50,0 m Hauptausleger · Main boom · Flèche principale 50,0 m Hauptausleger · Main boom · Flèche principale
12 3,0 -,0 -,0 -,0 -,0 -,0 12 3,0 -,0 -,0 -,0 -,0 -,0
14 3,0 3,0 -,0 1,2 -,0 -,0 14 3,0 3,0 -,0 1,2 -,0 -,0
16 3,0 3,0 2,7 1,2 -,0 -,0 16 3,0 3,0 2,7 1,2 -,0 -,0
18 3,0 2,9 2,7 1,2 -,0 -,0 18 3,0 2,9 2,7 1,2 -,0 -,0
20 2,9 2,8 2,6 1,2 1,1 -,0 20 2,9 2,8 2,6 1,2 1,1 -,0
22 2,8 2,7 2,5 1,1 1,1 -,0 22 2,8 2,7 2,5 1,1 1,1 -,0
24 2,6 2,5 2,3 1,1 1,1 1,0 24 2,6 2,5 2,3 1,1 1,1 1,0
26 2,5 2,4 2,2 1,0 1,1 1,0 26 2,4 2,4 2,2 1,0 1,1 1,0
28 2,3 2,2 2,1 1,0 1,0 1,0 28 1,8 2,2 2,1 1,0 1,0 1,0
30 2,2 2,1 2,0 1,0 1,0 1,0 30 1,4 1,7 2,0 1,0 1,0 1,0
32 2,1 2,0 1,9 1,0 1,0 1,0 32 1,0 1,3 1,5 1,0 1,0 1,0
34 2,0 1,9 1,9 0,9 1,0 1,0 34 0,6 0,9 1,1 0,9 1,0 1,0
36 1,9 1,8 1,8 0,9 0,9 0,9 36 -,0 0,6 0,8 0,6 0,9 0,9
38 1,5 1,8 1,8 0,9 0,9 0,9 38 -,0 -,0 -,0 -,0 0,8 0,9
40 1,2 1,4 1,6 0,8 0,9 0,9 40 -,0 -,0 -,0 -,0 -,0 0,8
42 0,9 1,1 -,0 0,8 0,9 0,9 42 -,0 -,0 -,0 -,0 -,0 -,0
44 0,7 0,9 -,0 0,7 0,8 0,9 44 -,0 -,0 -,0 -,0 -,0 -,0
46 -,0 0,6 -,0 0,7 0,8 0,8 46 -,0 -,0 -,0 -,0 -,0 -,0
48 -,0 -,0 -,0 -,0 0,8 0,8 48 -,0 -,0 -,0 -,0 -,0 -,0
50 -,0 -,0 -,0 -,0 0,6 -,0 50 -,0 -,0 -,0 -,0 -,0 -,0
AC 80-1 04/99 29.06.1999 10:32 Uhr Seite 11
Tragfähigkeiten entsprechen ISO 4305 und DIN 15019.2 (Prüflast = 1,25 x Hublast + 0,1 x Auslegereigengewicht, auf die Ausleger-
spitze reduziert).
Das Gewicht der Unterflaschen sowie die Lastaufnahmemittel sind Bestandteile der Last und von den Tragfähigkeitsangaben
abzuziehen.
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.
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.
Technical description
Carrier
Drive/steering 8 x 6 x 6.
Frame Monobox main frame with outrigger boxes integral, of high-strength fine-grain structural steel.
Outriggers Four hydraulically telescoping outrigger beams with hydraulic jack legs.
Engine Daimler-Benz OM 402 LA water-cooled 8-cylinder engine. Output to DIN: 280 kW (380 hp) at
2100 rpm. Max. torque: 1775 Nm at 1200 rpm. Fuel tank capacity: 400 l.
Transmission Allison automatic transmission, transfer case with off-road range.
Axles 1st: steering. 2nd: steering. 3rd: rigid, non-steering, 4th: steering. Axles 1, 2 and 4 with planetary hubs.
Differential lock-out control on 2nd axle: longitudinal and transverse. 1st and 4th axle: transverse.
Suspension Hydropneumatic suspension, all axles hydraulically blockable.
Wheels and tyres 8 x 14.00 R 25 on 11.25-25 rims; tubeless road-tread tyres. All axles single-wheeled.
Steering Dual-circuit semiblock mechanical steering with hydraulic booster.
Brakes Service brake: dual-line air system, acting on all wheels. Parking brake: spring-loaded type.
Sustained action brake: engine exhaust brake and constant decompression valve.
Electrical equipment 24 V.
Driver’s cab Rubber-mounted steel cab with safety glass, slide-by side windows, carrier controls, driver’s and
passenger’s seat, vertically adjustable steering wheel, heated outside mirrors, rotary beacon.
Superstructure
Hydraulic system Driven off carrier engine at low revs, 1 variable-displacement axial piston pump and separate fixed-
displacement pump for 4 simultaneous, independent working movements.
Hoist Fixed-displacement axial-piston motor, hoist drum with planetary reduction integral and spring-applied
holding brake.
Slew unit Hydraulic motor with planetary reduction, foot-pedal brake and spring-applied holding brake.
Derricking unit 1 differential cylinder with pilot-controlled lowering brake valve.
Crane cab Spacious all-steel comfortable cab with sliding door, large folding-out windscreen, roof window with
armoured glass, controls and instrumentation for all crane movements, working light. Self-contained air
heater and 7-day programmable timer, thermostat controlled. Windscreen washer and intermittent-
control wiper.
Main boom Boom base and 5 telescopic sections of fine-grain structural steel, telescoping with partial load,
buckling-resistant Demag ovaloid design.
Counterweight 8 t in sections of 5.1 t, 1.7 t and 1.2 t (6.8 t fitted on superstructure, 1.2 t hydraulically stowed on carrier
deck).
Top-steer facility
Safety devices Electronic safe load indicator with digital read-out 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.
Hydraulic servo control Hydraulic pilot control through self-centering control levers.
Optional equipment
Drive/steering 8 x 8 x 8.
Tyres Optional 16.00 R 25 on 11.25-25 rims; 20.5 R 25 on 17.00-25 rims.
Tow coupling D-value 12 t or 19 t, air-brake connection.
Hoist II Fixed displacement axial-piston motor, hoist drum with planetary reduction integral and spring-applied
holding brake. Hoist II avoids re-reeving of hoist line when using the optional jib.
Main boom extension 1- or 2-part folding jib, 9.2 m or 17.6 m. 0°, 20° and 40° offset.
Additional counterweight 10 t, integrated into standard counterweight, installed hydraulically by the crane itself.
Heavy-lift attachment Additional sheaves on boom head for duties over 60 t.
Heavy-lift runner 1.20 m long, 3-sheave, for workshop applications. Stowed on carrier during transit.
AC 80-1 04/99 29.06.1999 10:32 Uhr Seite 17
S355.1
switch
S355.2 normally closed
switch
normally open
Model: Type: Replacement for: Date: Produced by: Tel No.: Fax No.:
Telescopic AC 25, 40-1, Dept. 8333 06332 06332
crane 50E, 80, 120 - 06. 98 Mr. Sieger 83 2575 83 2579
----------------------- --------------------------
(Benien) (Rübel)
1
Service Bulletin
No. : 60 - 11
Mobile Cranes
3
2
1
8
7
6
5
While the ignition remains switched off and provided you have not yet called up any in-
formation 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 super-
structure
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
3
2
1
8
7
6
5
3
Service Bulletin
No. : 60 - 11
Mobile Cranes
3
2
1
8
7
6
5
4
Service Bulletin
No. : 60 - 11
Mobile Cranes
3
2
1
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 va-
rious 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 sto-
red 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 sta-
tic 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
6
Service Bulletin
No. : 60 - 11
Mobile Cranes
3
2
1
8
7
6
5
7
Service Bulletin
No. : 60 - 11
Mobile Cranes
3
2
1
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 superstructu-
re (AC 395-1):
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 <50°C), the MFA 10 master instrument should
then be replaced.
Please note:
When placing an order, always state the crane model, chassis, superstructure and con-
struction numbers as well as the number of operating hours relevant to both the chassis
and the superstructure.
The new master instrument can then be programmed with the appropriate number of
operating hours for the crane.
Problems may also arise with the pressure switches of the warning display for the hy-
draulic filters on the AC 395 superstructure.
When the hydraulic oil is cold, the dynamic pressure ahead of the filter element some-
times increases so much that the relevant indicator light comes on.
As the temperature of the oil increases while the filter element remains clear of any
clogging, the indicator light should go out.
If the indicator light comes on again once the hydraulic oil is warm, you must find out
the reason behind this error display.
For example, it might be due to a defective pressure switch (spare part no. 420 358 12),
a broken cable etc.
9
Technical Training AC 80
Superstructure Counterweight
Angle indicator
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.
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.
Variable Displacement Pump A11VO Prior to finalising your design, please obtain a certified drawing.
anti-clockwise rotation
V g min
M16; 24 deep
Detail W
Vg max
M12;
17 deep clockwise rotation
S
DR/D
LR
Shaft ends
Z P
Splined shaft, DIN 5480 Parallel shaft, DIN 6885
W 50x2x30x24x9g with key AS 14x9x80 Connections
65 90 A, B Service line ports (without impeller) SAE 1" 420 bar
(6000 psi) high pressure series
A, B Service line ports (with impeller) SAE 1 1/4" 420 bar
(6000 psi) high pressure series
ø44,6
ø106
M16
M16
ø50
106
ø36
36
55
67
The constant power control controls the output volume of the Variation: Integral pressure cut-off (LRD)
pump in relation to the operating pressure so that, at a constant The pressure cut-off is in effect a constant pressure control
drive speed, the preset drive power is not exceeded. which swivels the pump back to Vg min when the preset operating
pB = operating pressure pressure is reached.
pB • Vg = constant This function overrides the constant power control, i.e. the constant
Vg = displacement
power control is effective below the preset operating pressure.
Optimum power usage is obtained by accurately following the The valve is integrated into the control housing and is set in the
power hyberbola. factory to a fixed pressure.
M A G T1 R T2
S M1 S M1
Constant power control LR Constant power control with integral
pressure cut-off (fixed setting), LRD
The output power curve is influenced by the efficiency of the pump.
When ordering, state in clear text:
– input power P (kW)
– input speed n (rpm)
– max. output flow qV max (L/min)
After all technical details have been clarified, a power diagram
can be produced by computer.
Variation: Load sensing valve (LRS) Variation: Electrical stroke limiter (LRU1, LRU2)
The load sensing valve is a flow control valve which operates as a The electrical stroke limiter allows the displacement to be
function of the load pressure to regulate the pump displacement in infinitely varied or limited as required.
order to match the requirement of the consumer unit. The displacement is set by means of the control current gener-
The pump flow is influenced by the external orifice (control block, ated by the proportional solenoid.
throttle) fitted between pump and serviced unit, but is not affected A 12V DC (U1) or a 24V DC (U2) supply is required for the control
by load pressure throughout the range below the power curve. of the proportional solenoid.
The valve compares pressure before and after the orifice and The electrical stroke limiter is overriden by the constant power
maintains the pressure drop (differential pressure ∆p) across control, i.e. below the power curve (power hyperbola), displacement
the orifice – and therefore the pump flow – constant. is adjusted in relation to the control current. If the set flow or the
If differential pressure ∆p increases, the pump is swivelled back operating pressure is such that the power curve is exceeded, the
towards Vg min, and if ∆p decreases the pump is swivelled out constant power control overrides the stroke limiter and reduces
towards Vg max, until a balance is restored within the valve. displacement until the power hyperbola is restored.
∆porifice = ppump – pserviced unit LRU1, LRU2 ➔Function: V g min to V g max (positive control)
∆p may be set within the range 14 bar to 25 bar. As the control current increases, the pump swivels to a larger
The standard setting is 18 bar. (Please state required setting in displacement. (Starting position at zero pressure: Vg max)
clear text). At operating pressure > 30 bar the pump swivels from Vg max to Vg min
The standby pressure for zero stroke operation (orifice closed) (pilot current < start of control).
is insignificant above the ∆p setting. Start of control at approx.: 400 mA (U1) 200 mA (U2)
The constant power control and the pressure cut-off are super- End of control at approx.: 1200 mA (U1) 600 mA (U2)
imposed on the load sensing valve, i.e. the load sensing function
Insulation class IP 54, control from Vg min to Vg max
operates below the set power hyperbola and set pressure.
A pressure of 30 bar is needed for the control. The oil required
The orifice is not included in the standard supply. for this is taken either from the high pressure or from the external
adjustment pressure at port G (≥ 30 bar).
If the operating pressure is ≥ 30 bar and Vg min > 0 no external
control pressure is required and port G should be plugged before
commissioning. If port G is not to be used then the parts of the
shuttle valve are to be removed from the pump (see note on
repair instructions RDE 92500-R).
operating press. pB in bar
800
operating curve LRU2
pilot current I in mA
600
400
200
V g min displacement V g max
0 0,5 1,0 displacement
Vg min Vg V g max
Vg max
orifice M A G T 1 R T2
M A G X T1 R T2
S M1
The following are used for control of the proportional solenoid:
M1 ● Proportional amplifier PV _______ (see RE 95023)
S
● Proportional amplifier VT 2000 ___ (see RE 29908)
Constant power control with pressure cut-off and
● Chopper amplifier CV __________ (see RE 95029)
load sensing valve, LRDS