Liebherr Crane Control Load Sensing with LICCON Electro-Hydraulic Regulation Service Manual

Service-Manual Crane control Load Sensing with LICCON Electro-hydraulic regulation

slewing

telescoping

hoisting

luffing

oil pressure supply

Control block LS

Liccon

LS-pressure

var. displ. pump/s

P-pressure

899516108

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Crane control - LICCON / Load Sensing OW10 Electro-hydraulic regulation Table of contents Simplified functional diagram .......................................................................................... 4 General fundamentals on the electro-hydr. Load-Sensing system .................................. 5 Principal diagram of the entire function (example: LTM 1080/1) ..................................... 6 Functional principal - Load Sensing with Liccon crane control ........................................ 7 Principal diagram on the activation of the variable displacement pump/s (Liebherr) ...... 8 Description of the activation of the variable displacement pump/s (Liebherr) ................. 9 Principal diagram on the activation of the valve units (Barmag/Bucher) ....................... 10 Description of the activation of the valve units (Barmag/Bucher) .................................. 11 Principal diagram on the Liccon Load-Sensing regulation (Liebherr) ............................ 12 Description of the Liccon Load-Sensing regulation (Liebherr) ...................................... 13 Description (fundamentals) of the Load-Sensing regulator (Liccon-ZE 2)..................... 15 Test and adjustment of LS control (only LTM 1090/2 and 1120/1) Flow diagram on test sequence, basic adjustment / initial current pumps .................... 27 Checking and adjusting Diesel engine idling speed ...................................................... 28 Checking pressure sensors (DA) „P and LS“ values .................................................... 28 Checking mechanic pump zero position (Q-min) .......................................................... 29 Checking control oil pressure supply ............................................................................. 29 Checking/adjusting basic adjustment pump regulator ................................................... 30 Checking/adjusting initial current pump regulation (P1/P2) ........................................... 31 Flow diagram on test sequence, final current pump variation ....................................... 33 Checking/adjusting final current pump regulation (P1/P2) ............................................ 34 Procedure for modification of initial and final currents .................................................. 36 Short instructions for manual test and adjustment on crane types LTM 1055/1, 1060/2, 1080/1, 1090/2, 1090/3, 1100/2, 1120/1 and 1150/1 Test and adjustment insructions for LS control ............................................................. 39 Outline on adjustment/setting values on LS pums and LS control blocks Adjustment/setting values on LS pump and LS control block on the LTM 1055/1 ........ 45 Adjustment/setting values on LS pump and LS control block on the LTM 1060/2 ........ 50 Adjustment/setting values on LS pump and LS control block on the LTM 1080/1 ........ 55 Adjustment/setting values on LS pump and LS control block on the LTM 1090/2 ........ 60 Adjustment/setting values on LS pump and LS control block on the LTM 1090/3 ........ 65 Adjustment/setting values on LS pump and LS control block on the LTM 1100/2 ......... 70 Adjustment/setting values on LS pump and LS control block on the LTM 1120/1 ......... 75 Adjustm./set. values on LS pump and control block on the LTM 1120/1, from Muli 20 .. 80 Adjustment/setting values on LS pump and control block block on the LTM 1150/1 ..... 85 Liebherr-Werk Ehingen GmbH Kundendienst: juh1 / july-2004

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Crane control - LICCON / Load Sensing OW10 Electro-hydraulic regulation

Liebherr-Werk Ehingen GmbH Kundendienst: juh1 / july-2004

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Crane control - LICCON / Load Sensing OW10 Electro-hydraulic regulation Table of contents LS Control, autom., checking-adjusting by setting programs Setting assistance for the LTM 1090/3 .......................................................................... 91 Description of hydraulic pumps Set up and function - double variable displacement pump LPVD 100 EL/DA ............. 109 Set up and function - variable displacement pump LPV 140 (only LTM 1055/1) ......... 113 Set up and function - variable displacement pump A11 V0 (only LTM 1060/2) ........... 121 Outline on Load-Sensing (LS) control blocks ........................................................ 125 LS control block (Bucher/Barmag) on the LTM 1055/2 ............................................... 126 LS control block (Rexroth) on the LTM 1060/2 ............................................................ 128 LS control block (Bucher/Barmag) on the LTM 1080/1 ............................................... 130 LS control block (Bucher/Barmag) on the LTM 1090/2 ............................................... 132 LS control block (Bucher/Barmag) on the LTM 1090/3 ............................................... 134 LS control block (Bucher/Barmag) on the LTM 1100/2 ................................................ 136 LS control block (Bucher/Barmag) on the LTM 1120/1 ................................................ 138 LS control block (Bucher/Barmag) on the LTM 1120/1 ................................................ 140

Edition: Juli 2004

Liebherr-Werk Ehingen GmbH Kundendienst: juh1 / july-2004

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Liebherr-Werk Ehingen GmbH

Kundendienst: juh1 / july-2004

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electriic connection working pressure LS - pressure signal P - pressure signal P - pressure

distribution valve block

shuttle valves

crane functions

pressure sensor P

pressure sensor LS

Liccon control

master switch

variable displacement pump(s))

monitor

Crane control - LICCON / Load Sensing

OW10 Electro-hydraulic regulation Electro-hydraulic „Load-Sensing system“

Simplified representation:

Crane control - LICCON / Load Sensing OW10 Electro-hydraulic regulation Electro-hydraulic „Load-Sensing system“ General fundamentals On the electro-hydraulic Load-Sensing system, the variable displacement pump and the distributing valve block are activated or regulated electronically by the LICCON control.

The electronically regulated Load-Sensing control has the function, to maintain a fixed (programmed) pressure difference ∆ p of e.g. 20 or. 40 bar (subject to the version) between pump pressure (P) and load pressure (LS) constant as far as possible.

For the acquisition of both pressures a pressure sensor is installed into the P- circuit and a pressure sensor into the LS-circuit and electrically connected with the LICCON control.

The pump pressure (P) is acquired before the distributing valve and the load pressure (LS) after the distributing valve (with the highest load pressure) in the control block.

LICCON control and pump ensure an e.g. 20 bar differential pressures before Process: the valve block.

The feeding volume of the pump is controlled continuously by the pressure difference ∆ p and regulated by the LICCON control.

This means:

P = 20bar LS = 0bar (at none activated working movement)

pressure sensor LS distributing valve

pressure sensor P

sectional pressure balance

Liebherr-Werk Ehingen GmbH Kundendienst: juh1 / july-2004

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Liebherr-Werk Ehingen GmbH

Kundendienst: juh1 / july-2004

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-Y5

-Y10

-Y6a

-Y1a

-Y4a

electric control

M-LS

-B12

-Y3

M-P1

-B11

- Y49

control line telesc. ram „retracting“ control line lowering brake

working line telesc. ram and release of telesc. sections

-Y6b

-Y1b

control bloc LS

-S 49

hoist winch

-Y4b

pump pressure line control pressure line load signal line

lowering brake valve

pressure sensor (-B2)

luffing ram

Elemetary diagramm

M-P

pump 1

pump 2

gear pump

-Y106

Variable displ.. pump Liebherr-LPVD 100

-Y105

central units

working line telesc. ram „out“, hoist gear„lowering“ working line telesc. ram „in“, hoist gear „lifting“,luffing ram „extension“

M-A2

-Y38

telesc. ram

Crane control (example: LTM 1080/1) with electrohydr. Load Sensing System

Crane control - LICCON / Load Sensing

OW10 Electro-hydraulic regulation

Crane control - LICCON / Load Sensing OW10 Electro-hydraulic regulation Electro-hydraulic „Load-Sensing system“ Functional principle of the Load Sensing System with LICCON control At the load sensing system, the Liebherr variable displacement pumps (LPVD) and the Barmag directional valves are activated or controlled by the Liccon control (ZE 2).

The Liccon control takes place via an electron. controller (on CU 2) dependent on the control signals of the master switches and on the actual service condition signals such as pump pressure, load pressure signal and engine speed.

The control of the proportional directional control valves on the valve units is performed within the first controller circuit, while the control of the proportional pressure regulators on the variable displacement pumps takes place within the second controller circuit (see also description of the block diagram, load sensing controllers).

In case of the load sensing system, the load pressure signal (consumer with the highest load) is transmitted by a load pressure sensor (LS), via the Liccon control, to the control valves of the pumps. This ensures the control of the pump variation angles to adapt the feeding flow to the requirement of the consumers via the respective directional control valves and to maintain the pressure difference necessary on the pilot pistons of the directional control valves.

The service pressure adapts itself automatically to the load pressure during that process.

When the maximum service pressure (of a function) is attained, the feeding flow to the consumer with the highest working pressure is limited by a pressure relief valve in conjunction with a sectional pressure balance (see description, directional control valves Barmag).

If the feeding volume necessary is not attained during the control of various consumers, the pilot piston or the directional control valve of the fastest working motion is reset automatically by the Liccon control.

In order to guarantee a load-independent control of the consumers, a sectional pressure balance (inflow pressure balance) is connected with each directional control valve. The pressure balance piston retains the balance or the pressure difference of the consumer pressure and the pump pressure on the corresponding pressure balance. That ensures that even the consumer with the highest load pressure is supplied with oil, or it prevents that not only consumers with low load pressure (reduced resistance) are supplied with oil. For more details, refer to description valve units (Barmag).

Liebherr-Werk Ehingen GmbH Kundendienst: juh1 / july-2004

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Crane control - LICCON / Load Sensing OW10 Electro-hydraulic regulation Elementary diagram for control of the double variable displacement pump LPVD example: on LTM 1080/1

Inductive electron. pressure pressure sensor controller sensor sensor engine „LS“ (ZE2) „P“ speed

Sitzkontakt Schalter

control dir. contr. valves

control pump

Liccon central unit

load pressure signal (LS) pump pressure signal (P1,P2)

M-Px (120bar)

Ma2

control valve pump 2 (-Y106)

4 A1

A2

7 Fa

2 1

Ma1

M-Px 45bar (100bar)

P

control valve Pump 1 (-Y105)

3

M-P

Filter Hydr. diagram for Pos. 3

P1 10 BAR

P2

NORMALBETRIEB

=D+D2 -Y38

A

NOTBETRIEB A3 PUMPE 1

A2

A1

PUMPE 2

2

P V6

=F+F3-Y105

V8

=F+F3-Y106

3 bar

V2

105 bar

V7

30 bar 45 bar

M-P

Ma2

Ma1

V1

V5

100 bar

7

A2

T2

T1

A1

355 bar

355 bar

Fa T5

4

S

Hydr. diagram for Pos. 1 Liebherr-Werk Ehingen GmbH Kundendienst: juh1 / july-2004

M-Px (45 bar)

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Filter

1 double var. displ. pump (Liebherr - LPVD) 2 control pump 3 valve block contr. pressure 4 pressure relief valve (45 bar)

Crane control - LICCON / Load Sensing OW10 Electro-hydraulic regulation Electro-hydraulic „Load-Sensing system“ Description of the control – variable displacement pumps (1+2) The pressure control valves on the pumps 1+2 control proportionally to the electr. control, the control pressure (pump variation pressure) applied to the pressure control valves (-y31/-y32).

The supply of the control pressure is realized by a separate control pressure pump (Px = approx. 45 bar) during idling of the pump (control valves without current) and minimum variation position of the pump (electr. control approx. 200 – 220 mA).

In case of a pressure build-up in the P line (pump 1 / 2) above approx. 45 bar, the control pressure oil circuit (pump control pressure) is fed by pump pressure oil circuit (P1/P2).

The pump control pressure can be tested at measuring point ”Ma1” (pump 1) and ”Ma2” (pump 2).

Note: a)The variable displacement pumps deliver (at idling speed and electrically non controlled) a circulation pressure of approx. 4 -8 bar to compensate for the overflow oil volume. b)At the start of the Diesel engine (= control ON), the variable displacement pumps (P1/ P2) are activated by means of the Liccon control with approx. 180 mA which increases the pump circulation pressure to approx. 14 - 18 bar. c) Further details in respect to the double variable displacement pump LVD – see separate description.

Outline on pump regulation (delta-p) on the LTM 1090/2: • from crane no. 1, the pressure difference (delta-p) is = 40 bar • from crane series 60 (from crane no. 025064), the pressure difference (delta-p) is = 20 bar on the LTM 1120/1: • from crane no. 1, the pressure difference (delta-p) is = 40 bar • from crane series 25 (from crane no. 023733), the pressure difference (delta-p) is = 20 bar on crane types - LTM 1055/1, 1060/2, 1080/1, 1090/3, 1100/2 and 1150/1 • always from crane no. 1, the pressure difference (delta-p) is = 20 bar

Liebherr-Werk Ehingen GmbH Kundendienst: juh1 / july-2004

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Crane control - LICCON / Load Sensing OW10 Electro-hydraulic regulation Elementary diagram for control of the valve units (dir. control valves Barmag)

control pump

Sitzkontakt Schalter

control dir. contr. valves

Inductive electron. pressure pressure sensor controller sensor sensor engine „LS“ (ZE2) „P“ speed

Liccon central unit

pump pressure signal (P1,P2)

load pressure signal (LS)

B3

OUT

Aus

IN

DUE 3 1.2

A

B

b

IN

305 bar

A2

DOWN

UP

B1 T

luffing UP

T

a

DUE 2 0,4

M-LS

=D+D2 -B11 P =

=D+D2 -B12 P =

Liebherr-Werk Ehingen GmbH Kundendienst: juh1 / july-2004

UP

P1

T1

XL

Y2 X

DUE Z 1.2

360 bar

DUE P 1.2

300 bar

A1

DUE 4 1.2

T

DOWN

DUE 3 1.2

UP

P

Auf

=D+D2 -Y4a

a

A

B

b

140 bar

Auf Ab

DUE 5 1.2

=D2+D2 -Y1a =D+D2 -Y4b

DUE 4 1.2

P

a

UP

hoist winch UP

DOWN

B2

telescoping extension

310 bar

A3

DUE 4 DUE 5 1.2 1.2 145 bar

Ein Ab

OUT

T

=D+D2 -Y6a =D+D2 -Y1b

a

P

A

DUE 3 1.2

B

T

b

=D+D2 -Y6b

P2

M-P

P1 - 10 -

Crane control - LICCON / Load Sensing OW10 Electro-hydraulic regulation Functional description of valve units (Barmag) - hoist gear, luffing and telescoping Description of pilot control of directional control valves The pilot control is performed by proportional valves (M1/M2) which are triggered by the programmed LICCON system.

The LICCON control depends on the control signals of the master switches and the message ”actual operating condition” (pump pressure, load pressure signal, engine speed).

Note: When initiating a working motion, the electr. control signal to the directional control valve M1 or M2 (pilot piston -1- will be extended) precedes the control signal to the pump.The control pressure (max. 320 bar) for actuation of the directional control valve is taken from the P line of the double variable displacement pump (e.g. LPVD 140).

In the neutral position of the pilot piston (6), the load signal line (5) to the reservoir is relieved.

Description of the control of the valve units (working pressure) 1. Working position – individual mode The actuation of the pilot piston (6) of a valve unit (section) results in the emission of the load pressure signal (5) to the sectional pressure balance (3) and via a shuttle valve chain (4) to the pressure sensor (LS) which transmits the load signal ”LS”, via the Liccon control, to the proportional control valves of the variable displacement pumps (P1/P2) (see also block diagram, load sensing controller).

The volume flow of the pump working pressure increases at the opened profile section (2) of pilot piston (6) until the differential pressure (Dp = approx. 40 bar or 20 bar) set by the Liccon control, is attained between the load pressure (LS) and the pump pressure (P).

2. Working position – parallel mode When activating additional or simultaneous actuation of various pilot pistons (6), the ”LS” pressure sensor receives the signal of the highest load pressure via the shuttle valve chain (4) and the pump pressure attains the respective value.

The pressure difference between the pump pressure and the lower working pressures of the remaining sections is compensated by the assigned pressure balances (3).

Example of control: In case of the represented functions (principle diagram), the following functions are triggered: Luffing, hoist winch UP and boom extension.

The load signal is given by function ”boom extension”.

Set-up - valve unit (Barmag) M1 dir. control valve (prop.)

M2 dir. control valve (prop.)

1 pilot piston 1.1 emergency pin 2 flow profile section 3 sectional pressure balance 4 shuttle valve (chain) 5 load pressure signal (LS) 6 main control piston (dir. contr. valve) 7 working pressure limiter valve Legend: pump pressure control pressure (control piston – dir. contr. valve)

1 M1

1.1 3 4

7 5

6

load pressure signal working pressure tank runback Liebherr-Werk Ehingen GmbH Kundendienst: juh1 / july-2004

M2

2 - 11 -

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