Liebherr Lehr Buch

description
Gomponent
of electricity
UW01- Fundamentals
i'-l--'
',
U
R
unir A=+
Gomponent
description
UW 01 - Fundamentalsof electricity
fudmedby:|mpim/Edfujl9'u07/ved:1
Libher-WrkEhln96nGmbH- Tchnlcaltralning
Onlyfor LIEBHERR
servicepersonnel
-3-
UBIIIRR
description
Component
of electricity
UW01 - Fundamentals
1. Introductionto electricity/ electronics
1.1Definitions
>1.1.1Voltage
ifthercarea different
twopoints(e.9.theterminals
ona battery)
Anelectdcal
voltage
isproduced
between
poinb.
ateachofthese
number
ofeleclrons
thesizeofthevoltage.
inelectrons
determines
Themagnitude
ofthisdifierence
ofanelectrical
voltage.
Forexaminthegeneration
separation
inthevoltage
sourc(fig'l) results
Charge
ple,thechemical
to
migraie
tolhe
causes
negatively
charged
electrons
insidea dlargingbattery
reaction
negative
terminal.
respectively.
atthepositive
andnegative
lerminals
andsuelusofelectrons
Thismeans
lhereisa shortage
thehigherthe
Thehigherthe
charge
differenlial,
ina voltage
between
thetwopoles.
Thisresults
diference
(potential
diference
involtage
difference).
1 '
., t-.t
l-
d.rg rdc It J
by chargeseparation
Fig.1:Voltagegenerated
thesedifferent-sized
charges.
in an attemptto compensate
Electrical
voltageis produced
Voltagecausescurrentto flow.
Theunitof voltageU is givenin Volt(V).
Libhetr-WkEhingnGnbB -T6chni t.ainlng
Onlyfor LIEBHERR
servicepersonnel
-4-
UTBIIIR
Componentdescription
of electricity
UW01 - Fundamentals
>1.1.2Current
voltagedifferences.
Electrons
attemptto compensate
Curentcanonlyflowin closedcircuits.Voltagecauseselectricalcurrentto flow.
movementof freeelectrons.
Electrical
currentis the dlrectional
Closinga circuitby applyinga voltageforcesall freeelectronsto movein a certain
direction.
Thiscauseselectricalcurrentto flowfromthe negativeterminalthroughthe
loadsandwiresto the positiveterminal.Electronsperformelectricalwork.
.:lr
,;r
-r
-rtr,I-
Convenlionalcunentflow
Fio.2: Flow ofelecttonsin an electricalcitcuil
Everyelect calcircuitmusthave:
. Voltagegenerator
.
LOaO
Wres
lMovementof eLectrons+
Fig.3: Electrical
circuit
Note;
suchas switches,relaysor fusesmightalsobe included.
Othercomponents
state.
Switchesaredrawnin thelrnon-actuated
andoverload.
Fusesarefittedto protectelectricalcircuitsagainstshort-circuits
Li6bher-WsrkEhingenGmbH- Tecnnl@ltEining
personnel
OnlyforLIEBHERR
service
-5-
TIEIIIRR
Gomponentdescription
UW01 - Fundamentals
of electricity
current",currentflowsfromthe positiveto
Accordingto the definitionof "conventional
thenegative
terminal.
The unitof currentstrengtht is givenin Ampere(A).
il
Conventional
-__>
Fig.4: Batteryas an electrcnPumP
DirectCurrent"DC"flowsin onlyone directionthrougha circuit.

are constant;
Thecurrentis steadyprovidingvoltageandresistance
'rl
II
E
Time [ -------->5: Diroctcurrent
anddirection:
Alternating
curentAC alwayschangesin its magnitude
Movement
of electrons
IVlovement
ol elechons
Period
Fig.6:Altemating
c!nent
Liebheii-WekEhingenGmbH
Onlyfor LIEBHERR
servrcepersonnel
-6-
UIBHIRR
of electricity
UW01 - Fundamentals
>1.1.3Electricalresistance
Electrons
do notflowfreelywhena voltageis appliedto an electricalconductor.
materialshavedifferentnumbersof freeelectrons.
Depending
on theircomposition,
provide
whichopposethe
differentlevelsof resistance
Consequently
thesematerials
current.The movementof electronsis thereforesloweddownat differentrates.
of theflowof electronsis referredto as electricalresistance.

Obstruction
R is givenin Ohm(O).
The unitof resistance
= 1VA).
=
(1 Ohm= 1 o 1 VoltAmpere
Thereare differenttypesof resistors:
. Fixedresistors
. Variableresistors
' Potentiometers
(resistors
witha slidingcontact)
--z-
-G
reslsrcr
I
--f --rresistorwiih
slidingcontact
resistorwith
taps
--G
vadable
resistor
li
tully-variable
resistorwith
slidingcontact
step-cnange
resistorwith
slidingcontact
Fig. 7: Resisiorsymbols
Unwantedresistance:
' Poorlysolderedconnections
. Badpluggedcontacts
. Faultywiresandconnections
. Rustedgroundconnections
(corrosion
resistance)
Resistancedesignations:
=
500f)
500R
=
0.5o
0R5
=
200000
2OK
=
1K5
1 , 5 K o= 1 5 0 0 K o
Libher-WerkEhlngenGmbH- T6chnl lralning
servicepersonnel
Onlyfor LIEBHERR
UBIIIRR
UW01 - Fundamentals
of electricity
>1.1.3Ohm'slaw
TheappliedvoltageU in a closedcircuitwillcausea currentlto flowthroughresistorR
(fiSl).
the resistanceR.
Theratioof voltageU to currentI determines
Georg
Simon
Ohm,namely"Ohm'slaw".
Thislaw is namedafterits discoverer
Derivation:
Fora constantresistance,
currentwill increaseas the voltageincreases.
to one another(U - l).
Thismeansthal cunentI andvoltageU are proportional
R increases.
Fora constantvoltageU, currentwilldecreaseas resistance
proportional
R areinversely
to oneanother(l - 1/R).
Thismeansthatcunentlandresistanc
of Ohm'slaw (U=R-l).
theaboveresults
in thedellnition
Combining
Unit;
R = V
in an eleclrical
Fig.8: Vadables
circuil
theequation:
The followingaid can be usedto remember
Note:
Simplyuseyourfingerto coverthe desiredsymbol!
Liebheii-Wei<EhingenGmbH-Techni@ lraning
Onlyfor LIEBHERR
servicepersonnel
-8-
IIIBilTNR
Componentdescriplion
UW01 - Fundamentals
of electricity
Measurement
examples:
Resistance
UinV
R , = 2 Q Irin A
R z =1 Q Irin A
Shortcircuit
z,a
i0
10
i0
Fig.9:Currentversusvollage
Voltage
BinO
Ur=5V I . , i n A
Uz=1ov Irin A
Shortcircuit
1 , 2 5 0,83 0,675
2,5
1,66
t,Jc
U,C
1,0
Fig.10:Currentversusresistance
Liebhetr-We*EhingenGmbH- Techn@l tralning
Onlyfor LIEBHERR
servicepersonnel
-9-
IITBHIRR
UW0'l - Fundamentals
of electricity
>1.1,4Resistornetworks
Seriesresistors:
R1
R2
R3
Fig.11:Seriesnetwork
Seriesnetworksserveas voltagedividers.
LEDs(e.9.witha nominal
voltage
ol2.4V)to
Pre-resistors
are requiredwhenconnecting
the 24Von-boardsupplyon mobilecranes.
Thefollowinglawsapply:
|
- t - t -
Thesamecurrentflowsthroughall the resistofs.
Ubt= Ur+ U, +...
Thetotalvoltageis the sumof all partialvoltages.
R.. = R,+ R,+...
is the sumof all partialresistances.

Thetotalresistance
Liebher-Wft EhingnGnbH - Tchnlcallbining
Onlyfor LIEBHERR
servicepersonnel
- t0 -
ITBIITRR
UW01 - Fundamentalsof electricitlr
Parallelresistors:
l',
Fig. 12:Parallelnetwork
Parallelnetworksserveto dividethe current.

Thefollowinglawsapply:
l,"c= lr + lr+ ...
All the resistorshavethe samevoltage.
U,.,= U,= U,= ...
Thetotalcurrentis the sumof all partialcurrents.
of thetotalresistance
isthesumofall recipro1,/R*=t76,*17*,*... Thereciprocal
catedoartialresistances.
Ll6bh6r-W6rkEhlngnGmbH- Technil tEining
personnel
OnlyforLIEBHERR
service
- 1 1-
TTEHINR
UW01 - Fundamentals
of electricity
1.2Measuremeni
technology
inslruments
>1.2.1Typesof measurement
Thereare twotypesof measurement
instruments:
. Analogue
multimeter
. Digitalmultimeter
Analoguemultimeter:
,.t,.
_-.--;;-- .f
'; ,,r''= -ll;:t
Fig.13:Analoguemultimeter
Connections:
groundconnection
COM:
v/o:
voltageand resisiancemeasurement
inAmpere-range
currentmeasurement
currentmeasurement
in milli-Ampere
range
Advantages:
. Rapidchanges
in measured
vari
dursn drv vdrry
nEcr r.
If correctlyused,often
moreaccurate.
Disadvantages:
. Whenusing
movingcoilmechanisms,
it is only
possible
DCvoltageand
to measure
current.
. Measurement
rangemustalwaysbe
manually
selected.
Note:
Themeasurement
depending
on thevariable
beingmeasured.
leadsmustbe re-plugged
Alwaysselectthehighest
measurement
rangewhenmeasuring
an unknown
variable.
Thenselectthemeasurement
rangewheretheneedleis in theupperthirdof thescale.
Liebheir-Werk
EhingenGmbH- Technicaltraining
personnel
Onlyfor LIEBHERR
service
-12-
ITBHTRR
UW01 - Fundamentals
of electricity
1,2.1Typesof measurementinstrumenls
Digitalmultimeter:
Fig. 14: [.4etrixMX22
Fig.15:chauvin
AmouxMM3000
Fig.16:chauvin
Arnoux
Conpa2010
Connections:
grounoconneqton
coM:
measurement
V/O:
voltageand resistance
in Ampere-range
currentmeasurement
range
mA:
cun-entmeasurement
in milli-Ampere
Disadvantages:
Advantages:
. Rapidindication
of measuredvalues . Difficultto noticemeasurement
. The measurement
ran9ecnanges.
rangeis often
automatically
selectedby the
measurement
instrument.
. On someinstruments
the measured
valuescanbe storedor
transferred
to a PC for further
analysis.
Note:
depending
on the variablebeingmeasured.
Themeasurement
leadsmustbe re-plugged
Liebheir-Werk
EhingenGmbH- Techni@llining
personnel
Onlyfor LIEBHERR
service
-13-
lTIBIITRR
UW01 - Fundamentals
of electricity
>1.2.2Using measurementinstruments
Measuring
electricalvoltages:
Thevoltmeter(fig 1) is switchedin
Theelectricalvoltageis measuredusinga voltmeter.
parallelto thevoltagesourceor load.A voltmeteralwaysmeasuresthe voltagedifference
points.ThetypeofvoltageAC- or DC must - be selected.
betweentwo measurement
lu
Fig.17rVoltagemeasurement
Fig.18:Voltage
measurement
Note:
probes
Thevoltageacrosseachloadcanbe individually
measured.
The measurement
mustbe applieddirectlyin frontof and behindthe loads(fig2).
Caution:
whenmaking
Theredandblackleadsmustbe connected
to V and COMrespectively
voltagemeasurements.
Liobhon-Werk
Ehingen
lraining
GmbH- Technica
OnlyforLIEBHERR
servicepersonnel
-14-
UEBilENR
of electricity
UW01 - Fundamentals
Pdudby'*pI0/Edfton
Measuringelectricalcu enls:
Theammeteris placedin the circuit,t . e .
Electrical
currentis measuredusingan ammeter.
it is switchedin seriesin eitherthe supplyor returnlineto the load.
.<-
Fig.19:Currentmeasurement
Fig,20:Currentmeasurement
Caution:
to mA(orA) andCOMrespectively
when
The redand blackleadsmustbe connected
makinocurrentmeasurements.
Liebhrr'w*Ehlnssn
GmbH- TechnlllEinins
personnel
Onlyfor LIEBHERR
service
_ 15 _
I.TIBHINN
of electricity
UW01 - Fundamentals
Resistancemeasurements:
Theresistance
valueis determined
usinoa director indirectmeasurement
or the compomeasurements
eitherrequirethe circuitto be interrupted
Directresistance
of
measurement
is
very
imprecisenentto be removed.Thistype
measurement
Fio,21: Directresistance
at the resistor.
Indirectmeasurements
are basedon voltageandcurrentmeasurements
fromthe measuredvaluesusingohm's law.
Theresistance
is calculated
Therearedifferentootionsfor oerformino
an indirectmeasurement;
l u t p
measurement
/ voltageerrorcircuit
Fig.22:Indirectresjstance
Fig.23: Indirectresislance
measurement/
curentenorcircuit
Caution:
The redand blackleadsmustbe connected
to R andCOI\4respectively
whenmaking
resistance
measurements.
Liebher-W* Ehhgon GmbH-Technicaltraining
personnel
Onlyfor LIEBHERR
service
- 16 -
UIBlIINR
UW04- Driveunit /
dieselengine
Onlvfor LIEBHERR
Service
oersonnel
Glossary:
pressure
pressure
Absolute
sensor:Theabsolute
sensoralwaysrelatesitsmeasurement
to a referencepoinl
AGR:
Exhaustrelurn
ECU:
ControlUnit(enginecontrolunit)
Electronic
EDC:
DieselControl
Electronic
(injection
systemfor Dieselengines)
OT
Topdeadcenter
PLD:
Pumplinanozzle
pressure
pressure
sensormeasures
thepressure
difference
Relative
sensor: A relative
betweentwotestvalus
UT
Bottomdeadcenter
ZMEi
Unilto bs measured
UW04 - Driveunit / dieselengine
Liebher-Werk
Ehingen
GmbH- Techniltraining
personnel
OnlyforLIEBHERR-Service
- J -
ITIBIIRR
Component
description
Liebhetr-We* Ehingen GmbH - Techni@l tinhg
personnel
Onlyfor LIEBHERR-Service
-4-
UIBHNR
uw041. Inlineengine
>1.1General
Inlineengineis the namegivento an enginewhosecylindersare arrangedin a line.
>1.2Motordesignation
Model
emissions
Optimised
Supplementary
designation
Numberof cylinders
Production
series
Dieselengine
Supplementarydesignations:
NA Suctionengine
TB Turbo-charged
engine"slightlycharged"
T
Turbo-charged
engine
Tl
Turbo-charged
enginewithchargeair cooling
S
Short(shortpistonstroke)
L
Long(longpistonstroke)
Model:
A3
M
A5
A6
A7
injectionpump
Distributor-type
MW-/ P3000 Injectionpump
P7'100- Injectionpump
pump+ EDC
P7100- lnjection
(EDC= Electronic
DieselControl)with LH ECUl
PistonvalveinjectionpumpEDCwith LH ECU4or ECUS
PLD(PumpLineNozzle)withLH ECU-UP/cR
CR (CommonRail)withLH ECU-UP/CR
Typedesignations
for inlineengines:
.D924
.D926
.D846
.D934
.D936
Distinguishingcharacteristicsof inline engineswhich can be determinedfrom their
type designation:
Production
series+ no.of cylinders= 3-digit!
ftaininq
Liebhen-Werk
Ehinsen
GmbH- Technical
personnel
_5 _
UIBIIIRN
>1.3Layout
Overview:
Rockerlever
Injectionnozzle Intakevalve
Pushrod
Dipstick
Oilfilter
Piston
lnjection
pump
Connecting
roo
Crankshaft
Oilpan
Plunger
Liebher-Wei<EhingenGmbH- Techniel tra ning
personnel
-6-
Camshaft
Starter
motor
lIEHINR
>1.4Installedenginetypes
D846- A5 / 6 CylinderDieselInlineEngine:
Exhaustgas
FSC(FuelService
Center)
. Suctionfilter
. Finefilter
. Manualdelivery
pump
Flameglowplug
EnginecontrolunitECU5
generator
Liebher-WrkEhingenGmbH- Techni@ltraining
personnel
- 7-
lTIBHINR
UW04 - Driveunit/ dieselengine
D846- A7 / 6 CylinderDiesetInlineEngine:
FSC{FuelService
Centef)
. Suciionfilter
. IVanual
delvery
pump
Enginecontrolunil
ECU UP/CR
High-pressure
pump(railpump)
air
Compressed
pump
FueldeTivery
Exhaustwatercooler
Oilfilier
Liebher-werkEh ngen GdbH - Technicaltiring
personnel
Onlyfor LlEBHERR-Service
-8-
Flameglowplug
Genetor
lTIBHIRR
Component
description
D924- A4 / 4 CylinderDieselInlineEngine(ow engine);

EnginemntroluniiECU1
Fuelpreliminary
filterunit
Fuelllnefilter
D926- A5 / 6 CylinderDieselInlineEngine:
Heatingflange
FLrel
finefilter
Oilfilter
Fuelpreliminary
filterunit
Liebher-Werk
Ehingen
GmbH' Technilhaining
personnel
-9-
UIBHTNR
D934-A6 / 4 CylinderDieselInlineEngine(ow engin):

Enginecontrolunit
ECUUP/CR
Fuelfinefilter
Oilfilter
Plug-inpr.rmps
Coolant
pump
Fuelprelimin
filterunil
Fueldeliverypun
Starter
molor
pressedair
compressor
Oilcooler
Exhauslgas
turbocharger
D936-AO / 6 CylinderDiesellnline Engine:

Engine
control
unit
ECU UP/CR
Fuelfinefilter
Fulpreliminary
filtorunit
Uebher-We* Ehingen GmbH - Technil Aaining
personnel
-10-
HIBHNR
2. V-engine
>2.1General
givento an enginewhosecylindersare anangedin a V-forV-engineis the designation
matron-
>2.2 Motordesignation
Model
emissions
Optimised
designation
Supplementary
Numberof cylinders
Production
series
Dieselengine
Supplementarydesignations:
TB Turbo-charged
engine"slightlycharged"
T
Turbo-charged
engine
enginewithchargeair cooling
Tl
Turbo-charged
Model:
A3 A4 A5
A7
P7800- Injectionpump
P7800- Injectionpump
+ EDC(electronic
drivecontrol)
Piston
valve
injectionpump
H-RP43
+ EDC(electronic
drivecontrol)
CR (CommonRail)withLH ECU-UP/CR
Typedesignationfor V-engines:
.D9306
.D9308
.D9406
.D9408
.D9508
Distinguishingcharacteristicsof V-engineswhich can be determinedfrom their
type designation:
Production
series+ no.of cylinders= 4-digit!
UebheFWei< EhinsenGmbH- Techni@lt alning
personnel
_f
lTIBITIRR
Gomponent
description
>2.3Layout
Overview:
Oilseparator
Pushrod
pump
Injection
Plunger
Rockerlever
Dipstick
lntakevalve
Rockerlever
Outletvalve
Injection
nozzle
Piston
Camshaft
Oilcooler
Connecting
rod
Crankshaft
Oilfilier
Oilpan
Connecting
rod
Exhaust
9as
turbocharger
Injectionnozzle
Startermotor
Liebher-werk
Ehingen
tralring
GmbH- Technlcal
personnel
-12-
IIIBIIIRR
2.4Installedenginetypes
D9406-A5 / 6 CylinderDieselV-Engine:
Fuelfine filter
Generator
Coolantpump
D9408- A5 / 8 CylinderDieselV-Engine;
Oilfilter
Engineconlrcl unitECU4
Coolantpump
Fuelflnefilter
Fuelprcliminary
filterunit
Air conditionrngsysiem
Generalor
Liebher-We* EhlngenGmbH- Techncal lraining
personnel
- ' t 3-
IIIBHRR
D9508- A7 / 8 CylinderDieselV-Engine:
Oil separalor
Heatingflange Exhaust
gas
turbochargef
Actuating
cylinder
exhaustflap
(enginebrake)
Generalor
Aircondilioning
compressor
High-pressure
pump
Enginecontrolunit
ECUUP/CR
FSC(FuelService
Center)
D9508- A7 / 8 CylinderDieselV-Engine:
Heatingflange
Exhaustgas
turhochaQer
Oilseparator
Enginecontrolunit
ECUUP/CR
Oilseparator
Oil filter
Starter
motor
Coolantpurnp
Generator
Airconditioning
compressor
Liebher-Werk
Ehingen
GmbH- Technillralning
personnel
-14-
FSC (FuelService Center)
lIIBIIIRR
3. Dieselengine,general
>3.'l Modeof operation
and self-ignition
of the fuel/ air
TheDieselenginealwaysworkswith internalcarburation
mixture.Dieselenginesworkmostoftenaccordingto thefourcyclesystem.
>3.2Work cycles(supplyphases)of the four cycle system

Fuelinjector
Suctioncycle (1. cycle):

The pistonmovesdownwardin direction
of the bottomdead center(UT position).
The intakevalvesare open and air flows into
the combustionchamber.
Note:
At the start of the 1. cycle,the exhaustvalves
are also open for a shorttime.
Due to this valve overlap,the incomingfresh
air flushesthe combustionchamber.
Compressioncycle (2. cycle)
Fuelinjeclor
Thepistonmovesup andthe air is compressed.Thecompressed

air heatsup dueto
heat
is
the compression and far abovethe selfignitiontemperature.
lntakevalve
Towardsthe endof the compression

cycle,Jlliquid
fuel
is
injected.
This
forms Fuelis
nelyatomized,
injected
a fuel/ airmixture,
Afterthe ignitiondelay(timefromwarmup to
self-ignition),
the fuelmixtureignitesby itself.
Theintakeandexhaustvalvesare closed.
Ll6bhe(-WerkEhi.genGmbH- Technicalfiaining
personnel
- 15 -
lTIBHINR
Gomponent
description
Workingcycle (3. cycle):

Theignition,whichoccursshortlybeforethe
Fuel,
top deadcentertriggersthe combustion.
whichis stillinjectedafterthe startof ignition,
burnscompletely.
pressurepushesthe
Theresultingcombustion
pistonin directionof the bottomdeadcenter
(uT position).
Theintakeandexhaustvalvesare closed.
Piston
moving
gases(hydrocarbon,
Combustible
nitrogen
oxide,carbonmonoxideand carbonparticles)
are created.
Fuelinjector
Exhaustcycle (4. cycle):

The intakevalvesare closed.
Theexhaustvalvesareopen.
The pistonmovesupwardand pushesthe
burntgasesintothe exhaustsystem.
Liebheii-Werk Ehingen GmbH - Techniel lraining
personnel
Exhaust
- 16 -
lTIBIIIRR
Component
description
4. Injectionsystem
>4.1 Electronicdieselcontrolsystem EDCwith pistonvalve pump - A5
Layout:
Theelectronic
dieselcontrolsystemwith pistonvalvepump- A5 comprisesan
withinjectionadjuster(regulatiinlineinjectionpump(pumphousingand pumpelements)
of the injectionstarttimeand extremelyexactsupply
on).Thispermitspreciseregulation
of thefuel.
Fig.1: Overview
ofpistonvalvepump
Injection
nozzleouUets
[,4agnet
to adjuststartof supply
"Pistonvalve"actuator
(changestadof supply)
Pistonvalve
Regulationrcd
Camshaft
quantityactuator- EDC
Injection
(regulation
rodcontrol)
Fig.2: Pistonvalvepump
Libhr-we* EhingnGnbH - Technicataining
personnel
OnlyforLlEBHERR-Service
Fig.3: D846-A5withpistonvalvepump
ITEHIRR
Component
description
Fig.4:Engine
control
unit(ECU)
Function:
. The pumpelementsare controlled
via the camshaftof the injectionpump.
. Theinjection
pressure
is dependent
on theengineRPM.
. Variablestartof supply(startof injection)andvariableinjectionquantity
(injection
duration).
- Thestartof injectionis modiJled
by regulating
the pistonvalve.
(closed-loop
controlled
regulation
circuit)andactuated
Thisis electronically
by meansof the pistonvalveactuator.
- The needlemovementsensorsignalsto the EDCcontrolunitthe actual
injectiontime.
- Thefunction
oftheEDCsupplyquantity
controlis thesameas forconventional
rod is actuatedby the EDC
EDCinlineinjectionpumps.The regulation
quantityactuator.Thecontrolsystemusesan electronic
controlunittogether
withan inductiveacknowledgement
device(regulation
transducer).
Liebher-Werk
Ehingen
GmbH-Techni training
personnel
-18-
lIIAHRR
>4.2 PLD(PumpLineNozzle)- A6
Layout:
. ThePumpLineNozzle(PLD)systemis a modular
injectionsystem.
regulatedhigh-pressure
electronically
. Thiscomprises
injectionlineand a nozzle
an injectionpump,a shorthigh-pressure
per
(figure
1).
cylinder,
see
holdercombination
Fig. 1: OverviewPLD engine

I\,4anualbleeding
pump
UniiPump
Solenoidvalve
on prugrn pump
Fuelpreliminary
filterunit
Fueldelivery
pump
Fuelfinefilter
Solenoidvalveon
prugrnpump
Liebhe(-WerkEhi.genGmbH-Technicaltraining
personnel
-19-
UIBIIERR
Fig.2:Overview
PLDengine
1 Nozle holder(claw)
2 Cylinderhead
3 lnjectionIine
Nozzle
5 Solenoidvalve
6 Fulfeed
7 P!mp
a Camson camshaft
Function:
. The injectionpumpsare drivenby the camshaft.
. Thestartof injectionand injectionquantityare adjustedusinga solenoidvalve
for eachcylinder.
The solenoidvalveon the injectionpumpis controlledby the
enginecontrolunit.
. Theinjectionpressureis dependent
on the engineRPM.
. Moderndistributor-type
injectionpumpscangeneratea maximumpumppressureof
800-1000bar.The useof currentPLDsystemsallowsan increase
to a maximumpumppressureof approx.1500bar.
Fig.3: D936-A6PLDongine
Enginecontrolunit
ECUUP/CR
cooledJuel
Liebheri-WkEhingnGmbH- TechnicallEining
personnel
-20-
lTIBIIRR
Component
description
UW04 - Driveunit/ diesele ngrne
>4.3CommonRail - 47
Layout:
. The CommonRailSystemis an electronically
regulatedhigh-pressure
injection
pipe(CommonRail).
systemwitha commondistribution
Low pressurecircuit:
Thisconsistsof a fuelsuctionsection,feedpressuresectionandfuelreturnfuelfilter,fuelfeedpumpand
Thisincludesthefueltank,fuelpre-heating,
(ZME).
electricalrailpressureregulation
Highpressuresection:
pump,thehigh-pressure
lines,
Thiscomprises
the high-pressure
per
(Rail),
reservoir
andan injector cylinder
thehigh-pressure
Electroniccontrols:
the railpressure
the electronic
controlunit,the sensorequipment,
Thiscomprises
shut-off
valve.
regulation
valve,the solenoidvalvesfor the injectorsandthe
Fio.2: D846-A7- Overviewof commonrail
FuelServiceCenter (FSC)withfine
fuelandsuction
2-step
filter,manualfeed High-pressure
reseNok
high-pressure
DBV
pumpandfuel
(Rail)/ manifold
withhigh- (RailDBV)
p.e-heating
pressureregulation
circuit
1
R"it or"""rr"
(RDS)
sensor
\
\
\
\ ,
,
, +\ \ +\ t r
To
injector
Relumlinefrom
injectors
0.5bar
r lr
e # \ ' * , t i= u
controlunit
(cooledby
fuel)
etectt
ratlpressure
regulation
valve(zME)
RailPressure
5 barfeedpressLlre
1.5bar- Flamestarting -
Liebhen-Werk
EhingenGmbH- Technil Laining
personnel
Fuelsuctionline
High-pressure
pump
Fuelreturnlineto tank
0.5bar- lnjectorreturnline
-21 -
lTTBIIIRR
UW 04 - Driveunit / dieselengine
Function:
pumpprovidesthe requ'redfuel pressureunderall operating
The high-pressure
reservoir.
conditions
andfeedsthefuel intothe high-pressure
The high-pressure
diesel.
reservoir(CommonRail)storesthe pressurised
Sincethe high-pressure
reservoir(Rail)storesa largeamountof fuel,the injectorsand
pressurefluctuation.
combustion
chambersare suppliedwilhoutanysignificant
pressure
The injection
is thereforenotdependent
on the engineRPM.
The pointedinjectorlip on the CR nozzlecloses

ifthe systempressureis veryhigh.
automatically
Thehigh-pressure
regulation
and controlofthe
injectionstaruduration
are completely
independent
of
one anotherand havea variableadiustment.
Fig.2: fuelcooled engine

controlunit ECU UP/CR
Fig.3: D846-A7- Commonrail engine
LiebheE-Werk
EhingenGmbH- Techn'callraining
personnel
-22-
5. Sensors
speedsensor
>5.1Rotational
Purpose:
the RPMandcrankanThe impulsetransmitters
arefittedto theflywheelanddetermine
gle.Thesevaluesare requiredfor the correctactuationof the injeetors(startand
durationof injection*).
Additional
tasks:
. Engineshutoff viathe controlunitat overspeed
. Monitoring
for gradientviolationof RPMdifference
(forexampleif distancebetweensensorandflywheelis too Iarge)
. Recognition
of ignitionpointposition,,topdeadcentei'(OT)on engineswith
versionA5.
Layout:
The RPMsensorscaneitherbe inductivesensorsor hallsensors.
provide
lines.
havetwoconnection
an analogue
signaland
Inductive
impulse
transmitters
provide
have
lines.
threeconnection
Hallimpulsetransmitters
a digitalsignaland
sensors.
BothRPMsensorsare usedas incremental
aresometimesusedto determine
Forsafetyreasons,two identicalimpulsetransmitters
is theworkingsensor;in casethisfails,the
the engineRPM.Theflrstimpulsetransmitter
second
auxiliary
impulsetransmittetThe engineis
switchesto the
systemautomatically
fail.
stoppedif bothimpulsetransmitters
InductiveRPMsensor:
RPMsensor
Fig.1;Wiringdiagramexcerptinductive
Fig.3: Originalillustraton,
inductive
RPN4
sensor
Flywheel
Teeth
lnductive
RPMsensor
Liebher-Werk
Ehingen
GnbH-Tch.icaltrainlng
personnel
-23-
lTIBIIIRR
Gomponent
description
Schematicdiagram,inductive
RPMsensor
HallRPMsensor:
HallRPMsensor
Fig.4rWingdiagrcm
excerpt
Fig.3: Originalilluslration,HallRP[/ sensor
Hall
RPI\4sensor
Teeth
Flywheel
Liebhed-WeA
lraining
Ehingn
GmbH- Technical
personnel
-24-
UEBHINR
>5.2 RPMsensoras camshaftsensor*
Task;
the position"Ziind-OTZylinder1" (= lgnilisn
The camshaftsensoris usedto recognize
=
1).
OT topdeadcentercylinder
Thecamshaftsensoris locatedon engines,versionA6 andA7 on the camshaft.
Design:
sensor.
Thecamshaftsensoris a Hallsensor,whichis usedas an incrementat
Fig.1: Widngdiagramexcerpt
sensor
Camshaft
Note;
Hallsensorsmaynotbe usedfor inductivetests(Dangerof destruction).
view,camshaft
Fig.3: Schematic
sensorD846-A7
Fig.2: Originalillustration,
camshaft
sensorD846-A7
Camshaft
gear
Flywheel
Function:
the engine
Thecamshafisensoris installedon the camshaft.Forthe startingprocedure,
requiresa certaininitialposition.Thisso-calledignitionoT (topdeadcenter)is detected
by the camshaftsensor.
Note:
Thecamshaftgearturnsduringthe courseof the4 cycles 1 x by 360', theflywheel2 x
360".
' = onlyon engineswithPLDor CommonRaillechnology
training
LiebheF-Werk
Ehingen
GmbH-Tochnical
personnel
-25 -
ITIBIIIRR
EE|.|fM4id/fusgab1ol
>5.3 Oil Dressuresensor

Puroose:
. Wamsusersaboutlowoil pressure
. lmorovedmotororotection
. Recordsoil pressurewarningsin the errormemoryof the controlunit.
Layout:
Theoil pressuresensormeasuresretal|veDressure.
Supply:
Pressurerange:
Outputvoltage:
lmax= 15 mA
0 to 10 bar relative
0.5V = 0 bar/ 4.5V = 10 barlinear
Fig.2: Oil pressure

sensoa
Fig.1: Extractof circuitdiagramforoil
IJ
Fig.3: Originalpictureof oil pressure
Fig.4:Oilpressuredisplay
Display
engineoil pressure,
(1-1obar,
lLED=1bar)
Oilpressure
Engineoil pressure
warning
(dependent
on RPMandenginetype)
Liebheii-We* EhingnGmbH- Technil lraining
personnel
-26-
lTIBHINR
E6|d|er|*epid/lE!,e
Function:
variesas its shapechanges.
Theelectricalresistance
of the coatedmembrane
Thechangesin shapecausedby increasedsystempressurealterthe electricalresistanceandeffecta changein voltageacrossthe resistorbridge(5Vsupply).
(depending
on theappliedpressure).
Thisis amThisvoltageis in therange0.....70mV
plifiedbythemeasurement
V
circuitto a valuein therange0.5........4.5
Electical
connectrons
lvleasurement
circuit
l\,4embrane
with
sensotetement
Pressure
connection
Fastening
thread
Fig6: Principle
sensor
design- oil pressure
Membrane:
'1Piezo-resistive
bridge
2 Thicklayermembrane
3 Pressure
chamber(,,Bubble")
4 Ceramicsubsfate
Liebher-We* EhingenGmbH-Techni training
personnel
OnlyforLlEBHERR-Service
-27 -
ITBIIIRR
>5.4 Chargeair pressuresensor
Purpose:
(LDAfunction)
injectionlimitation
is usedto
Chargeair-dependent
in thelowRPMrange(upto approx.1500rpm).
limitsmokeemissions
At speedsabove1500rpm,thereis no injection
(restricted
Thishashelpedimprovethe dynamic
limitation
smokeemissions).
regulation
systems,one alwaysassume
responseof the unit.In contrastwith mechanical
quantity
the maximuminjection
whichis thenlimited.
Layout:
Thechargeair pressuresensormeasuresabsolutepressure
pressure)
(Thesensoralsotakesintoaccountthe atmospheric
Supply:
Pressurerange:
Outputvoltage:
lmax= 5 mA
0.5to 4 barabsolute
=
0.5V 0.5bar/ 4.5V = 4.5barlinear
pressure
sensor
Fig.2:Originalpiciureof chargeairpressure
sensor0846-45
Chargeair pressure
sensor
Function:Seeoil oressuresensor
Ll6bh6-WelkEhln96n
GmbH-Tsch.icaltraining
personnel
-28 -
lIIBHINR
UW 04 - Driveunit / dieselengine
>5.4 Chargeair pressuresensor
Purpose:
(LDAfunction)
is usedto
Chargeair-dependent
injectionlimitation
limitsmokeemissions
in thelowRPMrange(upto approx.1500rpm).
At speedsabove'1500rpm,thereis no injection
(restricted
Thishashelpedimprovethe dynamic
limitation
smokeemissions).
regulation
systems,one alwaysassume
responseof the unit.In contrastwith mechanical
quantity
whichis thenlimited.
the maximuminjection
Layout:
Thechargeair pressuresensormeasuresabsolutepressure
pressure)
(Thesensoralsotakesintoaccountthe atmospheric
Supply:
Pressure
range:
Outputvoltage:
lmax=smA
0.5to 4 barabsolute
=
0.5V 0.5bar/ 4.5V = 4.5barlinear
pressure
sensor
Fig.2: OriginalpictureofchargeairpressuresensorD846-A5
Chargeair pressure
sensor
Function:Seeoil oressuresensor
Liebher-We*Ehinsen
GmbH- Iechniltraininq
personnet
-2a -
lIIBIITRR
>5.5 Coolanttemperaturesensor
Purpose:
. Warnsuserswhenthe coolanttemperature
warningthresholdis reached.
. Reducesenginepowerwhenthewamingthresholdis exceeded.
(e.g.for
safetyreasonsthe regulation
systemautomatically
reducesenginepowerif the
coolanttemperature
is too high).
. Errormessage.
Layout;
Fig.2: Overviewofcoolant
Figl: Extractof circuitdiagramfor cooanilemperature

sensor
temperalure
sensor
Fig.3: O.iginalpictureofcoolantlernperaturesensorD846-A5
Fig-4: Coolanttemperature
disptay
Coolanttempeaature
(30-120'C,1LED=10')
Coolanttemperatu
re sensor
Dieselengineoverheating
(LEDon=T>120'C)
Function:
js monjtoredby a temperature
Thetemperature
sensorwithan NTCcharacteristic
(semiconductor),
i.e.the measuredresistance
willdecreaseas the temperature
rises.
Thecurveis notlinear.
Liebh6(-Werk
Ehingen
cmbH- Technietrraining
personnel
-29-
UIBTIINR
Gomponent
description
5.6 Chargeair temperaturesensor
Purpose:
in the chargeair
TheChargeair temperature
sensormeasuresthe temperature
is
Forsafetyreasonsthe regulatormustreducethe powerif the chargeair temperature
toohigh.
Layoul:
Fig.2: Overview
ofchargeair
temperauresensor
Fig.1: Extractof circuitdiagramfor

chargeairtemperature
sensor
sensorD846-47
Fig.3: Originalpictureof chargoairtemperature
Chargeak temporature
sensor
Function:
Thetemperature
is monitoredby a temperature
sensorwithan NTCcharacteristic
(semiconductor),
willdecreaseas the temperature
rises.
i.e.the measuredresistance
Thecurveis not linear.
Example:
= 75"C
= 0% reduction
Tl
= 17%reduction
T3 = 90"C
Liobheii-WrkEhingenGmbH- Techni@ltEining
personnel
-30-
lTIBIIIRR
UW04 - Driveunit / dieselengrne
>5.7Atmosphericpressuresensor
Puroose:
Lessair is suckedin at altitudedueto the lowerair density.
Theinjectedfullloadquantitycannotbe combusted.
of smokeand increasedenginetemperatures.
Thiswill resultin the development
problem
whichcouldoverspeed
dueto the lower
is the exhaustturbocharger
Afurther
air density/ exhaustcounterpressureat constantinjectionvolume.
Thisis preventedby meansof injectionreduction.
Layout:
pressuresensoris integratedin the regulator
FrommodelsAOonwardsthe atmospheric
part
(Figure1).
unit
of
the
engine
control
andtherefore
or is defective;
the altimetercannot
Thewholeunitmustbe replacedif thismalfunctions
be orderedseparately.
Fig.2: A5 withallitudepressure
sensor
Fig.1: ECU UP-CR/A6 /A7 with

Atmosphericpressuresensor
pfes6ure
Atmospheric
sensor
Function:
pressurewillchangedeThealtitudevaluesare onlyrelative,becausethe atmospheric
pending
on theweather
andaltitude.
pressure(ambientpressure)
fallsbelow840mbar
Onlywhenthe atmospheric
(approx.1550m abovesea level)willthe regulatorstartto reducethe injectedfull load
volumeaccording
to the specifiedcharacteristics.
Powerreduction
example:
1000 130!l
(mbar)
Libhtr-Werk
ng
Ehingen
GfrbH-Tech.icltrain
personnel
- 3 1-
550
4850;
23.1
24.1
EZE
3S50.
19.5
19.6
5S0
3100,
'14.2
774
2250i
040
1550'
l EDO '1S00 2104

24.4
?3.3
1S.1
1S.1
18.0
14.8
13.S
13.6
12.6
10.0
10.1
8.9
8.4
72
00
0.0
0.0
0.0
0rl
IIBHIRR
>5.8Air filter underpressuresensor"Air filter OK"
Purpose:
Theairflter underpressure
on thedisplayunitin thedriver's
sensorseryesto indicate
cabif thereare highlevelsof dirtin the air filter Thisindicatesto the driverthatthe air
filtermustbe exchanged
or cleaned
Layout:
Theair lllterunderpressure
sensor(opener)openswhenan underpressure
situationoccurs.
Fig.2: Originalpictureot airfilter
Underpressure
sensorD846-A5
Fig. 1: Exkactofcircuit diagram

for air filter underpressufesensor
Displaydirtin airfilter
Function:
closed)is in theairsuctionlineof the
Theairfilterunderpressure
sensor(normally
engine.The underpressure
sensoris normallyclosed.lf thefllteris clogged,an underpressurewillformafterthe filterandthe switchwill open.
A dirtyair filteris indicatedby display"Dirtin air filter"(Fig3).
Liebheir-Wer*
Ehingen
l6inin9
GmbH- Technical
personnel
-32-
lTIBHRR
6. Enginepreheating
>6.1Enginepreheatingvia flamestartingdevice
Puroose;
Theinjectedfuelignitesin the hot,highlycompressed
Dieselengineswithself-ignition.
witlbecomeprogressively
morediffidropsself-ignition
air.lf the suctionair temperature
is no longerpossible.
cult.At a certainpointknownas the coldstartlimit,self-ignition
preheat
purpose
the
sucked
in air to ensurethatthe
The
of theflamestartingdeviceis to
dieselenginewillstartevenat lowoutdoortemperatures.
suchas whiteand
the suckedin air willminimisethe amountof pollutants
Preheating
whenstartingthe engineat lowtemperatures.
coldsmokeemissions
Layout:
Fig.1: Extractofcircuitdiagramforflamestartingdevice
ng.
z. vrg
d, P,L'urc
u, ,,.,,,E
Jd,u,iv
vcv,LL
\--
V
A
ln
Itl
I
Flameglowplug
Solenoidvalve,releases
fuelto flameglowplug
Flamestartingdevicescompriseone or moreflameglowplugs,a coolanttemperature

lampandif
sensor,electromagnetic
valvefor fuelrelease,an engineECU,an indicator
requireda pressurereducerfor thefuelsupply.
Fig.3. Flameglowplug
glowplug
Pencil-type
withheatingspiral
Fuelfeed
Coatpipe
Liebheir-Werk
EhingenGmbH- Techniel training
personnel
-33-
UIBIIIRR
Funclion:
Theflameglowplugis screwedintothe suctionmanifoldpipe.
glowplugwhichis surrounded
by a coat
Theflameglowplugconsistsof a pencil-type
oioe.
Thefuelis dosedvia a solenoidvalveand nozzleand sprayedintothe heaterplug.lf fuel
glowplug,
in the coatpipethencomesintocontactwiththe hot shaftof the pencil-type
thiswill be evaporated
andflowto the outletopeningon the coatpipedueto a lackof air,
Thefuel is mixedwiththe suckedin air and ignitedby the glowingdomeon the flame
glowplug.Theheatof theflamejet heatsihe suckedin airtherebypermitting
thediesel
engineto be startedevenin coldoutdoortemperatures.
Nole:
is below20'C, flamestartcontrolis switchedon andtheflame
lf the coolanttemperature
"l") (preheating
glowplugmustbe pre-heated
time).
switch(inposition
usingignition
time
controllamp(Figure4) is lit. Oncethe preheating
Thisis indicatedif the preheating
preheating
to
flash
until
the
engine
is
started.
lamp
will
start
expires,the
control
Fig.4:Preheating
controllight
Preheaiing
controllight
Fig.5: Schematic
of a flamestartsystem
6
5
4
Prefilter
3
4
5
6
7
I
I
10
Leakoil line
pump
Supply
Overflow
valve
Solenoid
valve- releaseoffuel
Flameglowplug
pump
Injection
Suclionline
Fueltank
Liebher-Wei<EhingenGmbH- Technicallraining
personnel
-34-
IIIBIIIRR
via heatingflange
)6.2 Enginepreheating
PurDose:
The purposeof the heatingflangeis to preheatthe suckedin air to ensurethatthe diesel
enginewillstartevenat lowoutdoortemperatures.
suchaswhiteand
theamountof pollutants
Preheating
thesuckedin airwillminimise
In contrastto the
coldsmokeemissions
whenstartingthe engineat lowtemperatures.
flamesta.tingdevice,the heatingflangedoesnotcombustanyoxygen.Thisleavesmore
oxygenfor ignitingthe fuel.
Layout:
Fig.2: Originalpictureof heatingflange:
Fig. 1: Exlractof circuitdiagramfor LTM1070-4.1:
I
R9
NEIZFLANSCH
I ,9kt4
-M5P1
Heatingspiral
/1ll,l
Flange
housrng
R
I . l A S S EM O T O
Function:
Theheatingflangeis builtintothe suctionpipeandconsistsof a flangehousingwith integratedheating
ofapprox.1000'Cand
spiral.Theheating
spiralcanreachtemperatures
servesto oreheatthe suctionair.
Note:
is below10'C,the heatingflangecontrolis switchedon and
lf the coolanttemperature
usingignitionswitch(in position"l") (preheating
the heatingflangemustbe pre-heated
time).Heatingflangecontrolis alsoactivatedif the coolant
is below-10 "C
is below25 "C andthe chargeair temperature
temperature
whenthe preheating
conirollamp(Figure3) is lit.Once
Thepreheating
timeis indicated
timeexpires,the preheating
controllampwillstartto flashuntilthe engithe preheating
ne is started.Whenthe engineis startedwithheatingflangecontrol,the idlingspeedof
increased
to supportthe battery.
somedeviceswill be automatically
Fig.3: Prehealingconirollight UW engine
Fig.4: PrehealingconlrollightOW engine
Preheating
conlrollight
Liebher-WerkEhingenGnbH - Techni@llralning
personnel
-35-
lIIBTIRR
>7.Chargeair coolingwith turbocharger(exhaustturbocharger)
7.1Task
Thechargeair coolingwithturbochargeis usedto increaseperformance.
Oil pressureline
for lubrication
7.2Design
Chargeair (compressedair flow)

to chargeair cooler
Fig.1: Exhaust
turbocharger
D 846TlAT wiihWastegate
lntakeair
fromairfiller
(freshajr)
Exhaustoutlet
(to exhaustpipe)
Turbinehousing
(drive)with
bypassflap
Chargepressure
conlrol
valve(prcssure
dispense0
to controllhe bypassflap
Compressor
housrng
lineto
Bypass
pressure
charge
regulalion
Libhen-Werk
training
Ehingn
GmbH- Technlcai
personnel
-JO-
lTIBITIRR
7.3Function
Fig.1: Functional
schematic
of chargoak coolingwithturbochargeon inlineenginoD846
J
1
2
3
4
lntakeairfromairfilter
(freshair)
Exhausttubocharger
lntakemanifold
Chargeairapprox.
'120'Ccompressed
airflow)
Chargeaircooler
5
6
7 Coolair
Chargeak approx.50 C'
I
I
1 0 Coolantcircuit
1 1 Exhalstmanifold
/ exhaustflow
1 2 Exhaustemission,
approx.600'
enginedependson the amountof air andfuel,which

Theperformance
ofthe combustion
is availablefor combustion.
Toincreasethe performance
of the engine,moreair andmorefuelmustbe therefore
suoDlied.
However,
to supplymorefuelis onlyeffectiveif alsosufficientoxygenis availablefor its
combustion.
of the necessaryoxygen,it willcause
lf additional
fuelis supplied,withoutthe availability
the engineto smokesignifcantly.
(charged)in an exhaustturbocharger
and
Forthisreason,thefreshair is precompressed
is obtainedat the
Thisway,a higherspecificperformance
thendirectedto the cylinders.
RPM.
and
at
the
same
engine
samedisplacement
Liebhn-WerkEhingenGmbH-Technielt alning
personnel
-37-
lIIBHINR
Fig.3: Functionalschematic
oi an exhaustlurbocharger
1
2
3
4
5
6
7
8
9
'10
'11
12
13
'14
Oildischarge
Shaft
Radialbeadng
Axialbearing
airflow)
Chargeair (compressed
to chaeeaircoolef
lntakeak fromairfilter
(freshair)
Compressorgear
Comprcssor
housing
Oilsupply
Bea ng housing
Turbinegear
Exhaustoutlet
Turbinehousing
Exhaustmanifold
/ exhaustflow
(aircompressor).
lt consistsmainlyof a comA turbocharger
is in principlea compressor
pressorgear(5) anda one-stageturbinegear(9),whichare connected
witha common
(2)
rotate
the
same
rotational
speed.
shaft andtherefore
at
exThe turbinegear(9) transfersa largepartof the normallyuselesslydeflagrating
haustenergyinlo rotationalenergyand drivesthe compressorgear (5).The compresair to the individualengine
sor geardrawsin freshair and suppliesthe precompressed
cylinders.
On Dieselengineswithturbochargeand chargeair cooling,to furtherincreasethe cylinder chargingandfor thermalrelieve,a chargeair cooleris set in frontof the watercooler
To intakeair requiredfor combustion
is thereforedirectedto the cylindersafterprecompressionin the chargeair cooler,cooledto approx.50" C.
Fig.4: FLncliona'
withWaslegate
schematc
of anerhaustturbocharger
1
2
3
Chargepressure
controlvalve
(pressure
dispenser)
Bypassline/ chargepressure
Bypassflap
To limitthe chargepressure(peakpressure),
on someexhaustturbochargers,
a bypass
pfessure
(Wastegate)
(pressure
is installed.
A charge
controlvalve
dispenser)is actuated
withchargeair and controlsthe bypassflap.The chargepressureis limitedby the openingbypassflap,by directingpartof the exhaustflowpastthe turbinegearanddirectly
intothe exhaustsystem.
Llebhsr-Werk
lraining
Ehingen
GmbH- Tchnical
personnel
-38-
I.TIBilINR
-
>8.AGRlexhaustreturn)
8.1Task
Theexhaustreturn(AGR)is usedto limitthe nitrogenoxydes(NOX)in the exhaust,
of fuel.
whichare createdduringthe combustion
to obtainthe specifiedemissionlimitvaluesfor combustion
Thisreductionis necessary
enginesin vehicles.
8.2 Design
Fig1: Exhauslreturnon D 846TlAT
.,fl02
AGR-Modulo:
AGR-Valvewith
electro-pneumatic
shutofi flap(pn
cylindernot energized
= closddmper)
lntakemanifold
Exhaustmanifold
AGRhealxchangr
Liebhen-werkEhinggnGmbH- Technicallraining
personnel
-39-
ITIBIIRR
8.3Function
Fig.1: Functional
schematic
ofan exhaustret!m
1
2
3
5
6
7
I
10
11
12
Exhaust
turbocharger
Exhaustmanifold
Intakeair(freshair)
Air filter
Intakemanifold
with
incoming
chargeair
Dieselengine
Chafgeaircooler
AGRvalve
Electro-pneumatic
shulofi flap
peakvalves
Pressure
AGRheatexchanger
Exhaustoutlei
Partof the exhaustis directedagainthrougha pipeto the freshair for combustion.

Dueto
thig.ririxture
of cooledexhaustand the resultinglackof oxygen,the combustion
tempera.tuie is lowered.
Basedon this measure,the portionof carbonmonoxideand unburnthydrocarbons
increases.Thiscanbe reducedagainby an exhaust-gas
catalyticconverter.
An evenbetterreductionof nitrogenoxidesis obtainedby coolingthe exhaustgasesoff.
ln thatcase,the heatis discharged
to the ambientair via anAGRheatexchangerbefore
mrxng.
Fromtwo dischargepointsin frontof theturbocharger,
the exhaustis directedin s;parate
pipesthroughthe heatexchanger,
whichis connected
to the coolantcircuit.
Thecooledoff exhaustis mixedto the addedair in the intakemanifoldvia oressureoeak
valves,whichutilizethe pulsatingpressureofthe exhaustflow Theexcessoxygenof the
chargeair is therebyreducedand its specificheatcapacityis increased.
Bothinfluences
lowerthe combustion
temperature
andtherebythe nitrogenoxydeformationin the exhaust.
Liebheii-Werk
Ehingn
GmbH- Technical
lining
personnel
-40-
lTIBHRR
>9. Exhaustflap (enginebrake)
9.1Task
fuelsupply,thenthe bralf the machineis drivendowna downhillslopewithinterrupted
kingactionof the engineis greater,the smallerlhe placedgearis.
flap is utilized.
ofthe engine,the restrictor
To increasethe brakeperformance
Thisrelievesthe standardbrakesand reducestheirwear.
9.2Design
Fig.1: Restrictorflap
D 846TlAT
to exhaust
Workingcylindef
Restdctorflap
Restrictor
flap
Pae6sudzed
a;rconnection
Fig.2:ExhauslflapD 9508A7
Reslrictorflap
Workingcylinder
Exhaustflap
Llbhn-Wsi(
Ehlngn
GmbH' Techniltraining
personnel
- 4 1-
ITETIBR
Component
description
9.3 Function
Fig.1: Functional
.estrictor
flap
schematic
Backdup
gases
combustion
connection
Air pressure
Workingcylinder
Exhaustflaprestrictor
flap
Restrictorflap
to the
Therestrictorflapis installedin the exhaustline,whichleadsfromthe turbocharger
mufflerToincreasethe brakingactionof the engine,the4th cylinder(exhaustcycle)is alsoused
for comDression.
Whenmovingthe steeringcolumnleverall theway back,the restrictorflap is almost
closedvia the pneumatically
actuatedworkingcylinder.
completely
gasesaretherebybackedup in frontof the restrictorflap.
Thecombustion
the engineis sloweddown
resistance
on the pistons!n the cylinder,
Dueto the increasing
more.
Simultaneous
withthe closingof the restrictorflap,the fuelsupplyis shutoff or reduced.
- = upllon
Liebher-Weft EhingenGmbH- Techni@llEining
personnel
-42-
lIBlmn
>10Auxiliarybrakesystem(ZBS)
10.1Task
in additionto the exhaustflap,an
Toincreasethe Dieselenginebrakingperformance,
brakesystem(ZBS)is installed.
10.2Function
is createdin the exhaustmalf the exhaustflapis closed,an exhaustcounterpressure
nifolddueto the backup of exhaustgases.Duringthe exhaustcycleof the neighboring
cylinder,
shortlyafterthe intakecycle,an exhaustpressurewaveis createdin the area
Thisexhaustpressurewave,with
of the bottomdeadcenterin the exhaustmanifold.
pushes
piston,
The
the
exhaust
valvesopenmomentarily.
thesupportof the hydraulic
by the hydraulicpistonfromclosingagain.Theexhaust
exhaustvalvesare prevented
cycleandthe working
held
open
a gapwideduringthe compression
valvesare therefore
cycle.
Note:
occursdueto the
Eventhoughthe exhaustvalvesareopena smallgap, a compression
actionon theengine.
of thepistonin cycle2. lt hasa braking
dynamic
upwardmovement
gets
it
reducesits upward
piston
center
area,
the
more
into
the
top
death
Thefurtherthe
Thistimespanin the
speedandat the top deadcenter,it initiatesits reversemovement.
pressure
its
throughthe slightly
is
to
reduce
compression
top deadcenterarea enough
openedexhaustvalveto a largeextent.
pressure(cycle3) is thereof the pistondueto the compression
Thedrive(acceleration)
(increased
brakingaction).
fore eliminated
Liebheii-WerkEhingenGmbH- Techni@llralning
personnel
-43-
UIBHINR
Fig.1: Functional
schematic
cylinderheadin brakeoperation
lllt leverpiston(4)lies
againsttheoutletvalve,
dle to lubeoil prcssure
(3)Sealedthrough
(2)
counterholder
Dueto the cam

(9),the tilt lever(10)
swingsawayfromthe
(2).
counterholder
Therelievebore(8) is clearedand
prevents
theclosingof the piston(4) abutsinsideon the tilt
the oulletvalve(3)
lever('10).
Afier openingof the
outletvalve (3) in
enginebrakeo
the extendedpiston(4
lntakecycle
Compression
cycle
Liebher-Wsrk
Ehingn
GmbH- Technlcal
lrainlng
personnel
-44-
Workingcycle
Exhaustcycle
1IIBHRN
descriPtion
Gomponent
UW05- Goolingsystem/
Fandrive
servicepersonne
Onlyfor LIEBHERR
Gomponent
description
UW05 - Coolingsystem/ Fandrive
Liebhetr-weft
Ehingen
GmbH- Technical
lralning
personnel
OnlyforLIEBHERR
service
ITBHIRR
1. Cooling system, general
>1.1Purpose
fan drivefulfilsthefollowingfunctions:
Thecoolingsystemwithintegrated
. Hydraulic
oil cooling
. Cooling
theenginecoolantandgearoilheatexchanger
. Chargeair coolingfor the turbocharger
. Coolingthe coolantin the air conditioning
system*
>1.2Layout
fan driveessentially
comprises
the followingcompoThecoolingsystemwithintegrated
nents:
. Fanpump
. 2 fan motorswithfan impellers
. Chargeair cooler
. Watercooler
. l\ilultiple
oil coolers/ heatexchangers
. Liquefierair cond.system*
Liquefier
Aif conditioningsystem
(condenser)
Oilcooler
Hydraulics
(airloilcooler)
Oilcooler
gearbox(airl
Transfer
oil cooler)
Heatexchanger
gearorl
(airloilcooler)
Watercooler(airl
coolantcoole4
Coolanttank
Chargeair cooler
(air/aircooler)
Fanmotor
Fanmotor
Fig.'1:LT[,,]
1100-4.1
Fandrivelayout
* = option
aainrg
Liebher-werk
Ehingen
GmbH- Technical
OnlyforLIEBHERR
servicepersonnel
-4-
UEBIIIRR
UW05 - Goolingsystem/ Fandrive
Pumpoil press!re
Replenishing
Fanmotor
Tankreturn
Hydra!licoiltank
Fig. 3: Overview- fan motor
Fig.2: Fan motor
>1.3Function
Thisforcesair to flowpastand
Thefan pumpdrivesthefan motorsandiheirimpellers.
air
cooler,
water
coolerand liquefier*.
coolthe heatexchangers,
oil coolers,charge
oil cooler.
Thehydraulicoil or lubrication
oil is cooledwhenit flowsthroughits respective
Thewatercoolerservesto coolthe engineandgearoil heatexchangerusinga coolantis cooledby air flowingthroughthe chargeair cooler
watermixture.The
turbocharger
gaseous
in
cooling
system*flowsthrougha liquefer(condenser)
where
The
coolant the
preventsanyof the systemsfromoverheating
whilstalsoimproving
it condenses.This
performance.
A replenishing
valveis fittedto protectthe fan motor.lf thedieselengineis switched
off,the fan motoris no longerdrivenby thefan pump.The inertiaof thefan willcauseit
to runon untilit comesto a siandstillby itself.Thefan motornowactsas a pump.The
pumpedoil for thefan motor(pump)candirectlyreturnfromthe pumpingsidevia the
replenishing
valve(non-return
valve)to the suctionside.Thispreventsthe collapseof the
oil columnwhichwouldotherwiseseverelydamagethe fan drive.
* = option
Ehingn
Liebhen-Wsrk
GmbH- Techniltrainlng
personnel
OnlyforLIEBHERR
service
- 5 -
ITBHIR
UW 05 - Coolingsystem/ Fandrive
2. Coolingsystems
2.1Coolingsystemwiththermalpressurevalves
>2.1.1Purpose:
Cooling
systems
withthermalpressure
valvesregulate
thespeedof thefanmotorand
impelleraccordingto the temperature
of the hydlaulicoil,chargeair and enginecoolant.
>2.1.2Design
Fig.4: Overuiew
of coolingsystemswiththermalpressure
valves
Pressure
spdng
Valveblock Pressure
spring
Thermoelement
Fig.5: Culawayviewotthermalprcssurcvalve
Liebher-Werk
Ehingn
GmbH- Technical
llaining
personnel
Onlyfor LIEBHERR
service
-6-
lTIBHIRR
Chargeair pipe
Thermalpressure
valvechargeair
pipe
Controlpressure
valve
forthemal pressure
Retumfromthermal
pressure
valve
valve
Fig.6: Thermalpressure
lraining
Liebher-werk
Ehingn
GmbH- Techni@l
personnel
service
OnlyforLIEBHERR
UBTIIRR
UW 05 - Goolingsystem/ Fandrive
chaqe ajrcooler
Thermalprd&lThemalp
surevalve Tl surevalve
Replenishingvalve
- coolingsys{emwithlhermalpressure
valves
Fig.8: Overview
)2.1.3Function
Thermalpressurevalvesare on thewatercooler,oil heatexchangerandchargeair pipe
togetherby a controlpressurepipe.
andconnected
pressure
measureeachof thetemperatures
andset the
Thethermal
valvespropofiionally
controlpressurefor regulating
the pump.
pump
to drivethe fan motoris dependenton the control
Theflowratedeliveredby the
pressure.
Thethermalpressurevalvesare openat lowcoolant,chargeair and clutchconverteroil
Thepumpproduces
minimalflow.
temperatures.
Thefan doesnot run or onlyrunsslowly.
lf the temperature
of the coolant,chargeair or clutchconverteroil risesintothe
regulation
zonefor the respective
thermalpressurevalve,the valveclosesdueto the
increasthermoelementexpanding
whichincreases
the pumpflowrateand continuously
es the fan sDeed.
The pumpregulatorservesto regulatetheworkingpressurein the hydraulicsystem
withinthe adjustablerangeof the pump.The pressurecanbe fullyadjustedat the control
vatve.
Thepressurelimitingvalvelimitstheworkingpressureto its maximumpermittedvalue
whilstalsoreducingthe flowrate.
Liebher-Wek EhingenGmbH- Technicallining
personnel
Onlyfor LIEBHERR
service
-8-
ITBHIRR
2.2 Coolingsystemwith bypasscontrol
>2.2.1Purpose:
Coolingsystemswithbypasscontrolregulatethe speedof thefan motorand
of the hydraulicoil, chargeair andenginecoolant.
impelleraccordingto thetemperature
)2-2-2 Design
Proportional
solenoidvalve(bypass
Pressure
limitingvalve
(DBV)
Fig.9: Bypass
5 C| l i L T BE D ] N G U N G
EII
Fig.'10jExcerptfromeleclrical
circuitdiagramL,WLTM1045-3.1
LTM1045-3.1
Fig.11:Excerptfromhydraulic
schematic
Liebher-Werk
Ehinsen
GmbH- Technicl
traininq
personnel
OnlyforLIEBHERR
service
- g -
1IIBHINR
I_l I.:,.:;.]ll''-r',
,.rl
Fig.12:Coolerschematic
LTM1045-3.1
Proportional
solenoidvalve
(bypassvalve)
Pump
- Coolingsystemwiihbypasscontrol
Fig.13:Overview
Liebher-Werk
training
Ehingn
GmbH-Tschnical
personnel
OnlyforLIEBHERR
service
- 10 -
lIIBHIRR
Component
description
>2.2.3Function
sensorsto monitorthe engineoil temThe ECU(enginecontrolunit)usestemperature
perature,coolanttemperature
andchargeair temperature.
requirements,
the ECUcontrolsthefan coolingsystemand
Depending
on the cooling
(bypassvalve).
solenoidvalveaccordingly
actuatesthe proportional
solenoidvalveis actuated(bypassvalve),someof the
lf the proportional
oilflowsthroughthe bypassanddirectlyintothetankwithoutflowingthroughthefan motot
Thisreducesthefan sDeed.
The pressurelimitingvalvelimitsthe operatingpressureof thefan motorto a
pre-defined
maximum
valueof e.g.210bar.
Nole:
solenoidvalve(bypass
set if the proportional
Themaximumfan speedis automatically
valve)(-Y8)fails.
Liebhen-wekEhingen
GmbH- Technlcal
lraining
servicepersonne
Onlyfor LIEBHERR
- 1 1-
UETITRR
fanpump
2.3Coolingsystemwithvariable
>2.3.1Purpose:
ihespeedof thefanmotorand
witha variable
fanpumpregulate
Cooling
systems
of the hydraulicoil, chargeair and enginecoolant.
impelleraccordingto the temperature
>2.3.2Design
-Y50CYBold)
Proportionalvalve,fan
dnve
Fig.14:FanpumpLT|V1100-4.1
Fig.15:Excerpifromelectrical
circuitdiagramUW LTM1100-4.1
Liebher-WerkEhingenGmbH- Technil lralning
OnlyforLIEBHERR
servicepersonnel
ITIBIITRR
Prcducdbyj$pid/Edi'oni3M07/veBon:1
-::.l
f. .-
E
T
r I
1 . ,
:*,jix;'*'**,
I
l}"''+;----l
I t
r--;;;----
Fig.16:Cooler
LTN,4
1100{.1
schematic
l-E ::l^",:/
Pump
1...x..s;.i::....ifi
i...'..: 'lrl-'Hi
/:\
t I-liF..l
Fanmotor
- Coolingsystemwilhvadablefan pump
Fig.17:Overview
Li6bh6n-Werk
Ehingn
GmbH- Tchnilvainins
personn
OnlyforLIEBHERR
service
- ' t 3-
UEHINR
Gomponent
description
UW05 - Goolingsystem/ Fandrive
>2.3.3Function
sensorsto monitorthe engineoil temThe ECU(enginecontrolunit)usestemperature
perature,coolanttemperature
andchargeair temperature.
Depending
on the coolingrequirements,
the FCUcontrolsthe fan coolingsystemby applyinga PWI\4outputsignalto the fan pump.
Applyingcurrentto the proportional
valve"fandrive"-Y50will reducethe fan speed.
Note:
set if the proportional
solenoidvalvefor thefan
The maximumfan speedis automatically
driveCY50)fails.
Liebh6ir-W*
Ehingen
GmbH-Technical
training
personnel
OnlylorLIEBHERR
service
-14-
UTBlIINR
Component
description
UW06- Transmission
Onlyfor LIEBHERR
servicepersonne
Glossary:
CAN
Controller
areanetwork
ECU:
Electronic
controlunit(enginecontrolunit)
EDC;
Electronic
dieselcontrol(injectionsystemfor dieselengines)
TCU
controlunitfor
controlunit= Electronic
Transmission
gearchangeson
actuatingthe electro-hydraulic
systems.
6WGtransmission
EST
Electronic
controlunit
TC
Torqueconverter
lT
Intarder
cV
Splittergroupor splitterdrive
GP
sectiongroup
Downstream
WSK(WK)
bypassclutch)
Converter
clutchunit(converter
WSV
Clutchsafetyvalve
WGV
Clutchbackpressurevalve
WT
Heatexchanger
NFS
stopvalve
Downstream
Slip
in rotationalspeedbetween
Slipis usedto describethe difference
two elements.
Kick-down
the accelerator
describesthe actionoffullydepressing
"Kick-down"
and overriding
anyspeedsettings
(onlyavailableon 6WG-transmission
systems).
Dropbox
ofthe transmission.
Thedropboxis situateddownstream
Countershafts
fromonedriveshaftto an intermediate
shaft
lf thepoweris transferred
shaftis referred
to as a
andthenbackto a driveshaft,thisintermediate
countershaft.
Component
description
UW06 - Transmission
lndex
Contentspage1
Libhetr-werkEhingnGmbH- Technil trainrg
personnel
Onlyfor LIEBHERR
service
-3-
ITTBHIRR
UW06 - Transmission
Liebher-WerkEhingenGmbH- Technl@llraining
personnel
Onlyfor LIEBHERR
service
-4-
ITBITIRR
Transmission
Prcdudby:|waFlo/Edito:20M07/Ve6on]2
general
1.Transmission,
Purpose:
.
.
.
.
.
of the engine
Thetransmission
formspartof the powertrainand is downstream
to the tractiveeffortdelts taskis to convertthe enginespeedandtorqueaccording
vehicle
mandedby the
ratio
Startingandselectingthe geartransmission
opeEtion*
Gearchangesandclutch
Neutralandreversingthe rotationwhendrivingin reverse
Design:
Fig.4:Overview
of powertrain
Function:
on the
Thetransmission
systemmayhaveseveralforwardand reversegearsdepending
mooet.
Thetransmission
ratioi is givenby the ratioofthe numberof teethon the drivengear
the speedandtorque.Variousgearwheel
wheelanddrivinggearwheel;thisdetermines
sets(As-Tronic)
or planetwheelsets(6WG)are usedto providedifferenttransmission
ratiosi.
* = option
uebhefi-we EhlngonGmbH- Techniclttaining
personn
OnlyforLIEBHERR
service
-3-
IIIBHIRR
Gomponent
description
UW06 - Transmission
2. Transmission
overview
>2.1Automatic
:
transmission
Automatictransmission
systemsconsistof a hydro-dynamic
torqueconverteranda
powershifttransmission
downstream
withmultiplegearsandan integrated
or flangedon
transfergearbox.
A clutchis not requiredto changethe transmission
ratio.
Thegearchangeis performed
withoutthe interruption
of powertransfer.
.
ERGOPOWER
ZF 6WG310. without retarder
___rT
Fio.5: Overview
ERGOPOWER
ZF 6WG310
Allison CLBT755- with retarder

CLBT755DB
rI
Fig.6: Overview
AilisonCLBT755
wilhretarder
Llbhen-We* Ehingen GmbH - Techniel tEining
personnel
OnlyforLIEBHERR
service
-6-
lTIBTIIRR
Gomponent
deseription
UW06 - Transmission
P'lnuedby:repi/Ediddn:200107/Vedon:2
>2.2Gearbox:
ratios.
Gearboxes
consistof severalgearwheelsetsto allowdifferenttransmission
ratio.Thisinterrupts
the powertransfer
A clutchis requiredto changethe transmission
duringgearchanges.
2.2.1Automaticgearbox;
.
- with clutch
ZF '12A'52302
nax inNt ba!6 n NMGe

bnadz = NW (ryrbk*fi
r 100)
pd*ide)
Fig.7: Ove.view
ZF 12452302- withclutch
2.2.2Automaticgearboxwith upstreamconverter:
.
- with upstreamconverterand reiarder

ZF 12AS3002-TC
12AS3002-TC
n*
hpd brque in NM(btu x 100)
vaianr2= Nw (pdrbk{tPosdb.l
rc2
12AS3002
- wilhlpstreamconverter
andretarder
Fig.8: Overview
2F 12AS3002-TC
' = option
Liebher-WerkEhingenGmbH- Technil taining
Onlyfor LIEBHERR
servicepersonne
UIBlIINR
UW06 - Transmission
ZF 12TC3040SO- with upstreamconverlerand intarder

12TC30405
__TTT
TC HD
12AS3040TC/IT
12TC3040SO
converter
andintarder
Fig.9: Overview
ZF 12TC3040SO- withupstream
)2.3 Semi-automatic
transmission:
systemsare a specialtype of gearbox.
Semi-automatic
transmissions
Operating
the clutchwill engagethe gearwhichwas previouslymanuallyselected.
.
ZF ECOSPLIT165/15'l- with clutch

16S/151
Engine
Numbdge,G+
Cad6n
Ca.ddn
shaft
shan
TTT
|
Fig.10:Ovorview
ZF ECOSPLIT
163/151-with clutch
Liebher-Wek Ehing. GmbH- Technil tbining
personnel
Onlyfor LIEBHERR
service
-8-
ITBIIIRR
Transmission
3. Automatictransmission
3.1General
do nothavea gearstickor clutchpedal.
Automatictransmissions
Theclutchis replacedby a torqueconverterwithconverterbypassclutch(Fig11).This
providesa positivemechanical
to allowsmoothgearchanges.
connection
are planetarygears.Theyconsistof severaldrivingstagesand
of planetarygears.
differentnumbers/combinations
The
by the manufacturer.
and basedon a logicdetermined
Gearselectionis automatic
performed
gear
disc
clutch.
The
by activating
the corresponding
transmission changeis
the converterclutchunitis closed,
controlled.Unless
transmission
is electro-hydraulically
as frictionheatin the oil.
someof the poweroutputby the engineis dissipated
converterbypassin firstgearto
alreadyincludea mechanical
power
provideuninterrupted
transfer.
to the
transferspowerfromthe transmission
transmission
Thismeansthatthe automatic
provide
gear
fast
change.
Automatic
transmissions
outputdrivesystemevenduringthe
gearchangetimesandoptimisedgearchangepoints.
>3.1.1Converterwith converterclutch unit

Purpose:
.
.
.
theenginetorque
converts
andtransfers
the clutch
allowssoftstartingwithoutoperating
vibrationin the engine
dampensany rotational
Design:
Bypassclutchwithdiscset
Piston
Converter
clutchunit
bypassclutch)
{converter
Drive
T.ansmission
inputshaft
Turbinewheel
(seconoary
wheel)
Guidewheel (deflectionwheel)
C!p springs
Pumpwheel iprimarywheel)
discbypassclutch
Fig.11:Converierwith
Liebhed-We* EhingenGmbH - Technll kaining
personnel
Onlyfor LIEBHERR
service
-9-
ITBHIRR
UW06 - Transmission
Torsiondamper
(primary
wheel)
Converter
clutchunit
(converter
bypassclutch)
Guidewheel
idefleclion
Turbinewheel
(secondary
wheel)
viewofthe converter
Fig-12:Cut-away
Turbinewheel
(secondary
wheel)
Torsiondamper
(primary
wheel)
Guidewheel
(deflectionwheel)
Converter
cluichunil
(converler
bypass
clulch)withtrictionpad
of converter
withfrictionpadbypassclutch
Fig. 13:Overview
Function:
Pump,turbineandguidewheelarelocated
insidea sealedhousing
whichis completely
filledwithoressurised
oil.
The movementandforceis transferred
by the meltpressureof the flowingoil.Thedriving
gearwheel(pumpwheel)and drivenwheel(turbinewheel)are thereforenot
in directmechanical
contact.Thisexplainsthewear-freecharacteristic
of the torqueconverter
Liebh6r-Werk
Ehingn
GnbH- T6chniltraining
OnlyforLIEBHERR
servicepersonnel
-10-
lIIBHIRR
- Transmission
Fig.14:Starl-up
- thepumpis drivenby engine

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

acteristic
stretchesdueto the flowof fluidpushingthe
turbinebladesbackwards
andforwards(fig15).The
Thetorquetransflowdirectiontendsto straighten.
missionratioreduces.Howeverit is notyet necessaryto diverithe oil withinthe guidewheelin orderto
pumpflowangle.
obtaintheoptimum
Fig. '15:Intermedialeposition
Oncethespeedsof thepumpandturbineareviTtuthrough
allyidentical,
theoilwillflowalmoststraight
the blades(fig16).
Duringthisphase,theflowis
guide
the
wheel
bladesfromthe rear/suction
against
side.Theguidewheelnowturnsin thesamedirecthe blocking
tionas thepumpandturbinebecause
effectof the one-wayfree-wheelhas beenlifted.The
Thetorqueis
conversion
rangehasnowfinished.
not boosted,insteadit is onlytransferredat a ratioof
1:1.
pointof the
Oncethispointis reached(coupling
converter),the converteracts as a fluidcoupling
with a higherefficiencythan duringnormalconverter
oDeration.
Whenreachingthe couplingpoint,the converter
clutchunit- WSK(alsoknownas converterbypass
beclutch)is closed.Thiscreatesa tixedconnection
pump
wheels.
This
disables
the
tweenthe
andturbine
to rise.
converterandthe efficiency
continues
point)
Fig.16:Aligned(coupling
Liebher-WeftEhingenGmbH- Technicltrainin9
personn
service
OnlyforLIEBHERR
- 1 1-
ITIBHTRR
Gomponent
description
UW 06 - Transmission
Turbinewheel Tp=
Pumpwheel
Oilflow
=.-l-
torque
of pumpwheel
torque
ofiurbinewheel
T R = torque ofguidewheel
frornengine t
TP
Casea: Tractiveload
ounng skrt-up
Ti Guide wheel
Nr=0
Vehicleis stationary
Case b: Tractive load ' n )

intermediatestate
Casec: Tractiveloadat .
couplingpoint
t
Fig-17:Conve.ter
torque
TheWsK-solenoid
valvewillswitchat a specificspeedandcreatea fixedconnection
betweenthe oumoandturbinewheelvia the converterclutchunit.
Thiseliminates
lossin thetransducer.
anyslipandhydraulic
Hydro-dynamic
WSKopen
operation
Glutchoperation
WSKclosed
Fig.18: Cut-away
drawingconverter
clutchunit in openandclosedstale
Liebher:We*Ehingn
GmbH- Tcnni6llining
personnel
Onlyfor LIEBHERR
service
lTIBITIRR
Transmission
pointWSK
Measuring
WSK-solenoid
valve
WSK
Connection
frofr controlunit
Systempressure
Venlinghole
clutchunii
Fio. 19:Solenoid
valvewSK - converter
The pressurised
oil for closingthe converterclutchunitis fed throughtheWSK-solenoid
valveto the pistonwhichcompresses
the discset.
Convertersafetyvalve
8.5bar
WSK-solenoid
valve
Converter
Converter
clutch
unit- WSK
Convertersafety
valve8.5bar
clutchunii
Fig.20: ExcerptlromcircuitdiagramWSK- converter
Liebher-WerkEhingenGrbH - Technicltralning
servicepersonne
OnlyforLIEBHERR
- 13 -
ITBHIRR
UW06 - Transmission
>3.1.2Planetarygear(planetaryset)
Purpose:
ratiounderload,i.e.withoutinterThe planetarygearis usedto changethe transmission
gear
power
allowsa verycompactartransfer.The innerteethon the ring
ruptingthe
rangement
of thegearwheels.
Design:
gear
Fig.21:llluslration
showingprinciple
of planetary
Function:
Thesimplestformof planeiarygears(fig21) consistsof a sungearwheel,planetcarrier
withplanetwheels,
anda ringgearwheel.
connected
In this basicplanetarygearset,the sungearwheelin the m'ddleis positively
gear
planet
wheel
with
inner
teeth.
throughseveral
wheelsto a ring
Thesungearwheel,planetwheelcarrieror ringgearwheelcaneitherbe driving,driven
or permanently
braked.
By permanently
brakingthe planetwheelcarrier,it is possibleto select
gear
gearwheel.In this casethe enginemust
a reverse
withoutthe needfor an additional
be connected
to the sungearwheelandthe axledriveto the ringgearwheel.
L!6bher-WerkEhingenGmbH Technil tfainng
personnei
OnlyforLIEBHERR
service
- ' 1 4-
UIBIIIRR
Transmission
Function:
gearsare advantageous
systemsfor
whencomparedto othertransmission
Planetary
ratiounderload,i,e.
as theyallowa changeof transmission
speedandtorqueconversion
transmiswithoutinterrupting
the powertransfer,andare morecompactfor comparable
planets.
Changesin direcoverseveral
sionratios.Thisis dueto loadbeingdistributed
tionare alsopossible.
Largetransmission
ratioto slowerspad
Fig.22i
locked,outputvia planetcarrier
Notransmission
ratio(= directiransmission)
Fig.23:(3.gear)sungearwheelandring
geararedriven,directconnction
uebher-werk EhingenGmbH- Tchnlcallraining
personnel
Onlyfor LIEBHERR
service
ratioto slowerspeed
Smallhansmission
Fig.24:(2.gear)dnggeardriven,
sungearwheel
locked,outputvia planetcanier
ratioto slowrspeed
Largelransmission
Fig.25:(Rear)sungearwheeldriven,planetset
locked,ouiputvia dnggar
-15-
UIBHRN
Component
description
Transmission
>3.1.3Discclutches
Purpose:
Discclutchesare usedto selectpre-setgears.
gearwheelsandthe
is established
betweenthe individual
A friction-locked
connection
planetset on the intermediate
(ZF-Ergopower
differential
transmissions)
or betweenindiplanet
(Allison
vidual
sets
transmission).
Thisestablishes
a connection
betweenthe inputand outputshafts.
Design:
of several
Theirdistinctive
featurewhencomparedto otherclutches,is the arrangement
frictionpadsin a row Thediscclutchesare cooledwithoil to providea higherpowerand
energyraung,
Discclutches
Fig.26: Disc clutchesbasedon the exampleofthe 6WG310
Function:
Depending
on the selectedgear,discclutchesactivatethe relevantgearwheelsetsor
planetsets.
controlThisresultsin differentspeedsandtorque.Discclutchesareelectro-hydraulically
ledandmaybe switched
underload.
Liebher-W6k EhingenGmbH- TechnicaltEining
personnel
Onlyfor LIEBHERR
service
- 16 -
lIIBHTRN
description
Gomponent
Transmission
3.2ZF Ergopower6WGtransmission
3.2.1General
>Electro-hydrauliccontrol unit
Purpose:
Thepurposeof the hydrauliccontrolunit(fig27) is to switchthe discclutchesin the autocontrolunit.
matictransmission
basedon the signalsfromthe electronic
Design:
thefollowingmaincomponents:
Theelectro-hydraulic
controlunitcomprises
. 6 proportional
(Y1-Y6)
valveswithpressureregulators
. l\4ainpressureregulation
valve
. Convertersafetyvalve
.
Tamâr.t"ra
ean<^r
Fig.27i Electro-hydraulic
conirolunitHSG94- 6wc-transmission
Temperature
sensor
ovedemperatureoil
sump/ coldstart
Fig.28:Temperature
sensor
Function:
valves(Y1-Y6),the corresponding
Depending
on the actuationof the proportional
switchedandthe pre-setgearis
discclutches(K1-K4,KV and KR)are hydraulically
engaged.Themainpressurevalvelimitsthe maximumswitchingpressureandreleases
the mainflowto the converterand greasingcircuit.Thefeedto the converterincludesa
convertersafetyvalvewhichprotectsthe converteragainstexcessiveinternalpressures.
aaining
Uebher-Werk
Ehingen
GmbH- Tschnical
OnlyforLIEBHERR
servicepersonn
UIBHTNR
Component
description
Transmission
>Electronicconlrol unit
Puroose:
Themainfunctionsof the electronic
controlunit(Ug29) are:
. Controlling
controlunitto automatically
the pressureregulatorfor the electro-hydraulic
gears
change
. Modification
of the optimumgearchangepoints
. Controlling
the kick-down
function
. Storageofall operatingerrorsand overloadconditions
. Converter
control*
. Gearrestriction
Design:
controlunitTCUEST-37- 6wctransmissions
Fig.29i Eleclronic
Function;
Thefollowingcriteriaaretakenintoconsideration
whenchanginggear:
. Speedof engine,
turbine,
centrewheelchainandoutput
. Transmissiontemperature
. Gearchangetype(up,down,reverseandselectinga gearfromneutral)
. Loadcondition(fulland partialload,traction,thrustwhilstalsotakingintoaccount)
. Loadchanges
duringthegearchange
Liebhetr-Werk
EhingenGmbH- Technil lra ning
OnlyforLIEBHERR
servicepersonnel
-18-
lIIBIIIRR
Transmission
>Function,general:
fortheERGOPOWER
series210,251,260,310conThezF-WGtransmission
systems
powershifttransmulti-gear
torqueconverteranda downstream
sistof a hydro-dynamic
gearbox.
transfer
missionwith integrated
Thetorqueconverteris a wear-freestart-updevicewhichfullyadaptsto the conditions
(requiredtorque).
on rollerelementbearings.
meshedand supported
All gearwheelsare permanently
gear
are
oil-cooled
and greased.
wheels,
bearings
and
disc
clutches
The
modeusingthe EST-37elecThetransmission
is switchedmanuallyor in fully-automatic
discclutches
tronicunit(seepage18 fig 29) and hydrautically-operated
valvesare controlledby a pre-setlogiccontrol.
Whenchanginggear,the proportional
Thiscausesa pistonto applypressureoil to the relevantdiscsetsandcompressthem.A
gearwheelsand
betweenthe individual
friction-locked
connection
is therebyestablished
differential.
A pressurespringforcesbackthe piston
the planetset on the intermediate
valvehasbeencancelled.
and releasesthe discset afterthe actuationof the proportional
gear)
builtintothe outputsection(planetary
Thepurposeof the intermediate
differential
compensais to transferdifferenttorouesto thevehicleaxlesandactsas an intermediate
lockmay
directionof the vehicle).The difierential
tionin the drivingdirection(lengthwise
betweenthe axles.
be usedto disablebothfunctionsandestablisha riqidconnection
Liebher-WerkEhingenGnbH - Techni@ltEining
personnel
OnlyforLIEBHERR
service
-19-
lIIBilENR
Gomponent
description
UW06 - Transmission
>3.2.2ERGOPOWER
6WG2r0
Valvefor converter
clutch{WK-valve)
Pressure
oilpipefrom
Pressure
oil oiDeftomcontrol
unitto WK-valve
VentpipeWK
Connection
to
heatexchangor
Connection
to
excnanger
OiltempeGture
regulator
(thermal
switc+ring
valve)
Electrohydlauliccontrol
unit
Connection
to heat
excnanger
Greasingpipefor
powertak-off
Oil fller pipewith oil dipstick
Output
flangeto rear
axle
Fig.30:6WG210ERGOPOWER
Liebher-WerkEhingenGmbH- Techniel lEining
Onlyfor LIEBHERR
servicepersonne
-20 -
UIBIIINR
description
Component
UW06 - Transmission
Valvefor converter
clutch
(WK-valve)
couplingbell
Converter
flangeto engine
Outputflangeto
fronlaxle
of thefront
Pneumatic
activation/deactivation
axledrive
differential
lock)
{longitudinal
Fio.31:6WG2'10
ERGOPOWER
training
liebher-we&Ehingen
GmbH- Tchnlcal
personne,
OnlyforLIEBHERR
service
-21 -
ITIBTIIRR
Component
description
UW06 - Transmission
P6ddby:|kepld/fuifon:20'04'077v.Eion:2
Pressure
oil pipefrom
conirolunit10
Changefilter
(blueZF-finefilter)
Fio.32:6WG210ERGOPOWER
Discclutches
Driveflangeto engine
Electro-hydraulic
conlrolunit
Gearwheels
Intermediate
differential
gear)
(planetary
Outputflangeto
frontaxle
Outputflangeto
rearaxle
Fig.33:6WG2'10
ERGOPOWER
Liebheii-We*
Ehinsen
GmbH- Technlcl
oainins
Onlyfor LIEBHERR
servicepersonnel
_ ZZ -
1TEHTRR
Transmission
for electro-hydraulic
conholunit
Connector
Electro-hydraulic
controlunit
(withtransmission
sensor)
sumptemperature
Changefiller
(blueZF-finefilter)
lnductive
sensor
ourpur
Fio.34:6WG210ERGOPOWER
Inductive
lnductive
sensor
sensor
intemalmiddlespeed pumpspeed
Conveder
clutchunit
lnductive
sensor
turbinesp6ed
Llbh6n-Wd.
EhhgnGmbH' Technil trainins
personnel
OnlyforLIEBHERR
seryice
-23 -
Cranehydraulics
On
ITIBTIERR
ComponentdescriPtion
UW06 - Transmission
Transmission
PumP
Drive
Disc
clutches
Discclutches
lntermediate differential
(planetarygear)
6WG210
viewERGOPOWER
Fig.37:Cut-away
lEining
GmbH- Tchni@l
Ehingen
Lrebher-werk
personnel
service
Onlyfor LIEBHERR
-24 -
lIIBHTNR
Transmission
measuring
oftheproportional
valvesto eachofthegearsandtheirassociated
Theallocation
page
(see
pointsis shownin theswitching
26 fig40) .
table(Fig39)andtheoilschematic
Forexample,if Y1 andYOare active(markedred),discclutchesK4 and K2 have
switched.
Thisselectsthe4th forwardgear.
valvesY1 andY6 can be checkedat measuring
Thecorrectfunctionof proportional
points60 and57 respectively.
points6WG210
of measuring
Fig.38:Overview
Fig.39: Switchchart6WG210
valves
areactuatedusingthe 6 proportional
Thesix discclutchesfor the transmission
Yl to Y6.The proportional
valve(pressurecontrollerunit)consistsof a pressureregulastopvalveandvibrationdamper.The controlpressurefor actuatingthe
tor,downstream
valve.Thepressureoil is
downstream
stopvalveis generatedby the pressurereduction
stopvalveto the relevantclutch.
fedthroughthedownstream
The pressures
to the clutchesinvolvedin makingthe gearchangearecontrolledby
for eachclutch.
meansof directproportional
driveswithseparatepressuremodulation
Thisallowshydraulicoverlapping
of the clutchesbeingswitchedon andoff.Thisresults
gearchangeswithoutanyinterruption
in tractiveeffort.
in immediate
Liebher-WerkEhingenGmbH- Tochniltra ning
personnel
OnlyforLIEBHERR
service
-25-
ITEHIRR
UW06 - Transmission
Oil schematic- Forwardslst gear

il Kr
s:
-f!44-
i1Kl
I
i
, I lut.,.l
(electrc-hydulic
coitrolunt)
convedflollpdpresde
rl!?!!r!!4q!L
Fig.40:Oilsche.natic
6WG210- FoMards1slgear
actuationis providedby the

Theoil supplyto the converterandtransmission
pump.Thispumpsucksthe oil fromthe sumpthroughthe coarsefilterand
transmission
pumpsit throughtheZF-finefilterto the mainpressurevalve.lf it is not possibleto maintaintheflowto the ZF-fineflltecthe lubrication
oil is directlyfed throughthe fllterdifferpressure
on theZF-display.
ence
valve(bypass
valve)andan erroris indicated
Note:
Older6wc{ransmissionsystemsare equippedwitha blackchangefilter(ZF-finefilter).
valve(internalbypass).
Theseincludean internalfllterpressuredifference
with
filter)withNew6wc-transmission
systemsareequipped a bluechangefilter(ZF-fine
pressure
outan internalfilter
difference
valve(withoutan internalbypass),see(fig40).
withthe
Forthisreason,
blackandbluechangechangefilteshouldonlybe replaced
sametype.
Liebher-WeREhingenGmbH- TechnicaltEining
personnel
Onlyfor LIEBHERR
service
UEBHINR
UW06 - Transmission
Wheelschematicforwarddriving direction:
o)
0)
.
(!
;,
.5
N
z5x
.e
.e
I
b
.9
E
t
;
_9
(')
cLO
V
E
5 BB6 Ece g
cs
5
!; !Ei i i!i !o !o ! : +
?g!E9C
" P {
2
c
'6
E
F
=-1=
^,J[-^
2
fo arddriving
direction
Fig.41:Wheelschemalic
Ergopower
6WG210
Liebher-We* Ehnqen GmbH- Iechnil lhing
personnel
service
Onlyfor LIEBHERR
_27
ITIBHTRR
UW06 - Transmission
Wheelschematicreversedrivingdirection:
3
e
>
o
oi
o
o)
N
E
5
E
.9
f
I
o)
,9
E
=
.9
E
o
stbnt
E* Y g g :
!!E!!EP4
'6
.9.
E
F
a
Fig.42:Whetschomatic
Ergopower
6WG210reversearivi_ng
Oireaion
Liebheii-WekEhingenGfrbH - Techni@ltEining
personnel
Onlyfor LIEBHERR
service
-28 -
UIBHINR
Transmission
Pdudby:pd/Edilon:200.07/venioi]2
6WG310
>3.2.3ERGOPOWER
.B27
sensor
Temperature
converter
output
-A69
Electro-hydraulic
controlunit,HSG94
-Y72
Solenoid
valve,
Converter
clutch
.824
lnductivesens
(engine/pump
speed)
-825
lnductive
sensor
Turbinespeed
-s70
Cranehydraulics
OFF/ON
826
lnductive
sensorintemal
N,4iddle
speed
.s31.
Driveaxle'1,
1=ON,0=OFF
ON/OFF
Fig.43rErgopower6WG3'10
Liebher-We* EhingenGmbH- Tchnlcallraining
personnel
Onlyfor LIEBHERR
service
-29 -
TTIBIIIRR
UW06 - Transmission
.B2A
lmpu|sesensor,
Tachograph
Outputf,angeto rearax'o
-B29
Inductive
sensor
Powertake-offsp6ed
Changeover
Off-roadgear/
torclgear
65
Off-roadgear
1=ON
Fig.44: Ergopowr
6WG310
Uebh3r-welk EhlngenGmbH- Tschnit taining
Onlyfor LIEBHERR
seryicepersonne
-30-
UEHINR
Transmission
Electro-hydraulic
controlunit
Converter
clutch!nit
Driveflange
2. Powertake-off
pump
Transmission
Itr
:-tl
axle
Coupling
,,KV/K1'
Retarder
Converler
KR
K2
Coupling
axle
"KFYK2'
Coupling
axle
"K4lK3'
Countershaft
Outputflange
Frontaxles
Outputflange
Rearaxles
I -
Axleactivation
(longitudinal
differential
lock)
Fig.45: Cut-away
viewErgopower
6WG310
Liebheii-WerkEhingenGmbH- Techni@ilraining
servicepersonnel
Onlyfor LIEBHERR
- 3 1-
lntermediatedifferential
(planelarygear)
lIBHINR
UW06 - Transmission
valvesto eachof the gearsand theirassociated

The allocationof the proportional
(see
table(Fig47) andtheoil schematic
pointsis shownin ihe switching
measuring
page33 - fig48).
andK2 have
F"i".r.pfJ if i2 andY6 are active(markedred),discclutchesK4
valvesY2
tnis setectsthe4th fonrvarigear.The correctfunctionof proportional
switcneO.
andY6 can be checkedat measuringpoints60 and 57 respectively'
poinls6WC310
of measur;ng
Fig.46:Overvlew
---Trcponionat
vatveactlre
!ed. no, of measudns pohll
Fig.47: Switchchari6WG310
Liebheir"weaEhinggnGmbH- Technil training
personnel
service
OnlyforLIEBHERR
-52-
lTTBIITRR
UW06 - Transmission
Oil schematic- Forwards'lst gear
il
*'
P6
a'
ir+-!!
(elecrb-hydEuliccontrolunit)
",u
co^veddulpdp$rc
i**'-cei
' i
i
:
i
I t
PoFdonarvadGcclld|(3
Fig.48:Oil schematic
1stgear
6WG310- Forwards
Liebher-WerkEhingenGmbH- Technil tEining
personnel
OnlyforLIEBHERR
service
-33-
lTIBHIRR
Component
description
UW06 - Transmission
3.3ALLISONtransmission
CLBT755 DB
>3.3.1ALLTSON
Design:
-R28
Temperature
sensor,
transmission
oil
Dropbox
(downstream
dropbox)
Fig.49:Allison
transmission
CLBT755withdropbox
=l*iJL
--
Electro-hydraulic
conkolunilwith
valvesfor conlrolling
the
solenoid
discclutches.
Temperature
sensor forwardand reversepressure
Fig.50:Allisontransmission
CLBT755withdropbox
Liebher-Werk
Ehinsen
Onlyfor LIEBHERR
servicepersonnel
- 34 -
UIBlIINR
Transmission
Transm:ssion
AllisonECU
Fig. 51: Transm;ssionECU
Discclutch4th
gear
DiscclutchfoMard
gear
Discclutchsih gear
Turbinewheel
Discclutch3rd
gear
Discclutch1stgear
Discclutch2nd
gear
Output
Guidewheel
clutchunit
Conveder
(conveder
bypassclutch)
Planetsets
controlunitwiihsolenoid
hydraulic
thediscclutches
valvesfor controlling
Torqueconverter
Frg.52. Ove/viewAlson lransmissionwithoJtreralder
Liebher-WerkEhingnGmbH
personnel
OnlyforLIEBHERR
s ervrce
-35-
lTIBIIIRR
UW06 - Transmission
withoutretarder
Fig-53:Cut-away
viewAllison
lransmission
Function:
Thetransmission
ratiosfor 5 forwardgearsandone reversegearare achievedusingfour
planetsets.Theseplanetsetsareactuated
controlled
discclutchusingsixhydraulically
meshed.
es.Allgearwheelsarepermanently
characteristic.
Thetorqueconverterensuresa smoothandjerk-freedriving-off
ln contrast
withZF 6WG-transmissions,
theAllisontransmission
CLBT755DBis
retarder.
Thisservesto providehydraulicbrakingassistequippedwitha hydro-dynamic
which
are
controlled
via the retarderactuator.Theretarder
anceand has2 brakingstages
is onlyactivewhenthe converterclutchunii is switchedon. Maximumbrakingassistance
is providedat highspeeds.
Thedownstream
transfergearboxis a dropbox.
to
Theaccelerator
sensor,speedregulatorand gearrangeselectortransmitinformation
valves.These
the ECU.The ECUanalysesthis information
andcontrolsthetransmission
pipes
usehydraulic
to controlihe shiftup/downand bypassfunctions.
For
The ECUcontrolunitalsomonitorsthe systemfor abnormaloperatingconditions.
pressureswitchesto monitorwhetherihe forexample,the ECUusestheforward/reverse
gearhasbeenhydraulically
selected
ward/reverse
switchedafterthe ECUhaselectrically
thisgear.
oilsump.lf a
TheECUalsousesan oilsensorto checktheoil levelin thetransmission
transmission
faultoccurs,an errorcodewill indicateihe typeof error.
Llebhen-WerkEhingenGmbH-Techni@ lfainng
personnel
OnlyforLIEBHERR
service
-36-
IIBHIRR
UW06 - Transmission
Prcdudby:|wapid/fu[oi20M07,vadon:2
4. Automaticshift transmissions
4.'l Automaticshift transmissionAS-TRONIC
General
>4.1.1
AnautomaticshifttransmissionisatransmissionSystemwherethedriverdoesnotop
controlunit
by an electronic
insteadthis is performed
atea clutchor thetransmission;
valves.
(gearingactuator)andelectro-pneumatic
and manualmodes'
Iiis possibleto selectbetweenfully-automatic
of a clutchby the driver
cylindersperformthegearchangefunctionOperation
Pneumatic
controlis coupledto
lwhetnerautomaticor manual)is no longerrequiredTransmission
separates'
ine gDC and bringsthe engineto the precisespeedwhenthetransmission
loadsare also
Clutchwearandhightransmission
iniJermits jert-ireeg"",
"h"ng"".
minimised.
training
GmbH- Technical
Ehingen
Liebhsn-Werk
servicepersonnel
Onlyfor LIEBHERR
-37 -
rIIBHRR
UW06 - Transmission
>4.1.2Transmission
Design:
systemis a combination
of an electro-pneumatically
TheZF-ASTRONIC
transmission
on the cranemodel,
shiftedclawtransmission
andan automaticdry clutch.Depending
includesan integratedhydraulicintarder
transmission
theZF-ASTRONIC
Plugto
clutchactuator
Transmission
actuator
Pl!9, vehicle
Solenoid
valve
(openaccumulator
chargevalve)
Heatexchanger
Oilfillingnozle
Oilinspection
plug
RPMsensordrive
shaft
Output
lntarder
Prop.solenoidvalve
(intarderactivation)
temperaCoolant
(heat
turesensor
output)
exchanger
Plugto intarderECU
Clutch
actuator
with
4 solenoidvalves+ bavel
sensors
Fig.54:Automatic
shifttransmissionAS-TRONIC
UebheF-Werk
Ehingen
personnel
service
OnlyforLIEBHERR
-38-
ITEIIIRR
UW06 - Transmission
Function:
The useof an automaticclutch(no clutchpedal)meansthatthe driverdoesnotneedto
by thetransmission
control.
operatethe clutch.Theactualgearchangeis performed
(the16-gear
section
modelhasa
TheZFAS-TRONIC
comprises
a maintransmission
has
a
3-gear
transmission),
as
well
as a splitter
4-geartransmission;
the12-gear
model
group(GP)basedon a planetary
group(GV)anda downstream
design.
section
Constant
K1
Transmissionoil
pump
Sectiongroup
gear)
iplanetary
Reversegeaf
Transmission
brake
Splittergroup
wheel
IVaintransmission
sectionwithreversing
(3-or 4- geariransmission)
gear-AS-TRONC
Fig.55:Cut-away
viewshowingsplittergroup,maintransmission
sectionandplanetary
Splittergroup
ReversegearReversingwheel
Transmission
bke
Outputflange
Ivlaintransmission
section
withrevers'ng
wheel(3-or
4- gearhansmission)
Secliongroup
gear)
(planetary
gear-AS-TRONIC
Fig.56:Ivlainviewshowingspliilergroup,maintransmission
sectionandplanetary
L ebher-WerkEhingenGmbH- Techni@llralnlng
servicepersonne
OnlyforLIEBHERR
-39-
ITIBHIRR
Transmission
The maintransmission
usesa claw-shift,
the splitterand planetgroupsare synchronised
is notsynchronised.
whereasthe maintransmission
performed
actuatorandtransmission
brake.
Synchronisation
is
by the transmission
Swiichingmodule
Swiiching
cylinderfor
tiongroup(range)
Selectorcylinderfor
maintransm;ssion
secton
(select)
Switching
cylinderfor
section(shift
lransmission
Switching
claws
Switchingcylinderfor
spliltergroup (split)
iv
$4,
It,
Fig.57i Overviewshowingswilchingclaws and swilchingcylinder
splittergroup
Switching
cylinder
formain
transmission
section
':.
,:.
sectlongroup
Selectorcylinderfor
maintransmission
sectton
Switchingclaws
viewclawtransmission
AS-TRONIC
Fig.58:Cut-away
Liebher-Werk
Ehinsen
GmbH- Technical
tEinins
personnel
OnlyforLIEBHERR
service
- 40 -
lIIBIIIRR
UW06 - Transmission
Pdudby:wprc/Editon:20&077ve8ioi]2
of a
Thetransmission
actuatorandclutchactuatorare the mostimportantcomponents
Thetransmission
actuatorperformsall the switchingactions
fully-automatic
transmission.
andfullycontrolsthe clutch.
to bothcountershafts.
Constants
K1 and K2 are usedto determinethe powerdishibution
gearis via the maintransmission
section.The
Thereturnto the mainshaftin a particular
group
provides
the
output
drive.
section
to the driver(e.9.gear
displayindicatesall relevantsysteminformation
Thedashboard
ratio,errorsetc).
>4.1.3Transmissionactuator
Purpose:
Thetransmission
actuator(fig60)fulfilsthefollowingtasks:
. Shiftoointcontrol
. Controlling
valvesusedto changegear
the electro-pneumatic
. Controlling
the clutchactuator
. Self-testwitherroroutput
. Sendgearindicatorsignalto the displayunit
. Processing
thefollowing:
of sensorsignalsto determine
- the currentpositionof all switchingcylinders
- thetransmission
inputspeed
- thetransmission
oil temoerature
- the amountof availableair pressure
. Communication
withthe enginecontrolunitandABs-controlunitvia the CAN-bus
. Controlling
the transmission
brake
WABCOidentification
plateon transmission
actuarcr
- WABCO
plate
identificaton
Fig.59:Transmission
acluatorAs-Tronic
Note:
of the previoustmnsmissionactuator
transmission
actuator(GS3.3)is a furtherdevelopment
(GS3.0)-Theyare not compatible.The transmission
actuatortype(GS3.3)is identitiedby the
plateaffixedto the transmission
actuator.
lastdigit"...007"on the WABCOidentification
Llebher-WelkEhingenGmbH- T6chnicaltraining
personnel
service
OnlyforLIEBHERR
-41-
UE]ITRR
UW06 - Transmission
Design:
electronics,
switching
Thetransmission
actuator(fig60) consistsof thetransmission
valves,pneumatically-operated
switchingcylindersand sensors.
actuatorwithtravelsensors.lts compactdeTheclutchactuatoris an electro-pneumatic
in
transmission
housing.
signallowsit to be integratedthe
Selectorcylinderfor
maintransmissionsection(select)
spliltefgroup (split)
Switching
cylindertor main
transmission
section(shift)
Switching
cylinderfor seciiongroupGange)
-A6.1
ECUtransmission
actuator with inlegratedelec-
tronictransmission
control
and
. vaversensors,
. temperature
sensoc
. air pressure
sensor,
. Speedsensor
(transmission
input)
Shiftrod
actuatorAs-Tronic,
loction
Fig.60rTransmission
F i g . 6 1Excerpt
E: x c fromschematic
for compressed
airsystem/ transmission
aciuator:
Legend:
-Y1
-Y2 and -Y3
-Y4 and -Y5
-Y6 and -Y7
-YBand -Yg
-Y10
Transmission
brake
Switching
cylinderfor splittergroup(split)
section(select)
Selector
cylinderformaintransmission
section(shifl)
Switching
cylinderfor mainiransmission
group
(range)
for
Switching
cylinder seclion
Releasing
ihe cyl;nders
withcompressed
ah
Libheii-We(Ehlngn
GnbH- Tschniltraining
personnel
Onlyfor LIEBHERR
service
-42-
UIB|ilNR
descriPtion
ComPonent
UW06 - Transmission
iio,",r *
".4",
eo"*' ' ooo'' u'"'" '
>4.1.4Clutch(dry'clutch)
iilffi
.
shaft
input
too",*1li:'i'l**P:HIll"J:i9,i::lil*,
*etransmission
"
to transferthe enginetorquero
iE::"*""'""
:fl!:#"J11;:",U*:gr""J"il"::::iffi
overroad
asainst
: : $,i#:fifi:*l;'$1'$'"-t"r components
clutches
andmulti-disc
(e g 12AS23O2)
clutches
single-disc
oetween
3i"Jlkr"n,,"r""
(e.g.16A52602).
Plate
clutchPressurc
sPrings
Membrane
TorsiondamPer
beadng
Throw-out
dive shaft
Transmission
Releaseiork
Actuating
Pisbn
Clutchactuator
clutchpads
(frictionpads)
Servicelid
nsmissions)
tErnrng
Liebhr-WeftEhingenGmbH Technll
servicepersonnel
Onlyfor LIEBHERR
-M-
UEHRN
UW06 - Transmission
plate
Clutchpressure
lVembrane
springs
Clutchpads
(fdctionpads)
Throw-out
beadng
Transmissiondriveshalt
Releasefoft
piston
Actuating
Clutchactuator
Servicelid
in 16-gear
transmissions)
Fig.64:Overview
ofa dual-disc
clutch(incorporaied
Throw-out
beadng
Releasefork
Acluatingpiston
Fig.65:Throw-oul
bearingwithrleaseiork
Liebhen-Werk
Ehinsen
GmbH- Techni@l
tEinins
personn
OnlyforLIEBHERR
service
_ 45 -
lIIBHIRR
description
Component
Transmission
Pfududby:iwep]d/Editon:20'0.'07lveB6n:2
Clutchpressureplate
Ciutchpad
(frictionpad)
Hubprofile
Torsiondamper
- rearview
Fig.67:Clutch
element
Fig. 66: Clutchdisc
Circlipand
releasewirefor beadngsnap-in
mechantsm
plate
Clutchpressure
spring
Membrane
Tangential
leafsprings
{prevenldragtorque}
Fig.68: Cluichelement- frontview
Function:
Theclutchdisc(fig66) hasrivetedfrictionpadson bothsidesand is fixedto the tEnsmissiondriveshaftusinga hub profileto preventrotation.Whenthe clutchis closed,the
drive
torqueis transfenedfromtheflywheeland clutchpressureplateto the transmission
shatt.
A membranespringprovidesthe requireddampingforce.Thethrow-outbearing(fiq65)
andactsas a leverto
springvia a "snap-inmechanism"
is connected
to the membrane
releasethe clutch.
vibrationbetweenthe engine
Thetorsiondamperon the clutchdiscdampensrotational
Thisincreases
the servicelifeof the powertrainand reducesnoise
andtransmission.
emissions.
Liebher-WerkEhingenGnbH - Techni@llining
personne
Onlyfor LIEBHERR
service
-46-
IIEIIIRR
UW06 - Transmission
Openingand closingthe clutch:

Situation
Neutral
Brake+ D
Startingup
(pressaccelerator)
Driving
Gearchange
Comment
CIutch
{l{F{F
{F
{F-
Libher-wek EhingenGmbH- Tchnl@llEining
personnel
service
OnlyforLIEBHERR
Engagingthe starting
gear:3rdgear
onlY
Fullload-release
whenclutchhasfullyclosed
- 4 7-
lTUIIRR
UW06 - Transmission
>4.1.5Clutchactuator
Purpose:
The clutchactuator(fig 69) seryesto open or closethe clutchwhichinterruots
the oowgearchanges.
er transferfrom the engineto the drive wheelsand allowautomatic
Design:
'' Travelsensor
@
Switchingvalves
Clutchaciuator
ng prslc
Controller
Fig.69:Clutchactlator
|
- !i15
-.TiJ
-ril6
Switchingvalvesclutch actuator-A69;
. -Y14- Quickly
closeclutch
. -Y15- Slowlycloseclutch
. -Y16- Quickly
openclutch
. -Y17-Slowlyopenclutch
Function;
Fig.70: Excerptfromschematic
forcompressed
valvesclutchactuator:
airsystem/ switching
Theclutchactuatorand its pneumatic

actuatingpistonsare controlledby the electronics
in the transmission
actuatorThisusesthe releaseforkto ooeratethe throw-outmechanismwhichinterrupts
the powertransferbetweenthe engineandthe shifttransmission
duringgearchanges.
pistonsis determined
The positionof the two pneumatic
usinga travelsensor.Twopairs
of redundant,
switchedvalvesare usedto openand closethe clutch.Slightdepression
of the clutchis possiblewhenperforming
delicatedrivingoff and manoeuvring
work.The
pointduringeverystart-upandforclutchactuatorzerosthe currentclutchapplication
wardsthis information
to the transmission
electronics.
A LICCON-special
screendisplays
theclutchwearas a numeric
value.
Llebhr-WerkEhingenGmbH- Techni@llra ning
personrel
OnlyforLIEBHERR
service
-48-
lIIBHTNR
Transmission
>4.1.6Intarder(secondaryretarder)
Generalfunctionsand overview
Puroose:
hydraulicbrakewithmultiple
retarder)is a wear-freepermanent
Theintarder(secondary
Thisrelievesthe loadon the service
in thetransmission.
brakingstagesthat is integrated
prevents
overheating.
(foot
brake
and
brake
brake)andengine
Design:
Heatexchanger
Accumulator
chargevalve
Oiltank
Coolanttemperature
sensor(heatexchange.
output)
Oilfilter
andoildrain
plugAS-Tronic
Prop.solenoid
valve
(intarder
activation
)
Plugto intarderECU
Fio.71:ZF 16A52602
withintarder
driveshaft.
Theintarderis coupledvia a boosterslageto thetransmission
The heatexchangeris directlyflangedontothe intarder.
Note:
blockbehindthe
Thesecondaryretarderis notfittedas a separateandindependent
henceits name"intarder".
transmission;
insteadit hasbeenintegrated,
Llebhii-WerkEhingenGmbH- Technil training
personne
Onlyfor LIEBHERR
service
-49-
UBIIRR
UW06 - Transmission
;d,*d
b,.""pd/E","" re
d,v.^""
chargevalve
Accumulaior
Heatexchanger
Oiltankintader
valve
Prop.solenoid
activaiion)
(intarder
oil pump
Stator(firmlY
to ihe housing)
attached
withintarder
Fig.72:ZF 16A52602
Oil pump
Oiltankintarder
Heatetchanger
viewintarder
Fig.73:Cut_away
Libhe -w& EhlngenGmbH' Tochnicalirainrng
personnel
service
Onlyfor LIEBHERR
-50-
lIEIIERR
UW06 - Transmission
Function:
cooling
is continuously
cooledbythecoolantin thevehicle
Theintarder
heatexchanger
circuit.
Accurn
ulatorchargevalve
Stator(firmlyattrached
to the housingi
Fig. 74: Intarderswitchedoff
chargevalve.Thisis done
Actuationof the intarder(braking)activatesthe accumulator
andcanbe performed
in several
by pullingthe steeringcolumnswitch(right)backwards
stages.Compressed
air thenforcesthe oil fromthe oil tankintothe workingcavitybetweenthe rotorandstator(rapidbrakingaction).
forcedisperses
the oil intothe stator
Theshapeof the rotorbladesandthe centrifugal
whichis fixedto the housing.Thisoil dispersion
effectbrakesthe rotorand hencethe veusinga heat
hicle.Frictionconvertsthe kineticenergyintoheatwhichmustbe dissipated
exchanger.
Accumulaior
chargevalve
(-
"ot0,""""0 "n
Oiltank
Stator(firmlyaitached
Heatexchanger
to thehousing)
- . .
- . . . .
Fig.75:lntarderactuated(braking)
Liebheii-WerkEhnsen GmbH- Technil trai.ing
personnel
service
Onlyfor LIEBHERR
- 51 _
UIBIITRN
Gomponent
description
UW06 - Transmission
Pduedbykfid/Edllm]20@07lvadon:2
Intardercomponents
. IntarderECU
lnstallation
location:centerconsole
participant
(120ohm
End
on CAN-BUS
resistor)
termination
Fig.76: IntarderECU
Theaccumulator
chargevalveis actuated
by the intarder-Ecuwhenthe intarderis
switchedon.Pneumatic
actuationof the oil
piston
(drainthe contentof theoil tank)
tank
Fig.77:Accumulator
chargevalve
Heat exchanger
The heatexchangeris a watercoolerwhich

is connected
to the vehiclecoolingcircuit.lt
ensuresthatthe intarderandtransmission
cooled.
are sufficiently
Fig.78: Heatexchangef
tfainins
Lrbhn-Wlk
Ehlnon
GmbH- Tgchnical
Onlyfor LIEBHERR
servicepersonnel
_ 52 _
UIBIIERN
Transmission
Oil tank
Reducesthe intarderresponsetimeby
drainingthe contentof the oil tank('1.4l) into
the intarderoil circuit.
Fig.79:Oiltank
Coolanttemperaturesensor-A68 81
Protectsthe coolingsystemagainstoverheatingduringintarderoperationthrough
reductionof the
temDerature-dependent
brakingtorque.
Fig.80:Coolanttemperature
Prop.solenoidvalve - Intarderactivation-Y68_Yl
Activation
of the hydraulicunitinsidethe
intardet
Actuationvia the intarder-EcUusing
a
PWM-signal.
activation
Fig.81:Prop.solenoidvalve- Intardor
lntarderswitch '
Switchon the centerconsoleto switchoff
the intarder
Fig.82:Intarderswitch"ON"/ "OFF
Liebhen-Wrk
Ehingn
GmbH- TechnillEinins
Onlyfor LIEBHERR
servicepersonnel
-53-
ITEIIRR
UW06 - Transmission
/ systemdesign
>4.1.7Components
linearCAN-BUS
witha startandend
participant
WheelRPMECU
. Optimising
the gearchanges
whentuminganddrivingon
differenttypesof terrain.
TransmissionECU
. Transmission
control
Keyboardunit
Selectfrom:
R,N,D
Gearup/down
Drivingprograms;
1 = Automatic
2 = Manual
l\4anoeuvring
mode
or off-roadgear
Displayunit
Displays:
' automaticmode
. manoeuvnng
mode
. gearcunentlyselected
. neutralposition
. errorcode
EngineECU
. Reduction
oftheengine
powerpriorto a gear
cnange
. Increasing
the torquein
manoeuvring
mode
IntarderECU
. Influence
of gear
changepointsto
increasethe braking
effect
Steeringcolumnswitch
. Activatingthe intarderin
switchposition1
. Changegearup/down
in manual
operation
. clutchooen/ closed
Fig.83:Components
/ systemdesign
Liebher-WerkEhingenGmbH- Technil aaining
OnlyforLIEBHERR
servicepersonnel
-54-
UEBHINR
UW06 - Transmission
4.2Automaticgearboxwith upstreamconverter
>4.2.1TC-Tronicwith rtarderZF12AS3002TC
Design:
thefollowingcomponents;
essentially
comprises
TheTC-Tronic
transmission
. 12As-Tronictransmission
. Converter
withconverterclutchunit
. Retarder
. Hydraulic
convertercontrol
. Electrical
retarderandconvertercontrol
. Clutch
Returnfrom heal
exchanger
-A61
Transmission
ECU,transmission
actuator
electronic
transmission
wit\ integrated
actualion
andlravelsensors,
temperature
sensor,airpressure
sensorandRPM
input)
sensor(transmission
Retarderregulation
valve,
Toheat
exchanger
-B27
Temperature
sensor
WSK,oiltempetLrre
= 40140OHIVI
20'
130' = 751OHM
Fillingnozzle
converter
Compressed
air connectionretarder
regulation
plug1
Oilfiller
Gearbox
-Y72
valve
Prcportional
(S/lVcontrolled)
1=WSK
closed
Clutch
Primaryretarder
TofqueconverterTC
withconverter
clutch
unitWSK,
Converter
reseryoir
Oilfilier
Fig.84:To-Tronic- ZF12AS3002TC
Liebhii-W* Ehin96nGmbH- Technil lEining
personnel
Onlyfor LIEBHERR
service
-55-
ITEHIRR
UW06 - Transmission
Oilfillefplug
Firsttimenlling
Converter
Oilfillerplug2 gearbox
-A69
Clulchacluatorwith4 magnetic
swilching
valvesandtravelsensorc
Fig.85:To-Tronic- ZF 12AS3002TC
Discset
Turbinewheel
(secondary
v'heel)
Clutch(dryclutch)
Transmission Splittergroup
orlpump
Reversegear
cup
springs
Converter
clutch
unil
Retarder
I\,4ain
transmission
section
wjlhreversing
wheel(3-gear
transmission)
Secliongroup
(planetary
gear)
Guidewheel
(defleciion Pumpwheel Transmission
brake
(primary
wheel)
w-heel)
12AS3002
- ZF12AS3002TC
F;9.86:Cut-away
drawingTC-Tronic
Liebheii-WrkEh n96n GmbH- Technil tEining
personnel
Onlyfor LIEBHERR
service
-56-
UIBHIRR
UW06 - Transmission
Clulch (dry clutch)
Tufuinewheel
(secondary
wheel)
Cupspdngs
Guidewheel
(defleclion
wheel)
Pumpwheel
(primary
wheel)
Fig.87: Cutaway modelof TC2
Liebhen-WrkEhingnGmbH- Techniel tkining
personnel
Onlyfor LIEBHERR
service
- 5 7-
lIIBHTRR
UW06 - Transmission
>Retarder
Puroose:
Theretarder(primaryretarder)is a wear-freepermanenthydraulicbrakewith multiple
unitbetweenthe engineand
brakingstages.The retarderis an independent
goodbrakingperformance
transmission
and providesparticularly
at highenginespeeds.
Theretarderrelievesthe loadon the servicebrake(footbrake)and enginebrakeand
preventsoverheating.
Design:
Retaderregulation
valve
Prop.solenoidvalve
(retarde.activaijon)
Staior(firmlyattached
to
the housing)
Heatoxchanger
Fig.88: Retarder/ZF 12AS3002TC
Ljebher-Werk
Ehlngn
GmbH- Tgchrical
tralnlng
personnel
OnlyforLIEBHERR
service
-58-
lIIBHIRR
Transmission
>Rtarder
Purpose;
Theretader (primaryretarder)is a wear-freepermanenthydraulicbrakewithmultiple
brakingstages.Theretarderis an independent
unitbetweenthe engineano
transmission
andprovidesparticularly
goodbrakingperformance
at highenginespeeds.
Theretarderrelievesthe loadon the servicebrake(footbrake)and e;gine brakeand
preventsoverheating.
Design:
Retarderregulaljonvalve
Prop.solenoidvalve
(retarder
activation
)
Stator(firmlyattached
to
ihe housing)
Heatexchanger
Fig.88: RetatdetI ZF 12AS3002 TC
Liebher-WelkEhingenGmbH- TechnicattEining
Onlyfor LIEBHERR
personne
service
-58-
UIBIIIRR
UW06 - Transmission
Function:
valve.
comprises
a stator,rotorand retarderregulation
Theretarderessentially
pulling
backwards
and can
steering
column
switch
the right
Brakingitselfis actuatedby
air appliedto the retarderregulation
in severalstages.Thecompressed
be performed
valvereleasestheflowof oil intothe retardercircuit.
the oil intothe statorwhich
The rotationas wellas the shapeof the rotorbladesdisperses
the
cycle
recommences.
is fixedto the housing.lt thenreturnsto the rotorwhere
movementofthe rotorand hencethevehicle
Thediversionof the oil delaysthe rotational
pressure
by
andfrictionintoheatwhichis transspeed.The kineticenergyis converted
ferredto the coolingwatervia a heatexchanger.
valve
Retaderregulation
Outletspiral
aircon
Compressed
Pressurcoilfrom
heatexchanger
Pressure
oilto heat
exchanger
Connection
coolingwater
Heatexchanger
Fig.89; OveNiewof retarder
Liebhen-WerkEhingenGmbH- Technil tfainng
personnel
Onlyfor LIEBHERR
service
-59-
UTBIIIRR
Gomponent
description
UW06 - Transmission
>Hydraulicconvertercontrol
Valveblockconverter
control
clutchun;t
converier
wsK (-Y176)
converter
clutchunit
WSK
Converter
back
pressuae
valve
Fig.90: Hydraulic
converter
control
aciuation
Retader requationvalve
\fiffirf
-----i'iLi'fi'illl3*'
x X .
- converter
- ZF12AS3002TC
Fig.91rExcerptfromschematic
controlTC-Tronic
Liebher-WerkEhingenGmbH- Technll lEining
personnel
OnlyfprLIEBHERR
service
-60-
lTIBHIRR
UW06 - Transmission
>Electricalconverterand retardercontrol
Electrical
converterand retardercontrolis performedby the ECU- EST41
retardefcontrolunitEST41
Fig.92:Converterand
>Clutch
plate
Pressure
; . ; : "
Ceranclutch
Fig.93:Clutchwithremovedp.essureplate
Membrane
sping
Pressure
beaiing
Fig.94: Clulchassembled
Llebhetr-Werk
EhingenGmbH- Technlcallbining
personnel
service
OnlyforLIEBHERR
- 6'l -
ITIBHINR
omponentdescriPtion
UW06 - Transmission
"fl* "
."'" r*',"". *'' *" "'
clutch:
the converterclutch unit and
>Openingand closing
qit||ztion
Neutral
Brake+ D
StartinguP
(pressaccelerator)
Driving
Gearchange
Brake+ D +
Manoeuvnng
button
Converter I
Ctutcn
-l F- {F{F- {F-l l-' {l.{l-- {l.*l

F{F
'{ l-' {l.-
trarnng
GmbH- Technical
Ehingn
Libhen-Werk
personnel
service
OnlyforLIEBHERR
Comment
-------'--------
converterclutchunll vvr^
opensat < n =.9501/mln
(turbine
speeo).
Engagingthe startinggear:
3rdor 2ndgear
Full load-release uruY
whenclutchhasfullycloseo
Converterclutcnunll vvor\
closesat n > 10501/mln
(turbine
speeo).
lighton thedisihe control
after
playunitextinguishes
ca. l secono. . .
WSKis closedto obtaln.
precisespeedratiosdunng
gearchanges.
-----'-:---:-
in"
;i;;i.:i:#,'#
"i;;;:
wllr
highconvertertorque
causethe craneto move
whenthe brakeis releaseo'
usingcon(manoeuvring
verter)
lIIBHENR
Transmission
>4.2.2TC-Tronicwith intarderZF 12TC3040SO
Puroose:
Conversion
of enginetorqueandspeedaccordingto the tractiveeffortdemandedby the
ratioselection.
vehicle.Automaticstartingandtransmission
gearchange,a converterclutchunit,a
with
an
automatic
Thetransmission
is equipped
cluichand an intarder.
Design:
converteroitchamber Plug,vehicle
Plugto clutch
acluarcr
Transmission
actuator
Oilfillingnozle
Gearbox
Pressure
reducing
valve/ compressed
airconnection
. TorqueconverterTC
with converterclutch
unitWSK,
. Dryclutch
Solenoid
valve
(openaccumulator
chargevalve)
Heat exchangef
Oiltank
intarder
Coolanttemperature
sensor
(heatexchanger
output)
Oilfillerplug
Gearbox
RPMsensor
driveshafr
Oilfilter and oil drain

plugAS-Tronic
Gearbox
12453040
Prop.solenoidvalve
(intarderactivation)
Plug10intarderECU
- ZF12TC3040SO
Fig.95:TC-Tronic
Liebher-We* EhingenGmbH- Techni@llining
personnel
Onlyfor LIEBHERR
seryice
-63-
UIBHINR
Component
description
UW06 - Transmission
Oilfillernozzle
converter
oilwith
oildipstick
-Y72
Proportional
valve
(S/vvcontrolled)
'1= WSKclosed
Temperature
sensorconverter
output,oiltemperature
= 40140OHM
20"
'130" = 751OHM
Oil drain plug WSK
Liftingpointsduring
lransportalion
and
installation
Changefilter
(pressure
filter);must
be replaced
during
everyoilchangel
.469
Oildrainplug
Clutchactuatorwith4 magnetic
on-offvalvesandtravelsensors
Changefilter
(suction
filter);mustbe replacod
duringeveryoilchangl
Fig.96rTo-Tronic- ZF 12TC3040SO
Li6bher-Wrk
Ehingn
GnbH- Tchnical
llalnhg
personnel
OnlytorLIEBHERR
service
-64-
- Transmission
Discset
Turbinewheel
(secondary
wheel)
(pfimarywheel)
-/
._.
t.-:-
._ _.:
___
!-
i__
t:
.'F
; i !
:-'-,'I
] r'
)/
1i
Cupspdngs
Converter
clutchunil
Torqueconvede
wilhconverter
clutchunitforTC3040SO
Fig.97:Cut-away
drawingtorqueconverter
Llsbher-WgrkEhingenGmbH- Techni@ltEining
personnel
service
OnlyforLIEBHERR
-65-
ITBHIRR
UW06 - Transmission
>Electricalintardercontrol
Electrical
intardercontrolis oerformedbv intardercontrolunitEST42 whichis locatedin
the centerconsole.
Fio. 98: lntardercontrolunil - EST42
>Convertercontrol
Converter
clutchunit
Converlerback
pressurevalve 6 bar
Switching
valveWSK
Convertersafety
valveI bar
Pressure
filter
Converterflling
and
pump
switching
Pressure
valveWSK13.5baf
Suctionfilter
- converlerconlrolTo-Tronic- ZF 'l2TC3040SO
Fig.99: Excerptfromschematic
Llebhon-wrk
Ehingen
GmbH- Techniltcinino
OnlyforLIEBHERR
servicepersonnel
_ 66 _
UIBTIIRR
UW06 - Transmission
>Differencesto ZF 12AS3002TC
is equippedwithan intarderinsteadof a primaryretarder'
TheZF 12TC3O4OSO
Intardercontrolis performedby an additionalintardercontrolunitEST42.
fillingandswitchingpumpis largerthanthaton previousTC-TRONIC
Theconverter
time'
the manoeuvring
modelsand improvesheattransfer.Thisincreases
valvelimitsthe pressurerequiredto closethe converterclutchunit
TheDressure
(converter
bypassclutch)to 13.5bar (to reducethe sizeof the spring'a converter
backpressureof 6 bar is used).
for the converter
Theconvertersafetyvalveprovidesmaximumpressureprotection
whentheoil is
is
utilised
(max.8 bar),The3rd positionof the convertersafetyvalve
extremelycold(theoil directlyflowsintothe sump).
Liebher-Wei( EhingenGnbH - TechnicaltrainFg
personnel
service
OnlyforLIEBHERR
lIIBIIIRR
Pduedb'kfiro]Edio20e07/ve6m:2
5. Semi-automatic
shift transmissions
(synchronous
>5.1ZFECOSPLIT
16S/151
transmission
withEasyshifr2.
gearchangesysiem)
Design:
.830
position
Tmvelsensor
downstream
group(section
groupswitched)
Switching
cylinder
Reversegear
Switching
arm
Valveblock
Speedsensorfor
tachograph
Maincompressed
aarconnection
for emergency
switching
Switching
cylinderfor
gears3/4and7/8
Switching
valvefor
group
oownstream
Switching
cylinderfor
gears1/2and5/6
Displaygearindicator
Switching
cylinder
group
downstream
(sectiongroup)
Hydro-pneumatic
clutch
lhrow-outcylinder
-r-.i
.,:..,]r,
Fig.100rECOSPLIT
16S151
Liebheir-Werk
EhingenGmbH, T6chni@ttEining
OnlyforLIEBHERR
servicepersonnel
-68-
UIBHIRR
Component
description
Transmission
Fftdu.edby:*pd/fuiddn:2ded7lveBifr:2
Design:
Transmission
control
unitEST28
-s394
Switch"SplittergroupON"
-s396
Switch"Transmission
neutral"for antigasand
startinginhibitor
-829
Travelsensor"Gearengaged"
and neutral-pos."
Fig.101:ECOSPLIT
16S151
Function:
Thegearstagesof the Easyshift2-changesystemsare selectedon the steeringcolumn
switchby the driver.
requiredfor
A displayshowingthe gearsis alsoinstalled.
Thisshowsall the information
drivingoperation(e.9.howmanygearsto changeup/downas wellas the selectedgear).
Thisdisplayis controlledby the electronic
controlunit.
LiebheE-Werk Ehingen GmbH - Technil tlaining
OnlyforLIEBHERR
servicepersonnel
-69-
UBIITRR
Thecontrolunitprocesses
all incomingsignalssuchas the gearpositionof the transmisgear
sion,transmission
speedetc.,andforwardsthe electricalsignalfor the pre-selected
to the valveblock.Thesolenoidvalvesrequiredto actuatethe switchingcylindersare
integrated
in thisvalveblock.
Theclutchpedalmustbe fullydepressed
to performthe gearchange.Depending
on the
pre-selected
gear,the corresponding
pneumatically
switchingcylinderis
switchedby a
tripswitch.A signaltransducer
sendsa pulseto the clutchpedaloncethe gearchange
hasbeenperformed
by the transmission.
Thispulsecan be felt at the pedaland prompts
the driverto engagethe clutch.ln orderto protectthe engineandtransmission,
the elecgear
permitted
tronicsonlyallows
changeswhichliewithinthe
speedrangesdefinedby
thevehicleandtransmission
manufacturers.
Swtchinscylin;error
Legend:
-Yl to -Ys
-Y6
-Y8
-Y13
Actuating
lhe switching
cylinder
Sectiongroup
Neuiral
Splittergroup
Fig.102:Exceptfiom schematic
Easyshift
Liebhetr-Werk
Ehln96nGmbH- Techni@ltGining
OnlyforLIEBHERR
servicepersonnel
-70 -
ITIBHIRR
description
Component
UW07- Transfergearbox/
Driveshafts
service
OnlvforLIEBHERR
Dersonnel
UW 07 - Transfergearbox/ Drive shafts
Prcddby:|*epid/Ed!m:]3o07/veEon:1
Ehingen
GmbH-Techniltralning
uebhen-werk
personnel
service
OnlyforLIEBHERR
-3-
ITIBHINR
UW07 - Transfergearbox/ Driveshafts
Transfergearbox
)'1.Transfergearbox,general
1.1Purpose
Vehiclesare equippedwitha transfergearboxif severalaxleshaveto be ddvenat the
sametime.Thisis locatedbetweenthe transmission
andthe axleandcomDensation
gearson the driveaxles.
Thetransfergearboxperformsthe followingtasks:
. Torquedistribution
to multipleaxlegears
. Extendsthegeartransmission
range(roadgear/ off-roadgear)
. Drivespumps(e.9.emergency
steeringpump)via powertake-off
' Blocksspeedcompensation
(differential
lock)in caseof excessiveslipdifferences
betweenthe drivewheels
'1.2Layout
Drivewheel
roadgear
Drivowheel
off-roadgear
Drive
Switching
cylinder
off-roadgear/ neulral
/roaogear
Shiftclaw
Powertake-off
Outputto roar axles

Outputto frontaxles
Longitudinal
differential
based
gear
on a planetary
Longitudinaldifferntiallock
Fig.1: Cut-away
viewof thetranstergearbox
Liebher-Weik Ehlngn GmbH - Techniel training
OnlyforLIEBHERR
servicepersonnel
-4-
UEIIIRR
UW 07 - Transfergearbox/ Driveshafts
1.3Longitudinaldifferentiallock for transfergearbox

Purpose:
betvveen
thefront
compensation
differential
lockblocksthe differential
Thelongitudinal
and rearaxlesduringoff-roaddriving.
Design:
Air connection
lock
Longiiudinal
differential
transfergearbox
Controlswitch
lock
Longitudinal
differential
fork
Switching
Switchingsleeve
lock
differential
Fig.2: Culawayviewofthe longitudinal
Function:
lock(e.9.clawcouanda mechanical
lockconsistsof a standarddifferential
A differential
(off-road,
iceetc.).
pling),whichis manuallyswitchedin duringdifficultdrivingconditions
function.
Thisdisablesthedifferential
and its compensation
Manualbutton,
pressfor 2-hand
operation
lock
Fig.3: Switching
in the longitudinaldifferential
Note:
lockandsafetynotesaregivenin the
differential
The switchingorderfor the longitudinal
model.
for the specificcrane
operatinginstructions
lraining
LlebheF-Werk
Ehinsen
GmbH- Technlcal
servicepersonne
OnlyforLIEBHERR
- S _
ITBHIRR

Frcdudby rep.t/editun:13.04.077v8Eion:r
2, Single-stagetransfer gearbox
>2.1 KesslerW 3750
Dsign
Non-return
valve,
Pipefromoil cooler
Drive
Non-retum
valvo,
Pipeto oil cooler
Emergency
steering
pump
Wheeldriven
axialpistonpump
for centering
cjrcuit
AHL
-B2A
Pulsogenorator
fortransfergearbox
tachograph
Oillevelcheck
/ oilfill
plug
Outputto frontaxles
differentiallock
30
Contactswitch
Longitudinal
transfer
differential
gearbox,acknowledgement
Fig.4: Transfergearbox- KesslerW3750
Libher-WerkEhingenGmbH- Technil iEining
personnel
OnlyforLIEBHERR
service
-6-
ITIBIIIRR

>2.2SteyrPuch3800
Design
Pulsegenerator
for hansfer
gearbox
tachograph
valve,
Non-retum
Pipeto
oil cooler
Emergency
steeringpump
Outputto rearaxles
Outputto frontaxles
.s122
Contactswitch
Longitudinal
differential
transfergearbox,
acknowledgement
for
ak connection
Compressed
lock
difierential
longitudinal
Oildrainplug
/ oilfill
Oillevelcheck
plug
- SteyrPuch3800
Fig.5: Transfergeadox
Liebhetr-Wrk
EhingenGmbH- Technil lraining
personne
service
Onlyfor LIEBHERR
UBHRN
Design
Outputto frontaxles
Outputlo rearaxles
Longitudinal
differential
based
gear
on a planetary
Fig.6: Cut-away
viewofiransfergearbox- SteyrPuch3800
Liebheii-WerkEhingnGnbH - Technil lraining
personnel
OnlyforLIEBHERR
service
-8-
UBITIRR
3. Two-stagetransfer gearbox
>3.1 Changeoverroad gear/ neutral/ off-roadgear
Purpose:
mechanism
betweenroad
transfergearboxesare equippedwitha changeover
Two-stage
gearandoff-roadgear(thereis alsoa neutralpositionfor the transfergearbox).
gearreduction
whichincreases
vehicletractionon
Theoff-roadgearis an additional
off-roadterrain.
Design:
Controlswitch
geafon
Off-road
Air conneclion
NeutElposition
Emergencyswitchio
Neutral
Air connection
gearOn
Off-road
Air @nnection
Roadgear on
Adjustment
screw
Switchrod
Fig. 7: Cut-awayview - Changeove.betweenroad gear/ off-roadgear
Function:
betweenroadgear,off-roadgearand
Compressed
air is usedto controlthe changeover
neutralposition.Theoff-roadgearis switchedin andout usingthe "Off-roadgear"button
(tortoise)
on the keyboardunit.
Buttonoff-roadgear
gear)
(crawling
Fig.8: Changeover
betweenroadgear/ off-roadgear
Note:
for switchingin off-roadgearandtowingmode.
Referto the operatinginstructions
Liebheir-Werk
EhingenGmbH- Technil tining
personnel
service
OnlyforLIEBHERR
-9-
UTBHINN
>3.2KesslrVG1600
Design
.s.fi0
Controlswitchoffroadgear(On)
Compressed
airconnection
for longitudinal
differental
lock
Emergenry
steeringpump
'l,lS
Contact switch
Oulputlo frontaxles
Longitudinal
differentialtransfergearbox,
acknowledgement
Oil coolertransfer
gearbox
Air connection
off-road
gearON
Non-retum
valve,
Pipeto oil cooler
Air connection
neutralON
Switching
cylinderoff-roadgear/
neutral/roadgear
Air connection
road
gearON
Pulsegenerator
Ior
transfergearboxtachograph
Non-return
valve,
Pipefromoilcooler
Oillevelcheck
/ oilfill
plug
Outputto rearaxle
Oildrainplug
gearboxKesslerVG 1600
Fig.9: Transfer
llsbher-WerkEhingon
GmbH- Technittrahlng
Onlyfor LIEBHERR
servicepersonne
-10-
UIBHTNR
Switchingsleev
Drivewheel
roadgear
Longitudinaldifferentiallock
Outputto rearaxles
Output{ofrontaxles
Longiiudinaldifferentialbased
gear
ona planetary
Fig.10:Cut-away
viewtransfergearboxKesslerVG 1600
Uebher-WerkEhingenGmbH- Techni@liEining
personnel
OnlyforLIEBHERR
service
- '11-
ITIBHIRR
Gomponent
description
>3.3SteyrPuchVG2100
Design
Switchingcylinderoff-roadgear /
neutral/roadgear
Air connection
off-road
gearON
Emergency
sreenngpump
Airconnection
neutralON
Air connection
roadgoarON
Non-return
valve,
Pipeto oil cooler
.G4
PulsegeneGtorfor
tansfergearbox
tachograph
oitntl
plug
Output
to rearaxle
Oil levelcheck
plug
.S161Contact
versaldifforential
On=1
Outplt to front axle

Oil drainpl
Fig.11:TransfergearboxSteyrPuchVG 2100
Liebhen-Wrk
Ehlngen
GmbH- Technilhainlng
Onlyfor LIEBHERR
servicepersonnel
-12-
UIBHIRR
>3.4KesslerVG2600
Design
Switchcylinderoff roadgear/
neutral/ roadgear
valve,
Non-retum
Pipefron oil cooler
Emergency
steeringpump
.828
for
Pulsegenerator
Iransfergearbox
tachograph
Contactswilch
Longitudinal
tialtransfer
acknowledgement
Outputto rearaxles
Outputto ftont axles
Compressed
air@nnection
for longitudinal
difierential
lock
Airconneclion
roadgearON
Airconnection
neutralON
Contactswitch,
acknowledgement
Ofi roadgearON
off-road
Air connection
gearON
.s64
Contactswitch,
acknowjgdgement
Road gear ON
Fig.12: TransfergearboxKessler2600
Ehingen
GmbH- TschniiEining
Llsbher-WeR
servicepersonne
OnlyforLIEBHERR
- 13 -
UEHINR
Switching
cylinderoff-road
gear/ neutral/roadgear
Powertake-off
Outputto rearaxles
Outputto front
Longitudinaldifferentialbased
on a ptanerygear
Fig.13:Cut-away
viewtransfergearboxKesslef2600
Liebher.-Werk
Ehlngn
GmbH- Tchnical
tralning
Onlyfor LIEBHERR
personnel
service
-14-
IIBIITRR
>3.5KesslervG 3750
Design
Air connection
Air conngction
off-roadgearON
neutral
ON
A'r connection
roadgearON
-s65
Contactswitch
off-roadgear"ON"
.s64
Contactswitch
roadgear"ON"
-828
for
Pulsegenerator
transfer
tachograph
geatbox
axialpistonpump
for centering
circuitAHL
/ oil
Oillevelcheck
plug
Outputlo front axles
for
compressed
ak conneclion
lock
longitudinal
differential
-s30
Contactswitch
transfer
Longitudinal
differential
gearbox,acknowledgement
gearboxKessler3750
Fig.14:Transfer
U6bh6n-Wrk
Ehlngn
GmbH- Technillraining
OnlyforLIEBHERR
servicepersonnel
- 15 -
UBIIRR
Drivewheel
ofJ-roadgear
Switchingcylinderoff-roadgear /
neuhal/roadgear
Switching
sleeve
Oulpulto rearaxles
Outputto frontaxles
Longjtudinal
difierential
lock
Longitudinal
differential
based
on a planeErygear
Fig.15rCut-away
viewtransfergoarboxKessler3750
Uebheii-WerkEhingnGmbH- Technil training
Onlyfor LIEBHERR
servicepersonnel
-16-
UIBIIERR

>3.6 KesslerVG 1600combinedwith axle
Design
for
Pulsegenerator
transfergearbox
tachograph
Drive
Pipet9 oil cooler
Pipefromoilcooler
42
Contactswitdl
transversal
difierential
axle2 Compressed
air
connection
for
switching
in axle1
Compaessed
airconnection
for off-roadgear
Outputto frontaxles
Contactswitch
swtchin axle1
for
Compressed
airconnection
roadgear
-s64
switch,
Contact
roadgearON
Contactswitch,
off-roadgearON
Outputto rearaxles
for
ak connection
Compressed
switching
in axle2 / longitudinal
differential
lock
Contaciswitch
Switchin axle2 /
longitudinal
dlfferential
lockfortransfergearbox
withaxle
Fig. 16:TransfergearboxKesslerVG 1600combined
Liebher-Werk
Ehinen
GmbH- Tchnlcal
lraininq
servicepersonnel
Onlyfor LIEBHERR
_fl
llIBHIRR
Swltchingsleevo
.s64
Contact
switch,
roadgearON
Contactswitch,
off-roadgearON
Outputto frontaxles
31
Contactswitch
switchin axle1
Longitudinaldifferenlial
contactswitch
Switchin axle2 / longitudinal
differcntial
lockfor transfer
geadcox
Fig. 17:Cut-away
viewtransfergearboxKesslerVG '1600combined
withaxle
Liebher-WerkEhlngnGmbH- technil tEining
personnel
OnlyforLIEBHERR
service
- 1 8-
ITIBIIRR
Driveshafts
>1.Driveshafts,general
1.1PurDose
Driveshafts(cardanshafts)are usedto evenlytransferthe torquefromthe transmission
to thetransfergearboxandfromthe transfergearboxto the axledrive.
anyangularmotion.
Cardanjointsat eachendof the driveshaftcompensate
provides
within
the driveshaft.
compensation
longitudinal
A slidersection
Cardanjoint
Slidersection
Cardanjoint
(cross-toothed
)
Fig.18:Driveshaft(cardanshaft)
1.2Layout
LTNI1400-7.'1
Fig. 19:Driveshaftinstallation
Liebhen-werkEhinsgnGmbH- Tchnil tEinins
Onlyfor LIEBHERR
servicepersonne
_ 1g -
rIBHINR
Type"A"
withgreasenippleon slidersectionand cardanjoint
Fig.20:Ddveshafttype"A"
Typ"8"
greasenippleonlyon cardanjoint(lowmaintenance)
Fig.21:Driveshafttype"8"
Type"C"
withoutgreasenipple"maintenance-free"
@I-,rm D
Fig.22:Ddveshafttypo"C"
Ubher-Werk
Ehingen
GmbH- TechniliEining
Onlyfor LIEBHERR
servicepersonnel
-20-
ITIBIIIRR
description
Gomponent
UW08- Axleswith attachments
servicepersonne
Onlyfor LIEBHERR
UW08 - Axles with attachments
seryiceTraining
Liebhefi-We*
Ehlngn
GmbH- Cuslomer
servicepersonne
OnlyforLIEBHERR
lIIBIITRR
UW08 - Axleswith attachments

1. Kessleraxles
1.1Axles,general
>1.1Puroose
Theaxlecombinesdrive,steering,axlesuspension
and brakingcomponents
whichfullil
purpose:
thefollowing
. Transferring
the drivetorque
. Supporting
the maximumaxleloads(12tand 14ton roads)and maximumaxlepressures(off-roaddriving). Switchingin the differential
locksduringoff-roaddrivingor in caseof difficultcondittons.
>1.2 Layout
Steeringarm
Axle struts
(transverse
controlarm)
Steeringcylinder
Tracking
rod
Trackinglevef
Trailingarm
Brak6cylinder
Fig. 1:Axle, general
Liebheii-WekEhingenGmbH- CustonrSorulcTralnlng
Onlyfor LIEBHERR
servicepersonnel
-4-
ITBIITRR
Tralning
Liebher-WeR
Ehingen
GhbH- Customer
Srvice
OnlyforLIEBHERR
servicepersonnel
-3-
UIBIIRR
Poduc!by:kpidTEdroi: i3.04.07/vecron
2
1.2Axle types
axls
>1,2.1Non-driven
Fixedaxle
(axlecannotbe steeredor driven)
fromschematic
forfixedaxle
Fig.2: Excerpt
- 3rdaxle
LTM1100-5.1
Fig.4: Fixedaxle
Steering axle
(axle can be steered but is not driven)
Fig.5: Steeringaxle
Fig.3: Excerplfromschematic
- 3rdaxle
LT[.41220-5.1
Liebher-wei<
Ehlngn
GmbB- clslomerserviceTrahing
personnel
service
Onlyfor LIEBHERR
- C -
rIIBHINR
>1.2,2Permanentlydriven axles
Driveaxle
(axlecannotbe steeredand is permanentlydriven)
- 2ndaxle
Fig.6: ExcerptfromschematiclTl\4
1100-5.1
Steeringdrive axle
(axlecan be steeredand is pormanentlydriven)
Fig.7: Excerptfromschema{c
- 4thaxle
LTM1070-4.1
Liebher-We*Ehingen
GmbH, Customgr
S6rvic6
Tining
OnlyforLIEBHERR
servicepersonnel
Fig.8: Steeringdrivea(lo
-6-
rIIBHINR
fudu.edbywepd/fulonrsed/VeEon
>1.2.3Drive-throughaxles(axleswitchedin)
Axle with intermediatedifferential
(switchingin/outthe wheel-drivedrivenvia the intermediatedifferential)
Fig.9; Excerpllrom schematicLTM 1120-5.1- 4lh axle
11:Axlewiihintermediate
differenlal
Fiq. 10:Axle with intermedialedifferential
Fig. 12: Overviewshowingaxle wilh intermedialedifferential

Training
Ehingen
GmbH- Customer
Seruice
Liebhsr-wsrk
personnel
service
OnlyforLIEBHERR
- 7 _
TTIBHINR
Gomponent
description
Axle with drive-throughdeactivation

(switchingin/outthe wheel-drive)
Fig.13:Exceptfromschematic
LTM11004.1with8x8drive- 2ndaxle
Fig. '14:Axle with drive-throughdeactivation
Fig.16:Axlewithdrive-through
deactivation
ilF-<.F;
fr4*,tr
'FII'
-r-'
Fig.15:Oveaview
showingaxlewithdrive-through
deactivalion
Liebher-w* EhingonGmbH- CustomerSeNiceTEining
Onlyfor LIEBHERR
servicepersonnel
-8-
UIBIIIRR
ProdGdby:wepd/Edi[on:13807/veEon:2
Axle with axle deactivation

(switching in/out the wheel-drive for a downstream axle )
Fig.17:Excerptfromschematc
withdrive- 3rdaxle
LTI\,'|
1100-4.1
Fig. 18:Axle deaclivation
Frg.19: Overviewshowingaxle with axle deaclivalion

Liebher-We* EhingsnGmbH- CuslomerSeryiceTbining
personnel
service
onlyfor LIEBHERR
-9-
UIBIIIRR
1.3Axle drive
>1.3.1Drive
Switchingsleeve
Transversaldiiferentiallock
Compensationbevelgear
Axleshaftwheel
Difierentialhousing
Axlehousi
Cam switch
Drivebevelgear
Connection
Compressedair
Housing
Axledrive
Spring
Crownwheel
Driveflange
Fig.20:Cut-away
viewof axledrive
Liebher-WerkEhingenGhbH - CuslomerSeryiceTraining
personnel
Onlyfor LIEBHERR
service
- 10 -
lTTBTITRR
>1.3.2Wheelside
Aciuationcylinder
Ringgear
Suspension
bracket
Wheelhub
Planetary
wheel
Trackinglever
viewof axledrivewheel-side
Fig.21:Cut-away
Training
Liebher-WeR
Ehinqen
GmbH- qrstomorSeryice
personne
OnlyforLIEBHERR
service
_f
UTBIIRR
Component
description
Brakectuation
cylinder
Whel hub
\ryheelbolts
Sungear
Ringgear
Planetary
wheel
Wheelhubcover
Fig.22: Planetary
drive/ brakedrum/ wheelhubcover
Liebher-WerkEhingenGmbH- CuslomsrServicTraining
Onlyfor LIEBHERR
servicepersonne
_n
rIEHRR
gear
1.4Differential
/ Compensation
general
>1.4.1Differential,
Purpose:
Whenmakingturns,thewheelson an axletraveldifferentdistancesandshouldtherefore
notbe coupledtogetherin a fixedmanner.
gearis to compensate
the speed
Thepurposeof the differential
or compensation
to
the torque the drivewheels.
differences
betweenthe drivewheelsandevenlydistribute
Design:
Drivebevelgear
Axleshaftwheels
Compensation
bevel
gears
leftaxleshaft
righl axle shaft
Crown
Compensation
housing
Fig. 23: Overviewof differentialgears
Lebhen-Werk
Ehinsen
GnbH- ClstomersetoceTEinins
personnel
OnlyforLIEBHERR
service
- 13 _
IIIBHINR
Gomponent
description
UW 08 - Axles with attachments
>'1.4.2Transversedifferentiallock
Puroose:
gearhasa detrimental
effectif a drivewheelspinson an
Forexample,the compensation
lockdisablesspeedcompensation
differential
icy or softroadsurface.Thetransversal
axle.
lt
is
used
to
connect
bothdrivewheelstogether
betweenbothwheelson a drive
the appliedtorque.
whenthe speeddifferences
aretoo Iargeandevenlyd;stribute
Design:
Fig.28: Exampleof transve6aldifbrentiallock
lock
Fig.27: Exampleof transversal
differential
Fig.29: LTN41100-4.1Exampleof transversaldifferentiallocks

Function:
lock.
Atransversedifferential
and a mechanical
Thisis locatedbetweenbothwheelson an axleand is usedas an axledifferentialtoprovidecompensation
betweentwowheels.
Forexample,whenmakinga turn,the outerdrivewheelwillturnfasterby the sameproportionthatthe innerwheelis turningslower.
Theamountoftorquetransferis determined
by the drivewheelwiththe pooradhesionto
the roadsurface.
(offThe lock(e.9.a clawconnection)
is manuallyswitchedin duringdifficultconditions
perso
that
the
differential
no
longer
roaddriving,iceetc.)to disable/lock
the differential
formsthe describedcompensation
function.
Liebhr-W6k EhlngnGmbH- CustomerSedice TEininS
Onlvfor LIEBHERRseryiceoersonnel
- i5
UBIITRR
differential
lock
>1.4.3Longitudinal
Purpose:
The longitudinal
differential
lockblocksthe differential
compensation
betweenthe front
and rearaxlesduringoff-roaddriving.
Design:
-s30
Contact
switch,
Longitudinal
differential
lockON = 1
Fig.30:Exampleof longitudinal
lock
differential
Compressed
air
connectron
Longitudinal
differential
- Longitudinal
Fig.31:ExcerptfromcircuitdiagramLTIV1100-4.1
lock
differential
Function:
A differential
and a mechanical
lock(e.9.clawcoupling),whichis manuallyswitchedin duringdifficultdrivingconditions
(off-road,iceetc.).
Thisdisablesthe differential
and its compensation
function.
Liebher-wsrk
Ehinqen
GmbH- CustomerSeruiceTEinins
_ 16 _
personne
Onlyfor LIEBHERR
service
ITEIITRR
>1.4.4Switchingin differentiallocks
Engagethe fronttransversa,differentiallock
Engagethefrontandreartm
locks*
versaldifferenlial
Longitudinal
differential
lockor allwheeldrive
Engagethe reartransversaldifferential
lock
Man!albutton,
Pressfor 2-hand
operation
shouldbe engaged
Fig. 32: Switchingin lhe differentiallocks
Caution:
of e.g.40 km/his aciivatedwhenthe differential
a speedrestriction
On someequipment
(see
instructions).
in
respective
operating
locksare switched
Thedifferential
locksshouldonlybe $witchedin whenthe vehicleis stationaryandin the
followingorder(seeoperatinginstructions).
Switchingsequence
lock(s)
1. Longitudinal
differential
lock(s)rear
2. Transversal
differential
differential
lock(s)front
3. Transversal
* = option
Lisbhotr-WelkEhingenGmbH- CuBtomerSetui@Training
personnel
service
OnlyforLIEBHERR
- 1 7-
lTIBIIIRN
UW 08 - Axles with attachments
2. Retarder
2.1Telmaeddycurrentbrake
>2.1.1Purpose
Assiststhe normalservicebrake.The powertrainis brakedby the generatedelectromagneticfields(eddycurrents).
>2.1.2Design
Ex. TelmaFocalF2200:
(fittedto last axle)
- electro-magnetic
Telmaretarder
- friction-free,
wear-free
- silentrunning,
maintenance
friendl,
- shortresponsetimes(350ms)
- braking
powerdependent
on enginespeed
Fig.33:Eddycurrentbrake
Electrical
connect'on
(4-stage)
Airgap
Coolingblade
Rotor
(softirondisc)
Rotor
(softirondisc)
Driveshaftflange
Fig. 34: llluslrationshowingprincipleof eddy cuffentbrake
Liebher-Werk
Ehingen
GmbB- Customer
SeruiceTining
personnel
OnlyforLIEBHERR
service
- 18 -
ITIBHIRR
UW 08 - Axleswith attachments
fudmedby:|wepid/Edfoi13'@07/VaEon:
>2.1.3Function
Rotors
The rotorsare firmlyattachedto the dfiveshaft.
The statorbehveenthe two 2 rotorsis iirmlyaf

tachedto the axle.
to the
Thecoilsareattached
polarity:
statorwithalternating
plus- minus,minus- plusetc.
ThestagesontheTelmaareusedto excitetheopDositecoils.Thiscausesmorcor lesscunentto flow

Amagneticfieldis createdwhich
throughthecoi19.
penetratesbothrotors.
Sincethisbrakeconvertskineiicenergytoheat,
Themagnetic
fieldinducesoddycunentswhich
brakethe rotors,driveshaftanddriveaxlewheels the rotorsarefittedwithcoolingribsandfan
blades.
Tlaining
Liebher-werk
Ehingen
GFbH- Customer
Sryice
personne
OnlyforLIEBHERR
service
-19-
IIIBITTRN
>2.1.4Actuation
lf an eddy currentbrake is fitted,it can be switchedon by pullingback the "steering
columnswitchright"and increasing
the brakinglevelin severalstages
(seefig.2).
- 9 0
; <
Fig.36: Rightsteeringcolumnswilch
Fig. 35: Switchingin the retarderbased

on lhe exampleof LTI\,I1100-4.1
data
>2.1.5Technical
TelmaFocalF2200;
Voltage
Max.braking
torque
gap
Nominal
air
Current
levelStage1
Stage2
esak)
Stage3
Stage4
per currentcircuit
Resistance
(20'c r 5%)
per coil
Resisiance
(i5%)
Weight
Dimensions
24V
2200Nm
1 . 4m m
274
54A
8'1A
107A
0,732A
0,364c)
174kg
5 1 0x 5 1 0x 2 4 0m m
L ebher-WerkEhingenGhbH - CuslomerSeryiceTfainng
personnel
OnlyforLIEBHERR
service
- 20 _
ITIBHIRR
UW10-Partl-Steering
personnel
OnlyforLIEBHERR
Service
UWl0-Part1-Steering
Llgbhor-WerkEhingonGmbH- Tchnil Laining
personnel
OnlyforLIEBHERR
Service
-2-
lIBHRR
UW10-Partl - Steering
!lbhr-W( EhlngenGmbH- Technil haining
Onlyfor LIEBHERR
Servicepersonnel
-3-
TTEHINR
UW10-Part1-Steering
Liebhen-Werk
EhingnGmbH- T6chnlc6ltralning
Onlyfor LIEBHERRServicepersonnel
-4-
UBHTRR
Frontaxle steering
UWl0-Part1-Steering
1. Steering
>1.1General
steering,mobilecranesare alsoequippedwithhydraulic
Apartfromtheirmechanical
power-assisted
steering.
of dual-circuit
steeringsystemswith3 pumps(steeringcircuitl, steering
Theinstallation
vehicleswith
on commercial
steeringpump)is mandatory
circuitll andemergency
severalsteeredaxlesin orderto complywithstatutorysafetycriteriawhilstalsoimproving
independent
by two completely
highlevelof safetyis underlined
steeringcomfort.This
eachotherduringnormaloperation.
steeringcircuitswhichcomplement
Ddveshaft
Steeringrod
Steedngarm
Remolesteeringmotor
Steeringgear
fle rod
Steering
cylinder
Steeringarm
steering
Fig. 1:lllustration
showingpdncipleof tront-axle
Liebhen-werkEhingenGmbH- Tcbnil lEining
personnel
Service
OnlyforLIEBHERR
- 5 i
lIEHINR
UW10-Part1-Steering
>1.2SteeringcircuitpumpsI and ll
Purpose:
Thesteeringcircuitpumpssupplypressureto the hydraulicpower-assisted
steering
for thefrontaxlesteeringcylinders.
Design:
pumpHaldexBamsGmbH
e.g-double-gear
WPl5A2B330330-Anti-clockwise
rotalion
pumpsteeringcircuit1 and2
Hydraulic
Fig.'1:SteeringpumpsLTt41400-7.1
Fig.2:Principle
ofa gearpump
Fig 3l.ut-awaymodelofagearpump
Function:
SteeringcircuitpumpsI and ll aredirectlyattachedto the engine.Theyare drive-independentandsupplythe requiredpumppressureto the steeringcylindersvia the steering
gear.Thishydraulically
assiststhe steeringmotion.
Liebheir-Wrk
EhingnGmbH- Technil tEining
personnel
Onlyfor LIEBHERR
Service
-6-
ITIBHIRR
Front axle steering
UWl0-Part1-Steering
steeringpump
>1.3Emergency
Purpose:
ofthe
steeringpumpis to ensurethe steeringcapability
The purposeof the emergency
pump
2
has
failed.
engine
or
steering
craneevenwhenthe
Design:
steedng
Emergency
pump,radialpiston
pump
steedng
Emergency
pump,
Gearpump
sauei DanfosssNP
3/44DSC07
steeringpump
Bild2: Emergency
LTMl100-4.1
Fig.1: Emergency
steeringpump
LTM1400-7.1
Function:
of the
Theemergency
sleeringpumpis fittedto the transfergearboxor the drive-side
transmission.
steeringpumpwillcontinueto
The pumpis wheeldriven.Thismeansthatthe emergency
pumpoil evenwhenthe engineis turnedoff,providing
the craneis movingforwards.
on the speedofthe crane.
The pumpoutputis thereforedependent
pump
oil
from
the
emergency
steeringpumpis directlydiverted
lf steering
ll is driven,the
to the tank.
Steeringpumpll will notoutputanyoil whenthe engineis turnedoff.Theemergency
pumpsupplies
circuitll.
steering
oiltosteering
Highspeed
Lowspeed
highp'.rmp
speed
lowpumpspeed
steering
highlevelof power-assisted
lowlevelof poweFassisied
steeing
\J/
Liebhetr-Werk
EhingenGmbH- Technicallrainhg
personnel
Onlyfor LIEBHERR
Service
TIEIIIRR
Front axle steering
UW10-Part1-Steering
>1.4 Flow rate indicator

Purpose:
Flowrateindicator(-S118)is installedin steeringcircuitI and monitorsthefunctionof
steeringcircuitI andsteeringpumpl. In caseof a fault,the cabwarninglightfor steering
circuitI willbe lit.
Design:
-Si18
Fig. 1:Flowindictor
Fig-2: Excerptfromhydraulic
schematic
for chassi6:
Fig.3: Excerptfromelectrical
schematic
for chassis:
Function:
Theflow rateindicatorincludesa contactswitch(normally-closed).
lf the oil flowdropsbelowa certainrate,the contactswitchwilltrip andthe cabwarning
lightfor steeringcircuitI is lit.
Waminglight
SteeringcircuitI
pump)
(Steering
m
ug4
EI
Let
Etr
n4
HI
Fig.4:WarninglightsieeringcirculiI
LiebheB-Werk
EhingnGmbH- Technil lrain ng
OnlyforLIEBHERR
Servicepersonnel
-8-
I.TTEIIRR
/ supporting
>1.5Multiwayvalveoil supplyaxlesuspension
PurDose:
The multiwayvalve-Y5 setsthe dil flowof the steeringcircuitpumpll freeto the axle
suspension
/ supporting.
valve
4/2
'1= Mulliway
/ supporling
axlesuspension
0 = Steeringboosterofthe frontaxle
Design:
-MP2O
point,
measuring
pressure
of thepump
steeringcircuit2
valvesteeringboosterLTl,l1100-4.1
fig. 1: I\rulliway
flowcontroller
20 l/min
fig 2: Exceapt
fiomelectrical
6chematic
N,lultiway
valve- LTIV1100-4.1
Function:
the hydraulicoil of the steeringcircuitpumpll is
lf the4/2 multivalve-YSis notactivated,
whois integratetd
in
releasedto supportthesteeringof the frontaxle.Theflowcontroller,
theMultiway
valve,limitsthedilflowto 20 l/min.
the hydraulicoil of the steeringcircuitpumpll is
lf the4/2 multivalve-Y5 is activated,
/ supporting.
releasedto the axlesuspension
Liebhed-Wei<Ehhqn GmbH- Techni@llEining
personne,
OnlyforLIEBHERR
Service
_g _
ITIBIITRR
Frontaxle steering
UWl0-Partl - Steering
>1.6 ZF-valveblock 7760with flow rate indicator,sequencevalve and DBV

Purpose:
Flowrateindicator(-S119)is installedin steeringcircuitll and monitorsthefunctionof
steeringcircuitpumpll or the emergency
steeringpump.
lf a faultoccursin steeringcircuitll (auxiliarysteeringpump),the warninglighton the cab
displayunitfor steeringcircuitll will be lit.
Design:
(P2)
Connection
Emergency
steeringpump
Contactswilch-S119
(T)to
Connection
IANK
Nozzle
(Pl)
Connection
Pumpsteering
circuitll
Non-return
valve
(blocksthe oil return
fow)
Pressure
limitingvalve
(150bar)
'1:ZF valve block
Connection(A) to
steennggear
Pl
Pumpconneclion
for steering
circuitll
P2 Emergency
steeringpump
connecaon
A Sleeringgearconnection
T Oil boxconnection
1 Sequence
valve
2 Flowrateindicalor
limitingvalve
3 Pressure
(150bar)
4 Non-retum
valve
Fig.2: Cut-away
modelZF valveblock7760
Liebhetr-Work
Ehlngen
GmbH- Techniltraining
personner
OnlyforLIEBHERR
Service
- 10-
TTEHIRR
Front axlesleering
UW10-Part1-Steering
5 C H L, jT rE l t e a
-:Ll9
Fig.4i Excerptfrom hydraulic

schematicfor LTIM1100-4.1
Fig.3: Exceptfromelectrjcal
schematic
for LTM1100-4.1
Function:
,.8)
Warninglight
Steeringcircuitll
steeringpump)
{auxiliary
q@GEE@
trdF;Jt tffit ffil
steeringpump)
Fig.5: Warninglightsteerjngcircuiill (auxiliary
pumpll to
steering
Thevalveblockhousing
contains
a control
slidevalvewhichconnects
correctly.
steeringcircuitll providingit is functioning
steeringpumpto the oil boxvia the returnchannel.
Theoil flowsfromthe emergency
lf the mainoil flowrateof steeringpumpll dropsbelowa certainlevel,the controlslide
pumpto steering
circuit...
steering
valveclosesandconnects
theemergency
steering
Theelectricalcircuitof theflowrateindicatorwill be closedif the emergency
pump
pumpfailsor thereis reduced
lightfor
steering
ll.Thewarning
oilflowthrough
pump
pump)willbe litto signalthefailureof steering
steering
circuiill (auxiliary
steering
pump.
ll or theemergency
steering
Liebheir-Werk
EhingenGmbH- fechnicallEining
personnel
Onlyfor LIEBHERR
Service
_f
UIBIITRR
Frontaxle steering
UW10-Part1-Steering
>1.7ZF half-blocksteeringgear7421
Purpose:
The purposeof the half-block
steeringgearis as follows:
. Hydraulicpower-assisled
steeringfor mechanical
steeringmovements
. Steeringstop(pressurereductionin hydrauliccircuitbeforewheellockis reached)
Note;
The half-block
steeringgearis fittedin craneswith3 or moresteerablefrontaxles.
ZF half-block
Steeringgear 7421
Fig.1: Dual-circuit
designwithmechanicl
steedngstop
Advantage:
Highoil flowmakingit suitablefor "largemachines"
Disadvantage:
Expensive
as it is manufactured
in lowquantities.
Liebheii-WerkEhingenGmbH- Technil Laining
personnel
OnlyforLIEBHERR
Service
UEIIRR
description
Component
UW10- Part1 - Steering
Design:
steeringgearhousingincludesthe steeringvalvesas wellas the entire
TheZF-half-block
steeringgeat Twohydrauliccontrolvalvesbeforeand afterthe steeringnut
mechanical
are centrallyalignedwiththe steeringspindleand attachedto the steeringgear.Poweris
ballthreadontothe steering
fromthe steeringspindlethrougha recirculating
transferred
mechanism.
nutwhichin turntransfersit to the segmentshaftvia a cog
systemsis onlypossiblevia the
hydro-steering
steeringfor half-block
Power-assisted
externalsteeringcylinder
screw(wo|m)
sleerlngnut
Stee ngspindle
Segmentshaft
(sectorshaft)
Fig.2: Cul-awayview ofa duaFcircuitdesignwith mechanicalsteeringstop
Fig.3: Excerptfrom schematic:hydrauliccontrol

Pressurisedair systemFig. LT[,41400-1
Li6bhen-We*EhingenGmbH-Techni lra ning
personnel
OnlyforLIEBHERR
Service
- 13 -
ITIBHIRR
Front axlesteering
UW10-Part1-Steering
Dual-circuitsteoringsystemwith 3 pumps:
Steeringcircuitll
SteeringcircuitI
10 5 2 10
Sleeringspindle
tumsin clockwisedirection
Fig.4:Steeringcircuitpumpsrunning
1 Steering
circuitpumpll
(Worm)
2 Screw
3 Valveblock7760
a
b
c
d
(S119)
FIN mteindicaror
Sequene varve
Nonilumlalve
Non-eiumvalve
7 Steeringspindle
8 Oilbox
9 Steering
circuitpumpI
10 Pressure
limitingvalve
11 Flowrateindicalor(S'118)
12Wo*ing cylinder
'13Segmentshafl
4 Replenishing
valve
5 Steeringnut
6 Emergoncy
steeringpump
Liebher-WrkEhingenGmbH- Tchnlcaltralning
personnel
OnlyforLIEBHERR
Service
ITEIIRR
Component
description
UW10-Part1-Steering
Steeringcircuitll
Steedng
1'l
10
5 2
10
Steering
spindlotumsin
clockwise
direction
Fig.5: Emergency
sleeringpumprunning(enginehasstopped)
1 Steering
circuitpumpll
2 Screw
3 Valveblock7760
a
b
c
d
Fl@ Ete indicior(S119)

Sequencevalve
NoMetun lve
Non-ellln valve
7 Steedngspindle
I Oilbox
I SteeringcircuitpumpI
'10Pressure
limitingvalve
(S118)
1'1Flowrateindicator
12Workingcylinder
13Segment
shaft
4 Replenishing
valve
5 Steeringnut
6 Emorgency
steeringpump
lraining
Liebher-Wrk
Ehlngn
GmbH- Tschnicl
personnel
Onlyfor LIEBHERR
Service
- 15 -
UEIIRR
Frontaxle steering
UW10- Part'l - Steering
Workingpipe
Wheellockright
steeringckcuilI
WorkingpipeWheellock
pipe
leftsteering
circuitll (connection
3) Working
wheellock
righlsteering
circuit
Workingpipe (connection4)
Drive
mechanical
11
(connection
4)
(steering Wheellocklefl
ourpur
steedngcircuitI
(segment
shaft)
t-..1,,:) (connection
3)
l a n Kr e l u r n - '
Sleeringcircuit
| (connection
2)
Tank
retun
= Steeringorcu
.
,/
2)
{connection
-MPl
-MP2
DBV
Pumpinlet
Pumpinlei
pEssureWod{ng
pressure Steeringcircuitll
Steeing
circu
t I Steering
circuit Working
point fconnection1)
measurement
| (connection
1) measuEmentpoirt
sleering
circuitL steennq
circuitll
Fig.6: Component
(clockwise
overview- half-block
steeringgear- clockwise
screw)
Caution:
On anti-clockwise
steeringgears,the rightand Ieftwheellockconnections
are
swappedover.
Workingpipe
Wod(ingpipe
wheellock
leftsteeringcircuit
ll (connectjon
3)
righisteering
circuit
ll (connection
4)
p inlet
i'i"ilXff[T'lr]
mechanical
output
(segment
shaft)
Tankreturn
Steering
circu+r
(COnnecton
DBV
Steeringcircujtll
- half-block
Fig.7: Componenl
overview
(clockwise
steeringgear- clockwise
screw)
Ll6bher-WerkEhingenGmbH- Technicllraining
OnlyforLIEBHERR
Servicepersonnel
- lO -
UTBIIIRR
description
Component
Frontaxle steering
Note:
Thereare clockwise
and anti-clockwise
steeringgears.The
typeuseddependson
position
the insiallation
of the steeringgearand
the arrangement
of the
steeringlinkage.
Fig.8: Examploof steednggear- clockwise,

exce@tfromcircuitdiagramLT[,11400-7.1:
g6ar- anti-clockwise,
excerptfromcircuitdiagramLTI\41'l00-4.1:
Fig.9: Exampleof st66ring
Liebher-W* EhlngenGmbH- Technicaltaining
Onlyfor LIEBHERR
Servicepersonnel
- 1 7-
UBHINR
Front axle steering
UW10-Part1-Steering
Function:
In orderto maintain
hydraulic
assistance
duringthesteering
movement,
the
screwand boihits connected
valvebushingsmustbe movedfromtheirneutralposition.
Thescrewis heldin the neutralpositionby cupsprings.A forcemustthereforebe applied
to overcome
thepre-tension
of ihe spring.
Thesteeringnuttogetherwiththe segmentshaftandsteeredwheelscounteracts
any
rotationalmovement.
Whensteering,poweris transferred
fromthe steeringspindleihrougha recirculating
ballthreadontothe steeringnutwhichin turntransfersit to the segmentshaftvia a
cogmechanism.
Thesteeringnut is movedbackandforthby this rotationalmovement
causing
thesegment
shaftto turn.
Thecontrolvalveis locatedinsidethe valvehousingandcentrallywith respectto the
steering
spindle.The
rotational
motionof thescrewspindle
willcauseaxialmovement
(backandforth)of the controlvalve.Thissetsthe controledgesin sucha way thatthe
pressurised
oil entersthe workingcylinderchamberfromthesteeringpump.
Releasing
thesteeingwheelwillcausethevalveto springbackto itsnormalposition;
the
returnflowis thereforemaintained.
Themechanical
steerjngstoppreventssteeringintothe wheellockpositionsat full
pressure.
hydraulic
Thisprotectsthe kinematicsteeringcomponents
frombeing
stressed.The
mechanical
steering
stopis adjusted
usingihe collarson thesteering
gear.
spindle
of thesteering
Liebheii-WerkEhlngenGmbH- Technicaltining
persornel
OnlyforLIEBHERR
Service
- 18 -
ITIBHIRR
Frontaxle steering
UW10-Part1-Steering
Checking and adjusting the mechanical steering stop:

(anti-clockwise steering gear)
Tesl procedure:
Slightlyrelievethe loadon the steeringaxles(liftusinghydr'support)- Tyresmuststill
be touchingthe ground.
Turnthe steeringwheelin the'right"directionwiththe enginerunninguntilyoureachthe
wheellockposition.
expectedvalue= I - 3 mm.
Checkthegap(play)on thewheellockcomponents.
The"left"steeringdirectionis checkedin the samemanner'
.
.
.
.
Adiustmentprocedure:
't.
2.
3.
4.
5.
Slightlyrelievethe loadon the steeringaxles(seetestprocedure).

Withthe enginerunning,turnthe steeringwheelto the .ightandjust beforethe pointof
usea spacerto maintaina gapof2 - 3 mm).
wheellock(if necessary
willreturnby approx.'l14
Turnoffthe engineandreleasethe steeringwheel(steering
steeringwheetturntowardsthe neutralposition).
Removeshoulderscrew(A)whenthe engineis tutned off .
Note:Collectanyescapingoil.
ring('1)
Pointa spikethroughthethreadedholefor shoulderscrew(A)to turnadjustment
againstthe directionof steeringwheelrotationuntilthe lipson all the rings
(2 and3) arealigned.
design
Fig. 10:Steednggear-antitlockwise,
dwing
cut-away
Fig.11:Steeringgear- anti-clockwise,
Liebher-Werk Ehingen GmbH - Technical fiaining
-19-
personnel
Onlyfor LIEBHERR
Service
ITIBHIRR
Gomponent
description
Frontaxle stering
UW10- Part 1 - Steering
Adjustmentring1
Adjustment
ring4
Fig.12:Half-block
gear-Adjustment
steering
Adjustingthe right end-position:
Adjustingthe left end-position:
smallersteering
Hexsocket
headspike
I
HexsocketI
headspikeI
I
V
l#;
7.
for largersteering
Up for largersteering
angle
Downforsmaller
steering
angle
In thispositionturnbackthe steeringwheeluntilshoulderscrew(A)canbe
screwedintothe nextholeon the adjustment
ring(1).
Screwin the shoulderscrew(A)andnewseal.
The leftwheellockis adjustedin thesamemanner,aftershoulderscrew(B)and
adjustment
ring(4)havebeenunscrewed.
The lipson rings5 and6 mustbe aligneo.
Note:
lfthe mechanical
steeringstopcatcheswhenthe maximumsteeringangleis reached,the
hydraulicpower-assisted
jresJrre).
steeringwillfa to ca. i0 bar(circulation
TechnicalinformationZF half-block
hydro-steeringtyp 7421
see manual8905090 08
Libher-W(Ehingen
cmbH- Technittraining
OnlyforLIEBHERR
personnel
Service
-20 -
UEIITRR
Front axle steering
UW10-Part1-Steering
>1.8ZF Servocomsteeringgeartype 8099

Puroose:
The puposeof the Servocomsteeringgearis as follows:
. Hydraulic
power-assisted
steeringmovements
steeringfor mechanical
. Steeringstop(pressurereductionin hydrauliccircuitbeforewheellockis reached)
Note:
The Servocomsteeringgearis fittedin craneswithlessthan3 steerablefrontaxles.
Design:
in compactdesign)
Fig.1: Cut-away
viewZF Servocom
steeringgear80gg(ballnuthydro-steering
Advantage:
production.
dueto high-volume
inexpensive
Disadvantage:
lowoil flowmakesit onlysuitablefor "smallmachines".
Liebheir-Werk
EhingenGmbH- Techni@ltGining
personnel
Onlyfor LIEBHERR
Service
-21 -
UBITIRR
Frontaxle steering
UW10-Part1-Steering
TheZF-Servocom
dual-circuit
housingincludessteeringvalves,a working
cylinderandthe completemechanical
steeringgearmechanism.
Bothsteeringvalvesconsistof the rotaryvalvesinsidethe screwwith6 controlgrooves
and2 controlsocketseach.
Atorcionbar,whichis drilledand bracedto the rotaryvalveandscrew,keepsthe steering
valvesin the neutralpositionprovidingno counter-force
is appliedto the steeringwheel.
Steeringspindle
Hydraulic
steeringstopvalves
steeringcircuitI
Hydraulic
steeringstop valves
steeringcircuitI
Hydraulic
steringstopvalves
steeringcircuitll
Fig.2: Cut-away
modelof Servocom
steoringgear
Fig.3: Excerptftomschemstic:
Controlhydra!lic
pressurised
airsystemMK 100(anti-clockwise)
Liebher-WrkEhlngnGmbH- Techniel irainlng
personnel
OnlyforLIEBHERR
Service
-22 -
rIBHRR
Fronl axle steering
UWl0-Part1-Steering
Workingpresu
re measuremeni
Workingpiperightwheellock
Workingpressu- output
circuit| (connection
2)
re measurement(sgment
shafr)
Thesegment
shaftcanalsobe
insertedfromthe
otherside.
pointsleedng
pipecircuitll
Tankreturn
Circuit
ll
Workingpiperight
wheellockcircuitll
(connection
22)
Replenishing
Oil replenishment
screw):
Fig.4: Overview- steeringgear - anli-clockwise(anti-clockwise
Gaution:f
gears,the rightand left wheellock connections
a re swapped
steering
On clockwise
over.
hydraulic
sleeringstopckcuitli
(rightsteering
direction)
WorkingpipeleftwheeltocK
1)
circuit| (connection
Replenishing
Oil repleni
menlsteering
circuitll
Tankreturn
Circuitll
Drive
(steering
wheel)
Fig. LTM1080-1
hydraulic
steering
slopcircuitI
(rightsteringdirection)
.MP4
hydraulic
steerjngslop
Workingpres- circuilll (leftsteering
suremeasure- direclion)
mentpoint
Workingpipe
leftwheellock
ckcuitll
steeringPump
(connection
z1) hydraulic
stopcircuitI (left pressure
steeringdirection)pipe
circuitI
- steeringgear-anti-clockwise
(anti-clockwise
screw):
Fig.5: Overview
L ebhen-WelkEhingenGmbH Technil iEining
personnel
OnlyforLIEBHERR
Service
-23-
IIIBIIIRR
Front axle steering
UWl0-Part1-Steering
Dual-circuitsteeringsystemwith 3 pumps(clockwise):
Fig.6: Steedngcircuitpumpsrunning:
'1 Steering
circuitpumpll
2 Sequenca
valve
3 Valveblock7760
4 Conbolvalvo1
5 Wo*ing cylinder
pump
6 Emergency
string
(S119)
7 Flowrateindicator
8 Oil box
I SteeringcircuitpumpI
10Oil box
11 Flowrateindicator
(S118)
Ubher-WerkEhingenGmbH- Tchnlctlining
personnel
OnlyforLIEBHERR
Service
12 Controlvalve2
'13Workingcylinder
l4 Steedngstopvalve
15 Ringgrcove
16 Ringgroove
17 Pistonpos;tion
indjcator
18Segmentshaft
19 Hydraulic
steeringstop
21 Piston
22 Steeringspindle
-24-
IIIBHINN
UW10-Part1-Steering
pumprunning(enginehasstopped)
Fig.7: Emergency
sLeering
1 Steedngchcuitpumpll
2 Sequence
valve
3 Valveblock7760
4 Controlvalve
1
5 Workingcylinder
6 Emergency
steeringpump
(S119)
7 Flowrateindicator
8 Oilbox
I Steering
circuitplmp I
10Oilbox
(S118)
11 Flowrateindicator
Ll6bh6tr-W6rk
EhlngnGmbH' Technil tEining
personnel
OnlyforLIEBHERR
Service
12 Controlvalve2
13Workingcylinder
14Sleeringstopvalve
15 Ringgroove
16 Ringgroove
'17Pistonpositionindicator
18 Segment
shaft
19 Hydraulic
steeringstop
20 Screw
21 Piston
22 Steeringspindle
-25-
UBHINR
Gomponent
description
Front axle steerino
UW10-Part1-Steering
Funclion:
Theforceis transferred
fromthe steeringwheelviathe steeringspindleand screwonto
the steeringnut.Thisin turntransferstheforcethroughthe segmentshaftandsteering
gearsandontothewheels.
Turningthe steeringwheeldeformsthe torsionbarwithinits elasticrangecausinga
twistingactionbetweenthe rotaryvalveandthe controlsockets.
Thiscauses
thepressurised
grooves
oiltoflowintothering-shaped
on thecontrolsockets.
Threesymmetrically
arrangedradialopeningsallowthe oil to reachthe circularcontrol
groovesfor the innerrotaryvalve.Whenthe valveis in the neutralposition,it flows
throughthe entryslitsand intothe axialgrooveson the controlsocket.
Fromiheretheoil reacheseachsideof ihe workingcylinder.
Bothsteeringvalveswill regulatea predeJlned
oil flowto the steeringcylindersdepending
on the requiredsteeringforce.Thisis fullyindependent
in twoseparatepipecircuits.
piston
Thesteeringassisiance
is controlledby oneof the twosteeringvalves.
Theothersteeringvalveopensthe pathfor the oil to provideexternalassistance
using
oneor moresteedng
cylinders.
Theactuatedsteeringcylindertherebyassiststhe mechanical
sieeringmovementand
reducesthe amountof effortexertedby the cranedriverduringsteering.
Steeringcircuitll is usedto supplythe Servocomas wellas a separatesteeringcylinder
andassumes
thesteering
function
duringnormaldriving
operation.
SteeringcircuitI suppliesone or moresteeringcylindeIsand is completely
shutoff by
fullyclosing
thereturnslitswhensteering
at standstill.
Oncethe desiredwheelpositionshavebeenreached,the controlvalvesare returnedto
theirnormalpositionby the torsionbar and blocktheflowof oil to the steeringcylinders.
Bothsteeringcircuitsare fittedwitha hydraulically
adjustable
steeringstopto protectthe
gear,wheellocksandsteering
pumpsagainstexcessive
steering
loadat themaximum
steering
angle.
Theadjustable
steeringstopvalvesin the housingallowa reducedapproachto the
steeringend position.
The steeringstopvalvesin steeringcircuitI are actuatedby the pistonmotionbeforethe
adjustment
screwreaches
thepistonendposition.
In contrast,the steeringstopvalvesin steeringcircuitll are openedby a camon the
segmentshaft.
As soonas the sieedngstopvalvehasopened,the steeringcan be turnedin furtherwith
increasedeffortandsignificantly
reducedhydraulicsupporito the wheellockor steering
position.
stoD
Liebhr-WerkEhingenGmbH- Technll training
personnel
OnlyforLIEBHERR
Service
-26 -
lTIBTITRR
Frontaxle steering
UW10-Part1-Steering
Checkingand adjustingthe hydraulicsteeringslop:
(steeringgear- anti-clockwise)
Testprocedure:
presskeysE + E) andlockthe
(simultaneously
to "NIVEAU"
1.
Movethevehicle
presskeysfc j + ffi).
(simultaneously
axlesuspension
(keyW ) to automatically
liftthecraneand
2.
Usetheoperating
unitforthesupport
alignit horizontally.
pointsl\,44
(steering
circuitl) andM5 (steering
a manometer
to measuring
3.
Connect
gear(pressure
up to 250bar).
circuitll) on thesteering
without
applying
anymajoreffortto the
turnthesteering
4.
Withtheengineidling,
is reached,
Oncethewheellockposition
rightor leftwheellockposition.
brieflycontinueturningthe steeringwheelto overcomethe returnforceof the
steeringvalveuntilthefixedsteeringwheellockpositionis reached.Thesteering
wheelshouldbe heldin thisposition.
mustnowbe
lf the steeringstophasbeencorrectlyadjusted,the manometer
permitted).
pressure
(approx.
40
to
90
bar
are
of ca.50 bar
indicating
an oil
lf the measuredpressureis too highor low,the pressuremustbe corrected
screws1 to 4 (see
steering
stopvalvesor adjustment
usingthecorresponding
nextpage)as describedbelow
Note:
SteeringcircuitI mustbe adjustedbeforesteeringcircuitll on all cranesJlttedwith
Servocomsteerino.
Adjustmentprocedure:
1.
2.
3.
4.
5.
6.
7.
turnthesteering
fullyto right.
As described
in point4. (seetestprocedure),
screw
screw1 andscrewin/outadjustment
Removetheflxingnutfromadjustment
directions
andanti-clockwise
1 if the pressureis too high/low(clockwise
respectively).
turnthesteering
in step4. (seetestprocedure),
Thenproceed
as described
fullyto the left.
screw2 andseta pressure
of 50 barusing
Remove
theixing nutfromadjustment
screw2, as describedin step2.
adjustment
whenfully
againin a righvleft
direction
andcheckthepressure
Turnthesteering
screws1
turnedin. lf necessaryre-adjustthe pressureto 50 bar using adjustment
or 2. Repeatthis processseveraltimesuntilthe pressureremainsconstantat ca.
50 bar.
There-tighten
screws1 and2.
thefixingnuton adjustment
to thosefor
circuitll aremadein a similarmanner
Theadjustments
forsteering
screws3 (rightsteeringdirection)
steeringcircuitI by screwingin/outadjustment
and4 (leftsteering
direction).
Liebheff-Werk
Ehngen GmbF -Techni lraning
personnel
OnlyforLIEBHERR
Service
-27.
UIBHIRR
Front axle steering
UW10-Part1-Steering
Adjustmentof left wheel

lock steedngcircuit1;
Adjustmentof right wheel lock

steeringcircuit1:
out
(more
pressure)
tn
(tess
pressure)
tn
(less
<-+
pressure)
Iool:
Size14 open-ended
I (hydraulic
steeringstopcircuitl,
rjghtsteeringdirection)
out
(more
pressure)
Ppanner
Specialtool
Size 5 Allen key
2 (hydraulic
steedngstop
circuitl, leftsteeringdirection)
Fig.8: Servocom
adjustment
4 (hydraulic
steering
stopcircuitll,
leftsleeringdireciion)
Adlustmentof left wheel

lock steeringcircuit 2:
tn
Ilaee nra.e,,.6\
A
I
3 (hydraulic
steeringstopcircuitll,
nghtsteeringdirection)
Adjustmentof right wheel lock

steeringcircuit 2:
in
Tobla
Size19open-ended
spanner
Size10open-ended
spanner
pressure)
TechnicallnformationZF
Servocomtype 8096and 8099
seemanual890510508
II
Y
out
(morepressure)
Liebhstr-Werk
Ehingen
cmbH- Tchnitlraining
personnel
OnlyforLIEBHERR
Service
-28-
out
(morepressure)
ITBIITRR
UW10- Partll - active

rearaxlesteering
Onlvfor LIEBHERR
Serviceoersonnel
UWl0 - Part ll - active rear axle steering
b':|repid/fuhon120207/V3cion2
Liihsr-Wd(
Ehingen
GmbH- Tchnlcal
lalnlng
Onlyfor LIEBHERR
Servicepersonnel
-2-
UEHINN
UW10- Partll - activerearaxlesteering
Liebheii-Werk Ehingen GmbH - Tchnil lrainlnq
personnel
OnlyforLIEBHERR
Service
_3 -
rIuftnR
UW10- Part ll - active rear axle steering
)1.
1. General
In orderto improvethe turningcharacteristics
and minimisetyrewear,all newcranes
do notmechanically
lock(pin)the steeringfor the rearaxles.The rearaxleson mobile
craneswith rearaxlesteeringare steeredelectro-hydraulically
and speed-dependentj
this is lockedto straight-ahead
at speedsaboveapprox.25 km/h(dependson particular
model).
Variouscomponents
are builtintothe activerearaxlesteeringto providethe highestdegreeof safety.
Theseensurethatthe steeredrearaxlesare automatically
posiresetto a straight-ahead
tionwhena faultoccurs.
Activerearaxlesteeringwasfirstfittedon LTNI1090-3(LTM1'100-4.1)
mobilecranesin
summer2003-
Advantagesof activerear axlesteering:

. Smallturningradiusfor roaddriving
. Lowtyrewear
. Perfectlyadjuststo the drivingsituation
. Highestdegreeof safety
. Simoleooeration
Lrebher-Werk
Ehingen
GmbH-Tschnicl
training
OnlyforLIEBHERR
Servicepersonnel
-4-
UIBHINR
Gomponent
description
X.l Layout
Stsrlngaxles:
1staxle
2hd axle
3rd axle
4th axle
;"::,"::",}
Axleswith
BoschCAN
proportional
valves
Fig.'1:Rearaxlesbasedon exampleof LTM1100-4.'l
uebheF-we* EhingnGmbH- Technlcaliraining
personnel
OnlyforLIEBHERR
Service
-5-
rlEHINR
Component
description
>1.2Steeringprograms(onlyon craneswith 4 axles)

P1 Roadsteering
Axles1 and2 are mechanically
steered
usingthesteering
wheel(hydraulically
assisted).Axles3 and4 are "activelv"steered
at speedsup to 30 km/h(speed-dependent)
anddepending
on thesteering
angleofthe
frontaxles.At speedsabove30 km/hthey
poare set and lockedin the straight-ahead
sition.
Altering
thesteering
angleas a functionof the speedprovidespreciseandstable
drivingbehaviour
at highspeeds,
tyrewear
is reduced
andmanoeuvrability
is significantly improved.
P2All-wheelsteering
Axles3 and4 are steeredin proportion
to
the steeringangleof the 1staxleto provide
possible
thesmallest
turningradius,max.
driving
speed20 km/h.
P3 Crabsteering
Axles3 and4 are steeredin the samefashionas axles1 and2 viathesteering
wheel,
max.drivingspeed20 km/h.
P5
P4 Steeringwithoul swing.out
Axles3 and4 aresteeredin proportion
to
program
Fig.2:Sleering
fora 4-axle
vehicle
thesteering
angleof the 1staxleso thatthe
rearof ihevehicledoesnotswingout,max.
drivingspeed20 km/h.
Note;
. lf a faultoccurswiththerearaxlesteer
P5 Independent
rearaxlesteering
ing,it is disabled
andlherearaxlesareeiAxles3 and4 are steeredusingkeysinde- therblockedto preventfurihersteeringor
pendentlyof the steeringanglefor axles1
set straightusingthe centeringcylinders
and2 anddepending
on whethercrabsteer- . Twoindependent
hydraulic
circuits
with
ingor turningis required,
max.drivingspeed wheel-driven
andengine-driven
hydraulic
20 km/h.
pumpto provide
ihe highest
degreeof
safety
P6 Rearaxle steeringlocked*
Axles3 and4 cannotbe steered.
* = device-dependent
(onmobilecraneswithup to 4 axles)
Lr"bh"r-Weh Ll'i19enCmol . scl-n,(dl.cinng
-6-
lTIBIIERR
>1.3Summaryof speedswith LTM1100-4.1
EI
= (
* [
sleringangloi string
ane LA2to kegrees.
hydEUlillyclampedo.
Permiltedspeedin travelprogramPi Roaddrivlrg
E
(E
Y
Pemitled speed for travel
50
g0vin
Km/h
Note:
on thetypeof mobilecrane.
Themaximum
speedsaredependent
Liebhetr-Werk
EhingenGmbH- Technicaltraining
UBHIRR
2. Steeringcircuit
>2,1 Componentoverview- Steeringcircuit
Conkolling"lndependenlsteeing P5"
Pl - Pq
fSteeringprograms
Controllight,rearaxlesteering-On
f f i @ t r @ @ @ @lrllrl
q@@tr8@@
E E
F-dF,{I rEr ffir

Steering progGms fo. active rear axle string
?1=
R o a dd i v i n g
(dependenton WG!B50 and drivinsspeed)
P2=
Alwhee steeing {dependenlon WG|B5o,
speedlimlted)
P3 =
Crab stee.ing(asfor BA2)
P4=
RedLrced
swing oul rat (as for BA2)
P5 =
Independentsteering
(speedlirnlled)
PO=
Sieerinolockedin centrcoosition
I LrccoN
rssr'(ow)
EAM2
Addr.3
EAM5
Addr.6
EAM1
Addr.2
Var displ.pump
HA-steering
Steedng
cylinder
'tAtl, a
*Addt "
,ffi
-850/ anglesensorlst axle

(inputfor actjverearaxlesteering)
Liebher-WerkEhingenGmbH- TechnicaltEining
personnel
Onlyfor LIEBHERR
Service
-8-
-B52
Anglesensor
4th axle
Angle sensor
3rd axle
UTBIITRR
>2.2 Pumpactive rear axle steering

Purpose:
pumpsupplies
hydraulic
oilto the the steerinqcircuitfor the active
Therearaxlesteering
rearaxlesteering.
Design:
as a pumpwithswashplatefor usein opencircuits.
Theaxialpistonpumpis designed
Therotation
angleis fullyadjustable.
-D22
Axialpistonpumpfor rear
axle steering\
A1OVO28.DFR1
N,4odel
3 1(incl.loadsensing
function)
-MP7
point,
lVeasuring
P1'lPump
rearaxlesteering
Nozzle/ filter
combination,
Nozzle0.6
(coldweather
Theso-calledcoldweathernozzleis usedto artifipressure

by 10 bar This
ciallyincrease
thestand-by
allowsthe pumpto operatequickerat coldoutdoor
temperatures.
Fig.4: Excerpt
fromcircuitdiagrarn
LTlt41100-4.1
Liebher-we* EhingenGmbH- Technllbining
personnel
Onlyfor LIEBHERR
Service
-9-
lIIBHTNR
Component
description
UW10- Part ll - activerearaxlesteering
DFRl
Al OVODFR1
Baureihe
31
DFR/DFR1
-a:r-],
[::pressure Leakage
HighpressureLowpressure Suction
oilpressure
Set pressure
Fig.5: Cufawayview- Pumpactiverearaxlesteering
AloVO / DFRl
Function:
Thepumpis equipped
witha flowregulator
thatallowsload-dependent
regulation
of the
pressure
pump
operating
(loadsensing
function).
The
flowrateregulates
itselfaccording
to theload.
Theflowrateregulator
is adjusted
to ensurethatthepumppressure
is alwayshigherthan
pressure.
themaximum
operating
lf thereareseveral
loads(steering
axles),shuttle
valvesareusedto determine
theprespressure.
pump
sureof theaxlewiththehighest
load
Thisis indicated
to the
flowrate
regulator
viatheloadsignalIineX.
Therotation
angleis thenregulated
so thattheflowrateis adjusted
to the
axlerequirement.
Theflowrateregulator
thencontrols
thepumpto opposethe
pressure
pressure
flowto occur.
causing
Theflowrateincreases
untilthedifferential
set
on thepumpregulator
is reached.
Thismeansthatthe systemalwayshasa certainpowerreserveoverthe loads.
Thediflerencebetweenthe loadpressureand pumppressureis alsoreferredto as the
stand-bv
Dressure.
L ebheii-WerkEhingenGmbH Techn@l lra ni.g
Orly tor LIEBHERRServicepersonre
- 10 -
1IIBHTNR
GomponentdescriPtion
>2.3 Bosch CAN proportionalvalves(steeringvalves)

Purpose:
valvessupplya precisequantityof oil and controlthe steerThe BoschCANproportional
on thevehiclespeedand selecteddrjvingprogram'
ingcylinders.Controlis dependent
Design:
Note:
The Boschcontrolblock is availablein 2- or 3-foldmodelsdependingon the vehicletype
pointreturnpressure
measuring
Pressure
pointpumppressure
measuring
Pressure
pointLS-pressure
measudng
Pressure
Fig. 6: Boschcontrolblock- 2-foldmodel
pointreturnpressure
measudng
Pressure
pointpumppressure
Pressure
measuring
pointLs_pressure
measudng
Pressure
Fig.7: Boschcontrolblock-3-foldmodel
Liobheii-WerkEhingnGmbH- TochnicaltEining
personnel
Service
Onlyfor LIEBHERR
rIIBHINR
Pre-controlvalve
Controlpiston
Slop valve
Pressure
balance
Controlboad
(Processo4
Resei spring
Controlchannels
Fig.8: Cut-away
view- Boschconllolblock
visualdisplay
diagnostics
Pre-control
valve
Controlpiston
Stopvalve
Errorsignal
diagnostics
Resetspring
Nominal
-CAN
-P0i
Pressure
Setpiston
oatance
induclive
displacement
Conlrclchannels
rransoucer
- Boschcontrolblock
Fig.9: Overview
Liebheii-WkEhlngnGnbH - Techni@ltEining
personnel
Onlyfor LIEBHERR
Service
-12-
IIBHINN
-Y231
Prop.valveaxle4
CANBoschvalve
-MP8
pointloadsignal
Measuring
prcssure
pump
rearaxlesteering
-Y232
Prcp.valveaxle3
CAN Bosch valve
Nozzle/ non-retum
valvecombination
(nozzle0.8)
Highpressure
filter
steeringcircuit
plateI
Fig.10:Steering
-A67
Pressure
limiting
valve,165bar
Liebhetr-Werk
EhingenGftbH - Technil Laining
personnel
OnlyforLIEBHERR
Service
- 13 -
UTBIIIRR
Shuttlevalves
'
Pressureredlcing valve
I
ls:
Note:
The BoschCANproportional
valvesshouldnot
be swappedoveras theyhavea factorylD and
are confioured
withan address.
BoschCANproportional
valve
Supplypressurebalance
BoschCANp.oporlional
valve
iii:'
Supplyp.essurebalance
Fig.11:ExceptfromcircuitdiagramLTM1100-4.1:
Function:
The proportional
valvesare controlledby the l/O modulesviathe CAN-busdependingon
the nominalvalueoutputby the controlsystem.Thegatevalveis onlyactuatedhydraulically(by meansof controlpressure).
An integrated
displacement
sensor(inductive)
internallymonitorsthe positionof the gatevalve.Thisis why the CAN-valveis alsoreferredto
gatevalve.
as an intelligent
An upstreamsupplypressurebalanceallowsload-dependent
regulation
of the operating
pressure(loadsensingfunction).Thepumpflowvolumeis distribuleddependingon the
loads.
Liebheii-WerkEhingenGmbH- T6chni@ltGining
personnel
OnlyforLIEBHERR
Service
-14-
IIIBIIIRR
UWl0 - Partll - activerearaxlesteering
>2.4 Steeringcylindr
Purpose:
for adjustingthe positionof the axlepivotandwheelsThesteeringcylinderis responsible
Design:
-tz4
Sleeringcylinder
axle4
-LZ3
Steeringcylinder
axle3
-LZ2
-u1
Steeringcylinder
axle1
Steeringcylinder
axle2
Fig.12:SteeringcylinderLTI\41100-4.1:
Liebher-Wft EhingenGmbH- Tchnil lEining
personnel
Onlylor LIEBHERR
Service
- 15 -
UBHINR
Component
description
Function:
Thesteeringanglefor the rearaxlesis dependent
on the steeringangleof the leading
axle(VA= axle1) andsteefedusingthe steeringcylinders.
Thesteeringangleof the leadingaxle(VA= axle'l) is measuredby an anglesensor
(nominalvalue
anglesensor),an electricalcontrolsystemis usedto controltheproportionalvalves(steeringvalves)andapplyhydraulicfluidto the steeringcylindersforthe
rearaxres.
Fig.13: Excerptfromhydraulic
schematic
LTM1100-4.1:
Uebher-W..k EhlngenGmbH- Techniel haining
-16-
ilIBHMN
Component
description
PdHb,rM'|d/Edl'hl2m07/v.E]m:?
Functlon:
Both| / O modulesmonitoreachothervia the CAN-BUS.
A2-channelcontrolsystemis usedto fulfilthe highsafetyrequirements.
lt is monitored
whetherthe specifiedsteeringanglenominalvalueis reached.
A continuous
nominal/actual
valuecomDarison
checkswhetherthe steeredrearaxles
followthe nominalvaluewithina giventolerance.
Appropriate
safetymeasuresare takenifthereis a largediscrepancy
betweenthe signals
Fig. 16:Excerptfiomcirc.uit
diagramLTIVI100-4.1:
Llbhr-wfi Ehingen GdbH - Techni@l tEining
personnel
Onlyfor LIEBHERR
Service
- 1 8-
UIBHINR
>2.6Anglesensor
Purpos:
anglesof theleadingaxle (VA= axle1)
thewheeldeflection
Theanglesensors
measure
3
to | / O modules
aswellasthesteering
axlesandfoMardthisdataovertwochannels
and4.
Design:
Theanglesensoris composesof thefollowing
primarycomponents:
. Permanent
magnetwithmagneticholder
. Housingwith2 anglesensorsand integrated
LED(green/yellow)
. Adjustment
button
\-/
systems.
intemalmeasuring
Eachsensoris equippedwithtwo independent
the
ln thedrivingdirection,
Eachsensorthereforeconsislsof two angletransducers.
=
anglesensorsareon the rightin the axlepivotof the leadingaxle(VA axle1) andthe
steeringaxles.
Anglesenso.
Adjustment
button
Drillhole
Fig.17:Anglesensorremoved
Fig.18:Alignth magnet
The magnetis flrmlyattachedto the axlepivotboltby the magnetholderTheangle

sensoris screwedto the steeringarm.Thereis an air gap betweenthe sensorandthe
magnet.
Whenthewheelis deflectedthe sensorturnswhereasthe magnetis stationary
Llbhn-Wrk
EhingenGmbH- Techni@ltrainhg
personnel
Service
OnlyforLIEBHERR
- t 9-
UBIIIRR
Sensor
Screwcover
Fig.19:Anglesensorwithoutcover
Fig.20:Anglesensorcomplete
Funclion:
Thesteeringangleof the leadingaxle(VA= axle 1) is measuredby anglesensor-B50
(nominalvalueanglesensor).An electricalcontrolsystemis usedto controlthe proportionalvalves(steeringvalves)and applyhydraulicfluidto the steeringcylindersfor the
rearaxles.The rearaxlesare thereforeelectro-hydraulically
steeredaccordingto the
vehiclespeedand pre-selected
operatingmode.
The steeredrearaxlesarefittedwithanglesensor-B51,-852...Thesemeasurethe actualvaluesof the steeringaxles.
Theanglesensors
aredual-channel:
- Channel
A outputs
a signalin therange0....20mA
- Channel
B outputs
a signalin therange20....omA
Anglemeasurement
range(usable
mech.range):
-45"............0"....-.......+45'
1 . 2 1m
1 A....................18.789mA
An erroris outputwhen:l<1mAandl>1gmA.
Sincethesesignalsactin an opposite
sense,theycanonlyoutputan identicalvalueof lomAwhenthewheelsare setto the
0.-position.
lf an anglesensoris replacedit mustbe zeroed.
Whenreplacing
l/O-Module
3 or 4, all anglesensorsmustbe zeroed(seetestprogram32).
Liebheii-w.kEhingenGmbH- Technil training
OnlyforLIEBHERR
Servicepersonnel
-20 -
ITIBITIRR
i1,
i
t ;1
l l
ii>
:l
- anglesensor:
1100-4.1
Fig.21: ExcerptiromcircuitdiagramLT[r1
SpEZIA!-BILD
S Y S T E M - F U N K T I O N :
=> ?, 3: analose werte ceber ginterachslenk@g
wxRT - Beschreibung
GR.ZE OPERAND
0.0>
o,o>
0.0>
0.0>
5 : 0.0>
0.o>
0.0>
0.0>
0_0>
0_0>
o_0>
1-2, 0 . 0 >
L 3 : 0.0 >
0.0>
0.0>
E A t l - v 3 -2 0 0 :
EA.M,V4.200:
EAfi.v3.201:
E4M.V4.201:
E A MV
. 3.2 02:
EAl4.V4.202:
E - A l "Vl .3 , 2 0 3 :
E 4 1 4 . v 4 . 2 0 3:
EAM_\r3.204:
EA}4_V4_204:
E4.M.\r3.213:
EAr.v4.213:
EA'll,v3,214:
E A J "V
I ,4 , 2 1 4 :
E4M,V4,215:
rTM 1090/3
va kF!
v}' KaEl b lcrad/lo]

!A1 Kanal a [Gd/10]
:
:
:
:
:
:
:
:
:
:
:
:
2
3
1
0
0
o
1
0
0
0
0
Lsrao/ f ut
: wrMerqeFr
: i,lintelgeber
: winLelgeber
winkelgeber
LA1 Kanal b
wiDkelgebet
LAz Kanal a c.adl101
LA2 Kanal b G r a d / x o l
fiiDkelgeber
LA3 Kdal
a Grad/101
Winkelgeber
b Gd/101
winkelgebet
LA3 (da1
LA4 Kaal
a
winketgebe!
Winl<e1geber LA4 Kanal b
z.nElielkleis
E, E3, ?: Druckschalte!
E. E4.4: DruckscfElte!
ZenErrcrkleis
Zentrielkleis
E. E3.0: DurchflusEEch.
'-enkpunpe
E. E4. O: DrrchflusssclElEer
Hi1fslsklrmp
E, E4,3:
Durchflusch.
EEEEEEEM
14000203 D
Fig.22: Excerptfromspecialpicture LT[/ 1100-4.1 - anglesensor:

Liebheir-Werk Ehingen GmbH - Tchnicallrahing
personnel
Onlyfor LIEBHERR
Service
-21 -
UEBIIIRR
3 Genteringcircuit
>3.1 Componentoverview- Centeringcircuit
.x
f
-li"-+",_r
.,,T.'
@
\"
6l
o
o
g
(\
o-
I
t
o-
E
Llebhr-WerkEhingenGmbH- Techni@ltEining
personnel
Onlyfor LIEBHERR
Servlce
UIBIIERR
UW10- Partll - active rear axle steering
>3.2 Centeringpump
Puroose:
Thecenteringpumpsuppliesoil to the centeringpumpso that
valvesin thecentering
cylinderareunblocked
a) Duringnormaloperation: thenon-retum
b) Durjngfaultconditions: centeringof the activerearaxlesteeringis assured
Design:
The centeringpumpis ffangedontothe transfergearbox.
for switchingbeA crossplateis mountedon the centeringpump.Thisis responsible
pump
(oil
when
driving
forwards
and
backwards.
right
left
rotation
supply
tween
and
non-return
valves:
Theflanged-on
crossplateincludesintegrated
=
(vertical)
.
0.1 bar
Non-retum
valveon suctionside
.
0.5 bar
Non-retum
valveon pressureside(horizontal)=
Crossplatefor leftand right

rotation
.D25
wheelddven
axialpistonpump
41OVO45
DFR
Rexfothcompany
(flowrate regulation
blocked)
Fig.23:LTM1100-4.1
LiebheF-WeftEhingenGmbH-Techni@ltslnhg
personnel
OnlyforLIEBHERR
Service
-23 -
UBHTNR
Flowte
(blocked)
Pressure
culoff 210bar
pumpLTM1100-4.1
Fig.24:Exce.ptfiom circuitdiagramfor centering
Function:
The pumpis set to the max.rotationangleusinga spring.
lf oil is pumpedby the pumpwhenno loadsare active,pressurewill buildup in the
system.In thiscasethe pressureis limitedto 210 bar by a pressurelimitingvalve.
Usuallythe pumpis mntrolledby the pumpregulation
valve(flowratecontroller).
The
pressurecut-offis onlya basicsafetymeasure.In thiscasethe pumppressureis maintainedat a constantvalueof 210 bar by the pressurecut-off.Thepumpregulation
valve
(flowrateregulator)
is not operational
Llbhr-Werk
Ehingen
GmbH- Tchnica,
lralnlng
personnel
Onlyfor LIEBHERR
Service
-24 -
UBHTM
description
Component
>3.3valve block active rear axle steering(AHL Block)

Purposei
components:
TheAHL-block
consistsof thefollowingindividual
.
.
.
.
.
.
Centering
valve
Blockingvalve
release
Solenoidvalve,hydraulicaccumulator
Pressureswitchcenteringcircuitmonitoring
Pressurelimitingvalve
Highpressurefilter
Design:
-Y222
5/2-wavvalve
centeringvalve
0 = centre
-Y226
-Y220
3i2a ay
valve
valve,blocking
Solenoidvalve
release
Pressure
accumulator
(preventscenteringwhenengineis switched
off)
Seea@umulator
chargevalve
Highpressure
circuit
filterhydraulic
centenng
Pressure
switc+r,
centering
prossure
monitoring
SeepressureswitchAHL
Fig.25:AHLBlockLTC1055J.1
Ubhsn-WerkEhingenGmbH- Technil lrslnlng
personnel
Service
OnlyforLIEBHERR
-25 -
UEHRR
SPEICHER
G A S F U E L L D RRU C
190BAR
Fig.26rExcerptfromckcuildiagram
AHLBlockLTC1055-3.1
>3.3.1Blockingvalve GY226):
Purpose:
Valveto openthe non-return
valveson the centeringcylinder.
Design:
See Fig25 and Fig26.
Function:
Duringnormalconditions
the blockingvalveis activatedandthe non-return
valveson the
centeringcylinderare open.Thisis deactivated
abovecertainspeedsdependingon the
drivingprogram.In thiscaseit is not possibleto furthersteerthe axles.
Liebhen-WeREhin96nGmbH- Tchnicllraining
personnel
Onlyfor LIEBHERR
Service
-26-
ITBITTRR
Pfuducdby:wepid/Ediboi12'02'07/v.Es:2
-Y222,...\l
>3.3.2Centeringval]'e(-Y22'1,
Purpose:
the steeringcylinder.
Change-over
valvefor releasing
Design:
SeeFig25 andFig26.
Function;
lf a faultoccurs,the centering
Thecenteringvalveis activatedduringnormalconditions.
valvedropsout causingthewheelsto be centred.
)3.3.3 Solenoidvalve- releasevalvehydro accumulatorGY220)

Purpose:
servesto maintainthe oil supplyto the centeringcircuitevenwhenthe
Theaccumulator
craneis notmoving.Thisallowssteeringat standstill.
Design:
SeeFig25 andFig26.
Function:
The hydraulicaccumulator
is flled at regularintervalsby -Y225(switchin steeringcircuit
filledby the centeringpump
ll) whenv < approx.skm/hand is continuously
whenv > skm/h.
to releasethe hydraulicacAs soonas the engineis running,valve-Y220is energised
willfall if steeringmovecumulator
for filling.The pressurein the hydraulicaccumulator
mentsare performed
whenthe engineis runningandthe vehicleis not moving.This
maintains
the releaseof the centeringcylindersat standstill.
The centeringandblockingvalvesdropoutwhenthe engineis switchedoff.At the same
dropsout andblocksthe pressureto the hydraulic
time,accumulator
chargevalve-Y22o
accumutatot
cylinder
fromthehydraulic
accumulator.
supplyto thecentering
Thisinterrupts
thepressure
prevents
is
switched
ofi.
centering
when
the
engine
This
Llebheii-WerkEhingenGmbH- Te9hni@ltraining
personnel
Service
OnlyforLIEBHERR
IIIBIIIRR
>3.3.4Pressureswitch - monitoringcenteringcircuit (89)

Purpose;
PressureswitchGS89)is usedto monitorthe centeringcircuit(erroranalysis).
Design:
Alsoseefig 25.
Fig.27:Pressure
switch,
pressuremonitoring
centering
Fig.28:Exlracifromhydraulic
schematic
pressure
Pressure
switchcentering
monitoring
Fig.29:Exiractfromcircuitdiagram
Pressure
swiichcenleringpressuremonitoring
Function:
> 180bar.lf the pressurefallsbelow180bar
Theswitchis closedat centeringpressures
>
at speedsv 10 Km/h,an errormessage
is output.
Liebh6r-WsrkEhlngenGmbH- Technil iining
personnel
OnlyforLIEBHERR
Service
-28-
UTEIITRR
> 3.4 Flow monitorAHL (90)

Purpose:
FlowmonitorGS90)servesio detecta brokepipeor leaks(erroranalysis).
Design;
Fig.30:FlowmonitorAHL
r-- = I
;i r. i-
L -.----.-t
Fig.32: ExcerptfromcircuitdiagramAHL
flowmonitor
Fig.31:Excerptfromhydraulic
schematic
AHL6owmonitor
Function:
pipe(1obar)exceeds
Blockingactionis takenifthe flowratethroughthe pre-tension
movement.
l/min
without
any
steering
approx.2
uebher-wftEhlngn
GmbH- Techniliraining
Servicepersonnel
Onlyfor LIEBHERR
-29 -
rIIBIIINR
by:]repd/Ediion:120207/Venion:2
>3.5 Directionalvalveemergencysupply centering

Puroose:
The4/2-wayvalveis energised
at regularintervalsto fill the hydraulicaccumulator
withoil
whentheengineis running.
Design:
-Y225
centering
by steeringcircuilll
Fig.33:Directional
valveemergency
supplycentering
LTM1100-4.1
rSiT0Tiu G
Fig_34:Excerptfromcircuitdiagramdireclional
valveemergency
supplycentering
LTM1100-4.1
Funclion:
Duringa "centering"
faultconditionthe 4/2-wayvalve-Y225is energised
for approx20
sec.Thisutilisesthe pressureof steeringpumpll to assistthe centeringcircuit.Thisensuresthatthe centeringactioncanbe performed.
Libhr-Weft EhingenGmbH-Technicaltrainlng
personnel
Onlyfor LIEBHERR
Service
-30-
UEHINR
description
Component
UW10- Partll - active rear axlesteering
>3.6 Pre-tensionvalve
Purpose:
the ringandpisin the fan returnline.lt pre-tensions
valveis integrated
The pre-tension
ton surfaceof the centeringcylinderto 10bar.
Thisensuresthatthe pistonrunsalonginsidethe centeringcylinder.
Thispermitsfastercente ng.
Design:
1 0 BAR
-MP6
point
Measuring
Pre-tension
10 bar,
Returnfan
Fig.35:Exceptfromcircuit
diagrampretensionvalve
LTt\,l1100-4.1
valveLTI\4
11004.1
Fig.36:Pre-tension
>3.7FaultdisplayAHL
greenlil
rapidflashing =>
slowflashing =>
everything
o.k.
Faullin steeringsystemwitherrcrcode
Faultin lhe LSB-busconnection
Cont\ollight,rearaxlesteer:ng
i@b:rE@@@@
g@Gtrtr@@
trtrtr8tr
Fig.37: FaultdisplayAHL
Note:
Thesteeringprogramkeyswillstartto flashin the event of a faulton the activerearaxle
steering.
Llebher-we*Ehingen
GmbH-Techni lralning
personnel
OrlyforLIEBHERR
Service
-31
ITIBHERR
by:|*epid/futroi:12'02'07/VeFioi:2
)3.8 Centeringcylinder
Purpose:
The centeringcylinderperformsvarioustasks.Theseare dependent
on the procedure
step(steering,
blockingandcentering).
Fig.38:Centering
cylinder
Pistonsurface
Ringsurface
Tappet
Fig.39:Cutwayviewcentering
cylinder
Fig.40: Excerptfrom ckcuit

diagramcentedngcylinder
Llebhr-Werk
Ehinge.GmbH- Tchnlcat
tralning
personnel
OnlytorLIEBHERR
Service
-32 -
rIIBHIRR
Component
description
>3.8.1Centeringcylinderduringsleeringaction:
themovement
to thecentering
cylinder
whichfollows
of 10 baris applied
Herea pressure
steering
cylinders.
axles
which
are
controlled
by
the
of the
(flowthrough
valve-Y226CY227))
valves-Y221| -Y222andblocking
centering
T=
Tankreturnviatankpipe "L4"
X=
plate "A71"are released

vaveson mounting
Thenon-retum
by crealingflowihroughblocklngvalve-Y226CY227)
pr+tensioning
pressure
totheringandpistonsudaces
ofthe
A=
Applylng
-Y221(-Y222)
nngvalves
cylinder
bycreating
flowthrough
thecente
centenng
Fig.41: Cut-awayview centring cylinderduringsteeringacton

--.--
r:
rl
TF--\
il-Illl
Blockingvalve
Centeringva ve
Fig.42: Overview- slee ng actionaxle 3

Liebher-werkEhingenGmbH- Technicaltrainng
-JJ
lIIBHIRR
>3.8.2Centeringcylinderduring blocking action:

Initiated
whena pre-defined
speedis exceededand duringfaultconditions.
ln this case
it is not possibleto furthersteerthe axles.The rear axles can only be steeredin the 0"
direction.
(flowthroughcenteringvalves-Y221| -Y220;!9 flow throughblockingvalve-Y226\-Y227))
T=
Tankreturnvia tankpipe"L4"
X=
Blocking
the non-reilrnvalvesby relevlngthe pressurein the X-pipe
(conneclion
to lank)by dropping
out blocking
valves-Y226(-Y227)
A=
Applying
h ghpressure
totheringandpiston
surfaces
ofthecenterjng
cylinder
by creaiingflow lhroughthe centeringvalves-Y221CY220)
F g. 43: Cut-awayview centerng cylinderduringblockingaction
ntering
cylinder
hasbeendesigned
so thatthesteering
anglecanonlybe reduced
s thecenireposition
whenhydraulic
clamping
is active(straight-ahead
driving).
Blockingvalve
Centering
valve
Fig.44: Overvlew- blocklngacuonaxle 3

Liebher-WerkEh ngen GmbH-Technicaltrainng
-34-
ITIBIIIRR
Gomponent
description
>3.8.3Centeringcylinderduringcenteringaction:
duringfauliconditions.
Centeingis performed
Highpressureis appliedto bothouterchambersof the centeringcylinderto forcethe
rapidreturnof therearaxlesto 0'steering.
Thecontrolsystemwill not initiatecenteringat speedsbelow3 Km/h.
(Ig flow throLrghcenteringvalves-Y221/ -Y222and blockingvalve -Y226(-Y227))
T = Tankrelum vla tank oioe "L4"
X=
Â.71"
Blockingthe non-reiumvalvesby relievingthe pressurein the X-plpe

(connectionto lank) by droppingoul blockingvalves-Y226 (-Y227)
Applying
hgh pressure
tothe ringandpistonsurfacs
of thecenlering
cylinder
by dfoppingout centeringvaves-Y221(-Y220).
Al the sametime both steeringcylindersare released-
Fig.45:Cufawayviewcenteang
cyllnderdurlngcentering
action
Blockng valve
Centerng valve
E g. 46 Overview
- cenlering
arreg
".t:on
Liebher-WefkEhingenGmbH- Techn@ltining
personnel
OnlyforLIEBHERR
Service
ITIBHIRR
UWl0 - Partll - activerearaxlesteering
>3.9 Safetymeasuresduring fault conditions

Thereare4 safetymeasures(l\,41
to [,44)whichcanbe initiatedfor activerearaxlesteeringwhena faultoccursin the activerearaxlesteeringsystem.
Almostall the safetymeasuresimmediately
blockthe rearaxlesteeringlt is thendeterminedwhether
or notthevehicleis currently
turning(angleof frontaxle>150).
However
thisdoesnotapplywhenthereis a faultin thefrontaxleanglesensor,
theangle
sensorof steeringaxle2 or the BoschCANproportional
valvefor steeringaxle2.
M1;Cenlrethe steering
Conditions:
Measure
l\r1is takenin eitherof thesecases:
. Case1: Thevehiclespeedis below3 km/hand no CAN-datais sentfromthe other
lO-module.
. Case2: Thevehiclespeedis above3 km/hand no curvedrivingis detected.In this
casethe pressurein the centeringcircuit(-S89)mustbe at its normallevel.
Valveactuation:
- flow is appliedto Y 225 (emergency
supplycentering)
for approx.20 sec
- thereis no flowthroughY 226 (blockingvalve).
- thereis no flowthrough
Y 221(centering
valveLA 1).
- thereis no flowthroughY 222 (centering
valveLA 2).
-Y231 and-Y232(CAN-valves
LA 1 and LA2) are setto a targetsteeringangle= 0o
Effects:
- Thecurrentspeedbecomes
themaximum
speed(upto 40 km/h).
- Thefaultnumberis displayed.
- Thecontrollightfor activerearaxlesteeringflashes.
- The buttonson the steeringprogramsflash.
- Thecenteringcylindersandaxlesareactivelymovedto ihe centreposition.
Liebher-WerkEhingenGmbH-Techni lranng
personnel
OnlyforLIEBHERR
Service
-36-
ITIBIITRR
description
Component
M2:Specialcase,blocksteering
Conditions:
Measure
Ml is takenin eitherofthesecases:
. Case1:Thevehiclespeedis below3 km/h,noturning;
in thecentering
thepressure
circuitis notO.K.
. Case2: Thevehiclespeedis above3 km/handflowmonitorCS90)is faulty
Valveactuation:
- thereis no flowthrough
valve).
Y 226(blocking
- flowcontinues
valveLA 1).
through
Y 221(centering
- flowcontinues
valveLA2).
ihrough
Y 222(centering
'Y231 and-Y232(CAN-valves
LA 1 and LA2) are set to a targetsteeringangle= 0o
(providing
anglevalueis O.K.).
Effects:
- Thecurrent
speed(upio 40 km/h).
speedbecomes
themaximum
- Thebuttons
programs
flash
on thesteering
M3:Specialcase,blocksteering
Conditions:
Thevehiclespeedis above3 km/handthemobilecraneis turning.
Valveactuation:
- thereis no flowthroughY 226 (blockingvalve).
- flowcontinues
through
Y 221(centering
valveLA 1).
- flowcontinues
valveLA2).
throughY222 (centering
-Y231and-Y232sleerthewheelsin the 0odirection,providing
the anglevaluesare still
position
untilthe"turning
O.K.lf theanglevaluesarenotO.K.,thewheelsareleftin this
criterion".
is no longerfulfilled.
Effects:
- Thecurrent
speedbecomes
themaximum
speed(upto 40 km/h).
- Thebuttons
programs
on thesteering
flash,
t = The "turningcriterion"
the angleof the frontaxle hasreducedby 3o
is completed-once
sincethe faultoccurred.
Liebher-We* Eh ngen GmbH- TechniltEining
- 3 7-
ITIBHIRR
M4: Spocialcase,centrestee ng (duringpoweroutage)

Conditions:
Centeringis electrically
triggered,no voltagepresent.
Valveactuation;
- Thereis no flowthroughY 226 (blockingvalve)(automatic).
- Thereis no flowthroughY22'l (centering
valveLA 1) (automatic).
- Thereis no flowthroughY 222 (centering
valveLA2) (automatic).
Effects:
- Thecurent speedbecomesthe maximumspeed(upto 40 km/h).
- The buttonson the steeringprogramsUash.
- Thecenteringcylindersandaxlesare activelymovedto the centreposition.
Liebher-Werk
Ehlngn
GmbH- Techniellraining
personnel
OnlyforLIEBHERR
Service
-38-
UIBIIERR
)4 Summary
AHL
Electro-hydraulic
steering:
in the BoschCANproporiional
valves.
Thesteeringis actuatedby the processors
therearaxlesareelectro-hydraulically
Thesteering
angleon theleading
axleis reduced;
operating
mode.
on thevehiclespeedandthepre-selected
steered
depending
intoa hydraulicactionby the proportional
valveson the
Thecalculated
angleis converted
pump.
pressure
is supplied
hydraulic
by an engine-driven A closedaxles.Therequired
loopcontrolcircuitis createdusingthe actualvaluesobtainedfromthe displacement
valvesandthe anglesensorson eachof the
measurement
systemon the proportional
rearaxles.
Thefollowing
modesaresupported:
operating
.
.
.
.
.
.
Roaddriving
All-wheelsteering
Crabsteering
raie
Reducedswing-out
Independent
steering
Rearaxlesteeringlockedin centreposition
The centering
valveis onlydeactivated
whena faultoccurs(no power);eachaxleis then
independently
steeredto 0'.
The blockingvalveis activated
duringfaultconditions
and whenthe maximumpermitted
Above V n..,i"s..*the axles
speedfor the activerear axle steeringis reached(V
",*,"n."*).(no power)and the
are controlleddown to 0", the blockingvalve is also activated
clamped.ln the blockedstatethe axlescan onlybe
corresponding
axlesare hydraulically
steeredtowards0' (themaximumangleis thenthe currentangle).
Centering
valve:
valve:
Blocking
valveforreleasing
thesteering
cylinder
Change-over
Valveto openthenon-return
valveson thecentering
cylinder
(exception
is the blockingvalve
Thesevalvesare onlyactivatedduringfaultconditions
The
aboveV .,""n"".",).
lt mustbe ensured
thatthesevalvesalsoswitch"mechanically".
centeringvalveshouldnotbe activatedwhendrivingfor testpurposesas it affectsthe
drivingcharacteristics.
Eventhoughthe blockingvalveis activatedwhendriving,no tests
shouldbe carried
out.
insteadthereis a cyclictestafter
Thesevalvesarethereforenottestedwhentravelling,
therelevant
testprogram.
lt is verified
whether
ENGINE
ONor by callingup thefunctional
valve"dropsout"andswitchesto a safesiate.
Liebheir-Werk
EhingenGmbH- TechnicaltGining
personnel
Onlyfor LIEBHERR
Service
-39-
ITTBHIRR
Gomponent
description
HA - steering:
Hydraulic
fluidis appliedto theproportional
pump-D22(via
valvesby rearaxlesteering
highpressurefilter"steeringcircuii").
Theflowrateof the LS-controlled
rearaxlesteeringpumpis controlleddepending
on
pressure,
thedifferential
thevolumeflowis dependent
on theloads.
Themaximumpressureof the steeringcircuitis limitedby a pressureregulatorandan
pressure
additional
limiting
valve.
On thesecondary
sidethesteering
cylinders
areprotected
by pressure
limiting
valves.
Switching
theblocking
valvesunblocks
thecentering
non-return
valves,releases
the
hydraulic
clamping
of theHA-steering
and
allowsHA-steering.
Thecentering
valvesarealsoswitched,
theconnection
to thepistonand
pistonrodsideofthesteering
is
cylinder blockedandthecentering
cylinder
is
released
intothetank.
Thesteering
anglefortherearaxlesis nowdependent
on thesteering
angleof the
frontaxles.
Thesteering
angleof theleading
axleis measured
by an anglesensor(nominal
valueanglesensor),an electricalcontrolsystemis usedto controlthe proportional
valves
(steering
valves)andapplyhydraulic
fluidto thesteering
cylinders
fortherearaxles.
Thesteeredrearaxlesare equippedwithanglesensorsthat monitorthe specifiedsteeringangle- nominalvalue.
A continuous
nominal/actual
valuecomparison
checkswhether
thesteeredrearaxles
followthe nominalvaluewithina giventolerance,
appropriate
measuresaretakenif
thereis a discrepancy
between
thesesignals.
Liebhetr-Wefk
Eh ngen GmbH-Technicaltraining
personnel
Onlyfor LIEBHERR
Service
-40-
lTIBHIRR
Gomponent
description
Centering:
pumpD25supplies
circuit
via
hydraulic
fluidto thecentering
centering
Thewheel-driven
circuitcentering".
filter"Hydraulic
thehighpressure
The highpressurein the centeringcircuitis protectedby a pressureregulatorand a pressurelimitingvalve.Thecenteringcylindersare alsofittedwithpressurelimitingvalves.
pressure
swiichat v >10km/h.
is monitored
by a pressure
Thecentering
is 0.
angle- nominalvalue
is activated
thesteering
Whencentering
valvesare releasedandthe relevant
Theblockingvalvesare poweredoff,the non-return
Steering
is no longerpossible.
clamped.
axlesarehydraulically
anglecanonlybe reduced
designed
so thatthesteering
cylinder
has
been
Thecentering
driving).
clamping
is active(straight-ahead
whenhydraulic
towards
thecentreposition
piston
piston
powered
rod
sides
of
the
steering
off,
the
and
valves
are
also
Thecentering
valveanddischarged
intothetank.
areconnected
by thecentering
cylinder
Thepressuregeneratedby axialpistonpump(D25)centresthe HA.
withcentering
on 3 of the
1400-7.1
is onlyequipped
fortheLTN/I
Therearaxlesteering
valvewhen
4 steeredrearaxles(HA),theothersteeredaxleis releasedby a directional
centenng
occurs.
Moniloringof the centeringpipe:
valve.Duringsteering
angle
limiting
by a pressure
Thefancircuitreturnis prelensioned
pistons
and
pressure
cylinder
viatheflowmonitor
is applied
to thecentering
reduction,
applied
in
the
centre.
causing
them
to
be
switched
centering
valves,
with no steeringmoveIf theflow raterequiredto applythe centeringpistonsat standstill
mentis > 2 l/min,a pipehasburstor a leakhasoccurred.
measuresare thentaken.
Appropriate
Theflowmonitoroutputsan errormessage.
Liebhen-WerkEhingenGmbH- TechnlcaltrainLng
personnel
Onlyfor LIEBHERR
Service
UIBHTRR
Llbhr-Wqk EhingenGmbH- Tchni@ttainins
OnlyforLIEBHERR
Servicepersonnel
-42-
r|EIIINR
Component
description
UW12- Axle suspension
Onlvfor LIEBHERR
service
oersonnel
suspension
Liebheri-Werk
EhingenGmbH- Technil tEining
personnel
OnlyforLIEBHERR
service
-3-
lIIBIIIRR
Component
description
UW12-Axle suspension
Ubhr-We* EhlngnGmbH- Tchnicltralnlng
Onlvfor LIEBHERR
serviceoersonne
-4-
UBHINR
UW12 -Axle suspension

1 Axle suspension,general
>1.1PurDose
wearon thecrane
cushions
thevehicleandreduces
TheNiveaumatik
axlesuspension
androads.
It can be lowered,raisedor drivenat a specillclevel(springstrutcentrepositionor terrain
application.
compensation)
to suita particular
applications:
Thevehicleis raisedor lowered
in thefollowing
. Automatic
(suspension
in drivingmode)forallaxles
andmanualleveladjustment
. Loweringthe cranestructureto reducethe headroom
. Raisingthe cranestructureto improvethewadingcapability
. Raisingthefrontend (or rearof thevehicle)to increasethe gradient
. Lateraltiltingof the cranestructureto facilitatedrivingon slopes
>1.2Layout
Thesuspension
andaxlecompensation
are hydro-pneumatic.
Cylindersarefitted
canbe adjusted
betweenthe axleandthevehicleframe.Thesuspension
characteristics
pressureon the hydro-pneumatic
tank.The
usingthe oil leveland gaspre-tensioning
viathekeyboard
Niveaumatik
suspension
is operated
unitin thecab.
cylinder
Axlesuspension
Axle blockjngvalves
'/ Nitrogen
bladderacclmulator
(suspension
component)
Fig. 1: F gure showingprincipleof axle suspension- layout

Liebheri-We*Ehnqen GmbH- Iechnil lralnins
servicepersonnel
Onlyfor LIEBHERR
_5 -
1TIBITIRR
UW12 -Axle suspension
Prcdmedby:iEpi0/Ediddni29'0306/\hreion:4
,H5
i E
16
17
18
19
Fig.2:Hydraulic
axlesuspension
LTN4
1050-3.1:
Uebheir-Werk
Ehingen
cnbH - Technicat
tainirg
Onlyfor LIEBHERR
personnel
service
-6-
lIBHTNR
Gomponent
description
UW12 - Axlesuspension
Function
fifstaxleon therighl
Fillingihe axlesuspension
cylinderforthe
(raisethevehicle)
-Y13,
Draining
theoilfromthefirstaxleonthe right(lowervehicle)
2.
Solenoidvalve
Pressure
compensation
fof thecrosswise
axlesuspension
cylinders.
The
3.
Diaphragmreservoir
pistonsudaceforiherightaxlesuspension
cylinder(1staxle)is connected
on theleftaxlesuspension
cylinder(axles2 and3).
to theringsurfaces
Blocking
theaxlesuspension
for axle1 righi
4.
Axle blockingvalve
-Y9,
posjuon
Valve
in
rest
axle
blocking
valvesin lockingposition
5.
5/2 Way-solenoid
CYga)
(axlesuspension
valve
blocked)
- ValveswitchedCYgb)axleblocking
valvesopen
(axlesuspension
sptung)
axle1 right(canbe blocked)
6.
Axlesuspension
cylinder Suspension
-561,Levelswitch
Acknowledgement
axlesuspension
axle'1right(41 = fill;A2= drain)
7.
-Y18, Solenoidvalve
8.
Fillingihe axlesuspension
cylinderforthe
2nd and3rdaxlesonthe dght
(ralsethevehicle)
-Y19, Solenoidvalve
9.
Dfainingtheoilfromthe2ndand3rdaxleon the right(lowervehicle)
foraxles2 and3 right
10. Axle blockingvalve
Blocking
lhe axlesuspension
forthecmsswise
axlesuspension
cylinders
when
11. Diaphragmreservoir Pressure
compensalion
piston
axlesuspension
is sprung.The
suriacefortheleitaxlesuspension
to lhe ringsurfaces
on therightaxlesuscylinder('1staxle)ls connected
pensioncylinder(axles2 and3)whenthe axlesuspension
is "sprung".
-Axlesuspension
for axles2 and3 blocked
12. -S50,Contactswitch Acknowledgemeni
13. Axlesuspension
cylinderSuspension
14. Axlesuspension
cytinderSuspension
;
axlesuspension
axle3 right(A1= fill;A2 = drain)
15. -563,Levelswitch
Acknowledgement
flrstaxleontheleft(raisevehicle)
16. -Y10,Solenoid
valve Fillingtheaxlesuspension
cylinderforihe
-Y11,
17.
Solenoid
va,ve Draining
the oilfromthefirstaxleonthe left(lowervehicle)
for axle1 left
18. Axleblocking
valve
Blocking
the axlesuspension
19. -S51,Contactswiich Acknowledgement
axlesuspension
axle1 sptung
forlhe crosswise
axlesuspension
cylinders.
The
20. Diaphragm
reservoir Pressure
compensation
pistonsurfaceforthe leit axlesuspension
cylinder(1staxle)is connected
on therightaxlesuspension
cylinder(axles2 and3).
to the ringsurfaces
(can
21. Axlesuspension
cylinderSuspension
axle1 left
be blocked)
22. -560,Levelswilch
Acknowledgement
axlesuspension
axle1 left(Al = fill;A2= drain)
23. -Y16,Solenoid
valve Fillingthe axlesuspension
cylinderforthe2ndand3rdaxleonthe left
(raisevehicle)
24. -Y17,Solenoid
valve Draining
lhe oilfromlhe 2ndand3rdaxleonthe eft (lowervehicle)
the axlesuspension
for axles2 and3 left
25. Axleblocking
valve
Blocking
compensation
forthecrosswise
axlesuspension
cylinders
when
26. Diaphragm
rcseNoir Pressure
axlesuspension
is sprung.Thepistonsurfaceforthe dghtaxlesuspension
to theringsufaceson theleftaxlesuscylinder(1staxle)is connected
pensioncylinder(axles2 and3)whentheaxlesuspension
is "sprung".
(can
27. Axlesuspension
axle2 left
be blocked)
cylinderSuspension
28. Axlesuspensioncylinder
Suspension
axle3 left(canbe blocked)
axlesuspension
axle3 left(A1= fill;42 = drain)
29. -562,Levelswitch
Acknowledgement
Pos. Designation
-Y12,Solenoidvalve
1.
Fig.3: Explanationof the positionnumbers/ hydraulicaxle suspenslonLTM 1050-3.1

Liebheii-W* Ehingen GmbH -Technicaltrain ng
Onlyfor LIEBHERRservicepersonnel
-7
UIBHIRR
2 Nitrogentank
>2.1Purpose
Thegeneralpurposeof the nitrogentankis to absorba volumeof fluidunderpressure
andreleaseit as required.Nitrogentanksarethereforeusedin combination
withaxle
suspension
cylinderson axlesuspension
systems.
>2.2 Layout
Bladderaccumulators
anddiaphragm
reservoirs
havea storagebladder
andmembrane
respectively
to separatethegas (nitrogen)
fromthe hydraulicoil.
pressure
Gasfill
P0 (pre-tension
Sioragecapaciiyin litres
Gas fill pressureP0 cn be
changedusinga fillingand
iestingdevice
ldentificalion
plate
Gasvalve(nitrogen
fill
Nitrogenfilling
tanK
pressure
Operating
PS
InDar
Storage
bladder
Hydrauljcoil
Oil valve(mushroom
Ventingscrew
Connection
to the
hydraulic
system
charge
discharge
Bladderaccumulator Bladderaccumulatof
empty
Bladderaccumulator
cnarge0
Fig.4:BladderaccumulalorFirmaRexroth
Liebher-WerkEhingenGmbH- Technil tralning
personnel
OnlyforLIEBHERR
service
-8-
IIBHIRR
suspension
Sioragecapacityin lilres
Gas fill pressureP0 cn be

changedusinga fillingand
testingdevice
u r.i.
330
BARrs-3./so"c
"l"ifl'1"*Xi:"--l---'--ps
"rooc
PT472 BAR
sBo330-2,8E1/663U-3304K050
Plugscrew
plate
ldentificiion
(stampedin)
Nitrogen
filling
Tank
I\,4embrane
(rubber)
Hydraulic
oil
Closinghead
to the
Connection
hydraulic
sysiem
cl-1arge
discharge
Diaphragm
rcseNoir
empiy
Fio. 5: Bladdefaccumulator-FirmaHYDAG
reseNoir
Diaphragm
discharged
Diaphragm
reservoi
cnargeo
Fillingand testingdevice
for diaphragmreservoirs
Fillingand testingdevice
ior bladderaccumulators
Fillinghose
Fig.6: F:llingand testingdevice
u8bhr-wedEhlngsn
GmbH- Techniltining
Onlyfor LIEBHERR
servicepersonnel
UIBHTNR
Gomponent
description
UW 12 - Axle suspension
Fillingand teslingdevice
Fillinghose
Membrane
HydraLr'ic
accumu,ator
Fig. 7: Schematicofthe fillingand testingdevice
2.3Function
Bladderaccumulator:
Duringnormalconditions
the storagebladderis pre{ensioned
with nitrogenvia the gas
valve(gasfill pressureP0)and completely
fillsthe steeltanktherebyclosingthe mushroomvalve.Oncethe oil pressurein the hydraulicsystemreachesthe gaspre{ension
level,hydraulicoil flowsthroughthe mushroom
valveintothe accumulator
to compress
the nitrogenin the bladder.Thevolumeof nitrogenwillthereforereduceby the amountof
absorbed
hydraulic
oilvolume.
Dropping
theoil pressure
causesthenitrogen
to expand
andforcethestoredhydraulic
oil backintothehydraulic
system.
Diaphragm
reservoir:
Diaphragm
reservoirs
are equippedwitha diaphragminsteadof a bladderto separatethe
gaslillpressure
fromthehydraulic
oil,
Thememblaneexpandsvia the screwplugandoperatesthe closinghead
Theyare usedfor lowstoragevolumesand usuallyhavebetterdynamiccharacteristics
whencomoared
to bladder
accumulators.
Llebher-WerkEhingenGmbH- Technl lralning
OnlyforLIEBHERR
servicepersonnel
-10-
ITBHIRR
3 Axle suspensioncylinderwith proximityswitch
)3.1 Purpose
Suspension
andequalisation
component
betweenthe axleandthe vehicleframe,Raising
lateral
and loweringthe cranestructureand
tilting.
Theaxlesuspension
cylindersarefittedwithproximityswitchesfor automaticheight
regulation.
>3.2 Layout
Actuatingthe appropriate
solenoidvalvespumpshydraulicoil ontothe pistonsurfaceof
theaxlesuspension
the vehicleis loweredby
cylinderand raisesthe vehicle;conversely
pressure
pision
valves
release
the
oil
from
the
actuatingsolenoid
to
surface.
Thehydraulicoil whichis forcedoutor flowsontothe ringsurfaceof the axlesuspension
cylinderservesto dampenany movement.
K
R
K = piston surfaceR = ring surface Fig.8: Axlesuspension

cylinder
Uebher-WeREhingenGmbH-Techniel Laining
personnel
OnlyforLIEBHERR
service
- 1 1-
ITIBHIRR
Component
description
l\,4obile
craneswithup to 4 axlesarefittedwithlevelswitcheson the 1stand lastaxle;
mobilecraneswithmorethan5 axlesusuallyhavethemfittedon the1standpenultimate
axle.
Levelswitch-S6xcomprises
two proximityswitches(A1and42).
heightregulation.
Thelevelswitchis usedforautomatic
Theset positionof thevehiclefor drivingmode (vehicleat correctheight)is detected.
Theoutputsignalsof bothproximityswitchesare dependent
on the boomstatusof the
(seetable).
axlesuspension
cylinder
Gondilion
Vehicleraised/ lowerlevel
Vehicleat correctlevel
A1
0
0
1
1
Vehiclelowered/ raise level
A2
0
'I
Proximltyswitch
(inductivesensor)
0
1
K
R
Levelswitch
Axlesuspension
cylinder
pos
ossLl
lble
po
ions
00s
osilii
Ithe
rh
witcl
Exceetfromschematic:
ProximityswjlchA1
Proximity
switch
Proximity
switch,q1
__z
tl_,.,
t-;=L
Pr;ximityswitch42
K = oiston surfaceR = ring surface -
ffi
L ebheii-werkEhing6nGmbH -Techni t6inng
OnlyforLIEBHERR
servicepersonnel
-12-
ITIBIIIRR
4 Axlesuspension
sprung/ blocked
>4.1 Purpose
Theaxlesuspension
is blockedwhenthe craneis supported(craneoperation)
andin
(free-standing
craneoperation)drivingmodewithequipment
Theaxlesuspension
is setto sprungfor roaddriving(drivingmode).
X.2 Layout
Compressed
airconkol
lineAxlesuspension
blocked/ sprung
50.
Contactswitch,
Axlesblocked
Fig. 10:Axle blockingvalve LTIV1030-2.1
Pistonforvenljngvalve;
Axlesuspension
blocked
Fig.11:AxleblockingvalveLTM1030-2.1
Li.bhotr-WrkEhlngnGmbH- Techniel tEining
personne
OnlyforLIEBHERR
service
- 13 -
UBHIRR
;:::
Component
description
UW 12 - Axlesuspension
-Yga
-YSb
Axlesuspension
Fig.1215/2Waysolenold
va ve, pneumatjcchangeoveraxle suspensionblocked/ sprung- LTll 1045-3.1
>4.3 Function
Axle suspension
lowered
level
rarse0
Drivingwithloads
Supportvehicle
Manually
raisethe vehicle
[,,lanually
lowerthevehicle
Roaddrivingmode
Axle suspensioncylinder
blocked
sprung
X
X
X'
X-
X
X
prnciple
Fig.l3: Figure
showing
ofsprurgaxlesuspenson
* = On y on mob le craneswlth 5 or more axlesor on all newlydeve oped crane modelsfrom 2007
(withoutpiperupt!reprotection).
L ebher-WerkEhin9enGmbH- Technlcaltrairing
-14-
IITBHIRN
Solenoidvalve
Ralse(flll)
Solenoidvalve
Ralse(fili)
Solenoidvalve
Lower(drain)
Solenoidvalve
Lower(drain)
Contaciswitch,
Axles blocked
Contactswitch,
Nitrogen
bladderaccumuLator
(suspension
component)
Axlesuspension
cylinderleft
Nitrogen
bladderaccumulator
(suspension
component)
Solenoidvalve,
pneumaticchangeoveraxle
suspension
blocked/ sprung
cylinderdght
Fig.,l: Schera.;col sprLngaxlFsuspersior
L ebhen-WerkEhingenGmbH-Techniltfain ng
personnel
service
Onlyfor LIEBHERR
ITBHIRR
Crosswiseswitching:
On mobilecraneswith up to 4 axles(appliesto revisedor newlydevelopedmachines
from2005),vehicleroll is preventedby crosswiseswitchingof the axlesuspension
cylin(e.9.whenbrakingthe vehicle)
ders.Thisimprovestrackingstability.Pitchingmovements
are exaggerated,
howevertheyare negligible
dueto the improveddrivingcharacteristics.
.
.
The pistonsurfacesofthe axlesuspension

cylinderson the frontaxlesare connected
cylinderson the diagonally
to the ringsurfacesof the axlesuspension
oppositerear
axles.
The ringsurfacesofthe axlesuspension
cylinderson the frontaxlesare connected
1o
the pistonsurfacesof the axlesuspension
cylinderson the diagonally
oppositerear
axles.
Fig. 15: Schemaiicof the axle suspensionswilchedin crosswiseconfiguration
Liebher-WerkEhingenGmbH- Techniel tGining
personnel
Onlyfor LIEBHERR
service
- lO -
UBHINR
Parallelswitching:
machines
to revised
or newlydeveloped
On mobilecraneswith5 or moreaxles(applies
not
cylindersis
used.
from2005)crosswise
switchingof the axlesuspension
cylindersare connectedin parallel.
In thiscasethe axlesuspension
switchingcanbe
Thetrackingstabilityof thesemachinesis so goodthatcostlycrosswise
omitted.
.
.
to the ringsurcylinderis connected

The pistonsurfacefor the leftaxlesuspension
cylinder
of thesameaxle.
faceon therightaxlesuspension
to the pistonsurcylinderis connected
The ringsurfacefor the leftaxlesuspension
cylinder
of thesameaxle.
faceon therightaxlesuspension
in parallelconfiguration
switched
Fig.16rSchematic
ofthe axlesuspension
Liebhetr-Wed(
EhingenGmbH- Techni@llraining
personnel
OnlyforLIEBHERR
service
- 1 7-
lTIBIITRR
Gomponent
description
Highpressure
Cl6mpedpressurc
Controlpressure
Lowpressufe
- Crosswise
Fig.17:Axlessuspension
LTl,./1050-3.1
configuration
/ axleslspensionsprung
Liebheri-Werk
EhingenGmbH- Technil lEining
personnel
OnlyforLIEBHERR
service
- t8-
IIIBHIRR
UW12- AxlesusPension
p.ma
lll
?
b, repLot ra;i"", zg.ososi v.a-'
-' '^"
I l.j !
Highpressurc
pssuf
Clamped
controlprcssure
LowPressure
lmpactto leftwheel,axle1 e.g causedby

unevenroadsurface
sprung_
/ axlesuspension
configuration
LTI\,1050-3'1- Crosswise
Fig.18:Axlessuspension
lmpacitolefiwheel,axle1
_
Uebher-WelkEhingsnGmbH TchnicllEinrng
servicepersonnel
Onlyfor LIEBHERR
- 19 -
UEHINN
In this example:
. ihe vehiclehas been set to a
horizontallevel
axles 1 and 2+3 are blocked
axle compensationis switched
the cranehas laleralstability
- Drivingwithequipment
Fig.19:Figureshowingprinciple
of blockedaxlesuspension
Note:
In thisexample:
. all axlesareblocked
. the craneis supported
without
tyres
- Suppoded
Fig.20: Figureshowingprinciple
of blockedaxlesuspension
tfalning
Liebhrr-weft
Ehingn
GnbH-Technical
personnel
OnlyforLIEBHERR
service
-20 -
UEITIRR
!!
i,i'o-I rn
"l';" 1- l
1**-I- - -
Highprssure
ctampdprssure
Controlpressure
1050-3.1
Fig.21:Excerptfiomaxlesuspenson LTI\,4
/ AIle suspelsionblocked
Liebher-we*Ehingon
GmbH- Technl lraining
servicepersonnel
Onlyfor LIEBHERR
-21 -
TTIBHIRR
Component
description
>5.3 Function
Buttonfoa
"automatic
level
Axle blocking "ON"
Button
"Manuallevel
Fig.22:
Note:
The"2-hand
mustbe operated
duringmanualandautomatic
levelcontrol(when
button"
controlling
the vehicleheight).
The mobilecranecanbe manuallysetto the correctlevelwhenin a sprungor blocked*
state.Thefunctionindicators
on the "manuallevelcontrol"buttonswillflashwhenthe appropriatesuspension
cylindershavereachedthe requiredlevelforroaddriving.
Forsafetyreasons(riskof toppling)the mobilecranecanonlybe automatically
setto the
correctlevelwhenin a sprungstate.
Thefunctionindicatoron the "automatic
levelcontrol"buttonwill be lit whenautomatic
levelcontrolis activeandflashwhenthellnal oositionis reached.
Thefunctionindicators
on the "manuallevelcontrol"buttonswillflashwhenthe relevani
suspension
cylindershavereachedthe requiredlevelforroaddriving.
* = Only on mobilecraneswith 5 or moreaxlesor on all newlydevelopedcrane modelstrom
2007(withoutpiperuptureprotection)
Liebheii-WerkEhingenGnbH -Technicaltraining
Onlyfor LIEBHERR
servicepersonnel
-22 -
UIBIITRR
Component
description
5 Axle blockingvalve/raise- lowervehicle
>5.1 Purpose
Actuatingthe solenoidvalveson the axleblockingvalvewillloweror raisethe vehicle.
)5.2 Layout
-Y19
Solnoidvalvs
Lowerrighl rear
-Yt 8
Solenoid
valve
Raiserightrear
P
Pressuresupply
Nozzle
(forspeed
regulation)
Note:
A nozle";nside
fittingcontrolsthesteady
raisingactionforthe
vehicle.
Tankreturnpipe
SP
Diaphragm
reservoh
valveLTM'1030-2.1
Fig.23:Axleblocking
M
Meas!renent point
Workingpipe
Raisevehicle
l
I
Workingpipe
Lowervehicle
Fig.24:Axleblocking
valveLTM1030-2.1
Onlyfor LIEBHERR
servicepersonnel
i1,,
J i4+
-,1'.-.''
Fig.25:Excerptfromschematic
LTN,I
1030-2.'1
valve
/Axle blocking
* = not fittedon all lnobilecranes.

Liebher-Wrk
Ehingen
GmbH- Tchnicl
lining
-23 -
lIBHINR
Gomponent
description
Highpressure
pressure
Clamped
contro pressure
Fig.26:Excerptfromaxlesuspension
LTM1055-3.1
/
ALrtomatically
raisevehicleto req!kedlevelinsprungslate
Nole:
lf thevehicleis automatically
raisedto the requiredlevelin the sprungstate,highpressureis appliedto the pistonand ringsurfacesof the axlesuspension
cylinder.
Theaxlesuspension
cylinderextendsdueto the difference
in surfaceareabetweenthe
pistonsurfaceand ringsurface.
Liebherr-Werk
Ehin96nGmbH- Technil trainlng
OnlyforLIEBHERR
servicepersonner
-24-
IIBIIIRR
Gomponent
description
6 Axle compensation valves
>6.1Purpose
switched
on
mustbemanually
Onmachines
with5 or moreaxles,axlecompensation
is activated,
it is sub-divided
intotwo
lf axlecompensation
whendrivingwithequipment.
groups.
front
well
as
the
rear
axles.
will
occur
between
the
axles
as
Axlecompensation
>6.2Layout
-S55Camswitch
compensatron
Fig.27: Axle compensationvalveLTM 1200-5.1
>6.3Function
Automatic
level
comrol
Axle blocking "ON"
2-handbutton
Note:
. Axlecompensation
is automatically
activatedwhenraisingor loweringthe axle
suspension.
. lvlanual
is
axlepressurecompensation
is
onlypossible
whentheaxlesuspension
blocked.
Fig.28:Cabkeyboard
unit
Liebheii-WerkEhingenGmbH- Technicallralning
personnel
OnlyforLIEBHERR
service
-25-
UIBHINR
suspension
.Y6a
Solenoid
valveaxlecompensation
1 = no compensalion
(compensation
axles1-2/ 3 / 4-5)
.Y6b
Solenoid
valveaxlecompensation
1 = withcompensation
(compensation
axles'1-2/ 3-5)
,il;
.s53
.s55
Camswilch
Camswitch
AxlecompensationAxlecompensation
hydraulic
LTM1200-5.'1
Fig.29:Excerptfromschemalicfor
axlesuspension
/Axle compensation
LiebheF-Werk
EhingenGmbH-Technil Lainlng
personne.
OnlyforLIEBHERR
service
-26 -
IIEITTRR
Froducedby:|wepid/Edidd:29,03'06/6don:4
Hlghprssure
C ampedpressure
Controlpressufe
Lowpressurc
LTM1200-5.1
/
fig. SO,fr""rpt fror
fo|.hyd|.uuli"
axlesuspension
""h"r"ti"
blocked
/ Drivingwithequipment
Axlesusponsion
L ebher-Werk
Ehinqen
GmbH- Technillraining
personnel
OnlyforLIEBHERR
service
_27 _
l
llrBll IRR
UW 12 - AxlesusPension
7 Raise/ lower axles (largemachineswithout active rear axle steering)
>7.1Purpose
oneor
rearaX|esteering,
andindependent
rearaxlesteering
active
Without
on machines
moreaxlesmustberaised.
>7.2Layout
-Y30
Raiseaxles3+4
(iill ringsurface)
-Y31
Loweraxles3+4
(emptyringsurface)
-s80
Pressureswitch,
>120bar= Acknowledgement
Axles3+4up
-Y32
Raiseaxles3+4
(emptypistonsurface)
F g'31 HydtdLlcblock- Raiseax'esL fl\,l1250/1
>7.3Function
Automaiiclevel
conlrol
--1
l
-
\,r*
lEl
-.- -"1-,;;,-i,;-'
'oN"
Axre
brockjns
__l|
axtes
,/Ra$e
lqf aalft=/flr-1-- tw
'
f
rodslo thi
sleering
Release
blockHydraulic
Fig.32:Excerptfromschemaiic
RdrseaxresLTI\,I1250/1
i
;.
:..i ti-5
i
i r,,
::..,=----...\,.= I
.,t-i.. ... ,
'
'
'
'
'
, . : .
t
'.
eE.
Fig.33:Cabkeyboardunite.g.LTM1250/1
EhingenGmbH _Techni@varnng
Liebheir-Werk
personnel
service
OnlyforLIEBHERR
-28 -
UTTHINR
8 Piperuptureprotection*
>8.1Purpose
protection
is to increase
thepayload
fortheoperating
mode
ofthepiperupture
Thepurpose
prevents
protection
also
thesuspension
cylinderfrom
to read'.Thepiperupture
"free-standing
whichwouldotheMisecausethemobilecraneto tipovet
emptying
whena hoseruptures
>8.2Layout
Piperuptureprotection
Fig.34:Piperuptureproleclion
>8.3Function
cylinders,the pistonsideof
lf piperuptureprotection*
is fittedto the lastaxlesuspension
pylinder
This
is blocked.
is dampedwhentheaxlesuspension
therearaxlesuspension
point
arm
and
increases
displacesthetilting
of the mobilecrane.Thisextendsthe lever
to reat"by ca.20yo.
the maximumpayloadfor operatingmode"free-standing
posllevelling
pipe
protection.
is not
with
a
blocked
axlesuspension
lf
rupture
is fitted,
possible.Forthisreason,piperuptureprotection*
is no longerJittedon all mobilecrane
modelsfrom2007.
Note:
level
Whendrivingwithequipment,
the mobilecranemustthereforebe set to a horizontal
prevents
ground.
the cranefrom
This
andthe supportcylindersextendedca. scmoff the
tipping
whena hoseruptures.
Actuation
via -Ygbaxle
suspensron
sprung
Piperupture
proteclion
Fig.35:Excerptfromschematic
for pipeaupture
'= notfittedon all mobilecranes.
Liebhen-WeAEhingenGmbH- Tchnil tEininq
personnel
Onlyfor LIEBHERR
service
-29 -
lTIBIIIRR
descriPtion
Component
UW12 - AxlesusPension
fud,dbykald/Edb-400]v*.-a
9 Axle oscillation
>9.1Purpose
item
is an optional
is usedfor off-roaddrivingwith loads.Axleoscillation
Axleoscillation*
on2- and3-axlemobilecranes.
>9.2Layout
3/2Waysolenoidvalve(open)for
valve
theair switching
PiperuptureP
Fig.36: Except from circuitdiagramaxle oscillationLTIVI1045-31
t = Option
Liebher-WerkEhingenGnbH - Tchnil tEining
personnel
service
OnlyforLIEBHERR
-30-
lTIBIIIRN
5'ENEDRUC(LUFTAILAOE
LTIV1045-3.1
Fig-37:Excerpifromcircuitdiagmaxleoscillation
Axlesusoension
blockd- axleoscillation
aclive
Liebher-WerkEhingenGmbH- Technicallralning
Onlyfor LIEBHERR
servicepersonn
- 3 1-
lIBHIRR
Component
description
UW13 - Electricalcircuit
diagram
L T M1 0 9 0 - 4 . 1
LTM1100-4.1
Onlyfor LIEBHERR
Servicapersonnel
Gomponent
description
UW 13 - Electricalcircuitdiagram
Libhor-WerkEhingenGmbH- T6chnicaltEining
personnel
OnlyforLIEBHERR
Service
-3-
UEBHTRR
UW13 - Electricalcircuitdiagram
1. UsingLiebherrcircuitdiagrams
1.1Schematic
structure
>1,1.1Divisionchassis/ superstructur
(2).
Apartfroma fewexceptions,
chassis(1)andEuperstructure
L T M1 1 0 0 - 4:
0ltsaLrloT0n
( S T U F E' I I
/ IIER 3 )
L T M1 0 9 0 - 4 . 1
LTt41100-4.1
Linhtr-WeftEhingnGmbH- Technil lEining
personnel
Onlyfor LIEBHERR
Service
-4-
UEIMR
Component
description
UW {3 - Electricalcircuitdiagram
>1.1.2Footer
The footer(l) includes
various
data.
Uebhr-wlk EhingnGmbH- Tecbnlcallinlng
Onlyfor LIEBHERR
Servicepersonnel
- 5 -
>1.1.3Coverpage
Thecoverpagestatesthe versionof the electronic
circuitdiagram.
(uW)or
relates
to thechassis
Pagetitle (1)indicates
whether
thecircuitdiagram
(OW).
superstructure
and"Circuit
diagram
turntable
LTIV'1100-4.1"
are
"Circuit
diagram
EL.systemvehicle"
respectively.
staiedfor the chassisand superstructure
(e.9.LTM11004.1)
thetypedesignation
Distinctivefeatures(2)arelisteddirectlybeneath
-40"
KATll).
to identifythe specificmodel(e.9.
Otherdistinctivefeatures:
Chassis
versions:
Superstructure
versions:
-40' (CATI andll),dieselengine(stagelll)

Dolly,USA,Japan,-40' (CATI andIl)
Radioremotecontrolanddetachable
boom
1 1 0 -04
- 4 0 ' K A TI I
OIESELlIOTOR
(STU
FEIII / TiER
L ebhen-WerkEhingenGmbH-Technillra ning
personne,
OnlyforLIEBHERR
Service
lEBHERR
Gomponent
description
>1.1.4Indexof pages/ Tablof contents

The Indexof pags(1) is an alphabetically
sortedlistof all pagetitleswith
page
corresponding
circuitdiagram
numberreferences.
LiebheF-W6d<Ehingn GmbH - Tchnil lraining
Onlyfor LIEBHERR
Servicepersonnel
-8-
tBtffiR
>1.1.5Pagelayout
andF)
Eachpageof thecircuitdiagramis dividedinto8 columns(1-8)and5 rows(A,B,C,E
page
a
includes
reference
into40lleldsEach
Thisme;ns thateverypageis sub-divided
maybe foundinthe3rdcolumn
thatthecomponent
implies
columnlD e.g. 124,3.This
are not usedhere.
on page124.Rowidentifiers
Li6bher Werk EhingsnGmbH- Technil lEining
personnel
Service
OnlyforLIEBHERR
-9-
UEBTftRR
Component
description
>1.1.6Overviews
Overviewdiagramsare usedto illustratee.g.the installationlocationof componentsor
on mobilecraneswith databustechnoloqv
the connections
betweenunits.ForexamDle,
the LSB/ CANoverviewis listed.
Liebheii-WerkEhingenGmbH Technil trainn9
personnel
Onlyfor LIEBHERR
Service
- . t 0-
UEBItrRR
13 - Electricalcircuit diagram
Pbduced bv: weoiro/ Ed t on: 13.02.07/ VeEion: 1
Installationlocation
The chassisand superstructure
are each sub-dividedinto installationlocationgroups(1)
Chassis:
. H C a b
.
F
Vehicle
. S
Controlcabinet
Superstructure:
. K C a b
.
D
Turntable
. A
Boom
. S
Controlcabinet
Example:
=g+!-K53:30
Liebherr-WerkEhingenGmbH - Technicalt|aining
-z',t-
lEBHINR
Produd by: lw.piro / Edition:13,02.07
/Ve6lon:1
Resourcetype
All resources
aredividedintogroups:
Excerptfromlist:
.
.
.
.
.
.
.
A
F
K
M
R
S
X
Modules/ sub-modules
Safety devices
Relaysi contactors
Engine
Resistors
Switch
Plug
Valves
Example:
=U+H-K53:30
3t tl-
t R r o a R! t r r , r a 8 a r i t r T t L 1
3
c
F
l.'
a
3El:alEL;
=U+ri-Kt3:30
tJ
:30
It
Liebherr-WerkEhingenGmbH - Technicaltining
-22 -
IIIBTtrRR
UW 13 - Electricalcireuitdiagram
Producedbv: lweoio / Edilion:13,02.07/ Ve6ion: 1
Terminal/ signal
withDIN72552:
a numberin accordance
Everysignalis assigned
Excerpt:
. 1 5
. 3 0
. 30b
. 5 0
. D +
(+) Batteryswitchedafterignitionstartswitch
(+) Battery
(+) Batteryswitchedaftermasterbatteryswitch
Starter
Alternator
Example:
15 F44L
3 ! s C I I P E IB J H G
Atr: Jlil 7?ii,:
30
ll
3lb
a:
BEI:P:EL:
3Et:p
!,1111
B+. B
Liebhen-WerkEhingenGmbH -Technicaltraining
-23 -
UEBI#RR
Prcducedbv: weoiro/ Edition:13.02.07/ VeBion: 1
Resource index list

This table(resourceindex)may be usedto quicklylocatea resourceusino the reference
givenon the circuitdiagram.
Example:
-Al
may be foundon page26.1
-A
-t Type of resource
(Modules/ sub-modules)
-> Counter
t0..
1 r 1
:3.1
-A1
- t l
+H
3i.1
t'].'.1
t3.;,:
l!:,!
ll:.1
Liebherr-WerkEhingenGmbH -Technicaltraining
-24 -
T.EBHENR
P.oducdbv: lweoid/ Edilid: 13.02.07; v6id:
>1.1.14Revisionlist
The revisionlist detailschangesto circuitdiagramstogetherwith commentsand pagereferences.
Note:
Any rewiringwork on the cranemust be notedon the list by the personcarryingout these
modifications.
t
,
]
\
\
\
["------,*, t l
BLATT
BEt4ERKUNG
5 5 , 5 6 , 5 7 sPs-TExrE GEAND
ERT
59
1 0 71 1 3
BLATTEESCHRE] 8UNG
ERNEITERT
Liebherr-WerkEhingenGmbH - Technicaltraining
-25 -
UIBHTRR
Prcducedbv: lweoirc/ Edition:13.02.07/ V66ion: 1
>1.1.14Revisionlist
The revisionlist detailschangesto circuitdiagramstogetherwith commentsand pagereferences.
Note:
Any rewiringwork on the cranemustbe notedon the list by the personcarryingout these
modifications.
\
\
\
["-*---toot
BL A T T
59
1 0 71 1 3
BEI.4ERKUNG
SPS.TEXl6
EE I N D E R T
R ATTEFS'I
A F TR I I N l ]
ERIIElTERT
Ljebherr-WerkEhingenGmbH - Technicaltraining
-25 -
UTBHIRR
PFduced bv: lwelilo / Ediiion:13,02.07/ Vrsion:1
1.2 Generalpoints on schematics

)1.2.1 Cross-references/ continuation of cables
Source references(1) (sBL i 87.6)and
Destinationreferences(2) (58LF1L/ 89.3 and 5BLF1L2 | 120.51
are usedto followthe circuitdiagramacrossseveralpages.
-26 -
UEBHENR
Poduced by: iwepiro/ Editjon:13.02.07/ VBioni 1
)1.2.2 Cablecross-section
An identifiersuch as 2.5Q may appeardirectlynextto a cable.
This indicatesihe cablecross-section.
In this casethe cable cross-section(1) is 2.Smm'?.
' t ' t
it t t
1
. "F-r {
I
II
l
I
lt
i
1i' '.'-1
r
_ _.r,.i._
'l' _ _ _.r..i,_
'--
:',"
-27 -
T.EBHIRR
Prodo@dbv: weDiro/ Edition:13.02.07/ Version:1
)1.2.3 Cable identification/ core labels

The core label (1) providessourceand destinationreferencesfor a particularcore.
In this casethe sourceand destinationare -X50:2.3and -S17:30.2respectivelv.
Gore label:
=U+H-X50:2.3<ns>=u+H:g3[!
Explanation:
This core connectsconnectorblock-X50terminal2.3 to switch-S17 terminal30.2.both
of whichare in the chassiscab.
-28 -
UfBHTRR
Prcducedbv: lreoilo / Ediiion:i 3,02.07/ VeEioni 1
Locating the source:

Referto the resourceindextableto locatethe sourceof the core labelon the circuit
diagram.
Use the BMK (-X50)previouslydeterminedfrom the core labelto locatethe
corresponding
circuitdiagrampage(134.1)in the table.
Core label:
=U+H-X50:2.3<ne>=U+H-S1
7:30.2
_t
-:::9
i39.1
:33.:
-:1t9
:3e.1
:/
:11
r -x50
;; I
-tl
+H
I 1 9 .t
134.1
:39,5
Liebherr-WeftEhingenGmbH - Technicaltraining
-29 -
UEBIIERR
PDducedby: lwepio / Edilionr13.02.07/ Version:1

Gonnectorblock -X50(1) may be foundon page 133 column1.
The core labelindicatesthat it is Terminal2.3. (2)
Cross-reference(3) referencesthe 5th columnon page37.
Core label:
=U+H-X50:2.3<ne>=U+H-S1
7:30.2
Liebherr-WerkEhingenGmbH - Technicalt|aining
-30-
UEBHERR
UW 13 - Electricalcircuit diagram
Prcdlcd bv: lreoi.o / Ediuon:13.02.07
/ V6ion:1

The 5th columnon page37 alsocontainsconnectorblock -X50(1) withterminal2.3.(21.
Note:
Terminal2.3 also referencesthe destinationon page38.2.
Core label:
=U+H-X50:2.3<ne>=U+H-S1
7:30.2
Liebhen-WerkEhingenGmbH - Technicaltraining
- 3 1-
lEBDTERR
Prcducedbv: l@oilo/ Edilion:13,02.07/ VrsioniI
Locating the destination:

In orderto locatethe destinationof the core labelon the circuitdiagram,referbackto the
resourceindextable.
Use the BMK (17) previouslydeterminedfrom the core labelto locatethe corresponding circuitdiagrampage (38.2)in the table.
Gore label:
=U+H-X50:2.3<ne>=U+HjW:30.2
i l:.1
H5P16
:ll=.1
=[J
+H
8.2
=; L
t6r
t ii P a l
135,5
l1:
t:,3
8l
113
3iIJ
-32 -
UTBHTRR
Producedbv: l@oiro / Edition:13.02.07/VeFioni 1
Locating the destination:

Switch (1) -S17may be foundon page38 column2.
The core labelindicatesthat it is terminal (2130.2.
Gore label:
=U+H-X50'2.3<ne>=U+Hff :392
l ' i
-33-
T.EBTTERR
PFdued bv: lweoiro/ Ediiion:13.02-07/Ve6ion: 1
)1.2.4 Symbols for connectors

Connectors (1) are labellede.g.with -X8 17 and includea cross-reference(2) e.g.
{ 39.1to indicatethe pin assignment.
Liebherr-WerkEhingenGmbH- Technicaltraining
-34-
T.EBHINR
Producedbv: lreoiro / Edilion:13.02.07/ Ve6ion: 1
)1.2.5 Symbols for mech, switches

Mechanicalswitchesare eithermanually operated(1) e.g. -S23/ "Transfergearbox
neutral"or actuatedby meansof a pure mechanicalactuator (2) e.g. -564 / "Roadgear
ON" (camswitch).
+F
.ln
s-
lco
STRASSENGANG
EIN
-35-
IEBHIRR
Producedbv:lweoiro/ Edilion:13.02.07/ Ve6ion: 1
)1.2.6 Symbols for pressure switches

Pressureswitchesoperatewhen the air pressurerisesaboveor falls belowa specific
value.The switchtype can eitherbe Normallyopen (1) or Normally-closed(2).
Example:
Switch-S114opensat pressuresin excessof 5 bar.
-srt+[f
-36-
UEHTRR
Pbdlced be: lweDiro/ Edition:13.02.07/ VeBion: 1
)1.2.7 Symbols for inductive switches

The alternatingelectro-magnetic
fieldof Proximity switch (1) will changewhen it approachesmetal.
This in turn changesthe drawncurrent.
A pre-definedswitchingthresholddeterminesthe distanceat whichthe switchcloses.
- 3 7-
TEHINR
Produed bv:lweDiro/Edition:13.02.07/V66ion: 1
)1.2.8 Symbols for valves

Valves(1) are actuatedvia EAMsor CPUs.For example,theyopenor closethe oil circuit.
The free-wheeling
diodeservesto reduceinductivevoltageswhichoccurwhen the valve
is switchedoff.
Liebher-WerkEhingenGmbH - Technicaltraining
-38-
UETtrRR
Gomponent
description
UW 13 - Electricaleircuit diagram
Prcdlced bv: lreoiro / Edition: 13.02.07 / VeBion: 1
)1.2.9 Symbolsfor proportionalvalves

Proportionalvalves(1)aresymbolised
usingan additional
horizontal
line.
just
two states.The magnitudeof the currentdeterProportional
valveshavemorethan
minesthe flowrate.
Forexample,valve-Y66closesat a currentof 0.7[A].At currentsabove0.7[A]the proporto the riseof current.
tionalvalvewill openin proportion
\.,,1
,
::l
:Rtr.lRr . :Alli,lR< !Rt:lirrrl:
Liebhen-WerkEhingenGmbH - Technicalkaining
-39-
T.EBHIRR
UW l3 - Electricalcircuit diagram
Prodo@dbv:lreoiro / Edition:13.02.07/ Ve6ion: 1
>1.2.10Design and function of relays / relay contacts

Relaysgeneral;
A relayis composedof a coil with a magnetic core (1),an armature(2) whichactuates
at leastone change-overcontactand a free-wheelingdiode (3).
Note:
The free-wheeling
diodeservesto reduceinductivevoltageswhichoccurwhen the relay
is switchedoff.
Liebher-WerkEhingenGmbH- Technicaltraining
-40-
UEBHTNR
Component
description
UW l3 - Electricalcircuit diagram
Producd by: lwgpilo / Edilion: 13.02.07 / Vion; 1
Relaysgeneral:
Relayshavetwo separatecircuits,a control circuit (1) anda working circuit (2),
Controlcircuit (1) consistsof a switchand a relaycoil.
Workingcircuit (2) consistsof a relaycontactand load.
24V
'
L-=
Liebhen-WerkEhlngenGmbH- Technicaltraining
Onlyfor LIEBHERR
Servicepersonnel
-41 -
Poduced by. wpno/ Ed I on. 13.02.07/Ve6ion: 1
Relays general:
labelled.
Relay contacts (1) are individually
Test circuit (2) is fittedto the side of the housingcover.
The contactlabelscan also be foundon circuit diagram (3).
ilcl
Liebher-WerkEhingenGmbH - Technicalt.aining
Onlyfor LIEBHERR
Servicepersonnel
-42-
UEBHTRR
Produ.edbv: l@oiro / Edition:13.02.07/Ve6ion: 1
>1.2.'|1Symbols for relays

Symbols for relays:
lf 24Y andgroundare appliedacrossa relay coil (1) e.g. -K18,the relayclosesand
switchesits contacts.
The voltageappliedto the relaycan be tracedbackto indicatewhetherthe relayhas
beenactivated.
E.g.if -K18 is actuatedusingbutton (2) -S3 on masterswitch1 (left).
Relay-Kl B includesone relay contact (3).
Thereis a cross-reference
to page 141.7.
-K1B
may be foundon this page.
Relaycontact
r' lt
t
'
- - l
ll
"-l
-J.- |
-43 -
UEBHENR
UW 13 - Electrical circuit diagram
Poducd bv: lwgoio / Editiod:13.02.07/VeFion: 1
Relay contact (1) switchesthe loads"ON" and "OFF".

Relaycontactsmay be used in normally-closed,
normally-open
or change-overconfigurations.
Note:
Relaycontact-K18is normally-open.
The relaycontacthas a cross-reference
to page98.7.
Relaycoil -K18 may be foundon this page.
-k18
J30
t99,7 t'
83
t r t r
.-^!:,rlr;tt_r A_::)r, ;1!ii'iii1li1!E+-Ei,
-4-
T.EBHIRR
Produced bv: lreoiro / Edition: 13.02.07 / VeFion: 1
A relaye.g. -K51can alsoconsistof severalrelay contacts (1).

ln this case each of the relav contactshas its own cross-reference.
"" '= l+
r-----------------r
I ii;x
.. I
;l
'*'
'-1.:.-','
-45-
UEBHERR
Producedbv: lwgoilo/ Edilion:13,02,07/ Ve.sion:1
30,50
startswitch/ C1.15,
>1.2.12lgnition
I
i a*
.-;
-46-
UIBHTNR
PFdled bv: lreoiro / Editon:13.02.07/VeBion:1
Summaryof the most importantterminalsignals:

.
.
.
.
D 3 o( 1 )
30 (2)
15(3)
50 (4)
\
(+) Baftery iiliro,,roi-ie
(+) Batteryswitchedaftermainbatteryswitch(blue)
(+) Batteryswitchedafterignitionstartswitch(red)
(+)Starter(green)
:11f .
::+-
:1A
, _ . , L _ _ . - _ _ . L . _, . _
- 4 7-
lftBHTRR
P.oducdby: lsdrc / Edition:13.02.07/ Vlsion:1
>1.2.'13Gircuit diagram in PDF format

Acrobat Reader:
The Acrobat Readermay be used to view circuitdiagramson the PC.
Liebher.-Werk Ehingen GmbH - Tecinical training
Onlyfor LIEBHERR
Servicepersonnel
-48-
Producedbv: l@oiro / Edilion:13-02.07/ Ve6ion: 1
>1.2.14Usingthe BMK-list
General:
The BMKlist is usedto locateand searchfor all electricalcranecomponentssuch as
switches,valves,relays....
(OW).
The BMKlist is sub-dividedintothe chassis(UW)and superstructure
Thereare two methodsfor locatingresourcesin the BMK-list:
o Via the tableof contents
. Via the index
Technische Information
LTM 11OO-4-1 ab Krannr. 063 449
Ubersichtder Bauteilemit BetriebsmittelKennzeichnung(BMK)
TECHNISCHE
DATEN:
. max.Traglastbei2,5 m Aushdung:
100t
. max. Hubh6he mlt Ooppelklappspitze:
84 m
. max. Alsladunq mil DoppelklappspiEe:
58 m
. Teleskopauslegeruinge:
11.5- 52m
. Ballastvarianten:
0.81bls max.22 t
KOMPONENTEN:
. Aktive HinlerachslenkunS:
3. und 4. Achse eleklrohydfaulischgelenkt
. Fahrmotor:LiebherrD 846Tl A7 CommonRail
.Automalisirtes Schaltsetriebe:ZF 12AS 2302
. Kranantrleb:LlebherrD934Tr-E46 PLD
. Datenbus-Technik
mit 2 CAN-Bussnund 3 Ls-Bussen
b E
Liebhen-WerkEhingenGmbH- Technicaltraining
-49-
l|IAHERR
Producedbv: lweoiro/ Edluon:13.02.07
/Ve6ion:1
Table of contents:
The tableof contentsfor the UW and OW is sub-dividedinto severalsubiects
pagenumber.
and referencesthe corresponding
ir- ffi
-{'.u,r,,
*"" -\
Anschtvdvdn,
AEmhhg
Aisich /d
oruckbesrenzunssvatil im Krofinofi5ysls
Hohls.hruben
zu DrrknaMerungim Kr.frstoffst5rem....,...
..,.
.., . Zg
hihlen, BeleLEhtrn
Abslutabedieninheic
Seitsma*irunqs|eudnen.e.hs ...........................5
Ab,lt$cdi"rFir heil Seie nr+iaunqsl-udnFrlink.
a
Wasggkuhhe tuare AL'gasmkn-hrurE
Inrenbleuc|nug,Turn
Lufrug
33
.........
Kihlffi
und W:lfrela6cher
d-NiMU
Motdeurgsat,
Miftelkssole - H.uptsh.ltei g.netun SictErungen,Spannungswandler. l0

1t
Minelkonsole E/A lvloduleod Oaqnoredecker
12
Mirelkdde - Beeuckun$modul,
Inbder ECll
t3
Miftlkonele
- SLcheuge.
Drkseber urd \bnlile der Bretudaqe

KmpressorundTrockner
VefrilblGk lilGrerbrawhq
4 KaEl
16
Kr.heofi
hd -Tspebntr
Luldhedruck
Vorfher und T.nk
Adodasii.sSchahg.uiebe
ZF 12 AS 230? hn Inbtder: .......-.-..........

37
K u p p l u n g su- n d G e r i e b e s r e l l r
Pumpen, Lunsanrbb
od
......-.-....37
KuHndage
ABV AnsteErlerlte
Veneilergerieb
VG 2600- KontakEchah*
!nd Taclb!bd.,.....,..
... ... ,,..41
- UmsctEltdgSvossertce&indeg.ng
Veneilergeriebe
,,,,.,,,,,,,....,,..,...,,,,.,
42
Kontakrs.tElter an Ache I und 2
43
Motdansicttr
Kontahsch.lter
SclwungEdseite
. . . . ..... . . . . . . . 2 2
Krafreoff-sryice-Ceder
an Ache
3 und .l
Raddhahl-Sn5i)6.,.,.,....
Wi.belsoodbmeTelh. Fo6l F 2200'
45
KSC
LTM1100-4.1 - Unterwagenab Krannr.063 449. BMK- Baureiteubersichr
-50-
UEBHERR
Poduced bv: lweoio / Edition:13.02.07/ Ve6ion: 1
lndex:
in the BMK-list
The indexis an alphabeticlistingof all resources
togetherwith
pagereferences.
LTM 110o-4.1 - Unterwagen ab Krannr. 063 449 . BMK- Baureiteobersichr
M12...1
M1e...5:l
M20.,.
Mzt..g
M?m .20
MP0,.,52
MP1S20...4S
N
N1..56
P
R
RS.3l
Rr6..61
R25..12
S
s t . .t 0
5,1..9
s5...0
s12...7
s13,.,7
514...7
515...7
s16..7
s17.9
518.9
519..9
522...11,3a
523...r3
S30.,,ll
s31.,.13
s33.,.41
s.|l.,,,t3
s,r2...13
543...13
s44,.13
s50...60
5 5 r. 5 S
s60..5e
s61..5e
s62...58
s63...58
564...,12
s65...,r2
s89...53
sq0...52
5114...15
5r18..,47
5119...!
5159',,,e
s191...5
U
ul..t0
Y42...19
Y43...10
X
x2,o...3s
x4!..37
x45...37
x56...61
x64,,.9
x65..,9
x90...fl
x91...11,35
x92,..n,37
x93,..11,38
Y5...,rS
Y10...59
Y1r,.,59
Y1l..60
Y16..59
Y17..59
Yl8,.60
Y19..@
Y20,,17
Y24,.11
Y25 1t
- 5 1-
Yi0...3s
v5t'.17
v53...33
Y55...17
Y66...17
YS0!,..55
YSob...55
YS1a...55
Y01b,.,55
Y82a...55
YS2b...55
Y81a..,55
Y83b...55
Y8.lb..5,1
Y35b...5,1
Y86b..,5,1
Y102a.,.15
Y102b.,.15
Y107...8
Y10S...8
Y109...8
Y220..53
Y221...54
Y222..53
Y225...14
Y2?6..53
Y231...52
Y232...52
Y102.,32
r7O3..,24
y 1 1 1. 2 ?
v712...22
f113...22
v114...22
Y715,.,22
y116..22
UEBHERR
Pdduc6d bv: lweono/ Ediiion:13.02.07/ VeBionr1
Mainsection:
The mainsectionof the BMKlist illustratesand labelsall electricalresources.
The followingresourcedata is providedby the BMK:
o Installationlocation
.
(BMK)e.g. -S41
Resourceidentification
o (if relevant)the LSB address
o Additionalinformation
AnEiebstrang:
Koniaktschalteran Achse 3 und 4
Antriebstrang:
Koitaktschalter an Achse 1 und 2
s41
s42
Aclre I aeealDhr
2
alerdifi.'SPercAchse
LTM 1100-4.1 - Unterwagen ab Krannr. 063 449 . BMK- Bauteileribe.sicht
Liebherr-WerkEhingenGmbH - Technicalkaining
Onlyfor LIEBHERR
Servicepersonnel
-52-
1IEBHIRR
Poduced by: lwepiro/ Edluon:13.02.07/ Ve6ion: 1
PDF (Acrobat Reader):

The BMKlist can also be viewedusingthe AcrobatReader.
Tech nische I nformation

LTM 11OO-4-l ab Krannr- O63449
Ubersicht der Bauteile mit Betriebsmittel Kennzeichnung (BMK)
TCHNtSCHE DATENI
. n4. rrrgr.3r b.l r.t marsr.dlnE:
. mar. subhdhmir tlpp.rxrappspiE
.narAushdung mlt Ooppolkhpp6plts:
! m
. Lrsk.p.usr.grklng6:
r1,5- 52i
KOiTIPONEtITEN:
. Ak v6 tirnlcr.cnsrcnkung:
a unda Ach$ .|okronydburb.n q.r.nkr
. A!rom$|s|.n* sch.ngot.rob.:zF12As2102
. K..nanl ,ob:Llbher D034TrEA6 PID
. Dabnbustrchnll mll2 cAN-Bus<en
und, Ls-Buss.n
Liebherr-WerkEhingenGmbH- Technicalt|aining
Onlyfor LIEBHERR
Servicepersonnel
-53-
UEBHIRR
Component
description
PrDdu@d bv: lweoiro / Edition: 13.02.07 / Ve6id:
Liebhen-WerkEhingenGmbH - Technipaltrair ng
Onlyfor LIEBHERR
Servicepersonnel
-il-
UW14- Heating/
Auxiliaryheater
Onlvfor LIEBHERRServiceoersonnel
UW 14 - Heating/Auxiliary heater
Pmducedbv: lweoio / Ediiion:18 12.06/ VeFion: 2
lndex
...............4
1. Heating
................................10
2. Auxiliaryheater
2.1Category1.................
2.2Categoryll (40'C version).......
-3-
UEHTNR
Pbduced by: lwepi.o/ Edition:18.12.06/ Ve6ion:2
1. Heating
1.1General
)Purpose
The"standardheater"heatingsystemis usedto heatthe cranecab anddefrostthe windshields
whentheengineis running.
)Design
Valves
Watercircuit
- heating
Actuators
Displayunitwith
controllight
Auxiliaryheater"ON " /
Faultdisplay
Waterheater
pump
Circulation
Controlpanelwithbuttonsfor
heatingcontrol
Heaterunit
Thermo90ST.
Fig.1: Overviewshowinglocatonof installedheatingcomponentsincluding

heaterThermo90ST
auxiliary
* = Option (on mobile cranes with up to 5 axles)
Liebherr-WerkEhingenGmbH - Technicltraining
Onlyfor LIEBHERR
Servicepersonnel
_4 -
lTIBITIRR
P@ducedby: lwepilo/ Edilion:18.12 06 / Ve6ion:2
-M2'l
Controldrive
Air footwell/
Windshield
-A145
Drive
Fan
Heatexchanger
.M20
Controldrive
Recircul
air/freshair
viewx y'
Fig.2: WaterheaterunitchassisLTM1220-5.1
Fig.3: Heatexchanger
waterheaterunit
Outlet heatedair
Windshield
Fan
Heatexchanger
Ventilationflap
Footwell/ window
Heatexchanger
Water- heating
Outletheatedair
Footwell
View X
Ventilationflap
Recirculatedairlfreshair
Intakerecirculatedair
Intakefresh
atl
Fig.4: Waterheaterunitchassis- Internallayout
Onlyfor LIEBHERR
Servicepersonnel
-5-
lTTBHIRR
P'oducedby: lwepno/ Edition:18.12.06/Ve6ion:2
Pre-heatcab
lncreaseblower
speeo
Engine-dependent
AuxiliaryheatingON*
Reduceblower
speeo
Fig. 5: Controlpanelior heatingcontrol
Recirculatedair
Freshair
Windshield
Footwell ventilate
ventilate
-Y107
Valvewatercircuitheating
Enginerunning:
Valveopen
Engineat standstill:
Valveclosed
-Y108
Valvewatercircuitheating(switched)
/
Coldcabandenginepre-heating
Fig. 6: LTM 1220-5.1- Valveswater circuit
-Y109
Valvewatercircuitheating(switched)
/
pre-heatcab
. = Option
-6-
llElltRR
UW14'Heating/Auxiliaryheater
Prcdued by: lwopiro / Editon: 18.12.06 / ve^ton: 2
Coolantpump
Fig. 7: Coolantpump - D846-A7
Returncab/ from
heater
Liebhe.r-WerkEhingenGmbH - Technicaltraining
Onlyfor LIEBHERR
Servicepersonnel
-7-
UEHTNR
Prodlced bv: lsedlo / Edition:18.12.06/veclon:2
)Function
(Coolantgircuit)
1
2
3
4
5
Heat exchangervehicleheating(waterheater unit)

Dieselengine
Waterpump(coolantpump)
Cooler
Regulationvalve
Fig.8: Overviewof heatingsystemwithout auxiliaryheater
The water-cooled
dieselenginewarmsup duringoperationand the heat is transferredto
the watercircuit.
The pushbutton"Pre-heatcab"/ "Pre-heatengine"on the controlpanelis usedto modify
the switchingratioof the watercircuitvalves(-Y108and -Y109).
When the pre-heatedcoolantflowsthroughthe heat exchangerin the cab water heater
unit,the air is heatedand distributedby a blowerintothe cab.
Threepossiblesituationscan arise:
The engineonly heatsitselfup
The engineonly heatsthe cab
The engineheatsthe cab as well as itself(seefigure2).
Normalposition:
. The cab is pre-heatedusing1/3 of the heatingpower(stage1 - heatedwindshield
- SFlbrecirculated
air withfreshair content)
. The engineis heatedwith 213of the heatingpower
-8-
UBITERR
Producedbv: lEoilo / Edilion:18.12.06/ Ve6ion: 2
-Y108
Watercircuitvalve
Heating(switched)
/
tr
-Y107
Engine
pre-heat
/ preValvewalercircuitheating(switched)
heatcab
Fig. 9: Overviewof heatingsystemwith auxiliaryheater/ engineas sourceof heat
-9-
lIIBIIIRR
Prcducedby: lwepid / Edition:18.12-06/ VeEion:2
2.Auxiliaryheater
2.1Category|
2.1.1Waterheater- Thermo90S/90ST
)Purpose
is usedto pre-heat
water-cooled
enginesandactsas
Auxiliary
heaterThermo90S/90ST
thevehiclewindshields.
heaterfor heatingthethecabanddefrosting
an independent
)Design
S"-=--'
Auxiliarvheater:
lfnermo SOSISOST;
1 Combustion
air blower
2 Fuelconnection
3 Temperature
sensor
4 Temperature
limiter
5 lnlet- coolant
pump
6 Circulation
7 Outlet- coolant
8 Outlet- exhaustgas
9 lnlet- combustion
air
10 Control
unit
11 Buttonfor switchingon after
limiterhasbeen
temperature
activated
Fig. 10:Auxiliaryheater*
-A130
Controlunit
Auxiliarv
heater
-A131
Heaterunit
Thermo90ST
Fig.11:AuxiliaryheaterThermo90ST.
-10-
UIBHINR
UW 14 - Heating/ Auxiliaryheater
Prcd@d by: lwepio / Edition:18.12.06/VeBion:2
Controllight
heater"ON" /
Auxiliary
Faultdisplay
-M19
pump
Metering
heater
auxiliary
Fig.13: Displayunit
Fig.12:Meteringpumpauxiliaryheater
Fig. 14: Buttonenginepreheating
Fig.15:Timerauxiliaryheater"
Uebherr-WrkEhingonGmbH - Technicaltraining
Onlyfor LIEBHERR
Servicepersonnel
- f
lIEHINR
Producedbyr lwepid / Edition:18 12 06/ Version:2
)Function
tilil
o
Controllines
Fuelpipe
Exhaustpipe
Watercircuit
1
2
3
4
Heatexchanger
vehicleheaiing
fimer*
Dieselengine
Heaterunit
^:.^, ,r^1i^- ^..-^
c
6
7
urlcurauon
PumP
Walerpump(coolantpump)
Cooler
11
I
8
9
10
11
13
Regulation
valve
Exhaustsilencer
pump
Metering
Fuelsuctionoroe
12 Controlunit
13 Fueltank
Fig.16: Overviewof heatingsystemwith Thermo90S/STauxiliaryheater
The auxiliaryheateris switchedon usingthe "AuxiliaryheaterON" buttonor via the timer*. The waterheaterunitfunctionsindependently
of the vehicleengineand is connected
to the coolingsystem,fuel systemand electricalsystemson the vehicle.
Fuelis fed in externallyusingthe meteringpump.The heaterunittransfersthe heatgeneratedby the combustionof the dieselfuel intothe watercircuit.The circulationpumpensuresthat the coolantflowsthroughthe vehiclecircuit.The circulationpumpis switched
on by the controlunit.lt runsthe wholetime that the heaterunit is in operation.
the switchingratioof the watercircuitvalves(-Y108and -Y109)(Fig.2 and Fig.3).
. = Option
Onlyfor LIEBHERR
Servicepersonnel
-12-
IIIBHINR
Poduced bv: weono/ Ediuon:18.12.06/ VeEion:2
The sourceof heatcan be the engine,auxiliaryheateror both.Thereare threepossible

CASES:
.
.
.
Case 7; The engineis running(warm)and the auxiliaryheateris switchedoff

(seefig. 2).
Case2: The engineis turnedoff (cold)and the auxiliaryheateris switchedon
(seefig. 3).
Case3: The engineis running(warm)and the auxiliaryheateris switchedon (no fig.)
The timer*is usedto selectthe time at whichheatingcommencesin a time windowof up

to 7 davs.
-Y107
Valvewater circuitheating
Enginerunning:Valveopen
Valveclosed
-Y108
Watercircuitvalve
/
Heating(switched)
Heat cab
Freshair /
Windshield/
recirculatedair footwell
Engine
pre-heat
-Y109
Valvewater circuitheating(switched)/ preheatcab
Fig. 17: Overviewof heatingsystem with auxiliaryheatet - Engine is heating/
Auxiliary heater "OFF"
Servicepersonnel
Onlyfor LIEBHERR
-13-
UIBIIIRR
P.oducedby: lwepio / Edilion:18.12.06/VeBion: 2
-Y107
Valvewatercircuitheating
Enginerunning:
Valveopen
Valveclosed
-Y108
Watercircuitvalve
Heating(switched)
/
/
Freshair/
Windshield
recirculatedair footwell
+t
i+
-Y109
Valvewater circuitheating(switched)/ preheat cab
Fig.18:Overview
of heatingsystemwith auxiliaryheatet- Auxiliary heater
is heating / engine turned off
Onlyfor LIEBHERR
Servicepersonnel
-14-
llEHINR
UW 14 - Heating/ Auxiliaryheater
P r o d u c e d b y : l w e p i l o / E d i l i1o8n1: 2 0 6 / v e 6 o n : 2
1
2
3
4
10 11
13
14
--
Fueloioe
Combustion
air inlet
Combustion
air outlet
Water outlet
6
7
I
9
Combustion
air blower
Fuel connection
Glowplug
Bumer
Water outlet nozzle
Temperaturesensor
Flamemonitor
Pluggedconnection
Heat transfermedium
10
11
12
13
14
15
16
17
Combustionpipe
Temperature
limiter
Timel
Water fillingnozzle
pump
Circulation
Exhaustoutletnozzle
Meteringpump
Combustion
air fillingnozzle
heater
90S/,ST
auxiliary
Fig.19:Overview
ofThermo
)Fault diagnostics
The heaiingfaultdiagnosticsseryeto rapidlyidentifyany faults.SFlbThetype of fault is
indicatedby the flashingsignalson the Operationalindicatorlights -H628 on the display
unit.Afterfive shortsignals,countthe numberof longflashingsignals.
The numberof flashingsignalsallowsthe faulttype to be determinedusing
the codingbelow.
.
.
.
.
.
.
.
.
.
.
.
1x
2 x
3 x
4 x
4 x
6 x
7 x
8 x
9x
10x
11x
No start(after2 startattempts)
Abortedflame
Under-or overvoltage
flamerecognition
Premature
or short-circuit
Flamemonitorooen-circuit
or short-circuit
Temperature
sensoropen-circuit
pumpopen-circuit
or short-circuit
Metering
short-circuit
or
Blowermotoropen-circuit,
incorrect
soeed
Glowplugopen-circuit
or short-circuit
Overheating
pumpopen-circuit
or short-circuit*
Circulation
. = Option
Onlyfor LIEBHERR
Servicepersonnel
-15-
UIBNIIRR
Prcducedbv: lweoio / Edilion:18.12.06/ ve6ion: 2
)Fault rectification
Cancellingthe fault interlock:
A simplefaultinterlockmay be cancelledby switchingthe auxiliaryheateroff and then
backon.
Gancellingthe heating interlock:
In some casesa heatinginterlockmay occur.This is cancelledby interrupting
the operating voltagewhen the auxiliaryheateris switchedon
. lt is recommended
that the supplyfuse for the auxiliaryheateris takenout.
Liebhn-WerkEhingenGmbH - Technicaltraining
-16-
UIBIIIRR
Produeedby: lwepio / Editio.:18.12.06/ve6ion:2
2.2 Categoryll (-.40'Cversion)

2.2.1WaterheaterDBW2020
Purpose
enginesandactsas an indewater-cooled
is usedto pre-heat
Auxiliary
heaterDBW2020
pendentheaterfor heatingthethecabanddefrosting
thevehiclewindshields.
bythe
of -40",it is pre-heated
lf thedieselengineis startedat outdoortemperatures
DBW2020andAirtop5000untilit is ableto start.
withtheThermo90STwaterheater.
TheDBW2020
is notusedin combination
lDesign
1 Burnerhead
2 lgnition
unit
3 Coolant,outlet
(injection
tubeheating)
4 Thermostat
5 Heattransfermedium i
6 Exhaustoutlet
2
7 Control
unit1553/ 24V
. 5
Fig. 20: Overviewof auxiliaryheater DBW2020.56.
. = Option
- 1 7-
UIBlfiNR
Prcducedbv: lweoid / Edilion:18.12.06/veFion:2
Thermostatvalve 59'C
-A133
Heaterunit
D8W2020.32
-4132
Controlunit1555
Auxiliary
heater
t24V,90W,
23.3KW
Circulationpump
auxiliarvheater
Fig. 21: Auxiliaryheater D8W2020. in tool box - LTMl055-3.1
Cab circulation
pump
Fig.22:Cabcirculation
* = Option
Onlyfor LIEBHERR
Servicepersonnel
-18-
UTBIIIR
Producedbv: lseono / Edition:18.12.06/ ve6ion:2
) Function
1
hi
o
7
8
9
10
11
12
13
--1
Non-return
valve
pump
cab circulation
Cabheatexchanger
(waterheaterunit)
Valvewatercircuit-Y109
Cooler
tank
Coolant
expansion
Dieselengine
Themostatvalve59'
Non-return
valve
AuxiliaryheaterDW2020
pumpauxiliaryheater
Circulation
___:a __J
D 846A7
/ enginepre-heating
Fig.23:CoolingwatercircuitwithauxiliaryheaterD8W2020.65"
The auxiliaryheater(12) is switchedon usingthe "AuxiliaryheaterON" buttonor via the

of the dieselengine
timef. The auxiliaryheater(waterheaterunit)runs independently
and is connectedto the coolingsystem,fuel systemand electricalsystemson the vehicle.
Fuelis fed in usingthe internalmeteringpump.The waterheaterunittransfersthe heat
generatedby the combustionof the dieselfuel intothe SFlbwatercircuit.
the switchingratioof the watercircuitvalves(-Yl 08 and -Y109).The sourceof heatcan
be the engine,auxiliaryheateror both.
The auxiliaryheatercirculationpump(13) ensuresthat the coolantflowsthrough
the enginecircuiton the vehicle.
The coolantis pre-heatedin the shortenginecircuit.Whena temperatureof 59'C is
reachedin the shortcircuit,the thermostatswitchesthe coolantintothe maincircuitand
hencethe engine(Fig 1).
The cab circulationpump(2) ensuresthat the coolantflowsthroughthe cab circuiton the
vehicle.
The timer*is usedto selectthe time at whichheatingcommencesIn a time windowof up
to 7 davs.
* = option
-19-
IIIBHERR
Prcdu@dbv: lwe.ilo / Editionr1a 12 06 /Vecio.:2
21
20
Controlunii
2 Engine
3 lgnition
unit
Clutch
c
Combustion
air blower
6
Solenoid
valve
7 Plugconnector
o
Waternozzles
9 lgnition
electrode
1 0 Diffusernozzle
1 1 Thermalfuse
1
19
18
17
16
'12 Temperaturelimiter
13 Wateroutletnozzle
14 Heattransfer
medium
15 Combustion
chamber
16 Torsion
body
17 Exhaust
outlet
18 Flamemonitor
pump)
19 Fuelpump(internal
metering
20 Fuelpipes
21 Fuelinletwithregulation
15
't4
Fuelpipe
Combustion
air inlel
Combustion
airoutlet
Wateroutlet
Fig. 24: Overviewof auxiliaryheater D8W2020.65-
* = Option
-20 -
UIBIIIRR
P.oducedby: leepio / Edition:14.12.06/VeBion:2
2.2.2 Cab air heater AirTop2000S

)Purpose
TheAirTop 20005 air heateris installedon -40'C models(Cat ll) in additionto the auxiliary heater(D8W2020waterheater).
It is usedas a rapidindependentheater,whichis usedto heatthe cranecab and defrost
the vehiclewindows.
)Design
-A-134
Controlunit
Auxiliary
heater
-A135
Heaterunit
AirTop2000S
Fig.25:Auxiliaryheater/ air heater- AirTop20005-
-s25
Rotaryswitchair heater
. Switching
onioff
. Settingtheheateroutput
. Faultindicator
(blinkercode)
. Release
afterfault
Weekday
'llmer
Fig.26:
auxiliary
heater*
/
rotaryswitch
Alarmdisplay
Storagespace
Time
display
Operational
Standard
clock
withalarm
ProgramselectionlmmediateRetumflow Supply
heating
* = Option
-21 -
UTBHTNN
Component
description
PEducedby: lwepiro/ Edition:18.12.06/VeBion:2
)Function
1 Rotaryswitch
2 Heaterunit
3 Heatlransfermedium
4 Heaterblower
pump
5 Metering
6 Fueltank
Controllines
Fuelpipe
Exhauslpipe
lntakeair
Fig. 27: Overviewof heatingsystemwith AirTop2000S*
The rotaryswitchon the centerconsoleis usedto switchthe air heateron andoff and
determine
the heateroutout.
to
TheAirTop2000S
air heaterrunsindependently
of thevehicleengineandis connected
thefueltankandelectrical
systemson thevehicle.
pump.
Fuelis fed in usingtheexternalmetering
gasesresulting
fromthecomTheheattransfermediumis heatedby thecombustion
bustionof thedieselfuel.Theheatedair is directedbv thehotair blowerintothevehicle
compartment.
NOTE:
Changesin settingson the operatorcontrolsare executedby the
controluniVheater
unitwitha timedelav.
* = Ootion
Onlyfor LIEBHERR
Servicepersonnel
-22 -
UEHTNR
ttrHH8n
- 9Z-
ecrrues
louuosred
uu3Hsf 11roJ^luo
6ulu!e4lecluqoel- Hqug ue6uq3 VeM-xsqqn
6u[Paqard
auroua
uoung:62'6rl
NOreleeqfierlrxneuopng
- 0009oolrlvrolPsr4
rv :82 orl
l'e-990|,y!1"1
6u|}eoq-oJduorssrursueJl-SV
roJasoq 6u4eoH
0009dolrlV
lrunroleoH
i LgtVreleeqfuerlrxny
]!un
9StV-
eu!6ueleselp
uo duJnduorpalul
roj esoq6urleeH
u6;sag{
'dulnduolcefureurOue
leserpeq1leeq-erd
puesu:e}s,{s
uorsslursueJl
oruorf-sv}eaq-ordo1pesnosles! Jaleoqt;e ggggdolt;yeq1
'(releeqrole^
ozozMgcl)ralpoqruerll
-xneqllsorllol uonrppe
ul (ll le3) slopourO .0t- uo pellelsur
srroleoqre ggggdogryaq1
esodrn6l
ggggdo1.r;y
6ugleaq-ard
augEue
raleeq4V tZ'Z
z :uoEa^ / go-z t g I :uon!p3 / 0Lro.4 :^q p.snpord
rolBaqfte;;;xny/ FulleaH- tt Mn
uolldu3sopluouoduoS
uliltgn
'cz-
ocrruosuu3HEf ll roj Iluo

leuuosrad
6urure.4
leetuqcol- Hqurg us6utqf
ouqeaqleô
Jo
lrncJrc-Uorls lrncrc-uedo6n;dmolg
paooslsoJocur
'lrnorc-uado
i
ro llncrc-]Jor.ls
JoloruJolv\olE
Jolrnclrc-uedo
dund 6uueleyy
lrncrc-Uor.ls
ro
rosues
olnleledulof
lrncJrc-Uoqs lrncro-uedo
yncrrc-uedo
ro
lol!uott.tautpll
]rncJ!c-Uoqs
uorlru6ocer
oueU olnleuieJd
ebel;oruano
ro -lepul
eluBupauoqv
(slduape UelsZ laye) lels oN
oM-ltoqqol.l
x0L
x6
xB
xL
x9
xv
xv
xt
xz
xL
'(moleqees) burpoceq1
6ursnpeurulegopeq ol edfi llnpJeql s^ ollp sleuOtsOurqseg
JoJequlnuor1f
'sleu6ls6urqseg
6uo;1orequnu oql lunoo'sleu6rsUoLlsÛrUVqllS uoleoqrre ggggTdo;gyqlls r.ll
eq1Iq pelecrputst llneJJoed^l aqf
lo 9ZS-qclrAsfueloJuo OJ1eq1uo s;eubrsOurqseg
'sllneJIue Ilnuapr,{lprdelol eruasscnsou6etp
buneeqeq1
1;ne1
scglsou6elp
11ne3{
z :uors.A / 90 z f8l :lonrpl / 0jd.4 i^q pa.npqd
roleaqfte;!;xny/ oulleaH- tt Mn
uolldussopluouodruoc
Prcducedbl. lwepno/ Edition:18.12.06/ VeBion:2
ProgramselectionlmmediateReturnflow Supply
Fig.30:Tlmer
) Function
lf the temperatureselectionis switchedto "Coldcab" and the auxiliaryheateris switched
transmission
on by the bufton"AuxiliaryheaterON" or via the timer,the SFIbAS-Tronic
pumpare pre-heated.
systemand dieselengine-injection
of the vehicleengineand is connectedto
TheAir Top 5000air heatbrruns independently
the fuel tank and electricalsystemson the vehicle.
Fuelis fed in usingthe externalmeteringpump.
The heattransfermediumis heatedby the combustiongasesresultingfrom the combustion of the dieselfuel.The heatedair is directedby the hot air bloweronto the transmissionand the dieselengineinjectionpump.
Note:
and plug-inpumpsare heatedrespectively.
On CR and PLD enginesthe high-pressure
-25 -
UIBITTR
Producedbv: lweDno/ Edition:18.12.06/ Veeion:2
fuel tank - Auxiliaryheatingsupply(40' version)

2.2.4Supplementary
)Purpose
heateron -40'
the auxiliary
fuelfor supplying
fueltankholdsseparate
Thesupplementary
models.
)Design
-M36
pump
Metering
heater
Auxiliary
AirTop5000
SFlb(AirheaterAS-Tronic
/ fuelpump
transmission
pre-heating)
-M35
pump
Metering
AirTop2000S
heater
auxiliary
(airheaterin cab)
fueltankfor Cat. ll- - LTM1055-3.1
Fig.31: Supplementary
)Function
fueltankto theair
pumpsfeedtheseparate
fuelfromthesupplementary
Themetering
amountof fuelis supplied.
Onlytherequired
heaters(Airtop2000s/5000).
provides
fuelflow.
a constant
fuelpumpon the DBW2020
Theinternal
musthavea supplyandreturnline.
fuelpumptherefore
Theinternal
Servicepersonnel
Onlyfor LIEBHERR
-26 -
UEHIRR
Produed qr hplto / Ediltbn: 1a-12,06 / VeFion: 2
Liebhen-Werk Ehingen GmbH - Technical training
Onlyfor LIEBHERR
Servicepersonnel
-28 -
UW18- Others/Accessories
Projectnumber:
9996008
servicepersonnel
Onlyfor LIEBHERR
UW 18 - Others/Accessories
Prcdu@dby: l@pid / Edilion:11.06.07/VeBion:2
lndex
Trailing axles
1. LWE Trailing axle
Liebherr-WerkEhingenGmbH - CustomerServiceTraining
-3-
UEBIIIRR
P@d!@d b!. lwepilo / Edition: 11.06.07 / Ve6ion: 2
Trailingaxles
1. LWETrailingaxle
)1.1 Purpose
The trailingaxle is an optionalaxlewhichcan be attachedto specificvehiclemodels.
Attachingthe trailingaxle increasesthe maximumpayloadof the crane,for exampleto
allow extra ballastto be carried.
The maximumpermittedoverallloadis determinedby the numberof axlesmultipliedby
The penaltiesfor any
the permittedaxle load.The maximumaxle load is country-specific.
on
the
country.
excessloadwill also be handleddifferentlydepending
For example,if a craneoperatorwantsto carrythe full additionalballastfor a particular
craneoperation,it couldoccurthat the mobilecranewithouta trailingaxlewill exceedthe
maximumpermittedaxle loadfor roaddriving.
The hailingaxle is attachedto the rearof the mobilecrane.The total load is therefore
distributedbetweenthe axlesof the mobilecraneand the trailingaxle.
Mobilecranesfitted with trailingaxles thereforeallow the crane operatorto carry additionalballast.
)1.2 Layout
Fig. 1: LTM 1200-5.1withtrailingaxle

Liebhe.r-WerkEhingenGmbH - CustomerServiceTraining
Onlyfor LIEBHERR
servicepersonnel
-4-
UEHTNN
Others/ Accessories
Produ@d by: lwepid / Editjon: 11.06.07 / Ve6ion:2
with the exceptionof the

The activerearaxlesteeringfor the trailingaxle is independent
powersupply.The trailingaxle can thereforealso be fittedto mobilecraneswithout active rearaxle steering.
The mobilecranemustbe preparedaccordinglyfor operationwith the optionaltrailing
axle:
. Additionalanglesensorson the first and last axlesof the mobilecrane
. Electricalpreparations
. Hydraulicpreparations
. Cab controlinstruments(controllights and buzzer)
. Mechanicalpreparations
12t
Counterweight
Contentin box 0.61
Support
plates6.641
Fig.2: LTM 1200-5.1withtrallingaxleand counterweights
101
Counterweight
Counterweight
supports0.37t
framewith
Counterweight
toolkit0.75t
servicepersonnel
Onlyfor LIEBHERR
- 5 -
T.IEIITRR
UW 18 - Others/ Accessories
PmdEed by lrep|lo / Editon: ri 06.tt / veBid:
Therearetwo typesof trailingaxleswithactiverearaxlesteering:

. Trailingaxlewithdrumbrakes(Fig3)
. Trailingaxlewithdiscbrakes(Fig4)
Fig. 3: Trailingaxle wilh drum brake
Note:
Trailingaxleswithdrumbrak6sshouldonlybe fittedandoperatedon craneswithdrum
brakes,otherwisean errormessageis outputandthe trailingaxleis allowedto coast.
newaxlesuspension
cylinder
Fig.4: Trailingaxlewithdiscbrakes
Trailingaxleswithdiscbrakesshouldonlybe fiftedandoperatedon craneswithdisc

brakes,otherwisean errormessageis outputandthe trailingaxleis allowedto coast.
Liebhen-Werk Ehingen GmbH - Customsr Sewice Training
Onlyfor LIEBHERR
servicepersonnel
_6 _
UEIIRR
- Others/ Accessories
P@ducedbv: lweoio / Edilion:11.00.07/ VeEion:2
Type identificationfor vehicle and trailing axle:

The I / O modulesdetectthe connectedvehicletype by queryingthe pin assignmentof
both Harding-connectors.
(discbrakeswith drum brakes)to be
For example,this allowsprohibitedcombinations
detected.
Oncethe vehicletype is known,the lengthof the vehicleis also known.The steeringangle calculations
can then be made.
At presentone differentiatesbetween 12 differentvehicletypes:
Drumbrakes:
Typel:
fype2:
Type3:
Type4:
Type5:
Type6:
TypeT:
LTM1055-3.1
LTM1045-3.1,
LTM1045-3.1,
LTM1055-3.1(CR,PLDengine)
LTM11004.1
LTM1090-4.1,
1220-5.1
11
00-5.1
LTM
LTM
,
LTM1100-5.2
LTM1095-5.1,
LTM 1070-4.1
LTM ''|070-4.1(CR, PLD engine)
Disc brakes,first availablewith these engine interfaces:
TypeS:
Type9:
Type10:
Type'l1:
fype12:
(mechanical)
LTM1045-3.1,
LTM1055-3.1
1 (mechanical/elechical)
1, LTM1055-3.
LTM'1
045-3.
LTM11004.1
LTM1090-4-1,
LTM1150-5.2,
LTM1200-5.1,
LTM1130-5.1
LTM1095-5.1,LTM1100-5.2,
LTM1220-5.2
LTM1070-4.1
Liebhen-WerkEhingenGmbH - CustomerServiceTraining
_7 _
lIEIIRR
PDdued by: l@pilo / Edition: ll .06.07 / veBion: 2
Mountingpointstrailingaxle
holestrailing
Pinning
axle
Fig. 5: Mechanicalpreparationstrailingaxle
Four-foldliftingchains
Fig. 6: Trailingaxle conectlyattached
servicepersonnel
Onlyfor LIEBHERR
-8-
UEHINR
P f o d u c e bd y r l w e pO / E d t i o n : 1 1 0 60 7 / v e E o n : 2
Leverto releasethe salety plate

(allowsthe lrailingaxle to be unpinned)
Boltwith linchpin
rl
i'!
Directional
controlvalvewilh hand Supportfor trailingaxle
Ieverto controlthe pinningmecha- whenuncoupled
nism.
Liebherr-WerkEhingenGmbH - CustornerServiceTraining
servicepersonnel
Onlyfor LIEBHERR
_g _
Dualreleasevalve
(parkingbrakeand retarder)
UIBHIRR
Produ@dby:lwepio / Edilion:1106.07/ve6onl2
Bowdenwire
cable
Spring
Safety plateto
protectthe bolts
againstthe unintentionalrelease
of the pinning
mechanlsm
Pinningcylinder
Boltsfor mechanicallY
pinningthe trailingaxleto the
vehicleframe
Mountingpoints
Supportfor trailingaxle
whenuncoupled
Fig.8: Pinningand mountingthe trailingaxle

servicepersonnel
Onlyfor LIEBHERR
-10-
lIIBIIIRR
Prcducedbv: lsoill) / Edition:11.06.07/ V*id:
Fig.9: Installed
anglesensorshownon LTM1095-5.1
An additionalanglesensormustbe fiftedto the vehicleaxles(alwaysthe frontand rear

vehicleaxles)on the leftside of the vehicle.
Liebhen-werkEhingenGmbH - CustomerServiceTraining
Onlyfor LIEBHERR
servicepersonnel
_ fl
UEITRR
PEdled bv: lweDilo/ Edltion:IL06.07/VeBlon:2
-Y239
valve
Proportional
(BoschCANvalve)
-A181*
Brake pad
monitorright
-s57
Camswitchaxle
compensation
right
-A13
l/Omodule3
Supportcontrolun:tfor activating
the
testprograms"activerearaxlesteering
forthetrailing
axle".
-414
l/Omodule4
-s56
Camswitch
Axlecompensation
left
-A180Brakepadmonitor left
Fig.10: Installedsensors,modulesand valveson trailingaxle
-A13
l/Omodule3
-A14
l/Omodule4
rr'4
I
Supportcontrolunitfor activating
the
testprograms"activerearaxlesteeringforthetrailing
axle".
Fig.11: Controlcabinetfor the trailingaxle

* = Onlyon trailingaxleswithdiscbrakes
-12-
ITIBHINN
Pbdu@d bv:lweDiro/ Edilon: 1106 07 / vecion:2
1.3 Function
)1.3.1 Trailing axle, general
The trailingaxlesteeringfollowsthat of the vehicledependingon the vehicleoperating
mode.
betweenthe operating
On vehicleswithout"activerearaxlesteering"one differentiates
vehicles
with
activerear axlesteermodes"rearaxlesteeringlocked"and "released",on
betweenthe operatingmodes"roaddriving"and "off-road
ing (AHL)one differentiates
driving".
In orderto indicatethe operatingmode,vehicleswithAHL are equippedwith an interface
to the keyboardunit in the cab whereasvehicleswithoutAHL have an interfaceto mesteering
chanicallyoperatedcam switcheson the rearvehicleaxle.The electro-hydraulic
pre-selecf
processors.
the
Depending
on
by
two
steering
axle
is
controlled
for the trailing
ed operatingmode,the steeringangleis takenfrom the firstor last vehicleaxleand then
adjustedaccordingto the vehiclespeed.
The foffowing steering paftern has been defined for vehicles with AHL:
. "Roaddriving":Steeringangleinputfrom steeringanglesensoron leadingaxle (front
axle)and oppositesteeringof NLAto permita narrowturningradius.
. "Off-roaddriving":Steeringangleinputfrom steeringanglesensoron last steered
site use (crab
of steeringprogramsfor construction
vehicleaxleand imple;nentation
driver
etc.)
steering,manualsteeringby the
The folfowing steering pattern has been defined for vehicles without AEL:
. "Locked":Steeringangleinputfrom steeringanglesensoron leadingaxle (frontaxle)
and oppositesteeringof NLAto permita narrowturningradius.
. "Released":Steeringangleinputfrom steeringanglesensoron laststeeredvehicle
site use (crabsteering,
of steeringprogramsfor construction
axleand implementation
manualsteeringby the driveretc.)
Liebhefr-WerkEhingenGmbH - CustomerServiceTraining
Onlyfor LIEBHERR
servicepersonnel
_ i3
rlIBHERR
Producsd by: lwepid / Edilid: 11_06.07/ Ve6ion: 2
)1,3.2 Pinningand unpinningthe trailingaxle

Movethe leverdownto pinthe trailing
axte.
Fig.12:Down= pintrallingaxle
Move the lever up and at the same time

pull the bolt pullingdeviceto unpinthe
trailingaxle.
Fig.13:Moveup andpullboltretainer= unoin

trailingaxle
Note:
The levercan no longerbe movedup if the
dooron thetrailingaxleis locked.Thisis
preventedby a studin the doorof the trailingaxle.
Thisprevents
thetrailingaxlebeingunpinnedby an unauthorised
person.
Fig. 14: Mechanicalprotectionagainst

the trailingaxle beingunpinned
Liebher-Work
Ehingen
GrnbH- Customr
ServicTraining
Onlyfor LIEBHERR
servicepersonnel
- ,14 _
UEHTNR
PEdued br lweono/ Editon:11.06.07/VeFion:2
ryl
f:r
i
. T J ] TL T] ]
Highpressure(suppliedby gearpumpfor steeringclrcuitll)

Controlpressureafterpressurereducingvalve24bar
pressurelbar)
Retumsteeringcircuitll (pre-tension
Loadindication
Dressure
- Pintrailingaxle
LTM1200-5.1
Fig.15:Excerptfromhydrauliccontrolschematic
servicepersonnel
Onlyfor LIEBHERR
- 15 _
UEHRN
P@dued by: lwepio / Edilion:11.0607 / Ve6ion: 2
)1.3.3 Openingand closingthe parkingbrakefor the trailingaxle

.
To closethe parkingbrakeon the trailingaxle,pull out the

red pushbufton.
To releasethe parkingbrake,push in the red pushbufton.
Note:
The parkingbrakecan be closedwhen uncoupledor attached.
Fig.16: Releasingand closing the parkingbrake
)1.3.4 Opening and closing the service brake for the trailing axle
Toclosetheservicebrakeon thetrailingaxle,pulloutthe
blackpushbutton.
pushin the black pushTo releasethe service_brake,
/
button.
Note:
The servicebrakecan only be closedwhen uncoupled.
Fig.17:Releasing
andclosingthe servicebrake
red pushbutton
pulledout=
parkingbrake
closed
blackpushbutton
pulledout=
servicebrakeclosed
red pushbutton
pushedin =
parkingbrake
open
black pushbutton
Dushedin =
servicebrakeoDened
Fig. 18: Releasingand closingthe service brake
Note:
The dual releasevalveis a boughfin part.This makesthe black pushbutton moreor
less redundant!
Liebher-WerkEhingenGmbH - CustomerServiceTraining
_ 16 _
llBHTNR
UUITIgN
ecrruas
lauuosred
uu3H83ll roJ^luo
-
8t
6ururerr
e.ln,esreurolsnc- Hqurgueourqa
rre,1,1-rJoqqor-r
arnssordcuaqdsourlv(:repessaldLuoc)
aJnssord
aNesarJlV 'uadoolerq 6urryed'(uedo)paleredo e)erq
lou
ualsls Jtepsssalduoculol] ldl$x3 :!z 6ll
aclrues- uor]rsod
6unupeqi uraFe 6ullle4roj sBeuraq9s
uoDnq
uollnq
-qsnd por -qsnd Icelq
outlloJluos
'6rues
lll lrncJlc
-ol atnssaJoiv
'pesolcsr alerq ourlredaql esr^Jei.llo'uoDnqqsnd por ql ur ourqsnd,t1lnl

uadoaq lsnura)erq butlled eq1
Iq penerqcesl slql' uorlrsoddurnupeql ur (pasunssaJd)
'olxe 6urlle4aLllJoJruolsls olerq aql ol rre pesserduocser;ddnsstql
'uortrsod6urnr.rp
o)erq ocrruoseql JoJ(uoDnqqsnd
eq1ol Iceq sbuuds,{llecr1eu.ro1ne
palceuuoc
eql ol
sl elxe outlterleql se uoossv
Icelq) e^le^ aseeleJeql'auerc olrqou-r
polProdolou alerq oelruos- olxe oulllPrl sr.llJo uolllsod 6u;npg g'g'11
z:uoroe /,t090 t|:uoflp: / 0Jda4:Iq panpord
solJossaccv/sror.llo- 8|, ,\ n
uolldllcsop luouoduog
louuosodacrruos
uuf H83ll roj ^luo
tnHltgll
Ll
ou!u!e{e3!^rosJouropnc- Hqureuaourq!,1,aM-!aqqa!'r
'pssunsseJd
sr ropull^c-dolsulaql uaq^ pesolcs! olerq ool^Jsseql
'posunsseJd
sr ropurlfic-dolsulaql ustlivlpousdosl elelq buryed eq1
:oloN
dolsurlo uorpunr:020u
rapurc ourrerq
6ursnpauado
JrPpasseJduro3
(uo[cas 6uuds)alaq 6uqre6
re passordLuoo
6ursnpasolc
aueJqLuaur)
oIBJqac!ruas
elaq 6ur4e6
elpjq ocNas
aFe ourle4eql rol urals^sre pesse:duo3:61 0t3

(elErqunrp ro] ^tuo)nEO
(JepreleJ
pueo)erq0uqred)
e4e^ aseolorleno
o
'eru3s
lllllncJ|3
-ar olnssalo Jtv
olxE 6u!l!pJloql uo sluouodruocuralsfs Jle passaJduoCI't't<
z :uorsA/ l0 !o ll :uoop3 / 0oo4t :^q p@npod
souossocev/sroqlo- g|,Mn
uolld!rcsopluauodruoS
P@dued by: lwepid / Edition:11.06.07/ Ve6ion:2
)1.3.7 Driving position of the trailing axle - service brake operated

Operatingthe servicebrakeon the mobilecranewill pressurisethe controlline.The compressedair appliedto connection1 on the trailerbrakevalveis fed to the Tristopcylinder
for the servicebrake;servicebrakingthen occurs.
Air pressurereserve,circuitlll
*#l+r
IiH Hf
blackpush- red Pushbutton
button
Fig. 22: Excerptfrom compressedair system schematicfor trailingaxle in the drivingposition- service
brakeoperated(closed),parkingbrakeopen.
air)
Air reservepressure(compressed
pressure
Atmospheric
\Jur ruur Pr voJ\rr e
Note:
Connection1 on the trailerbrakevalveventsafteruncouplingor if the air reservepressure pipeio the trailingaxleruptures.The full tank pressureappliedto connection1-2 is
fed to the brakecylindersfor the servicebrakevia connection2. The trailingaxle is then
automaticallv
braked.
Onlyfor LIEBHERR
servicepersonnel
-19-
UEHTRR
P.oducedbv: weoio / Editon: 11.06.07/ VeGion:2
)1 .3.8 Uncoupledstate of the trailing axle - park position

The black pushbutton is stillin the drivingposition(fullyextended).The air reservepressure is thereforeonlyappliedto connection1-2of the trailerbrakevalve.
lf no compressedair is appliedto connection1 of the trailerbrakevalve,the trailerbrake
switchesover.Connection1-2 is connectedto connection2 insidethe
valveautomatically
trailerbrakevalve.This causesthe servicebraketo close(pressurise).
Howeverthe brakingactionof the servicebrakewill reduceover time due to the effects
of leakage.The parkingbrakeshouldthereforebe closed(vented)afterthe trailingaxle is
detachedfrom the vehicle.This is achievedby pullingout the red pushbutton. Oncethe
air reservepressuredrops,the servicebrakereleasesand the parkingbrakeis appliedto
the samedegree.The trailingaxle is thereforealwaysbraked.
I-l
+El
l : t F t' i{
V:; -ar -l
black push- red pushbutton

button
Fig. 23: Excerptfrom compressedair systemschematicfor trailingaxle when uncoupled servicebrake

closed,parkingbrake open.
air)
pressure
Atmospheric
Liebherr-WorkEhingenGmbH - CustomerServiceTraining
_ 20 _
UIBIIIRR
Prcdled by: lwepno/ Edilion:11.06.07/ ve6ion: 2
Note:
The red pushbutton mustbe pulledout when the trailingaxle is detached.This causes
the parkingbraketo close(vents).Otherwisethe trailingaxleis not braked.
To immediately
closethe parkingbrake,pressthe black pushbutton afterdetachingthe
trailingaxle.Connection1 on the trailerbrakevalveis pressurisedand connection2 is
vented.This causesthe servicebraketo open (vented).
I
+ U
t
l
-h-i
cJ
t.
U Y
I --black push- red pushbutton
button
- servicebrake
for trailingaxlewhenuncoupled
Fig.24:Excerptfromcompressed
air systemschematic
open- parkingbrakeclosed.
air)
Atmosoheric
oressure
Liebherr-WerkEhingenGmbH - CustomerServicTraining
_ 21
IIIB|IINR
Prcdued by: lwepilo/ Edition:11.0607 / veBion:2
)1.3.9 Active rear axle steering components for the trailing axle
Pressurereducingvalve24bal
pressure
forhydr.adiust
(minimum
ingthe CAN-valves)
Coastingvalve
DBV
(limitsthemax.
steeringpressure
for externalwheel
impact)
t-
DBV
(limitsthe
max. internal steering
pressure)
--
,-
CAN Boschvalve
2-waypressurebalance
3-waypressurebalance
IIACHLAUfACHSE
Pinning
for trailingaxle
Thermalexpansion
tank
DBV
when
Loadindication
(determines
themaximum
the pressure
andpinning
unpinning
forpinningandunaxle
trailing
pinning
thetrailingaxle)
Fig.25: Excerptfrom hydrauliccontrolschematicLTM 1200-5'1:
Couplingthe hydraulichoses:
pressure.
hosesat increased
io couplethe steering
difficult
or extremely
It is notpiossible
to allowthermalequalisation'
A tankhasbeenintegrated
(dueto a risein temperapressure
to increased
maybe subjected
TheaxleSuspension
letdownwhen
be
completely
thevehiclemust
ture).In orderto dealwitfithissituation,
pressure
to drop.Any
Thiscausestheaxlesuspension
theirailingaxleis uncoupled
can
be coupledup.
axle
trailing
willnothavea seriousimpact;the
in pressure
increase
_ 22 -
UEHTRR
Prcducedby: lwepim/ Edition:11.06.07lVe6ion:2
>1.3.10Steeringoperationfor the trailingaxle
It
l i
Tankto allowthermal
equalisation
(supplied
circuitI or ll)
by gearpumpforsteering
Highpressure
pressurel bar)
Returnsteeringcircuitll (pre-tension
pressure
Loadindication
Fig.26: Excerptfrom hydrauliccontrolschematicLTI/ 1200-5.'l- Steeringoperationfor trailingaxle
Note:
lf the engineis runningand thereis no faultcondition,the hydraulicoil will continuallyflow
lf no hydraulicoil flowsthroughthe flow monitor,
throughthe flow monitor(transducer).
it indicatesa faultin the hydraulicsystemand an errormessageis output.This provides
monitoringof the hydraulicconnectionsand any potentialleaks.
_ 29 -
UBHTRR
- Others/ Accessorles
Podu@d by: lwepio / Editon:1106 07 / Ve6ion:2
fault conditions
)l .3.11Releasingthe trailing axle during
CoastingGY229notactive) i f-:t
i
II
I .FN
Highpressure(supplledby gearpumpfor steeringcircuitll)

pressurelbar)
Returnsteeringcircuitll (pre-tension
position)
betweenthe ringandpistonsurface(coastingor floating
Pressurecompensation
Loadindication
Pressure
@ematicLTM1200.5.1.Re|eaSingthetrai|ingax|eduringfau|t
conditions
-24 -
IIEIITRR
Prcdued by: lwepim/ Edilion:11.06.07/ Ve6ion: 2
>1.3.12Faultdisplayand fault handling

Onlyoperatethe cranewiththe trailingaxle oncecontrollight-H21 "Trailingaxlecondition"has extinguished.
lf controllight-H21 "Trailingaxle condition"flasheswhen driving,thereis a fault in the
steeringsystem.
Buzzer-H19 "Trailingaxlefault"soundsat the sametime to audiblynotifythe driverof the
faultin the trailingaxle.
switchesto "Coasting"
The trailingaxle is no longeractivelysteeredand automatically
(floatingposition).
of the vehicle.
This changesthe drivingcharacteristics
-H21
Controllight"Trailingaxlecondition"
-H22
Warninglight"Brakepadson trailing axleworn"
axle
Fig.28:Control
lightstrailing
-H19
Buzzer
axle
Faulton trailing
Fig- 29: Buzzet fault on trailingaxle

Liebherr-WerkEhingenGmbH - CustomefServiceTraining
Onlyfor LIEBHERR
servicepersonnel
_ ZS _
UIBHTNR
Component
description
Produed by lwepi.O/ Edilion:11.06.07
/VeBion:2
1.3.13 Hydraulicvehicle components

Mobilecranespreparedfor use with trailingaxleshaveseveraladditionalhydrauliccomponents,i.e.theydifferfrom machinerywhichhas not beenpreparedfor use with trailing
axles(see excerptfrom hydraulicschematicwith trailingaxle Fig Fig 31 and Fig 32).
largersteeringpump
Flowdivider
I
.
imij,Tr-"1
,l lil
Fig.30: HydraulicschematicLTM1200-5.1
withtrailingaxle
Liebhen-WerkEhingenGmbH - CustomerServiceTraining
_ 26 _
ITIBIIIRR
Produed btx l@pto / Editd: 11.06.071Ve6ion:2
-Y197
Changeover
oil
supply
mG
l'*d
l u E u H E R R w r {|
l*
Bs,3
Fig. 31: HydraulicschematicLTM1200-5.'lwith trailingaxle
Hydraulic
coupling:
Whenthetrailingaxleis not
attached,conneclpipesPNandTN.
Liebhen-WerkEhingenGmbH- CustomerSewiceTraining
Onlyfor LIEBHERR
servicepersonnel
_ 27 -
IIIBITIRR
Prcducedby: lwepiro/ Edilion:11.06.07
/VeBion:2
1,3.14Testsystemfor the trailingaxle

as wellas to starustop
thetest
Thesupportcontrolunitis onlyusedfor displaypurposes
programs
for thetrailingaxle.
ilIEHINN
TctlDaoqtafi|nc
( Unterwaoenl
@s!ss
Note:
The currentdescriptionfor the test
systemcan be queriedvia Lissy
usingprojectnumber9996008.
Fig-32: Descriptionof test systemfor the lrailingaxle
Fig. 33: Supportcontrolunit for the trailingaxle
Liebherr-WerkEhingenGmbH - CustomerSe ice Training
servicepersonnel
Onlyfor LIEBHERR
_ 2g _
UEHTNR
Functionaldescription
UW 19 - Emergencyoperatingmodes
Produ@dbv: lweoio / Edilion:06-06-07/VeFion:3
UW19- Emergency
operationfor the chassis
-1-
lIEHTNR
Produed by: lwepid / Edilion:06.06.07/ Vecion: 3
Note:
purposes
is for information
onlyandservesto improvethe
Thisdescription
understanding
of thereader.
Gaution:
Theoperatinginstructions
andtest programsfor a particularcranemustbe readbefore
givenin theoperating
lf in doubt,followthe instructions
attempting
emergency
operation.
program.
instructions
andtest
Liebher.-WerkEhingenGmbH - Technicaltraining
-2-
llBHTNR
Prcduced by: lwepio / Edilion: 00.06.07 / Version: 3
Index
1. Emergency operation - chassis
- support..
.............................5
1.1Emergency
operation
'1.2Emergency
- blower
conlro|......................
........................-...7
operalion
'1.2.1Emergency
- modelusing"blowercontrolwiththermalpressurevalves"..7
operation
- modelusing"blowercontrolwithhydrostatic
blowerdrive"...8
operation
1.2.1Emergency
..........................10
1.3Transmission
emergency
operalion.......................
forowc{ransmission
systems.........................10
1.3.1Emergency
transmission
operation
forAllison
transmission
systems......-.-.-............11
transmission
operation
1.3.1Emergency
Liebherr-WerkEhingnGmbH - Technicaltraining
-3-
UEIIRR
PEdued br lrep|lo / Edition 06 06 07 / Vecim: 3
Liebherr-Werk Ehingen GmbH - Technical training
-4-
UEHINN
Produed by: lwepno / Edilion: 06.06.07 / Version: 3
1. Emergencyoperation- chassis
)1.1 Emergencyoperation - support
In case of an electricalcontrolfailureon the directionalvalvesfor the support,it is
possibleto manuallyretracUextend
them on some cranesby pressingthe magnetic
pistonon the affectedvalve.The pressurestage must also be pre-selected.
As soon as the pressureon the magneticpiston is released,the actuatedmovement
is halted.To ensure emergencyoperationof the slidingbeams and support,
valve -Y5 "Oil supplysupport/ axle suspension"(-Y24 = old designation)must be
manuallyactuated.This requiresa special"valvecap" (Fig. 2) which is screwedonto
the magneticcoil of -Y5. The slidingbeams and supportscan be extendedor retracted by manuallyoperatingthe appropriatevalves.
Procedure:
- the engineis running
- the hydraulicsystemis operational
- the pressurestageis pre-selected
LTM1100-4.1
/ axlesuspension
Fig.1: Pressure
supplysupport
Note:
On cranemodelsLTM 1030-2.1
and LTM 1040-2.1valve caps
must be screwedonto two directionalvalves(rotationvalves).
.Y5
Oilsupplysupport/ axlesuspensron
Fig.2: Pressufesupplywith
varvecap
-5-
UEBHENR
FunctionaldescriPtion
oPeratingmodes
UW 19 - EmergencY
Produ@dby: lwepilo/ Edilion:06.0607 /Version:3
for
Ex.pushbufton
of
manualoperation
the support
block1TM11004.1
Fig.3: Support
ScrewfittingEmergencY
operation- (new)RotationvalveslD.
No.476670108
ScrewfittingE#"tg"n"Y
operation(old)Rota1100tionvalves(LTM
4.1/1TM1090-4.1)lD.
No.790533908
Screwfitting
valvessuPPort
Directional
lD.No.790065608
Fig. 4: Emergencyoperationscrew fittingtypes
Liebherr-WerkEhingnGmbH - Technicaltraining
-6-
lIUIERR
Prcdued bv:lweDio/ Edidon:06.06.07
/ VeEion:3
)1.2.1 Emergencyoperation - model using "blower control with hydrostatic blower drive"
Emergencyoperationusingthe test programsfor the hydrostaticblowerdrive- Test43
(manual)and Test44 (automatic):
Purpose:
Thesetest routinesserueto checkthe functionof the hydrostaticblowerdrive.
Testprogram43 setsthe selectedspeedin 10%-stepsbetween0..100%,test program
between
44 is executedautomatically
and increasesthe speedevery5s in 1O%-steps
0..100%.
Function:
The following4 keys (Fig.'l) on the keyboardunit must be operatedsimultaneously
to activatethe test program:
Fig. 2: Test programactive
Fig. 1: Activatetest program
lf the "testprogramis active",the 7-segmentdisplaysH162..H165(Fig.2)

(faultdisplay)will indicatea runninglight.
Keys Pl and P2 on the keyboardunit are used to select each test.
The@ - key is usedto startthe selectedtest.

The [J - keyis usedto stopthe selectedtest.
-8-
1IEIIIRR
Produ@dbv: lweoid / Edilion:06.06.07/ VeBion:3
displayson the controlunit.

uses boththe dual-7-segment
Visualisation
Upper display:
The selectedtest is indicatedusingboth 7-segmentdisplays(top left and top right)on the
keyboardunit.Duringthe automatictest sequence(test44) both 7-segmentdisplayswill
flashat approx.1 Hz (1/sec.)afterthe test has finished.
Lowerdisplay:
Blowersoeed"dr"is shownhereas a
percentage
(0..99(100).
Fig.3: Displayblowertest
Test43 remainsactiveuntilit is quit by pressingthe i-key.Onlythen is temperature-dependentcontrolre-activated.

The blowerspeedis increasedusingkeys P1 or P2.
CAUTIONTest 43!
Sincethe blowerregulationis switchedoff whenthe test programis active,ihe engineor
transmission
can overheat.Any warningis signalledby a continuousbeepingsoundfrom
the keyboardunit.
'100%untilthe i-keyon the
Test44 will finishautomatically
howeverthe blowerremainsat
controlis then re-activated.
chassisis pressed.Temperature-dependent
Error code:
No errorcodesare outputduringthe courseof thesetests.
Caution:
It is essentialto readthe test programfor the particularcranemodel.
-9-
UBHIRR
Producedbv: weoio/ Edilion:06.06.07/Verson: 3
1.3 Transmission- emergencyoperation

)1.3.1 Emergencytransmission operation for GWG-transmissionsystems
Purpose:
(emergency
Emergency
transmission
operation
drivingprogram)
servesto assistthecraneoperator
in drivingthecraneoutof thedangerareawhenthereis a faultinthevehicle's
electrical
system.
Function:
lf the electricalsystemon the vehicledetectsa fault (flashingLEDson all drivingkeys)
it automatically
switchesto the emergencydrivingprogram.An errorcode is shownon
the lower7-segmentdisplay(faultdisplay)of the displayunit.The transmissionis set to
automaticooeration.
Caution:
The emergencydrivingprogramdoes not includean enginestartmonitoringfunction.
The drivingrangecan also be selectedwithoutoperatingthe servicebrake.This fault
mustbe immediatelyrectifiedby servicepersonnel.
EMERGENCY-driving
rangeswitch(transmission
emergency operationswitch)to switchlhe transmissioninto
forwardgear,reversegear or neutral.
LSB-connector
Fig.1:Transmission
emergency
operation
switch
/ centre
console
LTM1070-4.1
Note:
Emergencytransmission
operationis only possiblewhen the vehicle'selectricalsystemhas detecteda fault.lf no fault is present,the
drivingrangeselectedusingthe emergencydrivingswitchis rejec!
ed. Demonstration
operation(e.9.during
of emergencytransmission
cranehandover)requiresLSB-connectors
on l/O modules1 and 2
to be unpluggedwhen the systemis not undervoltage.This
disconnectsthe transmission
from the BUS-SYSTEMcausingthe vehicle's
electricalsvstemto detecta failure.
Fig.2: lo-module
Gaution:
It is essentialto readthe operatinginstructions
for the particularcranemodel.
-10-
lIIBHIRR
Produ@dbv: lweoid / Edition:0606 07 /VeEion:3
)1.3.1 Emergencytransmission operation for Allison transmission systems

Purpose:
operation(emergencydrivingprogram)servesto assistthe
Emergencytransmission
craneoperatorin drivingthe craneout of the dangerareawhen thereis a fault in the
vehicle'selectricalsystem.
Function:
lf it is not possibleto set a drivingrangeusingthe drivingrangeswitch, performthe
followingactionsin the orderdescribed:
. Turnoff the engine
. Removeplug connection-X653.1
. Attachconnector-X653.1to -X653.2
. Startthe engine
. Selectthe desireddrivingrangeusingthe emergencydrivingswitch
Caution:
The emergencydrivingprogramdoes not includean enginestartmonitoringfunction.
The drivingrangecan also be selectedwithoutoperatingthe servicebrake.
Thisfaultmustbe immediaielyrectifiedby servicepersonnel.
, Faultdisday pushbuttons
"Diagnostics
all
test"for displaying
currenttransmissionfaults on the
displayunit
range switch
EMERGENCY-driving
(transmissionemergencyoperationswitch)
to switchthe transmissioninto
forwardgear,reversegear or
neutral.
Fig.1:Transmission
emergency
operation
LTM10704.1
switch/ centreconsole
-x653.1
l/Omodule
5/
Connector
Transmission
Allison
ECU
-x653.2
Emergency
operation
Allisonconnector
operation
Allisonconnector
Fig.2: Emergency
Caution:
for the oarticularcranemodel.
It is essentialto readthe operatinginstructions
_ ,11 -
ITTBHIRR
ftoduced by: lwepio / Edilton: 06.06.07 / \r'eFion: 3
Liebherr-WrkEhingnGmbH - Technicaltraining
-12-
UBIIRR
OW04- Slewingring connection
Onlvfor LIEBHERRServicepersonnel
OW 04 - Slewingring connection
Prcduced br lweDiro/ Edidon. 21 -02 07 I VeBian: 1
Index
1. Slewingring connectiongeneral
2 Toothedgep|ay............
3 Tilt p|ay..................
4 Greasingof slewing ring ..............-...............
..............8
..,...................8
6 Earthingduring welding work..................
Liebhen-WerkEhingenGmbH - Iechnica!training
-3-
IIEBHINR
Prcduced bv: lreono / EdiUon:21.02.07 / VeEion: 1
1. Slewingring connectiongeneral
)1.1 Purpose
(tumtable)
(slewingring)supports
thesuperstructure
on the
Theslewingringconnection
(rotating
chassis
bearing).
)1.2 Layout
of at leasttworings.Theseare
is a circularbearingconsisting
A slewingringconnection
(roller
rollers
or
elements).
using
ball
bearings
rotationally
connected
Greasenipple
Outerring
\
1..?a-
i\-,r
-
. t l
at,
t-
lntermediateoieces
a-
rDo
Fig.1: Ballbearingsupported
slewingring
o -
<D
Outergearteeth
Rollerelement
Fig.2: Ballbearingsupportedslewingring
Liebher.-WerkEhingenGmbH - Technicltraining
-4-
UEHINR
Poduced bv: lweoio / Edition:2102.07/ VeBion: 1
lnnerring
Fig.3: Rollerslewingring
--
Outergearteeth
Ring-shaped
rollerelementbearing
-)I
ring
Fig.4: Rollerslewing
Servicepersonnel
Onlyfor LIEBHERR
-5-
IITDHTNR
PEducedbv:lweDio / Edition:21.02.07
/ VeEion: 1
)1.3 Function
The innerand outerringsare connectedby meansof ball bearings(on smallercranes)or
a ring-shapedrollerelementbearing(on largercranes).
The outerring is connectedto the chassisusingexpansionscrewsand has outergear
usingexteeth.The innerring is connectedto the turntableframeon the superstructure
pansionbolts.Theslewinggear transmission
is permanently
fixedto the turntableframe.
The slewinggear pinionlocksintothe outergear teethon the outer ringof the slewing
ring connection.Driving
the slewinggear motorthereforedrivesthe innerringand hence
the wholeturntable.The turntablecan thereforeturn through360".
Slewinggear motor
geartransmission
Slewing
Fig.5: Slewingringconnection
Outerring
Innerring
Turntable
trame
-6-
1IEIIRR
Podlced br |repno / Edilton: 21.02-07 / Veîon: 1
)2 Toothedge play
Fig.6:Toothedgemeasurement
Toothedge play (torsionalplay) is used to describethe play betweenthe outer gear teeth
on the slewingring and the drivecog wheelon the slewinggear transmission.
On toothedslewingring connections,the tooth edge play must be adjustedat the narrowest pointon the toothgear duringassemblyor when replacingthe slewingring (thewidest
radiusof the slewingring is at this point).
The nanowest point on the tooth gear is markedby a punched-inplus-symbolbetween
the two teeth with red magkings.
)3 Tilt play
The tilt play increaseswith the track wear.
the innerandouterringon theslewthe radialplaybetween

Tiltplayis usedto describe
Ing nng connecuon.
MK= Tiltingtorque
Fig.7: Tilt play

Liebhen-WerkEhingenGmbH- Technicalkaining
Onlyfor LIEBHERR
Servicepersonnel
-7-
UEHTNR
PDducedby: laepiro/ Edition:21.02.07/ vecion: I
)4 Greasingof slewingring
Greaseis injectedintothe slewingringfrom the centrallubricationsystemusingthe progressivedistributorand greasenipple.The progressivedistributoris fiftedwith a proximity
switchto monitorthe strokeand determinethe amountof requiredgrease.
Fig. 8: Progressivedistributor
)5 Expansionbolts
Expansionboltsare usedto attachthe outerslewingringgear teethto the chassisand
the innerslewingringgedrteethto the turntable.Tighteningthe expansionboltsto the
requiredtorquewill expandand wedgethe boltscausingthemto grip.
Fig.10: Expansionbolt
)6 Earthingduringweldingwork
The earthingpointmustbe as closeas possiblewhen performingany weldingwork'
Neverweld on the turntableif onlythe chassisis earthed.Otherwisethe slewingring
components(rolleror ball bearingsas well as the ring contactsurface)couldbecome
permanently
damagedwhen arcingoccurs.
Servicepersonnel
Onlyfor LIEBHERR
-8-
UTTHERR
OW09- Luffinggear/
ballasting
Servicepersonnel
Onlyfor LIEBHERR
OW 09 - Luffing gear / ballasting
PEdu@d by: lwepilo/ Editon:30.01.07/ VeBion:1
Inhaltsverzeichnis
1. Luffing gear.............
1.1 Luffing gear general.......
..........................4
10
1.2 Luffing gear components......

1.2.1Loweringbrakevalveluffing9ear...........
.........................12
1 . 2 . 2P r e s s u rsee n s o lru f f i n gc y l i n d e r
13
......
2. Ballasting
......................13
2.1 Ballastinggeneral...
18
2.2Ballastingcomponents....
............10
-3-
lIIBHINR
Component
description
OW 09 - Luffinggear lballasting
Prcdled
by: l*epilo / Edilion: 30-01.07 / VeEion: 1
1. Luffinggear
1.1Luffinggeargeneral
)1.'1.1Purpose
or
Theluffinggearis usedto settheangleof the boom.lt is adjustedby extending
retractingone or bothof the luffingcylinders.
(radius).
Theluffingfunctionis usedto raiseor lowerthe loadandchangethe projection
;1.1.2 Design
Fig.1: Excerptfromluffinggearschemalicgeneral
Note:
Theluffinggearalwaysusesan openhydraulic
circuit.
personnel
Onlyfor LIEBHERR
Service
-4-
UBIIIRR
OW 09 - Luffinggear/ ballasting
Prcdu@dby: lwepid / Edilion:30.0107 / Ve6ion: 1
)1.1.3 Function
Luffing up:
lf the masterswitchis movedin the luffingup direction,the directionalconirolvalve
opens.The loadopposesthe hydraulicpressure.The oil pumpedby the hydraulicpump
is then initiallyblockedby the non-returnvalveon the loweringbrake.
The pressurewill then increaseuntilit is sufiicientto openthe non-returnvalve.The
hydraulicoil flowsthroughthe non-returnvalveon the loweringbrakeand the luffingcylinder is extendedcausingthe boomto be luffedup.
The luffingcylindercouldbe destroyedif it is fully retracted(to the block)or extended
withoutbraking,on LTM 1095-5.1(or later)this is preventedby reducingthe luffingup
actionbeforethe loadtorquerestriction(LMB)switchoff pointand reducingthe luffing
downactionbeforethe supportblockis reached.lfthe masterswitchis movedbackto 0',
the directionalcontrolvalvealso returnsto the centreposition,The directionalcontrol
followthe masterswitchsignal,insteadit closesaftera time
valvedoes not immediately
pressure
in the "luffing"pipedropsand the non-returnvalvefor
The
delay(integrated).
the loweringbrakeis closed.The boomis held in positionby the hydraulicoil whichis
trappedin the luffingcylinder.
Luffing down:
lf the masterswitchis movedin the "luffingdown"direction,the directionalcontrolvalve
loweringbrakevalve,"luffingdown"valveand controlpipecause
opens.The proportional
hydraulicoil to be appliedto the controlpistonof the loweringbrakeand opensit proportionallyfrom a presetvalue.
a connectionbetweenthe luffingcylinderpistonsurfaceand the tank;
This establishes
the weightof the luffingcylinderresultsin a controlledluffingdown action'
tank pipe.
This causesthe ring surfaceto suck hydraulicoil throughthe pre-tensioned
lf the boombecomesflatterduringluffingdown,the loadpressureincreasesin the piston
surfaceof the luffingcylinder.The initialflow of the luffingcylindermustalso be adjusted
if the loweringbrakeis actuatedand ihe pressurein the pistonsurfaceof the luffingcylinder increases.
Eachluffingcylinderis thereforefittedwith a pressuresensorfor measuringthe hydraulic
pressureat the luffingcylinderpistonsurface.
is usedto preventthe luffingdownactionfrom speeding
Pressurecompensation
up as the boombecomesflafter.
This is a hydraulicfunctionand can alsobe controlledon the LTM 1090/3or LTM 1100-4.1
by reducingthe masterswitchsignal.
lf the masterswitchis movedbackto 0" duringluffingdown,the directionalcontrolvalve
also returnsto its centreposition.
followthe masterswitchsignal,inThe directionalcontrolvalvedoes not immediately
steadit closesaftera time delay(integrated).
loweringbrakevalveis regulatedbackdown to lowerthe controlpipe
The proportional
pressurefor the loweringbrake.This will startto close,whichcausesthe luffingdown actionto be slowlybraked.
Liebherr-WerkEhingenGmbH - Technicalt.aining
-5-
UIBTilIRR
OW 09 - Luffinggearlballasting
Podued bv: lweoid / Edilion:30.01.07/ Ve6ion: 1
Shuttlevalve
H6
MI
q q
Proportional
valve
Actuationdirectional
controlvalve
DBVBlock
retainer
Directionalcontrolvalve
2-waypressure
oatance
Pressuresensor
lufflngcylinder
!iIPPZYLINDER
Cartridgevalve
pressure
loweringbrake
t
r-----;irPiitr --_-----t
Q)
Lt
4f2 way magnetic

VAIVE
Lufflngdown
1 . 5' .
I
Fig. 2: Excerptfrom luffinggear schematicgeneral

-6-
lIFilINN
Produed bv: lweoid / Edition: 30.01.07 / VeBion: 1
I.JI PPZYLII'IOER
--
High-pressure
Tank
Lowpressure
Controlpressure
Loadpressure
Fig. 3: Luffingcylinderpistonsurfacetensioned
Liebherr-WerkEhingenGmbH-
-fecinical
training
-7-
uElltiR
OW 09 - Luffing gear / ballasting
P@du@dbr lwepiro/ Edibon:3001 07 / ve6ion: 1
IIIPPZYLIiIDER
--
High-pressure
Tank
Lowpressure
Controlpressure
Loadpressure
Fig.4: Lufflngup
-8-
UEHTNR
Prcduced by: lwepio / Edition: 30.01.07 / ve6ion: 1
Pr
-:t=
-t
---I{lPPZYLINDER
-Ys ii
_Yl0
rTlF ! |
'fl
rrl
High-pressure
Tank
LOwpressure
Controlpressure
Load pressure
Fig. 5: Lufiingdown
-9-
UETTEiR
Prcdued by: lwepilo/ Edihon:30o1.07/ Ve6lon: 1
)1.2 Luffinggear components

1.2.1Lowering brake valve luffing gear
The loweringbrakevalveluffingtrapsthe
hydraulicoil in the pistonsurfaceof the luffing
cylinderto whichthe wholeweightof the boomis
applied.The loweringbrakesupportscontrolled
liftingand loweringof the boom.Luffing
down
loweringbrake
usingpressure-compensated
valvesis alwaysat the samespeedregardlessof
the boomangle,boomlengthor boomload.
On hydraulically-controlledequipment
Fig. 6: Loweringbrakevalvewithouthydraulic
without hydraulic overpressure
(e.9.LTI\,4
1030-2.1
overpressure
compensation
)
compensation:The speedof the
luffinggear is not adjusted.
Luffingdownwill speedup as the boombecomes
longerand flatter.
craneswith
On hydraulically-controHed
for
overpressurecompensation(e.gLTM1040-2.1):Fig.7: Excerptfromschematic
lowering
brake
valve
withoul
overpressure
Overpressure
compensation
andluffinggear
(e.9.LTM1030-2.1)
compensation
arehydraulically
controlled.
speedadjustment
Fig.8: Loweringbrakevalvewith hydraulic

(e.9.LTM1040-2.1
overpressure
compensation
)
-10-
UEilINR
Prcdu@dby: lwepio / Editon:30.0107 /ve6ion: 1
Fig. 9: Excerptfrom schematicfor loweringbrake

valve with hydraulicoverpressurecompensation
(e.9. LTM 1040-2.1)
Safetypressure-reliefvalve 430 bar is factory-
On cranes with electricalcrane control

systems (exceptions from LTM 15008.1 and LTM1300-6.1):
usesfinal
Overpressure
compensation
flow and initialflow adjustment.
For example,if the pressurein the ring
surfaceof the luffingcylinderincreases,
the finalflow is limitedwh'ereasthe initial
flow is increased.
The additionalhydraulicpressure
is only activatedduring
compensation
emergencyoperation.
car /.1^ n^r ..lilct\
-MP
Measuring
Control
pressure
Loweringbrake
Fig.10:Loweringbrakevalveluffing
on craneswithelectricalcranecontrol
(e.9.LTM1400-7.1)
systems
a
---f
-:-
Fig. 11: Excerptfrom schematic- lowering

brake on craneswith electricalcrane control
systems(e.9.LTM1400-7.1)
- 1 1-
1IEIIIRR
PEdued by: lwepi.o/ Edilion:30-01.07/ ve6ion: 1
1.2.2Pressuresensorluffingcylinder
sensormeasures
Theluffingcylinderpressure
pressure
in the luffingcylinderpithe hydraulic
stonsurfaceandis usedforthefollowing:
. Calculation
of the loadtorquelimiter
. Pressure-dependent
initialflowadjustment
forthe lufiingdownfunction
. Pressurecompensation*
. Loadstorage*
-B2
sensor,
Pressure
luffingcylinder
pistonsurface
Fig.12: Pressuresensorluffingcylinder
* = OPtion
-12-
IIIBHINR
OW 09 - Luffinggear Iballasting
Pmdu@d br lwetiro / Edilion: 30.01-07 / VeBion: I
2. Ballasting
2.1Ballastinggeneral
)2.1.1 Purpose
The ballastand the weightof the vehicleboth serveto counteractthe load.The term ballastingis used to describethe raisingand loweringof the ballastby the ballastingcylinder
and the associatedelectricaland hydrauliccomponents.
)2.1.2Design
cylinder
Ballasting
Ballast
Fig.13: BallastLTM1100-4.1
Fig.14: BallastLTM 11004.1/ Planview

Ballasting
cylinder
-13-
UBIIRR
Prcdued by: lwepno / Edilion: 30.01.07 / Ve6ion: 1
)2.1.3 Function
BALLASTIERUI{G
'^,1
i*
.,,i)*l- -'
Releasablel['26="--?ffi'
schematic
Fig.'15:Excerptfromgeneralballasting
personnel
Service
OnlyforLIEBHERR
-14-
-'T*T;
nonReleasable
returnvalve
UBHTNR
PEdued by: lwelno / Edilion: 30 01 07 / Version: 1
Ballast clamped:
The hydraulicoil in the ringsurfaceof the ballastingcylinderis clampedby the releasable
load holdingvalve.This holdsthe ballastin the requiredposition.The bladderaccumulator providesthermalpressurecompensation.
BAL
ERUI||G
___J11
lr-l
rl
.._^--ll__..
rl
i| ?^rlilFi I
fr -,,r1
TI r -
.ll
I'
r49
Ji,
t t T
r{l
rtr
I
xr-I
I
!
!
380_.I
^l
ft_
iI
*-
High-pressure
Tank
LOWpressure
Controlpressure
Fig.16: Ballastclamped
Liebhen-WerkEhingenGmbH - Technjcaltraining
-15-
lTIBIIIRR
P@dued by: lwepno/ Editon:30.0107 / ve6ion: 1
Ballastup:
lf pushbutton-5602 "Ballastup i down"is movedupwards,4/3directionalvalve-Y'l9a
is suppliedwhichreleaseshigh pressurevia the flow dividerand the loadholdingvalves
onto the ringsurfaceof the ballastingcylinder.The ballastingcylindersretractand raise
the load untilthe pushbuttonis released.A buzzerwill soundonce the ballastingcylinder
has beenfullvretracted.
B A L L A S TEI R U N G
----
High-pressure
Tank
LOWpressure
Controlpressure
Fig.'l7: Ballastup
-16-
IIIBHINR
PEdued b][ lwel'lo / Edition: 30.01.07 / VeBion: 1
Ballast down:
lf pushbutton-5602 "Ballastup / down"is moveddown,4i3 directionalvalve-Y19bis
suppliedwhichreleaseshigh pressurevia the releasablenon-returnvalveonto the piston
surfaceof the ballastingcylinder.The ballastingcylindersextendand lower the ballast
untilthe pushbuttonis released.A buzzerwillsoundoncethe ballastingcylinderhas been
fullvextended.
BALLASTI ERUNG
High-pressure
Tank
LowPressure
Controlpressure
Fig.18: Ballastdown
- 1 7-
llEHINR
Podu@d bv:lweDio / Ediuon:30.01.07
/ veGion: 1
2.2Ballastingcomponents
2.2.1Ballasting
cylinder
The ballastingcylindersare usedto raiseand
lowerthe ballast.
lf the ballastis e.g. restingon the chassis,it can
be pickedup by the ballastingcylinder.
T(\
Fig. 19: Ballasting
cylinder
Pistdnsurface
\ \
\\
:
Ringsurface
2.2.2Pressureswitch ballasting cylinder up

Everyballastingcylinderhas a supplypressure
switchfor measuringthq pressurein the ring
surface.The supplypressureswitch(normallyopen)switchesif a hydraulicpressuregreater
than 230 bar is applied.
Bothswitchesare in series.
LICCONinput"Ballastingcylinderup / down"
is onlyactivatedonce both cam switchesare
actuated.
Fig.20: Supplypressureswilch
2.2.3Cam switch ballasting cylinder down

actuatedon each
A cam switchis mechanically
ballastingcylinder(normally-closed)
as soonas
the ballastingcylinderis down (extended).
LICCONinput"Ballastingcylinderup / down"
is only activatedonce both cam switchesare
actuated.
LICCONinput"Ballastingcylindernot down"
is activatedif one of the cam switchesis not
actuated.
Liebherr-WefkEhingenGmbH - Technicaltraining
Onlyfor LIEBHERR
Servicepersonnel
-18-
Fig.21: Cam switch
HEHINR
PDdo@d bv: lweoio / Ediiion:30.01.07/ Ve6ion: I
2.2.4Pushbutton ballasting cylinder up / down

This pushbuttonhas a centrepositionfor
movingthe ballastup/downusingihe ballasting
cvlinders.
Fig.22: Switchballastup / down
ffi
602
Pushbutton
in roof
ballast
console,
up/down
2.2.5Buzzer ballasting cylinder up / down

cylinder
Fig.23: Buzzerballasting
The buzzeris eitherin ihe roof consoleof the

cab or in the controlcabinet.
superstructure
It will soundin both states,namelyballasting
cylinderup/down.
On oldercranesihis is indicatedby the lampon
the "Ballastingcylinderup / down"switch
r f -- - - r
**o
l[{sl_
- vuzzel
lFt4-rf |
rL\| Ell
Ballastup/down
2.2.6Hydraulicallyreleasedload holding valve

The hydraulically
releasableloadvalvetrapsthe
hydraulicoil at the ring surfaceto holdthe ballast
ln posrt|on.
lf ballastdown is actuated,the pressurein
the controlpipeslowlyopensthe load
holdingvalve-
-19-
Fig. 24: Load holdingvalve
IIIBIITRR
OW 09 - Luffinggear Iballasting
Prcdued bv: lweoid / Edilion:30.01.07/ Ve6ion: 1
2,2.7Releasablenon-returnvalve piston surface

The releasablenon-retumvalveis opened
when ballastup is actuated;this allowsthe oil to
escapefrom the ring surfaceintothe tank.
r-
z 1 -J
a
Fig.25: Releasable
non-returnvalve
2.2.8Hydraulicallyreleaseddual load holding valve*

On somecranesthe hydraulically
releasable
performs
dual load holdingvalvealso
the
functionof a basicload holdingand releasable
non-returnvalvefor the pistonsurface.
Fig.26: Dualloadholdingvalve
2.2.9Bladder accumulator
The bladderaccumulatoris connectedto the ring
surfaceof the ballastingcylinders.
It storeshydraulicoil up to a pressureapproxca.
150 bar and preventsthe ballastfrom moving
downwhen the craneis shut down.
Fig. 27'.Bladdetaccumulator
* = option
Liebherr-WerkEhingonGmbH - Technicltraining
-20 -
UEHENN
Component
description
Podled
by:lwepi.o/ Edition:30.01.07/ VeEion:1
2.2.10Flow divider
The flow dividerensureseoualretractionof
the ballasiingcylindersand constantliftingof
the ballast.
It dividesthe incomingflow intotwo specific
partialflowsusingthe throftleprinciple.
Sincethe controlpistonof the valve(Fig 30)
actsas a pressurebalance,this generally
alsoappliesif thereare differentpressures
in the oartialflows.
Fig.28: Flowdivider
Fig. 29: Flow dividerexcerpt

from circuitdiagram
InputC
Fig.30: Flowdividercut-awayview
-21 -
UBHINR
P'!du@d by: lwepid / Editon: 30 01 07 / VeEion:1
2.2.1'lPointer ballast Pick'uP

Pick up ballast:
. Turncranesuperstructure,
untilpointer"Turntableca.2'" is alignedwith the marked
screw"Referencepoint",the ballastingcylinderswill now be nextto the openingsfor
the ballastPick-uP.
. Lockthe turntable.
. Presspushbutton-s602 "Ballastup / down"down untilthe ballastingcylindersare
fullyextendedand the buzzersoundsor indicatorlamp is lit'
. Releasethe turntable.
. carefullyturnthe cranesuperstructure
to the right,untilpointer"Turntableca' 0"" is
alignedwith the markedscrew"Referencepo:nt",the ballastingcylinderswill now
extendintothe openingson the ballastplates.
. Lockthe turntableagain.
. Pressoushbutton-s602 "Ballastup / down"up untilthe ballastingcylindersare fully
retractedand the buzzersoundsor indicatorlamp is lit'
. Releasethe turntableagain'
Pufting down the ballast:
. rum cranesuperstructure,
untilpointer"Turntableca. 0'" is alignedwith the marked
screw"Referencepoint",the ballastcan now be lowered'
. Lockthe turntable.
. Presspushbutton-s602 "Ballastup / down"down untilthe ballastingcylindersare
fullyextendedand the buzzersoundsor indicatorlampis lit'
. Releasethe turntable.
. carefullyturn the cranesuperstructure
to the left,untilpointer"Turntableca' 2'" is
alignedwith the markedscrew"Referencepoint",the ballastingcylinderswill now be
nextto the openingson the ballastpick-up.
. Lockthe turntableagain.
. Presspushbutton-s602 "Ballastup / down"up untilthe ballastingcylindersare fully
retractedand the buzzersoundsor indicatorlamp is lit'
. Releasethe turntableagain.
Pointer
"Turntable
ca.2SDgr"
Pointer
"Turntable0""
markedscrew
"Reference
Point"
Fig-32: Pointerballastpick-upvariant2
Fig.31: Pointerballastpick-upvariant1
Liebhen-WerkEhingenGmbH -'fechnicaltraining
-22 -
IIEIIERR
\-
OW14- Telescopicboom
/ Telematics
OW 14 - Telescopicboom / Telematics
Prcdu@dby: lwepio / Ediion: 13.11.06/ ve6ion:01
Contents
'1.Telescopicboom
9enera1..,.,..........
................5
.....14
16
.....................24
7. Operatingmodes............
...........................32
9. Boom systems
-3-
1lBTTTRR
Prcdued bI lBprro / Edition: | 3 11.06 / VeBin:o1
Liebhen-We* EhingenGmbH - Technicaltraining
Onlyfor LIEBHERR
Servicepersonnel
-4-
lIEITIRR
Prcdued by: lwepiro / Edilion: 13.11.06 / veEion:o1
1. Telescopicboom general
)1.1 Purpose
manuallyor automatically.
Thetelescopicboommaybe extended/retracted
Thisprovides
cranewithvariableradiusandlift.Theboommustbe
thetelescopic
application.
loadin theintended
designed
to lifttheattached
p'|.2 Layout
Fig.1 : Diagramshowingprincipleof telecylinder
electrical/electronic sensors
piece
Articulated
(mainbody)
Telepinning
Telelll
gipperpinhydraulic
nrng
telescooic
dual-action
cylinder
yoke
Connecting
Telepinning
(Telepinpulling
mechanism)
a,r
Telepinning
il
comprisesthe followingcompon"ftl'l?v"
The boomessentially
Boom head
il
Articulatedpiece(mainbody)
Telescopiccomponentswith pinningholesat 0%, 46To,92Toand 100%. Rollerset
Boomheadwith hoistlimitswitch
cylinder
Dual-action
telescopic
gripperpinningat thefootof thehydraulic
cylinder
Hydraulically
actuated
to lockthe telescopicsectionstogether
Hydraulically
actuatedtele-pinning
moduleof the LICCONcrane
Electrical/electronic
controlsensors.an additional
controlsystem.
Uebhen-WerkEhingenGmbH - Technicaltraining
-5-
IIBHR
OW 14 - Telescopicboom/ Telematics
Producedby: lwepid / Edilion:13.11.06/ VeBion:o1
(pistonsurface)
K1 t<2 K3
(ringsurface)
R1 R2
Fig.2:1TM1400-7.1
Boom
Loweringbrake
valvecontroltele
cylinder
X
Rotatingunion ring
surface,loweringbrake
control,tele- /gripper
pinning
Tele-/ gripper
pinning
A
Rotatingunion
pistonsurface
telecylinder
Cabledrum
suppry
Lengthsensor
Fig.3 : LTC1055-3.1.1
Boomhead
-8929
Anglesensor
telepulley head
.s917
Terminal
box
pulleyhead
930
Hoistlimitswitchright
pulleyhead
931*
2. Hoist limitswitch
pulleyhead
left
* = option
Liebherr-WerkEhingonGmbH - Technicaltraining
-6-
UEHENR
Pbdued bv:lweolo / Edilion:13 1106 /ve6ionrol
piece
head/ articulated
F i g .4 : L T C1 0 5 5 - 3 . 1 .Boom
1
-s917
Terminalbox
-N2
Cabledrum
Articulatedpiece
-8909
Anglesensor
Telemainbody
-Mg0g*
'
-8921
Windsensor
Actuator
worKrng
lightsarticulated piece
L S B6 . 1 ,
Address19
-E907*
WorkinglightsarticuIrta.l
îaâ
Fig.5:Boomprofile
- = option
Liebherf-WerkEhingenGmbH - Technicaltraining
Onlyfor LIEBHERR
Servicepersonnel
UIBHTRR
Prodlced bv: lweoid / Edilion:13.11.06/Ve6ion:01
Fig.6 : Telescopic
boomfromrear
Polyamidebearingplate(slideshoes)
Polyamideslideblocks
for the tele cylinder
flexiblymounted
Polyamide
slideblocks
Polyamide
slideblocksr
Fig.7 : Telescopic
boomfromfront
Polyamide
bearingplates
(slideshoes)
Onlyfor LIEBHERR
Servicepersonnel
-8-
IIIBTItRR
description
Component
Producedbv: lweoio/Edilion: 13 1106/Ve6ion:o1
Fig.8 : Diagramshowingprincipleof telecylinderextensionmechanism
Lengthsensor
Telecylinder
yoke
Connecting
Telepinning
(Telepin pulling
mechanism)
.(
supplyto
pinning
device
t
t
i,-d.j4
Controlvalvet
ele-/ gripper
unpinning
Controlhead
Gripperpinning
Cylinderguide
comprises:
telescopicsystem"Telematics"
The automaticrapid-stroke
. a dual-actiontelescopiccylinder
. hydraulically
actuatedgripperpinningto selectthe activetele-component
. hydraulically
actuatedtele pin to lockthe telescopicsectionstogether
. electrical/ electroniccontrolsensors
Note:
The hydraulicoil for the tele-/ and gripperunpinningflowsthroughthe hydrauliccylinder
Onlyfor LIEBHERR
Servicepersonnel
-9-
UIBHTNR
Prod!@d by: lwepio / Edidonr13-11.06/VeBion:o1
The oval-shapedboom cross-sectionprovidesutmoststabilityduring bendingand

torsionAutomatedtelescopiccontrolis basedon the LICCONcranecontrolsystemto provide
provided
severalextensionlevelsfor the telescopicboom.The highlevelof functionality
gained
from
automatic
by
the
time
by this new boomtechnologyis characterised
telescopingand the resultingusefulvarietyof combinations.
460/o,
92o/oand 100oh.
Eachtefescopicsectionhas pinningholesat 0o/o,
principle
of telecylinder
Fig.9: Diagram
showing
lnductive
sensortele-/ gripperpinning
yoke
Connecting
Telepinning
(Telepinpulling
mechanism)
Telepinning
Lengthsensorlele cylinder
andpowersupplyto
pinning
device
Controlhead
Cylinderguide
pinning
Gripper
Induclive
sensorfor monitoring
the gripperpositions
Servicepersonnel
Onlyfor LIEBHERR
-10-
lTIBIIIRR
Prcdo@dbv: lweDio/ EdlUon:13.11.06/ ve6ion:o1
2. Gripperpinning/ telepinning
)2.1 Purpose
The gripperpinningservesto connectthe telescopiccylinderto a telescopicsection.Tele
pinningis usedto lockthe telescopicsectionstogether
;2.2 Layout
interlocked.
Gripperand tele pinningare mechanically
with the aid of the
This meansthat the telescopicsectioncan only be pinned/unpinned
yoke
gripper
with the telescopicsectionat the sametime.This
if the
is interlocked
upper
preventsa mechanicalmalfunctionof the telescopicsystem.
Fig.1 : Gripperpinning/ tele pinning
-Y40(-Y17)
Changeover valve
Telepinning/
Gripperpinning
Connectingyoke
Telepinning
(Telepin pulling
mechanism)
-s918
Inductivesensoras
proximityswitch ;
Telepinned
CPU1,LSB2 Address16
".r
-s919
lnduclive
sensoras
proximityswitch
Teleunpinned
CPU1,LSB2
Address17
pinning
Gripper
912
-s913
-s914
-s915
lnductive
sensor
as proximity
switch
rightpinned
Gripper
CPU1,LSB2
Address20
lnductivesensoras
proximityswitch
Gripperleftpinned
CPU1
, L S B2
Address18
lnductivesensor
as proximityswitch
Gripperrightunpinned
C P U 1 ,L S B2
Address21
lnductivesensor
as proximityswitch
Gripperleft unpinned
C P U 1L, S B2
Address19
-'t1 -
IIIBHTNR
P r o d u c ebdy r w e p r l o / E dr o n 1 3 1 1 0 6 / v e E r o n 0 1
Fig.3:Telepinning
Fig.2 : Telepinning
openingfor meInstallation
Hex socket head screwfor screwing in the tele pin (disassembly) chanicallyunpinningthe griPper pinningmechanism
whenhydraulicsystemis faulty
holegripper
Pinning
pinning
right
Fig.4:Telepin
Connectingyoke
Telepinning
(Telepin pulling
mechanism)
Spring
Pull
musnroom
)2.3 Function
the telescopicsections.A tele pin can
The springpushesup the tele pin to interconnect
usingthe connectingyoke if the gripperpinningis fullypinnedin
only be pinned/unpinned
tele.converselythe grippercan only be unpinnedfrom the telescope
the corresponding
if the connectingyoke (telepin pullingmechanism)has beenfullyextendedupwards
andthete|epinhasbeencomp|etelypinned.The|iponthete|epinpreventsunintended
unpinning,e.g.due to the tele pin snappingbackwhen the springbreaks.lf the gripperis
unpinned,the tele cylindercan be freelymovedand anothertele component
hydraulically
may be selected.lt is only possibleto pullthe tele pin if the gripperpinningwas previously pinnedto the tele cylinder.lnautomaticmodethe telescopiccylinderis retractedafter
ensuresthereis frictional
everypinningoperation.This so-called"tensioning"
lockingbetweeneachof the elements.Furthermoreit is guaranteedthat the pinning
systemis relievedby the extensionof the cylinderduringthe unpinningprocess(gripper
or telescope)therebycausingthe gripperor telescopeto be unpinned'
Servicepersonnel
Onlyfor LIEBHERR
-12 -
lIETITRR
Component
description
OW 14 - Telescopic
boom/ Telematics
P'.ducei by wep r01 EditLonl3 lr oti i V.rs:.n:ol
2.3 Function
F r g .6 : T e l ep r n n e dg. r i p p eur n p i n n e d :
T e l ep i n n e d
l:ri^^^r
,,nî^^6r{
F i g .7 : T e l ep i n n e dg, r i p p epr i n n e d :
Tele pinned
'
G r i p p epr i n n e d
F g . 8 : T e l eu n p r - ' r e dg.r o p e rp i n n e d :
L e b h e r r - W e r kE h i n g e n G m b H - T e c h n i c a l r a i n j n g
- .t:::i\./i3e
. ,
ae.:t-
-13-
lTIBHIRR
Produed by: lwepi.O/ Edition:13.1106 / Ve6ionrol
3. Trackingswitch
3.1Trackingswitch
)3.1.1Purpose
The trackingswitchesindicatewhetherthe gripperpinning

mechanismis in a pinnedpositionandwhich
tele has been selected.
23.1.2 Layout
908
901
Induclivesensor
a.s.proximity
switch
bripperposttron
ounng.emergency
operalton
No LSB sensor
Inductivesensoras
proximityswitch
Tele 1
C P U 1 ,L S B2
Address10
-x456b
Plug,
Gripper{elepinning
_s902
Inductive
sensoras
proximityswitch
feh- 2
CPU1,LSB2
Address'11
-s904
Inductive
sensoras
proximitv
swilch
l e l e4
-s903
Inductive
sensoras
proximityswitch
tete 3
CPU1,LSB2
Address13
CPU1,LSB2
Address'12
;3.1.3Function
Thediffering
heightsof thesignalarmsallow
theLICCONto usetrackingswitches
(induc_
tivesensors)
to detectwhetherthegripper
pinningmechanism
is in a pinnedposition
andwhichtelehasbeenselected.
Onlyfor LIEBHERR
Servicepersonnel
-14-
Signalarms
UIBHTRR
Produed bv: lweoto / Edilion:13.11.06/ Ve6ron:01
3.2 Dual tracking switch

)3.2.1 Purpose
The trackingswitchesindicatewhetherthe gripperpinningmechanismis in a pinnedpositionandwhich
tele has been selecled.
)3.2.2Layoul
-s902
-s901
Dualinductivesensoras
proximityswitch
Trackingsensor,left
LSB 5.2,Address11
Dualinductivesensoras
proximityswitch
Trackingsensor,right
LSB 5.2,Address10
Dual indicativesensor
,1:.
- r l
I . :
:c-
. r -
! Jt.KT:l'l
I r l
r - l : :
.::
11. r;E :rl:tiiLll;

S i 1 ! i - l n: x ! a F r : t s i l i L : t T
!.t
s!'lyrtr I
?,t
::1{::! i s:aRllrll
t ! 1 1 5 i ,? 1 i l . : : ; i s . : ! n L - [ j
ii:
iLit-i:
t - -
- - -
i:i
siilslR : ;li,l'inl:ti
si'ti"rn 2 s llinr'rii
ll i ir l I r
:
c:=
t-----
i '
f
I
L____!1]lil
AnalogueoutputTele
emergencyoperation
ri'1,.,1 :
i:{
Yi
l 1 : r - Hsr i ; a f ^ i : i
ili
G i S t ; t / , Ir ,
r:
:rl
it
;i!ailii:;:
i::iriLr:-
:-:
-':
)3.2.3 Function
The differingassignmentsof dummypanelsto plasticpanelsallowthe LICCONto use
dual trackingswitches(dualinductivesensors)to detectwhetherthe gripperpinning
mechanismis in a pinnedpositionand whichtele has beenselected.
-15-
UIBHTRR
Producedby: lwepro / Edihon:13.11.06/ Ve6ion:o1
4. Loweringbrake
)4.1 Purpose
The hydraulicoil for the telescopiccylinderringsurfaceis drainedintothe tank
in a controlledmannerwith the aid of the loweringbrakes.This causesthe retractionof
the telescopiccylinderwith eithernone,one or severaltelescopicsections.
)4.2Layout
Fig. 1 : Loweringbraketelescoping
Pressurelimitingvalve
is tactory-set(do not
adjust)
Lowering brake
valve V2
)4.3 Function
The "loweringbraketelescoping"consistsof two loweringbrakesS1 and 32. Lowering
brakeS1 is directlyactuatedby controlpressureX and opens the path for the regulatedflow of hydraulicoil from the ring surfaceinto the tank.At the same time control
pressurex is presentat the pressurelimitingvalve.Loweringbrake52 will only open
once the factory-setpressureis reached.Thisallowsfiner controlof inwardtelescoping
when underload.
Fig.2 : Extractfromcircuitdiagram- Loweringbraketelescoping
::ia:(C?
Liebherr-WerkEhingenGmbH -Technicaltraining
Onlyfor LIEBHERR
Servicepersonnel
- ' t 6-
TTBHINR
Prcdued by: lrepilo / Edilionr13.11.06/VeBion:o1
5. Telescopingcontrol:
5.1 Modelwithout hoist gear ll - Masterswitch left
- wilhouthoistgearll
Fig. I : LTM1095-5.1
fit
t
t-/
M52
fiI
5.2Modelwith hoist gearll - Masterswitchright

- withhoistgearll
Fig.2 : LTM1095-5.1
t@1
1""
,
.l flt-Z ' -.r-I f,li
t
t@L
M51
5,3 Foot pedal telescoping

Footpedaltelescoping
Fig.3 : LTM1400-7.1
l1l
I
-s501
Pedalsensor,footpedal
telescoping
Liebhen-WerkEhing6nGmbH - Technicaltraining
Er
ftt
- 1 7-
IIBIIIRR
Produed bv: lweDi.o/ Edi6on:13.1106/ve6ion:o1
6. Systems
)6.1 Telescopicboom in an open hydraulic circuit
Magneticvalvesare usedto controlthe variousfunctionsof telescopicboomsin open
hydrauliccircuits.
Pressurestagesare switchedin/outto achievethe requiredlevelsof functionalpressure
(seetableExtractfrom circuitdiagram).Theselevelsdifferdue to the varyingratioof
pistonsurfaceto ring surfaceand dependingon whetherthe tele cylinderis movedindechange-overbetweengripper
pendentlyor togetherwith othertelescopicsections.The
pinning/ tele pinningis performedusinga 2/3 way magneticvalve.The tele cylinderis
pinning).
equippedwith (see chapter:Gripper/tele
Fig. 1 : DualpumpA20VLO190EP
Pressure cut-off valve
-Y35
Dual-pumppumpS/6
Variabledispl.pump
Telescoping,luffing
A20VLO190EP
Lufflngup /
cylinder
(Pump6)
Pressure Iimiting valve

100bar
-Y34
Luffingup /
cylinder
(Pump5)
Non-returnvalve
Fig.2 : ControlblockLTM1400-7.1
P3/ l
DBV 320bar
Pressurestage
P5/V
DBV 12bar
P 1/ t
DBV170bar
P4/tV
DBV235bar
P2/
DBV220bar
-Y15
-Y11b
Lufflngup
Pressure
-Y'l2a
-Y11a
Pressurestage
Pressurestage
-Y10
Telescoping in
-Y14
Telescoping
out
-Y13
Pressure
-Y',l2b
Pressurestage
IIIBIIIRR
13.11.06/ VeEion:ol
Prcducedby: lwepio / Eda$on:
- Telescopicboom not actuated

Excerptfrom circuit diagramLTM1400-7.1
.E ::
,*f"t;
HG
HIH
HIH
\ 1 1 5\
=
ala
= \ \ \ \ 1\
l
\9
o)o
;t:)
O E
J.'F
:a= o)
Y',=c
; h o -o-
frRRR
+" l g
.
"
q)
o
o)
99)
>.9
; 3
.- *-f--t"
r r T -
2
o
o
2
o
T
- t -
3
d N
o >
.=z
c)
ct o
'6-
3
N
N
o >
! F
\ ( 5 O )
f'6.c-
_9
o
o g b
n 9
N g
o-9
> =
- . 4
Y ;
i 3
C F \
or x'
>.E
> 9
co6
$o-
q)
o-9
q)
-Qn
=>
O d r
!c!
o<
'==
! c
>\t
( 6 f
(r)
(l)
+o-
o 6
o
6
o,)
G o )
>,*
3 ;
c.t 9
(D
()
(,
ot
o o o -:a
E
o
=
> - - c
EHE E 9
6n9
N
N
p c
o-d
Liebher.-Werj<
EhingenGmbH - Technicaltraining
-19-
9)(D
_*6
au>
E *
x=
F- d,
d 9
UIBITIRR
Gomponent
description
OW14- Telescopic
boom/ Telematics
Produed by: lwepio / Edition:13.11.06 / Ve6ion:01
- Telescopingout GripperpinnedTeleunpinnedp2
Excerptfrom circuit diagramLTM1400-7.1
_ntn
\l
: ( a
r+H+ H+4
Hlf;
\
\9
R Rn RRR
. .
6
i
._
-
r----j]
i*
o
=
o
tro
o o
= o
iE
9 o -
0)
. = c Lo - =
gedE
l :
fE iXf. >i s. E
=^;3
='-9.;-9
-20 -
UTBHTNR
Producedby: wepio / Edibon:I 3 1106 / Ve6ion:01
)6.2 Telescopicboom in an open load-sensinghydraulic circuit

hydrauliccircuitsare controlThe varioustelescopicboomfunctionsin open load-sensing
led by meansof magneticvalves.Pressurestagesare switchedin/outto achievethe requiredlevelsof functionalpressure(seetableExtractfrom circuitdiagram).The changeover betweengripperpinning/ tele pinningis performedusinga 2/3 way magneticvalve
fittedon the tele cylinderloadpressureXL is appliedto a pressuresensorvia shuttle
valves.Magnetic
valve-Y49actuatesa cartridgevalveto establisha connectionbetween
the cylinderringsurfaceand the tank returnwhen telescopingout.
DBV Tele off

DB 140 BAR
Pressure stage P3
Fjg.1 : MaincontrolblockLTM1100-4.1
-Y12
Pressurestagep3
Fig.2 : MaincontrolblockLTM11004.1
DA 150BAR,PressurestageP2
DB 80BAR,Pressure
stageP1
-YOa
Prop.
valve,TeleON
Controlblock
protection
385BAR
DBV
Teleon,
DA 270 BAR
Stroke limitation
telescoping in
P4 270 BAR
-Y11
Pressurestage P4
?!9E!l?_{?gg,P4
Onlyfor LIEBHERR
Servicepersonnel
-21 -
ITIBHIRR
Pbd!@d by: lwepro / Edilion:13.11.06 / Version:o]
Excerpt from circuit diagram LTM11004.1- Telescopicboom not actuated
o
_
i
;
s
*
9,4\>
a
/
'
!.
9i
fi
a
l/T\l
v l
dl
rAr
l\21
o
3
= N
o >
0)o
.E2
o >
''....
.:..
= ;
!.
d9 16l
o
.o
qt
2(E
.9
(D
o)
zo
o(D
Ctr O
o o
E
c
5E
c . \
N P
N d
" l
= x
l
I
I
I
L-
(D
'--:
.o
() xi2
No-
q) o
o(g
o o
(')
'- -oO ^
o
3
_9
6
- otr
q)5
2 o
gE'
.9a
(l)X
:q?
x: .::
=e
=r o-
H+
f+# H+
9
:.ti
o -
9 P
\
t2
=P
o
o 2
o o
Liebherr-WerkEh;ngenGmbH- Technicaltraining
Onlyfor LIEBHERR
Servicepersonnel
-22 -
i.=
P E
?\a
:
o
Rt ai
->
a Rft
.9 6c i
d9
lTTBtffNR
- Telescoping
out GripperpinnedTeleunpinnedp3
Excerptfrom circuitdiagramLTMI'1004.1
g
CIr
q l H
'A
d t
E
! u
d t 2
m n
<
- t E
4
Lfi-U
I
I
tF
o
=
crt
CC.)
##
ulL
|-t
I
K
-
-?
J;
|i !
"+
\ \
4^
RK
f;
:
i c
= O
9 p qrt
a .n
6
Ya 9 . 9
CLE
E 9 >r -=
oa
. C : i
at=
= i
Uebherr-WefkEhingenGmbH - Technicaltraining
Servicepersonnel
Onlyfor LIEBHERR
-23 -
o t D
- t t
i = o
'9 or
; o
E
e
= o
O J
lTIBHIRR
Produed by: lwepid / Edilion:13.1106 / Ve6ion:o1
7. Operatingmodes
)7.1 Automatic telescoping operation
interfacewhichindicatesto
The LlccoN telescopingscreenis a dynamicfull-graphics
the cranedriverthe pinningstateof the telescopicboom,the relativepositionof each
telescopeand the extensionstateof the telescopiccylinder.The automatictelescoping
procedureallowseasytelescopingoperationof the telescopicboom by the cranedriver,
the telescopiccylinderor telescope.
sincehe is not responsibleor pinning/unpinning
simplifiesany telescoping
The LlccoN telescopiccontrolsystemthereforesignificantly
work;onlyihe requiredtelescopingtargetmustbe entered.The LICCONtelescopiccontrol systemdeterminesthe orderin whicheachtelescopeis movedto reachthe required
end oosition.
executedonce
actionsare automatically
All telescopicmovementsand locking/release
the requiredtelescopingtargethas beenspecified.The individualtelescopesare essentiallycontrolledto specificpinningstates,i.e.the movementsare alwaysto the telescoppositionsare not possible.
pinned.Intermediate
I92o/o| 100o/o
ic states oo/oI 460/o
The followingmovementsand actionsare executedby the system:

. Locking/releasing
the tdlescopiecylinder.
. Locking/releasing
the telescope.
. Orderof the telescopesbeingtelescopedto reachthe requiredend position.
This automaticprocedureis only executedas longas the masterswitchis beingoperated.The mainswitchis usedto determinethe directionand speedof the telescopic
movement.This allowsthe cranedriverto maintaincontrolof the crane.The directionof
cylindermovementis specifiedby the LlccoN computersystem. lf the telescopicboom
is extended,whereby it is necessaryto move currentlyunreachabletelescopes,first
telescopein untilthe last telescopebeingmovedis reached.In this case,firsttelescope
out).
in beforeextendingthe telescopicboom (telescoping
The automaticsymbolis displayedduringautomatictelescopingoPeration:
ae
I
qn0.l
Note:
by enteringa shortcodeor
mustbe setandconfirmed
Thecurrentsetupconfiguration
pressing
thefunctionkeys.
-24 -
IIIBIITRR
Prcdued bv lmoil() / Edition:13.11.06/ Ve6ion:01
Fig. 1 : Telescopingscreen
currentextensionlevel [%] of telescopes1 - 5
U-:Lai
= LUt 6 1
G Lt==
L'E
t . f
tr
LI
rc
E a@
g
K]
L.r!l@t
00 ,'10u/100/i00 /lffi
ffiM
Targetselectionfor
telescopes1 - 5
=mrctrrcm
ti--.
Functionkeys:
"F1":
"F3":
"F4":
"F5":
"F6":
"F7":
"F8":
Change-overbetweenautomaticmodeand manualtelescoping
Targetselectiontelescope1
Targetselectiontefescope2
press1x - Switchoff acousticsignal
press2x - Faultsvisuallydisplayedin symbolelement"Horn"will be
screen.
automatically
displayedon the errordetermination
Note:
screenor telescoping
Thetelescoping
targetcaneitherbe seton theconfiguration
screen.
-25 -
UTBHTNR
Produed by: lwepr0 / Edilion:13 1106 / vers on:01
Selectionof the telescopingtarget on the Fig. 2 : Configurationscreen

configurationscreen:
Use arrowkeys (4) to moveslidingmarker(1)
leftor rightto the column corresponding
to
the requiredtelescopicboomlength.
Note:
This selectionis storedwhen chanoinqto the
craneoperatrngscreen
s}|FI ,
Fr
F2l ;F3 :Fa
:F5: :t8
Selectionof the telescopingtarget using

Fig.3: Telescoping
screen
the telescoping screen:
Functionkeys F3 to F8 are assignedto each
telescope(e.9."F3" = Tele1).
The telescopingtargetis selectedby pressing
the functionkeysseveraltimes.
Eachtime the key is pressedthe targeted
extensionstateof the corresponding
telescope
is changedto the next percentagestep (0%,
46%,92%or 100%).Eacf of thesepositions
has pinningholefor telepinning.
a/: : . F 6 : : E N T f t
;irr!:-
lr-:!,
re...'i.,
:{::L'r::l{.;:
ri=+
=:>-ai
:gI.:
.=-
Note:
lf a flashingsymbolelementwith a crossed-outtelescopicboomappearson the first line
of the telescopingscreen,it is not possibleto unpinthe telescopicsections,the unpinned
load liftvaluehas beenexceededor no load lift chartis available.
Onlyfor LIEBHERR
Servicepersonnel
-26 -
IIIBIIIRR
Prcdu@dbv: l@oio / Ediiion:13.11.00 / VeBion:o1
the nexttelescoping
direction
on the
TheLICCONcomputer
systemalwaysindicates
screen.
telescoping
screenor craneoperating
Themasterswitchor footpedalmustbe operatedto followthe specifieddirection.
:'lll
i
- preselected
telescopic
targetreached
qno:
Targetdireciionof masierswitch:
t?l
l
-^*l
I
V - Demand:telescopein
RJfri
. - Demand:telescopeout
f,JIB ]
Note:
telescoping
actionhasbeen
Thedirectional
arrowwillextinguish
whenthepreselected
completed.
is alsovisuallydisplayed
on theoperating
screen.
Thisstate"Telescoping
targetreached"
Afterca. 3 to 5 secondsthis changesto the telescoping
screenif the masterswitchcontinuesto be operated.
Uebhen-WerkEhingenGmbH- Technicaltraining
Onlyfor LIEBHERR
Servicepersonnel
-27 -
UETTRR
Produ@dby: lwepio / Ediijon:13.11.06/VeEion:o1
)7.2 Manualtelescopingoperation
Telepinning
screen
Fig.1 : Telescoping
fIEIHETE
trEE
> !,4r ) 33r
8trtr
BN@
tr@@
4la/ 4E/ 4tr/ 4li / 4E- 4E
@@@
t--- /--- /--- /---
-\
trtrtr
trtrtr
Btr@
?-
F--,
llrell llezllllrellIIENTER
ll
Gripperpinning
Automaticmode
Two lines
Key Fl is usedfor the change-overbetweenmanualand automatictelescopingoperation.

Note:
from auiomaticto manualoperationis not possible,moveselector
lf the change-over
switch5618 to the centreposition.
-28 -
IITBIIERR
Produed by: lwepi.O/ Edilion:13.11.06/ Vecion:o1
Significanceof switch symbol 618

Unpinningthe telescopeby usinganothertelescope.
-Thetelescopeis only connectedto the tele cylinder.
-Thetele cylindercan be movedusinga telescope.
A connectionis establishedbetweenthe tele cylinderand
the telescooe.
-Thetele cylinderis connectedto the telescope.
-Thetelescopeis pinnedto anothertelescope.
-Thetele cylindercannotbe moved.
betweenthetele cylinderandthe telescope.
Loosenthe connection
-Thetele cylinderis free.
-Thetele cvlindercan be moved.
1.
Lock the tele cylinder to the telescope (close gripper pinning)
Firstpush-5618down.
-H613
Continuemovingthe tele cylinderuntilthe two linesare displayednext
to the requiredtelescopeand -H613is lit.
=' -'9.
,
TIP:
again,
Continuethe movementuntilthe two lineshaveextinguished
then very slowlymovebackuntilthe two linesreappear.
Moveswitch-5618 to the centrepositionto engagethe
gripperpins.
2.
Unpin the telescope (open tele pinning)
The nextstep is to switch-5618 upwards.
Unpinningis now performed.The telescopeshouldbe slightlyextendedto supportthis
action.The unpinningactionwill also be noticeable.
Moving the telescope
3.
The telescopecan be retractedby movingthe masterswitch.
if the telescopehas reachedthe end position,move-5618 to the centre
positionto pin the telescope.
Press5618 downto releasethe tele cylinder.
The tele cylindercan now be freelymovedif any othertelescopeshaveto be retracted.
The two lineson the telescopingscreenextinguish-H613now goes off again.Proceedas
describedin steo 1.
Liebhen-WerkEhingenGmbH - Technica!training
Servicepersonnel
Onlyfor LIEBHERR
- 29 _
UIBHTNR
Prcdued by: lreFrc / Ediiion: 13-11.06 / VeFid:ol
8. Hydro-mechanicaltelescoping
systemwith pulleyblock
)8.1 Purpose
Thetelescopicboommaybe hydraulically
extended/retracted.
Thisprovidesthe telescopiccranewithvariableradiusand lift.The boommustbe designedto liftthe attachedloadin the intendedapplication.
)8.2 Layout
Fig. 1 : 3-stagehydro-mechanical
telescopingsystemwith 2level pulleyblock
Articulatedpiece
Flatrope
Flatrope2
Telecylinder
Onlyfor LIEBHERR
Servicepersonnel
Retum cable 2
-30-
UBHINR
Arduced by: l*epiro / Fdition:13.11.06/ Ve6ion:01
Flat rope 1
Flatrope2
Returncable 1
Telecylinder
Retum cable 2
)8.3 Function
2 and3 are exTelescope1 is extended/retracted
usinghydrauliccylinders.Telescopes
tended/retracted
usinghydraulic
cylinders
together
withropesanda 2-levelpulleyblock
1,2 and3 are alwaysextended/retracted
synchronously.
system.Telescopes
- 3 1-
UBHINR
Prcdued br lrepiro / Edilion: 13.11.06 / VeEion:o1
9. Boomsystems
)9.1 Abbreviations
Telescopicboom
Extendedtelescopicboom
K/NZK
Foldingjib / hydraulicallyadjustable
Fixed latticejib
Luffinglafticejib
ry
Telescopicboom relaxed
Spacer
Denickboom
It
Suspended
ballast
SOWF)
-32 -
UEHENR
OW 14 - Telescopic boom / Telematics
Prcducedby: lwepid / Edilion:13.11.06/ Ve6ion:01
10.Reversalwindow
)10.1 Gripperpinningreversalwindow
(signalarms)areusedto applythegripperpinning.
Speedreduction
is
Thetrackswitches
controlledby the lengthsensor.
Figl: Reversalwindowgripperpinning
Telescoping
out
Telescoping
in
-----
O t u ( m d i m u ns p 6 e d )
<-
r
I
I
Q= 76 Unin (rcduced
spld lv.l firhout pins
I
i---T-
O= 3l Umin (rcduced
)10.2 Telepinningreversalwindow
of telepinningandthespeedreduction.
Thelengthsensorcontrol's
theapplication
Figl: Reversalwindowtele pinninghole
in
Telescoping
Telescoping
out
a*
<-
{ dimale Geschwindigkeit)
rerescope
in
I
---t- I
-1--it-t
O = 76 Uftin keduced
sp.d l.v.l wlthout pirs
q= 3t Umin {.educed
ben.oolid
!(.-_'
Note:
On cranemodelsLTM 1160-5.1and LTM 1200-5j the reversalwindowis pressure-controlledinsteadof time-controlled.
-33-
UEHENR
Component
description
Prodled by: lwed|{) / Edi[on: 13.11-06/ V4ion:01
Liebhen-Wsrk Ehingn GmbH - Technical training
Onlyfor LIEBHERR
Servicepersonnel
-34 -
UEIIRR
OW16- LICCONTestsystem
:II*Irngu:
f,'flrrrrrr
,s'rrlEEtrtrtrElAlEl
NurfUrLlEBHERR-Servicepersonal
Note:
test programs.
Thisdocumentexplainsthe procedurefor superstructure
program
wasselected'
engine
active"
39 ,,VentDiesel
As an example,test
test programs.In
Thisdocumentcanalsobe usedas a samplefor othersuperstructure
procedure
will deviateslightly.
this case,the
conesponding
for "Testprograms(chassisand superstructure)
Seealsothe description
to thecranenumber.
OW 16 - LICCONTestsystem
Prcducd by lwdpilo / Edilion: 18.10.06 / Vion: !
Contents
1. TestprogramsSuperstruc{ure
t.---'
Liebhen-We* Ehingen GmbH - Technical training
personnel
UIBHRN
Pmded by: lwpid / Edition: 14.10.06 / Vlsiod 1
Liebhen-werk Ehingen GmbH - Technical training
personnel
uErmn
Producedbv: lweoirn/ Edition:18-10.06/ Ve6ion: 1
1. TestprogramsSuperstructure
1.1 Test program 39 - Vent Dieselengine active (for PLD engines)
Fig.2 : Configuration
screen
1.1.1Releaseof i-key
I.E't,
Task:
The engineventingis usedto vent the fuel
linesbetweenpumpand nozzleon a PLD
engine.
=.=i-e
=!:=
*._-
G'.e
.'GjQ-
Basicprerequisite:
The enginesin the chassisand
the superstructure
mustbe turnedoff.
ito
1 . Switchthechangeoverswitch
to
UWOW(chassis
/ superstructure)
position.
,,Superstructure"
z.
-!!
:tl :;;i i
ir:, ri.. rnri6)
Fig.3 : Operatingscreen
Turnon thesuperstructure
battery
masterswitch.
, 7 a:
1::9
,-?:is-:
iEli
i 0 ::--==
3. Turntheignitionswitchsuperstructure
engineto position1 (15) (fig.1).
.J
LXJ
t2'9
Fig.1 : lgnitionswitchsuperstructure
engrne
position| (15)
Til i-
: < >_o:
l9
o - r 1rs)
tr /t\r(so)
grcFr 1
F3
IFE- .r
F{
it- \ = /rt
ENIER
Fig.4 : Operalingscreen
'l::8 : s-
*|
4 . Inthe configuration
screen(fig.2)
'
pressthebutton@ .
^ .T,
5 . lf errorsarepresent,
confirmerrorwith
theFl,,Horn"key(fig.3).
F +F r
press@ll
6 . In theoperating
""t""n,
+ ll@ll
at thesametime(fig.4),to open n w'
PROGRAM'
.
the,,SUPERVISOR
@a
t : = . : : :
personnel
- 5 -
-'!'
F1
F2
Fr
i1
::_
!/,
.1
lEq
, 1.' .
- /4,
;)ql
oo:o
trtr <it:o-:
Fs 11
!q
E:r,nEF.
TTTBilINR
Prcducedbv: lweoiro/ Edition:18.10.06/VeFio.i 1
7. Enterthe dailycoOe[-[-[-[
numberkeys (fig.4).
Note:
The dailycode is calculatedwith the Daily
codecalculator.In the LICCONPROthe dateandthe
GRAMSUPERVISOR,
cranenumberrequiredfor calculationis
snown.
- modify
Fig.5 : LICCONPROGRAI\4
SUPERVISOR
key(fig.5).
B. Press@,,rrrrOolfv"
- i-key
Flg.6 : LICCONPROGRAMSUPERVISOR
9. Presskeyl, j ,,Test
system"(fig.6).
personnel
- 6 -
IITBHTNR
Prcdu.edbv: lweoilo/ Edition:18.10.06/ VeE on: 1
- access
Fig.7 : LICCONPROGRAMSUPERVISOR
10.Presskey@ for,,ACCESS".
11. Enter
access
number
E - El . El
via numberkeys.
Note:
The releaseof the i-keyis eliminatedagain
at ignition'OFF".
- End
Fig.8 : LICCONPROGMM SUPERVISOR
12.Press
@,,rruo'key(fig.B).
'13.Press "f ruO'keyagain(fig.9).

@
- End
Fiq.9 : LICCONPROGMM SUPERVISOR
personnel
-7
UIBHINR
Pdduced by: lwepio / Ediiion:18.10.06/Ve6ion: 1
- accept
Fig.10 : LICCONPROGRAMSUPERVISOR
14.Press@l
(fig.10).
t"v to acceptthechange
Onlyfor LIEBHERR-Servicepersonnel
- I -
lITBHTNR
P o d u c e db v : l w e o n o/ E d t o n : 1 8 . 1 0 . 0 6 / V e 6 i o o : l
1.1.2Note source word description

(operand)
Fig.1 : StarttheMulti-CPU
testsystem
'1. Press keyto startthe

I
MultiCPUTest
system(fig.1).
key
2. Press
@,,svsrrv sPECIAL"
to see the specialviews(fig.2).
3. Press@ "pug"down"key(fig.3)
Fig.3 : Indexspecialviews
untilthemenuentry,,Engine
superstructure:
Testprograms,
errormemory"
appears
in thespecialviewoverview.
Note:
Thespecialviewoverview
canlookdifferentlyfor eachcranetype.
personnel
- 9 -
lIIBIIIRR
Pmduced by: hrspilo / Edition; 18.10.06 / VeBion: 1
Testpr.
super Fig.4 : Selectionspecialview:Enginesuperstr.:
4. Selectthemenuentry,,Engine
programs,
errormemo
structure:Test
, Daucre68/ - sllitr r 0) r '
pressing
down"
the
ry"by
@ ,,Cursor
key(fig.4).
.!
r.elflt,..rre
r.!l-,,D
tI]n@rMtr@
r?6 ,3rrl
Fig.5 : Specialview- Enginesuperstructure...
5 . Confirmthe selectionwithFE]
openthespecialview(fig.5).
to
6 . Notethe sourceworddescription
(theoperand)of test program39:

,,VentDieselengineacti,ve"
(forexampleQW2.39).'
EEENtfEE@
keytwice
7. PresstheEl ,,BACK'
tn a row.
training
Liebhen-Werk
Ehingen
GmbH-Technical
- 10 -
personnel
UEHRN
description
Component
Producedby: lwepO / Edition:I8.I 0.06/ Vercion:1
Fig.1 : Selection/ Test+ Error
1.1.3Changesourceword
+ enor key(fig.1).
1. PresslrsI ,,Test
F i g . 2 : S e l e c t i o/nA W L D I S - l N T
2. PresslEl_ll
key(fis.2).
,,AWLDIS-lNT"
3. WiththekeysE,o |E, setthecursor
to QW
4. Enterthe previouslynotedsourceword
description
via the numberkeys.
Note:
The sourceworddescdption
2.39mustbe
enteredwith 2039.
key(fig.3).
5. PresstheIEI ,,CHANGE"
training
Liebherr-Werk
EhingenGmbH- Technical
personnel
Fig.3 : Selectionchangesourceword
- 11
UIBHINR
P'oducdby: lwspno/ Edilion;18,10.06/ Ve6ion: I
Fig. 4 : Changeand accept sourceword
6. Viathenumberkeys,enterthevalue
039 (forTestprogram39) andconfirm
with[erTE (fig.4).
- 12 -
personnel
lIIBTIIRR
Poduced bv: weoiro/ Edition:i8.10.06/ Ve6 on: 1
Fig. 1 : Start SystemSpecial
1.1.4Checksourceword change
Note:
Afterchangingthe sourceword,it must be
ensuredthat the changewas accepted.
1. PresstheE ,,BACK"
keytwice.
key
2. Press@,,svsrev sPEC|AL"
(fis.1)
re../
PressE ,,page
down"keyuntilthe Fig.2 : Specialview- Enginesuperstructu
menuentry"Enginesuperstructure:
Testprograms,
appears
errormemory"
in thesoecialviewoverview.
4 . Selectthemenuentry,,Engine
Testprograms,
error
superstructure:
memory"
by pressing
the]Fl ,,Cursor
down"kev.
5. Confirmtheselection
with@]
opentheSpecialview.
to
6. Checkentry(fig.2).
Note:
Thepreviously
changedsourcewordmust
nowhavethechanged
value (39forTest
rogram39)
- 13 -
personnel
lIIBHINR
PEducedbv: lweoim/ Edition:14.10.06/ Ve6ion: 1
engine- position
1.1.5StartTestprogram39 - ,,VentDie- Fig.1 : lgnitionswitchsuperstructure
(50)
r
sel engineactive"
1. Turnthe ignitionswitchof the

superstructure
engineto positionll (50)
untilthesuperstructure
enginestarts
(fis.1).
Note:
To start Test program39 -,,VentDiesel engine active", a secondpersonis required.
with startingthe superSimultaneously
structureengine,the manualfuel pump
(fig. 2) must be actuated.The fuel system
is vented.Due to the increasedinjection
of fuel, the exhaustfumesare increased
significantly.
The ventingprocesscontinues only as long as the ignitionswitchis
engagedor untilthe engineis running.As
soonas the engineis running,the process is stoppedby the enginecontrol.The
QW settingsare deletedagainvia ignition
Manualfuelpump
..oFF".
- 14 -
personnel
IIIBIIRR
OW 20 - Emergencyoperatingmode
Pbduced bv:lweoio/ Edilion:0606 07 / veBion:3
OW20- Emergencyoperationfor
the superstructure
Onlyfor LIEBHERR
Servicepersonnel
-1-
1IBIIIRR
PDducedby: lrepno / Editon:06.06.07/ Ve6ion:3
Note:
purposes
Thisdescription
is for information
onlyandservesto improvethe
understanding
of thereader.
Caution:
Theoperating
instructions
for a particular
cranemustbe readbefore
andtestprograms
givenin theoperating
attempting
lf in doubt,followtheinstructions
emergency
operation.
instructions
andtestprogram.
-2-
UISIENR
PEdu@d by: lwepi.O/ Edition:06.06.07/ VeEion:3
-3-
1lIBHINR
ftldu@d by lwedo / Edirion: 06.06.07 / vellion: 3
Onlyfor LIEBHERR
Servicepersonnel
-4-
UEHINN
Prcducedbyr lwepiro/ Edition:06.0607/ Ve6lon:3
1. Emergencyoperationfor superstructure
1.1 Emergencyoperationwithout LICCON(via X-Not)
)1.1.1 General
Emergencyoperationvia the -XNOTconnectorsis usedwhen the LICCONcomputer
svstemfails.
Speed adjusiment:
A potentiometer
is usedto regulatethe speedfor the cranefunctionsThe speedregulationfunctionfor "Model1" only controlsthe slewinggear,whereas
"Model2" also includesthe hoistgear and luffinggear.
potentiometer
Speedregulation
potentiometer
Fig.1: Speedregulation
fir
Fig.3: Model2
Fig. 2: lvlodel1
Onlyfor LIEBHERR
Servicepersonnel
-5-
UTBHINR
PDdu@d bv: lweDio / Edalion:
06.06.07/ Ve6ion: 3
1.1.2Slewinggear
-Removeconnector-X55from the relaypanel.
-Removeconnector-XNOTfrom the relaypaneland pluginto socket-X55.
i ij ii ij ii i'r
:i, ' r I r ' : ' r | |
: - , I I r r i : I | | |
F::i:i
:.i:.jH
i
;
i i I i i i i i l:l
i riiiiliill
n
(:>fL,J
'
.I
"-- h
; E
ili
r: :turnleft
fir
r : turnright
-S622"Function
Pushbutton
driving
switch"(turnleftor right)
Caution:
Afterthe cranefunctionhasbeencompleted,removeconnector-XNOT
and plug
connector-X55
intosocket-X55.
Liebhen-WerkEhingonGmbH - Technicaltraining
Onlyfor LIEBHERR
Servicepersonnel
-6-
UIBHINR
Prcdlced bv: lweoio / Edition:06.06.07/Ve6ion:3
1.1.3Hoist gear I
-Removeconnector-X51on the relaypanel.
F ii i"; i; i; f;
l::
: _
' I
r r
' |
| |
' r
r r
' I
I t
I
I
F 1; J;:i l; fi
i i i i i l l l l l l
i i i i i r i l l l
ts
Lr.r +
Lc- Lcr+
q- j ,,
ir_+!' { - ,..
F;-,r-r ,1;lll
fii
rr : raisehoistgear I
fir
I : lowerhoistgear I
Pushbufton-5622 "Functiondriving
switch"(raiseor lowerhoistgear l)
to ,,raisehoistgear ll" the

To disable"hoistgear I unwound"operatesynchronously
pushbutton-5626 (-5620) "Pressurestage" *
I '-' l.
|t_il
1
I ilt_Eltl+l
\ : /
Caution:
removeconnector-XNOT
andplug
Afterthecranefunctionhasbeencompleted,
intosocket-X51.
connector-X51
* = Activating
pressure
onlywithappliances
with
of the,,Manual
boost"is necessary
pressure-sreps
-7-
1lEHENR
Poduce! bv: lweDiiO
/ Edition:06.06.07/ Ve6 on: 3
1.1.4Hoist gear ll
-Removeconnector-X52 on the relaypanel.
-Removeconnector-XNOTfrom the relaypaneland plug intosocket-X52.
3 i; i; i': ii i';
i
l ; l ' L
| r r r
t -
: i
r |
' I
| |
r l
r I
FI : r I, I= ri > i i ; F
i
i '
I - l
i i i i t l i i i l = l
. i i r ll : , | J L
-'
{---l------l
IL_d--:-l.:
:tr
c------H
f,i
r; : raisehoistgear ll
fir
I : lowerhoistgear ll
Pushbutton-S622"Functiondriving
swit6h"(raiseor lowerhoistgear ll)
to ,,raisehoistgear ll" the

To disable"hoistgear ll unwound"operatesynchronously
pushbufton-S626(-S620)"Pressurestage"*
/ r-r
\.
iEL+
Gaution:
and plug
Afterthe cranefunctionhas beencompleted,removeconnector-XNOT
connector-X52into socket -X52.
* = Activating
pressure
boost"is necessary
with
of the,,Manual
onlywithappliances
pressure-steps
-8-
lIIBHINN
Podlced bv: lweDiro/ Edilion: 06.06.07 / Ve6ion: 3
1.'1.5Luffinggear
-Removeconnector-X53 from the relay panel.
P'*itl: i:ft
1:: r r , r , I r I r I
l - lI ' r | , I r r r l
u:"1
:"i, :"i
:.1I
| i '
i r i , t
i i l i i r I i i lEl
i ill i iiiil.l
.e--!.-o....-o..!'
n
.-4*=_-u
L
-:: E
-'
fit
rr :luffingup
fir
: : luffingdown
Pushbutton-5622 "Functiondriving
swititr" 1tuffup/down)
-3626(-5620)"Pressure
stage"*
operatesynchronously
to ,,luffing
up"the pushbutton
/ '-. I.
|t-il
1
| iltd{Fl
I I|:II
t -
Caution:
After the crane functionhas been completed,removeconnector-XNOTand plug
connector-X53into socket -X53.
* = Activatingof the
pressure-sreps
,,Manualpressureboost"is necessaryonlywith applianceswith
Liebhen-WerkEhingenGrhbH- Technicaltraining
-9-
IIIBHINN
Podu@d bv: rweoio / Edition:06.0607 / Veclonr 3
1.1.6Telescoping
-Removeconnector-X54from the relaypanel.
-Removeconnector-XNOTfrom the relaypaneland plug intosocket-X54.
lilrli";lii
.- .Li
+)-
+
i i i i i ,i i i
i r i r l r r i l . i
'f
,", - il
;r
i'ii','.";i+
f
r-q
-q
. .
l-l
lr -.1
F'
:l :1 rE:( |
fI I
:: :telescoping
in
Fr
il|
:telescoping
out
Pushbutton-S628(-5622)
"Functiondrivingswitch"(telescopein/out)
Controllight-H619(-H613)"Gripperin position"
ffi
unpintele
pintele,
unpingripper
pingripper
Selectorswitch-5624(-5618)"Gripper
/ tele,unpinandpin"
-5620"Manualpressure
boost"
Pushbutton
Afterthecranefunctionhasbeencompleted,
removeconnector-XNOT
andplug
-X54connector-X54
intosocket
Emergency
is not possible
withouttheLICCON.
telescoping
operation
ontheLTM1400-7.1
Onlyfor LIEBHERR
Servicepersonnel
-10-
IIIBHINR
Producedby: lwepid / Editionr06 06 07 / Ve6ion: 3
Unpintele:
. Selector
switch-5624(-561B)0 -> ll
"Unpintele"
lt- l 4 tl
ltuilt=tl
-5628GS622)
"Telescope
Pushbutton
0 -> |
out"untiltheteleis unpinned.
-S626
pushbutton
(-5620)"Pressure
siage"*
T
nl,m l n l m I
n,lEllE$r*tllgFl
\ /
Telescopein and unpin the tele:

. Pushbutton-5628 (-5622)0 -> ll
"Telescopein"
-5626(-S620)"Pressurestage"*
pushbutton
n,lmll=+
n,l$llll
/-
llt.l I
lllqti*l
\/
.Switch-5624 GS618)Il -> 0

-
Select"Pintele"and
t4 tl
ft-tLtEtl
=
L_.I
I _ i . - I
.Pushbutton-5628 (-5622)0 -> ll
"Telescooein" and
.Operatepushbutton
-5626(-5620)"Pressure
stage"untilthetele-pinaudiblylatches.
l
i', lliriillf
lll-ll I
rl thdillJj
lil@l{f,|
I t-t
I
| \r^lll-1,
ll-ll
\-
* = Activatingof the
,,Manualpressureboost"is necessaryonlywith applianceswith
pressure-sreps
Onlyfor LIEBHERR
Servicepersonnel
-'t1-
UTBTTTRR
Prcducedbv: lweDio/ Edition:06.06.07/ VeFion: 3
Releasethe cylinder:
.Pushbutton-5628 CS622)0 -> |
"Telescoping
out"
operateuntilthe lockingpin on the
telescopingcylinderis relaxed
f,r
fll
.Selectorswitch -5624 CS61B)0 -> |
Select"Gripperreleased"
Extendingand locking the cylinder:

.Pushbutton-5628 GS622)0 -> |
Operate"Extendcylinder"until-H619
(-H613)"Gripperin position"is lit
t-t
n,IffilFil,
llEll .6
n,lLsllEF LEI
-S624CS618)| -> 0
.Pushbutton-S628
(-5622)0 -> |
n,lffiTFl
"Lockgripper"
"Telescope
out"untilthe pin
latches
audiblv
n'l&llEli*
-12-
UTBHINR
Producedbv: lweoiro/ Edilion:06.06.07/VeEion:3
)1.2 Emergencylowering (emergencycrank)

Emergencyoperationis optionaland variesdependingon the cranemodel.A transformer
or externalhydraulicpowerunit assiststhe operatorin selectingand performing(using
the handlever)all cranefunctionsevenwhen the hydraulicshavefailed.Furtherdetails
are givenin the operatinginstructions
for the specificcranemodel- thesemust be
and is
observed.The followingdescriptiononlyappliesto cranemodelLTM1100-4.1
providedto improvethe understanding
of the reader.
Connectthe hydraulichoses
Set the ball valveon the chassisto emergencyoperation
Ballvalvechassis
Fig.2: Hydraulictransformer
Hydraulictransformer
and ballvalveon
Fig.1: Transformer
chassisLTM1100-4.1
Note:
The operatinginstructions
and emergencyoperationsignon the cranesuperstructure
both includea table(Fig.3) depictingall the possiblecranefunctions.
Onlyone movementcan be performedat any one time.
C
1
/4 \ s d 6{ "9 r( i .
\ 4d d6 { 6" }9 i
1\
A
9,
9- \ C {
"r
"y
* '
{ \ {
1
a/
U
powerunit(Hatz)
operation
Fig.3: Example
ot emergency
operation
signon LTN,'I11004.'1 Fig.4: Emergency
Liebher-werk EhingenGmbH - Technicaltraining
Onlyfor LIEBHERR
Servicepersonnel
-13-
lIEHINR
Poduced bv:lweDi'O/ Edition:06.06.07/ VeEion:3
Set the ball valvesfor a particularcranefunction(referto the tablein the operating

instructions
or the emergencyoperationsignon the cranesuperstructure
Valve1
Valve2
Valve3
Valve4
Valve5
Valve6
Valve7
Valve8
Fig.3: Exampleshowingballvalves1-8/ LTM1100-4.1
Note:
The ballvalvesmustalwaysbe fullyswitchedto the desiredswitchingposition.
- Carefullyoperatethe handleverto drivethe cranefunctionpreviouslyselectedusing

the ballvalves
Handlever
Fig.4: Ballvalve9 and handlever/ LTM11004.1
Note:
All ballvalvesmustbe switcheddownfor normal"craneoperation"
-14-
UIBHTNR
Prcducedbv: lweoio / Ediiion:06.06.07/VeEion: 3
)1.3 Manualemergencytelescoping operation using LICCONand key switch "-S81"

When performingmanualtelescoping(e.9.telescopingunderload),unpin/pinthe
telescopingcylinderand performthe telescopingactionby hand.
The markingon the telescopingscreenindicatesin whichtelescopethe pinningdeviceof
the telescopingcylinderis located.
The distanceto the telescopepinninghole can be read off on the telescoping
screento an accuracyof 1%. Manualtelescopingis only used in exceptional
circumstances
as automaticoperationpermitsthe rapidattainmentof any
telescopingstate.
Note:
The "Emergencytelescopingoperation"key switchshouldonly be turnedon by
authorisedpersonsinstructedin the use of the "Emergencytelescopingoperation"
feature.
C A U T I O N: Overloadprotection(LMB)and hoistlimitswitchare bypassed.
D A N G E R : Craneoperationwith key switch-SB1turnedon is prohibited.
Thereis a severeaccidentrisk!
Emergencytelescoping operation after the failure of an inductive sensor using
key switch "-S81":
Set key switch-SB1in the qontrolcabinetto emergencyoperation.
fT-'ii
*FHI
l}t ,tt']
Key switch
telescoping
The emergencyoperationsymbolis shownon the operatingscreen.

Emergencyoperation
Liebhen-WerkEhingenGmbH - Technicaltrainlng
Onlyfor LIEBHERR
Servicepersonnel
-15-
IIIBHINR
Poduced bv: lweDio/ Ed tion:06.06.07lVe6ioa:3
switchedoff when the engineis turnedoff.

Key switch-S81 is automatically
program,press
In the "telescoping"
"F1"
key
to switchto manual
telescoping.
The "Automatic
telescoping"
indicatorand the set values
for eachtelescopicsectionextinguish
on the LICCONmonitor.
The telescopiccylinderand
its telescopicsectionare locked
and releasedusingpushbutton-5618.
Functionkey F1 on the monitor

Press"Manualtelescoping"
"Automatictelescoping"
Unpintele
ilH
Pin tele,
pin gripper
unprngnpper
Function of switch positions -5618:

Positionfrom 0 -> ll
Telescopicsectionis unpinned,telescopiccylinderstays
lockedin telescopicsection(teleunpinning).
Positionfrom ll -> 0
Telescopicsectionis pinned(telepinningestablished).
Position0
Telescopiccylinderis lockedto telescopicsection;telescopic

sectionsare pinned(telepinningand gripperpinningactive).
Positionfrom 0 -> |
Telescopiccylinderis releasedfrom telescopicsection,

telescopicsectionsremainpinned(gripperunpinning).
Positionfrom I -> 0
Telescopiccylinderis lockedto telescopicsection,

Telescopicsectionsare pinned(gripperpinningestablished).
Controllight-H613is litto showthatthe

telescopiccylinderis in the lockedposition.
Onlyfor LIEBHERR
Servicepersonnel
-16-
.s.
m.
Controllight-H619CH613)
"Gripperin position"
IIIBHIRR
Functional
description
Poduced bv: lweoid / Edition:06.06.07/Ve6ion:3
HWI operation:
- Telescopeis telescopedin usingleft master
switch (or foot pedal)for craneswith t hoist
gear,startingwith the innermosttelescope.
HWll operation:
- Rotaryswitch for master switchfunction
mustbe set to telescopingoperation(left
position).
- Telescopeis telescopedin usingrightmaster
switch(or foot pedal)for craneswith 2 hoist
gears,startingwith the innermosttelescope.
f,r
l'.,-
f\
-";:
/-\
Ms2 I
fir
HWI - operation/ left masterswitch:
Note:
requires
the
Theexecution
of emergency
operation
systemon
engineto be runningandthe hydraulic
Telescoping
thesuperstructure
to be operational.
speedis reducedduringemergency
operation,
Rotaryswitchfor
masler switch
functionin HWll
operalon
t@L
t*'"
X
f
i
r
)
.
.
o
_L I tt ---J_
";:r
I
I
l@r
>fit X
___l_ | I ' _l_
ti:1
HWll- operation
/ rightmasterswitch:
Telescopingusing telescopingfoot pedal:
- 1 7-
UTBHINR
Prcducedbvrlweol.o/Ediuon:06.06.07/VeEion:3
Procedure:
Prereouisites:
- The telescopicsectionsare pinned(telepinningactive)
- The telescopiccylinderis pinned(gripperpinningactive)
1. Moveswitch-S118from position0 to position2 to unpin.
out" directionto releasethe
2. Movemasterswitch(or foot pedal)in the "telescoping
jumps
pin
tele
whichthen
backdue to the springtension.
3. Oncethe tele pin is released,movethe masterswitch(or foot pedal)in the
"telescoping
in" direction.
4. Beforereachingthe tele pinningholeat 0%, moveswitch-S118from position2 to
position0 to applythe tele pin.
5. Movethe masterswitchon the telescopingin directionuntilthe lockingpin on the tele
pin audiblylatches.
6. Movethe masterswitch(or foot pedal)in the "telescoping
out" directionto releasethe
pinning.
pin
gripper
locking on the
7. Moveswitch-S118from position0 to position1 to releasethe gripperpinning.
8. Movethe masterswitch(or foot pedal)in the "telescoping
out" directionuntil control
light-H613"Gripperin position"
is lit.
9. Moveswitch-S118from position1 to position0 to applythe tele pin.
10. Movemasterswitch(or foot pedal)in the "telescoping
out" directionuntilthe tele pin
pinned.
is
Liebherf-WerkEhingenGmbH - Technicaltraining
Onlyfor LIEBHERR
Servicepersonnel
-18-
IIEBHIRR
P'oducedby: lwepio / Edition:06.06.07
)1.4 Hydraulicemergencytelescopingoperation
hosefor Hydraulic
hosefor
Hydraulic
(blue)/
cylinder
lock(red) telepinning
/ connect2 to 4
connect
'l to3
Ball valve pinning tele (blue)
rodfor
Auxiliary
coupling
quick-release
connections
on
teleunpinning
mechanism
Couplingpoint turntable emergencyoperationgripperpinning(1)

Ball valvepinninggripper (red)B
-MP
point
Measuring
Telepinning
Ball valve
Pressureboost
emergencyoperttion telescoping(A)
-MP
Measuring
pointA2
Quick-reIeasecoupling
(3) Emerpncyoperation
girye r
ngUnpinning
telescopi
(red)
Membranevessel
Quick-rele asecoupling
(4) Emergencyoperation
telescopingunpinningtele
(btue)
Controlblockunpinning
Changeover valve
Telepinning/
Gripperpinning
\.-,'
-19-
;t
UEHINR
Producedby: lwepid / Edilion:06 06.07/ VeBion:3
Pre-requisites
for emergencyoperationwith ball valves:
- Craneengineis operational
- Operationalhydraulicplant
- Telescopepinningand gripperpinningmechanismsare operational
- Telescopiccylindercan be telescopedin/outusingmasterswitchor -XNot
- Priorto emergencyoperationwith ballvalves,the valvefor changingover

the gripperpinning/ tele pinning-Y40 GY17)mustbe electrically
disconnected.
- Set the telescopicboomas steepas possible.
The enginemust be turnedoff beforeconnectingor disconnecting
any
hydraulic
lines.
Hydraulichosescan only be connectedat a maximumdistanceof 2 m. If necessary,use
an auxiliarycouplingrod to couplethe hydraulichoses.
- Coupleup the hydraulichosesfor pinningthe telescopicsections(blue):
Connectcoupling1 to coupling3.
- Coupleup the hydraulichosefor gripperpinning(red):
Connectcoupling3 to coupling4.
- Turnon switch-SB1(emergencytelescopingoperation)in the controlcabinetif
telescopingwill be performedusingthe masterswitch.
- Switchto manualtelescopingin the "telescoping"
program,"F1".
The emergencyoperationsymbolappears.
- Set ballvalveA to emergencyoperation.

Moveball valveA from normalto emergencyoperation:
-BallvalveA in line -> Normaloperation
-BallvalveA at rightangles-> Emergencyoperation
-20 -
UIBHIM
PEducedbv:lweDl0 / Edilion:06.06.07/ veE onr 3
Pinningand unpinningof the telescopicsections(telepinning)and telescopiccylinder

(gripperpinning)is performedusingballvalvesB and C.
Telescoping
in/outis performedusingeitherthe masterswitchor pushbutton-5622
"Functiondrivingswitch"in X-Notoperation.
Lock/release
the telescopiccylinderusingballvalveB:
-BallvalveB pointingup -> telescopiccylinder(gripper)released
-BallvalveB pointingdown-> telescopiccylinder(gripper)locked
the telescopeusingballvalveC:
Lock/release
-BallvalveC pointingup ->telescope(telepinning)unpinned
-BallvalveC pointingdown-> telescope(telepinning)pinned
Gripperpinned
Telepinned
unpinned
Gripper
Telepinned
Gripperpinned
Teleunpinned
non-permissible
state
the hylf the telescopicboomhas beenfullytelescopedin, it it necessaryto uncouple

draulichosesfor emergencyoperation.
The enginemustfirst be switchedoff.
- Disconnectthe hydraulichoses.
- Set ballvalveA to "craneoperation".
- BallvalvesB and C must be set to pointdown.
- Afteremergencyoperation,removethe test adapterand allowthe fluidto flow
throughthe operationalvalve-Y40 (-Y17).
-21 -
UEIIIRR
Functional
description
Produced by: lwep r0 / Editon:06
06 07 / Ve6ion: 3
1.5Re-establish
tele status
tele status,general:
)1.5.1 Re-establish
rlRfft 0
E
O
LI[[!]r,1
rElttE:l]}fl1]G
;,1
:i z r'
1r.=1,
fT}{ffi
Ff5/_tfflFtfti
li Zt 0:
Llts
1 L&nlenribrdereLlzumVE.bol:a,lprll, lelelamsehquelli!
''r-l\,o..
=l:+,a}
,91Fi,
Ff :
i?:
:F3
:F.: :F5 56: :F7: .I!:
Fig.1:Telestatus
tipped:
Fig.2: Error
Fig.
Errormessage
message
The tele statusis tippedwhenthe commonmemorycard is replacedorthe LICCON

receivesa "tele-pinpinned"signal,eventhoughthe lengthsensoris in a positionwhere
thereis no pinninghole.
lf the tele statushas tipped,neitherautomaticnor manualtelescopingis possible.
. All numericvalueson the tqlescopingscreenare displayedas flashing"???".
. Symbolelement"Suppresstelescopingaction"and "STOP"are flashing.
. A systemerrormessage(telescoping
in) is shownon the operatingscreen.
CAUTION:
The flashingvaluesin the symbolelementswarn that the indicatednumericvaluesfor
"Currentload","Pulleyheadheight"and "Projection"
are not precise.
The tele statuscan be re-established

either manuallyor usingthe LICCONcontrol
system.
)1.5.2 Manuallyestablishtele status:
Manuallytelescopein by operatingkey button(D) "Assembly":
. Retractall telescopicsectionsup to the last tele.
. The cylindermustbe pinnedin the last telescope(telewith pulleyhead)and telescoped
in to a tele lengthlessthan 50%.
Liebherr-WefkEhingenGmbH - Technicaltraining
Onlyfor LIEBHERR
Servicepersonnel
-22 -
lIIBHTNR
Produced by: lwepid / Edilion: 06 06 07 / Vecion: 3
)1.5.3 Establishingthe telestatusvia the LIGGONcontrolsystem:

Fig. 3: Multi-CPUtest system
Gaution:
The dailycodeis requiredto set the tele
statususingthe LICCONcontrolsystemI
LICC0N
llfTl-zE-lEsTsYsrfi - VAsm $.m
L I l l 1 1 t r 0 /P2r o l o
N. ollml
1. PresstneE} "SystemSpecial"
key
on themulti-CPu
testsvstem.
I ^ . o
> U:A
c) LItltXR-ltR( ENll6El1S
;ISIEfIIII:
tffirFE;
S r 13
ffiflitrIRlB
;YSIBll{lFIeXnTI0l:
ITn:
lE
fiDffi
.twffi
tr-rF(rl1
RfFf 0l0r?
I |
ol.m-B
0374- 094168
m.rc-(E.s
m.04
:l
-_II-INI
F1
F2
F3
\\F4
.::z
-rq.4: :'pecralscreens
ffi
llLD-latei 0
/ F5
F6
F7
LI}l 1$0/2
tIHXSIfff
2. In the Systemspecial,selectspecial
screen"LMBSCREEN4 (manuallvset tele
status)".
Caution:
Thespecialscreennumberwillvary
ingon thecranemodel.
F8
$ ite 3/ 4
> 0,33rfl.6ft]-ESltrffigi,trIl[IfRt[I]i
0,34rEINfi1-fltrImB{,trIltrIfRt{Ili
0,35:n]sllltstrftftli, trIfzlfRlfili, KmKItr!{XII
0,36:EINIIIEI(PIffTI{,ft}'I!F.Il,
KMKLEIXTT
0.T/r IE-CKPItXtli,SIHEt, KffilltFtXIE
gREt,
0,38:F-)ftL
Kffil{IlStRTE
0,3r SftUnm / fEfi 16 EllsIELi{nIE
0.40:flttl fi$tXS}[Im ,/ KltFf, l{l{:l{I, m-tr(Elm trz
0.41rtutoTele,fhuptbild
0,42: turoTele,mo}{tl,l
0,43: tuioTele,mOFHIei
0,44rSbeitsbere
ichsbeeen,uns
0,45rLIB-I
0,46rLfiH
r].i rnl
*4;i-:a+trtr1tffi!Fe-q1jr'
- )6- )
! , a E : L i l B B l l l l 4 " " . r d . . w . F l l s er ? n r
r-l
F2
F3 F4
F5
F6 F7
F8
5: LMB SCREEN4
SYsTtI-FUNkTMI
SFUItr-BIII
=>0.48:LnBBILo4 (Telestatus
rEnlellsetzen)
3. Notedownthe datawordsand CPU.

Caution:
The datawordswill vary dependingon the
cranemodel.
L T I1 r S 0h/ 2o t o
Dl1.1?0
4. Changing
thedatawordsaccording
to the
extension
stateof thetelescopic
sections.
5. Entera number1-6in DW1.126to
indicate
in whichtelescopic
sectionthetele
0.0>D l 1 . 1 ? 1
3 : 0.0>Dr1.1Z
0.0>Dr1.12:
5 : 0.0>Dr1,1?4
6 : 0.0>Dr1,1.
7 l 0.0>IIl1,126
0.0)ul,ln
tzl
Lx,l
ttl
t2,1
0(25al
0,D rl5C3
0.D 05C4
0,D &C5t5
0,D 0@6
0,D 0.Sl
:
:
:
:
:
lm
lm
0
0
Tn
I
:
:
:
:
Zulinderin Teieflrmr
1:tlebern.0:tX
1 6,11 16,20,30:Error
tzl Telel aktuelleLaense
Tle
tzl
2 aktuelleLaense
tzl Tele3 akiuelleLaense
:
:
:
:
tzl Tele4 alluelle Laense

tzl Tele5 aliuelle Laene
tzl Tele 6 akluelle Laense
tcnl Arsfaf.laense Zul inder
cylinderis located.
-23 -
IIIBHINR
Poduced bv: lweoio / Fdiuon:06.06.07
/Ve6ion:3
LICC0N
- lT}5rr 6.m
|r.LTI-ZE-1tsTnSrt1
L T I1 m 0 /n2' o i o
m. (|lllm
> 1411]
ts
ITM :
01.m- f1
0?4 - u4sl
FIffl,|If 03.18 6.3l
mTnPfill 03.04
fRt!$Ft
6. SelectthecorrectCPUand presskey
0 1 2
"AWLDIS.INT".
F2
F3
F4
F5
F6
F7
F8
Fig.6: Multi-CPUtest system
L.
L.
tL.
L
.
L.
c-._.
rL._.
At_
I],I
tt.
L
[.
t1{._
oL._
6T
F
T
L
D.
F[
lr'T[
:
L
FL
L
P__
F-,
F..
Y
Y.
TtT
ru
IIL
t_tL
r$L
7. Nowenterin turnallthepfeviously
noted
words
with
tele
data
together the actual
lengths.
Illl.120.
F1
F2
0: lm
: Telelaense
1
F3
F4
F5
F6
F7
F8
Fig.7: AWL operandspecification

5 Y 5 T E }1- F U N |( T I 0 N :
SFgltrllll)
.) 0,,18rt!l BIL! 4 (Teles!.tusrBnuellse{rei)
ln.tr ryry
B. Checkthe valueson the soecialscreen.

9. Enterthe value-1 in DW 1.127to apply
the modifiedDW-values.
l:
?l
3:
4l
5:
6l
0.qiu1.120
0/,,j) Dl1. 121
r'/.o>Lw.Ia
0.D fl.t1.121
0.D II,l1.124
0.D Itll,1[\0) Itll.128
E : l]NDII,IL.TA
! : 0.0)
0.0>
1 : U.U>
0(ac .. 2 . 8.0>0cT4
. 3 , 0,D 016t5
0.D 0c5cE
.5: 0.D &e$:
: 6 10.0>0c66f
TI I
Fl
F2
|I.r
lm ..\.
l$
\r
l m f
t l
3r,t/
0
0
0
7ru
I
III
F3
Proto
LTfl 108122
ffixft{D
lfRT tuschreibuns
Telelaenqe1
I:/.)
Telelaenqee
V.l
Telelaens3
Izl
Telelaenae4
lzl
Telelaenq5
lzl
Telelaense6
l'/.1
lulinder in Tele flmr
-1rLjebetr,0r0(1S. ll-1E,a0,:0:trror
tzl r.le 1akluelle Laens
l7l ]ele 2 aktuell Laens
lrl i.le 3 aktuelle Laens
lzl Tele,4 altu-aLieLaense
lrl Tele 5 aliueLle Laense
trl Tele 6 altuelle Laense
lcml tusfahrlaenseZqlinde.
I n l l u l i n d e r i n T e l el h .
IIIE
F4
F5
F6
F7
F8
Fig-8: LMB SCREEN4 (manuallyset tele status)

Liebhefr-WerkEhingenGmbH- Technicaltraining
-24 -
IIIBHINR
Pbduced bv: lweDio/ Edition:06.06.07/ Vedon: 3
)1.6 EmergencyoperationTY-guying- Failureof monitor function keys - LTM1400-7.1

EmergencyoperationwithTY-stayropesis usede.g.when a functionkey on the
monitorhas failed.This is operatedusingthe controlpanelpushbuttons
for diagnostic
operationTY-guyropes.Momentary-contact
functionkeysare used.This requiresa
secondpersonunlessa controlpanelis pluggedin. Emergencyoperationis not possible
in the eventof a totalmonitorfailuresincethe TY programcannotbe activatedusingthe
F-key.
Caution:
The TY-diagnostic
systemand henceemergencyoperationwithTY-guyropesshouldonly
be activatedby authorisedspecialists(LIEBHERRcustomerservice).
paneldiagnostic
Fig.1: Control
operation
TY-guyropes
-s129
-s120
Switchoff TYtest
sysrem
SwitchonTYdiagnostics
sYStem
-s121
-s122
Function
keyF2On,Secure
TYframeswithguyropes
Functionkey Fl On,
RelaxTY-frames
-s124
-s123
Function
keyF4 On,
Foldout TY frames
Functionkey F3 On,
Fold in TY frames
-s125
126
Function
keyFGOn,
PutdownTY frames
Functionkey F5 On,
ErectTY frames
Onlyfor LIEBHERR
Servicepersonnel
-25 -
lIIBIIIRR
Functional
description
Pmduced bv: lwoilo / Ednion: 06.06.07 / velllon: 3
i,_
'
i-''
\-.,1!''
li
Liebhen-We..k
EhingenGmbH - Technicaltraining
Onlyfor LIEBHERR
Servicepersonnel
-26 -
UBHRN

Liebherr Lehr Buch

Uploaded by

Copyright:

Available Formats

Liebherr Lehr Buch

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Liebherr Lehr Buch

Uploaded by

Copyright:

Available Formats

description

Libhetr-WkEhingnGnbB -T6chni t.ainlng

Fio.2: Flow ofelecttonsin an electricalcitcuil

Fig.4: Batteryas an electrcnPumP

DirectCurrent"DC"flowsin onlyone directionthrougha circuit.

of theflowof electronsis referredto as electricalresistance.

Libher-WerkEhlngenGmbH- T6chnl lralning

Liebhetr-We*EhingenGmbH- Techn@l tralning

Thesamecurrentflowsthroughall the resistofs.

Ubt= Ur+ U, +...

Thetotalvoltageis the sumof all partialvoltages.

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

is the sumof all partialresistances.

Liebher-Wft EhingnGnbH - Tchnlcallbining

Parallelnetworksserveto dividethe current.

All the resistorshavethe samevoltage.

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

Thetotalcurrentis the sumof all partialcurrents.

Ll6bh6r-W6rkEhlngnGmbH- Technil tEining

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

Fig. 14: [.4etrixMX22

Liebhetr-We* Ehingen GmbH - Techni@l tinhg

Liebher-Wei<EhingenGmbH- Techniel tra ning

Liebher-werkEh ngen GdbH - Technicaltiring

D924- A4 / 4 CylinderDieselInlineEngine(ow engine);

D934-A6 / 4 CylinderDieselInlineEngine(ow engin):

D936-AO / 6 CylinderDiesellnline Engine:

FSC (FuelService Center)

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

Suctioncycle (1. cycle):

Compressioncycle (2. cycle)

Thepistonmovesup andthe air is compressed.Thecompressed

Towardsthe endof the compression

Workingcycle (3. cycle):

Exhaustcycle (4. cycle):

Liebheii-Werk Ehingen GmbH - Techniel lraining

Libhr-we* EhingnGnbH - Technicataining

Fig. 1: OverviewPLD engine

The pointedinjectorlip on the CR nozzlecloses

Fig.2: fuelcooled engine

Fig.3: D846-A7- Commonrail engine

Fig.3: Originalilluslration,HallRP[/ sensor

>5.3 Oil Dressuresensor

Fig.2: Oil pressure

Fig.1: Extractof circuitdiagramforoil

Fig.3: Originalpictureof oil pressure

Liebheii-We* EhingnGmbH- Technil lraining

Liebher-We* EhingenGmbH-Techni training

Figl: Extractof circuitdiagramfor cooanilemperature

Fig.1: Extractof circuitdiagramfor

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

l EDO '1S00 2104

Fig. 1: Exkactofcircuit diagram

Flamestartingdevicescompriseone or moreflameglowplugs,a coolanttemperature

Fig. 1: Exlractof circuitdiagramfor LTM1070-4.1:

Fig.4: PrehealingconlrollightOW engine

Chargeair (compressedair flow)

enginedependson the amountof air andfuel,which

Partof the exhaustis directedagainthrougha pipeto the freshair for combustion.

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