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ContChamp DRF 400 - 450

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

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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

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1 Engine - Environmental demands

 These engines complies with the


new demands for Tier 2 that took
effect in North America 2001 and in
Europe in January 2002

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1 Engine - Environmental demands

 Tier 2 according to North American and


European standard means that the demand on
different exhausted particles lowers from;
– 9,2 to 6,0 gram/kWh Nitric oxide
– 11,4 to 3,5 gram/kWh Carbon monoxide
– 0,54 to 0,20 gram particles/kWh

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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

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1 Engine - Turbo

 The turbo pressure in bar can be


read in the display (KID)
 Revs up to 120 000 rpm
 Lubricated and cooled by lubricating
oil from the engine

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1 Engine - Injection

 Amount of fuel and timing of


injection is electronic controlled by
Volvo computer EDC
 Always right amount of fuel at any
operating condition
 Lower fuel consumption and
minimal exhausts

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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)

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1 Engine - Cooling system

 Larger cooler with integrated:


- transmission oil cooler
- cooler for intercooler

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1 Engine - Cooling system

 Separate expansion tank with level


guard

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2 Gear box - General

 DANA Spicer Off-Highways


TE32418 (TE32000 > 36000, US to
SI units )
 4 gears forward & reverse
 Electronic controlled by TCU
 Automatic gear box as standard
 3 buttons shifts between automatic,
first and second gear

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2 Gear box - General

 Optimised for maximum pulling


power during the whole gearshifting
moment
 Sensors optimises softness and
pulling power
 Integrated cooler
 Transmission oil type Dexron III

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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

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2 Transmission - Valve house

 The TCU is connected to


2ND

FWD
all solenoid valves
1ST/3RD  The house is filled with oil
REV

DRIVE

2/4 SELECT

1/3 SELECT

PRESSURE FEEDBACK SENSOR

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3 Driveline - General

 Meritor
 Fits all models
 Implemented on DRD 2001

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3 Driveline - Propeller shaft

 Cross flange - More stable


attachment of the propeller shaft

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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

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4 Brakes - Accumulator charging valve

 Check points for measuring of


accumulator and pump pressure:

4. Check point brake pump pressure


5. Check point accumulator
charging pressure
11. Relief/drain valve accumulator
pressure

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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

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4 Brakes -
Cooling system

 Sensor in the tank regulates the


cooling (temp in diagnose menu)
• 65°C On
• 55°C Off
 Maximum 1,0 bars cooling pressure

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4 Brakes - Parking brake

 Electronic controlled parking brake


 Engages automatically when
machine is switched off

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5 Steering - General

 Lubrication points
 Improved quality

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5 Steering - General

 New design - Cut in one 150 mm plate


 Plastic material at the pivot suspension

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5 Steering - Priority valve

 New priority valve for steering

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6 Wheels - General

 Two wheel dimensions as standard


 Wheel nut protection as standard

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7 Load handling - General

 More powerful load handling with


better comfort
 Improved operative feeling
 Longer service intervals - fewer non-
operative hours
 Chain extension 20´ - 40´with
hydraulic motor

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7 Loadhandling - Boom

 Cable trailer chain on the left side


 Wider rear boom suspension
 No Lubrication on sliding plates

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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

certain dangerous situations Error codes


 If malfunctions occur in the machine Diagnostic tests
Adjustments
Settings
Software

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8 Control and monitoring system -
B C D
General

A - Function keys (KIT)


B - Warnings- and indication lamps (KIT)
C - Display (KID)
D - Alarm indicator

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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

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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

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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.

 WARNING indicates errors in the machine that


needs to be taken care of as soon as possible

 INFORMATION indicates problems that should


be attended

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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

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8 Control and monitoring system -
Diagnostic tests

 Navigate to Service menu


 Press Enter

 Code for diagnostic tests

 Select group by scrolling with arrow


keys
 Check functions in the machine

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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

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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

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9 Frame - New Design

 New ”Batman”, a new ”K”

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9 Frame - Instep

 New angled, safer instep

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9 Frame - Shaft

 Surface treated shafts

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9 Cabin - Pedals

 Brake pedal with new geometry -


gives better ergonomics
 New brake valve - smoother
retardation
 Hanging accelerator - electronic

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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)

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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

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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

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9 Cabin - Lever

 Direction indicator lever

 Gear and multi-function lever


– forward / reverse
– Window wiping, washing
– lights
– horn

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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

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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

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10 Hydraulics - Oil tank

 Return filters - magnetic sticks

 New breathing filter

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10 Hydraulics - Cooling system

 Separate cooling system for cooling and


filtration - 1 fixed pump
• 65°C On
• 55°C Off
 Sensor in the tank which considers the
accumulated heat in the oil
 About 600 litres of oil in the tank
 The temperature can be read in the KID

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10 Hydraulics - Hoses

 Thicker hoses reduces the drop in


pressure - better adaptation to the
oil flow - the oil speed reduces.

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10 Hydraulics - Couplings

 ORFS-couplings are more leak


proof compared to BSP standard-
couplings - the ” sweating” is
eliminated

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10 Hydraulics - Valves
Option: Sliding cab / support jacks
Front

Main valve
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10 Hydraulics - Valves
Charging valve for accumulators
Front

Brake
pressure
Unfiltered/
Drain

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10 Hydraulics - Components
Priority valve steering
Front

Oil filter servo


Solenoid Servo valve
valve p-brake Restriction
valve

Accumulator Servo
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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

Activates hydraulic pressure


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10 Hydraulics - Pumps
Pump brake Pump cooling
system Front
hydraulics

Pump steering,
Pump spreader, lifting, boom in/out
lifting, boom out

Pump steering,
Pump lifting, lifting, boom in/out
boom out

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2 Regulators 2 Regulators
10 Hydraulics - Main valve

 Main valve with integrated servo for


improved oil flow control -easier
service
 The servo control is built-in in the
valve to reduce the number of
components.

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10 Hydraulics - Rotation motors

 Same type as DRD

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10 Hydraulics - Hydraulic motor for
chain driven positioning

 Chain driven 20’- 40’ extension with


end-damping (DRD 2001)

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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

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10 Hydraulics - Blocking valve

 Blocking oil flow when the boom


isn’t in operation
 The lowering check valve has been
removed
 Emergency retraction of the boom
similar to emergency lowering

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10 Hydraulics Attachment

– Standard spreader
– Spreader with pile slope
– Combi attachment
– Over height spreader
– Tool carrier

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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

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11 Electrical system - General

 KDCS - Kalmar Distributed Control System


 CAN-bus system with redundant supply to
both CAN-bus and power supply
 Prepared for options in the software,
activated with a PC-programme
 ~400 Error codes
 >140 Diagnostic menus
 Reliable and safe system - used on the
RT240 (EDC, TCU, SCU, KID, 2xECU)

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11 Electrical system -
Comparison

DRD DRF

KCU

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11 Electrical system - Comparison

DRD DRF

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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
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11 Electrical system - Drive line
DRD DRF

 Mechanical regulated injection  Emission regulations step 2

(TWD1031VE)  Injection controlled by EDC

 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

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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

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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

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11 Electrical System - DRD

Drive Train

Electrical Servo Electrical System

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11 Electrical System - DRD

DRD Y2001

Drive Train

Electrical Servo Electrical System

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11 Electrical System - DRD

Drive Train
M

Electrical Servo Electrical System

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11 Electrical System - DRF

M
Distributed Control System

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11 Electrical System - DRF

KDU

Distributed Control System


KIT - Network with control units

KCU KID

KDU KDU

EDC TCU

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11 Electrical System - DRF

KDU

KCU - Kalmar Cab Unit


KIT
KIT - Kalmar Information Terminal
KID - Kalmar Information Display
KCU KID
EDC - Engine Diesel Control
TCU - Transmission Control Unit
KDU KDU KDU - Kalmar Distributed Unit
EDC TCU

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11 Electrical System - KCU

 Kalmar Cab Unit - Placed in the electrical central


in the cabin
 Controls the power supply for the control units
– Is central part of the communication between all the computers
– Deals with input signals from controls in the cabin and sends these
signals out on the communication network
– ’Gateway’ between CAN-bus communication for drive line and redundant
CAN-bus communication

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11 Electrical System - KIT

 Kalmar Information Terminal - Placed in the


steering wheel panel
 Warnings- and indication lamps
 Functions keyboard

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11 Electrical System - KID

 Kalmar Information Display - Placed in the


steering wheel panel
 Shows information from the systems units:
Messages, status, error codes
 Alarm indicator - red diodes if serious problems
in the control and monitoring system

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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

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11 Electrical System - KDU

 Kalmar Distribution Unit, 3 in standard machine - Placed inside the boom


tower, at the boom nose and at left side of the frame

 Controls in-signals from sensors and operating controls and sends steering
signals to relays and solenoid valves to execute mechanical movements or
electric signals

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11 Electrical System - KDU boom

KDU

- Landing pin sensors


- TW-lock sensors
KIT - Hydraulic valves
- Indicator lamps
KCU KID - Working lights, attch

KDU KDU

EDC TCU

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11 Electrical System - KDU front

KDU

KIT

KID - Front lights


KCU
- Pressure switches
- Hydraulic valves
KDU KDU
- Brake oil cooler
EDC TCU - Lift cylinders
valves&sensors

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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

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11 Electrical System - KDU Option

KDU front option controls:


– Support jacks
– Moving cabin
– Lever/Mini wheel steering
2x KDU combi spreader controls:
– Tilting cabin
– Bottom lift
KDU spreader option controls:
– Pile-slope
– Pile-slope
– Active tilt
– Active tilt
– ’Over height’ twist-lock

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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

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11 Electrical System - TCU

 Transmission Control Unit - Placed in the outer


electrical central
 Controls and monitors gear shifting
 CAN-bus between EDC/TCU - forward to the
KCU - forward the information from the drive line
to the rest of the units
 The APC200-display normally shows direction
and actual gear. At problems the E-lamp blinks
 Same information is shown in the KID

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11 Electrical System - Drive line

KDU

KIT

KCU KID

KDU KDU

EDC TCU - Injectors control


- Fuel consumption
- Optimised gear shifting
speed, torque, rpm
- Monitoring
- ‘Limp home’ function
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11 Electrical System - TCU
 ’Limp-home’ indicates a serious
problem in the transmission. The
E blinks,
Limp Home machine needs service at once.
indicates
 ’Limp-home’ happens in following
problems
cases:
SPICER OFF-HIGHWAY  Error indicated on out-signal from TCU
D
M  Problems on the rev sensor
E
F
S  To be able to drive to the workshop:
APC200

choose neutral and thereafter suitable


gear
 Every problem on the TCU causes an
Shows actual gear
error code in the KID, for example
52/01
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11 Electrical System - TCU

SPICER OFF-HIGHWAY  ’Shut down’ indicates a very serious


D
M inner or outer problem on the
E
F
S transmission. The machine can´t be
APC200
operated

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11 Electrical System - Fuses
 Main electrical central containing - main fuses, 30, 15, 15E fuses, relays
 TCU is placed here

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11 Electrical system - Fuses

 The cabin-located fuses are placed


behind the seat

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Electrical system - Wiring

 Deutsch connectors are used in the


wiring system

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11 Electrical System - Advantages

KDCS - Kalmar Distributed Control System provides a lot of advantages:


 Fast and safe information of machine data
 Improved diagnostics possibilities for both driver and workshop
 Improved planning of service and maintenance
 Makes trouble shooting easier
 Better possibilities to add wanted features to the machines
 Reduced number of wiring and connectors which reduces error sources

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Service and Maintenance

 First stop for service at 500h


 Improved accessibility
 Easier error detecting
 Easier trouble shooting
 Extended service intervals
 Lubrication-free sliding plates

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