AC100 Training Manual Ver.2.0 PDF

8331.
7 Technische Schulung
J.Christmann
22.01.03
Technical Training
Demag AC 100
Der krzeste 5-Achser mit nur 10,9 m
Unterwagenlnge
14,3 t Gegengewicht verfahrbar bei nur
12 t Achslast
Strkster 100-Tonner im Markt
Hoher Fahrkomfort durch modernste
Antriebstechnologie
The shortest 5-axle crane with a carrier
length of just 10.9 m
14.3 t counterweight carried on the
crane giving just 12 t axle load
Most powerful 100-tonne crane
in the market
State-of-the-art transmission ensures
high travel comfort
La 5-essieux la plus compacte avec
une longueur du chssis de 10,9 m
seulement
14,3 t de contrepoids transport
sur la grue sans dpasser 12 t de poids
lessieu
La 100-tonnes la plus puissante
du march
Transmission la pointe de la
technologie garantissant un grand
confort de conduite
www. dematic.com
14050
10995
3
8
6
0
3
9
9
5
7
0
0
0
13870
AC 100 10/99 07.10.1999 10:43 Uhr Seite 2
Inhalt
Contents
Contenu
Technische Daten Specifications Caractristiques
Abmessungen Dimensions Encombrement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Technische Daten Specifications Caractristiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Seite Page:
Hauptausleger Main boom Flche principale
Arbeitsbereiche Working ranges Portes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Tragfhigkeiten Lifting capacities Capacits de levage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Hauptauslegerverlngerung Main boom extension Rallonge de flche
Arbeitsbereiche Working ranges Portes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Tragfhigkeiten Lifting capacities Capacits de levage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Technische Beschreibung Technical description Descriptif technique
Unterwagen Oberwagen Zusatzausrstung . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Carrier Superstructure Optional equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Chssis Partie suprieure Equipements optionnels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
bersicht Standard-Traglasttabellen
Overview of standard duty charts Tableau synoptique des abaques standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
AC 100 10/99 07.10.1999 10:43 Uhr Seite 3
Abmessungen
Dimensions
Encombrement
AC 100 10/99 07.10.1999 10:43 Uhr Seite 4
AC 100 10/99 07.10.1999 10:43 Uhr Seite 5
Technische Daten
Specifications
Caractristiques
Achslasten Axle loads Poids dessieux
Grundgert mit Unterflasche, Bereifung 14.00 R 25 Basic machine with hook block, tyres 14.00 R 25 Machine de base avec crochet-
moufle, pneumatiques 14.00 R 25
Achsen Axles Essieux 5 x < 10 000 kg
Gesamt Total Total < 48 000 kg
Grundgert mit Hauptauslegerverlngerung 17 m, Unterflasche 14,3 t Gegengewicht, Bereifung 14.00 R 25 Basic machine with 17 m
main boom extension, hook block, 14.3 t counterweight, tyres 14.00 R 25 Machine de base avec rallonge de flche 17 m, crochet-
moufle, 14,3 t de contrepoids, pneumatiques 14.00 R 25
Achsen Axles Essieux 5 x 12 000 kg
Gesamt Total Total 60 000 kg
Arbeitsgeschwindigkeiten (stufenlos regelbar) Working speeds (infinitely variable)
Vitesses de travail (rglables sans paliers)
Antriebe Normalgang Schnellgang Max. zulssiger Seilzug
1)
Seil / Seillnge
Mechanisms Normal speed High speed Max. permissible line pull
1)
Rope diameter / Rope length
Mcanismes Marche normale Marche rapide Effort max. admis sur brin
1)
Diamtre du cble / Longueur du cble
Hubwerk I 60 m/min 110 m/min 72 kN 21 mm / 240 m
Hoist I
Treuil I
Hubwerk II 60 m/min 110 m/min 72 kN 21 mm / 240 m
Hoist II
Treuil II
Drehwerk Slewing max. 1,7
1
/min max. 1.7
1
/min
Orientation max. 1,7
1
/min
Ausleger-Teleskopieren Telescoping speed Vitesse de tlescopage 12,5 50 m: 300 s
Ausleger-Winkelverstellung Boom elevation Relevage de flche 1,5 +82: 55 s
Fahrleistungen Carrier performance Performance du porteur
Fahrgeschwindigkeit Travel speed Vitesse sur route
Vorwrts Forward Avant 80 km/h
Rckwrts Reverse Arrire 0 . . 6 km/h
Steigfhigkeit bei Transportgewicht Gradeability in travel order Capacit sur rampes en tat de transport sur route max. 40 %
Bodenfreiheit Ground clearance Dgagement au sol (14.00 R 25 / 16.00 R 25) 335/ 370 mm
3)
Unterflasche/Hakengehnge Hook block/Single line hook Crochet moufle/Boulet
Typ mgliche Traglast
1)
Anzahl der Rollen Gewicht D max. Einscherung Schwerlasteinrichtung
Type Possible load
1)
Number of sheaves Weight max. reeving Heavy-lift attachment
Type Charge possible
1)
Nombre de poulies Poids mouflage maxi Equipement levage lourd
125 100,0 t 7 1100 kg 2,00 m 14 1 Zusatzrolle/add. sheave/poulie suppl.
180 179,2 t 5 1930 kg 1,90 m 11
163 150,0 t 3 1700 kg 1,90 m 17
132 121,6 t 1 1550 kg 1,80 m 13
118 117,2 t Hakengehnge/ 1250 kg 1,70 m 11
Single line hook/
Boulet
Bemerkungen Remarks Remarques
1)
variiert je nach Lndervorschrift varies depending on national regulations varie en fonction des normes nationales
AC 100 10/99 07.10.1999 10:43 Uhr Seite 6
7,10 x 7,00 m 7,10 x 4,50 m
bersicht Standard-Traglasttabellen
Overview of standard duty charts
Tableau synoptique des abaques standard
AC 100 10/99 07.10.1999 10:43 Uhr Seite 7
Arbeitsbereiche Hauptausleger
Working ranges main boom
Portes flche principale
AC 100 10/99 07.10.1999 10:43 Uhr Seite 8
Tragfhigkeiten Hauptausleger
Lifting capacities main boom
Capacits de levage flche principale
25 t DIN/ISO
7,10 m x 7,00 m 360
Ausladung
Radius
Porte m
Ausladung
Radius
Porte
Hauptauslegerlnge Length of main boom Longueur de flche
1m
13
13
13,5
14
14,5
15
16
17
18
19
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44
46
m
3
3
3,5
4
4,5
5
6
7
8
9
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44
46
12,5
t,0
100,0
84,5
78,1
72,6
67,8
63,5
56,0
48,7
41,9
35,3
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
16,8
t,0
-,0
-,0
76,1
70,8
66,1
62,1
55,3
48,8
42,0
35,4
29,7
22,1
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
21,0
t,0
-,0
-,0
73,0
68,3
63,7
59,7
53,0
47,7
41,5
34,7
29,1
22,7
17,8
14,5
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
25,2
t,0
-,0
-,0
-,0
53,0
50,4
47,9
43,5
39,7
36,5
33,7
29,2
23,1
18,2
14,8
12,3
10,4
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
29,5
t,0
-,0
-,0
-,0
-,0
-,0
41,7
39,5
36,6
34,1
31,9
29,8
22,5
17,7
15,1
12,8
10,9
9,4
8,2
7,2
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
33,7
t,0
-,0
-,0
-,0
-,0
-,0
-,0
33,9
30,9
28,4
26,2
24,2
20,9
17,3
13,9
11,9
11,0
9,4
8,2
7,2
6,4
5,7
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
38,0
t,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
27,5
25,5
23,6
22,0
19,2
16,9
14,0
11,5
10,5
9,6
8,3
7,3
6,5
5,8
5,1
4,5
-,0
-,0
-,0
-,0
-,0
-,0
42,2
t,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
21,0
20,5
19,8
18,1
16,2
14,4
12,3
10,7
9,2
8,1
7,4
6,5
5,8
5,1
4,6
4,1
3,2
-,0
-,0
-,0
-,0
46,4
t,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
15,4
15,1
14,5
13,9
13,2
12,1
10,4
8,9
8,0
7,1
6,2
5,5
4,8
4,2
3,7
3,3
2,9
2,1
-,0
-,0
50,2
t,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
13,0
12,5
12,0
11,5
11,0
10,5
10,0
9,0
7,7
6,7
5,8
5,1
4,4
3,8
3,3
2,9
2,5
2,1
1,8
1,5
***
***
***
***
***
***
***
*
**
**
**
**
**
**
**
**
**
14,3 t DIN/ISO
7,10 m x 7,00 m 360
Ausladung
Radius
Porte m
Ausladung
Radius
Porte
Hauptauslegerlnge Length of main boom Longueur de flche
1m
13
13,5
14
14,5
15
16
17
18
19
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
m
3
3,5
4
4,5
5
6
7
8
9
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
12,5
t,0
84,5
78,1
72,6
67,8
63,3
52,6
42,4
33,0
26,8
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
16,8
t,0
-,0
76,1
70,8
66,1
62,1
52,7
42,6
33,1
26,8
22,4
16,4
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
21,0
t,0
-,0
73,0
68,3
63,7
59,7
49,0
39,4
33,9
27,6
23,0
17,0
13,1
10,4
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
25,2
t,0
-,0
-,0
53,0
50,4
47,9
43,5
37,1
32,3
28,0
23,5
17,4
13,4
10,7
8,7
7,2
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
29,5
t,0
-,0
-,0
-,0
-,0
41,7
39,5
36,1
30,4
26,2
22,8
18,0
14,0
11,2
9,2
7,6
6,5
5,5
4,7
-,0
-,0
-,0
-,0
-,0
-,0
-,0
33,7
t,0
-,0
-,0
-,0
-,0
-,0
33,9
30,9
28,4
24,5
21,4
16,4
14,1
11,3
9,3
7,7
6,5
5,5
4,7
4,0
3,4
-,0
-,0
-,0
-,0
-,0
38,0
t,0
-,0
-,0
-,0
-,0
-,0
-,0
27,5
25,5
23,4
20,5
16,0
14,3
11,5
9,4
7,9
6,7
5,7
4,8
4,1
3,5
3,0
2,6
-,0
-,0
-,0
42,2
t,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
21,0
20,5
19,8
16,2
13,8
11,5
9,5
7,9
6,7
5,7
4,9
4,1
3,5
3,0
2,6
2,2
1,4
-,0
46,4
t,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
15,4
15,1
14,5
13,0
11,2
9,1
7,6
6,4
5,4
4,5
3,8
3,2
2,7
2,2
1,8
1,5
1,2
50,2
t,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
13,0
12,5
12,0
11,5
10,5
8,7
7,2
6,0
5,0
4,1
3,4
2,8
2,3
1,8
1,4
1,1
0,8
***
***
***
***
***
***
***
***
***
***
***
**
**
**
**
**
**
**
**
**
**
**
**
**
* nach hinten ** Hauptauslegerlnge 45,0 m *** Hauptauslegerlnge 40,8 m
* over rear ** Length of main boom 45.0 m *** Length of main boom 40.8 m
* sur larrire ** Longueur de flche principale 45,0 m *** Longueur de flche principale 40,8 m
AC 100 10/99 07.10.1999 10:43 Uhr Seite 9
Anmerkungen zu den Tragfhigkeiten
Notes to lifting capacity
Conditions dutilisation
Tragfhigkeiten entsprechen ISO4305 und DIN 15019.2 (Prflast = 1,25 x Hublast + 0,1 x Auslegereigengewicht, auf die Ausleger-
spitze reduziert).
Das Gewicht der Unterflaschen, sowie die Lastaufnahmemittel, sind Bestandteile der Last und sind von den Tragfhigkeitsangaben
abzuziehen.
Kranbetrieb zulssig bis:
Staudruck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 N/m
2
Windgeschwindigkeit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9,8 m/s
Weitere Angaben in der Bedienungsanleitung des Kranes.
Anmerkung: Die Daten dieser Broschre dienen nur zur allgemeinen Information; fr ihre Richtigkeit bernehmen wir keine Haftung.
Der Betrieb des Kranes ist nur mit den Original-Tragfhigkeitstabellen und mit der Bedienungsanleitung zulssig, die mit dem Kran
mitgeliefert werden.
Ratings are in compliance with ISO4305 and DIN 15019.2 (test load = 1.25 x suspended load + 0.1 x dead weight of boom reduced
to boom point).
Weight of hook blocks and slings is part of the load, and is to be deducted from the capacity ratings.
Crane operation is permissible up to a
wind pressure of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 N/m
2
wind speed of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8 m/s
Consult operation manual for further details.
Note: Data published herein is intended as a guide only and shall not be construed to warrant applicability for lifting purposes.
Crane operation is subject to the computer charts and operation manual both supplied with the crane.
Le tableau de charges est conforme la norme ISO4305 et DIN 15019.2 (charge dessai = 1,25 x charge suspendue + 0,1 x poids
de la flche rduit la pointe de flche).
Les poids du crochet-moufle et de tous les accessoires dlingage font partie de la charge et sont dduire des charges indiques.
La grue peut travailler jusqu une
pression du vent de . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 N/m
2
vitesse du vent de . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9,8 m/s
Pour plus de dtails consulter la notice dutilisation de la grue.
Nota: Les renseignements ci-inclus sont donns titre indicatif et ne reprsentent aucune garantie dutilisation pour les oprations
de levage. La mise en service de la grue nest autorise qu condition que les tableaux de charges ainsi que le manuel de service,
tels que fournis avec la grue, soient observs.
AC 100 10/99 07.10.1999 10:43 Uhr Seite 10
Arbeitsbereiche Hauptauslegerverlngerung
Working ranges main boom extension
Portes rallonge de flche
AC 100 10/99 07.10.1999 10:43 Uhr Seite 11
Tragfhigkeiten Hauptauslegerverlngerung
Lifting capacities main boom extension
Capacits de levage rallonge de flche
25 t DIN/ISO
7,10 m x 7,00 m 360
Ausladung Verlngerung Extension Rallonge
Radius
Porte
38,0 m Hauptausleger Main boom Flche principale
9,2 m
0 20 40
1m
17
18
19
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44
46
48
50
52
54
56
t,0
14,4
14,2
13,7
13,1
12,2
11,3
10,4
9,7
9,0
8,3
7,4
6,4
5,5
4,7
4,4
4,2
3,9
3,6
3,2
2,9
-,0
-,0
-,0
-,0
-,0
-,0
-,0
t,0
-,0
-,0
-,0
9,3
8,9
8,6
8,3
8,0
7,7
7,5
7,1
6,8
5,8
5,0
4,3
3,9
3,7
3,6
3,3
2,9
-,0
-,0
-,0
-,0
-,0
-,0
-,0
t,0
-,0
-,0
-,0
-,0
-,0
7,1
7,0
6,8
6,6
6,5
6,4
6,3
6,1
5,3
4,5
3,9
3,8
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
17,0 m
0 20 40
t,0
-,0
7,4
7,1
6,9
7,0
6,5
6,0
5,6
5,3
5,0
4,7
4,4
4,2
4,0
3,8
3,6
3,3
2,8
2,6
2,4
2,3
2,2
2,1
1,9
-,0
-,0
-,0
t,0
-,0
-,0
-,0
-,0
-,0
4,8
4,6
4,3
4,1
3,9
3,7
3,6
3,4
3,3
3,2
3,1
3,1
3,0
2,8
2,4
2,2
2,1
2,1
2,0
-,0
-,0
-,0
t,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
3,6
3,5
3,4
3,3
3,2
3,1
3,0
3,0
2,9
2,9
2,9
2,9
2,6
2,3
-,0
-,0
-,0
-,0
-,0
-,0
Radius
Porte
9,2 m
0 20 40
1m
17
18
19
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44
46
48
50
52
54
56
t,0
-,0
-,0
10,0
10,3
9,4
8,7
8,1
7,5
7,0
6,5
6,1
5,7
5,4
5,1
4,4
4,2
3,7
3,2
2,8
2,4
2,1
1,8
1,6
1,0
-,0
-,0
-,0
t,0
-,0
-,0
-,0
-,0
-,0
7,1
6,8
6,5
6,2
5,8
5,5
5,2
5,0
4,7
4,5
4,1
3,8
3,4
3,0
2,6
2,2
1,9
1,6
1,4
-,0
-,0
-,0
t,0
-,0
-,0
-,0
-,0
-,0
-,0
6,1
5,8
5,5
5,2
5,0
4,8
4,6
4,4
4,2
4,1
3,7
3,5
3,1
2,7
2,0
-,0
-,0
-,0
-,0
-,0
-,0
17,0 m
0 20 40
t,0
-,0
-,0
-,0
6,4
6,2
5,8
5,5
5,2
4,9
4,7
4,4
4,2
4,0
3,8
3,6
3,5
3,3
3,0
2,7
2,6
2,3
2,0
1,7
1,4
1,2
1,0
0,9
t,0
-,0
-,0
-,0
-,0
-,0
-,0
4,3
4,1
4,0
3,8
3,6
3,5
3,3
3,2
3,0
2,9
2,8
2,7
2,6
2,6
2,3
2,2
1,9
1,7
1,4
1,2
0,9
t,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
3,2
3,1
3,1
3,0
3,0
2,9
2,9
2,8
2,7
2,6
2,5
2,5
2,1
2,1
1,8
1,2
-,0
-,0
Radius
Porte
9,2 m
0 20 40
1m
18
19
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44
46
48
50
52
54
56
58
t,0
10,8
11,7
11,3
10,7
10,0
9,3
8,7
8,1
7,5
7,0
6,5
5,7
4,9
4,6
4,2
3,8
3,6
3,2
2,8
2,5
1,8
-,0
-,0
-,0
-,0
-,0
-,0
t,0
-,0
-,0
-,0
8,8
8,4
8,1
7,8
7,5
7,2
6,9
6,6
6,1
5,3
4,5
4,1
3,9
3,4
3,3
2,9
2,6
2,3
-,0
-,0
-,0
-,0
-,0
-,0
t,0
-,0
-,0
-,0
-,0
7,1
6,9
6,7
6,5
6,4
6,2
6,0
5,9
5,5
4,8
4,1
3,9
3,5
3,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
17,0 m
0 20 40
t,0
-,0
7,2
7,0
6,5
6,1
5,7
5,3
5,0
4,7
4,5
4,2
4,0
3,8
3,7
3,5
3,4
2,9
2,8
2,6
2,3
2,2
2,1
1,8
1,6
1,1
-,0
-,0
t,0
-,0
-,0
-,0
-,0
-,0
4,5
4,3
4,1
3,9
3,7
3,6
3,4
3,3
3,2
3,1
3,1
3,1
2,9
2,6
2,5
2,2
2,1
2,0
1,7
1,2
-,0
-,0
t,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
3,4
3,3
3,2
3,1
3,1
3,0
2,9
2,9
2,8
2,8
2,8
2,8
2,4
2,4
2,0
-,0
-,0
-,0
-,0
-,0
Radius
Porte
9,2 m
0 20 40
1m
18
19
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44
46
48
50
52
54
56
58
t,0
-,0
-,0
-,0
8,4
7,9
7,5
7,1
6,7
6,3
6,0
5,7
5,4
5,0
4,4
3,8
3,2
2,8
2,4
2,0
1,7
1,4
1,2
0,9
0,7
-,0
-,0
-,0
t,0
-,0
-,0
-,0
-,0
6,9
6,4
6,1
5,7
5,4
5,2
4,9
4,7
4,5
4,3
4,1
3,5
3,0
2,6
2,2
1,9
1,6
1,3
1,0
0,8
-,0
-,0
-,0
t,0
-,0
-,0
-,0
-,0
-,0
-,0
5,5
5,2
5,0
4,8
4,6
4,4
4,2
4,1
4,0
3,7
3,2
2,7
2,3
2,0
1,6
1,3
-,0
-,0
-,0
-,0
-,0
17,0 m
0 20 40
t,0
-,0
-,0
-,0
5,6
5,4
5,2
5,0
4,8
4,6
4,4
4,2
4,0
3,8
3,6
3,4
3,2
2,9
2,5
2,2
1,8
1,6
1,3
1,0
0,8
0,6
-,0
-,0
t,0
-,0
-,0
-,0
-,0
-,0
-,0
4,1
3,9
3,8
3,6
3,4
3,3
3,1
3,0
2,9
2,8
2,7
2,6
2,5
2,2
1,9
1,6
1,3
1,1
0,8
0,6
-,0
t,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
3,2
3,1
3,0
2,9
2,9
2,8
2,7
2,7
2,6
2,5
2,5
2,4
2,1
1,8
1,5
1,2
0,9
-,0
-,0
***
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AC 100 10/99 07.10.1999 10:43 Uhr Seite 12
Tragfhigkeiten Hauptauslegerverlngerung
Lifting capacities main boom extension
Capacits de levage rallonge de flche
14,3 t DIN/ISO
7,10 m x 7,00 m 360
Radius
Porte
9,2 m
0 20 40
1m
17
18
19
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44
46
48
50
52
64
56
t,0
14,4
14,2
13,7
13,1
12,2
11,3
10,3
8,5
6,9
5,9
5,6
5,0
4,3
3,6
3,1
2,6
2,2
1,9
1,6
1,3
-,0
-,0
-,0
-,0
-,0
-,0
-,0
t,0
-,0
-,0
-,0
9,3
8,9
8,6
8,3
8,0
7,5
6,2
5,1
4,7
4,4
3,9
3,3
2,8
2,4
2,0
1,7
1,4
-,0
-,0
-,0
-,0
-,0
-,0
-,0
t,0
-,0
-,0
-,0
-,0
-,0
7,1
7,0
6,8
6,6
6,5
5,5
4,6
4,4
4,1
3,5
2,9
2,5
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
17,0 m
0 20 40
t,0
-,0
8,1
7,8
7,5
7,0
6,5
6,0
5,6
5,3
5,0
4,7
4,2
3,7
3,4
3,2
2,8
2,4
2,1
1,7
1,5
1,2
1,0
0,8
-,0
-,0
-,0
-,0
t,0
-,0
-,0
-,0
-,0
-,0
4,8
4,6
4,3
4,1
3,9
3,7
3,6
3,4
3,3
2,9
2,8
2,7
2,4
2,0
1,7
1,4
1,2
0,9
0,7
-,0
-,0
-,0
t,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
3,6
3,5
3,4
3,3
3,2
3,1
3,0
3,0
2,8
2,7
2,6
2,2
1,9
1,5
-,0
-,0
-,0
-,0
-,0
-,0
Radius
Porte
9,2 m
0 20 40
1m
17
18
19
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44
46
48
50
52
54
56
t,0
-,0
-,0
10,0
10,3
9,4
8,7
8,1
7,5
7,0
6,0
5,4
4,6
3,8
3,2
2,7
2,2
1,8
1,4
1,1
0,8
0,6
-,0
-,0
-,0
-,0
-,0
-,0
t,0
-,0
-,0
-,0
-,0
-,0
7,1
6,8
6,5
6,2
5,8
5,5
4,6
4,2
3,5
3,0
2,5
2,0
1,6
1,3
1,0
0,7
-,0
-,0
-,0
-,0
-,0
-,0
t,0
-,0
-,0
-,0
-,0
-,0
-,0
6,1
5,8
5,5
5,2
5,0
4,8
4,3
3,8
3,2
2,6
2,2
1,8
1,4
1,1
-,0
-,0
-,0
-,0
-,0
-,0
-,0
17,0 m
0 20 40
t,0
-,0
-,0
-,0
6,4
6,2
5,8
5,5
5,2
4,9
4,7
4,4
4,2
3,8
3,4
2,9
2,4
2,0
1,6
1,3
1,0
0,7
-,0
-,0
-,0
-,0
-,0
-,0
t,0
-,0
-,0
-,0
-,0
-,0
-,0
4,3
4,1
4,0
3,8
3,6
3,5
3,3
3,2
3,0
2,8
2,5
2,0
1,7
1,4
1,1
0,8
-,0
-,0
-,0
-,0
-,0
t,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
3,2
3,1
3,1
3,0
3,0
2,9
2,9
2,6
2,4
2,0
1,6
1,3
1,0
0,7
-,0
-,0
-,0
-,0
Radius
Porte
9,2 m
0 20 40
1m
18
19
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44
46
48
50
52
54
56
58
t,0
10,8
11,7
11,3
10,7
10,0
9,3
8,6
7,1
6,2
5,4
5,0
4,2
3,6
3,1
2,6
2,2
1,8
1,5
1,2
1,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
t,0
-,0
-,0
-,0
8,8
8,4
8,1
7,8
7,5
6,4
5,4
5,0
4,4
3,9
3,3
2,8
2,4
2,0
1,7
1,4
1,1
0,8
-,0
-,0
-,0
-,0
-,0
-,0
t,0
-,0
-,0
-,0
-,0
7,1
6,9
6,7
6,5
6,4
5,7
4,8
4,5
4,1
3,5
3,0
2,5
2,1
1,4
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
17,0 m
0 20 40
t,0
-,0
7,2
7,0
6,5
6,1
5,7
5,3
5,0
4,7
4,5
4,2
3,9
3,4
3,2
2,8
2,4
2,0
1,7
1,4
1,1
0,9
0,7
-,0
-,0
-,0
-,0
-,0
t,0
-,0
-,0
-,0
-,0
-,0
4,5
4,3
4,1
3,9
3,7
3,6
3,4
3,3
3,1
2,9
2,6
2,4
2,0
1,7
1,4
1,1
0,9
0,7
-,0
-,0
-,0
-,0
t,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
3,4
3,3
3,2
3,1
3,1
3,0
2,9
2,9
2,8
2,4
2,2
1,9
1,5
1,2
0,7
-,0
-,0
-,0
-,0
-,0
Radius
Porte
9,2 m
0 20 40
1m
18
19
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44
46
48
50
52
54
56
58
t,0
-,0
-,0
-,0
8,4
7,9
7,5
7,1
6,7
5,7
4,8
4,0
3,3
2,7
2,2
1,8
1,4
1,0
0,7
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
t,0
-,0
-,0
-,0
-,0
6,9
6,4
6,1
5,7
5,4
5,2
4,4
3,7
3,1
2,6
2,1
1,7
1,3
0,9
0,6
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
t,0
-,0
-,0
-,0
-,0
-,0
-,0
5,5
5,2
5,0
4,8
4,6
4,0
3,4
2,8
2,3
1,9
1,4
1,1
0,8
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
17,0 m
0 20 40
t,0
-,0
-,0
-,0
5,6
5,4
5,2
5,0
4,8
4,6
4,4
4,0
3,3
2,8
2,3
1,9
1,5
1,2
0,9
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
t,0
-,0
-,0
-,0
-,0
-,0
-,0
4,1
3,9
3,8
3,6
3,4
3,3
3,1
2,9
2,4
2,0
1,6
1,3
1,0
0,7
-,0
-,0
-,0
-,0
-,0
-,0
-,0
t,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
-,0
3,2
3,1
3,0
2,9
2,9
2,8
2,7
2,4
2,0
1,7
1,3
1,0
0,7
-,0
-,0
-,0
-,0
-,0
-,0
**
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AC 100 10/99 07.10.1999 10:43 Uhr Seite 13
Technical description
Carrier
Drive/Steering 10 x 6 x 8
Frame Monobox main frame with outrigger boxes integral, of high-strength fine grain structural steel.
Outriggers Four hydraulically telescoping outrigger beams with hydraulic jack legs.
Engine Mercedes Benz OM 502 LA water-cooled 8-cylinder engine (Euromot), output to DIN: 350 kW (476 hp)
at 1800
1
/min, max. torque 2300 Nm at 1080
1
/min. Fuel tank capacity: 500 l.
Transmission Automatic transmission (16 ranges), transfer case with longitudinal differential lockout control.
Axles Axle 1: steering; axle 2: with planetary hubs, steering, transverse differential lockout control;
axle 3: rigid axle, non-steer; axle 4: with planetary hubs, steering in crab steer mode, longitudinal
and transverse differential lockout control; axle 5: with planetary hubs, transverse differential lockout
control.
Suspension Hydropneumatic suspension, all axles hydraulically blockable.
Wheels and tyres 10 wheels fitted with 14.00 R 25 tyres, single wheels on all axles.
Steering ZF dual-circuit semiblock mechanical steering with hydraulic booster.
Brakes Service brake: dual-line air system with anti locking system. Parking brake: spring-loaded type,
on 2nd, 4th and 5th axles. Sustained action brake: constant decompression with butterfly valve,
exhaust brake, hydraulic retarder.
Electrical equipment 24 V system.
Drivers cab Rubber-mounted all steel drivers cab with safety glazing, electr. window winders, controls and
instrumentation, air-suspended and heated drivers seat, unsprung passengers seat, vertically
adjustable steering wheel, heated outside mirrors, rotaflare warning light.
Superstructure
Engine Mercedes Benz OM 904 LA water-cooled 4-cylinder in-line engine (Euromot), output 125 kW (171 hp)
at 2300
1
/min, max. torque 630 Nm at 1200
1
/min, fuel tank capacity: 200 l.
Hydraulic system 1 variable displacement axial piston pump to provide 4 simultaneous, independent working
movements and separate pump for slew unit.
Hoist Fixed displacement axial piston hydraulic motor, hoist drum with integral planetary gear reducer and
spring-applied multi-disk. Drum rotation indicator.
Slew unit Hydraulic motor with planetary gear reducer, change-over from brake to free swing by control lever,
spring-applied holding brake.
Boom elevation 1 differential cylinder with automatic lowering brake valve.
Crane cab Spacious all-steel comfortable cab with sliding door and large hinged windscreen, tiltable 20,
roof window with armoured glass, full instrumentation and crane controls, working light. Hot water
heater operated either self-contained or engine-dependent, with engine preheating and timer,
thermostat-controlled. Windscreen washer and intermittent control type windscreen wiper.
Main boom Boom base and 4 telescopic sections, fabricated from fine grain structural steel, telescoping ability
with partial load, buckling-resistant Demag ovaloid design.
Counterweight 14.3 t.
Safety devices Electronic safe load indicator with digital readout for hook load, rated load, boom length, boom
angle, load radius, analog display to indicate the capacity utilization, limit switches on hoist and
lowering motions, pressure-relief and safety holding valves.
Hydraulic servo control Hydro-electric pilot control through self-centering control levers.
Optional equipment
Drive/steering 10 x 8 x 8
Wheels and tyres 16.00 R 25 on 11.25-25 rims.
Tow coupling D-value 12 t or 19 t, air-brake connection.
Hoist II Fixed displacement axial piston hydraulic motor, hoist drum with integral planetary gear reducer and
spring-applied multi-disk brake. The use of hoist II avoids re-reeving the hoist line when using the
optional jib.
Main boom extension Side-folding 1 or 2-part jib, 9.2 m or 17.0 m. 0, 20 and 40 offset.
Hydraulic fly jib On request.
Additional counterweight 10.7 t, integrates into standard counterweight, installed hydraulically by the crane itself.
AC 100 10/99 07.10.1999 10:43 Uhr Seite 15
Subject to change without notice! 10/ 99
Zeichenerklrung
Key
Lgende
Gegengewicht counterweight contrepoids
Tragfhigkeiten, abgesttzt Lifting capacities on outriggers Capacits de levage sur stabilisateurs 360
D
D
AC 100 10/99 07.10.1999 10:43 Uhr Seite 17
engineering
mannesmann
dematic
Mobile Cranes Division
19.02.99
Profile of Product
All-terrain crane DEMAG AC 100
Max. lifting capacity: 100 t at 3 m radius
Max. load moment: 333 tm
Main boom length: 50.2 m, telescoping hydraulically
Main boom extension: 9.2 m / 17.0 m (two-part folding jib)
Max. boom lengths: 59.4 m / 67.2 m incl. boom extension
Travel speed: 80 km/h - tyres 14.00 R 25
Gradeability: approx. 40 %
Weight in travel order: 60 t, basic counterweight 14 t, hook block type 32,
14.00 R 25 tyres, drive 10 x 8 x 8, 17.0 m boom
extension
48 t, as above, but with 3 t counterweight
45 t, as above, but without counterweight
Axle loading: 5 x 12 t
Drive: 10 x 6
Steering: 10 x 8
Overall length: 14.1 m
Overall width: 2.75 m
Overall height: 3,99 m
Safety devices: standard
engineering AC 100
mannesmann dematic Profile of Product 2
1.0. CRANE CARRIER: Mannesmann Demag 5-axle carrier
Length: 11.00 m
Width: 2.75 m
Turning radius: 11.55 m
Drive/steering: 10 x 6 x 8
1.1. Steel structure:
1.1.1. Frame Torsion-resistant monobox main frame
with outrigger boxes integral, made from
high strength fine grain structural steel.
1.1.2. Outriggers Outrigger base
longitudinal: 7.10 m
transverse: 7.00 m
SLI-programme for second outrigger base:
longitudinal: 7.10 m
transverse: 4.50 m
4 hydraulically extending outrigger beams with jacking
cylinders. Controlled from each side of the chassis, or
from the cabin, monitored by 90 bubble levelling
indicator.
J acking cylinder stroke approx. 600 mm.
Outrigger pads remain fitted to jack legs during transit,
without exceeding the 2.75 m overall vehicle width.
4 outrigger pads 542 mm x 542 mm.
1.2. Drive and transmission:
1.2.1. Engine Type: Daimler-Benz OM 502 LA
Emission: EUROMOT
Output: 350 kW
at 1800
1
/min
Torque: 2300 Nm at 1080
1
/min
Cylinders: 8
Cooling: water circulation type
Fuel tank capacity: 450 l
1.2.2. Transmission Automatic transmission, 16 forward speeds and 1
reverse.
engineering AC 100
1.2.3. Transfer case between axles 2 and 4 with longitudinal differential
lockout control.
1.2.4. Drive 10 x 6
Axles 2, 4 and 5 permanently driven.
1: Steer ing, non-driving
2: With planetary hubs, transverse differential lockout
control
3: Rigid bogie axle, non-driving
4: With planetary hubs, longitudinal and transverse
differential lockout control
5: With planetary hubs, transverse differential lockout
control
1.2.5. Suspension Hydropneumatic suspension giving +/- 110 mm
height adjustment, all axles blockable hydraulically.
1.2.6. Wheels 10
1.2.7. Tyre size 14.00 R 25
1.3. Steering: 10 x 6 on-highway
Fully independent hydrostatic on both rear axles off-
highway (3rd axle raised).
1.4. Brakes: conforming to EC-directives
1.4.1. Service brake Dual-line air-operated braking system.
1.4.2. Parking brake Spring-loaded brake on axles 2, 4 and 5.
1.4.3. Sustained action brake Exhaust brake, constant decompression and butterfly
valve, and hydraulic retarder.
1.5. Electrical system: 24 V
3-phase alternator 55 A
2 batteries 12 V / 180 Ah
Lighting in compliance with EC-directives
engineering AC 100
1.6. Driver's cab: Rubber-mounted steel cab, 2.42 m wide. New design
full vision cab, comfortable equipment incl. heated and
air-suspended drivers seat, head and arm rests,
three-point seat belts, adjustable steering wheel,
safety glass used throughout, slide-by side windows,
windscreen defroster fans. 10 kW engine-dependent
hot water heater, electric windscreen washer and
wiper, sun visors, dashboard with clearly arranged
instrumentation, ample stowage space for small
articles, heated outside mirrors, rotaflare warning light.
1.7. Tools: Set of spanners, grease gun, tyre inflation kit, air
gauge, oil can, emergency triangle, first-aid kit,
emergency flasher, wet weather gear, safety helmet.
2.0. SUPERSTRUCTURE:
2.1. Steel structure:
2.1.1. Frame DEMAG fabricated fine-grain structural steel, all-
welded. Torsion-resistant weight saving longitudinal
beam construction.
2.2. Slew ring: Triple-row roller bearing slew ring with external ring
gear for ease of serviceand maintenance.
2.3. Crane drive:
2.3.1. Crane engine Type: Daimler-Benz OM 904 LA
Emission: EUROMOT
Output: 125 kW
Torque: 630 Nm at 1200
1
/min
Fuel tank capacity: 200 l
2.3.2. Hydraulic system 1 variable displacement axial piston pump for main
crane movements (load sensing / hydro-electric pilot
control), separate pump for slew system, hydraulic oil
cooler.
This enables the operator to engage 4 independent
motions at the same time.
Reservoir capacity: 1400 l.
engineering AC 100
2.3.3. Hoist Fixed displacement axial piston motor, hoist drum
with integral planetary gear reducer and spring-applied
multi-disk brake. Hydraulic braking, drum rotation
indicator.
Drum diameter: 455 mm
Rope diameter: 21 mm
Rope length: 240 m
max. line pull: 72 kN
max. line speed: 110 m/min
2.3.4. Slew system Hydraulic motor with planetary gear reducer,
free swing engaged by joystick lever, spring-
applied holding brake.
Slewing speed infinitely variable 0 - 1.7
1
/min.
2.3.5. Boom elevation 1 differential cylinder with automatic lowering
brake valve.
Elevation: - 1.5 to 82
Elevation time: - 55 sec
2.3.6. Controls The crane is controlled by 2 self-centering servo
levers, ergonomically positioned next to the
operators seat (cross-type control levers for
2 working motions each). The working speed
is controlled by both the engine revs and the
lever position. Hydro-electric pilot-control.
2.4. Operators cab: Comfortable all-steel cab with sliding door and
hinged windscreen, tilts back 20, safety glass used
throughout, roof window with armoured glass, washer
and intermittent control wiper for front and roof
window. Full instrumentation and crane controls.
Working light, rotaflare warning light on upper frame.
Steps on both front and side to facilitate access, roller
blind, holder for beverage cans. 5 kW hot water heater
operated either self-contained or engine-dependent,
used for engine preheating, thermostat-controlled with
timer, high-speed fan, defroster vents for all windows.
2.5. Counterweight: 25 t total.
In conformity with 12 t axle loading regulations when in
travel order with 14 t counterweight.
engineering AC 100
25 t counterweight can be carried on the crane though
axle loadings then increase to 14.5 t.
All counterweights are stowed hydraulically and
installed by the crane itself.
2.6. Electrical system: 24 V
2.7. Safety devices: Electronic safe load indicator with sealed touch-type
keyboard is standard, digital read-out for hook load,
nominal load, boom length and angle, radius,
integrated display to indicate the capacity utilization in
%, limit switches on hoist and lowering motions,
pressure relief and safety holding valves. Large
display.
2.8. Telescopic boom: Boom base and 4 inner sections fabricated
from fine grain structural steel.
The boom extends by one hydraulic cylinder. UNIMEC
system.
Boom head with 6 sheaves and parts to mount the
boom extension.
Total length: 50.2 m
Telescoping time from 10.1-50.2 m: 300 sec
2.9. Other equipment: Anemometer, fire extinguisher, outrigger spotlights,
2 working lights.
3.0. OPTIONAL EQUIPMENT:
3.1. Drive 10 x 8: Axle 1 driven additionally, steering, with planetary
hubs, connectable, transverse differential lockout
control.
Axle 2 additionally with longitudinal lockout control.
3.2. Wheels and Tyres:
3.2.1. 16.00 R 25
vehicle width 2.75 m / vehicle height 3.95 m
3.2.2. 20.5 R 25
vehicle width 3.00 m / vehicle height 3.95 m
3.2.3. Spare wheel, loose
engineering AC 100
3.2.4. Spare wheel with mount
3.2.5. Spare wheel with mount and hoist
3.3. Trailer tow coupling:

3.3.1. D-value =12 t, pin 40 mm

3.3.2. D-value =19 t, pin 50 mm
Incompatible with mounted spare wheel.
3.4. Air-conditioning: for carrier and upper cab, integrated into heating and
ventilation system.
3.5. Tropicalisation (up to 45C)
3.6. Exhaust with spark arrestor

3.7. Main boom extension, Fixed 1- or 2-part extension. 0, 20 and 40
folding, 9.2 m-17.0 m: offset.
1-part extension: 9.2 m
2-part extension: 9.2 m or 17.0 m
Folding to right side of boom base for transportation.
The scope of supply includes a ladder.
3.8. Hoist 2: Avoids re-reeving of hoist line when using the boom
extension. Technical data same as hoist 1. Tail swing
with hoist 2: 4900 mm.
3.9. Centralized lubrication: Carrier
3.10. Hook blocks with With fold-away rope guard to facilitate reeving,
safety hooks: with handles integral, and hooks with safety latches.
Type 125 (100 t) 7-sheave with ramshorn hook, max. 14 lines,
(1100 kg)
Type 80 (79.2 t) 5-sheave with ramshorn hook, max. 11 lines,
( 930 kg)
Type 63 (50.0 t) 3-sheave with ramshorn hook, max. 7 lines,
engineering AC 100
(700 kg)
Type 63 (50.0 t) 3-sheave with single hook, max. 7 lines,
(700 kg)
Type 32 (31.9 t) 1-sheave with single hook, max. 3 lines,
(550 kg)
Type 8 (7.2 t) single-line hook, (250 kg)
3.11. Stowage facilities: - for 1 or 3 sheave hook block
- for single line hook
- for mats
- for slings
3.12. rooster sheave
3.13. additional working light on boom base
3.14. Self-contained heater: 9 kW heater for carrier cab, with timer, used for
engine preheating.
3.15. Rotaflare warning light: 1 x additional rotating beacon for carrier cab.
3.16. Top steer facility
4.0. MISCELLANEOUS:

4.1. National regulations: Different national regulations for crane acceptance
and roadability can require alterations to serial cranes
ensuing technical and price modifications.
4.2. Standard painting: Superstructure: RAL 9003 - signal white
Carrier: RAL 7037 - dusty grey
4.3. Special painting and Special customer signwriting (decal) and all RAL
signwriting: colours.
Subject to change without notice.
Technical Training AC 100
Steering
AC100 Lenkstange e Technische Schulung
Hydraulic connection
B 358.2
Normally opened
B 358.1
Normally closed
Adjusting the proximity switches:
Important!!! Crab steering must be locked. Screw in
B358.1 till H344 (crab steering not locked) goes out.
Unlock crab steering. Screw in B358.2 till H345 (crab
steering unlocked) goes on.
Danger of accident!!! Axle 3 can automatically raise!!!!
Crab steering unlocked:
B358.1 not switched: LED on/closed. H344 on
B358.2 switched: LED on/closed. H345 on
Crab steering locked:
B358.1 switched: LED off/open. H344 off.
B358.2 not switched: LED off/open. H345 off.
Steering not locked:
B358.1 not switched: LED on/closed. H344 on
B358.2 not switched: LED off/open. H345 off
Carrier
Technische Schulung AC100 Bolzen Hundegang e
Pi n crabsteeri ng axl e 4
S355.1
switch
normally closed
S355.2
switch
normally open
Pin completely down
switch S355.2 open
pin lifted or completely up
switch S355.2 closed
Pin completely down
switch S355.1 open
pin completely up
switch S355.1 closed
Carrier Suspension
Technische Schulung AC100 Federungszyl e
Suspensi on cyl i nder wi th 2 proxi mi ty swi tches
hydraulic
connection
cylinder
steel
proximity switch
proximity switch
level position
too high
too high
cylinder
too high
too low
level
hydraulic
connection
bronze
Hydraulic
Technische Schulung AC100 Panel carrier right
Panel carri er ri ght hand si de
4 circuit safety valve
Y305D
Y305C
Y364.8
Y364.4
Y355.1
Y313
Y314
B360
100 bar
Y363
Y362
Y361
Y365 Y364.2
R325
Carrier
Technische Schulung AC100 Panel carrier left
Panel carri er l eft hand si de
Y364.1
Y365B Y365A Y343
Y356.2
Y356.1 Y344
MP1
MP2
Y310A
Y310B B359
Flow divider
Y305A
Y305B
Y346.7
Y346.3
Y366B
Y366A Y367
Y357
Pneumatic
Technische Schulung AC100 Druckschalter Handbremse e
Pressure swi tch parki ng brake (within the frame)
B310.3
2 bar
B310.2
5 bar
Carrier SPS
Technische Schulung AC100 Digsy UW e.doc
5V LED
status: green
DIAG LED
status: green
LED E1.1
Input 1.1
(Green when
24V input)
LED E2.1
LED E2.5
LED MK1
Status: off
LED MK2
DIAG LED
status: green
CPU module
Binary card 1
LED E6.6
LED E5.4
(ground input
not AC100)
LED A7.4
Output7.4
(Red when
24V output)
Binary card 2
SPS
Technische Schulung AC100 SPS UW e
CPU-Modul e
Function
- Computer with interfaces for data communication
- Engine RPM signal is adapted for the programming interface
- Two nine pin connectors are used for both serial interfaces (PI and CI )
- 2 LEDs DIAG(Diagnostic-LED)
green Program running
orange Internal housing temperature too high
Internal battery charge too low
Programming mode
SPC in waitstate
24V CPU < 14V
red EEPROM not installed
EEPROM or RAM error
out Program stopped, no program, LED
defective
blinking Received information on the PI or CI correct
- 5V LED
green CPU power supply functioning correctly
red CPU stopped, power supply < 4,65V
out CPU stopped, Power supply voltage missing,
LED defective
blinking red/green cyclical restarts/ Watchdog working
blinking red/oran. constant reset, defective internal component
- Switch S1=0: Subscriber receives address 0
- Switch S2=3: Data transmission rate 19200 Baud
- Jumper in position R: Communications interface (CI) is RS485
SPS
Technische Schulung AC100 SPS UW e
Bi nary I nput/Output (I /O-Modul e)
Function
Reception of 24V switched signals
Output of 24V control signals
16 input channels for 24V switched signals
16 output channels
8 for a current of up to 2A
8 for a current of up to 400 mA (These outputs can also be
configured as input channels)
The switch condition of the in- and output channels are shown through
LEDs
green for input channels
red for output channels
The Binary modules are addressed, therefore there is no need to set dip-
switches or jumpers.
2 LEDs are used as short circuit indicators, one LED for each output
channel. In case of a short circuit, the afflicted output channel is
automatically turned off. These LEDs can be found on the front plate and are
marked MK1-MK8.
The output channel short circuit indicators can show the following situations:
- Return current from an unswitched output channel
- Power supply < 17V
- Output current > 2.5A (Short circuit)
The short circuit indicators are only useful when the output channels are
connected to relays that have a low resistance protection diode built in. This
means that onl y rel ays wi th a l ow resi stance protecti on di ode may be used
to replace existing relays in an output channel of a binary I/O card, otherwise
the complete output channel will be turned off and proper function can not be
achieved.
Technische Schulung AC 100
Elektrik
Technische Schulung AC100 Meldeleuchtenmodul A.doc
Mel del euchtenmodul A
Nr. Funktion Function Farbe / Color
1
Gelndegang Off road Gelb / yellow
2
Getriebetemperatur Temperature transmission Rot / red
3
Wandlerschaltkupplung Tourque converter Gelb / yellow
4
Getriebelfilter Oilfilter transmission Gelb / yellow
5
Fehlercode Getriebe Transmission error Rot / red
6
Straengang On road Grn / green
7
Notkupplungspedal
ausklappen
Unfold emergency clutch pedal Rot / red
8
Kupplungsbertemperatur Temperature clutch Rot / red
9
Getriebelniveau Oil level transmission Rot / red
10
Fernlicht High beam Blau / blue
Elektrik
Technische Schulung AC100 Meldeleuchtenmodul B.doc
Mel del euchtenmodul B
1
Niveau hinten links Level rear left Gelb / yellow
2
Niveau vorne links Level front left Gelb / yellow
3
Hydrauliktemperatur Hydraulic temperature Gelb / yellow
4
Hydrauliklfilter Oilfilter hydraulic Gelb / yellow
5
Dolly Dolly Rot / red
6
Niveau hinten rechts Level rear right Gelb / yellow
7
Niveau vorne rechts Level front right Gelb / yellow
8
Lenkkreis 3 Steering circuit 3 Rot / red
9
10
Elektrik
Technische Schulung AC100 Meldeleuchtenmodul C.doc
Mel del euchtenmodul C
1
Vorglhen Glow plug Gelb / yellow
2
Ladekontrolle Batterie light Rot / red
3
Motorlstand Engine oil level Rot / red
4
Motorldruck Engine oil pressure Rot / red
5
Strung Motor Engine error Rot / red
6
Motorstop Engine stop Rot / red
7
Luftfilter Air filter Gelb / yellow
8
Khlwasserstand Water level Gelb / yellow
9
Khlmitteltemperatur Water temperature Rot / red
10
Fahrtrichtungsanzeiger Indicator Grn / green
Elektrik
Technische Schulung AC100 Meldeleuchtenmodul D.doc
Mel del euchtenmodul D
1
ABS Info ABS Info Gelb / yellow
2
ABS Anhnger ABS trailer Rot / red
3
ABS ABS Rot / red
4
Bremsdruck Break pressure Rot / red
5
Blinkeranzeige fr
Anhnger
Indication for trailer Grn / green
6
Bremsdruckreduzierung Reduction of brakepressure Gelb / yellow
7
Retarder Retarder Gelb / yellow
8
Wirbelstrombremse Telma Gelb / yellow
9
Handbremse Parking brake Rot / red
10
Betriebsbremse bettigen Activate brake Gelb / yellow
Elektrik
Technische Schulung AC100 Meldeleuchtenmodul E.doc
Mel del euchtenmodul E
1
Differenzialsperre lngs Differential lock longitudinal Gelb / yellow
2
Differenzialsperre quer Differential lock transvers Gelb / yellow
3
Kranbetrieb Crane operation Gelb / yellow
4
Hundegang 1 Crab steering 1 Gelb / yellow
5
Hundegang 2 Crab steering 2 Gelb / yellow
6
Umschaltung auf 3-
Punktsystem
Suspension 3 point setting Gelb / yellow
7
Federung gesperrt Suspension lock Gelb / yellow
8
Achsen halten Hold axles Gelb / yellow
9
Hundegang Crab steering Gelb / yellow
10
Achsen heben Raise axles Gelb / yellow
Technical Training AC100
Chassis Electrics
AC100 Betriebsmittelliste UW e.doc Technical Training
Equi pment l i st - chassi s
A170 Air conditioning Cab
A300 Engine control MR Engine
A301 Vehicle control FR Under passenger seat
A302 Adaption module ADM Under passenger seat
A308 Flasher relay Cab electrics
A310 Star point CAN Cab electrics
A312 Wiper impulse transducer Cab electrics
A320 Electric accelerator (FFG) Cab
A326L Mirror adjustment left Cab
A326R Mirror adjustment right Cab
A345 Central lubricating system (control unit) Rear cab
A360 16-slot binary board 1 Under passenger seat
A361 16-slot binary board 2 Under passenger seat
A386 ABS electronics Under passenger seat
A387 ABS information module Cab electrics
A390 Parking heater chassis timer Cab
A391 Parking heater chassis control unit Cab
A392 Parking heater chassis heater Cab
A400 EPS Under passenger seat
A401 Driving switch chassis Cab
A402 Clutch control KS Under passenger seat
A403 Automatic gear selection AG Under passenger seat
A404 Retarder electronics RS Under passenger seat
A410 ECU transmission Under passenger seat
A903 Voltage converter 24/12 V Cab electrics
A904 Radio Cab
A907 Radio telephone Cab
B2
B3
B57
B60
B61
B62
B63
B65 Retarder coolant temperature sensor
B66 Retarder oil temperature sensor
B170 Pressure switch air conditioning Cab
B171 Air conditioning
B172 Air conditioning
B301 Fuel level sensor Tank
B310.1 Pressure switch brake light Beneath cab
B310.2 Pressure switch parking brake (5bar)
B310.3 Pressure switch parking brake (2bar)
B310.4 Pressure switch parking brake up (2bar)
B310.5 Pressure switch parking brake down (2bar)
B310.6 Pressure switch parking brake circuit 1 (5bar)
B310.7 Brake pressure display
B322.1 Pressure switch steering pump 1 Left panelling
B322.2 Pressure switch steering pump 2 Left panelling
B323 Pressure switch air filter 1 Air filter
B324.1 Sensor return filter 1 Hydr. oil tank
B324.2 Sensor return filter 2 Hydr. oil tank
B358.1 Proximity switch steering rod not locked Steering rod
B358.2 Proximity switch steering rod unlocked Steering rod
Chassis Electrics
B359 Proximity switch 100 bar on axle 3
B360 Proximity switch 100 bar on axle 3
B370.1 Proximity switch level front top Suspension cyl.
B370.2 Proximity switch level rear right top Suspension cyl.
B370.3 Proximity switch level rear left top Suspension cyl.
B370.4 Proximity switch level front bottom Suspension cyl.
B370.5 Proximity switch level rear right bottom Suspension cyl.
B370.6 Proximity switch level rear left bottom Suspension cyl.
B401 Pulse generator tachograph Transmission
E300 Rotation chassis-superstructure Middle of slew rim
E301 Outrigger lighting Outrigger operating box
E302 Outrigger lighting Outrigger operating box
E304.1 Rear fog light Rear bumper
E305.1 Left headlight Front bumper
E305.2 Right headlight Front bumper
E306.1 Left dipped headlight Front bumper
E306.2 Right dipped headlight Front bumper
E332.1 Reverse light Front bumper
E336 Cab lighting Cab
F100.1 Main fuse chassis (50A) Battery compartment
F100.2 Main fuse chassis (100A) Battery compartment
F101 Ignition lock, voltage supply EPS, MKR, AGE,
RET, back-up fuse for F102, F112, F119, F123, F124,
F126, F127, F203, F207 (25A) Cab electrics
F102 Engine/transmission, charge monitor, load relay, neutral
transmission display (10A) Cab electrics
F103 Socket (5A) Cab electrics
F104 Left headlamp, headlamp display (10A) Cab electrics
F105 Right headlamp (10A) Cab electrics
F106 Left dimmed headlamp (10A) Cab electrics
F107 Right dimmed headlamp (10A) Cab electrics
F108 Back-up fuse for F104, F105, F116, F117, (25A) Cab electrics
F109 Cigarette lighter (10A) Cab electrics
F110 Rear fog light, lighting (10A) Cab electrics
F111 Outrigger lighting (10A) Cab electrics
F112 Rotaflare light, reverse light, horn, brake light
indicator display, handbrake (10A) Cab electrics
F113 Outriggers Cab electrics
F114 Operating hours, overspeed cutout,
Scandinavian light, differential lock, axle
locking, axle differential, crabwalk steering,
steering of superstructure (15A) Cab electrics
F115 Back-up fuse F113, F114, F120, F125, load (25A) Cab electrics
F116 Parking light, instrument panel lighting Cab electrics
F117 Parking light, sign lighting, lighting
outrigger operating box right Cab electrics
F118 Tachograph, MFD 10, (5A) Cab electrics
F119 Tachograph, MFD 10, indicator lights, (5A) Cab electrics
F120 Air conditioning, central lubricating system Cab electrics
F121 Air conditioning (25A) Cab electrics
F122 Air drier, horn, windscreen washer/wiper,
mirror heating/adjustment, seat heating,
timer for parking heater, fan (15A) Cab electrics
F123 CPU board (5A) Cab electrics
F124 Binary board, button raise level/axles,
unlock/lock crabwalk (10A) Cab electrics
Chassis Electrics
F125 Proximity switch level/crabwalk unlocked/locked,
pressure switch axle 3 100 bar, switch axle 3 unlocked /
locked (5A) Cab electrics
F126 CPU board (5A) Cab electrics
F127 Binary board, crabwalk (10A) Cab electrics
F128 Rotaflare lights, indicator display, voltage converter
CU interior lighting, cab lighting,
superstructure operation (15A) Cab electrics
F202 Terminal 15 engine control (10A) Cab electrics
F203 Fault diagnosis engine (10A) Cab electrics
F204 Fault diagnosis engine (10A) Cab electrics
F205 Terminal 30 vehicle control FR (10A) Cab electrics
F206 Terminal 30 ADM (10A) Cab electrics
F207 Emergency control transmission, digital input MKR (15A) Cab electrics
F208 Parking heater (15A)
F209 Parking heater timer (5A) Cab electrics
F210 Parking heater fan (10A) Cab electrics
F211 ABS (5A) Cab electrics
F214 ABS trailer (25A) Cab electrics
G301 Three-phase generator Engine
G302 Batteries 2 x 12V Rear cab
H305 Indicator light fault transmission Cab
H307 Indicator light fold out coupling Cab
H308 Indicator light coupling applied Cab
H308.1 Indicator left front Front bumper
H308.2 Indicator left side
H308.3 Indicator left rear Rear bumper
H308.4 Indicator right front Front bumper
H308.5 Indicator right side
H308.6 Indicator right rear Rear bumper
H309.1 Parking light left front Front bumper
H309.2 Parking light right front top Cab
H309.3 Parking light right side
H309.4 Parking light left rear Rear bumper
H309.5 Parking light left front
H309.6 Parking light right front Front bumper
H309.7 Parking light left front top Cab
H309.8 Parking light left side
H309.9 Marking lighting Rear bumper
H309.10 Marking lighting Rear bumper
H309.11 Parking light right rear Rear bumper
H309.12 Parking light right front
H309.13 Parking light right rear
H309.14 Parking light left rear
H310 Headlight display Cab
H310.1 Brake light left Rear bumper
H310.2 Brake light right Rear bumper
H311 Indicator light level rear left Cab
H312 Indicator light level front left Cab
H314 Indicator light air filter Cab
H316 Indicator light level rear right Cab
H317 Indicator light level front right Cab
H319 Indicator light steering pump 2 Cab
H320 Indicator light steering pump 1 Cab
Chassis Electrics
H322 Indicator light charge display Cab
H323 Indicator light oil level engine Cab
H324 Indicator light oil pressure engine Cab
H325 Indicator light fault ADM/MR
H326 Indicator light overspeed Cab
H327 Indicator light air filter Cab
H329 Indicator light engine temperature Cab
H330 Indicator light indicator vehicle Cab
H331 Indicator light ABS info Cab
H332 Indicator light ABS Cab
H333 Indicator light ABS Cab
H334 Indicator light brake pressure Cab
H335 Indicator light indicator trailer Cab
H337 Indicator light retarder Cab
H339 Indicator light handbrake Cab
H340 Indicator light activate brake Cab
H341 Indicator light longitudinal differential lock Cab
H342 Indicator light transverse differential lock Cab
H343 Indicator light superstructure operation Cab
H344 Indicator light crabwalk not locked Cab
H345 Indicator light crabwalk unlocked Cab
H347 Indicator light axle lock Cab
H348 Indicator light hold axle Cab
H349 Indicator light crabwalk selected Cab
H350 Indicator light axle 3 top Cab
K101 Relay overspeed Cab electrics
K102 Relay release operating hours Cab electrics
K103 Relay light Scandinavia Cab electrics
K104 Relay light Scandinavia Cab electrics
K105 Relay rotaflare light Cab electrics
K106 Relay handbrake Cab electrics
K107 Relay horn Cab electrics
K108 Relay steering of superstructure Cab electrics
K109 Relay crabwalk steering Cab electrics
K110 Relay ABS Cab electrics
K111 Relay ignition engine/transmission Cab electrics
K112 Relay condenser air conditioning Cab electrics
K113 Relay compressor air conditioning Cab electrics
K114 Relay ignition of superstructure Cab electrics
K115 Relay reverse signal Cab electrics
K116 Relay transmission neutral Cab electrics
K117 Relay crabwalk unlock/lock Cab electrics
K118 Relay ignition of superstructure Cab electrics
K119 Relay brake light Cab electrics
K120 Relay engine running Cab electrics
K201 Relay lock axles Cab electrics
K202 Relay switch to superstructure Cab electrics
K203 Relay switch to superstructure Cab electrics
K206 Relay transmission neutral Cab electrics
K301 Load voltage relay Cab electrics
L386.1 ABS sensor axle 1 left ABS distributor box
L386.2 ABS sensor axle 1 right ABS distributor box
L386.3 ABS sensor axle 2 left ABS distributor box
L386.4 ABS sensor axle 2 right ABS distributor box
Chassis Electrics
M301 Starter Engine
M302 Pump windscreen washing system Cab
M303 Windscreen wiper motor Cab
M404 Electric coupling Rear cab
P100 Multi-function display MFA10 Cab
P301 Tachograph Cab
P400 Display transmission Cab
R170 Air conditioning Cab
R301 150 Ohm Cab electrics
R302 1.6 KOhm Cab electrics
R303 3.3 KOhm Cab electrics
R310.7 Display brake pressure MFD10 Pedal
R325 Air drier Right of air tank
R328 Seat heater Cab
S300 Ignition start switch Cab
S301 Independent gas adjustment Cab
S302 Crabwalk steering left Cab
S303 Crabwalk steering right Cab
S305 Button level front Cab
S306 Button level rear right Cab
S307 Button level rear left Cab
S308 Button level automatic Cab
S309 Central lubricating system Cab
S312 Outrigger lighting Cab
S313 Switch rotaflare light Cab
S314 Switch rear foglight Cab
S315.1 Door contact switch left Cab
S315.2 Door contact switch right Cab
S316 Switch warning indicator Cab
S319.1 Plunger switch longitudinal lock actuated Axle 4
S319.2 Plunger switch longitudinal lock actuated Axle 2
S320 Plunger switch axle 1 connected Axle 1
S321.1 Plunger switch transverse lock actuated Axle 2
S326 Switch axle locking Cab
S327 Switch - hold axles Cab
S328 Switch crabwalk Cab
S331 Switch longitudinal differential lock Cab
S332 Switch transverse differential lock Cab
S334 Switch seat heating Cab
S335 Switch mirror heating Cab
S350 Switch electr. mirror adjustment Cab
S355.1 Crabwalk unlocked (axle 4) Axle 4
S355.2 Crabwalk not locked (axle 4) Axle 4
S360.1 Button raise axles Outrigger operating box L.
S360.2 Button raise axles Outrigger operating box R.
S370 Switch air conditioning Cab
S400 Steering column switch Cab
S404 Steering column switch cruise control/retarder Cab
S500 Button outrigger front right vertical extend/retract Outrigger operat. box (right)
S501 Button outrigger front right vertical extend/retract Outrigger operating box (left)
S502 Button outrigger front left vertical extend/retract Outrigger operat. box (right)
S503 Button outrigger front left vertical extend/retract Outrigger operating box (left)
S504 Button outrigger rear right horizontal extend/retract Outrigger operat. box (right)
Chassis Electrics
S505 Button outrigger rear right horizontal extend/retract Outrigger operating box (left)
S506 Button outrigger rear left horizontal extend/retract Outrigger operat. box (right)
S507 Button outrigger rear left horizontal extend/retract Outrigger operating box (left)
S508 Button outrigger rear left vertical extend/retract Outrigger operat. box (right)
S509 Button outrigger rear left vertical extend/retract Outrigger operating box (left)
S510 Button outrigger rear right vertical extend/retract Outrigger operat. box (right)
S511 Button outrigger rear right vertical extend/retract Outrigger operating box (left)
Y29 Solenoid valve
Y30 Solenoid valve
Y31 Solenoid valve
Y32 Solenoid valve
Y33 Solenoid valve
Y34 Solenoid valve
Y35 Solenoid valve
Y36 Solenoid valve
Y37 Solenoid valve
Y38 Solenoid valve
Y39 Solenoid valve
Y44 Solenoid valve retarder
Y94 Overspeed cutout Engine compartment
Y304A-FSolenoid valve steering drive superstr. Hydraulic block
Y305A Crabwalk turn of wheels
Y305B Crabwalk turn of wheels
Y305C Crabwalk turn of wheels
Y305D Crabwalk turn of wheels
Y306A Outrigger front right vertical Outrigger cyl.
Y306B Outrigger front right horizontal Outrigger cyl.
Y307A Outrigger rear right vertical Outrigger cyl.
Y307B Outrigger rear right horizontal Outrigger cyl.
Y308A Outrigger front left vertical Outrigger cyl.
Y308B Outrigger front left horizontal Outrigger cyl.
Y309A Outrigger rear left vertical Outrigger cyl.
Y309B Outrigger rear left horizontal Outrigger cyl.
Y310A Outrigger retract
Y310B Outrigger extend/suspension
Y313 Longitudinal differential lock
Y314 Transverse differential lock
Y331 Switchover handbrake in superstructure
Y343 Switchover steering circuit 1
Y344 Switchover steering circuit 2
Y355.1 Crabwalk unlock / lock axle 4
Y356.1 Crabwalk rear axle steering left Hydraulic block F.L.
Y356.2 Crabwalk rear axle steering right Hydraulic block F.L.
Y357 Hold axle 3
Y358A Steering rod unlock crabwalk
Y358B Steering rod unlock/lock crabwalk
Y361 Level front
Y362 Level axles 3/4/5 left
Y363 Level axles 3/4/5 right
Y364.1 Limit switch spring-loaded cylinder
Y364.7 Axle differential axle 3/4
Y364.8 Axle differential axle 3/4
Y365 Disconnect suspension circuit front
Chassis Electrics
Y366A Raise axles
Y366B Release level
Y367 Hold axles
Y386.1 ABS system axle 1 left ABS distributor box
Y386.3 ABS system axle 1 right ABS distributor box
Y420 Pneumatic valve engine brake Engine compartment
Y422 Pneumatic valve constant throttle Engine compartment
Initial set-up for AC100 transmission
1 Requirements :
- Set the tachograph in accordance
with the tyre size, (code switch)
- Bridge the neutral relay.
- Set the parameters for FMR,
ADM, ABS (according to tyre size)
with HHT / Minidiag 2.
- ABS sensors / valves: check
allocation in accordance with
instructions with HHT / Minidiag 2.
- Teach in accelerator pedal in ADM
and FMR with HHT / Minidiag 2.
- Teach in CAN environment with
HHT / Minidiag 2.
!! The ventilation procedure must be
carried out very carefully, as the
system must be properly vented to
ensure correct operation of the clutch.
The compressed air system must be
completely filled!!
!! Hydraulic lines must be correctly
laid.
Ventilation circuit: emergency pedal separator
2 Connect the ventilation unit to the
fluid tank ( Fig. 1 ).
3 Connect the ventilation hose to the
slave cylinder of the clutch separator
(Fig. 2)
!! Secure the ventilation hose on the
vent valve with a hose clamp.
Collecting container must hold at least
5 litres. The ventilation unit must be
completely full!!
4 Fold out the emergency clutch pedal
(Fig. 3).
!! Turn the release knob in the
clockwise direction (Fig. 4)
5 Switch on the ventilation unit. !! The pressure in the ventilation unit
should not fall below 1.5 bar!!
6 Open the vent valve on the slave
cylinder of the clutch separator (Fig.
2) and allow brake fluid to flow
through for approx. 3 mins.
!! Open the vent valve 90.
7 Actuate the emergency clutch pedal
quickly 3 times, holding it down for
approx. 3 seconds on the last time.
Then leave the brake fluid to flow for
approx. 15 s without actuating the
emergency clutch pedal.
8 Step 7 must be repeated 12 times.
9 Close the ventilation valve.
Ventilation circuit: Separator safety valve clutch booster
10 Connect the ventilation hose to the
clutch booster gear (Fig. 5).
!! Secure the ventilation hose on the
vent valve with a hose clamp.
Collecting container must hold at least
5 litres. The ventilation unit must be
completely full!!
11 Switch on the ignition and depress the
emergency pedal once
!! During this procedure solenoid
valve M1 is placed under current and
solenoid valve M3 on the safety valve
( Fig. 6 ) must not be placed under
current. The system is switched over
to the pedal circuit.
12 Switch on the ventilation unit !! The pressure in the ventilation unit
should not fall below 1.5 bar.
The ventilation unit remains switched
on during the ventilation process!!
13 Open the ventilation valve on the
clutch booster ( Fig. 5 ) and allow
brake fluid to flow through for approx.
3 mins.
!! Open the ventilation valve 90.
14 Actuate the emergency clutch pedal
quickly 3 times and on the last time
keep pressed down for approx. 3
seconds. Then allow brake fluid to
flow through for approx. 15 secs.
without actuating the emergency
clutch pedal.
16 Switch off the ignition for at least 7 s.
Ventilation circuit: El. clutch safety valve clutch booster
17 Fold in the emergency clutch pedal.
18 Switch on the ignition. !! During this procedure the solenoid
valve M3 on the safety valve ( Fig. 6 )
is placed under current and the
system is switched over to the
automatic circuit!!
19 Leave the brake fluid to flow through
for approx. 3 mins.
21 Switch off the ventilation unit.
22 Check the foot clutch values via HHT
/ Minidiag 2.
HHT EPS(GS) ACTUAL VALUE
VALUE 15
- Clutch pedal not pressed down,
value should be between 900 and
990.
- Press down the clutch.
- Differential values for when the
clutch is pressed and when it is
not pressed should equal Min 480.
- Write down the difference in
values.
23 If the differential value < 480 repeat
the ventilation procedure from
point 17 otherwise continue with
point 25.
24 Switch off the ignition for at least 7
secs.
Teaching in control unit EPS(GS)
25 Fill the compressed air system to the
maximum.
26 Apply the parking brake / switch off
the ignition.
27 Press down and hold the emergency
clutch pedal.
28 Press down and hold the function
button and the neutral button.
29 Switch on the ignition.
30 Teaching procedure is started
When the display flashes N
start the engine
When the buzzer sounds
release the emergency clutch
pedal.
press down the emergency clutch
pedal.
pedal.
press down the emergency clutch
pedal.
When N is displayed
pedal.
Release the function button and
neutral button.
Arrow flashing up / down.
Teaching procedure ended.
secs.
Fold in the pedal and then switch off
the ignition
32 Check the automatic circuit values via
HHT / Minidiag 2.
VALUE 15
- Gear in neutral value should be
between 900 and 990.
- Place in gear.
- Differential values between
neutral and in gear should equal
Min 480.
- Write down the value.
33 If the value < 480 or the difference
between point 22 and 31 > 40
counts, repeat the ventilation
procedure, commencing at point
34, otherwise continue with point
45
Continuing the ventilation procedure
34 Switch on the ignition.
35 Switch on the ventilation unit. !! The pressure in the ventilation unit
should not fall below 1.5 bar.
The ventilation unit remains switched
on during the ventilation procedure!!
36 Open the ventilation valve on the
clutch booster ( Fig. 5 ).
!! Open the ventilation valve 90!!
37 Actuate the semi-gear switch on the
shift lever, then leave the brake fluid
to flow through again for approx. 15
secs. without actuation.
40 Remove the ventilation unit.
41 Adjust the fluid level in the
compensator tanks.
42 Check the ventilation valves to make
sure that they are properly sealed
43 Check the automatic circuit levels via
HHT / Minidiag 2.
VALUE 15
- Gear in neutral value should be
between 900 and 990.
- Place in gear.
- Differential values between
neutral and in gear should be Min
480.
- Write down the value.
44 If the value < 480 and the difference
between point 22 and 43 > 40
counts, repeat point 34, otherwise
continue with point 45.
Continue set up
45 In the CU relay remove K152 /
remove the neutral relay bridge.
46 If possible delete fault MKR(KR).
46 Carry out a clutch adjustment via HHT
/ Minidiag.
HHT MKR(KS) ACTIVATION
CLUTCH ADJUSTMENT
Instructions given by HHT / Minidiag
47 Following successful adjustment of
the clutch, replace relay K152.
48 Teach in terminal W with HHT /
Minidiag 2.
HHT FMR(FR) TEACHING IN
TERMINAL W
Instructions given by HHT / Minidiag
49 Switch off ignition for at least 30 secs.
Teaching in control unit EPS(GS) with automatic circuit
50 Fill up compressed air system to the
maximum
51 Apply the parking brake / ignition off
52 Emergency clutch pedal should be
folded in.
53 Press and hold in function key and
neutral key.
54 Switch on the ignition
55 Teaching in procedure is started
Display N flashing
Start engine
Buzzer sounds 4x
N is displayed
Release the function key and
neutral key.
Arrows flashing up / down
Teaching in procedure ended
secs. Then switch on.
57 Delete all faults in electronics system
(if possible).
Set up completed
Counterweight
Technische Schulung AC100 Gegengewichtszyl neu.doc
Couterweight cylinder old
Lock valve
B50 (51)
cylinder up
B52 (53)
slew enable
! FB155 V 3.0 08.02.2000 17:11
NAME *GGW STEU
!
: GGW Steuerung
: Verfahren, Auf-und Ab-
: r sten des GGW
: **********************
:
:
:U E 25.1 OW nach hinten ss over rear
:U E 23.5 Taste GGW ab switch ccw down
:= A 19.2 Ventil GGW ab valve ccw down
:
:U E 23.4 Taste GGW auf switch ccw up
:= A 19.1 Ventil GGW auf valve ccw up
:
:
:UN E 23.3 GGW liegt nicht auf ccw not on claw
:U E 23.6 Taste Klaue zu switch close claw
:= A 19.3 Ventil Klaue zu valve close claw
:
:UN E 23.1 Drehen nicht freigegeben slew not allowed
:U E 23.0 GGW oben/unten ccw up/down
:= A 19.4 GGW unten ccw down
:
:U E 23.1 Drehen nicht freigegeben slew not allowed
:U E 23.0 Zylinder oben cyl. up
:UN E 23.3 GGW liegt auf ccw lays on claw
:O(
:U E 23.3 1 GGW liegt auf ccw lays on claw
:U E 23.2 1 Klaue auf claw open
:U E 23.1 1 Drehen frei slew enabled
:) 1
:= A 19.6 Drehwerk frei slew enabled
:
:UN E 23.3 GGW liegt nicht auf ccw lays not on claw
:= A 19.5 GGW entbolzt ccw unpinned
:
:BE
Counterweight
Technische Schulung AC100 Gegengewichtszyl neu e.doc
Counterweight cylinder
Lock valve
B56 ( 57 )
Clamp closed
B 52 ( 53 )
slew - enable
B 58 ( 59 )
CWT in Position
B54 ( 55 )
Clamp open
Position
indicator bar
ca. 60mm
B 50 ( 51 )
Cylinder up
Cable track
! FB155 V 3.0 29.06.2000 15:51
NAME *GGW STEU
!
: ZYL Steuerung GGW
: Verfahren, Auf-und Ab-
: rsten des GGW
: **********************
:
:
:U E 25.1 OW nach hinten SS over rear
:U E 23.5 Taste ZYL ab switch cyl. down
:= A 19.2 Ventil ZYL ab valve cyl. down
:
:U E 23.4 Taste ZYL auf switch cyl. up
:U E 23.7 Klaue in Position claw in position
:U E 23.2 Klauen auf claw open
:O(
:U E 25.1 1 OW nach hinten ss over rear
:U E 23.4 1 Taste ZYL auf switch cyl. up
:U E 23.3 1 Klauen geschlossen claw closed
:) 1
:= A 19.1 Ventil ZYL auf valve cyl. up
:
:
:UN E 23.7 Klaue in Position claw in position
:U E 23.5 Taste ZYL ab switch cyl. down
:O(
:U E 25.1 1 OW nach hinten ss over rear
:U E 23.6 1 Taste Klaue zu switch claw closed
:) 1
:= A 19.3 Ventil Klaue zu valve close claw
:
:U E 23.0 ZYL oben cyl. up
:O(
:U E 23.7 1 Zyl in Position cyl. In position
:U E 23.2 1 Klaue auf claw open
:UN E 23.1 1 Drehen frei slew enabled
:) 1
:= A 19.6 Drehwerk frei slew enabled
:
:U E 23.3 Klaue zu claw closed
:O(
:U E 23.2 1 Klaue auf claw opened
:UN E 23.7 1 Zyl in Position cyl. In position
:) 1
:= A 19.5 GGW entbolzt ccw unpinned
:
:U E 23.2 Klaue auf claw opened
:U E 23.7 Zyl in Position cyl. In position
:= A 19.4 GGW verbolzt ccw pinned
: A19.4 war GGW unten A19.4 was ccw down
: wird GGW verbolzt ccw will be pinned
:
:BE
Axle loads
Technische Schulung AC100 Achslasten e
Counter wei ght - Axl e l oads
4 variations are possible
1. 0 t CW, approx. 9 t axle load (no hook block, no MBE)
2. 2 t CW approx. 9,6 t axle load ( with single sheave hook block)
2 x 1 t CW permanently mounted to the SS frame
3. 12/13,3 t CW approx. 12 t axle load (with hook block, 17m MBE)
10/11,3 t lifted with cylinders and pinned to the SS frame
1 x 6,7/8 t, 1 x 3,3 t
while driving, the 6,7/8 t CW stays on the carrier, the 3,3 t plate is pinned
to the SS frame
4. 25 t CW approx. 14 t axle load
23 t lifted with cylinders and pinned to the SS frame
1 x 8 t, 1 x 8,6 t, 1 x 3,3 t, 1 x 3,1 t
while driving, the 8 t and 8,6 t CW stay on the carrier, the 3,3 t and the
3,1 t plates are pinned to the SS frame
Is the crane equipped with 14 tires, you have to add the 1,3 t piece in the lower
counter weight plate (6,7/8t).
05.07.00 8329 1
D E M A G A C 1 0 0
Axle loads and Counterweights
Counterweights at 60 t total weight
1.0 t fixed on either side of superstructure
+
3.3 t fixed at superstructure
+
+
6.7/8 t basic to be laid upon carrier
=
12 resp. 13.3 t total
05.07.00 8329 2
13.3 t counterweight (total weight: 60 t)
Drive 10 x 8 x 8, tyres 16.00 R 25
8.0 t basic plate laid upon carrier (front)
Central lubrication, rope box, tow coupling
Hook block, 1 sheave at main boom
D E M A G A C 1 0 0
05.07.00 8329 3
12 t counterweight (total weight: 60 t)
Drive 10 x 8 x 8, tyres 14.00 R 25
6.7 t basic plate, mounted at carrier front
Hook block, 1 sheave
17 m jib
D E M A G A C 1 0 0
05.07.00 8329 4
Drive 10 x 8 x 8, tyres 16.00 R 25
6.7 t basic plate, mounted at carrier front
Hook block, 1 sheave
9 m jib
D E M A G A C 1 0 0
05.07.00 8329 5
Counterweights with 48 t total weight
1.0 t fixed on either side of superstructure
=
2.0 to total counterweight
D E M A G A C 1 0 0
05.07.00 8329 6
Drive 10 x 8 x 8, tyres 14.00 R 25
2 t fixed at superstructure
Hook block, 1 sheave at main boom
D E M A G A C 1 0 0
05.07.00 8329 7
Drive 10 x 8 x 8, tyres 16.00 R 25
2 t fixed at superstructure
without hook block
D E M A G A C 1 0 0
05.07.00 8329 8
Maximum counterweight
+
8.0 t basic plate, laid upon carrier
+
3.1 t
+
8.6 t
=
25 t maximum counterweight
D E M A G A C 1 0 0
05.07.00 8329 9
Specialty:
8.6 t counterweight to be separated into:
2 units 2.7 t each
and
1 unit 3.2 t
Advantage:
Counterweight may be lifted with a
standard truck loader
D E M A G A C 1 0 0
Telescope
Technische Schulung AC100 Telezylinder e.doc
C-C
D-D
E-E
Telecylinder AC100
Telescope control
AC100
Date: 08.09.99
Original: C. Quien
Page:1 of 11
AC100 SVE II e neu.doc, Page 1 of 11
1.0 Allocation of the Initiators in the LPU
Fig. 1:
B1: in front of positionSection locking tele 1 and 3
B2: behind position Section locking tele 1 and 3
B3: in front of positionSection locking tele 2 and 4
B4: behind position Section locking tele 2 and 4
B5,B7,B9,B11: in front of position section pinning (1-4 sections), connected
via sliding contact PP (see above)
B6,B8,B10,B12: behind position section pinning, connected via
sliding contact FOP (see above)
B13: LPU locked
B14: Scan pinning right
B15: Scan pinning left
B16: Scan locking right
B17: Scan locking left
Page 2
AC100 SVE II e neu.doc, Seite 2 von 11
1.1 Definitions:
in front of position:LPU in telescoping-out direction with first initiator in switch
position (locking/pinning)
behind position: LPU in telescoping-out direction with second initiator in switch
Fine position : LPU in telescoping-out direction with both initiators in switch
1.2.1 Description of Locking and Pinning Unit Function
Two times two inductive proximity switches are fitted on the top of the locking and
pinning unit (B1-B4). These recognise the locking condition of the LPU and, in
conjunction with the length transducer of the telescopic section, identify the individual
tele sections. To prevent an incorrect identification of the sections as a result of length
tolerances, 2 initiators record the switching line of the boom sections 1 and 3 (right side
of the LPU), while two record the switching line of sections 2 and 4 ( left side of the
LPU). The in front of position of tele 1 and 3 is scanned by initiator B1, the behind
position by B2. The in front of position of tele 2 and 4 is indicated by activation of
initiator B3, the behind position by initiator B4. The current tele section can therefore
be clearly identified from the length signal and switch condition of the proximity
switches. The initiators, which reach the switch line first when telescoping out, mark the
in front of position. When the second initiator (behind position) reaches the switch
line, the "fine position" is reached, i.e. the lock pins are "shot" or "drawn". The locking
valves must be activated until the LPU sensors have registered a safe limit condition.
These limit conditions are:
LPU unlocked and pinned
LPU locked and unpinned
LPU locked and pinned
Control of the LPU functions is assumed by a C-task ( C -programming ), which is
performed in a shorter time interval. Because of the mechanical design of the LPU, the
situation is prevented in which a section is unpinned without first being locked. The
pinned status is queried via a switch gate, which moves with the pinning mechanism.
The combination of the switch signals of a total of five initiators allows a precise
allocation of the current pinning or locking status of the LPU. The allocation of the
initiator conditions, as shown in the logic chart in diagram 2, shows the possible pinning
and locking conditions of the LPU.
Page 3
Logic chart/locking and pinning conditions
Fig. 2.:
B13 B14 B15 B16 B17 Status LPU
0 0 0 0 0 E R R O R
0 0 0 0 1 E R R O R
0 0 0 1 0 E R R O R
0 0 0 1 1 E R R O R
0 0 1 0 0 E R R O R
0 0 1 0 1 E R R O R
0 0 1 1 0 E R R O R
0 0 1 1 1 E R R O R
0 1 0 0 0 E R R O R
0 1 0 0 1 E R R O R
0 1 0 1 0 E R R O R
0 1 0 1 1 E R R O R
0 1 1 0 0 LPU moving
0 1 1 1 1 Unlocked &
pinned
1 0 0 0 1 E R R O R
1 0 0 1 0 E R R O R
1 0 0 1 1 Locked and
unpinned
1 0 1 0 1 E R R O R
1 0 1 1 0 E R R O R
1 0 1 1 1 E R R O R
1 1 0 0 1 E R R O R
1 1 0 1 0 E R R O R
1 1 0 1 1 E R R O R
1 1 1 0 0 Locked & pinned
1 1 1 0 1 E R R O R
1 1 1 1 0 E R R O R
1 1 1 1 1 E R R O R
Fig. 3: Activated solenoid valves:
Speed Telescope in Telescope out
Max Y16.2,Y16.3,Y16.4 Y16.1
100mm/s Y16.2,Y16.3,Y16.4 Y16.1
40 mm/s Y16.2,Y16.3,Y16.4 Y16.1
10 mm/s Y16.2,Y16.3,Y16.4,
Y16.5
Y16.1
Fig. 4: Default values prop. valve flow - telescope:
Speed Telescope in Telescope out
Max Y16.2, mA Y16.1, mA
100mm/s Y16.2, mA Y16.1 mA
40 mm/s Y16.2, mA Y16.1 mA
10 mm/s Y16.2, mA Y16.1 mA
switched
not switched
switched
not switched
switched
not switched
Pinned & unlocked
locked & unpinned
locked & pinned
Page 4
1.2.2 Semi-automatic function process
Semi-automatic tele preselection:
The crane operator selects a boom configuration using the input menu and, as a result,
specifies a telescoping process and a prescribed sequence. The telescoping
sequences are coordinated by the tele control system. As the balance of the head
weight is changed within the boom during telescoping, the LPU has to be returned to its
end position once the telescoping sequence has been completed . The new load may
only be enabled once the LPU has returned to the area of the boom foot section.
This also prevents the oil volume in the hydraulic tank from reaching excessively high
temperatures.
The crane operator specifies the desired telescoping direction and speed via the pilot
control sensor. The LPU moves out of its basic position towards the rear bearing of the
selected section at the preset speed.
Once the control system detects a "need for action", the system reacts after a specified
time; this strategy remains the same for all LPU actions, and is explained in more detail
below:
Speeds during telescoping
200 mm
before PP
PP locking
reached
Position
locking
reached
Section
locked or
unlocked
Position
pinning
reached
Section
pinned or
unpinned
Vmax
80-100
mm/s
40mm/s
10mm/s
Page 5
1.2.3 Locking and unpinning boom sections
Input requirement: LPU unlocked, all sections pinned.
Locking:
The LPU travels to the locking position at the speed specified with the pilot control
lever. Independent of the movement of the pilot control sensor, the telescoping
movement is reduced to approx. 80-100 mm/s (Fig. 3) approx. 200 mm before the
desired locking position is reached. When the LPU reaches the in front of locking
position of the section prescribed by the control system during the telescoping
procedure, (proximity switch B1 or B3 activated), the telescoping speed is limited to
approx. 40mm/s (Fig. 3). At the same time a C-routine monitors when the exact position
is reached from the moment that the in front of position is reached (proximity switch
B1 or B3 activated). As soon as the corresponding proximity switch behind position is
reached (B2 or B4), the locking bolt is "shot" and the telescoping speed reduced to 10
mm/s (Fig. 3), whereby the SPS must continue to actuate the safety valve Y26 until the
"locking" procedure is completed (B13 activated).
Switching over:
Once the PDC receives the message "locked and pinned" (B13 ,B14 and B15
activated), the direction arrows in the display are switched over from "lock" to "unpin" in
the following program cycle and the telescoping speed is increased back to 40mm/s.
The arrows of the in front of and behind position for the section locking in the display
must be different to those for section pinning (eg inverse/normal).
Unpinning:
The crane operator telescopes in the displayed direction until the pinning sensors of the
selected rear bearing report back the fine position, with whose help the selected section
can be unpinned by the locking and pinning unit once the load has been transferred
(Y27). Here, too, the control ensures that self-activation of the valve control "unpin
section" (Y27) is deactivated again when the end position "unpinned and locked" is
reached.
Depending on the position of the boom section once the sensors have switched from
"lock" to "unpin" the control must react as follows:
in front of position section unpin:
Sensors register "in front of position" of the section unpinning reached (e.g. in
front of position for the 2
nd
boom section corresponds to B7 and B8 being
activated). The control enables movements for telescoping in and out, but
specifies a corresponding direction, if the target position has been exceeded by
L= 200 mm.
Page 6
Behind position section unpin:
Sensors register "behind position" for section unpinning reached. The control
enables movements for telescoping in and out, but specifies a corresponding
direction, if the target position has been exceeded by L= 200 mm.
The display provides information on the necessity of a change in direction and
the operator must reverse the telescoping movement of the boom using the pilot
control lever.
Fine position section unpin:
Sensors register "fine position" for section pinning reached. The C-task releases
the solenoid valve for the unpinning (Y27) and continues to activate it until the
section is unpinned and locked (initiators B13,B16 and B17 activated) and the
requirements for stopping the unpinning procedure are met.
1.2.4 Procedure for transporting, pinning and unlocking boom
sections
Input requirement: section locked and unpinned
Pinning:
Independent of the movement of the pilot control sensor, the telescoping
movement is reduced to approx. 80-100 mm/s approx. 200 mm before the desired
pinning position is reached (proportional valve Y16.1). When the section reaches
the in front of pinning position prescribed by the control system during the
telescoping procedure, (proximity switch B5,B7,B9 or B11 activated), the
telescoping speed is limited to approx. 40mm/s. At the same time, from the
moment the in front of position is reached (proximity switch B5,B7,B9 or B11
activated), a C-routine monitors when the exact position of the pinning position
prescribed by the control system is reached. As soon as the corresponding
proximity switch behind position (B6,B8,B10 or B12) is reached, the section pin
is "shot" and the telescoping procedure is reduced down to 10 mm/s (Fig. 3, Fig.
4), whereby the SPS must make sure that the pinning valve Y28 remains activated
until the entire "pinning" sequence is completed.
Switching over:
Once the PDC receives the message "locked and pinned" (B13 ,B14 and B15
activated), the direction arrows in the display are switched over from "pin" to
"unlock" in the following program cycle and the telescoping speed is increased
back to 40mm/s.
The arrows of the in front of and behind position for the section locking in the
display must be different to those for section pinning (eg inverse/normal).
Unlocking:
The crane operator continues to telescope until the sensors of the LPU report the
exact unlocking position of the LPU (B1&B2 or B3&B4 activated). With this signal
the locking pin is drawn (Y25). Here, too, the control ensures that self-activation of
the valve control "unlock section" (Y25) is deactivated again when the limit
position "pinned & unlocked" is reached.
Depending on the position of the boom section once the sensors have switched
from "pin" to "unlock" the control must react as follows:
Page 7
in front of position lock / unlock:
Sensors register "in front of position" for section locking reached. The control
enables both telescoping in and out, but specifies a corresponding direction if the
target position has been exceeded by L= 200 mm.
behind position lock / unlock
Sensors register "behind position" for section locking reached. The display
provides information on the necessity of a change in direction and the operator
must reverse the telescoping movement of the boom using the pilot control lever.
The control enables movements for telescoping in and out, but specifies a
corresponding direction, if the target position has been exceeded by L= 200
mm.
Exact position lock / unlock
Sensors register "exact position" for section locking reached. The C-task
releases the solenoid valve for unlocking (Y25) and continues to activate it until
the section is pinned and unlocked and the requirements for stopping the
unlocking procedure are met.
Page 8
2.0 Manual Control:
The manual control is not located on the tele control system, and enables the operator
to carry out a manual selection of possible locking/pinning positions, depending on
enabled sensor conditions. If the manual control program option is selected, the
maximum possible telescoping speed is limited to 150mm/s. Starting from this level,
there is a further reduction of the speed to 80mm/s if manual selection of an LPU
function is made and finally a reduction to 40mm/s when the in front of or behind
position is reached. It is to be assumed that, during crane operation, operating
conditions may occur, either as a result of maloperation or sensor failure, which can no
longer be covered by the tele control system. It is therefore necessary to enable the
crane operator to intervene manually in the telescoping and pinning sequences. In
order to make a decision on which movement can be authorised, however, it must be
possible to determine whether a) maloperation or b) sensor failure has caused the "exit"
from the tele control system. The type and extent of the error determines the reaction
that is required.
In case a) it is relatively easy to reaccess the control system by configuring the
equipment to the requirements for the next programme step in the telescoping
sequence.
2.1 Block overview telescoping sequence
Once the "circular structure" of
the telescoping sequence has
been interrupted as the result of a
fault, the entry conditions for the
next step in the programming
sequence must be selected
manually and passed on to the
tele control system for further
processing. All steps necessary
for this are indicated to the
operator on the display. All
sensor information as well as the
actual length value are output via
the display.
Start
Read in Data
Travel to section
Lock and unpin
section
Telescope section
to target position
Pin and unlock
section
All sections
processed?
Move LPU to
basic position
End
yes
no
Page 9
2.2 Troubleshooting
If the control system does not receive all information as the result of system faults or
sensor component failures, specified procedures can be authorised. In any case, a fault
evaluation has to be carried out, the result of which determines what further action is
required.
2.2.1 Initiator failure position scanning (B1-B12):
Telescoping out:
Fault in in front of position:
If, when telescoping out, the initiator for the behind (secondary) position
(B2,B4,B6,B8,B10,B12) is activated without the in front of position signal
(B1,B3,B5,B7,B9,B11) being present, there is a fault in the logic for the in front of
position.
Action: If the initiator for the behind position is triggered first, the equipment must be
telescoped in until the initiator switches off, and then telescoped out again until the
initiator is activated again. A fault message with specification of the initiator designation
is output.
Fault in behind position:
If, when telescoping out, the initiator for the in front of position is activated and then
deactivated again without any signal from the behind position being given, there is a
fault in the logic for the behind position.
Action: The system is telescoped out until the signal for the in front of position
switches off. Telescope in again until the initiator is activated again. A fault message
with specification of the initiator designation is output.
Telescoping in:
The switch positions for the in front of and behind position are designed for the
telescoping out procedure, in order to have a precise allocation to the sensor at all
times. Accordingly, the above-mentioned logic is reversed when telescoping in.
Fault in in front of position:
If, when telescoping in, the initiator for the in front of position (B1,B3,B5,B7,B9,B11) is
activated without the behind position signal being given first (B2,B4,B6,B8,B10), there
is a fault in the logic for the behind position.
Action: If the initiator for the in front of position is activated first, the system must be
telescoped out until the initiator switches off, and then telescoped in again until the
initiator switches back on again. A fault message with specification of the initiator
designation is output.
Fault in behind position:
If, when telescoping in, the initiator for the behind position is activated first and is then
switched off again, without the in front of position signal being given, there is a fault in
the in front of position logic.
Page 10
Action: The system is telescoped in until the signal for the behind position switches
off. It must then be telescoped out again until the initiator is reactivated. A fault
message with specification of the initiator designation is output.
For the above-mentioned cases, the target section is probably exactly in position. For
diagnosis purposes, a length transducer signal can be additionally evaluated, if it is
ensured that a length is stored when the first position signal is reached, the exact (fine)
position must be located within a distance of max 100mm from this position. A length
query must be carried out in order to ensure that the sensors do not evaluate a "wrong"
section.
The required locking and pinning procedures are authorised via sensors B13, B14 and
B15. The authorised functions are selected using the soft keys.
2.2.2 Initiator failure LPU status analysis (B13,B14,B15):
Fault observation:
Taking the truth table Fig. 1 as the basis for the function of the LPU status sensors,
only certain initiator errors can be covered by the system program. If, as a result of a
failure, a bit combination results which corresponds to that of a fault, it is not possible to
determine the locking and pinning condition of the LPU. For reasons of safety, the fault
of the status sensors of the LPU can therefore only be dealt with if a valid bit
combination in line with Fig. 1 is caused.
Fig. 4: LPU fault sequence
START
LPU manual
LPU position
OK ?
LPU
pinned
LPU unlocked
& pinned
LPU
locked
LPU locked &
pinned
LPU locked &
unpinned
Fatal error!
Direct operation
only possible using
code!
Enable manual
locking and
unlocking
Enable
manual
locking
Enable manual
pinning and
unpinning
Enable manual
unlocking and
unpinning
Enable
manual
pinning
Enable
manual
locking
ENDE
Pinning and locking sequences of the LPU
Emergency control sequence 4
no
no no no no no
yes
yes yes yes
yes yes
Page 11
2.2.3 Failure of the length transducer
Using the length transducer information, the system decides when the maximum
telescoping speed has to be reduced. Under operating conditions, maximum
telescoping speeds of 300 mm/s can be reached, which corresponds to a current
change of approx. 500 A /s. If this limit value is exceeded, there is a fault in the length
transducer. If no or only incorrect length information can be evaluated, all
locking/pinning procedures of the manual control authorised by the LPU sensors can be
selected. The fault is indicated on the display and dealt with as follows:
a) The control switches to "manual operation"
b) Telescoping in and out is authorised
c) Manual LPU functions are authorised
d) Maximum telescoping speed is reduced to 150 mm/s
e) Fault output on the display
PDC
Technische Schulung AC100 Handsteuerung Telekop e.doc
Manual telescope control
The following errors of the LPD sensors can be eliminated by an uncoded
handcontrol:
1. B13=0, B14=1, B15=1, B16=0, B17=0
2. B13=0, B14=1, B15=1, B16=0, B17=1
3. B13=0, B14=1, B15=1, B16=1, B17=0
4. B13=1, B14=0, B15=0, B16=0, B17=0
5. B13=1, B14=0, B15=0, B16=0, B17=1
6. B13=1, B14=0, B15=0, B16=1, B17=0
Those configurations of the sensors can also occur when the LPD is on its way to
pin or unpin. Therefore the error message in the PDC screen will only appear
after 5 seconds of the above mentioned LPD positions. The following screen will
appear:
This screen tells you to press the button.
PDC
In this screen you can activate the manual uncoded control with the
button. The next screen will appear. The system will propose something to
eliminate the fault, here unlock.
If the system proposes unlock, but the button pin is pressed, then the system
displays that action on the screen, but nothing will happen. The signal will not
be sent to the solenoid valve. (see next screen).
PDC
When the proposed button is pressed, the screen shows it on the left side of the
icons and the system activates the solenoid valve which is displayed on the right
side of the icons( here Y25). The telescope speed will be reduced (Y16.5).
If this action has solved the problem than the proper proximity switches are
activated again and the screen will automatically change back to normal and
then the automatic telescope control will be activated again.
PDC
In the SVE (LPD) screen the coded manual control can be activated with the
button and a code.
If the button is pressed without being displayed on the PDC screen,
the manual control screen appears, but the buttons are not active.
SVE
Technische Schulung AC100 SVE Neu e
Slider for signal
behind pinning
position Tele 1-4
Slider for signal in
front of pinning
position Tele 1-4
Ground slider for
proximity switch
pinning Tele 1-4
+24V slider for
proximity switch
pinning Tele 1-4
B1 in front of locking position
Tele 1/3
B3 in front of locking position
Tele 2/4
B4 behind locking position
Tele 2/4
B2 behind locking position Tele 1/3
Telescope
Technische Schulung AC100 Lngengeber e.doc
Length and angle indicator
Length adjustment
Angle indicator
Length indicator telescope cylinder
Length indicator main boom
Superstructure Telescope
Technische Schulung AC100 Schleifkontakte Verbolzung e.doc
Sl i ders l ocki ng and pi nni ng
Position locking
Slider ground
Slider + 24V
Slider in front of
pinning position
Slider behind
pinning position
Technial Training AC 100
Technische Schulung AC100 Ausleger Innenansicht e.doc
Mai n boom rear vi ew
Locking position
tele 1
Locking position
tele 3
Locking position
tele 2
Locking position
tele 4
Pinning position tele
1,2,3,4
pins tele 1,2,3,4
pins tele 1,2,3,4
Telescope
Technische Schulung AC100 Hauptausleger von hinten e.doc
Sensor in front of
pinning position
B5,B7,B9,B11
Sensor behind
pinning position
B6,B8,B10,B12
Pin for boom
pinning
Hole for pinning
Pin for boom
pinning
Roller for LPU
centering
Roller for LPU
centering
Hole for boom
locking
Slider for
locking position
Telescope
Technische Schulung AC100 Nherungsschalter Verbolzen e.doc
Sensors in front of and behind pinning position
+
-
Signal
Signal
Proximity
switches
Telescope
Technische Schulung AC100 hyd. Notsteuerung Tele e.doc
locking
unlocking
unpinning
pinning
Technische Schulung AC100 Hauptausleger Schnitt quer e.doc
Cross secti on mai n boom
Main boom
Technische Schulung AC100 Auslegerschnitt e.doc
Cut through main boom
Notice of modification
No. : 58-75
Page 1 of 13
Type of crane: Model: Date: Established by: Phone: Fax No.: e-mail:
Dept. 8331.5 +49 6332/ +49 6332/ michael.weber
Telescopic crane AC 100 01.02.2001 Michael Weber 83-1744 91011594 @dematic.de
Solving telescopic problems under
unsupervised manual operation
Remarks: Modification has been carried out
on :
Modification has been carried out
by:
Order ref. no.:
Model:
AC 100
Serial number:
Country / Place / Date
Signature:
Please complete the sections above and return this page and page 4 to Product support de-
partment (Mr. Weber Fax no. see above)!

------------------------- --------------------------
Peter Benien Michael Weber
No. : 58-75
Page 2 of 13
Table of Contents
Page 3 1. General
1.1. Diagnosing faults and determining the condition of the LPU
(Locking and Pinning Unit)
Page 4
Page 5 and 6 1.2. Rectifying faults
Page 7 1.3. Possible causes of faults
Page 8 and 9 2. Menu guidance and code input
2.1. Menu guidance and monitor displays up to code input
- Overview of signals / proximity switches
Page 10 2.2. Entry of generic code
Page 11 3. Checking the length transducer signals
4. Activating "RESET"
Page 12 5. Activating "RESET LK"
Page 13 6. Determining the generic code
No. : 58-75
Page 3 of 13
1. General:
The reason for this documentation is to provide support to service personnel or colleagues on
call in their work of rectifying faults (using "unsecured manual operation").
It is not intended to extensively explain the design and function of the LPU and other elements
of the telescopic boom. We strongly recommend that you obtain more detailed information
with the help of relevant training materials or queries if questions or uncertainties remain.
This text can only deal with occurring faults and their rectification in a very general way. Sim-
ply put, it can be said that a majority of faults occur in the following manner:
1. A pinning / unpinning procedure has not been fully carried out (e.g. a pin is stuck).
2. A locking / unlocking procedure has not been fully carried out (e.g. a locking bolt is stuck).
3. The LPU has carried out pinning / locking procedures in the wrong section.
4. The crane operator accidentally activates a reset of the tele control system.
To keep matters simple, we recommend that when the above mentioned faults occur, you
retract all boom sections to their rear end position, pin lock them in that position, then retract
the LPU and carry out a "RESET". This procedure is described in more detail under point 1.2.
Required tools:
Item Description Description, instructions
1 Laptop Program PATKey V 2.00 is required
(can be obtained by enquiring at Dept. 8315)
1.1. Diagnosing faults and determining the condition of the LPU :
Before you actually begin to rectify any faults please clarify the following points (please use
page 4 for this and then send it back to us):
1. Which fault has occurred and during which activity did it arise?
2. Which proximity switch signals and other signals are there? (it would be best to call up
illustration 3 for this)
3. Is a fault message (e.g. E 87) displayed? If so, which one?
4. Which suggestion is the PDC offering?
5. Does the schematic illustration of the boom shown on the display correspond to the ac-
tual condition? (see point 2.1.)
6. Can the LPU move freely or is it stuck?
This can be ascertained by extending / retracting the LPU and checking if a section
moves or the length transducer signal "-B703" changes at the same time.
7. Does the length transducer "-B703" (length transducer of the LPU) display an extension
length and is it possible to assume that this value is correct? (if necessary, check with
the display of "-B702" [exterior length transducer, total length of main boom])
After clarifying these questions, the occurring fault can be analysed and the procedure for
rectifying it can be decided upon.
No. : 58-75
Page 4 of 13
Fault report
Serial number.: 77 ............. Date: ........................ Time: ..................... Temp.: ................C
Crane operator / Service personnel: ............................................ Phone:
..................................................
Immediately after a fault has occurred, please fill in the following illustrated LPU diagram.
Complete all areas marked with "...." (e.g. the areas for fault code, length code, etc.) and mark
the pending signals (e.g. "-B1", "-Y16.3", etc.) with a tick.
Please note the "DESIRED" and the "ACTUAL" values of the length code.
Other comments (fault origin, possibly feeder valve pressure, the time between the two last
telescopic procedures, rectifying attempts of the crane operator, etc.):
.............................................................................................................................................................................................................
.............................................................................................................................................................................................................
Fault occurred during (please tick):
W telescoping in W telescoping out W with case W without case
No. : 58-75
Page 5 of 13
1.2. Rectifying faults :
The following combinations of LPU proximity switches are required for safe LPU operation.
We strongly recommend that you only carry out a forwards / reverse movement when one
of the following conditions is in place:
B13 B14 B15 B16 B17 Condition of the LPU
0 1 1 1 1 Unlocked & Pinned
1 0 0 1 1 Locked & Unpinned
1 1 1 0 0 Locked & Pinned
In almost every case, the simplest way of rectifying faults is by following a procedure during
which all extended telescopes are individually retracted and a reset is then actuated.
For this procedure, please carry out the necessary steps in the following order:
Can the LPU move freely and to which length is it extended?
If the LPU cannot move freely, it is necessary to find out during which procedure it be-
came stuck. This procedure must then be reversed (it might be necessary to move the
LPU slightly forwards or backwards). Then you must clarify the direction in which the LPU
must be moved in order for it to achieve "fine position locking" of the boom section that is
extended to the greatest length.
Please take the following into consideration:
- The "empty" LPU must be "unlocked & pinned".
- While extending the LPU, each of the proximity switch signals "B5, B7, B9, B11" and
"B6, B8, B10, B12" are shown on the monitor in black.
The length of the extension distance from the LPU to the 45% hole is 4.5m +/- 0.5m, to
the 90% hole it is 9.0m +/- 0.5m and to the 100% hole it is 10m +/- 0.5m.
The boom section can be locked when "fine position locking" has been reached. This po-
sition is indicated when the proximity switch signals "B1" and "B2" (in BS 1 and BS 3) and
/ or "B3" and "B4" (in BS 2 and BS 4) are displayed at the same time. If, for example, only
"B1" (= preposition) is displayed, the LPU must be extended some more. In contrast, if
only "B2" (= postposition) is displayed, it must be slightly retracted.
After the generic code has been entered, the boom section can be locked by pressing the
key marked .
No. : 58-75
Page 6 of 13

If the system is extended a little further following the locking procedure, "fine position pin-
ning" is reached immediately afterwards. This position is indicated when the proximity
switch signals "B5, B7, B9, B11" and "B6, B8, B10, B12" are displayed at the same time.
If only one proximity switch signal is displayed, it is necessary to move the system for-
wards or backwards, depending on the displayed signal. Then the section can be un-
pinned by pressing the key marked .
After unpinning, the key must be pressed again in order to cancel the speed
reduction of the tele cylinder (the "-Y16.5" signal indicates that the speed reduction is acti-
vated).
The section can now be moved to its rear end position. In the area of the rear end posi-
tion, "fine position pinning" is indicated when the proximity switch signals "B5, B7, B9,
B11" (= preposition) and "B6, B8, B10, B12" (= postposition) are displayed at the same
time. In this case, the section can be pinned by pressing the key marked .
After pinning, "fine position locking" can be reached in most cases by extending a little bit
further. When the proximity switch signals "B1" and "B2" and / or "B3" and "B4" are dis-
played, the key marked can be pressed for unlocking.
After the completed unlocking procedure, the LPU is released again and the key marked
must be pressed again in order to cancel the speed reduction of the tele cylin-
der (the "-Y16.5" signal indicates that the speed reduction is activated).

After this, the next extended section can be tackled. After completed locking / unpinning
procedures, it can be retracted, etc.
No. : 58-75
Page 7 of 13
1.3. Possible causes of faults:
The pins in the LPU or in the boom sections can become stuck if the speeds are too high
during the locking and pinning procedures. Speeds can become too high if speed reduction is
not functioning correctly. The reason for this can be contaminated or bridged contacts caused
by material wear.
In such a case, please check the following areas:
check the grinding contacts in the rear bearing of the relevant section for contamination
and wear (see following picture),
check the plug-in connections, via which LPU signals are transmitted, for damp and other
contamination.
Check these
areas
No. : 58-75
Page 8 of 13
2. Menu guidance and code input:
2.1. Menu guidance and monitor displays up to code input:
Figure 1 (LLD picture)
By pressing the button marked on the LLD screen the following LPU picture is acti-
vated.
Figure 2 (LPU picture)
The following display will be shown when the key marked is pressed (Figure
3).
No. : 58-75
Page 9 of 13
Figure 3
Lock
LPU
Unpin
section
Pin
section
Unlock
LPU
The RESET button
is omitted in this
picture in the soft-
ware version 1.34
(data).
Overview of the signals / proximity switches:
"-B1" = Preposition locking tele 1 / tele 3
"-B2" = Postposition locking tele 1 / tele 3
"-B3" = Preposition locking tele 2 / tele 4
"-B4" = Postposition locking tele 2 / tele 4
"-B13" = LPU locked
"-B14" = Enquiry pinning right
"-B15" = Enquiry pinning left
"-B5, -B7, -B9, -B11" = Prelim. position pinning
"-B6, -B8, -B10, -B12" = Follow-up pos. pinning
"-B16" = Enquiry locking right
"-B17" = Enquiry locking left
"-Y16.5" = Valve speed reduction 10 mm/s (telescopic cylinder)
"-B703" = Length transducer interior
" " = System suggestion ( means: PDC has no suggestion)
if box is black: valve is switched
if box is black: valve is preselected
No. : 58-75
Page 10 of 13
2.2. Entry of generic code:
When the key marked is pressed again when figure 3 is displayed, the fol-
lowing display will be shown (figure 4). The generic code must be entered at this point.
You will obtain it by calling up the program "PATKey" on the laptop (see point 6 of this
documentation).
Figure 4
You will come to the following figure 5 after confirming your entry. It is now possible to
switch the indicated valves unsecured by the PDC.
Figure 5
Lock
LPU
Unpin
section
Pin
section
Unlock
LPU
No. : 58-75
Page 11 of 13
3. Checking the length transducer signals :
The following display will be shown on the monitor by pressing the key when the
LPU picture (see figure 2) is indicated.
Picture 6
You can check here if both length transducer values are approximately identical. This is indi-
cated by displaying "Length 1 MB". The top value (here: 33.6 m) is the one measured by the
length transducer, the bottom value (here: 33.7 m) represents the calculated value. If the dif-
ference between these two values is > 0.4, the fault message "E 87" will appear.
A larger difference between the values indicates e.g. the following fault:
Exterior length transducer is damaged or the rope has been reeled in unevenly
4. Activating "RESET" :
By the pressing the key marked , the graphic ACTUAL values of all telescopes
(see picture 6: 90%, 45%, 90% and 0%) are set to "0". This is why this key may only be acti-
vated when all telescopes actually are set to "0%" and the LPU is fully retracted.
Note: from software version 1.34 (data), a reset can be activated by pressing the key only
after the generic code has been entered.
Reset can also be activated with "Ignition Off / On" when the following requirements are ful-
filled:
all sections are retracted to 0% and are pinned,
the LPU has been retracted completely and is locked and unpinned.
No. : 58-75
Page 12 of 13
5. Activating "RESET LK" :
The following display is shown on the monitor by pressing when the LPU picture
(see figure 2) is indicated.
Figure 7
Operation mode can be selected by pressing the key. The selected operation
mode is shown inversely in the space "TYP ..." (here "TYP HA").
Now "RESET LK" can be selected using the curser keys () or ().
Another important note on this:
"RESET LK" resets the PDC to a defined length code. Accordingly, this can only be switched
when an extension procedure has been completely carried out.
Example:
"LK 17" was selected (4x 90%), however, there was a fault after the second BS was moved
to the 90% position. Now, the 2nd BS can be manually pinned and unlocked in the corre-
sponding position with the help of the generic code. The correct position is most quickly found
by first driving the LPU back to approx. 8m and then by driving it forward, taking the length
transducer signal "-B703" and the proximity switch signals into consideration. At 9.0m +/-
0.5m, the signals "B5, B7, B9, B11" and "B6, B8, B10, B12" should appear and shortly after-
wards, the signals "-B3" and "-B4". When "B5, B7, B9, B11" = 1 and "B6, B8, B10, B12" = 1
you can pin, after further extension (when "-B3" = 1 and "-B4" = 1) you can unlock.
Then the LPU is driven back, the first BS is manually locked and unpinned and brought into
the 90% position. After a pinning and unlocking procedure is manually carried out, the LPU is
once again driven completely back. Now the actual length code (LK) must be entered into the
HA program; only once this is done can a "RESET LK" be actuated.
After "RESET LK", the matching operation mode must be selected in picture 7 (e.g. here:
"TYP HA", "Counterweight 25.0", "Outrigger support area 7.0" und "Reeving number of the
hoist rope: 10"
After these measures have been taken, the PDC is ready for operation again. By following this
procedure, you will save time as you are not required to bring back all pinned boom sections.
No. : 58-75
Page 13 of 13
6. Determining the generic code
The allocation of the generic code can be started on the WINDOWS user interface with the
commands "Start", "Programs", "PATKey" and "PATKey". To do so, a number combination
such as the one shown in figure 8 must be entered in "Maschinencode" (= "Machine code:",
here 1135, in figure 4 : 3452, however, other combinations are also possible) and a time pe-
riod must be determined in "Gltigkeitsdauer"(= "Validity duration:", e.g. "60" for 60 minutes).
By pressing the "Return" key or clicking on "Zugangscode ermitteln" (= "Determine access
code"), the Patkey program calculates an 8-figure generic access code (here, for example
36869394). As shown in figure 4, this must be entered with the number field of the PDC sys-
tem (as shown in figure 4, little stars [ * ] will appear). After confirming with the "C" key, it is
possible to switch the valves shown in figure 5 (-Y25 to -Y28) in an unsecured manner.
Figure 8
Hydraulics
Technische Schulung AC120 Hydraulik Hauptblock e.doc
Main hydraulic block
Primary pressure
relief 380 bar
pressure relief valves set
according to drawing
LS pressure relief
320 bar
0,7 l permanent leak
Proportional valves
25 bar pilot controled
pressure relief
Superstructure Hydraulic
Technische Schulung Druckwaage e.doc
Posi ti on of the bal anci ng val ve wi th one movement engaged
If only one movement is engaged the balancing valve is completely opened. The
LS-Signal is send to all other balancing valves and the pump.
Superstructure Hydraulic
Technische Schulung Druckwaage e.doc
Posi ti on of the bal anci ng val ve wi th two movements engaged
With two movements engaged the balancing valve of the movement with the
higher pressure opens completely, the balancing valve of the movement with the
lower pressure close.
Hydraulics
Technische Schulung AC100 Hauptpumpe e
Mai npump A11VLO 190 LR3DS
(rear view)
This pump delivers oil for:
-telescope cylinder
-hoist 1 and 2
-luffing cylinder
-counter weight cylinders
-pilot pressure
DR
S
LR
LS-Signal from
function (X)
Working pressure from
slew pump on LR (Z)
MP
MLS
Hydraulics
Technische Schulung AC100 Drehwerkspumpe e
Sl ewi ng pump A10VG 45 EP21
*SLV = Speicherladeventil
Y14.1
Y14.2
Filter
boost pump
Pressure switch
2,5 bar
boost pressure
port 15-20 bar
Test point slew left test point slew right
air bleed
Control pressure
ports
shuttle valve to LR
of the main pump
Pump 3 for
SLV* and
tilting cabin
Control pressure
ports
Hydraulics
Technische Schulung AC100 Speicherladeventil e
Feeder val ve
The task of the feeder valve is to hold the pressure level in an accumulator circuit
between certain limit values (shut-off pressure, activation pressure). The switch
pressure difference equals approx. 18% of the shut-off pressure.
Note: If downstream consumers produce a higher pressure than the shut-off
pressure of the feeder valve, the feed circuit is raised to this pressure level.
The valve consists primarily of a pilot control with a pressure adjustment ele-
ment (1), pressure sensor (2) and return valve (3).
Switchover of the pump supply volume from accumulation pressure to neutral
circulation:
During the charging process, the pump supplies the accumulator circuit (SP) via
the return valve (3). The pressure is fed via the control line and pilot control to
the load signal side (4) of the pressure sensor (2). This throttles the pump flow
until the pressure, which builds up in the accumulator circuit, overcomes the
spring force of the pressure adjustment element (1). The force pilot control ele-
ment switches the load signal line (4) of the pressure sensor (2) to T. The pres-
sure sensor (2) then switches the pump supply current P to N and the return
valve (3) closes. The charging process is completed and the pump supply current
flows at reduced P through the charge valve.
P
N
T
SP
3
2
1
4
Picture
Hydraulics
Technische Schulung AC100 Bild Speicherladeventil e.doc
Feeder valve
Measuring point for
accumulation pressure
Adjustment of
accumulation pressure
Electric
Technische Schulung AC100 Meldeleuchtenmodule OW e
I ndi cati ons on the dashboard SS
Generator
not charging
Filter
hydraulicoil
Counterweight
unpinned
Slewing not
allowed
Counterweight
cylinders down
Glow plug
Air filter
Counterweight
pinned
Slewing
allowed
Counterweigh
t cylinders up
Multiple
warning
No
function
Engine
malfunction
Switched
top SS
Slew brake
Oil level
engine
Service Bulletin
No. : 60 - 11
Mobile Cranes
1
Model: Type: Replacement for: Date: Produced by: Tel No.: Fax No.:
Telescopic AC 25, 40-1, Dept. 8333 06332 06332
crane 50E, 80, 120 - 06. 98 Mr. Sieger 83 2575 83 2579
Information regarding the MFA 10 multifunction display in the cab of
the superstructure and/or chassis and its operation
On the strength of our receiving a number of enquiries on the matter, the following pa-
ges will hopefully provide a clarification as to how the MFA 10 multifunction display is
operated and help clear up the problems you seem to be having with the display of
actual values.
Location: MFA 10 Spare Part No.
Crane cabin AC 120 (395) 000 096 12
Drivers cabin AC 25, 40-1, 50E
(150),120 (395)
654 149 40
----------------------- --------------------------
(Benien) (Rbel)
Service Bulletin
No. : 60 - 11
Mobile Cranes
2
1) Operating the MFA 10 multifunction display:
1
2
3
4
5
6
7
8
While the ignition remains switched off and provided you have not yet called up any in-
formation on it, this display will show the correct time and the number of operating
hours elapsed (all LEDs are off).
A self-test will be carried out when the ignition is switched on
As soon as the ignition is switched on, the MFA 10 will carry out its own self-test.
All the different segments of the display will be activated and the LEDs will light up.
All the various sensors will then be checked. Any defective sensors will be shown up as
sensor error messages (SEnS 12 to SEnS 18) and this information will be stored.
The MFA will then be ready for operation.
Functions of buttons 1 to 8
1 - Fuel level
2 - Engine oil pressure
3 - Coolant temperature in the engine
4 - Transmission oil temperature in the chassis, hydraulic oil temperature in the super-
structure
5 - Engine speed
6 - Daily operating hours
7 - Line voltage of generator
8 - not assigned in the chassis, wind speed in km/h in the superstructure (optional)
As soon as one of the above buttons is pressed, its LED will light up. The relevant value
and unit symbol will be shown on the display.
Service Bulletin
No. : 60 - 11
Mobile Cranes
3
1
2
3
4
5
6
7
8
Displaying sensor error messages during the self-test
Sensor errors are displayed during the self-test as follows:
The relevant LED on button 1 to 8 lights up.
The unit symbol for the sensor found to be defective is shown on the display.
The number of the connector pin for static input is shown in the top line of the dis-
play, the static input (SEnS 12 to SEnS 18) of the defective sensor in the line at the
bottom of the display.
Sensor errors are shown as -- -- -- on the display once the self-test has been com-
pleted.

Setting the clock
Proceed as follows to set the time:
Press buttons 6 and 7 at the same time for five seconds.
The time will flash on the display.
Press button 5, 6, 7 or 8 until the correct time is shown.
To store the time you have set, press buttons 6 and 7 at the same time until the time
displayed no longer flashes.

Service Bulletin
No. : 60 - 11
Mobile Cranes
4

1
2
3
4
5
6
7
8

Confirming the warning limits (buzzer active)
A warning buzzer is triggered when a value which has been programmed into the sy-
stem has either not been reached or has been exceeded.
The value concerned will be shown on the display and the relevant LED on the button
will start to flash.
The warning limit will be automatically reset as soon as the value concerned returns to
normal.
To confirm this, press the relevant button for approx. three seconds until the buzzer
switches off. The display will then return to its original display mode.
You must always find out what caused the warning in the first place!
The warning limit Engine speed exceeded cannot be confirmed (switch off the buzzer).
When driving downhill, the speed of the vehicle must be reduced by braking until the
buzzer switches off.

Resetting the daily number of operating hours
Press button 6 for approx. three seconds.
The display will be reset to 0.

Service Bulletin
No. : 60 - 11
Mobile Cranes
5

1
2
3
4
5
6
7
8

Reading information on limit values being exceeded and reading sensor errors
from the memory store
The number of times limit values have not been reached or have been exceeded and va-
rious sensor errors are stored as messages. This memory store can be read.
Proceed as follows:
Switch off the ignition.
Press buttons 5 and 6 at the same time for at least three seconds.
First, the display shows the limit values from SEnS 0 to SEnS 11 which have been sto-
red and then any sensor errors from SEnS 11 to SEnS 18 which have also been stored.
Displaying limit values:
The top line of the display shows the number of times (how often) the relevant warning
limit has not been reached or has been exceeded.
The line at the bottom of the display shows the assignment of dynamic input in the
comparator (SEnS 0 to SEnS 4) and the assignment of static input in the comparator
(SEnS 5 to SEnS 11).
Displaying sensor errors:
The top line of the display shows the number of the connector pin which is used for sta-
tic input.
The line at the bottom of the display shows the assignment of static input in the various
sensors (SEnS 11 to SEnS 18).
This memory store can only be reset using the software!
The table overleaf shows how the various comparators and sensors are assigned to each
dynamic and static input.
Service Bulletin
No. : 60 - 11
Mobile Cranes
6

Limit values : (programmed limit values either not reached or exceeded)
Display Assignment
top line bottom line
SEnS 0 Engine speed
SEnS 1 n/a in the chassis,
wind speed in the superstructure
SEnS 2 n/a, bridge between pin 7 + 8
Number SEnS 3 n/a, bridge between pin 5 + 6
SEnS 4 n/a
of SEnS 5 transmission oil temperature in the chassis,
hydraulic oil temperature in the superstructure
SEnS 6 n/a
messages SEnS 7 coolant temperature in the engine
SEnS 8 n/a
SEnS 9 engine oil pressure
SEnS 10 n/a
SEnS 11 n/a

Sensor errors : (defective sensors, short-circuits, broken cables)
Display Assignment of sensors
top line bottom line
Pin No. 12 SEnS 12 transmission oil temperature
SEnS 13 n/a
Pin No. 11 SEnS 14 coolant temperature in the engine
SEnS 15 n/a
Pin No. 10 SEnS 16 engine oil pressure
SEnS 17 n/a
Pin No. 9 SEnS 18 fuel level

Service Bulletin
No. : 60 - 11
Mobile Cranes
7

1
2
3
4
5
6
7
8

Resetting the service interval display
The MFA 10 triggers a service interval display (SIA) to be shown every 250 operating
hours.
This display is intended purely to remind the crane driver to carry out the tasks speci-
fied in the lubrication and maintenance instructions for the crane concerned at the cor-
rect time.
The service interval display (SIA) can only be reset when the vehicle is stationary.
The service interval display is reset as follows:
Press buttons 7 and 8 at the same time and hold them down.
Switch on the ignition.
Wait a moment to allow the self-test to run its course.
Release buttons 7 and 8.
The display will show SIA 0.
The service interval display (SIA) will now be reset.
Service Bulletin
No. : 60 - 11
Mobile Cranes
8
2) Display of actual values:
1
2
3
4
5
6
7
8
All the information shown on the multifunction display in the cab of the superstructure
and/or chassis is given in the form of numerical values.
These numerical values are based on the signal values (voltage, current) issued by the
relevant pressure and temperature transmitters. In assessing the information shown,
remember to take into account the accuracy of each of the individual transmitters.
The transmitters have a tolerance of approx. 10%.
Ambient temperatures of below 0 C are not shown with a minus sign.
For example:
A coolant temperature of - 5 C will be shown as 0 C on the display.
In some cases, minimum values can be programmed into the system. This means that
these minimum values will be displayed until they are exceeded, regardless of the actual
situation.
Take, for example, the display of hydraulic oil temperature on the AC 120 superstructu-
re (AC 395-1):
Display of minimum value of approx. 40 C
The minimum value programmed into the system (approx. 40) will be shown on the
multifunction display up until it is exceeded, regardless of the actual temperature of the
hydraulic oil.
Service Bulletin
No. : 60 - 11
Mobile Cranes
9
The level of tolerance shown by the transmitters will however also affect the warning
limits already programmed. Variations may therefore be seen between models from the
same range.
As soon as the warning limit programmed into the system is reached, a buzzer will be
activated and the display will automatically switch over to the relevant value.
The value shown will be represented on the display and the relevant LED in the selector
button will start to flash.
If the warning threshold is exceeded, this can be confirmed (acknowledged) by pressing
the relevant button (for three seconds).
If you cannot determine the reason for the fault, e.g. defective transmitter or cable, this
might be because an error has occurred in the master instrument of the MFA 10. In this
case, the master instrument must be replaced.
If the customer expresses concern about the warning limit for the temperature of the
hydraulic oil (hydraulic oil temperature <50C), the MFA 10 master instrument should
then be replaced.
Please note:
When placing an order, always state the crane model, chassis, superstructure and con-
struction numbers as well as the number of operating hours relevant to both the chassis
and the superstructure.
The new master instrument can then be programmed with the appropriate number of
operating hours for the crane.
Problems may also arise with the pressure switches of the warning display for the hy-
draulic filters on the AC 395 superstructure.
When the hydraulic oil is cold, the dynamic pressure ahead of the filter element some-
times increases so much that the relevant indicator light comes on.
As the temperature of the oil increases while the filter element remains clear of any
clogging, the indicator light should go out.
If the indicator light comes on again once the hydraulic oil is warm, you must find out
the reason behind this error display.
For example, it might be due to a defective pressure switch (spare part no. 420 358 12),
a broken cable etc.
Electrics
Technische Schulung AC100 Armaturenbrett OW e.doc
Electrics Superstructure
AC100 Betriebsmittelliste OW e.doc Technical Training
Equipment list - superstructure
A110 Tilt shut-off control unit Cab
A130 Impulse generator windscreen wiper front Cab electrics
A131 Impulse generator windscreen wiper roof Cab electrics
A170 A/C control unit Cab
A190 Parking heating superstructure - timer Cab
A192 Parking heating superstructure - heater Rear cab
A210 Joystick left Cab
A220 Joystick right Cab
A300 Engine control MR Cab
A301 Adaption module ADM Cab
A303 Accelerator pedal FFG Cab
A700 LMI electronics Cab
A701 CPU board PAT Cab
A702 LMI module DS350C Cab
A703 Video board for display PAT Cab
A704 Digital input board (basic board) PAT Cab
A705 Digital output board (extension) PAT Cab
A706 Digital input board (extension) PAT Cab
A708 Digital output board (extension) PAT Cab
A710 Analog input board (extension) PAT Cab
A711 Analog output board (basic board) PAT Cab
A712 Analog output board (extension) PAT Cab
A905 Voltage converter 24/12 V Cab electrics
A906 Radio Cab
B1 Initiator in front of position LPU boom section1 and 3 LPU
B2 Initiator behind position LPU boom section 1 and 3 LPU
B3 Initiator in front of position LPU boom section 2 and 4 LPU
B4 Initiator behind position LPU boom section 2 and 4 LPU
B5 Initiator in front of position pinning boom section 1 to 4 Main boom
B6 Initiator behind position pinning boom section 1 to 4 Main boom
B13 Initiator LPU locked LPU
B14 Initiator pinned right LPU
B15 Initiator pinned left LPU
B16 Unpinned or unlocked right LPU
B17 Unpinned or unlocked left LPU
B18 Initiator lower limit position H1 Hoist drum
B18.1 Initiator rotation indicator H1 Hoist drum
B19 Initiator lower limit position H2 Hoist drum
B19.1 Initiator rotation indicator H2 Hoist drum
B43 Initiator superstructure position rear Slewing rim
B50 Initiator CWT cyl. position top CWT cyl. right
B51 Initiator CWT cyl. position top CWT cyl. left
B52 Initiator slew gear release CWT cyl. right
B53 Initiator slew gear release CWT cyl. left
B54 Initiator CWT claw closed CWT cyl. right
B55 Initiator CWT claw closed CWT cyl. left
AC100 Betriebsmittelliste OW e Technical Training
B56 Initiator CWT lying on claw CWT cyl. right
B57 Initiator CWT lying on claw CWT cyl. left
B109 Anemometer (speed indicator) X550
B110 Tilt indicator Cab
B170 High pressure switch A/C Rear cab
B190 Parking heater superstructure temperature sensor Cab
B191 Parking heater
B192 Parking heater
B601 Tank sensor superstructure Fuel tank
B605 Initiator slew gear siren Pinion protection superstr.
B622 Pressure switch air filter 50 mbar Air filter
B624 Pressure switch high-pressure filter 7 bar High-pressure filter
B625 Pressure switch return filter 2.5 bar Hyd. tank
B626 Temperature switch hyd. oil >85C Hyd. tank
B627 Pressure switch return filter 2.5 bar Hyd. tank
B701.1 Pressure sensor luffing cyl. bottom end Luffing cylinder
B702 Length angle sensor LWG 321 Main boom
B703 Length sensor tele cylinder Main boom (interior)
B707 Speed signal converter (frequency/mA) Cab
E18 Rotary joint H1 Hoist drum
E19 Rotary joint H2 Hoist drum
E112 Outer lighting front Cab
E113 Outer lighting rear Cab
E114 Outer lighting boom Main boom
E300 Rotary joint Slewing rim centre
F101 Ignition switch S 101 (25A) Cab electrics
F102 Em. stop eng. superstr., chassis op., eng. start chassis (10A)Cab electrics
F103 Continuous current (terminal 30) ADM (10A) Cab electrics
F104 Cigarette lighter, socket, horn, all-round lighting (10a) Cab electrics
F105 Outer lighting, instrument lighting,
anemometer (10A) Cab electrics
F106 A/C (10A) Cab electrics
F107 Voltage converter, radio (10A) Cab electrics
F108 A/C (25A) Cab electrics
F109 Current supply PAT, (10A) Cab electrics
F111 Windscreen wiper roof/front, MFA10, indicator
lights fault, timer parking heater, fan Cab electrics
F115 Joystick left/right, length transducer tele cyl., pressure
transducer, speed signal converter, length
angle transducer (10A) Cab electrics
F112 MFA10 Cab electrics
F113 Cab adjustment, dead man's switch, slew gear
free-running, telescoping loads, speed
slew gear/hoist 2/luffing gear/hoist 1, high speed Cab electrics
F114 Oil cooler motor (15A) Cab electrics
F116 Siren overload, slew gear siren, oil cooler relay,
support front superstructure, (10A) Cab electrics
F117 Aircraft warning light (10A) Cab electrics
F118 Initiators superstructure to the rear/lower limit switch,
tilt shut-off (10A) Cab electrics
F119 Parking heater timer (10A) Cab electrics
F120 Fan (10A) Cab electrics
F121 Parking heater control unit Cab electrics
F123 CWT cyl. up or down, claw open (10A) Cab electrics
F124 Terminal 15 engine control MR (10A) Cab electrics
F125 Diagnosis engine (10A) Cab electrics
F126 Diagnosis engine (10A) Cab electrics
F127 Switchover pilot control, switchover
speed of hoists, slew gear brake
proximity switch CWT, proximity switch LBU, (10A) Cab electrics
F600 Main fuse superstructure (50A) Battery
G601 Rotation current generator Engine
G602 Battery superstructure
H18 Rotation indicator H1 Cab
H19 Rotation indicator H2 Cab
H106.1 Clearance light CWT left Counterweight
H106.2 Clearance light CWT right Counterweight
H110 Horn superstructure Lower cab
H111.1 Main boom head lighting 1 Main boom head
H114 Rotaflare light superstructure Main boom head
H114.1 Rotaflare light superstructure Main boom head
H115 Aircraft warning light Main boom head
H700 Indicator light LLD bridging Cab
H700.1 Siren LLD shut-off Outside cab
H701 Indicator light HLS bridging Cab
H705 Indicator light luffing gear raise Cab
K1 Time relay for A705 Cab electrics
K2 Relay tilt indication (optional) Tilt indicator
K3 Relay tilt indication (optional) Tilt indicator
K101 Relay oil cooler Cab electrics
K102 Emergency stop engine Cab electrics
K103 Relay A/C condenser fan Cab electrics
K104 Relay A/C compressor Cab electrics
K105 Rotaflare light Cab electrics
K110 Release relay fan Cab electrics
K221 Release relay raise luffing gear Cab electrics
K224 Relay LLD shut-off Cab electrics
K227 Relay hoist limit switch Cab electrics
K228 Relay hoist limit switch Cab electrics
K229 Relay buzzer for overload (only GB) Cab electrics
K230 Relay outriggers left rear/front vertical Cab electrics
K231 Relay outriggers right rear/front vertical Cab electrics
K232 Relay outriggers (enable only one horizontal cyl.) Cab electrics
K233 Relay outriggers (enable only one horizontal cyl.) Cab electrics
K234 Relay enable slew gear Cab electrics
K238 Load relay superstructure Cab electrics
K600 Load relay superstructure Cab electrics
K605 Time relay slew gear siren Cab electrics
M104 Fan motor Cab
M105
M118 Motor oil cooler Rear cab
M130 Wiper motor front screen Cab
M131 Wiper motor roof window Cab
M132 Windscreen washer pump Cab
M171 Motor condensator fan Rear cab
M190 Water pump parking heater Rear cab
M191 Fuel dosing pump Rear cab
M601 Starter superstructure engine Engine
N700 Power supply PAT Cab
P100 Multifunction display MFA10 Cab
P200_1 Indicator light CWT cyl. up Cab
P200_2 Indicator light enable slew gear Cab
P200_3 Indicator light CWT lying on claw Cab
P200_4 Indicator light air filter Cab
P200_6 Indicator light CWT down Cab
P200_7 Indicator light slew gear not released Cab
P200_8 Indicator light CWT cyl. claw closed Cab
P200_9 Indicator light high-pressure filter Cab
P200_10 Charge control light Cab
P201_2 Indicator light oil level Cab
P201_3 Indicator light fault engine Cab
P201_5 Indicator light fault chassis Cab
P201_9 Indicator light slew gear brake Cab
P201_10 Indicator light crane operation Cab
P700 Display console PAT Cab
R170 Temperature control A/C Cab
R171 Air temperature sensor Rear cab
R172 Icing protection A/C Rear cab
S2 Hoist limit switch Main boom
S6 Button enable slew gear (pilot control lever left) Cab
S7 Button speed change
Slew gear/hoist 2 (pilot control lever left) Cab
S8 Button speed change
Lower luffing gear/hoist 1 (pilot control lever right) Cab
S9 Button high speed (pilot control lever right) Cab
S10 Dead man's button (pilot control lever left) Cab
S11 Dead man's button (pilot control lever right) Cab
S14 Switch slew gear brake Cab
S14.1 Direction key slew gear left (pilot control lever left) Cab
S14.2 Direction key slew gear right (pilot control lever left) Cab
S15.1 Direction key raise luffing gear (pilot control lever right) Cab
S15.2 Direction key lower luffing gear (pilot control lever right) Cab
S16.1 Direction key telescope out (pilot control lever left) Cab
S16.2 Direction key telescope in (pilot control lever left) Cab
S18.1 Direction key raise hoist 1 (pilot control lever right) Cab
S18.2 Direction key lower hoist 1 (pilot control lever right) Cab
S23 Switch switchover pilot control (optional) Cab
S61 Button move CWT Cab
S62 Button CWT claw up Cab
S100 Emergency stop - engine Cab
S101 Ignition switch superstructure Cab
S103 Engine start - chassis Cab
S110 Horn button Cab
S112 Switch outside lighting Cab
S114 Switch rotaflare light Cab
S115 Switch aircraft warning light Cab
S116 Switch lighting Cab
S119 Switch inside lighting Cab
S120 Switch raise speed:superstructure Cab
S130 Switch windscreen wiper front Cab
S131 Switch windscreen wiper roof Cab
S132 Button washer pump Cab
S170 Switch A/C Cab
S191 Switch - fan Cab
S210 Zero point button (pilot control lever - left) Cab
S220 Zero point button (pilot control lever right) Cab
S600 Main battery switch Cab
S700 Bridging switch LLD Cab
S701 HLS bridging Cab
S705 Bridging switch raise luffing gear Cab
S707 Switch switchover speed: hoists Cab
S708 Switch telescoping loads Cab
S801 Button - vertical outriggers in/out Cab
S802 Enable button outriggers vertical/horizontal left Cab
S803 Enable button outriggers vertical/horizontal right Cab
S804 Enable button outriggers vertical overall Cab
S805 Button outriggers horizontal in/out Cab
X550.7 13 pin bridging plug HLS (825 ) X550
Y1 Solenoid valve enable pilot control pressure Rear cab
Y10 Solenoid valve enable slew gear Rear cab
Y14 Solenoid valve - slew gear brake Rear cab
Y14.1 Solenoid valve - slew gear left Slew gear pump
Y14.2 Solenoid valve - slew gear right Slew gear pump
Y15.1 Solenoid valve raise luffing gear Control block
Y15.2 Solenoid valve lower luffing gear Control block
Y16.1 Solenoid valve extend tele cyl. 1 Control block
Y16.2 Solenoid valve - retract tele cyl. 1 Control block
Y16.3 Solenoid valve - bypass tele cyl. bottom end Tele cyl.
Y16.4 Solenoid valve - bypass tele cyl. rod end Tele cyl.
Y16.5 Solenoid valve speed tele cyl. Tele cyl.
Y18 Solenoid valve disc brake H1 Lower brake valve
Y18.1 Solenoid valve raise hoist 1 Control block
Y18.2 Solenoid valve lower hoist 1 Control block
Y19 Solenoid valve disc brake H2 Lower brake valve
Y19.1 Solenoid valve raise hoist 2 Control block
Y19.2 Solenoid valve lower hoist 2 Control block
Y25 Solenoid valve unlock LBU LBU
Y26 Solenoid valve lock LBU LBU
Y27 Solenoid valve unbolt boom section LBU
Y28 Solenoid valve bolt boom section LBU
Y45 Solenoid valve tilt cab Rear cab
Y46 Solenoid valve tilt cab Rear cab
Y61A Solenoid valve CWT up Rear cab
Y61B Solenoid valve CWT down Rear cab
Y170 Compressor coupling A/C Rear cab
Y200 Solenoid valve CWT claw closed Rear cab
1
Eberspcher
J. Eberspcher
GmbH & Co.
Eberspcherstr. 24
D-73730 Esslingen
Phone (central)
(07 11) 939-00
Fax
(07 11) 939-0500
http://www.
eberspaecher.de
These Troubleshooting and Repair Instructions apply
to the following heater versions:
HYDRONIC B C at. N o.
B 5 W S 12 Volts 20 1777 05 00 00
B 5 W S 12 Volts / fully equipped 20 1778 05 00 00
Contents Page
Functional description ................................................. 2
Sectional diagram ....................................................... 3
Functional diagram B 5 W S ........................................ 4
Functional diagram D 5 W S ........................................ 5
Specifications ............................................................. 6
First check the follow ing if faults occur ........................ 7
Fault diagnosis w ith the tim er m odule ......................... 8
Fault diagnosis w ith the diagnostic unit....................... 9
Fault code, fault description,
rem arks, rem edial action .................................. 10 14
Faults w hich the diagnostic system does
not indicate ................................................................14
R epair instructions ........................................... 15 23
A ssem bly draw ing B 5 W S ....................................16
A ssem bly draw ing D 5 W S ....................................17
W iring diagram .....................................................24, 25
Fuel quantity m easurem ent........................................26
HYDRONIC C at. N o.
D 5 W S 12 Volts 25 2031 05 00 00
D 5 W S 12 Volts / fully equipped 25 2032 05 00 00
D 5 W S 24 Volts 25 2009 05 00 00
20 1777 95 11 54 05.1998 Subject to alterations Printed in G erm any J. Eberspcher C 47 / 48
Troubleshooting and repair instructions
2
Functional description
The H YD R O N IC can be w ired up to operate as an auxiliary
heater only or as a com bination of auxiliary heater and
add-heater the latter serving to com pensate for a lack of
heat dissipation from the vehicle engine.
Auxiliary heater operation
Switching on
The pilot lam p in the operating elem ent (tim er m odule, sw itch,
etc.) com es on w hen the H YD R O N IC is sw itched on.
The w ater pum p starts up, and after a defined pre-rinsing
and preglow program has been com pleted the com bustion
air blow er, glow plug and m etering pum p com e on.
O nce a flam e has been detected and the com bustion process
has stabilised, a tim e control sw itches the glow plug off.
Heating mode
D epending on heat dem and, the H YD R O N IC alternates
betw een H IG H and LO W settings.
The tem perature thresholds are perm anently program m ed in
the electronic control unit.
If the heat dem and in the LO W setting is so low that the
cooling w ater reaches a tem perature of 85C , the heater
sw itches to the O FFsetting, then continues to run for about
130 seconds.
The pilot lam p is also lit w hile the heater is in the O FFsetting,
and the w ater pum p continues to run until the heater is
restarted.
Switching off
W hen the heater is sw itched off, the pilot light goes out and fuel
feed is shut off. A lso in the case of H YD R O N IC D 5 W S, the
glow plug is sw itched on for 20 seconds.
The com bustion air blow er and the w ater pum p run on after
the heater is sw itched off (for 50 sec in the case of B 5 W S
and for 120 sec in the case of D 5 W S) and are then sw itched
off autom atically.
Stationary ventilation
Stationary ventilation m eans that it is possible to activate the
vehicle blow er directly via the tim er m odule or via radio w ave
rem ote control T4 bypassing heater operation in order to
ventilate the vehicle interior w hich often becom es extrem ely
hot in the sum m er before setting off (separate w iring, see
W iring diagram , pp. 24 and 25).
Diagnosis
If the control unit detects a fault at start-up of the H YD R O N IC
or w hile the H YD R O N IC is in operation, it is indicated on the
tim er m odule display w ithin 15 seconds in the form of a fault
code (F + 2-digit num ber).
If the heater is operated in conjunction w ith the M initim er, the
fault code can be read out of the control unit by connecting a
diagnostic unit (C at. N o. 22 1512 89 00 00). A n adapter cable
(C at. N o. 22 1000 30 71 00) is required in order to connect
the diagnostic unit.
Safety devices
The flam e is m onitored by the flam e sensor and the m ax.
perm issible tem perature by the overheat sensor.
B oth influence the control unit, w hich shuts dow n the
H YD R O N IC in the event of faults.
If the H YD R O N IC does not ignite w ithin 90 seconds after
the start of fuel feed, start-up is repeated.
If the H YD R O N IC does not ignite repeatedly w ithin 90
seconds after the start of fuel feed, a fault shutdow n takes
place.
If the flam e goes out by itself w hile the heater is in operation,
a restart is initially carried out.
If the H YD R O N IC does not ignite w ithin 90 seconds after
the start of fuel feed, or if it ignites but goes out again, a fault
shutdow n takes place.
The fault shutdow n can be cancelled by briefly sw itching the
heater off and on again.
In the event of an overheat (e.g. shortage of w ater, poorly
ventilated coolant circulation system ), the overheat sensor is
tripped, fuel feed is shut off, then a fault shutdow n is
activated.
O nce the cause of the overheat has been elim inated, the
H YD R O N IC can be restarted by sw itching it off and on again
(prerequisite: the H YD R O N IC has cooled dow n sufficiently).
If the voltage drops below approx. 10 Volts or 20 Volts or
rises above 15 Volts or 30 Volts, a (delayed) fault shutdow n
is activated.
If the glow plug is defective or an electrical lead running to
the m etering unit is broken, the H YD R O N IC does not start.
The blow er m otor speed is m onitored continuously.
If the blow er m otor does not start or becom es blocked, a
fault shutdow n is activated.
Please note!
The H YD R O N IC m ust alw ays be sw itched off w hen re-
fuelling.
The H YD R O N IC m ust not be operated in garages.
The coolant should contain at least 10% antifreeze all year
round as protection against corrosion.
W hen perform ing electric w elding w ork on the vehicle,
disconnect the plus term inal of the battery and connect to
G N D in order to protect the control unit.
A lso sw itch on the H YD R O N IC briefly (for approx. 10 sec.)
once a m onth outside the heating period in order to prevent
the w ater pum p and burner m otor seizing up.
B efore sw itching on or pre-program m ing the heating m ode,
m ove the heating lever of the vehicle to the W A R M
(m axim um ) setting and the blow er to the slow setting(low
pow er consum ption).
O perating instructions for tim ers and sw itches are supplied
w ith the operating elem ents.
If it is necessary to use other sw itches as per usual in
autom otive engineering, they m ust have a m inim um rating of
1 am pere.
3
Sectional diagram (heater shown: HYDRONIC B 5 W S)
1 C om bustion air blow er
2 Electric m otor
3 H eat exchanger
4 C om bustion cham ber
5 G low plug
6 Flam e sensor
7 Tem perature sensor
8 O verheat sensor
9 C ontrol unit
A = Exhaust gas
B = Fuel
V = C om bustion air
W A = W ater outlet
W E = W ater inlet
10 C om bustion air hose
11 Exhaust pipe w ith silencer
12 M etering pum p
13 Strainer built into m etering pum p
14 M ain fuse
15 Interface / 8-pin plug
16 W ater pum p
17 Relay, vehicle blow er
18 Tim er m odule
4
Functional diagram HYDRONIC B 5 W S
Switching temperatures
High Low 80 C
Low Off 85 C
Off On 75 C
Low High 75 C
Vehicle blower
On 30 C / Off 20 C
5
Functional diagram HYDRONIC D 5 W S 12 Volts / 24
Volts
Switching temperatures
High Low 80 C
Low Off 85 C
Off On 75 C
Low High 75 C
Vehicle blower
On 30 C / Off 20 C
6
Specifications
HYDRONIC B HYDRONIC
Test code S 288 S 274
H eating m edium W ater, coolant
H eating capacity control H igh / Low
Fuel G asoline (com m ercially available) D iesel (com m ercially available)
R ated voltage 12 Volts 12 Volts or 24 Volts
H eating capacity H igh Low H igh Low
5000 1500 5000 2200 W atts
Fuel consum ption 0,69 0,21 0,62 0,27 l / h
Electric pow er consum ption (excl. w p) at 12 Volts at 24 Volts
at start-up < 100 < 100 < 100 W atts
in H igh setting 37 37 37 W atts
in Low setting 10 12 12 W atts
O perating range
Low er voltage lim it 10 10 20 Volts
A n undervoltage safety device built into the control unit
sw itches the heater off at approx. 15 Volts or 28 Volts
U pper voltage lim it 15 15 28 Volts
A n overvoltage safety device built into the control unit
sw itches the heater off at approx. 15 Volts or 28 Volts
Perm issible operating pressure up to 2.5 bar overpressure
M inim um w ater flow rate 300 l /h
C O
2
value 10,5 % by vol.
C O in exhaust gas
<
0,1 % by vol.
Sm oke spot num ber acc. to B acharach < 4
R adio interference suppression leve VH F 3 SW 4 M W / LW 5
A m bient tem perature
H YD R O N IC in operation -40 C to + 80 C -40 C to + 80 C
M etering pum p in operation -40 C to + 20 C -40 C to + 80 C
H YD R O N IC and m etering pum p not in operation -40 C to + 125 C -40 C to + 125 C
W eight approx. 2,9 kg
incl. w ater pum p and m etering pum p
Specifications water pump
(the w ater pum p cannot be activated externally)
W ater flow rate against 0.1 bar 12 Volts = 800 l / h 24 Volts = 900 l / h
Electric pow er consum ption 12 Volts = 16 W atts 24 Volts = 12 W atts
These specifications include the tolerance
of + 10 % of rated voltage standard for heaters
unless otherw ise specified.
+ 1 % by vol.
- 2,5 % by vol.
7
First check for the following if faults occur
C heck the fuel level.
M echanical dam age of com ponents.
W hen m aking transition to w inter operation: Is there still sum m er diesel in the fuel line?
C heck the exhaust and com bustion air pipes.
C heck fuses.
Check voltage supply V
bat
(terminal 30)
D isconnect the 8-pin plug S1/B 1 and m easure the voltage applied to plug B 1 betw een term inal jack 1 (red (rt) 2.5 m m
w ire) and term inal jack 2 (brow n (br) 2.5 m m w ire).
In case of deviation of the battery voltage, check the fuses, supply leads, G N D connection and the positive term inal on
the battery for voltage drop (corrosion, open circuit).
Check switch-on signal (S+)
D isconnect the 8-pin plug S1/B 1 and then press the key on the operating elem ent. M easure the voltage applied to plug
B 1 betw een term inal jack 7 (yellow (ge) 0.5 m m w ire) and term inal jack 2 (brow n (br) 2.5 m m w ire).
If no voltage is applied, check the supply lead (yellow (ge) 0.5 m m w ire), the 5A fuse (item 2.7.1 in w iring diagram on
pp. 24 and 25) and the operating elem ent.
Check operating element (timer module/Mini timer)
D isconnect the plug from the operating elem ent and bridge the red (rt) 0.5 m m w ire and the yellow (ge) 0.5 m m w ire.
If no voltage is applied to plug B 1 betw een term inal jack 7 (yellow (ge) 0.5 m m w ire) and term inal jack 2 (brow n (br)
2.5 m m w ire), replace the operating elem ent.
Please note!
To carry out additional troubleshooting, the tim er m odule or the diagnostic unit w ith adapter cable is
required to interrogate the fault m em ory in the control unit and, if need be, to cancel the control unit interlock.
See pages 8 and 9 for C at. N o. and operation.
Strap connector
Strap connector
8
Interrogating the fault memory in the control unit using
the timer module
The electronic control unit can store up to 5 faults w hich can
be read out and displayed w ith the tim er m odule.
The current fault is alw ays w ritten to m em ory location F1.
Preceding faults are transferred to m em ory locations F2 F5.
The content of m em ory location F5 is overw ritten if necessary.
Interrogating the fault memory
Condition: The H YD R O N IC is sw itched off.
Press the C the heater is sw itched on then press
the A, hold it dow n and then press the P key w ithin
2 seconds. The heating sym bol flashes and the current
error is indicated.
The errors stored in m em ory locations F1 to F5 can be
called up using the E and F keys.
Fault codes, fault descriptions, rem arks/rem edial action
are described on pages 10 to 14.
Please note!
N ot only a faulty com ponent but also a faulty current path
leads to a fault m essage being displayed.
See page 14 for faults w hich the diagnostic system does
not indicate.
If the heater is not operated in com bination w ith the
tim er m odule, fault diagnosis can be perform ed using
the diagnostic unit (see page 9).
Fault diagnosis with timer module
Tim er m odule display (D ) C at. N o. 22 1000 30 34 00
Tim er m odule display (G B ) C at. N o. 22 1000 30 36 00
If the control unit detects a fault w hen the H YD R O N IC is
sw itched on or w hile the H YD R O N IC is in operation, the
tim er m odule indicates this using an error code com prising
the letter F and as a 2-figure num ber w ithin 15 sec.
R eadout on display, e.g. F64 (current fault)
+ flashing heating sym bol
Fault codes, fault descriptions, rem arks/rem edial action are
described on pages 10 to 14.
Reasons for interlocking of control unit
O verheat
If the H YD R O N IC overheats 10 tim es in succession fault
012 fault m essage F15 is displayed, i.e. the control unit is
interlocked.
Too m any failed starts
If the H YD R O N IC perform s 10 unsuccessful attem pts in
succession fault 050 fault m essage F50 is displayed,
i.e. the control unit is interlocked.
Cancelling the control unit interlock
by erasing the fault memory
Condition: The electrical connection betw een the 12-pin plug
(term inal jack 10 of the tim er m odule) and term inal 15 (ignition)
is in place.
Press key C the current fault (F15 or F50) is displayed
then press
the A key, hold it dow n and press the P key w ithin
2 seconds.
The tim er m odule is now in the Interrogate fault m em ory
program .
N ow , proceed as follow s:
Turn off the ignition (term inal 15).
Press keys A and P sim ultaneously and hold them dow n,
turn on the ignition (term inal 15) and w ait until the follow ing
m essage appears on the display.
1 Tim e
2 Preselect
3 H eat
4 Back
5 Forw ard
6 D isplay
The control unit interlock is cancelled after 3 seconds,
after w hich the heater starts up.
M essage displayed after D isplay flashing
heater has started heating sym bol not flashing
M essage displayed after D isplay flashing,
turning ignition O N heating sym bol not flashing
9
Fault diagnosis using the diagnostic unit
Connecting the diagnostic unit
Lay the w iring from the diagnostic unit to the w iring harness as
show n in the diagram and connect.
C onnect the 8-pin plug to the diagnostic unit and sw itch on the
H YD R O N IC w ith the operating device.
Interrogating the fault memory with the diagnostic unit
The electronic control unit can store up to 5 faults w hich can
be read out and displayed w ith the diagnostic unit.
The current fault is alw ays indicated as A Fw ritten to m em ory
location F1.
Preceding faults are transferred to m em ory locations F2 F5.
The content of m em ory location F5 is overw ritten if necessary.
Interrogating the fault memory
Press key D, and the fault w ill be displayed:
AF = C urrent fault
3-figure num ber = Fault code
Fault codes, fault descriptions, rem arks/rem edial action are
described on pages 10 to 14.
Reasons for interlocking of control unit
O verheat
If the H YD R O N IC overheats 10 tim es in succession fault
012 fault m essage A F 015 is displayed, i.e. the control
unit is interlocked.
Too m any failed starts
If the H YD R O N IC perform s 10 unsuccessful attem pts in
succession fault 050 fault m essage A F 050 is
displayed, i.e. the control unit is interlocked.
Cancelling the control unit interlock by erasing the fault
memory
A fter elim inating the cause of the fault, press the tw o keys L
sim ultaneously for at least 2 seconds.
The control unit interlock is now released and stored faults F1
to F5 are erased.
Sw itch the H YD R O N IC off and on again.
Please note!
N ot only a faulty com ponent but also a faulty current path leads
to a fault m essage being displayed.
See page 14 for faults w hich the diagnostic system does not
indicate.
1 D iagnosis call up fault code
2 Erase stored fault
3 Erase stored fault
4 B ack, faults F5 F1
5 Forw ard, faults F1 F5
6 D isplay
D iagnostic unit C at. N o. 22 1512 89 00 00
Please note!
A n adapter cable C at. N o.
22 1000 30 71 00 is required to
connect the diagnostic unit to the
w iring harness of the H YD R O N IC .
1 H YD RO N IC
2 D iagnostic unit
3 A dapter cable
4 C able harness diagnostic unit
5 M ini tim er
10
Fault code Remarks
Fault description Remedial action
010 O vervoltage cut-out
011 U ndervoltage cut-out
012 O verheat
(softw are threshold value)
014 Possible overheat detected
(difference evaluation)
Please note!
The H YD R O N IC w ith date of m anufacture up to
12.97 has the follow ing values:
D ifference betw een tem perature values of overheat
sensor and tem perature sensor > 15K .
W ater tem perature at overheat sensor m in. 70C
015 Equipm ent disabled m ax. perm issible num ber
of 10 possible overheats exceeded
O vervoltage is continuously applied to control unit for at least
20 seconds H YD R O N IC is not operational
D isconnect connector B 1/S1, start the vehicle engine and
m easure the voltage applied to plug B 1 betw een term inal
jack 1 (red (rt) 2.5 m m w ire) and term inal jack 2 (brow n
(br) 2.5 m m w ire).
If the voltage is > 15 Volts or > 28 Volts, check the
alternator controller or the battery.
U ndervoltage is continuously applied to control unit for at
least 20 seconds > H YD R O N IC is not operational
D isconnect connector B 1/S1, sw itch off the vehicle engine,
and m easure the voltage applied to plug B 1 betw een
term inal jack 1 (red (rt) 2.5 m m w ire) and term inal jack 2
(brow n (br) 2.5 m m w ire).
If the voltage is < 10 Volts or < 20 Volts, check the fuses,
the supply leads, the G N D connections and the positive
term inal on the battery for voltage drop (corrosion).
Is sufficient voltage present during the engine start-up
procedure?
Tem perature at overheat sensor > 125C
C heck w ater circulation system :
- check all hose connections for leaks
- is a restrictor fitted in the w ater circulation system ?
- w as attention paid to the correct direction of flow during
installation of therm ostat and check valve?
- has the w ater circulation system been bled carefully?
- check w ater pum p for function
C heck tem perature sensor and overheat sensor and
replace if necessary. See page 22 for reference values.
D ifference betw een tem perature values of overheat sensor
and tem perature sensor > 25K .
The prerequisite for this fault code being indicated is that the
H YD R O N IC is in operation and that the w ater tem perature at
the overheat sensor is at least 80C .
The control unit is interlocked.
R elease the control unit interlock by erasing the fault
m em ory w ith the tim er m odule or the diagnostic unit (see
pages 8 and 9).
C heck the w ater circulation system :
11
Fault code Remarks
017 O verheat detected EM ER G EN C Y STO P
(hardw are threshold value)
020 G low plug interruption
021 Short-circuit, overload or ground fault at glow plug
output
Important!
In the case of the H YD R O N IC 12 Volts, carry out
functional check using m ax. 8 Volts.
functional check using m ax. 18 Volts.
Exceeding the prescribed voltages w ill result in
irreparable dam age to the glow plug.
Pay attention to the short-circuit-proofing of the
power supply unit.
030 Speed of com bustion air blow er m otor outside
perm issible range
Important!
functional check using m ax. 8.2 Volts + 0.2 Volts.
functional check using m ax. 15 Volts + 0.2 Volts.
C heck the positive/negative lines for proper
connection.
power supply unit.
031 O pen circuit in com bustion air blow er m otor
Important!
connection.
power supply unit.
Tem perature at overheat sensor > 130C
C arry out a functional check on the glow plug as fitted. For
this purpose, unclip the 1.5 w hite (w s) w ire from term inal
jack 9 and the 1.5 brow n (br) w ire out of term inal jack 12 of
the 14-pin plug.
A pply a voltage of 8 Volts or 18 Volts 0.1 Volts to the glow
plug and m easure the current intensity after 25 seconds.
The glow plug is O K if the follow ing values are m easured.
If this is not the case, replace the glow plug.
8 Volt glow plug current intensity = 8.5A
18 Volt glow plug current intensity = 4.5A 1.5A
If the glow plug is O K , check the cable harness from the
glow plug for dam age and continuity.
If fault code 021 is displayed, also check glow plug for
assem bly of the connection piece and the corrugated
w asher. C heck cable harness for short circuit.
B low er w heel or com bustion air blow er m otor blocked
(frozen up, soiled, sluggish, cable harness rubbing against
end of shaft, etc.)
C lear blockage
M easure speed of com bustion air blow er m otor using m ax.
8.2 Volts + 0.2 Volts or 15 Volts + 0.2 Volts. For this
purpose, unclip the 0.75 brow n (br) w ire from term inal jack
14 and the 0.75 black (bk) w ire out of term inal jack 13 of
the 14-pin plug.
A ttach a m arking on the end of the com bustion air blow er
m otor shaft and m easure the speed w ith a contactless
tachom eter (see page 21).
If m easured speed < 10,000 rpm , replace the com bustion
air blow er.
If m easured speed > 10,000 rpm , replace the control unit.
C heck to see if the com bustion air blow er m otor w iring is
laid properly or dam aged.
the 14-pin plug.
air blow er.
+ 1 A
-1,5 A
12
Fault code Remarks
032 Short circuit, overload or ground fault of com bustion
air blow er m otor
Important!
connection.
power supply unit.
038 O pen circuit in vehicle blow er relay control
039 Short circuit, overload or ground fault in vehicle
blow er relay control
041 O pen circuit in w ater pum p
042 Short circuit, overload or ground fault in w ater pum p
047 Short circuit, overload or ground fault in m etering
pum p
048 O pen circuit in m etering pum p
050 Equipm ent has been disabled due to too m any
failed starts (10 start attem pts plus repeat start-up
for each start attem pt)
051 Tim e overshoot cold air blow ing
B low er w heel or com bustion air blow er m otor blocked
(frozen up, soiled, sluggish, cable harness rubbing against
end of shaft, etc.)
C lear blockage
B efore proceeding w ith the functional check on the com bu-
stion air blow er m otor, perform a resistance m easurem ent.
If m easured resistance is < 2 k, then a ground fault has
occurred replace the com bustion air blow er.
If m easured resistance is > 2 k, then a ground fault can be
ruled out m easure the speed of the com bustion air blow er.
the 14-pin plug.
air blow er.
C heck electrical lead routed to relay
R ectify open circuit. R eplace relay if necessary.
D isconnect relay. If fault code 038 is displayed, then the
relay is defective replace relay.
C heck supply lead to w ater pum p for continuity. For this
purpose, unclip the 0.5 brow n (br) w ire from term inal
jack 10 and the 0.5 violet (vi) w ire out of term inal jack 11
of the 14-pin plug.
R ectify open circuit. R eplace relay if necessary.
D isconnect connector in the w ater pum pline. If fault code
041 is displayed, then the w ater pum p is defective
replace w ater pum p.
D isconnect connector in the m etering pum pline. If fault
code 048 is displayed, then the m etering pum p is defective
replace m etering pum p.
C heck cable harness of m etering pum p for continuity. C lear
open circuit. R eplace m etering pum p if necessary.
M ax. perm issible num ber of safety tim e counters exceeded;
the control unit is interlocked.
R elease the control unit interlock by erasing the fault
m em ory w ith the tim er m odule or diagnostic unit.
C heck fuel quantity and fuel supply (see page 26).
A t start-up, the flam e sensor indicates a tem perature of
> 70C for longer than 240 sec.
C heck exhaust gas and com bustion air piping.
C heck flam e sensor see page 20 for reference values.
13
Fault code Remarks
052 Safety tim e exceeded
053 Flam e loss in H ighsetting
056 Flam e loss in LO W setting
060 O pen circuit in tem perature sensor
Please note!
The test can only be perform ed w ith a jum per strap
fitted in the 14-pin plug if the H YD R O N IC is still
installed in the vehicle or if a test bench is available.
061 Short circuit, overload or ground fault in tem perature
sensor
Please note!
064 O pen circuit in flam e sensor
Please note!
The m ax. perm issible num ber of start attem pts has been
used up.
C heck the fuel quantity and fuel supply (see page 26).
In the case of the H YD R O N IC B 5 W S, clean, and if
necessary replace, the strainer in the connection.
Attention!
In the event of flam e loss in the H ighor Low settings and if
start attem pts are still perm itted, the H YD R O N IC perform s a
restart follow ed by repeat start-up if necessary.
If the restart of repeat start-up w as successful, the indicated
fault code is cleared.
Fault (because a new start attem pt is no longer perm issible)
C heck the fuel quantity and fuel supply (see page 26).
C heck flam e sensor see fault codes 064 and 065.
R em ove the control unit and check the connecting cable of
the tem perature sensor from dam age. If the cable harness
is O K , then short the tem perature sensor route w ire in
14-pin plug from term inal jack 3 to term inal jack 4.
Sw itch on the H YD R O N IC .
- if fault code 061 is displayed, rem ove and check the
tem perature sensor (see page 22).
- if fault code 060 is displayed, check the control unit and
replace if necessary.
the tem perature sensor from dam age. If the cable harness
is O K , then disconnect the 14-pin plug from the control unit
and unclip the 0.5 m m blue (bl) w ire from term inal jack 3
and the 0.5 m m blue (bl) w ire from term inal jack 4.
Plug the 14-pin plug into the control unit and sw itch on the
H YD RO N IC
tem perature sensor (see page 22).
the flam e sensor from dam age. If the cable harness is O K ,
then short the flam e sensor route w ire in 14-pin plug
from term inal jack 1 to term inal jack 2.
Sw itch on the H YD R O N IC
- if fault code 065 is displayed, rem ove and check the flam e
sensor (see page 20).
14
Faults which the diagnostic system does not indicate
Fault description Remarks
Remedial action
H YD R O N IC does not start
The w ater pum p and the vehicle blow er start as soon as the
H YD R O N IC is sw itched on.
R em ove tem perature sensor and check (see page 22).
The vehicle blow er starts after the H YD R O N IC is sw itched on
stationary ventilationfunction is activated.
Set stationary ventilationsw itch to O FFposition.
Fault code Remarks
065 Short circuit, overload or ground fault in flam e sensor
Please note!
The test can only be perform ed if the H YD R O N IC is
still installed in the vehicle or if a test bench is available.
071 O pen circuit in overheat sensor
Please note!
072 Short circuit, overload or ground fault in overheat
sensor
Please note!
090 / 092 103 C ontrol unit defective
091 External interference voltage
the flam e sensor from dam age. If the cable harness is O K ,
then disconnect the 14-pin plug from the control unit and
unclip the 0.5 m m blue (bl) w ire from term inal jack 1 and
the 0.5 m m brow n (br) w ire from term inal jack 2.
H YD RO N IC
- if fault code 064 is displayed, rem ove and check the flam e
sensor (see page 20).
the overheat sensor from dam age. If the cable harness is
O K , then short the overheat sensor route w ire in 14-pin
plug from term inal jack 5 to term inal jack 6.
overheat sensor (see page 22).
the overheat sensor from dam age. If the cable harness is
O K , then disconnect the 14-pin plug from the control unit
and unclip the 0.5 m m red (rt) w ire from term inal jack 5 and
the 0.5 m m red (rt) w ire from term inal jack 6.
H YD RO N IC
overheat sensor (see page 22).
R eplace control unit
Fault in control unit caused by interference voltages radiating
from vehicle electrical system .
Possible causes:
Poor-quality battery, chargers, other sources of interference
> Elim inate interference voltages.
15
Please note the following during installation!
C arefully check all seals and O -rings. R enew if necessary.
A ll parts m ust be cleaned and checked for dam age prior to
assem bly. R enew if necessary.
Note:
The R epair Instructions describe how to repair the
H YD R O N IC in the dism antled state.
Repair Instructions Page
A ssem bly draw ing B 5 W S ......................................16
A ssem bly draw ing D 5 W S ......................................17
R em oving control unit
C hecking control unit................................................18
R em oving glow plug of H YD R O N IC D 5 W S
R em oving cable harness of glow plug .......................18
R em oving glow plug of H YD R O N IC B 5 W S
R em oving cable harness of glow plug .......................19
R em oving strainer and connection of
H YD R O N IC B 5 W S .................................................19
Page
R em oving and checking flam e sensor.......................20
M easuring speed of com bustion air blow er m otor....21
R em oving com bustion air blow er .............................21
R em oving com bustion cham ber...............................21
R em oving and checking overheat sensor and
tem perature sensor..................................................22
R em oving / installing heat exchanger ........................23
16
Sketch 1
Repair instructions for B 5 W S 12 Volts
1 C over jacket
2 C over com bustion air blow er
3 C ontrol unit
5 W ater cooling jacket
6 G low plug
7 Flam e sensor
8 C onnection
9 O -ring
10 Strainer
11 Bush
12 O verheat sensor
14 C om pression spring
15 O -ring
16 C able harness
17 Seal
18 Seal
19 H eat exchanger
21 O -ring
22 Engine cover
23 C able harness glow plug
24 Support
17
Sketch 2
Repair instructions for D 5 W S 12 Volts / 24 Volts
1 C over jacket
2 C over com bustion air blow er
3 C ontrol unit
5 W ater cooling jacket
6 G low plug
7 Flam e sensor
8 O verheat sensor
10 C om pression spring
11 O -ring
12 C able harness
13 Seal
14 Seal
15 H eat exchanger
17 O -ring
18 Engine cover
19 Adapter piece
(for 24 Volts version only)
20 C able harness glow plug
18
Removing control unit (see Fig. 1)
D etach the 4 fastening screw s from the blow er cover and
then rem ove the 4 fastening screw s from the control unit.
Lift up the control unit and detach the engine cover, taking
care to avoid dam aging the lining.
R em ove the control unit and disconnect the 14-pin plug.
For assem bly, first of all connect the 14-pin plug to the control
unit.
A ttach the engine cover to the com bustion air blow er, taking
care to avoid dam aging the lining.
Insert the bush of the w ater pum pcable harness into the
cut-out in the com bustion air blow er. Lay all electrical leads
betw een the electric m otor and housing and then insert the
control unit into the guide slot of the com bustion air blow er.
Insert and tighten the fastening bolts of the blow er cover
and control unit.
Checking control unit
A basic tester and a control unit adapter are required
for checking the control unit. The control unit adapter m akes
the electrical connection betw een the control unit and
the basic tester.
Fig. 1
Fig. 2
Removing the glow plug from the HYDRONIC D 5 W S
(see Fig. 2)
R em ove control unit
U nscrew the M 4 nut from the glow plug and rem ove the cable
harness.
U nscrew the glow plug from the housing.
Please note!
In the case of the H YD R O N IC D 5 W S 24 Volts, unscrew
the adapter piece from the glow plug and fit onto the new glow
plug.
Removing cable harness of glow plug
U sing a release tool m ade by A M P (C at. N o. 726519), unclip
the 1.5 w hite (w s) w ire from term inal jack 9 and the 1.5
brow n (br) w ire from term inal jack 12 of the 14-pin plug.
For installation, lay the cable harness betw een the electric
m otor and housing.
G low plug
A dapter piece for glow plug
(for H YD R O N IC D 5 W S 24 Volts only)
G low plug insert here
C ontrol unit
Engine cover w ith lining
14-pin plug
The basic tester is connected to the PC , and the control unit
can be tested by m eans of an installed test program .
C at. N o. B asic tester 22 1508 89 00 00
C at. N o. C ontrol unit adapter 22 1521 89 00 00
19
Removing glow plug of HYDRONIC B 5 W S (see Fig. 3)
U nscrew the M 4 nut from the glow plug and rem ove the cable
harness.
U nscrew the glow plug from the connection.
Removing cable harness of glow plug
U sing a release tool m ade by A M P (C at. N o. 726519), unclip
the 1.5 w hite (w s) w ire from term inal jack 9 and the 1.5
For installation, lay the cable harness betw een the electric
m otor and housing.
G low plug
G low plug insert here
Flam e sensor -w ith support
Removing strainer and connection from
HYDRONIC B 5 W S (see Fig. 4 and sketch 3)
Removing strainer
Take out com bustion air blow er
R em ove glow plug
R em ove O -ring and pull the strainer out of the connection
using round nose pliers.
C heck strainer and O -ring. R enew if necessary.
Removing connection
R em ove flam e sensor together w ith the support.
Press the connection out of the housing and then sw ivel
the fuel pipe outw ards.
C lean the connection and check the O -ring. R enew if
necessary.
Fitting connection and strainer
Insert connection into locating hole.
Sw ivel the fuel pipe into the initial position and then press the
connection into the locating hole.
Insert the support into the slot, and then feed the flam e sensor
through the hole in the support and insert it into the tapped
hole in the housing and screw securely.
Press the strainer into the connection until fully hom e.
Fit the O -ring on the strainer and insert it into the housing.
Please note!
The w elding spots of the strainer m ust face dow nw ards.
C arefully check the O -rings prior to installation. R enew if
necessary.
G low plug
C onnection
Support
Strainer
O -ring
Flam e sensor
Fig. 3
Fig. 4
Sketch 3
20
Removing flame sensor (see Fig. 5)
U sing a release tool m ade by A M P (C at. N o. 726534-1),
unclip the 1.5 blue (bl) w ire from term inal jack 1 and the 0.5
U nscrew flam e sensor from housing.
C heck flam e sensor. Replace if necessary.
For installation, lay the cable harness of the flam e sensor
betw een the electric m otor and housing.
Flam e sensor
Flam e sensor insert here
Checking the flame sensor (see sketch 4)
C heck the flam e sensor using the D igital M ultim eter. If the
resistance value of the flam e sensor lies outside the table of
values or the diagram , then replace the flam e sensor.
Fig. 5
Sketch 4
Table of values
Tem p. [C -50 0 10 20 30 50 80 90 100 130 150 200 250 300 350 400
R [ 803 1000 1022 1062 1097 1194 1309 1347 1385 1498 1573 1758 1941 2120 2297 2470
Vref [V 1,407 1,639 1,661 1,719 1,738 1,840 1,948 1,983 2,016 2,111 2,171 2,308 2,432 2,542 2,642 2,732
[
[
[
21
Fig. 7
Removing the combustion air blower (see Fig. 6)

R em ove flam e sensor
R em ove glow plug
U sing a release tool m ade by A M P (C at. N o. 726534-1), unclip
the 0.75 brow n (br) w ire from term inal jack 14 and the 0.75
black (bk) w ire from term inal jack 13 of the 14-pin plug.
Slacken the 4 fastening bolts in the blow er cover and detach
the blow er cover.
U nscrew the 3 fastening bolts and detach the com bustion air
blow er.
Please note!
B efore proceeding w ith assem bly w ork, carefully check the
seal betw een the com bustion air blow er and the com bustion
cham ber. Renew if necessary.
Removing the combustion chamber (see Fig. 7)
Slacken the 3 fastening bolts in the com bustion air blow er.
Lay the com bustion air blow er aside (the cable harness
of overheat sensor and tem perature sensor m ust not be
rem oved).
R em ove the com bustion cham ber from the heat exchanger.
Please note!
seals. R enew if necessary.
C om bustion cham ber
Jacket w ith heat exchanger
C om bustion air blow er
Seal com bustion air blow er / com bustion cham ber
Seal com bustion cham ber / heat exchanger
Fig. 6
C om bustion air blow er 14-pin plug

Electric m otor Seal
Sketch 5
Measuring speed of combustion air blower motor
(see sketch 5)
8.2 Volts + 0.2 Volts or 15 Volts + 0.2 Volts. For this purpose,
unclip the 0.75 brow n (br) w ire from term inal jack 14 and the
0.75 black (bk) w ire out of term inal jack 13 of the 14-pin plug.
m otor shaft (for instance a black-and-w hite disk) and m easure
the speed w ith a contactless tachom eter.
air blow er.
Electric m otor
B lack-and-w hite plastic disk
22
Removing the overheat sensor and temperature sensor
(see Fig. 8)
R em ove control unit, blow er cover and heat exchanger cover.
Slacken the com pression spring fastening bolt and detach
the com pression spring. R em ove the overheat sensor and
tem perature sensor from the locating hole in the heat ex-
changer w ith flat nose pliers.
U sing a release tool m ade by A M P (C at. N o. 726534-1), unclip
the tw o w ires of the tem perature sensor (term inal jack 3 0.5
blue (bl) and term inal jack 4 0.5 blue (bl)) and the tw o cables of
the overheat sensor (term inal jack 5 0.5 red (rt) and term inal
jack 6 0.5 red (rt)) from the 14-pin plug.
O verheat sensor
Tem perature sensor
C om pression spring
Checking overheat sensor and temperature sensor
(see page 6)
C heck the overheat sensor or tem perature sensor using the
D igital M ultim eter. If the resistance value of the overheat
sensor or the tem perature sensor lies outside the table of
values or the diagram , then replace the overheat sensor
or tem perature sensor.
Fig. 8
Please note!
The overheat sensor, tem perature sensor and cable harness
form a m odule, w hich m eans that they are not available as
com ponent parts.
B efore installation, coat the O -rings of the overheat sensor
and tem perature sensor w ith special-purpose grease, e.g.
H ellerine.
Table of values
Tem p. [C 0 10 20 30 40 50 60 70 80 90 100 110 120
R [k 32,54 19,87 12,48 8,06 5,33 3,60 2,48 1,75 1,25 0,91 0,67 0,50 0,38
Vref [V 4,275 3,960 3,561 3,100 2,611 2,135 1,705 1,339 1,041 0,805 0,622 0,483 0,376
[
[
[
Sketch 6
Tem perature (C )
R
e
s
i
s
t
a
n
c
e

(
k
O
h
m
s
)
23
Removing the heat exchanger (see Fig. 9)
R em ove com bustion air blow er
R em ove com bustion cham ber
Pull the overheat sensor and tem perature sensor out of the
locating hole in the heat exchanger w ith flat nose pliers.
Press the heat exchanger through the w ater connection (w ater
inlet) and out of the jacket using a screw driver.
Perform a visual inspection of the heat exchanger. C lean or
renew the heat exchanger if necessary.
H eat exchanger
Jacket
O -ring
W ater connection (w ater inlet)
Installing the heat exchanger (see Fig. 10)

Insert the heat exchanger into the jacket. The heat exchanger
m ust be installed so that the slot in the heat exchanger base
catches the detent of the jacket base. A s a point of reference,
the overheat sensor connection m ust m atch up w ith the
locating hole in the jacket.
Please note!
seals and the O -ring. R enew if necessary.
C heck that the heat exchanger is properly seated in the jacket
(the heat exchanger m ust be pressed firm ly into the jacket).
B efore installation, coat the O -rings w ith special-purpose
grease, e.g. H ellerine.
H eat exchanger
Jacket
D etent
Slot in base of heat exchanger
B ase of overheat sensor
Fig. 9
Fig. 10
24
Wiring diagram
HYDRONIC B 12 Volts and HYDRONIC 12 Volts / 24 Volts
not available to H YD R O N IC D 5 W S 24 Volts
25
Parts list
1.1 B urner m otor
1.2 G low plug
1.5 O verheat sensor
1.12 Flam e sensor
1.13 Tem perature sensor
2.1 C ontrol unit
2.2 M etering pum p
2.5.7 Relay, vehicle blow er
2.7 M ain fuse 20 A /12 V-15 A /24 V
2.7.1 Fuse, actuating elem ent 5 A
2.7.5 Fuse, vehicle blow er 25 A
2.12 W ater pum p
2.15.9 Sensor, outside tem perature
3.1.9 Sw itch, stationary ventilation
3.2.6 Tim er, M iniversion
3.2.9 Tim er, rectangular (m odular tim er)
5.1 B attery
5.1.2 Fuse holder in vehicle
5.9.1 Sw itch, vehicle blow er
5.10 Vehicle blow er
a) C onnect to D + for add-heat criterion (optional)
b) connect to + 15
c) Lighting term inal 58
d) Stationary ventilation (optional, see page 15)
e) External O N /O FF key (optional)
f) C ut open cable
i) R adio m odule connection
k) Sw itch (additional heating, e.g. <5C )
Length plus + length m inus:
from 3.5 m to 5.5 m > cross-section 4 m m
from 5.5 m to 8.0 m > cross-section 6 m m
Insulate unused cable ends.
The plug and socket housing are show n from the conductor
entry side.
R t = red
bl = blue
w s = w hite
sw = black
gn = green
gr = grey
ge = yellow
vi = violet
Please note!
In the case of vehicles equipped w ith heating or air conditioning
system , please observe our vehicle-related W orkshop Inform a-
tion on the blow er control.
If the W orkshop Inform ation is unavailable, pay attention to the
vehicle m anufacturers instructions regarding connection or
interface for blow er control.
20 1777 00 96 01 a
26
Fuel quantity measurement
Preparations for measurement (see sketch 7)
D etach the fuel line from the H YD R O N IC and place it in a
m easuring glass (10 cc. capacity).
A fter about 45 seconds, the m etering pum p starts to
pum p fuel.
W hen the fuel is com ing out sm oothly and free of bubbles,
the fuel line is filled and bled.
Sw itch off the heater and em pty out the m easuring glass.
Measurement
Sw itch on the heater.
A fter about 45 seconds, the m etering pum p starts to
pum p fuel.
K eep the m easuring glass at the level of the H YD R O N IC
during m easurem ent.
A fter about 90 seconds, fuel pum ping is sw itched off
autom atically.
Sw itch off the heater, as otherw ise start-up is repeated.
M easure the fuel quantity in the m easuring glass.
Please note!
O nly perform fuel quantity m easurem ent if the battery is
charged sufficiently!
D uring m easurem ent, the voltage applied to the control
unit m ust be at least 11 Volts/23 Volts and m ust not exceed
13 Volts/25 Volts.
Evaluation
C om pare the m easured fuel quantity w ith the values specified in the follow ing table.
If the m easured fuel quantity is above the m ax. perm issible value or below the m in. perm issible value, the fuel
m etering pum p m ust be replaced.
Fuel quantity H YD R O N IC B 5 W S H YD R O N IC D 5 W S
N om inal fuel quantity 11.5 cm
3
/90 sec. 8.0 cm
3
/90 sec.
M ax. fuel quantity 12.1 cm
3
/90 sec. 8.5 cm
3
/90 sec.
M in. fuel quantity 10.9 cm
3
/90 sec. 7.5 cm
3
/90 sec.
Sketch 7
27
Requirement profile for pilot
control and LLD functions on
the AC100
Page 1 of 16
Christian Quien, Dept. 8315
File: AC100 Anforderungsprofil e
1
1 Layout of the PDC unit
A701 A702 A703 A705 A706 A704 A707 A708 A709 A712 A713 A714 A715 A716 N700
Design. Function PAT designation Dematic ID no.
A701 CPU module 22 020 10 0100 000 281 12
A702 LLD module for DS 350C 22 020 10 0009 000 282 12
A703 Video controller board, driver for TFT- 22 020 30 0070 000 286 12
A704 16-slot digital input basic board 22 020 30 0052 000 287 12
A705 16-slot digital output extension 22 020 30 0066 000 289 12
A706 16-slot digital input extension 22 020 30 0058 000 288 12
A707 16-slot digital input basic board 22 020 30 0052 000 287 12
A708 16-slot digital output extension 22 020 30 0066 000 289 12
A709 RESERVE --------------- ---------------
A710 11-slot analog input 22 020 30 0030 000 290 12
A711 8-slot analog output 22 020 30 0022 000 291 12
A715 Reserve --------------- ---------------
N 700 DC / DC converter 450 17 1006 000 283 12
the AC100
Page 2 of 16
2
2 Pilot control sensor
Manufacturer Remote control units Berlin Kurt Oelsch GmbH
Type ST 2000i - X/Y/1/2/3/Ol/Or/W1A/St8/St10/01 w/o dust protection cap
Characteristic line and connection plan in accordance with TL ident.
no.: 00125912
Art. no.: 3495Z01-024.016
ldentical pilot control sensors are used on the left- and right-hand side
2.1 General signals of the pilot control sensor
- Current output:
4-20mA (connection in accordance with circuit diagram)
- Zero point switches:
All 4 zero point switches of a pilot control switch are connected in parallel.
With this signal the amplifier final stages of the analog output board are
limit switched with a time delay.
- Direction switches:
Authorisation of the outputs, emergency control.
- Switch S6 left
Slew gear free running
- Rotation indicator left
for hoist 2 (fed past the control to H18)
- Rotation indicator right
for hoist 1 (fed past the control to H19)
- Switch S9 right
High-speed switch for "raise luffing gear" and hoists switches S10 (le), S11 (ri)
Dead man's switch pilot control lever right and left
2.2 Assignment of the pilot control levers:
The pilot control sensor layout is aligned with the connections a4, a6 and a8 of the
16-slot digital input extension module A706.
For a crane without hoist 2, a6 is without current. If a machine is to be fitted with
hoist 2, DEMAG installs a permanent bridge to a8. The switch S23 is also only
optional for hoist 2 operation. Without hoist 2, the wiring for the pilot control is
installed by DEMAG in accordance with the customer's wishes.
The pilot control levers assign the following current levels to the movement
directions:
Lever moved fully forward (Y-direction): I=20mA
Lever moved fully backwards (Y-direction: I= 4mA
Lever moved fully to the right (X-direction): I=20mA
Lever moved fully to the left (X-direction): I= 4mA
Lever in middle position (): I =12mA
the AC100
Page 3 of 16
3
2.2.1 Standard setting without hoist 2
a4=0 a6=0 a8=0
Pilot control lever left Pilot control lever right
Signals of the pilot control sensor left
- Luffing switch S7: (S707 not actuated): slew gear slower <->faster
(S707 actuated): hoist 1 slower <->faster
Signals of the pilot control sensor right
- Luffing switch S8 Lower luffing gear slower <->faster
2.2.2 Option 1 without hoist 2
a4=0 a6=1 a8=0
Signals of the pilot control sensor left- luffing switch S7 Hoist 1 slower <->faster
- Luffing switch S8: (S707 not actuated): Slew gear slower <->faster
(S707 actuated): Lower luffing gear slower <->faster
Telescope
extend
Telescope
retract
Slew
right
Slew
left
Hoist1
lower
Boom
lower
Hoist1
raise
Boom
raise
Telescope
extend
Telescope
retract
Slew
right
Slew
left
Hoist1
lower
Boom
lower
Hoist1
raise
Boom
raise
the AC100
Page 4 of 16
4
2.2.3 Option 3 without hoist 2
a4=0 a6=0 a8=1
(S707 actuated): Lower luffing gear slower <->faster
- Luffing switch S8 Hoist 1 slower <->faster
2.2.4 Standard setting with hoist 2
a4=1 a6=0 a8=0
Control setting as for 2.2.1
Telescope
extend
Telescope
retract
Slew
right
Slew
left
Hoist1
lower
Boom
lower
Hoist1
raise
Boom
raise
the AC100
Page 5 of 16
5
2.2.5 Setting 1 with hoist 2
a4=1 a6=1 a8=0
(S707 actuated): hoist 1 and hoist 2 slower <->faster
2.2.6 Setting 2 with hoist 2
a4=1 a6=0 a8=1
- Luffing switch S7: (S707 not actuated): slew gear slower <->faster
(S707 actuated): hoist 1 and 2 slower <->faster
Slew
right
Slew
left
Hoist2
lower
Boom
lower
Hoist2
raise
Boom
raise
Hoist1
raise
Hoist1
lower
Slew
right
Slew
left
Telescope
extend
Telescope
retract
Hoist1
raise
Hoist1
lower
Hoist2
lower
Hoist2
raise
the AC100
Page 6 of 16
6
3. Digital inputs on 16 slot basic module A 704
Plug assignment scheme:
Input PIN a e Signal designation
DE0 02 + - Direction switch +X pilot control lever left
DE1 04 + - Direction switch -X pilot control lever left
DE2 06 + - Direction switch +Y pilot control lever left
DE3 08 + - Direction switch -Y pilot control sensor left
DE4 10 + - Zero point switch pilot control sensor left
DE5 12 + - Preselect switch S 708 telescope loads / erection loads
DE6 14 + - Luffing switch S7 left pilot control sensor pressed left
DE7 16 + - Luffing switch S7 left pilot control sensor right pressed
DE8 18 + - Direction switch +X pilot control lever right
DE9 20 + - Direction switch -X pilot control lever right
DE10 22 + - Direction switch +Y pilot control lever right
DE11 24 + - Direction switch -Y pilot control sensor right
DE12 26 + - Zero point switch of the left pilot control sensor right
DE13 28 + - Switch high speed S9
DE14 30 + - Luffing switch right pilot control sensor pressed left
DE15 32 + - Luffing switch right pilot control sensor pressed right
4. Digital outputs on 16 slot extension A 705
Output PIN Signal designation
DA0 a02 Activation Y1, enable pilot control pressure
DA1 a04 Activation Y14, slew gear parking brake
DA2 a06 Activation Y16.3, bypass bottom end
DA3 a08 Activation Y16.4, bypass rod end
DA4 a10 R E S E R V E
DA9 a20 Activation Y61a, CWT cylinder up
DA10 a22 Activation Y61b, CWT cylinder down
DA11 a24 Activation Y200, claw closed
DA12 a26 CWT down and claw closed
DA13 a28 CWT claw closed
DA14 a30 Slew gear locked
the AC100
Page 7 of 16
7
5. Digital inputs on 16-slot extension module A 706
DE0 02 + - Emergency operation active, switch outputs
DE1 04 + - Coding jumper H II
DE2 06 + - Switchover pilot control options
DE3 08 + - Switchover pilot control options
DE4 10 + - Switchover hoist speed adjustment H1/2
DE5 12 + - Static slew gear brake (S14)
DE6 14 + - R E S E R V E
DE7 16 + - R E S E R V E
DE8 18 + - CWT cylinder up B50, B51
DE9 20 + - Slew gear released, B52,B53
DE10 22 + - CWT claw up, B54,B55
DE11 24 + - CWT in position, B56,B57
DE12 26 + - R E S E R V E
DE13 28 + - R E S E R V E
DE14 30 + - R E S E R V E
DE15 32 + - R E S E R V E
6. Digital inputs on 16-slot basic module A 707
DE0 02 + - Preliminary position locking tele 1 and 3 (B1)
DE1 04 + - Follow-on position locking tele 1 and 3 (B2)
DE2 06 + - Preliminary position locking tele 2 and 4 (B3)
DE3 08 + - Follow-on position locking tele 2 and 4 (B4)
DE4 10 + - LBU bolted (B13)
DE5 12 + - LBU limit position (B14)
DE6 14 + - LBU locked (B15)
DE7 16 + - Preliminary position section bolting tele1-4 (B5,B7,B9,B11)
DE8 18 + - Follow-on position section bolting tele 1-4(B6,B8,B10,B12)
DE9 20 + - Superstructure locked to the rear (B43)
DE10 22 + - Lower limit switch H1(B18)
DE11 24 + - Lower limit switch H2(B19)
DE12 26 + - R E S E R V E
DE13 28 + - R E S E R V E
DE14 30 + - R E S E R V E
DE15 32 + - R E S E R V E
the AC100
Page 8 of 16
8
7. Digital outputs on 16-slot extension module A 708
Output PIN Signal designation
DA0 a02 Lock LBU (Y2)
DA1 a04 Unlock LBU (Y3)
DA2 a06 Bolt sections (Y4)
DA3 a08 Unbolt sections (Y5)
8. Reserve slot A 709
9. Analog inputs on 11-slot module A 710
Input PIN Signal designation
AE0 a14 Pilot control lever left X-direction
right stop = 20 mA, left stop = 4 mA
AE1 a16 Pilot control lever left Y-direction
rear stop = 4 mA, front stop = 20 mA
AE2 a18 Pilot control lever right X-direction
right stop = 20 mA, left stop = 4 mA
AE3 a20 Pilot control lever right Y-direction
rear stop = 4 mA, front stop = 20 mA
AE4 a22 Length telescope (B703) min= 4mA, max =20mA
AE5 a24 RESERVE
AE6 a26 RESERVE
AE7 e14 Total length main boom B702 min=4mA, max=20mA
AE8 e16 Angle main boom B702 min=4mA, max=20mA
AE9 e18 Motor speed B707 F/I converter PAT
AE10 e20 Pressure sensor luffing cylinder
the AC100
Page 9 of 16
9
10. Analog outputs on 8-slot basic module A 711
Input PIN Signal designation Terminal Piggy
AA0 e2 R E S E R V E X4
AA2 e10 Luffing gear up/down (A714) X5
AA3 e14 Hoist 1 raise/lower X5
AA4 e18 Hoist 2 raise/lower X6
AA5 e22 Slew gear left/right X6
AA6 e26 Telescope tele cylinder in/out X7
11. Analog outputs on 4-slot piggy module A 712
max. current =1A
Input PIN Signal designation/piggy connection Signal
AA0 a2/a4 Extend telescope / X7 0-1 A
AA0 e2/e4 Current output - 0-1 A
AA0 a6/a8 Retract telescope / X7 0-1 A
AA1 a10/a12 R E S E R V E 0-1 A
AA1 e10/12 Current output - 0-1 A
AA1 a16/a18 R E S E R V E 0-1 A
max. current =1A
AA0 a2/a4 Raise hoist II 0-1 A
AA0 a6/a8 Lower hoist II 0-1 A
AA1 a10/a12 Slew gear left 0-1 A
AA1 a16/a18 Slew gear right 0-1 A
the AC100
Page 10 of 16
10
max. current =1A
AA0 a2/a4 Luffing gear down 0-1 A
AA0 a6/a8 Luffing gear up 0-1 A
AA1 a10/a12 Raise hoist 1 0-1 A
AA1 a16/a18 Lower hoist 1 0-1 A
14 Digital output module A705
Assignment of the relays
Relay 1 a2
Function: enable valve for pilot control pressure Y1
The relay is always picked up in crane operation (e2). It drops out (a2) when the LLD
shut-off is activated. If "lower hoist" (1 or 2), "retract telescope" or slew gear are
activated, the relay has to be picked up again. If these movements are no longer
activated, the relay must drop out again, provided that the LLD shut-off is still active.
If, for example, "lower luffing fly jib" and "lower hoist" are driven into the shut-off
range at the same time, the relay should also drop out initially. The relay only picks
up when the control levers are returned to the zero position and then one of the load-
moment-reducing movements are carried out. If a movement is then carried out
which increases the load moment, the relay drops out.
The hoist limit switch shut-off is treated exactly as the LLD shut-off.
When the lower limit switch is shut off, the relay can always remain picked up.
When the LLD is bridged, the relay must pick up. The same applies when the hoist
limit switch is bridged.
Relay 2 a4
Function of static slew gear brake
The relay triggers the slew gear brake valve Y14. For the recognition of switch
conditions, two additional digital inputs are required. On the input board A706 the
switch S14 is connected to input a12 and the pilot control sensor switch S6 to input
a14.
Y14 =1 when S14 S6
the AC100
Page 11 of 16
11
v S14 slew gear under current (enable slew gear)
In addition the output should remain activated for 2 seconds once the movement is
completed. This prevents the static slew gear brake falling closed when the
superstructure is still turning.
15 Analog outputs
15.1 Solenoid valve data:
The following table shows the default values of the solenoid valve data which are set
on the machine:
Function/solenoid valve Entry
current
Start-up
current
Normal speed
current
High-speed
current
Slew gear right / Y14.1 200 mA 230 mA 560 mA -
Slew gear left / Y14.2 200 mA 240 mA 560 mA -
Extend tele / Y16.1 200 mA 460 mA 800 mA -
Retract tele / Y16.2 200 mA 480 mA 800 mA -
Luffing gear up / Y15.1 150 mA 450 mA 600 mA 660 mA
Luffing gear down / Y15.2 200 mA 400 mA 600 mA -
Raise hoist 1 / Y18.1 200 mA 440 mA 560 mA 680 mA
Lower hoist 1 / Y18.2 200 mA 440 mA 610 mA 680 mA
Raise hoist 2 / Y19.1 200 mA 440 mA 610 mA- 680 mA
Lower hoist 2 / Y19.2 200 mA 440 mA 610 mA 680 mA
15.2 Speed dependency
For the movements "raise luffing gear" and "lower hoist" the current is also controlled
in relation to the diesel speed. The purpose is to avoid an insufficient supply to the
valves at low speeds. At low speeds the maximum current is lower than at full speed
when the lever is fully deflected.
Minimum motor speed 800/min
Maximum motor speed 2200/min
15.3 Desired value changes
Via the luffing switches S8 and S9 in the pilot control sensors, the current to the
proportional valves can be changed directly by the driver. This is possible for the
movements - hoist, slew gear and lower luffing gear.
Example: slew gear
Starting current 240 mA
Normal speed current 560 mA at 100%
the AC100
Page 12 of 16
12
Proportional valve current 368 mA at 40% (240 mA +4(560 mA - 240 mA))
The changes in the desired values may only have a dampened effect, the current
must be changed via a ramp.
15.4 Regulation of the ramps
The function of the ramp is to limit changes in the solenoid valve current when the
pilot control lever is moved quickly. This causes start-up movements to be more
gentle. If the movement is started or stopped slowly, the ramp is not used.
Subsequent changes to the ramp times should be possible without much difficulty.
15.4.1 Ramp time at start of movement
The ramps are activated by the direction switch.
Slew gear 3 s
Raise hoist 3 s
Lower hoist 1.5 s
Telescope 1 s
Luffing gear 3 s
15.4.2 Ramp time at end of movements
All movements with the exception of the tele control 1s. The telescopes are switched
off once the preselected boom length is reached without stop ramps.
When the LLD is shut off, the solenoid valve currents for the movements "raise hoist"
and "raise and lower luffing gear" are driven directly to zero without ramps.
When the LLD prewarning is given (90% of the permissible load moment) the
solenoid valve currents are reduced to a maximum 50%. This applies to the
movements "raise hoist", "lower luffing gear" and "extend telescopic section". The
reduction is made using a time ramp. This ramp is determined empirically.
When the hoist limit switch is triggered, the solenoid valve current for "raise hoist"
and "extend telescope" are set to zero without a ramp.
When the lower limit switch is activated, the solenoid valve current for "lower hoist" is
set to zero without a ramp.
The speeds which can be changed using luffing switches S8 and S7 should initially
be set to an average value of 50% of the maximum current of the corresponding
movement with the "ignition on". The speed change should be continual. At a set
reduced speed, the full lever movement should remain available for activation.
The high speed should also be activated and deactivated using a ramp. This ramp
should also be determined empirically.
the AC100
Page 13 of 16
13
16 Slew gear control
Hydromatic displacement pump A10VG 45 EP21
The slew gear works in a closed circuit. In these types of system, the speed depends
on the lever position and the diesel engine speed. We want to look at two different
cases.
16.1 Slew gear without further movements
In this case the displacement angle of the pump depends on the lever path. The slew
gear speed is therefore proportional to the diesel speed.
16.2 Slew gear with other movements
If further movements are activated during slewing, it is important that the slew gear
speed is kept constant (with the same lever displacement), even if the diesel speed
changes. The displacement angle of the pump depends on the speed in this case.
the AC100
Page 14 of 16
14
16.3 Other movements with hoist
When movements are carried out and subsequently the slew gear is activated, the
slew speed is exclusively dependent on the oil flow which is currently available. In
this case the slew gear speed is therefore not kept constant.
Engine speed
Current
[mA]
800 1000 1200 1400 1600 1800 2000 2200
200 0 0 0 0 0 0 0 0
240 3.6 4.5 5.4 6.3 7.2 8.1 9 10
280 7.2 9 10.8 12.6 14.4 16.2 18 20
320 10.8 13.5 16.2 18.9 21.6 24.3 27 30
360 14.4 18 21.6 25.2 28.8 32.4 36 40
400 18 22.5 27 31.5 36 40.5 45 50
440 21.6 27 32.4 37.8 43.2 48.6 54 60
480 25.2 31.5 37.8 44.1 50.4 56.7 63 70
520 28.8 36 43.2 50.4 57.6 64.8 72 80
560 32.4 40.5 48.6 56.7 64.8 72.9 81 90
600 36 45 54 63 72 81 90 100
nmax =2200 U/min
Slew gear quantity in % in relation to speed and starting current
the AC100
Page 15 of 16
15
The following diagram is designed to explain the slew gear control. From a fixed
operating point 0, the pump quantity is changed via the displacement angle when the
slew gear is activated and at a constant engine speed (characteristic line 1). If the
speed is changed and the lever position kept constant, the volume also changes
accordingly (characteristic line 2). If a second movement is activated and the speed
is changed, the slew gear speed should remain constant (characteristic line 3).
Ansteuerstrom (%)
0
10
20
30
40
50
60
70
80
90
100
800 1000 1200 1400
1600 1800 2000 2200
the AC100
Page 16 of 16
16
9 LLD programming:
- LLD shut-off: Proportional valves set to zero
In addition the control lines to the
proportional valves are interrupted via relay contacts
In the LLD program different operating modes should be possible:
Erection program ->Boom can be telescoped out quickly to any length;
however only erection loads will be enabled.
Telescoping loads: ->Boom can be telescoped out under load in accordance
with specified telescoping sequences.
- HLS shut-off: Proportional valves are set to zero
The movements luffing fly jib down, hoist up and
extend tele are shut down.
.
Service Manual
Modular PDC
Version 1.2
Status 26.03.1999
Service Manual
Modular PDC
H.-P. Huwer, Dpt. 8315
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1. General instructions on working with computer components
In the following chapters the basic components of the modular "Pat Dynamics Control - PDC" are
described. The PDC is responsible (or will be responsible in the near future) for various control,
monitoring and visualisation tasks on the machines AC 100, AC 120, AC 300, AC 500-1, AC 650,
CC 2800 and CC 2500.
Certain basic rules, which apply to work with electronic instruments, must be followed when
carrying out maintenance and repair work on this system. In the following pages, these rules will
be outlined as they apply to the individual components and the definitions used will be explained.
General rule
Printed circuit boards (pcbs) or modules may only be inserted and removed off circuit!
Changes to the wiring, the coding switches/coding jumpers and fuses may only be made off
circuit!
EPROM electric programmable read-only memory
A memory module which can be programmed electrically using suitable programming appliances,
and which can only be read in normal mode. In order to be able to re-program the module it must
first be deleted by extended UV irradiation.
To enable the UV light to reach the actual chip, the EPROM has a window. Following
programming, this window is sealed off to the light using a sticker, in order to avoid unintentional
erasing, e.g. as a result of irradiation from the sun. This sticker may therefore only be removed
to erase the EPROM.
EPROMs can be destroyed by electrostatic charges. Before touching an EPROM, you must
always make sure that you are not carrying an electrostatic charge. Ideally, special earthing
armbands, electrostatic mats and tools etc. should be used for this purpose. If these accessories
are not available, at the very least equipotential bonding should be created between the PDC and
operator by touching a metal part of the PDC before touching the EPROM.
An EPROM is removed from its socket by pulling the EPROM evenly from both sides using an
IC extraction pincer. As an additional aid, a small screwdriver can be used to lever the EPROM out
of its socket alternately from both sides. This is the only way to prevent the EPROM pins from
becoming bent. A dismantled EPROM can be used again and should be returned to Dept.
8315.1. In addition, Dept. 8315.1 must always be informed when an EPROM is replaced.
An EPROM is inserted in its socket by first placing all pins in the holders. Any pins which may have
been bent must be straightened carefully (!). When all pins are located in their holders, the
EPROM is pressed into the socket evenly and without any slant. Subsequently, you must
check that all pins are correctly located in the socket, or whether pins are bent outwards or
inwards (difficult to see !).
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Ribbon cable
In order to link up contact series, ribbon cable with up to 68 cores is often used in computers.
These ribbon cables are either soldered directly into a pcb or are connected by means of
plugs/couplings. These plugs/couplings are usually fitted with insulation contacts. The ribbon cable
is inserted in the contact element and pressed into the insulation contacts with a plastic strip. The
plastic strip is then locked into the contact element. This type of assembly can support relatively
high mechanical loads, however a plug connection must never be released by pulling on a
ribbon cable. When releasing a plug connection, pull only on the plastic body. If a plug
connection is stuck, you can loosen it by carefully (!) levering with a screwdriver.
To avoid switching of the poles of the ribbon cable, at least the core / contact is marked with the
number "1" on the connection points of a ribbon cable (i.e. on the pcb). The ribbon cable itself
comprises different-coloured cores or a marking for the core with the number "1". It is normal, for
example, that grey ribbon cable has a red core marked as number "1".
In addition the plugs/couplings are mechanically coded with lugs and grooves and can only be
inserted easily in the correct direction.
Coding switches
To make one-off settings on a pcb, so-called coding switches are used. These are small rotary
switches with, for example, 10 or 16 positions. The coding switch is adjusted carefully (!) using
a small screwdriver. The position of the coding switch is indicated, for example, by a small arrow.
The different settings of the coding switch may only click into position lightly, i.e. the operator is
responsible for setting the precise switch position.
Coding jumpers
An additional option for making settings on a pcb is the use of coding jumpers. This involves
conductively linking two contact pins by means of small connectors. The connectors must be
inserted carefully and only in the specified direction. Extra connectors may not be inserted
on free contact pins.
Trimming potentiometers
In order to enable stepless adjustments, some pcbs are fitted with small trimming potentiometers.
These trimming potentiometers must be carefully turned with a suitable screwdriver.
Overtightening of the mechanical stop must be avoided, as the entire pcb has to be replaced if the
potentiometer is defective. The current position of the potentiometer is generally indicated with a
small marking (arrow tip, dash). If this is not the case, the correct position must be set by rotating
the potentiometer to both end stops to determine its range and then turning to the desired setting.
2. Layout of the plug-in pcbs in the computer
The plug-in pcbs described in the following chapters can be found in various positions and in
different quantities, depending on the appliance type and the technical features. It is possible to
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view the current configuration of the PDC, i.e. the type and position of the plug-in pcbs, on the
control console. The following image shows this screen display as an example for a CC crane.
CPUboard
LLD board Video board
PROWAY interface board
Piggy digital
input boards
Piggy digital
output boards
Piggy analog
output boards
Basic digital
input boards
Basic analog
output board
Analog input boards
Info menus
PROWAY users
Status
fields
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The following image shows the corresponding screen display as an example for an AC crane.
The principle layout of the plug-in pcbs remains the same, but the number and designations
change.
CPUboard
LLD board
Videoboard
PROWAY interface board
Piggy analog
output boards
Analog input boards
Info menus
Status
fields
Piggy digital
input boards
Piggy digital
output boards
PROWAY with
PROWAY users
Basic digital
input boards
Basic analog
output board
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The boards CPU, LLD (load limit device), PROWAY and video always occupy the first four
positions (as shown here).
On the following plug-in slots are the digital in- and output boards, whereby the basic board is
always inserted first, followed by the piggy boards.
After this come the analog in-and output boards. Again, the basic board is inserted first, followed
by the piggy boards.
The extreme right position is always occupied by the plug-in pcb with the voltage supply for the
entire computer
The status fields (in this example: ) provide information on the status of the plug-in boards.
The displayed symbols are explained via the info menus.
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3.1 Layout of the CPU board
The CPU board is the actual nerve centre of the PDC unit. This houses the processor, the memory
modules and all I/O modules required for operation. For a change in the software, only the
EPROM modules are of interest. These are arranged as follows.
The bottom number on each EPROM describes the plug-in position on the pcb. The EPROMs on
plug-in slots -11- and -12- contain the operating system software. The EPROMs on slots -21- and
-22- contain all control programs (SPS), data blocks, graphics, applications and configurations.
The EEPROM is located on the lower layer and cannot be replaced without dismantling the CPU.
A replacement of the EEPROM is not normally required.
RAM modules
System EPROM 12
System EPROM 11
Data EPROM 21
Data EPROM 22
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The EPROMs have various markings which have the following meanings.
ECIS
TFT1
M2
03.35
2CF3
-11-
General marking for the operating
system EPROMs
Not appliance-related, system
EPROM
Running index, updated with each
new program version
4-digit HEX number, check sum
Module slot number
B1
B2
System EPROM no. -11-
System EPROM no. -12-
39
01.08
AC
300
46DD
-21-
Machine code, e.g. here AC 300
Running index, updated with each
new program version
Machine designation in plain text
4-digit HEX number, check sum
Module slot number
C1
C2
User software,
EPROM no. -21-
User software,
EPROM no. -22-
The 4-digit HEX number represents the last 4 digits of the check sum on the complete binary
content of the EPROM. When a new EPROM is created or duplicated, it is essential that the
correct check sum is specified!
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The following connections and display elements are located on the front panel of the CPU board.
Switch and LED "Reset": System reset, cold start
Switch and LED "Abort": Warm start
Switch and LED "F1": Service button "F1" and display "F1"
7-segment display: Status and fault display
Switch and LED "F2": Service button "F2" and display "F2"
Port "1", RS 232: Download port for Etool
Port "2", RS 232: Debug and modem port
Port "3", RS 422: Reserved for console control
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3.2 Layout of the LLD board
The LLD board is to be seen as an independent processor board. It assumes all necessary tasks
and calculations for the load limit devices. For a change of software, once again only the EPROM
modules are of interest. These are arranged as follows.
The bottom number on each EPROM describes the slot on the pcb. The system EPROM -0-
contains the operating system software with all calculations. The data EPROM DAT contains the
data and parameters specific to the crane. The load EPROM TLK contains the actual carrying
loads. For the check sums, the same applies as outlined for the CPU.
System EPROM 0
Data EPROM DAT
Loads EPROM TLK
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The following connections and display elements are located on the front panel of the LLD board.
LEDs "RES", "INT", "1", "2", "3", "4": Service lamps for PAT
LED "Load": Display for overload
LED "A2B": HES display
Port "RS 232": Programming and parameter port for LLD
"Digital I/O X2": I/O plug X2, see circuit diagram
"Keyswitch X3": I/O plug X3, see circuit diagram
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4.1 Layout of the analog input board
The analog input boards read the measurement values of various sensors, with each board having
7 inputs. The unit comprises several boards with an identical layout, but which have to be
differentiated for the computer. For this reason, each board receives a clear address, which is set
using the address coding switch, see image. The addresses are counted, starting from "0" up to
the maximum "F", i.e. there are 16 possible addresses. Each address may only occur once in the
system for this board type!
When replacing a defective board, the same address must be set on the replacement board as
was set on the defective board. If two boards are replaced (e.g. for test purposes), the addresses
of the boards must also be replaced.
The address coding switch is to be turned carefully (!) using a suitable screwdriver.
If the correct address is not known for a board, the information on the address and module slot
can be obtained from the documentation of the company PAT.

Address coding switch 0-F
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4.2 Layout of the analog basic output board
The analog basic board produces variable electric control signals which are output via so-called
piggy boards. To this end, a maximum of eight signals are produced which are output via a
maximum of four piggy boards, i.e. each piggy board possesses two channels. The analog signals
are transferred via four connector plugs and ribbon cable to the piggy boards.
As with the analog input board, each analog basic output board possesses an address coding
switch which is used to assign each board an address which can only be allocated once in the
system. In this case too, when replacing a defective board the same address must be allocated to
the replacement board as was given to the defective board. If two boards are replaced (e.g. for
test purposes), the addresses of the boards must also be replaced.
The address coding switch is to be turned carefully (!) using a suitable screwdriver.
If the correct address is not known for a board, the information on the address and module slot
can be obtained from the documentation of the company PAT. As a rule the address is "0", as
there is only one analog basic output board in the system.
Furthermore, the analog basic output board possesses a coding jumper which can be inserted in
six different positions. This jumper sets the ripple frequency which is superimposed on the control
signal of the proportional hydraulic valves. The six positions correspond with the following
frequencies from the left to the right: 160 Hz, 80 HZ, 40 HZ, 20 Hz, 10 Hz, 5 Hz. In the following
image the ripple frequency is set to 80 Hz.
4 connector plugs for piggy boards
Coding jumper, 6 different positions
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4.3 Layout of the analog piggy output board
The analog piggy board receives two input signals from the basic board via a ribbon cable, which it
then amplifies and transfers to two consumers (e.g. proportional valves). The ribbon cable is
connected to a corresponding connector plug. The maximum output current is 1 amp for each
channel.
There are no address coding switches on the analog piggy output board. The address is
determined by the fact that each board receives its signals from the analog basis output board via
its own output or its own ribbon cable. This means that when the ribbon cable of the piggy boards
is replaced for test purposes, all connector cables must also be replaced !
The board also houses a fuse, with which the output steps are protected against short circuiting,
and a trimming potentiometer, which is used to set the ripple amplitude of the output board. This
potentiometer always remains in the middle position, unless specified otherwise.

Connector plug for the cable of the basic board
Trimming
Fuse
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4.4 Layout of the digital basic input board
The digital basic input board reads the measurement values of 16 binary sensors, i.e. "0"- or "1"-
values. In addition up to four digital piggy boards are operated via this board, which can either be
input or output boards. These boards are connected via a ribbon cable, with a cable being fed
from the first piggy board with a connector coupling to the basic board where it is inserted in the
connector plug. On the piggy board there is an additional connector plug, to which the ribbon cable
of the next piggy board can be connected etc. In this way, a maximum of four piggy boards can be
connected in succession. The board is fitted with a fuse, which safeguards all connected piggy
boards. If this fuse is defective, none of the piggy boards will work, even if the control display
states otherwise.
This board also has a unique address, which is set using the address coding switch (see image).
The addresses are allocated in ascending order from "0" up to the maximum "F", i.e. there are 16
possible addresses. Each address for this type of board can only be allocated once for each
system.
When replacing a defective board the same address should be set on the replacement board as
on the defective board. If two boards are replaced (e.g. for test purposes), the addresses of the
boards should be replaced.
The address coding switch should be turned carefully (!) using a suitable screwdriver.
If the correct address is not known for a board, information on the address and module slot can be
taken from the documents of the company PAT. Up to three digital basic input boards can be
found in the system.

Connector plug for ribbon cable
Fuse
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4.5 Layout of the digital piggy input boards
The digital piggy input boards also read the measurement values of 16 binary sensors. The
boards are, however, not independent, but are operated via the digital basic input boards. The
board is connected to the basic input board as already described via a ribbon cable with a
connector coupling. The connector coupling at the end of the ribbon cable is not shown here. Next
to the ribbon cable is the connector plug for the next piggy board.
The digital piggy boards are addressed by them being inserted at a certain point behind the basic
input board, they do not possess a coding switch. For example, if a maximum of four piggy boards
follow behind the basic input board, they are automatically awarded the addresses "0" to "3". This
means that the function of the digital piggy input boards depends on their slot position. If, for
example, two boards are replaced for test purposes, the connections on their front panels must
also be replaced. If this is not done, the digital input signals are connected to the wrong channels.

Ribbon cable with plug
Connector plugs for ribbon cable
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4.6 Layout of the digital piggy output board
The digital piggy output boards possess 16 floating relay outputs with make contacts. These
boards are also not independent and are operated via the digital basic input board. The board is
connected to the basic input board as described for the digital piggy input boards via a ribbon
cable with a connector coupling.
These boards are also addressed by their allocation to a specific slot behind the basic input board,
they also do not possess a coding switch. For this reason the function of the digital piggy output
boards also depends on their slot position. Consequently, if two boards are replaced for test
purposes, the connections on their front panels must also be replaced. If this is not done, the
digital output signals will be connected to the wrong consumers.
Each relay output is safeguarded with a miniature slow-blowing fuse of 2 A. The fuses are
plugged in and are mechanically fixed in place using two plastic strips which are screwed in. To
replace a fuse, the corresponding strip must be removed and then reattached once the new fuse
has been fitted. There are 2 spare fuses on the board for emergencies.

Ribbon cable with plug
Connector plug for ribbon cable
16 output relay
16 fuse for output relay
2 spare fuse
PAT GmbH Postfach 652 D-76260 Ettlingen Produktbereich
Baumaschinenelektronik
2000 PAT GmbH D-76275 Ettlingen Hertzstr. 32 - 34 ++49 (0) 7243 709-0 FAX ++49 (0) 7243 709-141 1 von 8
AC100 PDC Errorcodes.doc / 13.04.2000
Error Code Table (PDC-LMI)
DEMAG AC 100, AC 300, AC 500 and AC 650
Date: Apr. 13, 2000
System programs: LEDC V1.012 (18.02.2000) Part No.: 71 400 84 0268
LEDC V1.1G (05.04.2000) Part No.: 71 400 84 0275
LEDW V1.0E (07.03.2000) Part No.: 71 400 84 0271
Error Code Error Cause Remedy
O
Overload cutoff due to overload reduce load moment
P
prewarning
H
A2B switch the A2B switch is activated lower the hook block
E01
Fallen below radius
range or angle
range exceeded
fallen below the minimum
radius or gone past the
maximum angle specified in
the respective load chart due
to luffing up the boom too far
luff up the boom to a radius
or angle specified in the load
chart
E02
Radius range
exceeded or fallen
below angle range
gone past the maximum
radius or fallen below the
minimum angle specified in
the respective load chart due
to luffing up the boom too far
luff down the boom to a
radius or angle specified in
the load chart
E04
Operating mode not
acknowledged or
not existing
A non existing operating
mode has been selected
Correctly enter the operating
mode according to the
attribution of the operating
state
The selected operating
mode is not available in the
data EPROM or blocked.
Check programming of the
data EPROM
E05
Forbidden length
range of the main
boom
Boom has been extended
too far or not far enough,
e.g. if it is prohibited to go
beyond a certain maximum
boom length or with load
curves for jibs where the
main boom has to be
extended to a certain length.
Extend/retract boom to
correct length
Length sensor adjustment
has changed, e.g. the cable
slid off the length sensor
reel.
Retract boom. Check the
prestress of the cable reel
(cable must be taut). Open
the length sensors and
carefully turn the length
sensor pot counterclockwise
until the detent by use of a
screwdriver.
Clutch between length
sensor pot and drive is
defective
Replace complete clutch
including drive wheel and
adjust length sensor pot as
described above.
Length potentiometer
defective
Replace length
potentiometer
Cable between the central
unit to the length sensor is
either defective or
disconnected.
Check cable and plug,
replace, if need be
Electronic component in the
measuring channel is
defective
Replace analog board
E06
Radius range
exceeded or fallen
below angle range
during luffing jib
operation.
Gone past the maximum
radius or fallen below the
minimum specified in the
respective load chart due to
luffing down the jib too far.
Luff up the luffing jib to a
radius or angle indicated in
the load chart.
E07
Faulty
acknowledgment by
the overload relay
of the connection
board.
Relay should be
energized but 2nd
contact is indicated
off, or the 2nd
contact is indicated
on while the relay
should be
deenergized.
Overload relay defective
LMI board defective
Replace LMI board
E08
No
acknowledgment
from the anti-two-
block relay
refer to E07 refer to E07
E21
Upper limit value for
measuring channel
"length telescopic
boom" exceeded.
Bus error
length sensor is not correctly
connected.
defective
Length sensor is defective.
Check bus cable and plug
Correctly connect length
sensor
Exchange length sensor
E22
Upper limit value in
measuring channel
"pressure piston
side " exceeded
Bus error

Pressure transducer not
correctly connected

defective

Replace pressure
transducer.
Check bus cable as well as
plug
Correctly connect sensor.
Replace pressure
transducer
E23
measuring channel
"pressure rod side"
exceeded
as E22 as E22
E24
measuring channel
"force luffing jib"
exceeded
Bus error
Force transducer not
correctly connected
defective
Force transducer defective
plug
Correctly connect sensor
Replace force transducer
E25
measuring channel
"angle main boom"
exceeded
Bus error
Angle sensor not correctly
connected
defective
Angle sensor defective
plug
Correctly connect sensor
Replace angle sensor
E26
Lower limit value in
measuring channel
"angle luffing jib"
exceeded
as E25 as E25
E27
Lower limit value in
measuring channel
"length tele I +II"
exceeded
as E21 as E21
E2B
measuring channel
"angle boom head"
exceeded
as E25 as E25
E31
Error in the system
program
The system program PROM
is defective.
Replace system program
PROM (PROM No. 0)
E37
Error in the logic
program course
The system program PROM
is defective.
Computer module 80C537
defective.
LMI board defective
PROM (PROM No. 0)
Replace computer module
80C537.
Replace LMI board
E38
System program
and data EPROM
do not match.
The system program in the
LMI does not match to the
programming in the data
EPROM.
PROM or data EPROM
(PROM No. 1).
E39
System program
and RLC EPROM
do not match.
The system program in the
LMI does not match to the
programming in the RLC
EPROM.
PROM or data EPROM
(PROM No. 2).
E41
Error in the internal
write/read memory
(RAM) of computer
module 80C537
Computer module 80C537 is
defective.
LMI board defective
80C537.
Replace LMI board
E42
Error in the external
write/read memory
1st. part (RAM)
Write/read memory (CMOS-
RAM) or LMI board defective
Exchange LMI board.
E43
Error in the external
write/read memory
(RAM) of the main
board during on-line
programming
During on-line programming
an error has been detected
when writing on the external
working RAM
Plausibility check:
more than 24 sub operating
modes
number of load points per
length step >30.
Replace external working
RAM.
Replace LMI board.
The programming or number
of sub-operating modes and
load points.
E48
Cyclic RAM test.
Error in the internal
write/read memory
(RAM) of the
computer module
80C537
Computer module 80C537
defective.
LMI board defective
80C537.
Replace LMI board
E49
Faulty data in on-
line operation
No valid data in the
write/read memory of the
memory extension upon
data loading during on-line
programming
Exchange LMI board.
E51
Error in the crane
data EPROM or
EEPROM.
No valid data in the crane
data EEPROM.
Memory module wrongly
bridged.
Crane data EPROM
defective
Load crane data EEPROM
containing valid data.
Bridge memory module acc.
to memory type
Replace crane data EPROM
E52
Error in load chart
PROM.
bridged.
Load chart EPROM
defective.
to memory type.
Replace load chart EPROM
E56
Error in crane data
EEPROM.
bridged.
Crane data EEPROM
defective
to memory type
Replace crane data
EEPROM
E57
Error in serial crane
data EEPROM.
Serial crane data EEPROM
does not contain valid data.
Memory module defective
Write data on the serial
crane data EEPROM (by
means of test program or
on-line function), then restart
the LMI
Replace memory module.
E58
Error in the serial
analog data
EEPROM.
No valid data in the serial
analog data EEPROM.
LMI main board defective.
Write data on the serial
analog data EEPROM by
means of the test program,
then, restart the LMI
Replace LMI main board.
E60
The number of the
selected EPROM
base and the
programmed value
are not identical
Load chart EPROM
defective
Replace load chart EPROM
Base number not
programmed
Program the correct base
number (1 for base 1, 2 for
base 2)
Load chart EPROM wrongly
programmed
Check base programming in
the load chart EPROM.
E81
Too large difference
of the boom angles
at tip and base
boom.
The angle as to the
horizontal on the boom head
exceeds the main boom
angle by more than 5
degrees.
Check angle sensor on the
boom head.
Check angle sensor on the
base boom.
E82
More than 1 teles-
cope is unbolted
(exception: 3rd. and
4th telescope)
Only unbolt one telescope at
a time
E84
Wrong rigging
condition.
The selected rigging
condition is not contained in
the data EPROM.
Select another rigging
condition
Check the programming in
the data EPROM.
E85
Error in the radius
determination
The computed radius is too
small (negative deflection)
Check the programming in
the data EPROM.
E86
Faulty percentage
for at least one
telescope
Telescope has a percentage
<- 2% or >106 %.
Read out the percentages
on the console. If a
telescope has to be
extended too far: retract tele
and bolt
Length measurement Tele I
+II defective
Check length measurement
Tele I (see E17)
Measurement of overall
length defective
(see E11)
E87
Faulty length
measurement.
The determined
tele-combination
does not
correspond to the
length
measurement.
Error in the length memory.
Length measurement Tele I
+II defective
Overall length measurement
defective.
If wrong percentages are
displayed: retract and bolt all
telescopes. The error is
reset if the measured tele-
length corresponds to the
base boom length.
Tele I (see E27)
Check measurement of
overall length (see E21)
E88
Faulty main boom
position during
luffing jib operation
During luffing jib operation
the main boom is not in the
prescribed angle range
Angle measurement of main
boom defective.
Luff boom to the permitted
range
Check angle measurement
of the main boom.
E91
No data
transmission from
the ECIS console to
ECIS-LMI
LMI board defective
Dual Port RAM defective
Backplane board defective
Replace LMI board
Replace Dual Port RAM
Replace Backplane board.
E92
Error in the data
transmission from
the ECIS console to
the ECIS-LMI
LMI board defective
ECIS console defective
Backplane board defective
Replace LMI board
Replace ECIS board
Replace Backplane board
E93
Error in the data
transmission from
the ECIS - LMI to
the ECIS console
as E92 as E92
E94
No data trans-
mission from the
ECIS LMI to the
ECIS console
as E91 as E91
E97
Semaphore in the
dual-port RAM
cannot be read.
After several
readings the
content is not twice
identical.
as E91 as E91
E98
Semaphore in the
dual port RAM
cannot be written.
After several
writings and
readings the
content is not
identical.
as E92 as E92
Remark
If an error message is displayed that does not figure in this list, please immediately contact the
competent PAT service department.
ECIS - Software documentation page 1
SFehler_E.doc Rev.: 01 17.09.99
1.0 System errors
1.1 S 00nn Control error codes
S 0001 list of inputs not available
S 0002 definition error in list of inputs
S 0003 no space available for input chart
S 0004 variable in list of inputs doesnt exist in PDB
S 0009 undefined error in list of inputs
S 0011 list of outputs not available
S 0012 definition error in list of outputs
S 0013 no space available for output chart
S 0014 variable in list of outputs doesnt exist in PDB
S 0019 undefined error in list of outputs
S 0020 no control program available
S 0021 no space available for control blocks (coldstart)
S 0022 checksum error (coldstart)
S 0023 no data blocs in the EEPROM
S 0030 checksum error, control aborted
S 0090 input invalid (when application doesntt indicate 4 digit error codes)
S 0093 timeout in communication ECIS - LMI
S 0094 WatchCopyLMBData: CopyLMBData started again (modular ECIS only)
S 0095 WatchIO: I/O started again (modular ECIS only)
S 0096 WatchControl: control aborted
S 0097 WatchProfibus: polling started again
S 0098 CRC error in EPROM
S 0099 fatal error, control aborted
1.2 S 01nn Input invalid (control)
nn number of the last invalid input in the list of inputs (hexadecimal)
1.3 S 02nn Read data bloc: bloc doesnt exist
1.4 S 03nn Read data bloc: wrong length
1.5 S 04nn Read data bloc: wrong checksum
1.6 S 05nn Write data bloc: bloc doesnt exist
1.7 S 06nn Write data bloc: wrong length
1.8 S 07nn Write data bloc: error while writing EEPROM
nn number of data bloc (hexadecimal)
1.9 S0Enn Error codes application program
S 0E0D No application task found.
S 0E0E Fatal ERROR by searching application task !!
S 0E0F No PEARL-application-interface found.
S 0E10 Wrong PEARL-coded-application-interface found.
Please use newer system-EPROM !!
Expected system-EPROM >= (Versionsnummer)
S 0E11 PAT-ME2:
Wrong PEARL-coded-application-interface found.
Please use data-EPROM linked for Modular ECIS.
Data-EPROM was linked for Console ECIS.
Konsole2:
Wrong PEARL-coded-application-interface found.
Please use data-EPROM linked for Console ECIS.
Data-EPROM was linked for Modular ECIS.
S 0E12 No C-application-interface found.
S 0E13 Wrong C-coded-application-interface found.
Please use newer system-EPROM !!
Expected system-EPROM >= (Versionsnummer)
S 0E14 PAT-ME2:
Wrong C-coded-application-interface found.
Please use data-EPROM linked for Modular ECIS.
Data-EPROM was linked for Console ECIS.
Konsole2:
Wrong C-coded-application-interface found.
Please use data-EPROM linked for Console ECIS.
Data-EPROM was linked for Modular ECIS.

SVE-Errors
Error_T B13 B14 B15 B16 B17
00 0 0 0 0 0
01 0 0 0 0 1
02 0 0 0 1 0
03 0 0 0 1 1
04 0 0 1 0 0
05 0 0 1 0 1
06 0 0 1 1 0
07 0 0 1 1 1
08 0 1 0 0 0
09 0 1 0 0 1
10 0 1 0 1 0
11 0 1 0 1 1
21 1 0 1 0 1
22 1 0 1 1 0
23 1 0 1 1 1
25 1 1 0 0 1
26 1 1 0 1 0
27 1 1 0 1 1
29 1 1 1 0 1
30 1 1 1 1 0
31 1 1 1 1 1
Technical Training PDC
Seven Segment Display
PDC\7SEGMENTE DISPLAY E.DOC TECHNICAL TRAINING 1
General
With normal operating conditions the six outer segments will be lit one after the
other in anticlockwise direction.
In case of a malfunction error messages from the local I/O ( PPBus) and the display
and keyboard driver only are displayed.
E = with 6 digits following is the sequence of the display for error messages.
A = with 6 digits following is the sequence of the display for non-error messages.
The 6 digits are devided logically into 3 groups. The following tables are explaining
the code of these groups.
Example
E = 06 01 02 is on display
Decoding
E is an error message
Group 1 06 something with a Local IO Digital output card is wrong
Group 2 01 device malfunction or device is missing
Group 3 02 card number 2
That means that card number 2 in the configuration - a digital output card - doesn't
work or is missing.
Group 1
source or creator of the message
decoding of possible display:
00 Control (S5) in general
01 Control (S5) Input invalid
02 CPU- Card
03 Operating system RTOS-UH
04 Profibus
05 Local IO in general
06 Local IO Digital output card
07 Local IO Digital input card
08 Local IO Analogue output card
09 Local IO Analogue input card
0A Local IO Winch counter card
0C LMI
0D Keyboard/Display
0E Systemstart after booting of operating system RTOS-UH
0F Software interface LMI/LMI-Display
FF Unknown Message source
Group 2
message group
General
01 device malfunction or device missing
02 error in configuration
03 CRC-error
04 memory corrupted
05 not enough or too many interrupts
06 device missing to the configurated port
07 port double configurated
08 wrong portnumber
09 calibration failed
0A EEPROM defective or wrong data in EEPROM
0B parameter error in program
0C error in general PPBUS-parameters in configuration
0D no application found
0E error while loading an application
0F no PEARL-interface found (= error in DATA-EPROM's)
10 wrong versionnumber of the PEARL-interface
11 wrong identifier for hardware-version of the PEARL-interface
12 no C-interface found
13 wrong version number of the C-interface
14 wrong identifier for hardware version of the C-interface
15 operating mode table found of the wrong type
16 error in DPRAM
17 wrong version
18 device reports an error
19 corrupted report from a device
FF unknown message group
Group 3
Message number
The meaning of the message number depends on the codes of group 1 and 2 and
gives only further information about the message. So the main information is
kept in the codes of group 1 and 2.
If a code for group 3 is not given here, it usually does not have any important
meaning.
For group 1 codes 05 to 0A (local I/O) message number has the following
meaning:
Group 2 Codes 01, 02, 05-07, 09, 0A: message number is the number of the
local I/O card. Attention, counting starts with 0 (an not with 1) . .
Group 2 code 08: message number is the number of the invalid port or invalid
number of ports in the configuration.
Group 2 code 0C: message number specifies what's wrong in the general
parameters for the PPBus
16: Address specification in configuration doesn't fit to the
A16-mode
24: Address specification in configuration doesn't fit to the
A24-mode
FE: Invalid interrupt vector in configuration
FF: access mode in configuration is wrong (not A16 and not
A24)
For group 1 code 0D and group 2 code 01, group 3 code is the number of the
defective device, where 7 is the display and 1 is the separated keyboard.
3
Description of buttons
Startbild: Bildmodul 000 Buttons:
LOGO.BMP
1: not used
2: not used
3: not used
4: not used
5: not used
6: Buzzer off
7: not used
8: not used
Sprachauswahl: Bildmodul 002
SPRACH.BMP
no buttons available
4
Hauptmen: Bildmodul 010
LMB_T.BMP LMB_R.BMP
LMB_G.BMP
5
Tastenebene 1 - Bildmodul 010 Funktionstasten:
EBENE_1.BMP
1: Switching from level 1 to level S
2: Switching to next level
3: not used
4: Switching to length selection
5: Switching to load chart
6: Buzzer off
7: Tara button
8: Change operating mode/reeving
Tastenebene 2 - Bildmodul 010 Funktionstasten:
EBENE_2.BMP
1: Switching to next lower level
2: Switching to next higher level
3: Telescope display
4: not used
5: Speed swing/hoist/derricking
6: Buzzer off
7: Small display of relative radius
8: Zoomof current display

Tastenebene S - Bildmodul 010 Funktionstasten:
EBENE_S.BMP
1: not used
2: Switching to level1
3: Parameter adjustment
4: Switching to bus overview
5: Switching to service screen
6: Switching to language adjustment
7: Set time
8: Invert screen
6
Geschwindigkeiten: Bildmodul 024 Funktionstasten:
GESCHW.BMP
1: not used
2: not used
3: not used
4: not used
5: not used
6: Buzzer off
7: not used
8: Back to main screen
Betriebsartanwahl: Bildmodul 040 Funktionstasten:
BAVORW.BMP
1: Enter operating mode
2: Menu prompt operating mode
3: not used
4: Change reeving
5: not used
6: Buzzer off
7: not used
7
Traglasttabelle: Bildmodul 042 Funktionstasten:
TLT.BMP
1: not used
2: not used
3: not used
4: not used
5: not used
6: Buzzer off
7: not used
Lngencodeanwahl: Bildmodul 044 Funktionstasten:
LKANW.BMP
1: Selection- previous length code
2: Selection- next length code
3: Changelength code
4: not used
5: not used
6: Buzzer off
7: not used
8
Teleskopiergeschwindigkeit: Bildmodul 046 Funktionstasten:
TELE_GE.BMP
1: not used
2: not used
3: not used
4: not used
5: not used
6: Buzzer off
7: not used
Bussystembersicht: Bildmodul 050 Funktionstasten:
BUS.BMP
1: Switching to information local I/O-module
2: not used
3: not used
4: not used
5: not used
6: Buzzer off
7: not used
9
Businformationen: Bildmodul 052 Funktionstasten:
MBUSINF.BMP
1: not used
2: not used
3: not used
4: not used
5: not used
6: Buzzer off
7: not used
8: Back to previous screen
bersicht Digitaleingnge SVE: Bildmodul 058 Funktionstasten:
SVE.BMP
1: not used
2: not used
3: not used
4: not used
5: not used
6: Buzzer off
7: not used
8: Back to service screen
10
Digitaleingnge: Bildmodul 060 Funktionstasten:
A704.BMP
1: Overview analog inputs
2: not used
3: Overview digital outputs
4: not used
5: Overview digital inputs module A706
6: Buzzer off
A706.BMP
1: bersicht Analogeingnge
2: frei
3: bersicht Digitalausgnge
4: bersicht Digitaleingnge Karte A704
5: frei
6: Hupe aus
7: bersicht Digitaleingnge Karte A707
8: Zurck zur Service Menauswahl
11
A707.BMP
2: not used
6: Buzzer off
7: not used
Digitalausgnge: Bildmodul 066 Funktionstasten:
A705.BMP
2: Overview digital inputs
3: not used
4: not used
5: Overview digital outputs module A708
6: Buzzer off
7: not used
12
Digitalausgnge: Bildmodul 068 Funktionstasten:
A708.BMP
2: bersicht digital inputs
3: not used
4: Overview digital outputs Module A705
5: not used
6: Buzzer off
7: not used
Analogeingnge: Bildmodul 070 Funktionstasten:
A710.BMP
1: not used
2: Overview Digital inputs
3: Overview Digital outputs
4: not used
5: not used
6: Buzzer off
7: not used
13
Analogausgnge: Bildmodul 072 Funktionstasten:
A711.BMP
2: Overview digital inputs
4: Overview SVE
5: Overview J oysticks
6: Buzzer off
7: Overview of values calculated from the SLI

bersicht: Bildmodul 074 Funktionstasten:
M_A711.BMP
1: not used
2: not used
3: not used
4: not used
5: not used
6: Buzzer off
7: not used
14
SVE bersicht: Bildmodul 076 Funktionstasten:
SVE_UEBERS.BMP
1: Manually unlock SVE
2: Manual operation of SVE
4: Overview SVE
5: Manually unpin SVE
6: Buzzer off

15
Nullpunkt Ausladung setzen: Bildmodul 080 Funktionstasten:
SETNULLP.BMP
1: not used
2: not used
3: not used
4: Set zero point
5: not used
6: Buzzer off
7: not used
Nach Datengruppe A: Bildmodul 100 Funktionstasten:
DATA_A.BMP
1: not used
2: not used
3: not used
4: not used
5: not used
6: Buzzer off
7: not used
8: Back to previous screen
16
Analogeingnge SVE: Bildmodul 110 Funktionstasten:
AIN_SVE.BMP
1: not used
2: not used
3: Switching to SVE overview
4: not used
5: not used
6: Buzzer off

17
Description of symbols
Bus error - more information in screen
Error SLI
Time
Operating mode
Actual reeving
Actual length code
Error in control system

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8331.

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