for MobileHydraulics and CylinderSystems Hydraulic Cylinders

HS-E 10.102.0/02.15 Your Partner for Expertise. Cylinder solutions for all For cylinders and cylinder systems customer requirement in mobile applications

At a glance HYDROSAAR, part of the global Engineering expertise HYDAC group, develops and manufactures a broad range of hydraulic cylinders and cylinder systems for mobile applications. Development / design / strength calculation / testing Telescopic systems Drawing on our knowledge base, z Single-cylinder telescopic systems we develop the most appropriate To fulfil the stringent requirements hydraulic cylinder solution for required of the final product, we z Securing locking system your application. For example, employ the latest : z Telescopic guide system z 3D design innovative position sensor z Controller technology can be installed, or z Finite element calculation for the cylinder piston rods can be optimised design supplied with special surface z Structural analysis coatings. Our cylinder engineering z Non-linear stability calculations includes design and calculations z Structural durability analysis performed with cutting-edge 3D CAD and FE tools. Boom, outrigger and special cylinders Each cylinder is optimised individually to fulfil the customer’s Surface treatment processes z Weight-optimised, space-saving specific requirements. z Electroplating design z High-speed flame spraying and plasma z Integrated valve technology and Hydrosaar has been engaged sensors in mobile for more spraying (metallic and ceramic coatings) than a decade, supplying z Induction melting of compound layers global manufacturers of cranes, z Laser-welded and plasma-welded layers construction machinery, z Customised paint finishes (corrosivity agricultural and special- categories up to C5-M) purpose . Mining and excavator cylinders

z For high dynamic loads Lightweight z Structurally durable design z Weight-optimisation z Use of high-strength steel materials z Use of light metal and fibre-composite materials

Production capabilities: z Cylinder strokes up to 12,000 mm z Piston diameters up to 600 mm z Differential cylinders Functional safety – integrated sensors z Synchronising cylinders Suspension and The technical requirements with regard to accumulator z Plunger cylinders functional safety are based on the EN 954-1 EN 13849-1 IEC 62061 IEC 61508 z Telescopic cylinders standards IEC 61508 and EN 13849. cylinders

Machinery industry HYDAC provides: (electronics, hydraulics, pneumatics, mechanics) z Cylinder-integrated accumulators Controllers certified to - IEC 61508, SIL 2 (3) - EN 13849, Pl d (c) z Combined cylinder/accumulator Other components for applications with increased solution functional safety z Self-supporting suspension struts - Sensors - Valves Support provided throughout, from risk analysis HS-E 10.102.0/02.15 to certified function 2 3 5 Your Partner for Expertise. Cylinders For cylinders and cylinder systems for mobile technology. in mobile applications Light. Compact. System-based.

Production expertise

Manufacturing techniques Cutting-edge machine equipment that can be used for all kinds of machining work: - Deep-hole boring - Turning (CNC, NC and conventional) - Honing - Milling - Grinding

- Welding CNC lathe (12 m turning length) Automated submerged-arc welding system

Assembly and test bench z Cleaning and cylinder-assembly equipment z PLC-controlled hydraulic test benches for test pressures up to 1200 bar z Function and fatigue test benches

Paint application Cutting-edge paint technology for protection against wear and corrosion. z Sandblasting z Cleaning z Painting z Drying

Quality assurance Top quality is guaranteed by constantly monitoring all processes (from design to assembly), inspecting individual parts as well as finished products, monitoring of measuring equipment and contamination monitoring of the hydraulic oils used. Consistent quality is the result of very close collaborative relationships with customers and suppliers. HS-E 10.102.0/02.15 HS-E 10.102.0/02.15 3 4 Telescopic systems for mobile cranes

Telescopic systems In modern mobile cranes, the main boom is extended and retracted by a single-cylinder telescopic system. The systems are made up of the following main components: z Double-acting hydraulic cylinder in lightweight design z Guide frame z Securing locking unit (SLU) z unit including valve control Control and display z Internal oil feed z Telescopic guide system adapted to suit specific cranes z Telescopic boom and position detection z Reliable, flexible HY-TTC 90 controller, certified to z Position sensor system (optional) ISO 13849 In addition to customised systems, a system with the in-house developed SLU is available. z Universal mobile display with integrated HY-eVision controller Operating pressures: up to 350 bar z Customised control and visualisation software based on standard modules Stroke: up to 12,000 mm

Advantages and features: Advantages and features: z Complete hydraulic/mechanical/electric z Complete telescopic system package including control system from a single source z Specific interface programming z Flexible cylinder sizing z Customised visualisation z Cylinder and SLU produced to customer z On-site commissioning support specifications or our own design z Minimal cylinder weight

Securing locking unit – base mounted

Universal mobile display with integrated HY- eVision controller

Flexible HY-TTC 90 mobile controller

Flexible HY-TTC 500 mobile controller

Functional Safety Functional Safety PL d PL d SIL 2 SIL 2

Telematic system

HS-E 10.102.0/02.15 Controllers and visualisation HS-E 10.102.0/02.15

6 7 systems for mobile cranes Telescopic 8 HS-E 10.102.0/02.15 Special cylindersforcranes Boom cylinder into thecylinder. integral tanksarefrequentlyintegrateddirectly particular task.Hydraulicvalves,sensorsandalso customer requirements,asappropriateforthe cylinders aredevelopedandproducedinlinewith masts oralsototensioncrawlertracks. The cylinders orboltingcylinders,toextendraise counterweights, asmastfall-backprevention purposes incranes,forexampletoliftormove Hydraulic cylindersareusedforvariousspecial of upto9000mm. piston diametersofupto600mmandstrokes Hydrosaar manufacturesboomcylinderswith installed directlyonthecylinder. can beintegratedintothecylinderorblocks Counterbalance valvesorload-holding range. held leak-freeovertheentireoperating-pressure moves evenlywithlittlefrictionandtheloadis Seal andguidesystemsensurethecylinder normally manufacturedfromhollowtubes. the cylindercomponents. The pistonrodsare methods areappliedtooptimisethedesignof materials areusedandmoderncalculation are designedtobelightweight.High-strength by permissibleaxleloads,boomcylinders machinery. As theweightisgenerallyrestricted booms andjiboncranesconstruction The boomcylinderalterstheangleofmain and special cylinders and specialcylinders Boom, outrigger z z z z Benefits andspecialfeatures:

Integrated anti-rotation pistonrod Integrated valvetechnology High-strength materialsused Weight-optimised design

Counterweight cylinder withintegratedvalvetechnology anti-rotation Mast fall-backpreventioncylinderwithintegratedvalves,integraltanksand Lightweight boomcylinderfortelescopiccrane z z z z z Benefits andspecialfeatures:

Structurally durabledesign Integration ofvalvetechnology Special sealspreventanyleakage High-strength materialsused Lightweight design Steering andsuspensioncylinders Cylinders forvehicleoutriggers and steeringsystems. HYDAC alsomanufacturescompletesuspension In additiontooffering cylindersascomponents, as externalaccumulators. accumulators integratedintothecylinderaswell The suspensioncylinderscanbesuppliedwith pressure sensorsareavailableforthecylinders. from theHYDACHLT seriesandHYDAC conditions. Integratedpositionsensorsystems and coatingstailoredtosuittheoperating cylinders boastlow-frictionguide&sealsystems Hydrosaar suspensioncylindersandsteering steering andsuspensionfunctions. machinery, hydrauliccylindersareusedin In thechassisofmobilecranesandconstruction EN 13849). requirements forcomfortandsafety(inlinewith pressure sensors,tosatisfythemoststringent with integratedsensors,particularlypositionand leak-tightness. Hydrosaarprovidessolutions lightweight andmeetstrictrequirementsregarding support. Liketheboomcylinder, thecylindersare are normallyusedforextension,pivotingand installed onthevehicleframe.Severalcylinders that supportandmoveloadshaveoutriggers Mobile cranesandspecial-purposevehicles z z z z Benefits andspecialfeatures:

Corrosion-resistant piston-rodcoatings purpose vehiclesandcraneoutriggers Complete cylindersystemsforspecial- Extension cylinder, single-andmulti-stage to 600barwithintegratedvalvetechnology Outrigger cylinderforstaticpressuresofup

Steering cylinderwithintegratedpositionsensors Two-stage horizontalcylinderforoutrigger Outrigger cylinderformobilecranewithspecialmounting z z z z Benefits andspecialfeatures:

Integrated position sensortechnology Integrated endpositiondamping Low-friction design Integration ofaccumulator 9 HS-E 10.102.0/02.15

Boom, outrigger and special cylinders for cranes 10 HS-E 10.102.0/02.15 and anelectricalfeed. ports canbesupplementedwithcompressed-air supplied withaspecialcoating.Ifdesired,thehydraulic To ensurelongservicelife,therotation pistonsare number ofports,portsizeanddesign. The rotaryjointscanbeconfiguredintermsofthe machinery, Hydrosaaroffers customisedrotaryjoints. For excavators,cranesandotherconstruction are designedspeciallyfortheparticularapplication. coatings, combinedwithsealandguidesystemsthat service lifeisguaranteed,thankstospecialpistonrod for structuralstabilityevenathighcyclerates. A long track-tensioning cylinders. The cylindersaredesigned Hydrosaar suppliesboom,stick,bucket,jawand a highdegreeofrobustnessandavailability. excavators andminingexcavators, have to demonstrate Cylinders usedinexcavators,particularlylarge Rotary joints Rotary Excavator cylinders and mining Construction machinery z Benefits andspecialfeatures: z z z Benefits andspecialfeatures: z z z

Robust designfordynamicapplication Structurally durabledesignforhighcyclerates Integrated positionsensortechnology Up to16ports Up to420bar Piston coatingformaximumservice life Integration ofcompressed-air andelectricalfeed Hydraulic rotaryjointfor largeexcavator, 16-port Boom cylinderwithintegratedpositionsensorsystem Jaw cylinderforminingexcavator

Mobile miningmachines Road constructionmachinery life. and sealguidesystemstoguaranteealongservice are usedalongwithspecialpiston-rodcoatings,wipers applications areextremelyrobust. Appropriate materials such loads,theHydrosaarcylindersdesignedforthese result ofcontaminationandtemperature. To withstand mining andtunnellingareputundergreatstrainasa Hydraulic cylindersformobilemachinesusedinsurface pressure sensors,andalsointernaloilfeed. can befittedwithintegratedvalves,positionsensorsand best useoftheavailablespace.Ifdesired,cylinders tailored tosuittheconstructionmachinemake durability andfunctionalefficiency. The cylindersare machinery whichmeetsthestricteststandardsfor Hydrosaar suppliescylindersforroadconstruction z z z z z Benefits andspecialfeatures: z z z z Benefits andspecialfeatures:

Integration ofvalvetechnology Integration ofpositionsensor technology Special sealingsystems Special coatings Robust design Integration ofvalvetechnology Integration ofpositionsensortechnology Special sealingsystems Vibration-resistant design Expansion cylinderfor tunnelboringmachine Lift cylinderwithintegratedoilfeed 11 HS-E 10.102.0/02.15

Construction machinery and mining 12 HS-E 10.102.0/02.15 Suspension characteristics,suspensiondampercylinder Suspension-damper cylinders space. respect ofsuspensioncharacteristics,forcesandinstallation requirementsin specifically totakeaccountofthecustomer’s cylinders withintegratedgasaccumulators,developed to agriculturalmachinery. Hydrosaarsupplieshydraulic travel inmanymobilemachines,fromlargeminingvehicles Cylinders providesuspensionanddampingduringvehicle and accumulatorcylinders Suspension z Benefits andspecialfeatures: z z z z z Force in kN z 100 125 150 175 200 225 250 275

accumulators Cylinders withintegratedorexternalhydraulic Open andclosedhydraulicsystems Adjustable dampingcharacteristics Designed accordingtoPressureEquipmentDirective Self-supporting designpossible Piston-rod coatingtailoredtosuitoperatingconditions Low-temperature design(to-40°C) 25 50 75 0 0 1020304050607080 Quasi-statistical suspensioncharacteristics,∆z=±35mm,f0.5Hz Distance inmm

Suspension cylinderwith integratedaccumulator Cylinder foractiveheave compensationsystem Active heavecompensation solutions. combinations, HYDACprovidescylinder-integrated as primarycomponents.Inadditiontocylinder/accumulator which includecylinders,accumulatorsandvalveequipment HYDAC suppliesmachinebuilderswithsystemsolutions compensation playamajorroleinreducingconsumption. Hydraulic systemsforenergyrecoveryandactiveheave in themachineryusedtransshipmentoperations. Energy consumptionisofincreasingimportance,particularly z z z z Benefits andspecialfeatures:

Low-temperature design(to-40°C) Designed forspecificapplication Reduced drivepowerandoperatingcosts heave compensation Combined cylinder/accumulatorsystemforactive Real-world examples Active heavecompensation:Materialhandler

Force Stroke z z z Benefits: z z z Action/strategies:

Noise control Productivity increase Reduced fuelconsumption Boost operation Downsizing Energy recovery Compensation force Working load Base load Residual load 13 HS-E 10.102.0/02.15

Suspension and accumulator cylinders Cooling Systems 5.700 Electronics 180.000 Accessories 61.000 Compact Hydraulics 53.000 Fluid Service 79.000 Process Technology 77.000 Filter Technology 70.000 Accumulator Technology 30.000

www.hydac.com Local Expertise. Global Presence.

HYDAC SalesandServicePartners HYDAC Headquarters HYDAC Companies HYDAC INTERNATIONAL Contact GMBH

Internet: www.hydac.com Email: [email protected] Fax: Tel.: Germany 66280 Sulzbach/Saar Hirschbachstr. 7 +49 6897509-9791 +49 6897509-9700

HS-E 10.102.0/02.15