Professional Documents
Culture Documents
Service Training
November 2003
Lidhult - Sweden
A Partek Company
DRF 400 - 450
Longer service-intervals
Less lubrication points
Quality-improvements
Easier trouble shooting
More powerful and reliable machine
New environmental demands
A Partek Company
1 Engine - General Environmental friendly - electronic
controlled. EDC
Volvo as standard
Cooler with separate expansion tank
Lower fuel consumption
Better performance
Silencer underneath the machine
Air filter on left side - bigger filter
A Partek Company
1 Engine - Environmental demands
A Partek Company
1 Engine - Environmental demands
A Partek Company
1 Engine - Specifications
Volvo TWD1240VE
Power 246 kW/2000 revs (235)
Torque 1751 Nm/1200 revs
(1550/1100)
New by-pass filter, 3 oil-filters totally
Water cooled Intercooler
Longer service-intervals due to high
quality oil
Universal engine oil 15W40 VDS II
A Partek Company
1 Engine - Turbo
A Partek Company
1 Engine - Injection
A Partek Company
1 Engine - Specifications, Option
Cummins QSM11
Power 280 kW/2100 revs ( 235)
Torque 1898 Nm/11-1400 revs
(1550/1100)
Air-cooled intercooler
No by-pass filter (compare Volvo)
3 filters totally
Longer service intervals (new oil)
A Partek Company
1 Engine - Cooling system
A Partek Company
1 Engine - Cooling system
A Partek Company
2 Gear box - General
A Partek Company
2 Gear box - General
A Partek Company
2 Gear box - Sensors 4 sensorer optimerar växlingen;
4 sensors optimises the gear shifting:
1. Input revs from engine/
1. Engine speed/Temp
Converter temp
5. Temp switch 2. Output revs to universal drive shaft
3. Revs after torque converter/ Turbine
4. Drum speed 4. Revs before torque converter/drum
Other sensor
2. Output speed
3. Turbine speed 5. Temperature
A Partek Company
2 Transmission - Valve house
FWD
all solenoid valves
1ST/3RD The house is filled with oil
REV
DRIVE
2/4 SELECT
1/3 SELECT
A Partek Company
3 Driveline - General
Meritor
Fits all models
Implemented on DRD 2001
A Partek Company
3 Driveline - Propeller shaft
A Partek Company
4 Brakes - General
Separate brake system with a fan-
radiator - less heat and cleaner
hydraulic system
No Lubrizol needed
More efficient cooling of the oil
Electrical parking brake
One separate high pressure filter for
the brake system
Volume 140 litres
New breathing filter
Oil type API GL-4 SAE 5W30
A Partek Company
4 Brakes - Accumulator charging valve
A Partek Company
4 Brakes - Drive axle block
1
10
2
1
3
3
4
5
5
9
9. Check point brake pressure
6
8
10. Check point cooling pressure,
7
max 1,0 bar
A Partek Company
4 Brakes -
Cooling system
A Partek Company
4 Brakes - Parking brake
A Partek Company
5 Steering - General
Lubrication points
Improved quality
A Partek Company
5 Steering - General
A Partek Company
5 Steering - Priority valve
A Partek Company
6 Wheels - General
A Partek Company
7 Load handling - General
A Partek Company
7 Loadhandling - Boom
A Partek Company
8 Control and monitoring system -
General
Functions are in most cases
controlled electronically Monitoring functions
To warn the operator OP, cooling water temp,
Limit the machines functions at speed limit and so on
A Partek Company
8 Control and monitoring system -
B C D
General
A Partek Company
8 Control and monitoring system -
Operation menus
. t
1 2
m
.
Menus for the driver
Dynamic scale
rpm
kph Engine and gearbox info
Hydraulics
Loadhandling
°C
Service intervals
bar
.
Control of dynamic scale
Service menu
°C etc.....
°C
A Partek Company
8 Control and monitoring system -
Alarm information
Every alarm gives information to warn
the driver and also to give a possible
solution to the problem. The display is
C divided into 4 fields:
D E
B: Alarm level is shown with a symbol
B C: Shows alarm code
D: Cause of alarm
E: Which function affected by the alarm
A Partek Company
8 Control and monitoring system -
Alarm levels
STOP indicates a serious problem that can
adventure the drivers safety or breakdown of
the machine. Engine, transmission, OP. Must to
be taken care of immediately.
A Partek Company
8 Control and monitoring system -
Error codes
52 53
When error occurs, pos 35 always lit up.
All STOP and WARNING types - in KID
All active errors are stored in error code list, go
B
to Service Menu and press Enter 2 sec
Error codes under section D i MM
35
A Partek Company
8 Control and monitoring system -
Diagnostic tests
A Partek Company
8 Control and monitoring system -
Settings
INITIATION
Initiation
Before the machine is used for work,
BOOM ATTACHMENT
SLIDING-CAB STEERING mechanical and electrical tolerances
TIMES RETURN
CALIBRATION Calibration
SCALE STEERING For optimal use of important
DRIVE-TRAIN RETURN functions
A Partek Company
9 Frame - General
New design
6, 6.5, 7 and 7.5-meters wheel base
Extended frame width with 50 mm gives
better stability and service availability
Safer and more comfortable angled instep
A Partek Company
9 Frame - New Design
A Partek Company
9 Frame - Instep
A Partek Company
9 Frame - Shaft
A Partek Company
9 Cabin - Pedals
A Partek Company
9 Cabin - Air condition
2 models
– Thermostat regulated heat -
Standard
– Thermostat regulated heat/cold -
Option (equivalent to tropics)
Filter for re-circulation and fresh air
Pollen filter Option
Normal temperature 22° (Knob
straight up)
A Partek Company
9 Cabin - Cabin environment
Better ergonomics
New layout
Controls more together
Space to the right for extern terminal
More open space on the floor
New furnishing behind the chair
A Partek Company
9 Cabin - Steering column
Track lights in Touch-buttons and
switches, contrast is adjusted with
the function keys (+) and (-)
Warnings- and Indication lamps by
LED-lamps
Display with operating menus, error
code menus
A Partek Company
9 Cabin - Lever
A Partek Company
10 Hydraulics - General
Upgraded hydraulic system
More hoses - less pipes
Separate hydraulic oil
Less components - fewer possible
cooling system
points of leakage
2 Return filters as standard
Same pumps as in DRD 2000-03
1 Fine filter
Less heat generation in the system
ORFS-couplings standard -
No additives needs in hydraulic tank
less leakage
Fewer hydraulic couplings
A Partek Company
10 Hydraulics - General
Higher and shorter oil tank
One main valve
Thicker hoses
Double seals in the cylinders for lifting and extension (DRD 2001)
Constant pressure to attachment - no circulation when not in use (DRD 2001)
New design of the cylinders for smother start motion (DRD 2001)
Connection lifting cylinder valve integrated in cylinder end
A Partek Company
10 Hydraulics - Oil tank
A Partek Company
10 Hydraulics - Cooling system
A Partek Company
10 Hydraulics - Hoses
A Partek Company
10 Hydraulics - Couplings
A Partek Company
10 Hydraulics - Valves
Option: Sliding cab / support jacks
Front
Main valve
A Partek Company
10 Hydraulics - Valves
Charging valve for accumulators
Front
Brake
pressure
Unfiltered/
Drain
Accumulator Servo
A Partek Company
10 Hydraulics -Components
Transmission pumps
Front
Solenoid valve
switches off left
Gear selector
pumps during
valve for
boom in
electronic
gear shifting
Shuttle valve for oil
to the spreader
Pump steering,
Pump spreader, lifting, boom in/out
lifting, boom out
Pump steering,
Pump lifting, lifting, boom in/out
boom out
A Partek Company
2 Regulators 2 Regulators
10 Hydraulics - Main valve
A Partek Company
10 Hydraulics - Rotation motors
A Partek Company
10 Hydraulics - Hydraulic motor for
chain driven positioning
A Partek Company
10 Hydraulics - Spreader main valve
One valve for all spreader functions
Individual pressures for all functions
No restriction valves needed for rotation
Constant pressure - no oil re-circulation
Introduced on DRD 2001
A Partek Company
10 Hydraulics - Blocking valve
A Partek Company
10 Hydraulics Attachment
– Standard spreader
– Spreader with pile slope
– Combi attachment
– Over height spreader
– Tool carrier
A Partek Company
11 Electrical system - General
KDCS - Kalmar Distributed Control Smaller electrical central in cabin
System Trouble shooting via computers
Less wiring and connectors - fewer Redundant CAN-bus and CPU (processor)
possible error sources feeding
KDU
KIT
KID
KCU
KDU
KDU
EDC
TCU
A Partek Company
11 Electrical system - General
A Partek Company
11 Electrical system -
Comparison
DRD DRF
KCU
A Partek Company
11 Electrical system - Comparison
DRD DRF
A Partek Company
11 Electrical system - Servo
DRD DRF
Same functions and optional equipment
Distribution box in the cabin
as in DRD
Distribution box on the spreader (KDU
All signals and components are
since the summer 2001)
connected to the closest distribution
ECU2 & ECU3
unit/node
CAN-bus
– In the front of the frame, KDU
All components are controlled from the
– In the rear part of the frame, boom
cabin.
suspension, KDU
All signal goes to the cab
– Spreader, KDU
– Cab, KCU
Redundant CAN-bus
A Partek Company
11 Electrical system - Drive line
DRD DRF
I/O solenoid valves for gearshift All sensor are connected to EDC
All sensors/cables are connected to the Throttle, values from sensors, error codes,
cabin. all signals via CAN-bus
Spicer Off Highways (Clark) 36/40000 I/O and analogue solenoid valves for
gearshift
DANA Spicer Off Highways TE32000
A Partek Company
11 Electrical system - Codes & Calibration
DRD DRF
After receiving a code, full access to all After receiving a code, full access to
parameters. adjustment of start- and stop current.
No parameter limitations Values can only be adjusted between
permitted values.
Calibration is carried out in a similar
way as DRD
Installation and removal of modules and
load curves can only be done with a
PC-tool
A Partek Company
11 Electrical system - Diagnostics
DRD DRF
All components are controlled All components are controlled from the nearest
from the cab computer/node
Power supply /fuses in the cab Power supply/fuses in battery box and cabin.
~ 40 Error codes ~400 Error codes
8-10 diagnostic menus >140 diagnostic menus
A Partek Company
11 Electrical System - DRD
Drive Train
A Partek Company
11 Electrical System - DRD
DRD Y2001
Drive Train
A Partek Company
11 Electrical System - DRD
Drive Train
M
A Partek Company
11 Electrical System - DRF
M
Distributed Control System
A Partek Company
11 Electrical System - DRF
KDU
KCU KID
KDU KDU
EDC TCU
A Partek Company
11 Electrical System - DRF
KDU
A Partek Company
11 Electrical System - KCU
A Partek Company
11 Electrical System - KIT
A Partek Company
11 Electrical System - KID
A Partek Company
11 Electrical System - Cabin
- Display
- Joystick panel KDU
- Left front panel
- Steering wheel panel
- Accelerator, de-clutch
KIT - Wipers
- Climate system
KCU KID - Working lights, cab
KDU KDU
EDC TCU
A Partek Company
11 Electrical System - KDU
Controls in-signals from sensors and operating controls and sends steering
signals to relays and solenoid valves to execute mechanical movements or
electric signals
A Partek Company
11 Electrical System - KDU boom
KDU
KDU KDU
EDC TCU
A Partek Company
11 Electrical System - KDU front
KDU
KIT
A Partek Company
11 Electrical System - KDU rear
- Rear lights
- Boom sensors
- OP sensors, steering axle KDU
- Hydraulic oil cooler
- Drive-train
- Fuel sensor
KIT
- D+
- AC compressor
KCU KID
- Working lights, boom
KDU KDU
EDC TCU
A Partek Company
11 Electrical System - KDU Option
A Partek Company
11 Electrical System - EDC
Electronic Diesel Control - Placed on the
engine
Controls the engine injection
CAN-bus between EDC/TCU - forward to the
KCU - forward the information from the drive
line to the rest of the units
EDC have no switches and no display
Every problem in the EDC causes a error code
in the KID, for example 111/01
– OBS: EDC and TCU can have the same
error codes, the symbol differs them
A Partek Company
11 Electrical System - TCU
A Partek Company
11 Electrical System - Drive line
KDU
KIT
KCU KID
KDU KDU
A Partek Company
11 Electrical System - Fuses
Main electrical central containing - main fuses, 30, 15, 15E fuses, relays
TCU is placed here
A Partek Company
11 Electrical system - Fuses
A Partek Company
Electrical system - Wiring
A Partek Company
11 Electrical System - Advantages
A Partek Company
Service and Maintenance
A Partek Company
A Partek Company