SỬA CHỮA HỆ THỐNG ĐIỆN XE NÂNG KALMAR DRF 450 (Electrical and KDU )

ELECTRICAL SYSTEM - DRFTCU KDU KDU KDU TCU - Transmission Control Unit KDU - Kalmar Distributed Unit... ELECTRICAL SYSTEM - KCU D790-1 Cabin Control Unit... ELECTRICAL SYSTEM - KCU  Kal

ELECTRICAL AND ELECTRONIC CONTROL SYSTEM

ContChamp DRF 450

CIRCUIT POWER

Battery Disconnection Switch

Batteries: 2 x 12V – 140 Ah Engine off, battery voltage 23-25V Engine @ 2000 rpm, battery voltage 27-29V

CIRCUIT POWER

Battery Grounding

Alternator Volve TWD1240VE 2240W

CIRCUIT POWER

EL-Box Frame

CIRCUIT POWER

D793 TRANSMISSION CONTROL UNIT

CIRCUIT POWER

Inside Cabin

ELECTRICAL SCHEMATIC A43033.0100 (1/5)

-S150

REAR CONNECTORS

X200 X202 X206

Grounding Point 4043L, 4043R 4045L, 4045R

60462, 60502 4282

(A43037.0100 ¼)

ELECTRICAL SYSTEM - DRF

TCU

KDU

KDU KDU

EDC

KCU

KIT

KID

Distributed Control System

- Network with control units

ELECTRICAL SYSTEM - DRF

TCU

KDU

KDU KDU

TCU - Transmission Control Unit KDU - Kalmar Distributed Unit

ELECTRICAL SYSTEM - KCU

D790-1 Cabin Control Unit

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

D790-1 Cabin Control Unit

ELECTRICAL SYSTEM - KIT

 Kalmar Information Terminal - Placed in the

steering wheel panel

 Warnings- and indication lamps

 Functions keyboard

D790-2 Kalmar Information Terminal

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

D795 Kalmar Information Display

ELECTRICAL SYSTEM - CABIN

TCU

D790-1

D797-F D797-R

- Left front panel

- Steering wheel panel

D790-1 INPUT EMERGENCY STOP

A43033.0100 3/5

-S250

D790-2 INPUT SWITCH IGNITION

A43033.0100 3/5

-S150

D790-1 INPUT SWITCH LIGHTING

D790-2 OUTPUT MULTI SWITCH BEAM

-S162 A43037.0100 1/4

Main/ Dipped Beam

D790-1 OUTPUT BEACON LIGHT

-X428

A43037.0100 1/4

-H428

D790-1 INPUT SWITCH CAB INTERIOR LIGHT

A43037.0100 4/4

-D790-2

-S266LE -S266RI

Cab Door Braking Switch

D790-1 OUTPUT CAB INTERIOR LIGHT

D790-1 OUTPUT HOUR METER

D790-1 INPUT JOYSTICK CONTROLLER

A43040.0100 1/1

LEVER 815

D790-1 INPUT SWITCH PARKING BRAKE

A43042.0100 1/2

-S107

D790-1 INPUT SWITCH TWISTLOCK

A43043.0100 2/2

-S1003

Twistlock

D790-1 INPUT MULTI SWITCH GEAR

-S162 A43046.0100 1/1

Gear R-N-F

D790-1 INPUT ACCELERATOR/ DECLUTCH

D790-1 INPUT MULTI SWITCH WIPER

-S162 A43047.0100 1/1

D790-1 INPUT MULTI SWITCH HORN

-S162 A43056.0100 1/2

D790-1 OUTPUT HORN

-H850 A43056.0100 1/2

D790-2 INPUT CAB INTERIOR LIGHT

D790-1 INPUT SWITCH HAZARD

A43060.0100 1/1

-S109

D790-1 INPUT CLIMATE CONTROL

ELECTRICAL SYSTEM - KDU

ELECTRICAL SYSTEM - KDU

GREEN – POWER Battery Voltage OK

GREEN – SYSTEM Internal 5V DC OK

AMBER – MODE FLASHING:

0.5 Hz – Program OK

5 Hz – No Program Fixed – Set-up Mode RED – STATUS

ON - ERROR

KDU ATTACHMENT

D791-1 KDU ATTACHMENT

ELECTRICAL SYSTEM - KDU ATTACHMENT

TCU

D791-1

D797-F D797-R

D791-1 OUTPUT SPREADER LIGHT

-E406R -E406L

A43034.0100 1/1

-XE406L -XE406R

D791-1 INPUT SP LANDPIN SENSORS

A43043.0100 1/2

D791-1 INPUT SP TWISTLOCK SENSORS

A43043.0100 1/2

D791-1 OUTPUT SP TWISTLOCK SOLENOID

A43043.0100 2/2

Y6039 Y6040

Unlock TW

Lock TW

D791-1 OUTPUT SP INDICATION LIGHTS

-X405

A43043.0100 2/2

H561 H564

H563

D791-1 OUTPUT ROTATION SOLENOID

A43050.0100 1/1

Rotation Anti-clockwise Y6009

Y6008 Rotation Clockwise

D791-1 OUTPUT SIDESHIFT CONTROL SOLENOID

A43051.0100 1/2

Sideshift Left Sideshift Right

Y6020 Y6021

D791-1 OUTPUT 20’ – 40’ CONTROL SOLENOID

A43051.0100 1/2

40’ – 20’ In 20’ 40’ Out Y6018

Y6019

D791-1 INPUT SP DAMPLING SENSOR

B769

A43051.0100 2/2

KDU FRONT

D797-F KDU FRONT

ELECTRICAL SYSTEM - KDU FRONT

TCU

D791-1

D797-F D797-R

D797-F INPUT BRAKE PRESSURE SWITCH

A43037.0100 2/4

216

D797-F OUTPUT HEAD/ DIPPED LIGHTS

-X270 -X271

-E400L -E402R

A43037.0100 2/4

-E402L -E400R

D797-F OUTPUT SIDE POSITION LIGHTS

-X270 -X271

A43037.0100 2/4

D797-F INPUT BRAKE PRESSURE SWITCH

A43042.0100 1/2

-S200

-S204 Pressure SwitchBrake System Pressure

Pressure Switch Parking Brake

D797-F INPUT TEMPERATURE BRAKE OIL

A43042.0100 1/2

-B762

D797-F INPUT BRAKE PRESSURE SWITCH

A43042.0100 1/2

-S204 -S200

D797-F OUTPUT PARKING BRAKE SOLENOID

A43042.0100 2/2

Y642

D797-F OUTPUT BRAKE COOING FAN

A43042.0100 2/2

M674

D797-F INPUT PRESSURE SENSOR LEFT

D797-F INPUT PRESSURE SENSOR RIGHT

PRESSURE SENSOR

Pressure sensors at valve block

0-250Bar / 0.5-4.5V

D797-F INPUT DECLUTCH PRESSURE SWITCH

A43046.0100 1/1

-S220-2

D791-F OUTPUT MAIN VALVE SOLENOID

A43048.0100 1/1

Y6004 Y6005 Boom Lower

Boom Lift

D791-F OUTPUT LOCK VALVE SOLENOID

A43048.0100 1/1

Y6052

Y6002 Blocking Valve

Regeneration Valve

LEFT

D791-F OUTPUT LOCK VALVE SOLENOID

A43048.0100 1/1

Y6051

Y6001 Blocking Valve

Regeneration Valve

RIGHT

D797-F OUTPUT MAIN VALVE SOLENOID

A43049.0100 1/1

Y6006

Y6007 Boom Out

Boom In

D797-F INPUT BY-PASS SWITCH

A43055.0100 1/1

-S1005

D797-F OUTPUT HORN

A43056.0100 1/2

-H850

D797-F OUTPUT DIRECTION LIGHTS

-X270 -X271

A43060.0100 1/1

KDU REAR

D797-R KDU REAR

ELECTRICAL SYSTEM - KDU REAR

TCU

D791-1

D797-F D797-R

- OP sensors, steering axle

- Hydraulic oil cooler

D797-R OUTPUT BRAKE/ REVERSE LIGHTS

965 REVERSING BUZZER

D797-R OUTPUT REAR/ SIDE LIGHTS

965 REVERSING BUZZER

D797-R INPUT FUEL LEVEL

A43038.0100 1/1

-B757

D797-R INPUT BOOM ANGLE SENSOR

-B771

A43045.0100 1/2

D797-R INPUT OVERLOAD SENSOR

B7221L

7221R

A43045.0100 2/2

D797-R OUTPUT PUMP INTERUPTION SOLENOID

SERVO VALVE Pump Interruption

A43049.0100 1/1

Y6062

D797-R OUTPUT BOOM VALVE SOLENOID

Y6046

SERVO VALVE RE-GENERATION

Y6050

SERVO VALVE BLOCKING

A43049.0100 1/1

D797-R OUTPUT ACTIVATION TOPLIFT

A43050.0100 1/1

Y6003

SERVO VALVE Activation Toplift

D797-R INPUT HYD OIL TEMP SENSOR

A43053.0100 1/1

-B776

D797-R OUTPUT HYD OIL COOLER FAN

A43053.0100 1/1

-M668

D797-R OUTPUT REAR DIRECTION LIGHTS

D797-R OUTPUT REVERSING ALARM

A43067.0100 1/1

-H965 Reversing Alarm

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

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

ELECTRICAL SYSTEM - DRIVE LINE

KDU

KDU KDU

ELECTRICAL SYSTEM - TCU

 ’Limp-home’ indicates a serious problem

in the transmission The machine needs service at once

 ’Limp-home’ happens in following cases:

 Error indicated on out-signal from TCU

 Problems on the rev sensor

 To be able to drive to the workshop:

choose neutral and thereafter suitable gear

 Every problem on the TCU causes an error code in the KID, for example 52/01

SPICER OFF-HIGHWAY

APC200

M S

D E F

Limp Home indicates E blinks,

problems

Shows actual gear

ELECTRICAL SYSTEM - TCU

 ’Shut down’ indicates a very serious inner or outer problem on the

transmission The machine can´t be operated

SPICER OFF-HIGHWAY

APC200

M S

D E F

The machine communication is handled by a so-called CAN-bus

system The CAN bus system consists of control units connected to form a network.

D790-1

D795 D790-2

D791-1

The idea with a network is to share information Signal values are sent out by the control unit that, e.g, is connected to a sensor, other

controls units can use the signal for their functions.

The network consists of control units and segments Segment is the CAN-bus between the control units.

The CAN bus consists of two

twisted paired leads (twisted pair)

Redundant CAN bus means that every control unit has two

connections for communication The CAN bus is connected in series between the control units This mean that the CAN bus can handle loss of segment.

Communication with control unit engine (D794) and control unit transmission (D793) is separated from the redundant CAN bus The signals can be checked with diagnostic menu.

ELECTRICAL SYSTEM – START UP

When the machine isn’t in use, the electrical system is in a

powerless mode No power electronics or controls units are supplied with voltage.

When the machine is started, voltage feed is activated and the

redundant CAN bus is initiated.

Start up is handled by control unit cab (D790-1)

ELECTRICAL SYSTEM – START UP

The first pre-requisite for the machine to be able to perform any

action is to first establish the redundant voltage feed for control units and then establish CAN-bus communication to administer control

signals for functions.

Control unit establish communication

when: Operator’s door is opened

- Interior lighting is lit

- Flashing hazard lights are activated

- Start key in position 1

REDUNDANT POWER SUPPLY

KDU KDU

Start up

REDUNDANT POWER SUPPLY

CAN-bus

CAN high CAN low

‘Cockoo’

CAN high CAN low

Oscilloscope

‘Cockoo’

One message

1/1000 Sec One message

REDUNDANT CAN-bus

KDU KDU KCU KID KIT

CAN high CAN low

REDUNDANT CAN-bus

KDU KDU KCU KID KIT

Start up&

Red.Power

REDUNDANT CAN-bus

KDU KDU KCU KID KIT

Start up&

Red.Power

REDUNDANT CAN-bus

Start up

KDU KDU KCU KID KIT

Time Out

REDUNDANT CAN-bus

DRIVE-TRAIN CAN-bus

KCU

EDC TCU

DRIVE-TRAIN CAN-bus

switch and remove battery’s terminals

Welding must away from all control units and grounding lead should keep as near as possible to welding point.