Professional Documents
Culture Documents
000
Global Presence.
Local Expertise.
www.hydac.com
Filter Technology 70.000
Components,
Systems and Service
Process Technology 77.000
HYDAC Headquarters
HYDAC Companies
HYDAC Sales and Service Partners
Accessories 61.000
Telephone:
+49 6897 509-01
Fax:
+49 6897 509-577
e-mail: info@hydac.com
Internet: www.hydac.com
E 10.123.2/12.16
E 10.123.2/12.16
Note
Cooling Systems 57.000
E 10.123.2/12.16
E 10.123.2/12.16
(3/4-way) with joystick (hydraulic or electrical)
zz Demand-controlled fan control (hydraulic & electrical)
zz Increasing use of additional joystick steering
(with 20 km/h approval/no road approval)
2 3 4
Energy efficient, System intelligence System development
safe, Electro-hydraulic system
comfortable.
Joysticks Display Additional input devices
Trackball Keypad Joystick
HYDAC offers a variety of components and systems that meet these requirements and fulfil your
demands. In addition to standard components, HYDAC offers a comprehensive modular system Pedals Sensors Suspension EEC
designed for wheel loader applications. Furthermore, HYDAC will also work with you to develop a Diesel engine
jobs
E 10.123.2/12.16
E 10.123.2/12.16
zzControl blocks (monoblock/sandwich) HYDAC offers extensive consultation and support for customer projects with regard to:
zzPilot and primary control systems zz Hazard and risk (H&R) analysis
zz NoX See catalogue 18.500 – Control Technology for Mobile Machinery zz Definition and description of safety functions
ÖÖCompliance with the Emissions Directive zzIntelligent axes
See catalogue 180.000 – Electronic Product Catalogue zz Drafting safe system architectures and user interfaces (HMIs)
ÖÖReduced nitrogen oxide and zzCylinders, pumps and motors
CO2 emissions 6 7 8
"MATCH" development environment Sensors, system electronics
and control systems.
Mobile Application Tool Chain
Development environment for mobile working machines
Solutions perfectly tailored to the
System Definition Software Development
Application Programming
Commissioning / Validation & System Tests
Vehicle Level
application – all from a single source.
(ECU w/ *.hex)
“Standard” Application
Download hex File
IDE
Service
Config
Requirements, Use-/Test-Cases Software Frame
Auto Code Builder (ACB)
Test
Diagnostics,
Commissioning
Machine Error Definitions Complete System Definition
Test
Drivers (sensors, valves, …)
Unit & Test & Simulation Environment
Controller HW & I/O Definitions Test Frame Integration Remote Control Test Bench, SIL, Integration
Testing and Unit Tests, (Automated) Test Scripts
Functional Safety
Docu
Docu
Docu
PL d
SIL 2
Documentation
Linear position/distance sensors Inclination and angle sensors
Mobile Application Tool Chain
With the "MATCH" (Mobile Application Tool Chain) development environment, HYDAC offers a
tool chain for system-level software development by the customer that is specially suited to the
requirements of mobile machinery. "MATCH" supports development from defining the system at the
vehicle level and creating the application software to start-up, testing, and documentation. Functional Safety
Functional Safety
PL d
Functional Safety
PL d PL c
SIL 2 SIL 2
"MATCH" offers modules for:
Pressure transducers/ Sensors for increased functional e.g.: controller series, e.g. HY-TTC 77 and HY-TTC 500 HY-TTC 30X Displays with integrated HY-eVision² controller
zz Defining the system at the vehicle level pressure measurement switches safety requirements
(e. g. PL d, SIL 2)
zz Starting up and servicing the machine
zz The software test (e.g. on basis of HYDAC Electronic RTB Box) Sensors Mobile controller I/O Expansion Module Mobile display
zz Documentation
HY-TTC series HY-TTC 30X / 30XS HY-TTC eVision²
Furthermore, an "embedded Middle Ware" is offered which permits a hardware-independent
programming of the application and which contains a multitude of basic functions. A comprehensive Function Function Function Function
selection of library modules (e.g. for sensor and valve drives) is also available for an efficient
E 10.123.2/12.16
E 10.123.2/12.16
zz Transfer functions/signal elements
Special error modules can also be used to detect system errors.
See catalogue 18.500 –
See catalogue 180.000 – Electronic Product Catalogue Control Technology for Mobile Machinery See catalogue 18.500 – Control Technology for Mobile Machinery
9 10 11
Hydraulic systems HYDAC variable Our directional control valves
HYDAC's open center directional control valves offer you a modular 11 11 Optionally, our electro-hydraulic
system with robust, energy efficient and cost-effective solutions for 2 HYDAC fixed displacement additional steering systems
can enable you to put together
2
mechanical, pneumatic, hydraulic and electro-hydraulic controls. pumps are used to supply
secondary circuits and for 1
L R
L R 12 all-wheel steering types with
Features: pilot pressure supply. 2 3
C1
various steering modes, above
RS 160
In special combination, A C2
all for excavators and swivel
zz Available in monoblock, multi-section and sectional designs
T LS P
Open center directional control valve
zz Key data: Qmax ≤ 180 l/min; pmax = 350/420 bar
they are also suitable for B
15 T P loaders. For larger wheel
electro-hydraulic fan T A1 A2 loaders and industrial loaders,
zz Energy efficient Q-inlet option control. They are also A T1
N T P we can also realise additional
zz Robust, high quality and maximum controllability available as multiple-pump joystick control with our steering
combinations. systems.
zz Low internal leakage P
T3 PM A B A B A B T2
10 12 M
13
TPumpe
B C
L P
T
zz Optionally also for use with LS variable displacement pumps with hydrostatic steering or the vehicle braking
A
1
2
1
system.
2
transmission drive. Via the
1
2
integrated thermo-bypass, 8
P
excessively warm oil can 6 7
be channelled to the cooler
Key data for open center directional control valves (see photos on right): directly before it passes 13 For medium-sized wheel loaders
through the filter and and larger, we can alternatively
zz RS 160 directional control valve ÖÖQmax= 60 l/min; pmax= 250 bar
DX-6
enters the tank. Thanks to 9 provide our motor-pump
zz RS 210 directional control valve ÖÖQmax= 70 l/min; pmax= 300 bar the built-in counter-balance assembly (DC1) for emergency
Open center directional control valve
valve, a slight overpressure SP A T steering supply. The assembly
zz DX-6 directional control valve ÖÖQmax= 140 l/min; pmax= 350 bar
B
2
pressure cut-off that is ready for
the intake characteristics of M installation, available in a 12-volt
1 3 3 1
1
2
1
the connected pumps 2
or 24-volt version. An integrated
2
2
2
1
2
VA
system with which to design load-compensated, energy efficient 14 The hydropneumatic hoist
4 The fillers/breathers P VSt
stabilising unit (HSE) is used
load-sensing controls for mechanical, pneumatic, hydraulic and (ELF/BF) are important
electro-hydraulic controls. to hydraulically decouple the
components in all hydraulic hoist (boom) from the front
systems. They ensure that carriage of the wheel loader,
Features: LX-6
filtered air always reaches
Load-sensing directional control valve preventing pitching vibrations
zz Multi-section and sectional designs the tank in the event of oil
level fluctuations. They 5 from occurring during transport
zz Key data: Qmax ≤ 180 l/min; pmax = 350/420 bar journeys. It can be adjusted to
also prevent oil from suit any machine and any load
zz Extra-long 10 mm spool stroke for high-precision control
escaping unchecked during conditions. This allows it to
zz Independent of the load, parallel operation is possible without mutual off-road driving (integral significantly increase the driving
interaction baffle). stability, steering performance
zz Simple integration of secondary valves and overall driving safety of the
zz Inlet selector for safe flow distribution wheel loader. Various systems
can be provided, depending on
zz Electrical shut-off of pump flow
the wheel loader size.
zz Optional spool position indication of the main spool control 5 Accessories specially 6 Mobile cooler combinations 7 The fan drives can be realised on the Priority valves (MPV) are 9 Pilot control manifolds are used to
HX-1 8 needed to distribute flow, with
designed for various tanks, (CMS) for demand-driven basis of electric or electro-hydraulic supply hydraulic joysticks and other
zz Possible to shutdown individual sections whilst maintaining full Load-sensing
such as fluid level gauges, cooling of all kinds of media controls for the speed control of one function given priority low-pressure applications in wheel
functionality in remaining sections directional control valve
clamping bands, clamps of circuits (water, oil, charge air, the fan motor. To prevent any drop and the remaining flow made loaders. They can optionally be fitted
various designs and ball diesel, etc.). Available in cooler power, reversing can be available to other actuators. A with a diaphragm accumulator 15 6/2-way selector valves are
typical application for priority used for additional control of
valves. customised to suit individual optionally integrated to change the (to safeguard emergency function)
supply is a braking system or a further actuators from one single
requirements and installation fan’s rotation direction, to enable the and a pressure filter.
steering system. oil supply. Particularly used
Key data for load-sensing directional control valves (see photos on right): conditions, and as extra/retrofit cooler fins to be “purged”. In combination with low-pressure
in retrofits for quick couplers
cooler. valves, additional actuators can be
or multi-function attachments
zz HX-1 load-sensing directional control valve ÖÖQmax= 120/35 (prop) l/min; pmax= 250 bar controlled, such as safety shutdown
(such as sweepers, high-tipping
and parking brake.
E 10.123.2/12.16
zz LX-6 load-sensing directional control valve ÖÖQmax= 180 l/min; pmax= 350 bar buckets, bottom-dump or
E 10.123.2/12.16
E 10.123.2/12.16
grapple buckets and rotating
LX-6 + HX-1 gripper jaws).
See brochure no. 5.254 – Mobile Valves Directional control valve combination-kit Available in various power
See brochure 5.256 - HX1 ranges.
12 13 14
Focus on energy efficiency Applications
for wheel loader functions
Hydraulic start-stop technology We offer you different solutions for the various primary and auxiliary functions of your wheel loader.
2
it is often useful to have the option of 3-way proportional valve specially designed for adjustable- to be combined in one space-saving unit that is optimised for of either a manifold with an adequately large accumulator
of functions performed by the valves increases, reducing emergency override connection.
adjusting the accumulator solutions to system pressure limiting in mechanical driving gears and the installation space. L R volume or a DC pump unit to supply the steering valves.
size and weight. Like the slip-in proportional pressure converter drives 1 The result is a precision controllability. L R
suit the particular wheel loader. HYDAC Safeguarding the Hose lines and pipes can be shortened or eliminated and Our emergency steering unit (DC1) is an integrated motor-
reducing valves specially developed for pilot circuits, Advantages:
provides the perfect resources for this, wheel loader hoist by
2
zz Maximum pressure setting with high mechanical precision the plasticC1tank, which also functions as a fan casing, can be pump assembly that is supplied ready for installation, with a
which are used for all axles and controlled directly via the 2 3
with its wide variety of diaphragm accu- means of pressure zz Back-pressures from the coolant circuit have no effect on zz Low hysteresis and high resolution due to innovative designed to optimise air flow. temperature switch to protect it from overload. Thanks to its
joystick. Or the “mini-valves” that can handle flow rates of
mulator nominal volumes. For long and relief & check valve the pressure setting (also DB10SE/SPE) manual
A emergency override connection C2 compact
P design, it requires little space.
up to max. 20 l/min. Furthermore, this design has resulted in additional noise T LS
narrow installation spaces, for example, DBRV16P
The following classic functions can be controlled: zz Boost function: possible for higher torques zz Flow-optimised valve design reduction.
piston accumulators from the SK280 1 B T P
Technical data:
series can be utilised to create perfect zz Supplying hydr. joystick control zz pmax = 100 bar, Qmax = 120 l/min zz Compact design All in all, we have a compact, powerful and low-noise module
packaging.
T
zz Sections with symmetrical design (hand levers can be A1 with
A2 charge air, oil and coolant cooler, with the oil tank zz DC = 12 / 24 V
zz Switching off pilot circuit/joystick integrated with all functions such as the filling level display,
DB10SE and DB10SPE pressure relief valves with flat mounted on A or B side) zz P = 50 to 250 bar A T1
zz Proportional control of additional circuits breather filter and return line suction filter.
performance curve zz Electro-hydraulic operation available with or without zz Qmax = 18 l/min
zz 2nd speed change-over, disabling axles, etc. Quick-coupler control with one single manual emergency override
zz Ideal for clutch applications zz Pnom = 2.2 kW
zz Various cylinder actuating functions, support, etc. valve: WKDR10YP zz End plate with internal or external pilot oil supply Technical data:
(pressure directional spool valve) zz pmax = 350 bar, Qmax = 120 l/min zz Drive speed = 2500 rpm
P
A B A B A B
T
E 10.123.2/12.16
E 10.123.2/12.16
E 10.123.2/12.16
zz Very good behaviour in cold oil
A
1
2
1
zz High flow rates for direct-acting valves
2
B
2 4 Accumulator block for emergency steering supply
1
2
Pressure sensors zz pmax = 60 bar, Qmax = 100 l/min
See brochure 5.307 – DC1 Compact Power Units
P
3 1
Example circuit diagram
16 See brochure 5.300 – Product Overview, Compact Hydraulics See brochure no. 5.254 – Mobile Valves 17 18
Hoist suspension Hydro-pneumatic cab
suspension
Hydraulic supply
The hoist stabilising units from the HSE series, The specifications set down by the European Vibration Optimal solutions from the
HYDAC technology platform.
in combination with diaphragm and piston accumulators, Directive 2002/44/EC and the German Noise and
reduce the pitching vibrations in the wheel loader. Vibration Safety and Health at Work Ordinance
Depending on the size of the HSE units, they are equipped with (LärmVibrationsArbSchV) limit the permissible exposure
valves for load-pressure adjustment and turning on the lifting values and action values for whole-body vibrations
cylinder of the wheel loader. The units are available in the sizes affecting the machine operator.
HSE-10 to HSE-16, depending on the lifting cylinder sizes. The current solutions involving elastic cab bearings are
only able to reduce the higher frequencies of engine
vibrations. Reducing the accelerations in the low-
frequency vibration range can only be achieved by cab
suspension systems with floating bearings. We supply
hydropneumatic cab suspension units adjusted to suit the
various cab weights. Depending on the design and the
version, the units are equipped with fixed, switchable or
proportionally controllable damping devices for various Plastic tanks
application types. The streamlined form with integrated
piston accumulator enables space-saving installation in
the pillars of the wheel loader cabs.
HSE-10 HSE-16
The HSE-SK400 units are made up of a piston accumulator and The reduction in whole-body
integrated pressure valves for load adjustment and switching on the vibrations inside the cab improves
the relative movements between RKM RFM MFX MDF ILF HFM BF ELF
spring damper units up to a permissible operating pressure of 400 PGE100 PGI100
bar. human and machine and the
comfort, efficiency and health Stat-Free®
protection for the machine operator. filter elements
HSE-SK400
Ecomicron®
LPF LPFP LFM DF MFM DFM PI Mobilemicron®
The reduction in pitching vibrations in the wheel loaders impro- PPV100S and PPV101 MGE102 Bladder, piston and diaphragm accumulators for mobile applications Fuel pump for diesel fuel Diesel PreCare filter Filters ≤ 100 bar Filters > 100 bar Air filters, filter elements and accessories
ves their driving stability. This makes it possible to achieve higher
transport speeds and material handling capacities. The diaphragm
and piston accumulator design and harmonised dimensioning of the
HSE valve series, from a single source, enables optimum adjust- Drive technology Accumulators Fuel pumps Diesel filtration Filtration
ment to suit the machine and the work application.
See brochure 10.116.8 - Hoist Stabilising Unit HSE-10 See brochure 10.116.6 - The pump range includes fixed and variable displacement pumps of HYDAC offers a wide product portfolio of accumulators and zz Fuel pump for diesel or hydraulic oil zz Suction-side pre-filter and water trap
See brochure 10.116.5 - Hoist Stabilising Unit HSE-16 FDE2 Cabin Suspension Element various designs from 0.25 ccm/rev to 560 ccm/rev and setting ranges dampers for a very wide array of hydraulic applications involving zz Flow rate zz Manual or automatic water discharge Our broad filter range offers inline filters (LF, MDF, DF) with Tank and filtration systems
of up to 400 bar. The motor range includes displacement motors from mobile machines. This enhances the working comfort and various pressure ratings and materials in addition to filler/ A comprehensive range of hydraulic and breather filters, fitted with
functionality of the machines and thus minimises stress for both -- Diesel: up to 80 l/min zz Option: water sensor, fuel pre-heater,
1.07 ccm/rev to 28.21 ccm/rev and a setting range of up to 300 bar. breathers (ELF) for the hydraulic tanks. We also have a broad high-quality filter element material ensures high operational safety and
humans and machines. manual/electrical filling/booster pump
Electro-hydraulic steering HYDAC fixed displacement pumps for auxiliary circuits and
Typical accumulator tasks and benefits resulting from them
-- Mineral oil: up to 15 l/min
zz Installation position optional zz Variants for diesel engines up to >3000 kW
range of in-tank return line filters (RF) and return line & suction
boost filters (RKM). Specially designed in-tank return elements
extended maintenance intervals, e.g.:
Return line / return line suction filtration
include: Guarantees the fuel purity required of modern common rail diesel engines (RMTR) offer good distribution of oil flow in the tank, highly
E 10.123.2/12.16
E 10.123.2/12.16
E 10.123.2/12.16
and HYDAC accumulators can be used worldwide with country- 16889.
steering system in the event of large external forces. from 1.07 ccm/rev to 28.21 ccm/rev and peak pressure up to 300 bar. specific acceptances. zz The practical flow rate can, for
Motor performance class [kW]
example, be measured at the
See catalogue 2.902.6 – Pump Overview wheel loader and then simulated See catalogue 70.000 - Fluid Filters
See brochure 10.116.9 – HY-Steer See catalogue 2.902.1 0 – Motor Specification See catalogue 30.000 – Accumulator Technology See Brochure 7.125 - Diesel PreCare on a 1:1 basis on the test bench. See brochure 10.777 - Filtration and Fluid Care
Electro-hydraulic auxiliary steering for all-wheel & crab steering
19 20 21 22
Cooling Additional solutions Fluid conditioning systems
Hydraulic oil cooling
Perfectly tailored to the To provide flexible servicing on machines,
there are convenient mobile units for Customer benefits:
Clean filling and flushing
Cylinder systems
monitoring, service and control concepts. A - Customer service
zz Non-return anti-cavitation valves variety of sensors - HYDAC Service
Oil Condition:
zz Manually adjustable pressure relief valves provides the ideal basis for the - HYDACLAB®
Our cylinder systems are notable for their
Communication
zz Inversely proportional pressure relief valves (fail-safe valves) development of such integrated Satellite HMG 4000
versatility and extreme compactness. We Customer benefits: system solutions.
Additional solutions
Mobile (SMS)
offer cylinder drives with integrated valve Our own Service Center offers you a Internet
Contamination:
technology and guarantee optimal operation of comprehensive customer service. Oil condition, e.g. time deterioration - CS 1000
your machine, even with increased operational We support you with the design, assembly, or presence of contaminating fluids
Hydraulic supply
loads: maintenance and commissioning of your can be determined via the saturation
zz Special mobile cylinders for large wheel system. We begin working closely with the level, temperature, change in electrical
loaders and mining wheel loaders, with customer right from the development stage. conductivity, change in dielectric constant
integrated distance measurement system Because of our knowledge, we can achieve (HYDACLAB®)
Cylinder with distance measuring system
and special coating for the forged piston rod. the best cylinder solution for your product,
Saturation level (AS)
e.g. by using special surface coatings for
zz Special suspension cylinders Particle contamination (CS)
the piston rod. FE simulations or fatigue
(low-friction design) Pressure (HDA)
strength calculations also come under our
zz Steering cylinder with integrated distance Engineering Standard. Flow rate (EVS) GSM modem GPS Joysticks Displays Keyboards Data storage
Proportional Selector valve measuring system Fluid level (ENS, HNT)
E 10.123.2/12.16
E 10.123.2/12.16
E 10.123.2/12.16
zz Telescopic and special cylinders In combination with portable measuring
Example of fan control application
Steering cylinder with integrated distance measuring instruments (HMG series), this data can be
The cylinders can also be designed with system recorded and analysed to supplement the See brochure 10.122 – Condition Monitoring for Efficient Life Cycle Cost Management, see
weight-optimisation, end cushioning or distance
See Brochure 5.315 - A Breath of Fresh Air in Electro-Hydraulic Cooling Control See brochure HS-D 10.102 – Cylinders and Cylinder Systems for Mobile Hydraulics machine electronics (service). catalogue 180.000 – Electronics Product Catalogue
measurement system.
23 24 25