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17 0 118 MB
SEBM027607
MACHINE MODEL
SERIAL NUMBER
HD465-7 HD605-7
7001 and up 7001 and up
• This shop manual may contain attachiments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice. • HD465-7, HD605-7 mounts the SAA6D170E-3 engine. For details of the engine, see the 170-3 Series Engine Shop Manual.
© 2003 All Rights Reserved Printed in Japan 03-03(02)
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CONTENTS No. of page
01
GENERAL
10
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ................................................................. 10-1
20
TESTING AND ADJUSTING ............................................................................... 20-1
30
DISASSEMBLY AND ASSEMBLY ................................................................. 30-1
90
OTHERS
00-2 ➂
........................................................................................................................... 01-1
............................................................................................................................... 90-1
HD465-7, HD605-7
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SAFETY
SAFETY NOTICE
SAFETY SAFETY NOTICE IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose.
¤
To prevent injury to workers, the symbol is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. • •
Always wear safety glasses when hitting parts with a hammer. Always wear safety glasses when grinding parts with a grinder, etc.
3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, hand shield, cap and other clothes suited for welding work. 4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. PREPARATIONS FOR WORK 7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. 8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. 10.Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
00-3
SAFETY
PRECAUTIONS DURING WORK 11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit. 12.The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits. 13.Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 14.When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 15.When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16.When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 17.When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires. 18.As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts.
00-4
SAFETY NOTICE
19.Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. • When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated. 20.When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. 21.When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22.When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23.When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. 24.Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.
FOREWORD
GENERAL
FOREWORD GENERAL This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards. TESTING AND ADJUSTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating "Problems" with "Causes" are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them. MAINTENANCE STANDARD This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION. OTHERS This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL
REVISED EDITION MARK
VOLUMES Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:
W h en a m an u a l is r e vis ed , a n e d itio n ma rk ( ....) is recorded on the bottom of the pages.
Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Each issued as one Electrical volume: Attachments volume: · volume to cover all models
REVISIONS
}
These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be available. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-todate information before you start any work.
FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number. Example 1 (Chassis volume): 10 - 3 Item number (10. Structure and Function) Consecutive page number for each item. Example 2 (Engine volume): 12 - 5 Unit number (1. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item. 3. Additional pages: Additional pages are indicated by a hyphen (-) and number after the page number. File as in the example. Example: 12-203 10-4 12-203-1 10-4-1 Added pages 12-203-2 10-4-2 12-204 10-5
00-6
123
Revised pages are shown in the LIST OF REVISED PAGES next to the CONTENTS page.
SYMBOLS So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols.
Symbol
Item
Remarks
¤
Safety
Special safety precautions are necessary when performing the work.
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing the work.
Weight
Weight of parts of systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc.
Tightening torque
Places that require special attention for the tightening torque during assembly.
Coat
Places to be coated with adhesives and lubricants, etc.
Oil, water
Places where oil, water or fuel must be added, and the capacity.
Drain
Places where oil or water m u s t b e d r a i n e d , a nd quantity to be drained.
s
4 3 2 5 6
FOREWORD
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS HOISTING
¤ •
Heavy parts (25 kg or more) must be lifted with a hoist, etc. In the DISASSEMBLY AND ASSEMBLY section, every part weighing 25 kg or more is indicated clearly with the symbol
4
If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: 1) Check for removal of all bolts fastening the part to the relative parts. 2) Check for existence of another part causing interference with the part to be removed.
WIRE ROPES 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard "Z" or "S" twist ropes without galvanizing) Rope diameter
★
Allowable load
mm
kN
tons
10 11.5 12.5 14 16 18 20 22.4 30 40 50 60
9.8 13.7 15.7 21.6 27.5 35.3 43.1 54.9 98.1 176.5 274.6 392.2
1.0 1.4 1.6 2.2 2.8 3.6 4.4 5.6 10.0 18.0 28.0 40.0
Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.
100%
88%
79%
71%
41% SAD00479
3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load. Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident.
¤
4) Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load kN {kg} when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 kN {1000 kg} vertically, at various hanging angles. When two ropes sling a load vertically, up to 19.6 kN {2000 kg} of total weight can be suspended. This weight becomes 9.8 kN {1000 kg} when two ropes make a 120° hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 39.2 kN {4000 kg} if they sling a 19.6 kN {2000 kg} load at a lifting angle of 150°.
The allowable load value is estimated to be onesixth or one-seventh of the breaking strength of the rope used.
2) Sling wire ropes from the middle portion of the hook.
00-7
FOREWORD
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
¤ ¤
Before carrying out the following work, release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank. Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container.
Disconnection 1) Release the residual pressure from the hydraulic tan k. Fo r d e tails , se e TES TIN G AN D ADJUSTING, Releasing residual pressure from hydraulic tank. 2) Hold adapter (1) and push hose joint (2) into mating adapter (3). (See Fig. 1) ★ The adapter can be pushed in about 3.5 mm. ★ Do not hold rubber cap portion (4). 3) After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against (3) until it clicks. (See Fig. 2) 4) Hold hose adapter (1) or hose (5) and pull it out. (See Fig. 3) ★ Since some hydraulic oil flows out, prepare an oil receiving container. Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (See Fig. 4) ★ Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (See Fig. 5) ★ When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.
00-8
Type 1
FOREWORD
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 3
1) Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.
1) Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn lever (4) to the right (clockwise).
2) Hold in the condition in Step 1), and push until cover (3) contacts contact surface a of the hexagonal portion at the male end.
3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.
3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.
•
•
Disassembly
Type 2
Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.
Connection
Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.
00-9
FOREWORD
COATING MATERIALS
COATING MATERIALS ★ ★
The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly and assembly are listed below. For coating materials not listed below, use the equivalent of products shown in this list.
Category
Komatsu code
Part No.
Q'ty
Container
LT-1A
790-129-9030
150 g
Tube
LT-1B
790-129-9050
20 g (2 pcs.)
Polyethylene container
LT-2
09940-00030
50 g
Polyethylene container
LT-3
790-129-9060 (Set of adhesive and hardening agent)
Adhesive: 1 kg Hardenin g agent: 500 g
Can
LT-4
790-129-9040
250 g
Polyethylene container
Holtz MH 705
790-126-9120
75 g
Tube
Three bond 1735
790-129-9140
50 g
Polyethylene container
2g
Polyethylene container
Adhesives
Aron-alpha 201
790-129-9130
Loctite 648-50
79A-129-9110
50 cc
Polyethylene container
LG-1
790-129-9010
200 g
Tube
LG-5
790-129-9070
1 kg
Can
Main applications, featuresr •
Used to prevent rubber gaskets, rubber cushions, and cock plug from coming out.
•
Used in places requiring an immediately effective, strong adhesive. Used for plastics (except polyethylene, polyprophylene, tetrafluoroet hl ene and vi nyl chl oride), rubber, metal and non-metal.
• •
Features: Resistance to heat and chemicals Used for anti-loosening and sealant purpose for bolts and plugs.
•
Used as adhesive or sealant for metal, glass and plastic.
•
Used as sealant for machined holes.
•
Used as heat-resisting sealant for repairing engine.
• • •
Quick hardening type adhesive Cure time: within 5 sec. to 3 min. Used mainly for adhesion of metals, rubbers, plastics and woods.
• •
Quick hardening type adhesive Quick cure type (max. strength after 30 minutes) Used mainly for adhesion of rubbers, plastics and metals.
• • •
Resistance to heat, chemicals Used at joint portions subject to high temperatures.
•
Used as adhesive or sealant for gaskets and packing of power train case, etc.
•
Used as sealant for various threads, pipe joints, flanges. Used as sealant for tapered plugs, elbows, nipples of hydraulic piping.
•
Gasket sealant • LG-6
790-129-9020
200 g
Tube
• •
00-10
Features: Silicon based, resistance to heat, cold Used as sealant for flange surface, tread. mab Used as sealant for oil pan, final drive case, etc.
FOREWORD
Category
COATING MATERIALS
Komatsu code
Part No.
Q'ty
Container
Main applications, featuresr •
LG-7
790-129-9070
1g
Tube
Three bond 1211
790-129-9090
100 g
Tube
LM-G
09940-00051
60 g
Can
•
Adhesives
Molybdenum disulphide lubricant
LM-P
09940-00040
200 g
•
Used as heat-resisting sealant for repairing engine.
•
Used as lubricant for sliding portion (to prevent from squeaking).
•
Used to prevent seizure or scuffling of the thread when press fitting or shrink fitting. Used as lubricant for linkage, bearings, etc.
Tube •
G2-LI
SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA-160CNLI
G2-CA
SYG2-400CA SYG2-350CA SYG2-400CA-A SYG2-160CA SYGA-160CNCA
Various
Various
Molybdenum disulphide lubricant
SYG2-400M
400 g (10 per case)
Belows type
Grease
Various
Ftures: Silicon based, quick hardening type Used as sealant for flywheel housing, intake manifold, oil an, thermostat housing, etc.
•
General purpose type
•
Used for normal temperature, light load bearing at places in contact with water or steam.
•
Used for places with heavy load
Various
00-11
FOREWORD
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH) ★ In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in the table below. Thread diameter of bolt
Width across flats
mm
mm
6 8 10 12 14
10 13 17 19 22
16 18 20 22 24
24 27 30 32 36
27 30 33 36 39
41 46 50 55 60
Thread diameter of bolt
Width across flats
mm
mm
Nm
6 8 10 12
10 13 14 27
7.85 1.95 18.6 4.9 40.2 5.9 82.35 7.85
Nm
kgm
0 0.15 0 0.3 0 0.7 01 02 28.5 0 3 39 0 4 56 0 6 76 0 8.5 94.5 0 10.5 135 0 15 175 0 20 225 0 25 280 0 30 335 0 35
0 1.4 03 07 0 10 0 19 279 0 30 382 0 39 549 0 59 745 0 83 927 0 103 1320 0 140 1720 0 190 2210 0 240 2750 0 290 3290 0 340
1.35 3.2 6.7 11.5 18
13.2 31 66 113 177
kgm
0 0 0 0
0.8 1.9 4.1 8.4
0 0.2 0 0.5 0 0.6 0 0.8
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS ★ In the case of flared nuts for which there is no special instruction, tighten to the torque given in the table below.
SAD00483
Thread diameter
Width across flat
mm
mm
Nm
kgm
14 18 22 24 30 33 36 42
19 24 27 32 36 41 46 55
24.5 4.9 49 19.6 78.5 19.6 137.3 29.4 176.5 29.4 196.1 49 245.2 49 294.2 49
2.5 0.5 5 2 8 2 14 3 18 3 20 5 25 5 30 5
00-12
Tightening torque
0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0
FOREWORD
STANDARD TIGHTENING TORQUE
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS ★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the table below.
Thread diameter
Width across flat
Tightening torque
mm
mm
Nm
kgm
10 12 16
14 17 22
65.7 6.8 112 9.8 279 29
0 0 0
6.7 0.7 11.5 1 28.5 3
0
0 0
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS ★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter
Width across flat
Tightening torque
mm
mm
Nm
14 20 24 33 42
Varies depending on type of connector.
34.3 4.9 93.1 9.8 142.1 19.6 421.4 58.8 877.1 132.3
Norminal No.
02 03, 04 05, 06 10, 12 14
kgm
0 0 0 0 0
0 0.5 01 02 06 0 13.5
3.5 9.5 14.5 43 89.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS ★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter
Width across flat
Tightening torque
mm
mm
Nm
kgm
08 10 12 14 16 18 20 24 30 33 36 42 52
14 17 19 22 24 27 30 32 32 n 36 n n
7.35 1.47 11.27 1.47 17.64 1.96 22.54 1.96 29.4 4.9 39.2 4.9 49 4.9 68.6 9.8 107.8 14.7 127.4 19.6 151.9 24.5 210.7 29.4 323.4 44.1
0 0 0 0 0 0 0 0 0 0 0 0 0
0.75 0.15 1.15 0.15 1.8 0.2 2.3 0.2 3 0.5 4 0.5 5 0.5 7 1 11 1.5 13 2 15.5 2.5 21.5 3 33 4.5
Norminal No.
08 10 12 14 16 18 20 24 30 33 36 42 52
0 0 0 0 0 0 0 0 0 0 0 0 0
00-13
FOREWORD
STANDARD TIGHTENING TORQUE
TIGHTENING TORQUE FOR 102 ENGINE SERIES 1) BOLT AND NUTS Use these torques for bolts and nuts (unit: mm) of Cummins Engine. Thread diameter
Tightening torque
mm
Nm
6 8 10 12
10 2 24 4 43 6 77 12
kgm
0 0 0 0
1.02 2.45 4.38 7.85
0 0.20 0 0.41 0 0.61 0 1.22
2) EYE JOINTS Use these torques for eye joints (unit: mm) of Cummins Engine. Thread diameter
Tightening torque
mm
Nm
6 8 10 12 14
8 2 10 2 12 2 24 4 36 5
kgm
0 0 0 0 0
0.81 1.02 1.22 2.45 3.67
0 0.20 0 0.20 0 0.20 0 0.41 0 0.51
3) TAPERED SCREWS Use these torques for tapered screws (unit: inch) of Cummins Engine. Thread diameter
Tightening torque
inch
Nm
1 / 16 1/8 1/4 3/8 1/2 3/4 1
3 1 8 2 12 2 15 2 24 4 36 5 60 9
kgm
0 0 0 0 0 0 0
0.31 0.81 1.22 1.53 2.45 3.67 6.12
0 0.10 0 0.20 0 0.20 0 0.41 0 0.41 0 0.51 0 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE) ★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified. ★ Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque (Nm {kgm}) Nominal size Width across of hose flats
Taper seal type
Face seal type
Nominal thread Thread size size - Threads per Root diameter (mm) (mm) (Reference) inch, Thread series
Range
Target
19
35 - 63 {3.5 - 6.5}
44 {4.5}
14
9 – - 18UNF 16
14.3
22
54 - 93 {5.5 - 9.5}
74 {4.5}
–
11 – - 16UN 16
17.5
24
59 - 98 {6.0 - 10.0}
78 {8.0}
18
–
–
04
27
84 - 132 {8.5 - 13.5}
103 {10.5}
22
13 – - 16UN 16
20.7
05
32
128 - 186 {13.0 - 19.0}
157 {16.0}
24
1 - 14UNS
25.4
06
36
177 - 245 {18.0 - 25.0}
216 {22.0}
30
3 1 – - 12UNF 16
30.3
(10)
41
177 - 245 {18.0 - 25.0}
216 {22.0}
33
–
–
(12)
46
197 - 294 {20.0 - 30.0}
245 {25.0}
36
–
–
(14)
55
246 - 343 {25.0 - 35.0}
294 {30.0}
42
–
–
02
03
00-14
FOREWORD
ELECTRIC WIRE CODE
ELECTRIC WIRE CODE In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire Cable O.D. (mm)
Current rating (A)
Applicable circuit
0.88
2.4
12
Starting, lighting, signal etc.
0.32
2.09
3.1
20
Lighting, signal etc.
65
0.32
5.23
4.6
37
Charging and signal
15
84
0.45
13.36
7.0
59
Starting (Glow plug)
40
85
0.80
42.73
11.4
135
Starting
60
127
0.80
63.84
13.6
178
Starting
100
217
0.80
109.1
17.6
230
Starting
Norminal number
Number of strands
Dia. of strands (mm2)
Cross section (mm 2)
0.85
11
0.32
2
26
5
CLASSIFICATION BY COLOR AND CODE Circuits Priority Classification
1
Primary
Charging
Ground
Starting
Lighting
Instrument
Signal
Other
Code
W
B
B
R
Y
G
L
Color
White
Black
Black
Red
Yellow
Green
Blue
Code
WR
BW
RW
YR
GW
LW
2 Color White & Red Code
WB
3 Color White & Black Code 4
Auxiliary
WL
Color White & Blue Code
WG
5 Color White & Green Code 6 Color
n n
n n n n n n n n n n
White & Black Red & White Rellow & Red Green & White Blue & White BY
RB
YB
GR
LR
Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow BR
RY
Black & Red Red & Yellow
n n n n
RG
YG
GY
LY
Yellow & Green
Green & Yellow
Blue & Yellow
YL
GB
LB
Red & Green Yellow & Blue Green & Black Blue & Black RL
YW
GL
Red & Blue Yellow & White Green & Blue
n n 00-15
FOREWORD
CONVERSION TABLE
CONVERSION TABLE METHOD OF USING THE CONVERSION TABLE The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below.
EXAMPLE • Method of using the Conversion Table to convert from millimeters to inches 1. Convert 55 mm into inches. (1) Locate the number 50 in the vertical column at the left side, take this as , then draw a horizontal line from . (2) Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down from . (3) Take the point where the two lines cross as . This point gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches. 2. Convert 550 mm into inches. (1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the left) to convert it to 55 mm. (2) Carry out the same procedure as above to convert 55 mm to 2.165 inches. (3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
A B
C
C
A
B
B Millimeters to inches 1 mm = 0.03937 in
A
00-16
0
1
2
3
4
5
6
7
8
9
0 10 20 30 40
0 0.394 0.787 1.181 1.575
0.039 0.433 0.827 1.220 1.614
0.079 0.472 0.866 1.260 1.654
0.118 0.512 0.906 1.299 1.693
0.157 0.551 0.945 1.339 1.732
0.197 0.591 0.984 1.378 1.772
0.236 0.630 1.024 1.417 1.811
0.276 0.669 1.063 1.457 1.850
0.315 0.709 1.102 1.496 1.890
0.354 0.748 1.142 1.536 1.929
50 60 70 80 90
1.969 2.362 2.756 3.150 3.543
2.008 2.402 2.795 3.189 3.583
2.047 2.441 2.835 3.228 3.622
2.087 2.480 2.874 3.268 3.661
2.126 2.520 2.913 3.307 3.701
2.165 2.559 2.953 3.346 3.740
2.205 2.598 2.992 3.386 3.780
2.244 2.638 3.032 3.425 3.819
2.283 2.677 3.071 3.465 3.858
2.323 2.717 3.110 3.504 3.898
C
FOREWORD
CONVERSION TABLE
Millimeters to Inches 1 mm = 0.03937 in
0
1
2
3
4
5
6
7
8
9
0
0.039
0.079
0.118
0.157
0.197
0.236
0.276
0.315
0.354
10
0.394
0.433
0.472
0.512
0.551
0.591
0.630
0.669
0.709
0.748
20
0.787
0.827
0.866
0.906
0.945
0.984
1.024
1.063
1.102
1.142
30
1.181
1.220
1.260
1.299
1.339
1.378
1.417
1.457
1.496
1.536
40
1.575
1.614
1.654
1.693
1.732
1.772
1.811
1.850
1.890
1.929
50
1.969
2.008
2.047
2.087
2.126
2.165
2.205
2.244
2.283
2.323
60
2.362
2.402
2.441
2.480
2.520
2.559
2.598
2.638
2.677
2.717
70
2.756
2.795
2.835
2.874
2.913
2.953
2.992
3.032
3.071
3.110
80
3.150
3.189
3.228
3.268
3.307
3.346
3.386
3.425
3.465
3.504
90
3.543
3.583
3.622
3.661
3.701
3.740
3.780
3.819
3.858
3.898
0
Kilogram to Pound 1 kg = 2.2046 lb
0 0
0
1
2
3
4
5
6
7
8
9
2.20
4.41
6.61
8.82
11.02
13.23
15.43
17.64
19.84
10
22.05
24.25
26.46
28.66
30.86
33.07
35.27
37.48
39.68
41.89
20
44.09
46.30
48.50
50.71
51.91
55.12
57.32
59.53
61.73
63.93
30
66.14
68.34
70.55
72.75
74.96
77.16
79.37
81.57
83.78
85.98
40
88.18
90.39
92.59
94.80
97.00
99.21
101.41
103.62
105.82
108.03
50
110.23
112.44
114.64
116.85
119.05
121.25
123.46
125.66
127.87
130.07
60
132.28
134.48
136.69
138.89
141.10
143.30
145.51
147.71
149.91
152.12
70
154.32
156.53
158.73
160.94
163.14
165.35
167.55
169.76
171.96
174.17
80
176.37
178.57
180.78
182.98
185.19
187.39
189.60
191.80
194.01
196.21
90
198.42
200.62
202.83
205.03
207.24
209.44
211.64
213.85
216.05
218.26
00-17
FOREWORD
CONVERSION TABLE
Liter to U.S. Gallon 1l = 0.2642 U.S. Gal
0
1
2
3
4
5
6
7
8
9
0
0.264
0.528
0.793
1.057
1.321
1.585
1.849
2.113
2.378
10
2.642
2.906
3.170
3.434
3.698
3.963
4.227
4.491
4.755
5.019
20
5.283
5.548
5.812
6.076
6.340
6.604
6.869
7.133
7.397
7.661
30
7.925
8.189
8.454
8.718
8.982
9.246
9.510
9.774
10.039
10.303
40
10.567
10.831
11.095
11.359
11.624
11.888
12.152
12.416
12.680
12.944
50
13.209
13.473
13.737
14.001
14.265
14.529
14.795
15.058
15.322
15.586
60
15.850
16.115
16.379
16.643
16.907
17.171
17.435
17.700
17.964
18.228
70
18.492
18.756
19.020
19.285
19.549
19.813
20.077
20.341
20.605
20.870
80
21.134
21.398
21.662
21.926
22.190
22.455
22.719
22.983
23.247
23.511
90
23.775
24.040
24.304
24.568
24.832
25.096
25.361
25.625
25.889
26.153
0
Liter to U.K. Gallon 1l = 0.21997 U.K. Gal
0
1
2
3
4
5
6
7
8
9
0
0.220
0.440
0.660
0.880
1.100
1.320
1.540
1.760
1.980
10
2.200
2.420
2.640
2.860
3.080
3.300
3.520
3.740
3.950
4.179
20
4.399
4.619
4.839
5.059
5.279
5.499
5.719
5.939
6.159
6.379
30
6.599
6.819
7.039
7.259
7.479
7.969
7.919
8.139
8.359
8.579
40
8.799
9.019
9.239
9.459
9.679
9.899
10.119
10.339
10.559
10.778
50
10.998
11.281
11.438
11.658
11.878
12.098
12.318
12.528
12.758
12.978
60
13.198
13.418
13.638
13.858
14.078
14.298
14.518
14.738
14.958
15.178
70
15.398
15.618
15.838
16.058
16.278
16.498
16.718
16.938
17.158
17.378
80
17.598
17.818
18.037
18.257
18.477
18.697
18.917
19.137
19.357
19.577
90
19.797
20.017
20.237
20.457
20.677
20.897
21.117
21.337
21.557
21.777
0
00-18
FOREWORD
CONVERSION TABLE
kgm to ft. lb 1 kgm = 7.233 ft. lb
0
1
2
3
4
5
6
7
8
9
0
0
7.2
14.5
21.7
28.9
36.2
43.4
50.6
57.9
65.1
10
72.3
79.6
86.8
94.0
101.3
108.5
115.7
123.0
130.2
137.4
20
144.7
151.9
159.1
166.4
173.6
180.8
188.1
195.3
202.5
209.8
30
217.0
224.2
231.5
238.7
245.9
253.2
260.4
267.6
274.9
282.1
40
289.3
296.6
303.8
311.0
318.3
325.5
332.7
340.0
347.2
354.4
50
361.7
368.9
376.1
383.4
390.6
397.8
405.1
412.3
419.5
426.8
60
434.0
441.2
448.5
455.7
462.9
470.2
477.4
484.6
491.8
499.1
70
506.3
513.5
520.8
528.0
535.2
542.5
549.7
556.9
564.2
571.4
80
578.6
585.9
593.1
600.3
607.6
614.8
622.0
629.3
636.5
643.7
90
651.0
658.2
665.4
672.7
679.9
687.1
694.4
701.6
708.8
716.1
100
723.3
730.5
737.8
745.0
752.2
759.5
766.7
773.9
781.2
788.4
110
795.6
802.9
810.1
817.3
824.6
831.8
839.0
846.3
853.5
860.7
120
868.0
875.2
882.4
889.7
896.9
904.1
911.4
918.6
925.8
933.1
130
940.3
947.5
954.8
962.0
969.2
976.5
983.7
990.9
998.2
1005.4
140
1012.6
1019.9
1027.1
1034.3
1041.5
1048.8
1056.0
1063.2
1070.5
1077.7
150
1084.9
1092.2
1099.4
1106.6
1113.9
1121.1
1128.3
1135.6
1142.8
1150.0
160
1157.3
1164.5
1171.7
1179.0
1186.2
1193.4
1200.7
1207.9
1215.1
1222.4
170
1129.6
1236.8
1244.1
1251.3
1258.5
1265.8
1273.0
1280.1
1287.5
1294.7
180
1301.9
1309.2
1316.4
1323.6
1330.9
1338.1
1345.3
1352.6
1359.8
1367.0
190
1374.3
1381.5
1388.7
1396.0
1403.2
1410.4
1417.7
1424.9
1432.1
1439.4
00-19
FOREWORD
CONVERSION TABLE
kg/cm2 to lb/in2 1kg/cm2 = 14.2233 lb/in2
0
1
2
3
4
5
6
7
8
9
0
0
14.2
28.4
42.7
56.9
71.1
85.3
99.6
113.8
128.0
10
142.2
156.5
170.7
184.9
199.1
213.4
227.6
241.8
256.0
270.2
20
284.5
298.7
312.9
327.1
341.4
355.6
369.8
384.0
398.3
412.5
30
426.7
440.9
455.1
469.4
483.6
497.8
512.0
526.3
540.5
554.7
40
568.9
583.2
597.4
611.6
625.8
640.1
654.3
668.5
682.7
696.9
50
711.2
725.4
739.6
753.8
768.1
782.3
796.5
810.7
825.0
839.2
60
853.4
867.6
881.8
896.1
910.3
924.5
938.7
953.0
967.2
981.4
70
995.6
1010
1024
1038
1053
1067
1081
1095
1109
1124
80
1138
1152
1166
1181
1195
1209
1223
1237
1252
1266
90
1280
1294
1309
1323
1337
1351
1365
1380
1394
1408
100
1422
1437
1451
1465
1479
1493
1508
1522
1536
1550
110
1565
1579
1593
1607
1621
1636
1650
1664
1678
1693
120
1707
1721
1735
1749
1764
1778
1792
1806
1821
1835
130
1849
1863
1877
1892
1906
1920
1934
1949
1963
1977
140
1991
2005
2020
2034
2048
2062
2077
2091
2105
2119
150
2134
2148
2162
2176
2190
2205
2219
2233
2247
2262
160
2276
2290
2304
2318
2333
2347
2361
2375
2389
2404
170
2418
2432
2446
2460
2475
2489
2503
2518
2532
2546
180
2560
2574
2589
2603
2617
2631
2646
2660
2674
2688
190
2702
2717
2731
2745
2759
2773
2788
2802
2816
2830
200
2845
2859
2873
2887
2901
2916
2930
2944
2958
2973
210
2987
3001
3015
3030
3044
3058
3072
3086
3101
3115
220
3129
3143
3158
3172
3186
3200
3214
3229
3243
3257
230
3271
3286
3300
3314
3328
3343
3357
3371
3385
3399
240
3414
3428
3442
3456
3470
3485
3499
3513
3527
3542
00-20
FOREWORD
CONVERSION TABLE
Temperature Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right. 1°C = 33.8°F
°C
°F
°C
°F
°C
°F
°C
°F
–40.4 –37.2 –34.4 –31.7 –28.9
–40 –35 –30 –25 –20
–40.0 –31.0 –22.0 –13.0 –4.0
–11.7 –11.1 –10.6 –10.0 –9.4
11 12 13 14 15
51.8 53.6 55.4 57.2 59.0
7.8 8.3 8.9 9.4 10.0
46 47 48 49 50
114.8 116.6 118.4 120.2 122.0
27.2 27.8 28.3 28.9 29.4
81 82 83 84 85
117.8 179.6 181.4 183.2 185.0
–28.3 –27.8 –27.2 –26.7 –26.1
–19 –18 –17 –16 –15
–2.2 –0.4 1.4 3.2 5.0
–8.9 –8.3 –7.8 –7.2 –6.7
16 17 18 19 20
60.8 62.6 64.4 66.2 68.0
10.6 11.1 11.7 12.2 12.8
51 52 53 54 55
123.8 125.6 127.4 129.2 131.0
30.0 30.6 31.1 31.7 32.2
86 87 88 89 90
186.8 188.6 190.4 192.2 194.0
–25.6 –25.0 –24.4 –23.9 –23.3
–14 –13 –12 –11 –10
6.8 8.6 10.4 12.2 14.0
–6.1 –5.6 –5.0 –4.4 –3.9
21 22 23 24 25
69.8 71.6 73.4 75.2 77.0
13.3 13.9 14.4 15.0 15.6
56 57 58 59 0
132.8 134.6 136.4 138.2 140.0
32.8 33.3 33.9 34.4 35.0
91 92 93 94 95
195.8 197.6 199.4 201.2 203.0
–22.8 –22.2 –21.7 –21.1 –20.6
–9 –8 –7 –6 –5
15.8 17.6 19.4 21.2 23.0
–3.3 –2.8 –2.2 –1.7 –1.1
26 27 28 29 30
78.8 80.6 82.4 84.2 86.0
16.1 16.7 17.2 17.8 18.3
61 62 63 64 65
141.8 143.6 145.4 147.2 149.0
35.6 36.1 36.7 37.2 37.8
96 97 98 99 100
204.8 206.6 208.4 210.2 212.0
–20.0 –19.4 –18.9 –18.3 –17.8
–4 –3 –2 –1 0
24.8 26.6 28.4 30.2 32.0
–0.6 0 0.6 1.1 1.7
31 32 33 34 35
87.8 89.6 91.4 93.2 95.0
18.9 19.4 20.0 20.6 21.1
66 67 68 69 70
150.8 152.6 154.4 156.2 158.0
40.6 43.3 46.1 48.9 51.7
105 110 115 120 125
221.0 230.0 239.0 248.0 257.0
–17.2 –16.7 –16.1 –15.6 –15.0
1 2 3 4 5
33.8 35.6 37.4 39.2 41.0
2.2 2.8 3.3 3.9 4.4
36 37 38 39 40
96.8 98.6 100.4 102.2 104.0
21.7 22.2 22.8 23.3 23.9
71 72 73 74 75
159.8 161.6 163.4 165.2 167.0
54.4 57.2 60.0 62.7 65.6
130 135 140 145 150
266.0 275.0 284.0 293.0 302.0
–14.4 –13.9 –13.3 –12.8 –12.2
6 7 8 9 10
42.8 44.6 46.4 48.2 50.0
5.0 5.6 6.1 6.7 7.2
41 42 43 44 45
105.8 107.6 109.4 111.2 113.0
24.4 25.0 25.6 26.1 26.7
76 77 78 79 80
168.8 170.6 172.4 174.2 176.0
68.3 71.1 73.9 76.7 79.4
155 160 165 170 175
311.0 320.0 329.0 338.0 347.0
00-21
FOREWORD
UNITS
UNITS In this manual, the measuring units are indicated with Internatinal System of units (SI). As for reference, conventionally used Gravitational System of units are indicated in parentheses { Example: N {kg} Nm {kgm} MPa {kg/cm2} kPa {mmH2O} kPa {mmHg} kW/rpm {HP/rpm} g/kWh {g/HPh}
00-22
}.
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD Radiator, torque converter oil cooler, after cooler, work equipment oil cooler, fuel cooler ......... 10- 3 Brake oil cooler............................................ 10- 4 Power train skeleton.................................... 10- 5 Output shaft................................................. 10- 6 Drive shaft .................................................. 10-7-1 Torque converter and transmission hydraulic piping......................................................... 10- 8 Torque converter ......................................... 10-10 Transmission ............................................... 10-18 Transmission valve...................................... 10-27 E-POCV ...................................................... 10-28 Axle ............................................................. 10-38 Differential ................................................... 10-42 Final drive.................................................... 10-44 Wheels ........................................................ 10-46 Suspension.................................................. 10-48 Suspension cylinder .................................... 10-50 Rear axle support ........................................ 10-56 Steering column........................................... 10-58 Steering linkage........................................... 10-59 Brake piping ................................................ 10-62 Brake valve.................................................. 10-64 Emergency brake valve............................... 10-67 Relay valve.................................................. 10-68 Front brake off valve.................................... 10-69 Accumulator charge valve ........................... 10-71 Accumulator ................................................ 10-75 Slack adjuster.............................................. 10-76 Brake ........................................................... 10-78 Proportional reducing valve......................... 10-83 Parking brake solenoid valve ...................... 10-84 Steering and hoist hydraulic piping.............. 10-86
Steering and hoist hydraulic system diagram...................................................... 10-88 Dump body control ...................................... 10-90 Hydraulic tank ............................................. 10-91 Steering control valve .................................. 10-92 Crossover relief valve .................................. 10-96 Steering cylinder .......................................... 10-97 Demand valve.............................................. 10-98 Hoist valve ................................................. 10-102 EPC valve.................................................. 10-108 Hoist cylinder ............................................. 10-109 Hydraulic pump.......................................... 10-110 Air conditioner............................................ 10-114 Machine monitor system............................ 10-119 Engine control system ............................... 10-134 Automatic shift control system ................... 10-136 Payload meter (card type)...................... 10-151 Automatic emergency steering system...... 10-184 Automatic suspension system ................... 10-188 Retarder control system ............................ 10-192 Sensors, switches...................................... 10-204 Dump control lever .................................... 10-212 [Related to VHMS controller] VHMS controller ........................................ 10-216 BLOW-BY pressure sensor ....................... 10-216 Engine oil pressure sensor ........................ 10-217 Exhaust temperature sensor/amp ............. 10-218 Ambient temperature sensor...................... 10-218 Communications (orb•••orbcomm) controller/antenna...................................... 10-219 Payload meter (Having VHMS) ................. 10-220
For details of VHMS, see TESTING AND ADJUSTING.
HD465-7, HD605-7
10-1 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
DRIVE SHAFT
DRIVE SHAFT
1. Front drive shaft 2. Rear drive shaft
10-7-1 (6)
Outline • The power from the engine is transmitted through the output shaft, the front drive shaft (1) and the transmission, to the rear drive shaft (2).
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING
10-8
HD465-7, HD605-7
AXLE
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
AXLE FRONT
1. Wheel hub Unit: mm
No.
Check item
2
Wear of oil seal sliding surface
10-38 (6)
Criteria
Remedy
Standard size
Tolerance
Repair limit
280
0 –0.130
—
Repair or replace
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SUSPENSION
SUSPENSION
1. Front suspension cylinder 2. Radius rod (Upper rod) 3. Rear suspension cylinder 4. Radius rod (Lower rod) 5. Arm (A-frame)
Outline The suspension system supports the weight of the chassis, and absorbs the shock from uneven road surfaces to provide a comfortable ride for the operator. At the same time, it maintains the stability of the machine by ensuring that all four wheels are always in contact with the ground surface. In this way, it allows the machine to demonstrate its full performance in items such as acceleration, braking, and turning, even when traveling at high speed. Hydropneumatic cylinders are used for the suspension cylinders to reduce the shock. With hydropneumatic cylinders, the suspension cylinder is charged
10-48 (6)
(sealed) with oil and nitrogen gas. This acts as a shock absorber (spring and damper) by contracting and expanding the nitrogen gas and oil to absorb the load from the road surface. In addition to these functions, the front suspension employs an automatic suspension system. In this system, the force of the suspension is automatically changed by selecting the dumping force to match the travel conditions and load conditions. This further increases the stability and riding comfort of the machine.
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SUSPENSION
Function 1. Front suspension The front suspension cylinder functions as a shock absorber and spring, and is connected by spherical bearings to the lower arm (A-frame) and main frame. The wheels move up and down in accordance with the retraction and extension of the suspension cylinder to maintain the proper alignment for the wheels and to improve the stability of the machine.
2. Rear suspension The differential housing is supported by the frame and two radius rods at the bottom, and at the top by two inverted-V-shaped rods and two suspension cylinders. It is connected to these at both ends by spherical bearings. It transmits the load and motive force through the top and bottom rods. The inverted-V-shaped rods at the top also function to maintain the center of the machine (axle). Employment of the inverted-V-shaped link improves the rolling steering characteristics.
HD465-7, HD605-7
10-49 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SUSPENSION CYLINDER
SUSPENSION CYLINDER FRONT
1. 2. 3. 4.
Feed valve Cylinder (with axle) Rod Valve (for bleeding air and mounting pressure sensor) 5. Air bleeding valve 6. Tube
10-50 (6)
7. 8. 9. 10.
Air cylinder Valve assembly Damping force selector valve Damping force selector valve lever
A : Port B : Port
HD465-7, HD605-7
SUSPENSION CYLINDER
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
Unit: mm
No.
Check item
Criteria Tolerance Shaft
Hole
Standard clearance
160
–0.043 –0.106
+0.240 0
0.043 – 0.346
0.4
Standard size 11
Remedy
Clearance between piston rod and bushing
Clearance limit Replace bushing
12
Clearance between piston rod and bushing
160
–0.043 –0.106
+0.540 +0.360
0.403 – 0.646
0.7
Replace bushing
13
Clearance between cylinder and wear ring
200
–0.05 –0.26
+0.115 0
0.05 – 0.375
0.8
Replace wear ring
Repair limit
14
Elasticity of leaf spring
Max. 0.3 mm
Replace Measuring method: Measure protrusion and elongation stopper. All the conditions below must be fulfilled.
15
Deformation of stopper
HD465-7, HD605-7
Elongation : Max. 5 mm Protrusion: Max. 2 mm No cracks
10-51 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SUSPENSION CYLINDER
Structure and operation The suspension cylinder acts as a shock absorber and spring. The inside of the cylinder is divided into gas chamber A which is charged with nitrogen gas, and oil chamber B which is filled with oil. Oil chamber B and oil chamber C are conmected by tube (6) and valve body (8). a Nitrogen gas When the machine is traveling, the wheels follow the unevenness of the road surface, and an external force in the updown direction is applied to the suspension cylinder. When this happens, the volume of the nitrogen in gas chamber A changes elastically under the input force, and absorbs the external force. The nitrogen gas is sealed by a rod and oil, so it is always subjected to a pressure corresponding to the external force, and acts as an air spring. b Principle of generation of damping force Inside valve body (8) are orifice plate (8a) and leaf springs (8b) and (8c). They restrict the flow of oil between oil chamber B and oil chamber C, and create a damping force. i) Action when retracting When the nitrogen gas is compressed by the external force from the road surface, the oil in oil chamber B flows from oil chamber B through the valve (8) and tube (6) to oil chamber C. The oil flowing through the valve from direction Z to orifice plate (8a) is throttled by orifices in four places to generate a damping force. ii) Action when extending When the external force from the road surface weaken, the pressure of the nitrogen gas extends the rod, and the oil in oil chamber C passes through tube (6) and valve (8) and flows to oil chamber B. The oil inside the valve flows from direction X and passes through two orifices from orifice plate (8a) to generate a damping force.
10-52 (6)
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SUSPENSION CYLINDER
c. Variable shaft mechanism In the valve body, bypass circuit D is provided before and after orifice plate (8a), so the oil flow is divided into oil flowing through orifice plate (8a) and oil flowing through the bypass circuit D. The oil flowing through bypass circuit D passes through a shaft with orifices at two places on the inside circumference, and flows to oil chamber C or oil chamber B according to whether it is retracting or extending. The shaft is connected to an air cylinder driven by a signal from the retarder controller, and the size of the orifices automatically changes according to the condition of the machine. The damping force is set at three levels (MEDIUM, HARD, SOFT) according to the size of the orifices through which the oil is passing.
HD465-7, HD605-7
10-53 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SUSPENSION CYLINDER
REAR
1. 2. 3. 4. 5.
Feed valve Cylinder Rod Air bleeding valve Ball
10-54 (6)
HD465-7, HD605-7
SUSPENSION CYLINDER
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
Unit: mm
No.
Check item
Criteria Tolerance
Remedy
Hole
Standard clearance
Clearance limit
Shaft 180
–0.043 –0.106
+0.246 0
0.043 – 0.352
0.4
2
Crearance between piston rod and bushing
180
–0.043 –0.106
+0.246 0
0.043 – 0.352
0.4
3
Crearance between cylinder and wear ring
220
–0.050 –0.260
+0.115 –0.008
0.05 – 0.375
0.8
Standard size 1
Crearance between piston rod and bushing
Replace
Structure and operation The suspension cylinder has the function of both a shock absorber and spring. When a fixed amount of oil is sent from oil chamber (6) through orifices (4) and (5) to cavity (2), the oil is throttled by the orifices and a shock-absorbing effect is obtained. a) Retracting action When the machine is traveling and it hits a bump or object on the road, the wheels are pushed up, and the cylinder rod is pushed inside the cylinder. When this happens, the nitrogen gas inside chamber (7) is compressed, the oil in chamber (6) is sent through both orifices (4) and (5) to cavity (2), and cavity (2) is filled more quickly than when extending. b) Extending action When the machine has passed any bump or object on the road surface, the cylinder rod is pushed up by the weight of the wheels and axle and the pressure of the nitrogen inside chamber (7). As a result, the amount of oil in cavity (2) is reduced, and pressure is applied to the oil remaining in cavity (2). This pressurized oil closes orifice (4) with check ball (3), and is sent to chamber (6) through only orifice (5), so the flow of oil passing through the orifice is controlled so that it is less than during retraction. In this way, the amount of oil returning to chamber (6) is restricted to provide a shock absorbing effect.
HD465-7, HD605-7
1. 2. 3. 4. 5. 6. 7.
Air bleed Cavity Check ball Orifice Orifice Oil chamber Nitrogen gas chamber
8. Cylinder rod 9. Cylinder 10. Feed valve a : When extending b : When retracting
10-55 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
REAR AXLE SUPPORT
REAR AXLE SUPPORT
1. Rod 2. Rod 3. Axle 4. Suspension cylinder
10-56 (6)
HD465-7, HD605-7
REAR AXLE SUPPORT
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
Unit: mm
No.
Check item
Criteria Tolerance Shaft
Hole
Standard clearance
–0.030 –0.076
+0.046 0
0.030 – 0.122
0.3
0.110 – 0.180
0.5
0.030 – 0.122
0.3
0.110 – 0.180
0.5
Standard size 5
Clearance between rod mounting pin and bushing 70
6
Clearance between inner and outer for bushing
100
7
Clearance between suspension cylinder mounting pin and frame or axle
70
8
Clearance between inner and outer for bushing
100
HD465-7, HD605-7
Remedy
–0.030 –0.076
+0.046 0
Clearance limit
Replace
10-57 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
STEERING COLUMN
STEERING COLUMN
1. Steering shaft 2. Steering column 3. Lock lever 4. Yoke 5. Joint shaft 6. Steering valve
10-58 (6)
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
STEERING LINKAGE
STEERING LINKAGE
1. Center lever 2. Tie rod 3. Arm (A-frame) 4. Knuckle arm
HD465-7, HD605-7
10-59 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
10-60 (6)
STEERING LINKAGE
HD465-7, HD605-7
STEERING LINKAGE
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
Unit: mm
No.
Check item
Criteria Tolerance Standard size
5
Clearance between inner and outer for knuckle arm bushing
Shaft
Hole
165
Remedy Standard clearance
Clearance limit
0.150 – 0.300
0.7
6
Clearance between bushing and pin
85
0 –0.035
+0.054 0
0–
7
Clearance between steering cylinder mounting pin and bushing
45
–0.025 –0.064
+0.069 +0.030
0.055 – 0.133
0.3
8
Clearance between inner and outer for bushing
80
0.120 – 0.250
0.4
9
Clearance between tie rod mounting pin and bushing
40
0.055 – 0.133
0.3
10
Clearance between inner and outer for bushing
110
0.120 – 0.250
0.4
11
Clearance between arm mounting pin and bushing
55
0.060 – 0.152
0.3
12
Clearance between inner and outer for bushing
100
0.110 – 0.180
0.5
13
Clearance between arm mounting pin and bushing
70
–0.030 –0.076
+0.091 +0.045
0.075 – 0.167
0.3
14
Clearance between center lever mounting pin and bushing
55
–0.030 –0.076
+0.197 +0.137
0.167 – 0.273
1.0
15
Clearance between inner and outer for bushing
80
0.120 – 0.250
0.4
16
Clearance between tie rod mounting pin and bushing
40
–0.025 –0.064
+0.069 +0.030
0.055 – 0.133
0.3
17
Clearance between suspension cylinder mounting pin and bushing
60
–0.030 –0.076
+0.046 0
0.030 – 0.122
0.3
HD465-7, HD605-7
–0.025 –0.064
–0.030 –0.076
+0.069 +0.030
+0.076 +0.030
0.089
0.3
Replace
10-61 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BRAKE PIPING
BRAKE PIPING
10-62 (6)
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
BRAKE PIPING
Front brake cut valve Relay valve Slack adjuster Emergency brake valve Brake valve Parking brake valve Accumulator charge valve Accumulator (parking brake) Accumulator (rear brake) Accumulator (front brake) Proportional reducing valve (for retarder)
HD465-7, HD605-7
10-63 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BRAKE VALVE
BRAKE VALVE
1. Pilot piston 2. Rod 3. Lower cylinder 4. Spool 5. Upper cylinder 6. Spool
10-64 (6)
A : To rear brake B : To front brake C : To transmission oil pan D : From front accumulator E : From rear accumulator
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
Operation Upper portion • When brake pedal (1) is depressed, the operating force is transmitted to spool (3) through rod (2) and spring (4). When spool (3) goes down, drain port a is closed, and the oil from the pump and accumulator flows from port A to port C and actuates the rear brake cylinders. Lower portion • When brake pedal (1) is depressed, the operating force is transmitted to spool (3) through rod (2) and spring (4). When spool (3) goes down, spool (5) is also pushed down by plunger (6). When this happens, drain port b is closed, and the oil from the pump and accumulator flows from port B to port D and actuates the front brake cylinders.
BRAKE VALVE
Applying brake when upper valve fails • Even if there is leakage of oil in the upper piping, spool (5) is moved down mechanically when pedal (1) is depressed, and the lower portion is actuated normally. The upper brake is not actuated. Applying brake when lower valve fails • Even if there is leakage of oil in the lower piping, the upper portion is actuated normally.
When actuation is balanced Upper portion • When oil fills the rear brake cylinders and the pressure between port A and port C becomes high, the oil entering port H from orifice e of spool (3) pushes against spring (4). It pushes up spool (3) and shuts off the circuit between port A and port C. When this happens, drain port a stays closed, so the oil entering the brake cylinder is held and the brake remains applied.
HD465-7, HD605-7
10-65 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
Lower portion • When spool (3) in the upper portion moves up and the circuit between port A and port C is shut off, oil also fills the front brake cylinder at the same time, so the pressure in the circuit between port B and port D rises. The oil entering port J from orifice f of spool (5) pushes up spool (5) by the same amount that spool (3) moves, and shuts off port B and port D. Drain port b is closed, so the oil entering the brake cylinder is held, and the brake is applied. • The pressure in the space in the upper portion is balanced with the operating force of the pedal, and the pressure in the space in the lower portion is balanced with the pressure in the space in the upper portion. When spools (3) and (5) move to the end of their stroke, the circuits between ports A and C and between ports B and D are fully opened, so the pressure in the space in the upper and lower portions and the pressure in the left and right brake cylinders is the same as the pressure from the pump. Therefore, up to the point where the piston moves to the end of its stroke, the effect of the brake can be adjusted by the amount that the pedal is depressed.
10-66 (6)
BRAKE VALVE
Brake released Upper portion • When pedal (1) is released and the operating force is removed from the top of the spool, the back pressure from the brake cylinder and the force of the spool return spring move spool (3) up. Drain port a is opened and the oil from the brake cylinder flows to the transmission oil pan return circuit to release the rear brakes. Lower portion • When the pedal is released, spool (3) in the upper portion moves up. At the same time, the back pressure from the brake cylinder and the force of the spool return spring move spool (5) up. Drain port b is opened and the oil from the brake cylinder flows to the transmission oil pan return circuit to release the front brake.
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
EMERGENCY BRAKE VALVE
EMERGENCY BRAKE VALVE
HD465-7, HD605-7
10-67 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
RELAY VALVE
RELAY VALVE
1. Spool 2. Upper cylinder 3. Lower cylinder 4. Spool
Function • This valve operates the brake depending on the parking brake release pressure controlled by the emergency brake pedal.
A : To front brake P : From accumulator Pp: From emergency brake valve T : To transmission oil pan
10-68 (6)
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
FRONT BRAKE OFF VALVE
FRONT BRAKE OFF VALVE
WHITE
1. Connector 2. Solenoid A : To front brake P : From brake valve T : To transmission oil pan
HD465-7, HD605-7
Function • This valve is installed on the brake oil circuit between the brake valve and the front brake. When the front brake off switch of the operator's seat is pressed, the solenoid is energized, and the valve cuts off the circuit between the brake valve and the front brake.
10-69 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ACCUMULATOR CHARGE VALVE
ACCUMULATOR CHARGE VALVE
ACC : To accumulator P : From hydraulic pump PP : From accumulator T : To transmission oil pan
Specification • Cut in pressure : 14.2 MPa {14.5 kg/cm2} • Cut out pressure: 20.6 MPa {210 kg/cm2} Function • The accumulator charge valve is actuated to maintain the oil pressure from the pump at the specified pressure and to store it in the accumulator. • When the oil pressure reaches the specified pressure, the oil from the pump is connected to the drain circuit to reduce the load of the pump.
HD465-7, HD605-7
10-71 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
1. Main relief valve (R3) 2. Valve body 3. Relief valve (R1)
10-72 (6)
ACCUMULATOR CHARGE VALVE
4. Relief valve (H1) 5. Filter 6. Filter
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
Operation 1. When no oil is being supplied to accumulator (cut-out condition) • The pressure at port B is higher than the set pressure of the relief valve (R1), so piston (8) is forcibly pushed up by the oil pressure at port B. Poppet (6) is opened, so port C and port T are short circuited. • The spring chamber at the right end of spool (15) is connected to port C of the relief valve (R1), so the pressure becomes the brake oil tank pressure. The oil from the pump enters port P, pushes spool (15) to the right at a low pressure equivalent to the load on spring (14). It also passes through orifices (17), (18) and (16), and flows to the brake oil tank.
HD465-7, HD605-7
ACCUMULATOR CHARGE VALVE
2. When oil supplied to accumulator 1) Cut-in condition • When the pressure at port B is lower than the set pressure of the relief valve (R1), piston (8) is pushed back down by spring (5). Valve seat (7) and poppet (6) are brought into tight contact, and port C and port T are shut off. • The spring chamber at the right end of spool (15) is also shut off from port T, so the pressure rises, and the pressure at port P also rises in the same way. • When the pressure at port P goes above the pressure at port B (accumulator pressure), the supply of oil to the accumulator starts immediately. In this case, it is decided by the size (area) of orifice (17) and the pressure difference (equivalent to the load on spring (14)) generated on both sides of the orifice. A fixed amount is supplied regardless of the engine speed.
10-73 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
2) When cut-out pressure is reached • When the pressure at port B (accumulator pressure) reaches the set pressure of the relief valve (R1), poppet (6) separates from valve seat (7), so an oil flow is generated and the circuit is relieved. • When the circuit is relieved, a pressure difference is generated above and below piston (8), so piston (8) moves up, poppet (6) is forcibly opened, and port C and port T are short circuited. • The spring chamber at the right end of spool (15) is connected to port C of the relief valve (R1), so the pressure becomes the brake oil tank pressure. • The pressure at port P drops in the same way to a pressure equivalent to the load on spring (14), so the supply of oil to port B is stopped.
10-74 (6)
ACCUMULATOR CHARGE VALVE
3. Main relief valve (R3) • If the pressure at port P (pump pressure) goes above the set pressure of the relief valve (R3), the oil from the pump pushes spring (3). Ball (11) is pushed up and the oil flows to the brake oil tank circuit, so this set the maximum pressure in the brake circuit and protects the circuit.
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ACCUMULATOR
ACCUMULATOR
1. Valve 2. Top cover 3. Cylinder 4. Piston Function • The accumulator is installed between the accumulator charge valve and the brake valve. It is charged with nitrogen gas between cylinder (3) and free piston (4), and uses the compressibility of the gas to absorb the pulse of the hydraulic pump or to maintain the braking force and to make it possible to operate the machine if the engine should stop. Specifications Front brake Gas used : Nitrogen gas Charge amount : 3,500 cc Charging pressure: 11.8 MPa {120 kg/cm2} Rear brake, Parking brake Gas used : Nitrogen gas Charge amount : 4,000 cc Charging pressure: 6.9 MPa {70 kg/cm2}
HD465-7, HD605-7
10-75 (6)
SLACK ADJUSTER
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SLACK ADJUSTER
1. Cylinder 2. Check valve 3. Piston A : Inlet port B : Outlet port
Unit: mm
No.
Check item
Criteria Tolerance Hole
Standard clearance
Clearance limit
Shaft –0.030 –0.076
+0.074 0
0.030 – 0.150
0.25
Standard size 4
Clearance between body and piston 55
Remedy
Standard size 5
Slack adjuster spring
10-76 (6)
Replace
Repair limit
Spring coefficient
Installed length
Installed load
Free length
Installed load
0.45 N/mm {0.046 kg/mm}
97
45.6 N {4.7 kg}
–
–
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
Function • The slack adjuster is installed in the brake oil line from the brake valve to the brake piston. It acts to keep the clearance between the brake piston and discs constant even when the brake discs are worn. in this way it acts to keep a constant time lag when the brake is operated.
•
SLACK ADJUSTER
If the brake pedal is depressed further, and the oil pressure discharged from the brake valve goes above to set pressure, check valve (3) opens and the pressure is applied to port C to act as the braking force. Therefore, when the brake is applied, the time lag is a fixed value.
Operation 1. When brake pedal is depressed • Before the brake is depressed, piston (4) is returned by the distance of stoke S (full stroke). When the brake pedal is depressed, the oil discharged from the brake valve flows from port P of the slack adjuster and is divided to left and right cylinders (2), where it moves piston (4) by stroke S to the left and right. 2. When brake pedal is released • When the brake is released, piston (4) is returned by brake return spring (8) by an amount equivalent to the oil for the stroke S, and the brake is released. In other words, return stroke T of brake piston (7) is determined by the amount of oil for stroke S of the slack adjuster. The time lag of the brake is always kept constant regardless of the wear of the brake disc. •
When this is done, brake piston (7) moves by a distance of stroke S. In this condition, the closer the clearance between the brake piston and dics is to 0, the greater the braking force becomes.
HD465-7, HD605-7
10-77 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BRAKE
BRAKE FRONT
1. Piston 2. Pad 3. Disc
10-78 (6)
HD465-7, HD605-7
BRAKE
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
Unit: mm
No.
Check item
4
Wear of pad (remaining thickness of wear material)
5
Missing portion of pad
6
Face runout of disc (Note 1)
7
Wear of disc (thickness of disc)
Criteria
Remedy
Standard size
Repair limit
19.5
3.0
–
Ratio of surface: 10%
0.15
0.50
30
Less than 27
Replace
Correct of replace
Replace Open crack in radial direction 8
Damage to disc surface
– Electric wear, marked damage (Note 2)
Correct
Note 1: • If there is excessive face runout of the disc, check the front wheel bearing also. Note 2: • If the depth of the scratch exceeds 1.5 mm. • If the whole pad is worn, the disc has been rubbed by mistake by the pad rear plate, the rear plate metal is melted to the disc, or there is protrusion. • If there are vertical scratches other than concentric scratches.
HD465-7, HD605-7
10-79 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BRAKE
REAR
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Inner gear Retainer Outer gear Plate Disc Damper Piston Spring (for parking brake) Cylinder Cylinder (for parking brake)
10-80 (6)
HD465-7, HD605-7
BRAKE
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
Unit: mm
No.
Check item
11
Backlash between outer gear and plate
12
Backlash between inner gear and disc
13
Thickness of plate
Criteria
Remedy
Standard size
Repair limit
0.21 – 0.64
2.2
0.21 – 0.64
2.2
Standard size
Repair limit
2.4
2.15
14
Thickness of disc
5.1
4.6
15
Thickness of damper
6.9
5.1
16
Thickness of damper
3.4
3.0
Warping of disc friction surface
Standard warping
Repair limit
17
Max. 0.45
0.7
Max. 0.50
0.7
Standard size
Repair limit
93.9
86.2
18
Warping of plate and damper friction surface
19
Assemble thickness of plate and disc
HD465-7, HD605-7
Replace
10-81 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BRAKE
Operation of brake • When the brake pedal is depressed, pressure oil from the brake valve moves brake piston (7) to the right in the direction of the arrow. This presses disc (5) and plate (4) together and generates friction between the disc and plate. The wheel is rotating together with the disc, so this friction reduces the travel speed and stops the machine.
Operation of parking brake • The parking brake contained in the rear brake is structurally designed to operate mechanically by spring (8) force and to be released by hydraulic pressure. • The parking releasing hydraulic pressure acts on the parking brake piston (10) from the accumulator through the brake valve and parking brake solenoid. • With the parking brake switch at the driver's seat in the travel position, the parking releasing hydraulic pressure releases the parking brake by pressing the parking brake piston (10) and retracting the spring (8).
•
•
Function • The rear brake is of an oil cooled multiple disc type, and it operates as a parking brake by use of spring.
10-82 (6)
When the brake pedal is released, the pressure at the back face of brake piston (7) is released, so the piston is moved to the left in the direction of the arrow by the internal pressure, and this releases the brake.
With the parking brake switch in the parking position, the parking brake solenoid is demagnetized and the parking releasing hydraulic pressure is released. Then, the parking brake is engaged through the parking brake piston (10), brake piston (7), plate (4), and disk (5) pressed by spring force.
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PROPORTIONAL REDUCING VALVE
PROPORTIONAL REDUCING VALVE
1. Filter 2. Connector 3. Solenoid assembly A : From slack adjuster P : From slack adjuster T : To transmission oil pan
HD465-7, HD605-7
Function • The proportional reducing valve is a valve used for retarder control. It is installed between the slack adjuster and the transmission oil pan in the brake circuit. It varies the discharge pressure of the pressure oil in accordance with the turning angle of the retarder control lever, so the retarder control can be carried out as desired.
10-83 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PARKING BRAKE SOLENOID VALVE
PARKING BRAKE SOLENOID VALVE
1. Connector 2. Solenoid B : To parking brake P : From emergency brake valve T : To transmission oil pan
10-84 (6)
Function • The parking brake solenoid is installed in the brake oil circuit between the emergency brake valve and the rear brake. When the parking brake switch is set to PARK, the solenoid valve is demagnetized and cut off the parking brake release oil pressure. Then, the spring force will operate the parking brake.
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
STEERING AND HOIST HYDRAULIC PIPING
STEERING AND HOIST HYDRAULIC PIPING
10-86 (6)
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
STEERING AND HOIST HYDRAULIC SYSTEM DIAGRAM
STEERING AND HOIST HYDRAULIC SYSTEM DIAGRAM
10-88 (6)
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HD465-7, HD605-7
STEERING AND HOIST HYDRAULIC SYSTEM DIAGRAM
10-89 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
DUMP BODY CONTROL
DUMP BODY CONTROL
1. 2. 3. 4. 5. 6.
Dump control lever Hydraulic pump (SAR(3)80+80+(1)6) Hoist valve EPC valve Body positioner sensor Hoist cylinder
10-90 (6)
Function • The positioner sensor senses the body operation, and from this data the retarder controller controls output to the EPC valve.. • The signal from the dump control lever is controlled by the retarder controller, and actuates the EPC valve. The pilot pressure generated by the EPC valve moves the spool of the hoist valve and controls the hoist cylinder.
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC TANK
HYDRAULIC TANK
1. Breather 2. Drain 3. Oil level gauge
HD465-7, HD605-7
10-91 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MACHINE MONITOR SYSTEM
MACHINE MONITOR SYSTEM
Network data 1. From machine monitor to each controller • Switch input data • Option setting data 2. From each controller to machine monitor • Display data related to each controller • Service mode data • Troubleshooting data 3. From transmission controller to machine monitor • Model selection data
HD465-7, HD605-7
10-119 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
Outline • With the machine monitor system, the controllers on the network use the data from the sensors installed to all parts of the machine to observe and control the condition of the machine and transmit that data as network data to the machine monitor. • The machine monitor is a system to display these data and inform the operator of the condition of the machine. • There are two types of display on the machine monitor: the normal mode and the service mode. • The items that are always displayed for the operator are the normal mode items. Their main content is as follows. 1. Normal display items • Meters (speedometer, tachometer) • Gauges (engine water temperature, torque converter oil temperature, retarder oil temperature, fuel level) • Pilot display • Service meter, odometer (character display) 2. Items displayed when there is abnormality Caution, action code display (if an action code is being displayed, press machine monitor mode selector switch (2), then release it. A failure code (6-digit) is then displayed.) 3. When the filter, oil replacement interval is reached, the item needing replacement is displayed in the character display. 4. Other functions using the character display and the machine monitor mode selector switch to operate include the following: Total reverse distance traveled display, filter, oil replacement interval reset, telephone number input, and language selection. •
To make it easier to carry out troubleshooting of the controllers (including the monitor panel itself), a service mode function is provided. Its main content is as follows. 1. Displaying trouble data for electrical components, deleting from memory • Displays electrical components failure data from each controller that is saved in machine monitor • Deletes data from memory 2. Trouble data for machine • Displays machine failure data from each controller that is saved in machine monitor 3. Real-time monitor • Takes input and output signal values recognized by each controller on network and displays in real time.
10-120 (6)
MACHINE MONITOR SYSTEM
4. E-POCV compensation This is used for the initial adjustment of the transmission. 5. Changing replacement time for filter, oil. This changes the original setting for the replacement interval. 6. Snapshot For details, see "TESTING AND ADJUSTING, Execution of Pm Clinic with Manual Snapshot (another name: Quick PM)". 7. Controller initialize This function is used to set the machine monitor when the machine is shipped from the factory. The service mode has the following functions. Setting service meter • This can set service meter values recorded in machine monitor memory • However, values can only be increased from present value (they cannot be decreased). Setting total travel distance • This can set travel distance values recorded in machine monitor memory • However, values can only be increased from present value (they cannot be decreased). Setting distance traveled in reverse • This can set values for distance traveled in reverse recorded in machine monitor memory. • However, values can only be increased from present value (they cannot be decreased). •
The machine monitor system consists of the monitor panel, buzzer, and switches, network, controllers on the network, and the sensors inputting data to the monitor panel.
•
If the payload meter (having VHMS) is set optionally, execute display of load mass and setting of items related to the payload meter, too. For details, see "OPERATION MANUAL" and "STRUCTURE, OPERATION, and MAINTENANCE STANDARD, Payload meter (having VHMS)".
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MACHINE MONITOR SYSTEM
3) Real-time monitor This function is used when checking the input and output signals recognized by the controllers on the network. The real-time monitor display on the character display is as shown below. *** : Displays name of item ##### : Displays ID No. given to each item %%% : Displays data. If units are used, the unit is displayed on the right side of the data By specifying the ID No. given to each item, it is possible to display the desired 2 items at the same time. The character display when a second item is displayed at the same time is as shown below. ##### : Displays specified ID No. %%% : Displays data. If units are used, theunit is displayed on the right side of the data 4) ECMV compensation For details of this function, see TESTING AND ADJUSTING, Adjusting transmission, 2. ECMV compensation. 5) Changing filter, oil replacement time For details of this function, see the Operation and Maintenance Manual, OPERATION, Character display portion, Filter, oil replacement time display. This is used when changing the replacement interval. 6) Snapshot function When the VHMS controller is installed, this menu is displayed. For details, see "TESTING AND ADJUSTING, [Items related to PM Clinic], Execution of Pm Clinic with Manual Snapshot (another name: Quick PM)". 7) PLM setting function When payload meter (having VHMS) is set optionally, this menu is displayed. For details, see "STRUCTURE, OPERATION, and MAINTENANCE STANDARD, Payload meter (having VHMS)". 8) Controller initialize This function is used only at the factory, so do not touch it. 9) Setting service meter This is used when replacing the machine monitor with a new part, and setting the appropriate service meter reading for the machine. For details of the method of operation, see TESTING AND ADJUSTING, Adjusting machine monitor. 10) Setting travel distance total This is used when replacing the machine monitor with a new part, and setting the appropriate travel distance total value for the machine. For details of the method of operation, see TESTING AND ADJUSTING, Adjusting machine monitor. 11) Setting reverse travel distance total This is used when replacing the machine monitor with a new part, and setting the appropriate reverse travel distance total value for the machine. For details of the method of operation, see TESTING AND ADJUSTING, Adjusting machine monitor.
10-132 (6)
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
2. Method of operation For details of the method of operating each ser vice mode function, see TROUBLESHOOTING. For details of the method for setting the service meter, travel distance total, and reverse travel
HD465-7, HD605-7
MACHINE MONITOR SYSTEM
distance total, see TESTING AND ADJUSTING. REMARK : When the starting switch is turned OFF, it returns to the normal mode.
10-133 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
Safety functions 1) Down-shift inhibition function If gearshift lever is operated D → 6-L, 6 → 5-L, 5 → 4-L, 4 → 3-L, 3 → 2-L, 2 → L For example, when traveling in D (F6), even if the gearshift lever is operated to 4, the transmission does not shift directly F6 → F4. It shifts down F6 → F5 → F4 in turn according to the travel speed. (The transmission does not jump two speed ranges if the operator makes a mistake when operating the gearshift lever. This is to prevent the engine from overrunning.) 2) Neutral safety function This circuit prevents the engine from starting if the gearshift lever is not at the N position, even if the starting switch is turned to the START position. (This is a safety circuit to prevent the machine from moving unexpectedly when the engine is started.) 3) Directional inhibition function When traveling forward at a speed of more than 4 km/h, even if the gearshift lever is operated to positions R, the transmission will not be shifted immediately to travel in reverse. The speed range is shifted to N and the engine speed is lowered to reduce the travel speed. When the travel speed goes below 4 km/h, the transmission is shifted to REVERSE. (To prevent overload on power train, to improve durability and reliability) 4) Power train overrun prevention rear brake function When the engine speed exceeds 2,500 rpm in high-speed mode or 2,400 rpm in low-speed mode, the central warning lamp flashes and the warning buzzer sounds. When the engine speed exceeds 2,600 rpm in high-speed mode or 2,450 rpm in low-speed mode, the rear brake is activated automatically. (To prevent overrun of engine, torque converter, and transmission, to improve durability and reliability) Condition in which high speed mode can be selected: Any of coditions below is sattisfied (1) Shifting up is possible (2) Gear shift is placed in any of F7, N, and R positions Condition in which low speed mode can be seleced: In the condition other than high speed mode 5) REVERSE safety The machine will not travel in reverse if the dump control lever is not at FLOAT and the dump body is not completely lowered. (Turnover prevention function)
HD465-7, HD605-7
AUTOMATIC SHIFT CONTROL SYSTEM
6) Speed range limit function when dump body is raised. After dumping the load, if the body is not completely lowered, shifting up is limited. If the gearshift lever is at D, the machine starts in F2, and if it is at positions 6 to L, the machine starts in F1. The transmission does not shift up until the body is completely lowered. Self-diagnostic function The controller carries out self-diagnosis of the system and displays any abnormalities. If any abnormality is detected by the self-diagnosis function, the abnormality data is transmitted to the network and is displayed as an action code on the machine monitor. The transmission system caution, warning lamp, or alarm buzzer may also be actuated.
10-147
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PAYLOAD METER
PAYLOAD METER
(CARD TYPE)
(CARD TYPE)
STRUCTURE OF SYSTEM
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.
Shift lever neutral detection switch (relay) Body FLOAT signal (reterder controller) Clinometer Pressure sensor (for front left) Pressure sensor (for front right) Pressure sensor (for rear left) Pressure sensor (for rear right) Suspension cylinder Payload meter Lamp drive relay External display lamp Battery Fuse (for external display lamp) Fuse (for controller) Memory card Travel signal sensor RS232C output (PC cable communication) socket Battery charge signal (alternator terminal R)
HD465-7, HD605-7
Outline • A dump truck is supported by 4 suspension cylinders. By measuring the total of the loads on each cylinder, it is possible to know the mass on the springs of the dump truck. The measurement of the load mass is obtained by calculating the difference between the mass when empty and the mass when full. Payload meter displays the load mass calculated as above on the monitor screen and displays the load level on the external display lamps. The load mass, distance, time, time when engine was turned ON/OFF, time of occurrence/cancellation of abnormalities or warnings, and other data of each transportation cycle are automatically saved in memory. These data can be later transmitted to a PC or written in a memory card. It also has an estimation display function: when loading the next load, the new total load mass is estimated and the appropriate lamp flashes. This prevents overloading.
10-151 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PAYLOAD METER
(CARD TYPE)
BLOCK DIAGRAM OF PAYLOAD METER
•
•
If a dump truck having the VHMS controller is equipped with the payload meter (having VHMS) optionally, the payload meter (card type) cannot be mounted. When the payload meter (card type) is installed for the first time, replaced, or removed on a dump truck having the VHMS controller, perform "setting of rotary switch 2 (SW2) of the transmission controller" and "setting with VHMS initial setting manual (tool)". For setting procedure, see STRUCTURE, OPERATION, and MAINTENANCE STANDARD, "Initial Setting of Payload Meter" and TESTING AND ADJUSTING, "Initial Setting of Payload Meter", and [Items related to VHMS controller] "VHMS Initial Setting Manual (Tool)".
10-151-1 (6)
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PAYLOAD METER
(CARD TYPE)
PRINCIPLE OF CALCULATION 1. Outline A dump truck is supported by 4 suspension cylinders. By measuring the total of the loads on each cylinder, it is possible to know the load mass on the springs of the dump truck. The measurement of the load mass is obtained by calculating the difference between the mass when empty and the mass when full. The load on each cylinder can be calculated from the internal pressure and sectional area of the suspension cylinder. [Load bearing on suspension cylinder] W = PB SB – PT (SB – ST) Where W = Load bearing on suspension cylinder PB = Bottom pressure PT = Top pressure SB = Cross-sectional area of cylinder ST = Cross-sectional area of rod Because of the structure of the suspension cylinder, PB PT Therefore, the load can be calculated as follows. W = PBST
10-152 (6)
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PAYLOAD METER
(CARD TYPE)
2. Measurement of mass when empty (Calibration) Drive the empty dump truck at a speed of about 10 km/h for about 30 seconds, and then measure the average load and use it as the mass when empty. The reason why the mass is measured while the dump truck is traveling is that the sliding resistance of the suspension cylinders must be averaged by extracting and retracting the cylinders by changing the condition of the dump truck. The measured mass when empty is saved as a calibration data in the memory in the controller. 3. Measurement of mass when full Load the dump truck and measure the mass at that time. When loading for this purpose, set the gearshift lever in the "N" position and set the dump control lever in the "FLOAT" position on a ground where the longitudinal inclination of the dump truck is ± 5°. 4. Correction on slope If the dump truck is loaded on a slope, the measured mass is different from the mass measured on a level ground. To solve this problem, the longitudinal inclination of the dump truck is measured and the measured mass is corrected according to the inclination angle. (Correction range of inclination angle: ± 5°) 5. Detecting distance, travel speed (payload meter ) The travel speed and distance are detected from the travel signal sensor on the truck. ★ Travel signal sensor: Transmission output speed sensor
HD465-7, HD605-7
10-153 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PAYLOAD METER
(CARD TYPE)
FEATURES OF EACH DEVICE 1. Payload meter Payload meter receives signals from the pressure sensors, clinometer, body float sensor, gearshift lever (neutral sensor switch on Payload meter ), etc., calculates the load mass with the microcomputer in it, displays the calculation result on the panel, and indicates the load level on the external indicator lamps. 1) General locations of payload 1. Display 2. Communication "receiving" lamp (Rx busy) 3. Communication "transmitting" lamp (Tx busy) 4. Memory card access lamp (CARD busy) 5. Mode switch 6. Calibration/clear switch 7. Total/shift switch 8. Light/increment switch 9. Memory card 10. Cover ★ Communication "transmitting" lamp (3) lights up even when the communication cable is not connected to a PC or when there is defective connection. ★ When not inserting or removing memory card (9), always keep cover (10) closed.
10-154 (6)
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PAYLOAD METER
(CARD TYPE)
LEFT FACE
•
Details of switches on left face No.
Name
Type
1.
Load mass compensation trimmer
Rotary volume
–20% – (Counterclockwise)
2.
Speed compensation trimmer
0 – F rotary selector switch
0 : 107% –7 : 107% – F : 92%
3.
Distance compensation trimmer
0 – F rotary selector switch
0 : 107% –7 : 107% – F : 92%
4.
Model selector switch
0 – F rotary selector switch
According to model selector code table
5.
Memory card use switch
2-stage selector switch
Up : Not used Down : Used
6.
Clinometer use switch
2-stage selector switch
Up : Not used Down : Used
7.
Mass unit setting switch
2-stage selector switch
Up: t (Metric ton), Down: US ton (Short ton)
8.
Switch forcible prohibition setting switch
2-stage selector switch
Up : Permitted Down : Prohibited According to Permitted/prohibited setting table for switches
B.
Buzzer volume adjustment
Rotatory volume
Turn CLOCKWISE to DECREASE volume Turn COUNTERCLOCKWISE to INCREASE volume
★ The switches are adjusted before the machine is shipped. Only No. 7 and No. B can be adjusted. For this reason, do not touch any other switch.
HD465-7, HD605-7
Remarks +20% (Clockwise)
If it should become necessary to adjust any switch except No. 7 or No. B (for example, when compensating the speed or distance calculation or the payload value), please contact your Komatsu distributor to have the switch adjusted.
10-155 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
•
PAYLOAD METER
(CARD TYPE)
Table of model selector code No. of model selector switches
Model
0 (*1)
HD1200-1 STD Large-tire Cummins engine
1
HD785-3 STD Large-tire Komatsu engine
2
HD465-5 STD Small-tire Komatsu engine
3
HD325-6 STD Large-tire Komatsu engine
4 5 6
HD785-3 STD Small-tire Komatsu engine
7
HD465-5,7 STD Large-tire Komatsu engine
8
HD405-6 STD Large-tire Komatsu engine
9
HD985-3 STD 30:00-51 Komatsu engine
A
HD605-5,7 STD Large-tire Komatsu engine
B
HD785-5 STD Large-tire Komatsu engine
C D E
*1. The PLM on HD1200-1 has a different part No.
•
Permitted/prohibited setting table for switches Left side switch No. 8
Left side switch No. 5
Top (prohibited)
Bottom (permitted)
Top (memory card not used)
Permitted (1)
Permitted (2)
Bottom (memory card used)
(3)
(4)
(1) Left side switch No. 5 (top), No. 8 (top) All switches can be operated. (2) Left side switch No. 5 (top), No. 8 (bottom) Calibration, data all clear, time, date setting operations only are possible. (3) Left side switch No. 5 (bottom), No. 8 (top) All switches can be operated. (4) Left side switch No. 5 (bottom), No. 8 (bottom) Calibration, data all clear, card dump, time, date setting operations only are possible.
10-156 (6)
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PAYLOAD METER
(CARD TYPE)
Payload meter has the following basic functions. i) Power ON (reset) When the power is turned ON, all functions are checked and displayed.
★ If the engine is started during the flow for this display, even there are items left to display, the display will switch after several seconds to iii) Normal operation display.
HD465-7, HD605-7
10-157 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PAYLOAD METER
(CARD TYPE)
ii)
Measuring empty mass (calibration) The mass of the machine when empty is measured and this is used as the calibration data. These data are retained even when the power is turned OFF. iii) Normal operation display (for details, see the Operation and Maintenance Manual) See the Normal operation display. iv) External display lamp drive (estimated display) The chart on the right shows the mass display level for the external display lamps during the normal operation display. The estimated display shows the estimation of the total mass when one more load is added. The applicable lamp flashes to prevent overload.
Normal operation display Shift lever position
Dump lever position
Stopped
N
FLOAT
Mass display (*1)
Mass display
Traveling
Except N
FLOAT
Time display
OFF
Stopped
N
FLOAT
Mass display
Mass display and estimated display
Traveling
Except N
FLOAT
Mass display
OFF
Stopped
N
FLOAT
Mass display
Mass display and estimated display
Traveling
Except N
FLOAT
Travel distance displayed in units of m from 0 – 160 m (each 5 m)
OFF
Traveling
Except N
FLOAT
after completion, changes to time display
OFF
Stopped
N
FLOAT
Mass display
Mass display
When dumping (*2)
N
FLOAT→ RAISE → LOWER → FLOAT
Aggregate mass display (*3)
OFF
Abnormality, warning generated
—
—
(Error code displayed in order of priority)
See Operation and Maintenance Manual
Condition of the machine
Payload meter display
External display lamps
Empty
During loading, before reaching 50% of correct mass During loading, after reaching 50% of correct mass
Loaded
(*1) When load is less than 50% of correct mass, display shows 0 t. (*2) For details of conditions taken as dumping, see v) Content of memory (1). (*3) The aggregate mass display is shown in units of 100 t. (Rounded to the nearest 100)
10-158 (6)
HD465-7, HD605-7
PAYLOAD METER
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
(CARD TYPE)
V) Content of memory (for details, see Operation and Maintenance Manual) Cycle data ★ The period between one dumping operation and the next dumping operation is taken as one cycle and the data are recorded. ★ The cycle data are recorded when the dumping conditions are fulfilled (see right). ★ The maximum limit for cycle data in memory is 2900 cycles.
Item Engine operation number Month Day Time Hour Time Minute Machine ID Open ID Load mass Empty travel time Empty travel distance Empty max. travel speed Empty average travel speed Empty stopped time Loading stopped time Loaded travel time Loaded travel distance Loaded max. travel speed Loaded average travel speed Loaded stopped time Dumping time Limit speed Warning items/cycle Analog spare 1 MAX electric potential MIN electric potential Average electric potential Analog spare 2 MAX electric potential MIN electric potential Average electric potential Digital spare 1 Lo frequency Digital spare 2 Lo frequency
HD465-7, HD605-7
Unit
Range
Integer Month Day Hour Minute Integer Integer t (Metric ton) or US ton (Short ton) min km km/h km/h min min min km km/h km/h
1-65535 1-12 1-31 Displayed as 0-23 0-59 0-200 0-200 0-6553.5
min min km/h
0-6553.5 0-25.5 0-99
V V V
0-4.0 0-4.0 0-4.0
V V V
0-4.0 0-4.0 0-4.0
Times
0-255
Times
0-255
Displays value and set value at time of dumping
0-6553.5 0-25.5 0-99 0-99 0-6553.5 0-6553.5 0-6553.5 0-25.5 0-99 0-99
Displays set value at time of dumping
Data processing on PC Data inside cycle are handled separately as spare signal input data.
10-159 (6)
PAYLOAD METER
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
(CARD TYPE)
Engine ON/OFF data ★ Each time the engine was stopped and started is recorded. ★ The maximum limit in memory for engine ON/OFF data is 115 ON/OFF sets. Item
Unit
Range
Engine operation number Year (last 2 digits) Month Day Time Hour Time Minute
Integer Year Month Day Hour Minute
1-65535 Consecutive number for operation of engine 0-99 1-12 1-31 Shows when engine was switched ON Displayed as 0-23 0-59
Year (last 2 digits) Month Day Time Hour Time Minute
Year Month Day Hour Minute
0-99 1-12 1-31 Displayed as 0-23 0-59
Aggregate load mass
t (Metric ton) or US ton (Short ton) Times
0-9999000
Total number of cycles
0-9999
Shows when engine was switched OFF
Total value between engine ON and engine OFF
Abnormality, warning data ★ Each time a payload meter abnormality or warning is generated or cancelled is recorded. ★ The maximum limit in memory for abnormality or warning data is 230 generated/cancelled sets Item
Unit
Range
Engine operation number when error code was generated Frequency of generation after engine is switched ON Year (last 2 digits) Month Day Time Hour Time Minute
According to Integer Times
1-65535 1-255
Year Month Day Hour (0 – 23) Minute
0-99 1-12 1-31 Displayed as 0-23 0-59
Engine operation number when cancelled Year (last 2 digits) Month Day Time Hour Time Minute
Integer
0-65535
Year Month Day Hour (0 – 23) Minute
0-99 1-12 1-31 Displayed as 0-23 0-59
10-160 (6)
Shows when error code was generated
Shows when error code was cancelled
HD465-7, HD605-7
PAYLOAD METER
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
(CARD TYPE)
Data for aggregate load mass, total number of cycles ★ It is possible to calculate and record again from any desired time the aggregate load mass and total number of cycles for each time that the dumping conditions are fulfilled. ★ The calculation is started again for both values when the data for aggregate load mass and total number of cycles are cleared. ★ The maximum limit in memory for aggregate load mass and total number of cycles is 999900.0 t (Metric ton) or US ton (Short ton) and 9999 cycles respectively. Item
Unit
Range
t (Metric ton) or US ton (Short ton) Times Year Month Day Hour Minute
Aggregate load mass Total number of cycles Year (last 2 digits) Month Day Time Hour Time Minute
0-999900.0 0-9999 0-99 1-12 1-31 Displayed as 0-23 0-59
Shows aggregate from time when data were cleared
Shows date and time when data were cleared
Other data Content
Item
Unit
Range
Operator check mode set data
Machine ID Open ID Limit speed Option code
Integer Integer km/h Integer
0-200 0-200 0-99 0-11
Operator check mode set in input operation
Calibration performance data
Year (last 2 digits) Month Day Time Hour Time Minute
Year Month Day Hour Minute
0-99 1-12 1-31 Displayed as 0-23 0-59
Date and time when calibration was performed
User write data
Data 1 Data 2 Data 3 Data 4
HD465-7, HD605-7
20 Characters 20 Characters 20 Characters 20 Characters
Comments that can be written freely into payload meter. Note: Input and settings are possible only from PC through cable communications. (For details, see software manual.)
10-161 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PAYLOAD METER
(CARD TYPE)
Calibration data ★ These are saved in RAM each time calibration is performed. ★ The maximum limit in memory for calibration data is 15 sets. Item
Unit
Range
Year Month Day Time Hour Time Minute Model selection code
Year (last 2 digits) Month Day Hour Minute Integer
00-99 1-12 1-31 0-23 0-59 0-F
Suspension pressure (front left) Suspension pressure (front right) Suspension pressure (rear left) Suspension pressure (rear right) Mass on spring (front) Mass on spring (rear)
x 98 kPa x 98 kPa x 98 kPa x 98 kPa t (Metric ton) t (Metric ton)
0-6553.5 0-6553.5 0-6553.5 0-6553.5 0-6553.5 0-6553.5 –9.99 – +9.99 0-9.99999 0-9.99999 0-9.99999 0-9.99999 0-6553.5
Tilt angle
x 180 rad Front wheel tilt compensation factor Integer Rear wheel tilt compensation factor Integer Integer Front wheel link factor Integer Rear wheel link factor t (Metric ton) Mass on spring (empty)
Shows values and settings when cali bration was performed Shows values before compensation factor was calculated
Load mass calculation data (analog data) ★ These are saved in RAM when the load mass calculation data are required. ★ The maximum limit in memory for load mass calculation data is 180 sets. Item
Unit
Year Month Day Time Hour Time Minute Suspension pressure (front left) Suspension pressure (front right) Suspension pressure (rear left) Suspension pressure (rear right) Mass on spring (front) Mass on spring (rear)
Year (last 2 digits) Month Day Hour Minute x 98 kPa x 98 kPa x 98 kPa x 98 kPa t (Metric ton) t (Metric ton)
Tilt angle
x 180 rad Integer Integer Integer Integer t (Metric ton)
Front wheel tilt compensation factor Rear wheel tilt compensation factor Front wheel link factor Rear wheel link factor Mass on spring (empty) (Calibration value) Trimmer gain value Load mass Backup battery voltage The above data items
10-162 (6)
Integer t (Metric ton) V –
Range 00-99 1-12 1-31 0-23 0-59 0-6553.5 0-6553.5 0-6553.5 0-6553.5 0-6553.5 0-6553.5 –9.99 – +9.99 0-9.99999 0-9.99999 0-9.99999 0-9.99999 0-6553.5 0.7500 –1.2500 0-6553.5 0-25.5
are retained even when the power is switched OFF.
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
vi) Forced display of aggregate load mass, total number of cycles Forced display of existing abnormalities and warnings By operating the
switch of payload
meter II, it is possible to carry out forcible display of these items. For details, see the Operation and Maintenance Manual. vii) Operator check mode By operating the switch of payload meter , it is possible to carry out the following items. For details, see the Operation and Maintenance Manual. Memory card dump Data all clear Abnormality, warning exists/cancelled, input signal condition display Machine ID setting Open ID setting Limit speed setting Option code setting Time, date correction viii) Dimming of display portion It is possible to adjust the brightness of the payload meter II display portion to 10 levels with the switch. ix) Downloading saved data It is possible to download any data recorded in payload meter to a PC through a cable (ANSI/ E1A RS-232C). For details, see the PC software manual provided by Komatsu.
PAYLOAD METER
(CARD TYPE)
x) Service check mode By operating the switches of payload meter , it is possible to forcibly carry out display, setting, and correction of the following items. Detailed calibration data display The display shows the date, suspension pressure, etc. when the latest calibration was carried out. Detailed load mass calculation data display (analog data) The display shows the suspension pressure and machine angle used when calculating the present load mass. Memory card dump (service area) This writes all the data displayed for Items 66 and 6-7 to the memory card inserted in the machine. ★ This function is available only when the No. 5 switch on the left side of the controller (memory card use switches) is set for "Use" Data all clear (service area) This forcibly deletes all the calibration data and analog data, except for the latest calibration data. ★ Before clearing the data, always download the data to a PC or carry out Card dump. Input signal condition display This displays some of the signal conditions for the sensors input to payload meter and the present recognition condition of the payload meter. Forced initialization This forcibly deletes all the data in payload meter . ★ Before carrying out this operation, check the time and date. Always carry out the operation with the machine unloaded. Do not carry out the operation unless necessary. Extra load mass setting when loading The extra load can be forcibly input or corrected to set the load mass when loading. Available range for setting: –9 – +9 (%)
HD465-7, HD605-7
10-163 (6)
PAYLOAD METER
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
(CARD TYPE)
Load mass fixed display and cycle data recording, load mass value setting 1) Load mass fixed display When displaying the load mass in the range shown in the table below, it is possible to input and correct to set the display for the load mass when loading is completed (when loading at least 50% of set load mass and traveling 160 m and starting to dump), not the real-time load mass. Setting
Range
TALKS not set (option codes 0 – 3, 10, 11 set) When there is permission to start TALKS set
option codes 4 – 9 set
When disconnection of line from payload meter is requested
Payload fixed display
The time that machine is stopped when loading at least 50% of set load mass and traveling 160 m and starting to dump
Load mass when stopped in previous cycle
The time that machine is stopped from permission to move off to starting to dump
Load mass last displayed in previous cycle (Final radio transmission value)
The time that machine is stopped from disconnection of line to starting to dump
Load mass last displayed in previous cycle
2) Switching load mass fixed display in cycle data recording If the load mass fixed display in Item 1) above is applicable, it is possible to input and correct the data to set the load mass inside the cycle data in Item 6-1 to the fixed display load mass value. Possible set range: 00, 01, 10 Possible set value table Display
Load mass fixed display
Recorded load mass value
00
Yes
Load mass fixed display value
01
Yes
Value when dumping load
10
No
Value when dumping load
Loading completion recognition travel distance setting This is used to input and correct the values to set the travel distance recognized as completion of loading by payload meter . Possible set range: 0 – 255 (m) Loading start recognition load mass setting This is used to input and correct the values to set the load mass recognized as the start of loading by payload meter . Possible set range: HD325-6 1 480 – 1,480 [ x 100 t] HD405-6 HD465-7 HD605-7
10-164 (6)
690 – 1,690 [ x
1 100
t]
HD785-5 1,000 – 2,000 [ x HD985-3
1 100
t]
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PAYLOAD METER
(CARD TYPE)
Zero ton display range setting This is used to input and correct the values to set the range of the zero display on the load mass display. Possible set range: 5 – 10 [%: ratio of correct load mass] External display lamp display range setting This is used to input and correct the values to set the lamp display load mass range when displaying the load mass. Possible set range: Lamp 1 (green)
A : 510 – 255
Lamp 2 (yellow)
B : A – 255
Lamp 3 (red)
C : B – 255
The set value is displayed as a proportion (%) of the correct load mass. ■ Of the service check mode functions, the following functions can be downloaded to a PC using the PC downloading software provided by Komatsu. • Calibration data • Load mass calculation data (analog data) For details, see the software manual. (1) Method of operation ALways actuate the service check mode Note, and are actuated on the HD12001 when the parking brake is ON or when the brake lock is ON, and on machines other than the HD1200-1 when the shift lever is at the N position and when the dump lever is at FLOAT. is actuated only when the power is ON. ★ When the service mode is working, on the HD1200-1, set the parking brake to ON or the brake lock to ON, and on machines other than the HD1200-1, set the shift lever to the N position and the dump lever to FLOAT. If they are operated to other positions, the payload meter will return to the normal operation display, but in this case, the data set and input in the service check mode may not be processed correctly.
HD465-7, HD605-7
10-165 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
10-166 (6)
PAYLOAD METER
(CARD TYPE)
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PAYLOAD METER
(CARD TYPE)
(a) Operation for calibration data display
Set to CHEC display, then press From CALO flashing
switch
for at least 2 seconds.
Last 2 digits of year for date when CAL was carried out
Display: CALO
Month and day for date when CAL was carried out Hour and minute for date when CAL was carried out
Every time the
switch
Model selection switch (decimal value) when CAL was carried out
is pressed,
the display changes in the order shown on the right. If switch is pressed at any time during the display in Steps or , the display will return to CHEC. (End)
x 98kPa P'FL (Front left) x 98kPa P'FR (Front right) x 98kPa P'RL (Rear left)
Suspension pressure less than 100 x 98 kPa: XX.X More than 100 x 98 kPa: XXX.X
x 98kPa P'RR (Rear right) t
Mass on front axle π 2 (P'FL+P'RL)) (= – F 4 D–
t
Mass on rear axle 2 (P'RL+P'RR)) (= –π4 D R –
Angle of tilt when CAL was x 180 rad carried out Front axle tilt coefficient
Less than 100 t: XX.X More than 100 t: XXX.X Appears when value is negative ↓ (–) X.XX
Rear axle tilt coefficient X.XXX Front axle link coefficient Rear axle link coefficient Spring-up mass calculated according to calibration
Same number of digits as and
CALO flashes Returns to and repeats sequence All displayed values are rounded to the value given.
HD465-7, HD605-7
10-167 (6)
PAYLOAD METER
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
(CARD TYPE)
(b) Operation for payload calculation data (analog data) display
Set to CHEC display, then press
From ALLO flashing or A.FUL flashing Hour, minute
switch
for at least 2 seconds.
Display: ALLO
(when data in memory is less than 170 cycles) A.FUL (when data in memory is more than 170 cycles) A.FUL (when data in memory is more than 180 cycles)
Every time the
switch
is pressed,
the display changes in the order shown on the right.
x 98kPa P'FL (Front left) x 98kPa P'FR (Front right) x 98kPa P'RL (Rear left)
Suspension pressure less than 100 x 98 kPa: XX.X More than 100 x 98 kPa: XXX.X
x 98kPa P'RR (Rear right) t
Mass on front axle π 2 (= – D– (P'FL+P'RL)) 4 F
t
Mass on rear axle π 2 (= – D– (P'RL+P'RR)) 4 R
Angle of tilt when CAL was x 180 rad carried out Front axle tilt coefficient
Less than 100 t: XX.X More than 100 t: XXX.X Appears when value is negative ↓ (–) X.XX
Rear axle tilt coefficient
If switch is pressed at any time during the display in Steps or , the display will return to CHEC. (End)
X.XXX Front axle link coefficient Rear axle link coefficient t —
Spring-up mass calculated according to calibration GT
t
Present load mass
V
Backup battery Voltage
Same as
and
→ Gain trimmer Same as
and
X.X
ALLO flashing Returns to (1) and repeats sequence All displayed values are rounded to the value given.
10-168 (6)
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PAYLOAD METER
(CARD TYPE)
(g) Operation for setting extra load mass when loading
( f ) Operation for performing forced initialization
Set to CHEC display, then press
Set to CHEC display, then press switch and at the same time for at least 2 seconds.
switches , , and at the same time for at least 2 seconds.
Display: S.5EL Display:
Press
switch
:
Press
for at least 2 seconds.
switch
.
Display UP : XX present set value: for + : X for – : – X If it is necessary to correct the setting, press
The display becomes : (lighted up) (2 seconds), and when all the data is completely cleared, it automatically displays F.CAL. (End) After that, it carries out the process from 10.
.
If it is desired to stop the forced initialization operation when the display is : ,
switch
and correct.
When the correction operation from Step is completed, press switch at any time to return to the CHEC display. (End)
press switch (4), and the display will return to CHEC without performing the forced initialization operation.
10-172 (6)
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PAYLOAD METER
(CARD TYPE)
(h) Operation for setting load mass fixed display and cycle data record value
Set to UP : XX display, then press switch Display: PL : XX (present set value) If it is necessary to correct the setting, press switch
and correct.
When the correction operation is completed, press switch at any time to return to the CHEC display. (End)
HD465-7, HD605-7
10-173 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PAYLOAD METER
(CARD TYPE)
( i ) Operation for setting loading completion recognition travel distance When the correction operation from Step is completed, press switch (1) at any time to return to the CHEC display after displaying O.XXX (input value). (End) If it is impossible to set the input values even when switch is pressed, it displays O.XXX (input value) and returns to Step
.
Set to PL : XX display, then press switch Display: O.SEL
Press
switch
.
Display: XXX If it is necessary to correct the setting for the units, press
switch
and correct. Press
switch
.
Display: XXX If it is necessary to correct the setting for the tens, press
switch
and correct. Press
switch
again.
Display: XXX If it is necessary to correct the setting for the hundreds, press
switch
and correct. If
switch
is pressed again, the dis-
play will return to XXX, so it is possible to correct the units again.
10-174 (6)
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
( j) Operation for setting loading start recognition load mass
PAYLOAD METER
(CARD TYPE)
When the correction operation from Step is completed, press switch at any time to return to the CHEC display. (End) If it is impossible to set the input values even when switch is pressed, it returns to Step .
Set to O.SEL display, then press switch Display: P.SEL
Press
switch
.
Display: XXXX If it is necessary to correct the setting for the tens, press
switch
and correct. Press
switch
.
Display: XXXX If it is necessary to correct the setting for the hundreds, press switch Press
and correct.
switch
again.
Display: XXXX If it is necessary to correct the setting for the thousands, press switch If
and correct.
switch
play will return to Step rect again.
HD465-7, HD605-7
is pressed again, the dis, so it is possible to cor-
10-175 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PAYLOAD METER
(CARD TYPE)
(k) Operation for setting 0 ton display range
Set to P.SEL display, then press switch Display: H.SEL
Press
switch
.
Display: – – XX (present value) If it is necessary to correct the setting, press switch
and correct.
When the correction operation from Step is completed, press switch at any time to return to the CHEC display. (End)
10-176 (6)
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
( l) Operation for setting display range of external display lamps
Press
PAYLOAD METER
switch
(CARD TYPE)
again.
Display: d.XXX (present value of lamp 4) If it is necessary to correct the display range for lamp 4, press switch Press
and correct.
switch
again.
Display: E.XXX (present value of lamp 5) If it is necessary to correct the display Set to H.SEL display, then press
switch
switch Display: E.SEL Press
range for lamp 5, press
switch
and correct.
When the correction operation from Step is completed, press switch at any time to return to the CHEC display. (End)
.
Display: A.XXX (present value of lamp 1) If it is necessary to correct the display
If it is impossible to set the input values even when switch is pressed, it displays d.FAL (input value) and returns to Step .
range for lamp 1, press switch Press
and correct.
switch
.
Display: b.XXX (present value of lamp 2) If it is necessary to correct the display range for lamp 2, press switch Press
and correct.
switch
again.
Display: C.XXX (present value of lamp 3) If it is necessary to correct the display range for lamp 3, press switch
HD465-7, HD605-7
and correct.
10-177 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PAYLOAD METER
(CARD TYPE)
2. Pressure sensor The pressure sensor is installed at the bottom end of the suspension cylinder and acts to measure the pressure at the cylinder bottom.
When replacing pressure sensor (1), leave the valve (2) installed to the suspension and remove only pressure sensor (1). When removing or installing pressure sensor (1), be careful not to let valve (2) rotate. When removing pressure sensor (1), the action of valve core (3) prevents the suspension pressure from going down.
The output characteristics of the sensor are as shown in the diagram on the right. Voltage between pin (1) (GND) and pin (3) (output) of each pressure sensor connector or voltage of output (pins (4), (5), (6), (7)) of each sensor when pin (3) of payload meter controller connector (PM6) is grounded
Pressure sensor
1. Sensor 2. Tube 3. Connector
10-178 (6)
HD465-7, HD605-7
PAYLOAD METER
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
(CARD TYPE)
5. Self-diagnostic function The controller always observes the condition of the sensors and outputs, and if any abnormality occurs, it displays an error message. Error message display Order of display priority 1
Content Dump lever at position other than FLOAT (except when dumping)
Judgement standard —
—
Error code display Controller display
External lamp display
Cancellation of display
Timing for display
b-FL ON
All flash
When removed
[for HD1200-1] When parking brake or brake lock is ON
b-FL ON
—
When removed
[for HD1200-1] When parking brake or brake lock is OFF
Cd flashes
—
When removed
Removal detection only for card dump
2
Memory card removed
3
Drop in backup battery voltage
Defective contact or voltage below 2.7 V
F-09 flashes
—
When removed
Except during loading
4
Cycle data memory FULL
See (*1)
See (*1)
—
See (*1)
Except during loading
Engine ON/OFF data memory FULL Abnormality, warning data memory FULL Aggregate load mass, number of cycles data memory FULL 5
Disconnection in terminal R
Output below 2 V when engine is running
F-18 flashes
All flash
When removed
When engine is running
6
Abnormality in sensor power source (18 V)
Output is less than 15 V and power source voltage is more than 20 V
F-20 flashes
All flash
When removed
Any time
7
Short circuit with ground, disconnection in front left suspension pressure sensor system
Suspension pressure sensor input signal is 0 kPa or below
F-21 flashes
All flash
When removed
Any time
8
Short circuit with ground, disconnection in front right suspension pressure sensor system
F-22 flashes
9
Short circuit with ground, disconnection in rear left suspension pressure sensor system
F-23 flashes
10
Short circuit with ground, disconnection in rear right suspension pressure sensor system
F-24 flashes
10-180 (6)
HD465-7, HD605-7
PAYLOAD METER
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
Order of display priority
Judgement standard
Content
11
Short circuit with power source in front left suspension pressure sensor system
12
Short circuit with power source in front right suspension pressure sensor system
Suspension pressure sensor input signal is 220 x 98 kPa or more
Error code display Controller display F-25 flashes
Short circuit with power source in rear left suspension pressure sensor system
F-27 flashes
14
Short circuit with power source in rear right suspension pressure sensor system
F-28 flashes
15
Short circuit with ground, disconnection in clinometer system Short circuit with power source in clinometer system
External lamp display
Cancellation of display
Timing for display
All flash
When removed
Any time
All flash
When removed
Any time
F-26 flashes
13
16
(CARD TYPE)
Clinometer input signal above + 10 x
180
rad
Clinometer input signal above – 10 x
180
F-31 flashes
F-32 flashes
rad
17
Calibration not performed or abnormality in RAM
Calibration data in memory damaged
F • CAL flashes
All flash
When removed
Any time
18
Short circuit in external display lamp No. 1 relay
F-41 flashes
Short circuit in external display lamp No. 2 relay
See Remarks column
When removed
19
When coil is conducting electricity, relay coil short circuits with power source
Except when loading (for external display lamps, see Remarks column)
20
Short circuit in external display lamp No. 3 relay
F-43 flashes
21
Short circuit in external display lamp No. 4 relay
F-44 flashes
22
Short circuit in external display lamp No. 5 relay
F-45 flashes
23
Defective cycle data payload (*2)
See (*2)
L.bad flashes
—
Start of empty travel
Start of dumping start of empty travel
24
Over speed limit
Travel speed is over set speed limit
SP:SP flashes
—
Set value – 2km/h
When problem occurs
25
Defective communications or defective setting of option code
F-71 F-73 F-80 F-81 F-91 F-92 F-93 F-94 F-95 F-96 F-97 F-98 F-99
—
When removed
10-182 (6)
F-42 flashes
—
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
Saving abnormality, warning data (PC software display code) Records (000-025)
PAYLOAD METER
(CARD TYPE)
Remarks Calibration cannot be performed when there is abnormality
(000-026)
(000-027)
(000-028)
Records (000-031)
(000-032)
Applicable only when clinometer "use" switch is at "use" Calibration cannot be performed when there is abnormality
Records (000-019)
Load mass calculation stopped while problem occurs
Records (000-041)
External display lamps actuated as follows Applicable lamp Machine stopped: Always ON Machine traveling: OFF Other lamps during loading: Specified actuation Other than loading Machine stopped: Flashes Machine traveling: OFF
(000-042) (000-043) (000-044) (000-045) —
—
Records (000-071) (000-073) (000-080) (000-081) (000-091) (000-092) (000-093) (000-094) (000-095) (000-096) (000-097) (000-098) (000-099)
HD465-7, HD605-7
—
10-183 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
AUTOMATIC EMERGENCY STEERING SYSTEM
RELAY TIMER
1. Dial 2. Lock 3. Pin
Set time: 1 seconds
HD465-7, HD605-7
Outline The relay timer is a delay timer to prevent the emergency steering system from being actuated when the flow switch is acuated mistakenly by the pulse of the oil ro fluttering of the flow switch. With this relay timer, the relay points are switched after electric current is passed through the coil for the time set by the timer.
10-187 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
AUTOMATIC SUSPENSION SYSTEM
AUTOMATIC SUSPENSION SYSTEM
1. Dump control lever 2. Retarder controller 3. Suspension cylinder 4. Solenoid valve 5. Hydraulic cylinder
10-188 (6)
Outline The front suspension mode (damper force) is automatically switched according to the travel condition and load condition to give a more comfortable ride to the operator and to improve the travel stability. For details of the internal mechanism of the suspension, see SUSPENSION
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
AUTOMATIC SUSPENSION SYSTEM
AUTOMATIC SUSPENSION MODE SELECTION CONTROL With the front suspension, the mode (damping force) is automatically changed according to the travel conditions and load conditions to ensure a comfortable ride and to improve the travel stability of the machine. The control patterns and functions of the modes (damping force) are as shown in the table below.
When a liner has been installed to the body for HD465 to make it equivalent to the rock body, the increased load on the springs will affect the loaded/unloaded judgement in the table below. In this case. Select the machine model to HD605 by the switch for the transmission control system. S:Soft M:Medium H:Heard Set mode
Control pattern
Function
Content of control
Empty S
Distinguishing empty/loaded
To set damping force according to load on machine
Internal pressure of front suspension cylinder is measured and compared with standard valve
Anti-roll
To prevent the chassis from rolling when turning at high speed
This detects the travel speed and steering angle, and switches the mode according to certain conditions. (Not controlled when traveling empty)
To prevent nose-diving when braking
The damping force is made stronger when the brakes are applied.
To prevent the front from lifting up when dumping
The damping force is made stronger when the dump body control lever is at any position except FLOAT.
To improve stability when traveling at high speed
Detects travel speed and selects damping force. (No control when traveling empty)
Anti-dive
Anti-lift
High speed stability
HD465-7, HD605-7
M
Loaded H
S
M
H
(When turning)
(Brake (Brake ON) OFF)
(Float)
(Brake (Brake ON) OFF)
(Other than Float)
(Float) (Other than Flot)
10-189 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
AUTOMATIC SUSPENSION SYSTEM
AUTO SUSPENSION SOLENOID VALVE
1. Connector 2. Solenoid A : To hydraulic cylinder head B : To hydraulic cylinder bottom P : From pump T : To transmission oil pan
10-190 (6)
Function • The automatic suspension solenoid valve is installed in the circuit between the hydraulic pump and the suspension cylinder. The valve switches oil pressure of the hydraulic cylinder which is installed to the front suspension, according to signal from the retarder controller. Two solenoid valves are combined to select three modes of Soft, Medium and Hard.
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
AUTOMATIC SUSPENSION SYSTEM
STEERING ANGLE SENSOR
1. Body 2. Tube 3. Connector
Function • A round disc with teeth like a comb is installed to the steering column, and as this passes through the slit in the sensor, the sensor outputs a pulse signal. The suspension controller can obtain the steering speed from the number of pulses per unit of time.
STEERING ANGLE SENSOR
1. Body 2. Tube 3. Connector
HD465-7, HD605-7
Function • A round disc with teeth like a comb is installed to the steering column, and as this passes through the slit in the sensor, the sensor outputs a pulse signal. The suspension controller can obtain the steering speed from the number of pulses per unit of time.
10-191 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
RETARDER CONTROL SYSTEM
RETARDER CONTROL SYSTEM
10-192 (6)
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
RETARDER CONTROL SYSTEM
RETARDER CONTROLLER
1. 2. 3. 4. 5.
Self-diagnostic display window Rotary switch Motherboard Case Connector
Outline The retarder controller has the following functions. 1. Retarder control The electromagnetic proportional valve is controlled according to the operating angle of the retarder control lever and actuates the retarder. 2. Overrun prevention, retarder control when there is transmission abuse The electromagnetic proportional valve is controlled based on the command (ON/OFF command) from the transmission controller and actuates the retarder by a fixed amount. 3. Hoist control This controls the hoist EPC valve (electromagnetic proportional valve) and hoist selector valve (ON/OFF valve) according to the position of the dump control lever and actuates the dump body.
HD465-7, HD605-7
4. Automatic retarder speed control This device controls retarder braking force by movement of electromagnetic proportional control valve to maintain the machine speed set by the automatic retarder machine speed setting switch when driving down hills. 5. Automatic Suspension Control The controller switches output to the automatic suspension solenoid valve according to the travel conditions and loading conditions such as unloading or loading, turning. braking, etc. according to the signal sent from various sensors, and the controller switches damping force of front suspension in three stages of Soft, Medium and Hard. 6. ASR Control (Option) The controller detects slips of the drive wheels according to machine speed and steering angle of the right and left drive wheels, and the controller controls the ASR proportional valve so that the speed difference between the both wheels become constant. The brake torque is transmitted to the lower speed wheel by braking the higher speed slipping wheel, so the traveling ability is improved.
10-193 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
RETARDER CONTROL SYSTEM
7. Transmission of network data 1) Retarder actuation, float caution, parking brake actuation, accumulator oil pressure drop warning, and other data are transmitted to the monitor panel. 2) The overrun prevention, retarder command when there is abuse, and other data sent from the transmission controller are received. 3) The reverse inhibit, and other data are transmitted to the transmission controller.
10-194 (6)
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
RETARDER CONTROL SYSTEM
CN1 Pin No.
Specification
Signal name
Function
Remarks
1
D_OUT_0
Automatic suspension solenoid 1
H side (1A)
AUTO SUS SOL A
2
D_OUT_2
Automatic suspension solenoid 2
H side (1A)
AUTO SUS SOL B
3
D_OUT_4
H side (1A)
4
D_OUT_6H
24V/L side
5
D_OUT_7H
24V/L side
6
D_OUT_8
Push button retarder switch
L side (150mA)
7
Battery direct
Battery direct IN
8
Power GND
GND
9
Power supply +24V
Power supply +24V
P/B RETARD SW (FOR E/G Controller)
10
D_OUT_1
Front brake cut solenoid
H side (1A)
FRONT BRAKE CUT SOLENOID
11
D_OUT_3
Kick out solenoid
H side (1A)
KICK OUT SOLENOID
12
D_OUT_5
Hoist changeover valve
H side (1A)
DUMP CHANGE CONTROL VALVE
13
D_OUT_6L
Brake cut relay output
H side/GND
BRAKE CUT RELAY
14
D_OUT_7L
Sensor power supply
H side/GND
SENSOR POWER
15
D_OUT_9
Body float signal
L side (150mA)
BODY FLOAT SIG (FOR PLM)
16
Power GND
GND
17
Power supply +24V
Power supply +24V
CN2 Pin No.
Specification
1
Signal name Solenoid power supply +24V
Function
Remarks
Solenoid power supply
2
A_OUT_4A+
Shut off valve
0 – 1A
SHUT OFF VALVE (+) (FOR ASR)
3
A_OUT_4B+
—
0 – 1A
—
4
A_OUT_5A+
—
0 – 1A
—
5
A_OUT_5B+
—
0 – 1A
—
6
V_OUT
7
A_OUT_0+
Rear wheel retarder EPC output
0 – 1A
RETARD BRAKE VALVE (L) (+) (MANU AND AUTO)
8
A_OUT_1+
EPC output for ASR (left rear wheel)
0 – 1A
RL BRAKE VALVE (+) (FOR ASR)
Interlocked with A_OUT0 (0 – 5V)
9
A_OUT_2+
EPC output for ASR (right rear wheel)
0 – 1A
RR BRAKE VALVE (+) (FOR ASR)
10
A_OUT_3+
Hoist EPC valve
0 – 1A
DUMP CONTROL PCV (+)
11
V_OUT
12 13
Power supply +24V A_OUT_4A, 4B–
14 15
Interlocked with A_OUT1 (0 – 5V)
A_OUT4AB (COM) Suspress, steering speed sensor power +12V
Sensor power supply
Shut off valve (–) (option)
A_OUT5AB (COM)
(option)
Retarder lever, steering angle potentio power +5V
Sensor power supply +5V (400mA)
A_OUT_5A, 5B–
16
Solenoid power supply
17
A_OUT_0–
A_OUT0 (COM)
RETARD BRAKE VALVE (–)
18
A_OUT_1–
A_OUT1 (COM)
RL BRAKE VALVE (–) (OPTION)
19
A_OUT_2–
A_OUT2 (COM)
RR BRAKE VALVE (–) (OPTION)
20
A_OUT_3–
A_OUT3 (COM)
DUMP CONTROL VALVE (–)
21
HD465-7, HD605-7
Power GND
10-195 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
RETARDER CONTROL SYSTEM
CN3 Pin No.
Specification
Signal name
Function
Remarks
1
D_IN
Connector check 0 (pull up)
CONNECTOR CHECK 1
2
PLS_AC_IN_0
Wheel speed sensor (left rear wheel)
—
WHEEL SPEED (RL) (FOR ASR)
3
PLS_AC_IN_1
Wheel speed sensor (right rear wheel) —
WHEEL SPEED (RR) (FOR ASR)
4
PWM_IN
5 6
Hoist lever, body potentio ARSC set switch power +5V
Potentio power +5V (20mA)
7
A_IN_0
Steering angle potentiometer
A_IN0 (+)
S/T ANGLE POTENTIO (+) (FOR ASR)
8
A_IN_1
—
A_IN1 (+)
—
9
A_IN_2
Accumulator oil pressure sensor (front)
Pull down/(up)
ACC OLL PRESS (FRONT)
10
A_IN_3
Accumulator oil pressure sensor (rear) Pull down/(up)
ACC OLL PRESS (REAR)
11
A_IN_35
—
Pull up/down4
—
12
PLS_AC_IN_2
Steering angle speed
—
S/T SPEED SENSOR (FOR AUTO SUS)
13
PLS_AC_IN_3
Transmission output shaft speed sensor
—
T/M OUTPUT SPEED (+)
Speed GND
GND
14 15
PWM_OUT
16
Analog sensor GND
17
A_IN_0(–)
18
A_IN_1(–)
GND(Analog) A_IN0 (–)
S/T ANGLE POTENTIO (–)
A_IN1 (–)
19
A_IN_4
Suspension pressure sensor (left front wheel)
20
A_IN_5
Suspension pressure sensor (right front wheel)
Pull down/(up)
SUS PRESS (FR)
21
A_IN_6
—
Pull down
—
22
A_IN_7
—
Pull up (1K)
—
23
A_IN_8
Retarder oil temperature sensor
Pull up (4.7K)
RETARD OIL TEMP
24
A_IN_9
—
Pull up (150)
—
25
A_IN_10
Pull up (4.7K)
26
A_IN_11
Pull up (4.7K)
27
A_IN_12
28
A_IN_13
29
A_IN_14
Pull up (4.7K)
30
A_IN_15
Pull up (4.7K)
31
A_IN_16
Accelerator signal
Pull down
ACCEL SIGNAL (T/M) (FOR ARSC/ASR)
32
A_IN_17
Hoist lever potentiometer 1
Pull down
DUMP LEVER POTENTIO1
33
A_IN_18
Body potentio
Pull down
BODY POSITION SENSOR
34
A_IN_19
Hoist lever potentiometer 2
Pull down
DUMP LEVER POTENTIO2
35
A_IN_20
ARSC set switch
Pull down
ASRC SET SW (FOR ARSC)
36
A_IN_21
Manual retarder lever signal
Pull down
MANUAL RETARD LEVER
10-196 (6)
Pull down/(up)
SUS PRESS (FL)
Pull up (4.7K) —
Pull up (4.7K)
—
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
RETARDER CONTROL SYSTEM
CN4 Pin No.
Specification
Signal name
Function
1
RS422 TX (+)
RS422 TX (+)
2
RS422 RX (+)
RS422 RX (+)
3
RS232C TXD
RS232C TXD
4
RS232C RXD
RS232C RXD
5
RS485 (+)
RS485 (+)
6
S-NET (+)
S-NET (+)
7
RS422 TX (–)
RS422 TX (–)
8
Flash switch (ON/OFF)
Flash switch (ON/OFF)
9
RS422 RX (–)
RS422 RX (–)
10
GND (serial)
GND (serial)
11
RS485 (–)
RS485 (–)
12
S-NET (+)
S-NET (+)
HD465-7, HD605-7
Remarks
10-197 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
RETARDER CONTROL SYSTEM
CN5 Pin No.
Specification
Signal name
1
Function Connector check 1 (to GND)
Remarks CONNECTOR CHECK 2
2
D_IN_0
Pull up (5mA)
3
D_IN_1
Service brake switch
Pull up (5mA)
SERVICE BRAKE PRESS SW
4
D_IN_2
Retarder switch
Pull up (5mA)
RETARD BRAKE PRESS SW
5
D_IN_3
Parking brake switch
Pull up (5mA)
P/B, EMERG BRAKE PRESS SW
6
D_IN_4
Lever validation 1 switch
Pull up (5mA)
LEVER VARIDATION SW 1
7
D_IN_5
Lever validation 2 switch
Pull up (5mA)
LEVER VARIDATION SW 2
8
D_IN_6
—
Pull up (5mA)
SYSTEM FILTER
9
D_IN_7
Retarder cooling filter switch
Pull up (5mA)
RETARD COOLING FILTER
10
D_IN_8
—
Pull up (8mA)
—
11
D_IN_9
—
Pull up (8mA)
—
12
D_IN_10
Inclination switch
Pull up (8mA)
INCLINATION SW
13
D_IN_11
—
Pull up (8mA)
—
14
D_IN_12
—
Pull up (8mA)
—
15
D_IN_13
—
Pull up (8mA)
—
16
D_IN_14
—
Pull up (8mA)
—
17
D_IN_15
Memory clear switch
Pull up (8mA)
MEMORY CLEAR SW
18
D_IN_16
Engine starting signal
Pull down
KEY SW (E/G START SIGNAL)
19
D_IN_17
ABS signal
Pull down
COMMAND FROM ABS
20
D_IN_18
—
Pull down
—
21
D_IN_19
—
Pull down/potentio power +5V
—
22
D_IN_20
Brake wear sensor (left rear wheel)
Pull up/down 1
BRAKE WEAR RL
23
D_IN_21
Brake wear sensor (right rear wheel)
Pull up/down 1
BRAKE WEAR RR
24
D_IN_22
Exhaust brake command (from transmission controller)
Pull up/down 1
EXHAUST BRAKE COMMAND (FROM T/M)
25
D_IN_23
Overrun prevention command (from transmission controller)
Pull up/down 1
OVERRUN COMMAND (FROM T/M)
26
D_IN_24
ASR actuating pressure switch (left rear wheel)
Pull up/down 2
RL BRAKE PRESS SW (FOR ASR)
27
D_IN_25
ASR actuating pressure switch (right rear wheel)
Pull up/down 2
RR BRAKE PRESS SW (FOR ASR)
28
D_IN_26
—
Pull up/down 2
—
29
D_IN_27
—
Pull up/down 2
—
30
D_IN_28
—
Pull up/down 3
—
31
D_IN_29
—
Pull up/down 3
—
32
D_IN_30
—
Pull up/down 3
—
33
D_IN_31
—
Pull up/down 3
—
34
D_IN_32
—
Pull up/down 4
—
35
D_IN_33
—
Pull up/down 4
—
36
D_IN_34
—
Pull up/down 4
—
10-198 (6)
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
RETARDER CONTROL SYSTEM
RETARDER CONTROL FUNCTION RETARDER CONTROL SYSTEM DIAGRAM
Retarder lever control • The operating angle of the retarder lever is detected by the potentiometer and a current corresponding to this is output to the electromagnetic proportional valve to actuate the retarder. Overrun prevention, retarder control when there is transmission abuse • The electromagnetic proportional valve is controlled based on the command (ON/OFF command) from the transmission controller and actuates the retarder by a fixed amount.
HD465-7, HD605-7
10-199 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
RETARDER CONTROL SYSTEM
Relationship between retarder lever potentiometer and output to electromagnetic proportional valve
➀ To improve the initial response of the electro➁ ➂ ➃
magnetic proportional reducing valve, the output (trigger output) is set to a high value. To make the actuation of the hydraulic pressure smooth in the low pressure range, the output is set to a high value. In the range where the retarder is normally used, the output is proportional to the angle of the lever. To make the opening of the hydraulic pressure smooth in the low pressure range, the output is set to a low value.
10-200 (6)
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
RETARDER CONTROL SYSTEM
HOIST CONTROL FUNCTION HOIST CONTROL SYSTEM DIAGRAM
1. Hoist control function When the engine is running, the EPC and valve (electromagnetic proportional valve) and selector valve are controlled according to the operation of the dump control lever and operate the dump body. 2. Lever positioner function The dump control lever has four positions: RAISE, HOLD, FLOAT, and LOWER. If the dump control lever is operated to the RAISE position, the dump body is raised, and when the top of the dump body reaches the set position of the body position sensor, the lever is returned to the HOLD position. If the lever is kept at the RAISE position, the RAISE output continues to be given.
4. Control when starting switch is turned to ON, OFF, or START Starting switch at ON: The output is set to HOLD, regardless of the position of the lever. If the engine is not started, even if the hoist lever is operated, the condition remains at HOLD. Starting switch at OFF: The dump body is held in position regardless of the position of the lever. Engine started: Immediately after the engine is started, the output is set to HOLD, regardless of the position of the lever. After the lever is moved to the HOLD position, it becomes possible to carry out normal operations.
3. Body seating speed control When the dump body is lowered and reaches the position just before it is seated, the area of opening of the EPC valve is throttled to control the lowering speed of the dump body and reduce the shock when the dump body comes into contact with the chassis. HD465-7, HD605-7
10-201 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
RETARDER CONTROL SYSTEM
5. Float caution function If the output is not FLOAT or the dump body is not fully lowered, the float caution lamp on the monitor panel lights up. "FLOAT OUTPUT" and "SEATED" → Float caution OFF "NO FLOAT OUTPUT" or "NOT SEATED" → Float caution ON 6. Reverse inhibit function The retarder controller judges if it is permissible to travel in reverse or not, and transmits the result of the judgment through the network to the transmission controller. "FLOAT OUTPUT" and "SEATED" → Reverse travel permitted "NO FLOAT OUTPUT" or "NOT SEATED" → Reverse travel not permitted 7. Calibration function To absorb any inherent error in the dump body potentiometer, calibration is carried out to recognize the dump body seating and the body cylinder stopper condition. After adjusting the installation of the body potentiometer or after replacing the retarder controller, carry out calibration in the following order. Order of dump control calibration (hydraulic oil temperature: 80 – 90°C) 1) Lower the dump body completely, run the engine, and keep the lever at FLOAT for at least 5 seconds. (Check that the float caution has gone out.) 2) Operate the lever to the RAISE position until and raise the dump body until it contacts the stopper. Keep the lever at the RAISE position with the cylinder at the stopper position for at least 5 seconds. 3) Run the engine at low idling and operate RAISE → FLOAT with the dump body raised to the maximum height, then lower the dump body completely. Repeat this operation 10 times. 4) Run the engine at high idling and operate RAISE → FLOAT with the dump body raised to the maximum height, then lower the dump body completely. Repeat this operation 10 times.
10-202 (6)
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SENSORS, SWITCHES
SENSORS, SWITCHES ENGINE SPEED SENSOR
1. Magnet 2. Locknut 3. Wiring harness 4. Connector
10-204 (6)
Function • The engine speed sensor is installed to the ring gear of the flywheel housing. It uses the rotation of the gear teeth to generate a pulse voltage and transmits a signal to the transmission controller.
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SENSORS, SWITCHES
ACCELERATOR SENSOR
1. Connector 2. Connector 3. Pedal Outline Accelerator signal • This is installed under the operator's cab. The accelerator pedal has two accelerator sensors for engine controller and transmission controller. When the accelerator pedal is depressed, the movement rotates the shaft of the potentiometer inside the accelerator sensors. As a result, the resistance changes. A fixed voltage is impressed between the No. 1 – 3 pins of both potentiometers. A voltage signal corresponding to the angle of the accelerator pedal is sent from the No. 2 pin to the engine and transmission controllers. Idling validation signal • This is installed under the operator's cab. When the accelerator pedal is released, signal 2 (No. 5 pin) is connected to the ground; when the accelerator pedal is depressed, signal 3 (No. 6 pin) is connected to the ground. The engine controller then detects the condition.
HD465-7, HD605-7
10-205 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SENSORS, SWITCHES
RETARDER OIL TEMPERATURE SENSOR
1. 2. 3. 4.
Thermistor Plug Wiring harness Connector
Function • The sensors are installed to the retarder piping. They take the change in resistance of the thermistor as the change in the temperature and transmit a signal to the retarder controller. The signal is sent from the retarder controller through the network to the machine monitor panel to display the temperature level. When the display on the monitor panel reaches the specified position, the lamp lights up and the buzzer sounds to warn of an abnormality.
RADIATOR WATER LEVEL SENSOR
1. Float 2. Sensor 3. Connector
10-206 (6)
Function • This sensor is installed to the top of the radiator, and when the cooling water level goes below the specified level, the float goes down and the switch goes OFF. The maintenance caution lamp lights up and the character display shows message to warn of abnormality.
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SENSORS, SWITCHES
TRANSMISSION OIL FILTER SENSOR
1. Body 2. Tube 3. Connector A : Low pressure pickup port B : High pressure pickup port
Function • This sensor are installed to each filter, and when the filter becomes clogged, and the difference in pressure between the low-pressure side and high-pressure side reaches the specified pressure, the switch goes OFF. The maintenance caution lamp lights up and the character display shown message to warn of abnormality. Actuating pressure: Transmission oil filter sensor: 275 kPa {2.8 kg/cm2} Principle of switch: Pressure difference sliding piston type
HD465-7, HD605-7
10-207 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SENSORS, SWITCHES
FUEL LEVEL SENSOR
1. Connector 2. Float 3. Arm 4. Body 5. Spring 6. Contact 7. Spacer
10-208 (6)
Function • The fuel sensor is installed to the side face of the fuel tank. The float moves up and down according to the fuel level. This movement of the float is transmitted by the arm and actuates a variable resistance. This sends a signal to the monitor panel to indicate the remaining fuel level. When the display of the monitor panel reaches a certain level, a warning lamp flashes.
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SENSORS, SWITCHES
AIR CLEANER CLOGGING SENSOR
1. Indicator 2. Spring 3. Adapter
HD465-7, HD605-7
Function • The air cleaner clogging sensor is installed to the outward port of the air cleaner. If the air cleaner becomes clogged and reaches the set pressure (negative pressure), the maintenance caution lamp lights up and character display shows message to warn of the abnormality.
10-209 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SENSORS, SWITCHES
BODY POSITIONER SENSOR
1. Bearing 2. Rotor 3. Connector
10-210 (6)
Function • The body position sensor is installed to the rear of the chassis. When the angle of the dump body changes, the shaft receives sliding resistance through the link installed to the dump body, and the dump body angle is detected.
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SENSORS, SWITCHES
TILT SWITCH
1. Magnet 2. Plate 3. Gasket 4. Print card 5. Bracket 6. Plate 7. Plate 8. Plate 9. Connector
HD465-7, HD605-7
Function • If the chassis tilts to the left or right, the disc magnet moves to the left or right. If the chassis tilts into the roll-over danger range, either the left or right switch is turned OFF. If the dump lever is operated to the RAISE position in this condition, the lamp lights up and the buzzer sounds to warn of the danger.
10-211 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
DUMP CONTROL LEVER
DUMP CONTROL LEVER
10-212 (6)
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
DUMP CONTROL LEVER
1. Lever 2. Rod 3. Spring 4. Spring 5. Retainer 6. Body 7. Body 8. Bushing 9. Solenoid 10. Nut 11. Rod 12. Detent spring 13. Retainer 14. Ball 15. Seat 16. Potentiometer 17. Lever 18. Rod 19. Rod 20. Detent spring
HD465-7, HD605-7
10-213 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
DUMP CONTROL LEVER
Function • When lever (1) is operated, rod (18) moves up or down according to the amount the lever is operated, and rotates potentiometer (16). • The amount the control lever is operated (travels) is detected by the potentiometer, and this is sent as a signal voltage to the controller. • One potentiometer is installed and outputs two related signal voltages as shown in the "Output voltage characteristics" graph. Operation 1. Dump control lever operated to FLOAT • When LOWER rod (2) is pushed by lever (1) and moves down, ball (14) contacts protrusion a of rod (11) during the stroke. (Before start of actuation of mechanical detent) • When rods (2) and (11) are pushed in further, ball (14) is being held by detent spring (12). While pushing retainer (13) up, it escapes to the outside, and rod (11) passes over protrusion a. • When this happens, rod (18) on the opposite side is pushed up by spring (4). Ball (14) is moved to the small diameter side of protrusion b of rod (19) by retainer (13) that is being held by detent spring (20). • Even if the lever is released, rod (18) is held in position by the pushing force of the ball and protrusion b of rod (19), so the lever is held at the FLOAT position.
10-214 (6)
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
2. Dump control lever FLOAT canceled • When lever (1) is returned from the FLOAT position, it is pushed down by a force greater than the holding force of rod (19), detent spring (20), retainer (13), and ball (14). 3. Dump control lever operated to LOWER • When lever (1) is operated further from the FLOAT position, it moves to the LOWER position. • Rod (18) is pushed up by the spring (4) in accordance with the amount lever (1) is operated. • Lever (17) and rod (19), which are installed to the rotating shaft of potentiometer (16), are interconnected, so a voltage matching the up or down movement of the rod is output from potentiometer (16).
DUMP CONTROL LEVER
4. Dump control lever operated to RAISE • When RAISE rod (18) is pushed by lever (1) and moves down, ball (14) contacts protrusion a of rod (19) during the stroke. (Before start of actuation of mechanical detent) • When rods (18) and (19) are pushed in further, ball (14) is being held by detent spring (20). While pushing retainer (13) up, it escapes to the outside, and rod (19) passes over protrusion a. • When this happens, rod (2) on the opposite side is pushed up by spring (4). • When an electric current is flowing to solenoid (19), if rod (2) is pushed up, nut (10) is held in contact with bushing (8). • As a result, rod (2) is held at the pushed up position, so even if the lever is released, it is held at the RAISE position.
5. Dump control lever RAISE canceled • When lever (1) is returned from the RAISE position, it is pushed down by a force greater than the attraction force of the solenoid. Or, when the solenoid power source is turned OFF, the RAISE position is canceled and the lever returns to the N position.
HD465-7, HD605-7
10-215 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
VHMS CONTROLLER BLOW-BY PRESSURE SENSOR
VHMS CONTROLLER For details of the basic precautions, outlines, method of sending and receiving data, and the procedure for the initial setup, see TESTING AND ADJUSTING (Drawing No. WJ021JD0500). Specifications 1. Voltage of power supply : DC20V - DC30V 2. Size : W272 x D169 x H72 (mm) Function The VHMS controller collects and stores signals from each sensor and signals from the machine controller. It also gives commands for transmitting the accumulated data through the communications satellite.
BLOW-BY PRESSURE SENSOR Specifications 1. Voltage of power supply : DC5V 2. Output voltage : 0.5V (engine stopped) and up 3. Size: Mount (portion a) : R 1/4 : Outside diameter of seat receiving pressure : ø 37 : Length of cable: 1,110 mm Function The blow-by sensor converts the pressure inside the engine crankcase into a voltage and inputs this into the VHMS controller as the blow-by pressure.
10-216 (6)
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ENGINE OIL PRESSURE SENSOR
ENGINE OIL PRESSURE SENSOR Specifications 1. Type of sensor : Thermistor 2. Range of measurement : 40 – 130 °C : 80 – 130 °C (guaranteed precision ± 2 °C) 3. Max. power consumption: 0.5 mW 4. Pressure resistance : 4.9 MPa {50 kg/cm2} 5. Temperature range : --30 to 140 °C 6. Performance table Tempera- Resis- Tempera- Resis- Tempera- Resisture tance ture tance ture tance (°C) (kΩ) (°C) (kΩ) (°C) (kΩ) 30
35.27
80
6.571
110
2.887
40
24.28
85
5.682
115
2.544
50
17.05
90
4.931
120
2.248
60
12.20
95
4.293
125
1.992
70
8.884
100
3.750
130
1.769
a : Heat sensing portion of sensor, outside diameter of mount R 1/4 Function The engine oil temperature sensor is installed to the engine oil filter. It inputs the change in temperature to the VHMS controller as a change in the resistance of the thermistor.
HD465-7, HD605-7
10-217 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
EXHAUST TEMPERATURE SENSOR/AMP AMBIENT TEMPERATURE SENSOR
EXHAUST TEMPERATURE SENSOR/AMP Specifications 1. Rated voltage : DC24V 2. Detection temperature range : 100 – 1,000 °C : 300 – 800 °C (guaranteed accuracy ± 10 °C) 3. Output voltage characteristics: See table below 4. Actuation temperature range : --40 to 110 °C 5. Consumption current : Max. 30 mA a : Heat sensing portion of sensor, outside diameter of mount R 1/8 b : Amp c : Connector (power source end) d : Connector (sensor end) Output voltage characteristics (ambient temperature: 20 °C) ••• Reference value Detection temperature (°C)
50
100
400
700
800
Output voltage (V)
1.191
1.397
2.626
3.899
4.316
Function The exhaust temperature sensor is a thermoelectric type temperature sensor. It is installed to the turbocharger inlet port and outputs the exhaust temperature data to the VHMS controller.
AMBIENT TEMPERATURE SENSOR Specifications 1. Electricity consumption 2. Pressure resistance
: Max. 0.5 mW : 0.98 MPa {10 kg/cm2} 3. Detected temperature range (surrounding) : --30 to 120°C 4. Retention temperature range: --30 to 140°C 5. Performance table below Detection temperature (°C) Resistance (kΩ)
--20
--10
0
10
20
50
30.32 18.58 11.74 7.623 5.077 1.712
a : Heat sensing portion of sensor, diameter of mount 16 x 1.5 Function The ambient temperature sensor inputs the ambient temperature to the VHMS controller as a change in the resistance of the thermistor.
10-218 (6)
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
COMMUNIVSTIONS (ORB• • • ORBCOMM) CONTROLLER/ANTENNA
COMMUNICATIONS (ORB• • • ORBCOMM) CONTROLLER/ANTENNA CONTROLLER Specifications 1. Power supply voltage : DC12V – DC30V 2. Size : W306 x D152 x H52 (mm) Installation location Install under assistant's seat. Connector portion CN1A (ORB-A) : AMP070-14 CN1B (ORB-B) : AMP070-10 CN2 : Communications antenna cable connector
ANTENNA Specifications 1. Type : Helical whip antenna (1) 2. Impedance : 50 Ω 3. Input terminal : M-P type 4. Length : 165 ± 20 mm a : Communications antenna mount Installation location Install pole at right front of machine and set antenna on top of it. Function The antenna transmits the data collected and accumulated by the VHMS controller through the communications satellite to the computer center.
HD465-7, HD605-7
10-219 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PAYLOAD METER
PAYLOAD METER (HAVING VHMS) SYSTEM CONFIGURATION
10-220 (6)
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
Outline • A dump truck is supported by 4 suspension cylinders. By measuring the total of the loads on each cylinder, it is possible to know the mass on the springs of the dump truck. The measurement of the load mass is obtained by calculating the difference between the mass when empty and the mass when full. Payload meter displays the load mass calculated as above on the monitor screen and displays the load level on the external display lamps. It also has an estimation display function: when loading the next load, the new total load mass is estimated and the appropriate lamp flashes. This prevents overloading. •
The operation data, including the load mass of each transportation cycle, can be saved in the internal memory and downloaded with special software (if equipped). As the special software, the download software for Payload meter (card type) set for HD465/ 605-5 can be used as it is. The hauled load mass can be input by the following alternative 2 methods. (1) Save the load mass when the dump lever is moved from the FLOAT position to another position in a dump area (This method is set when shipped). (2) Input and save the hauled load mass by statistically processing the data sampled during the travel from the loading area to the dump area (New method).
•
The VHMS controller executes the functions of the payload meter and saves the data of each transportation cycle. It displays, sets, and operates various items through the machine monitor and network. When the payload meter is installed for the first time or the VHMS controller is replaced, the necessary items of the VHMS controller must be set again. Payload meter (card type) set for HD465/6055 can be installed for a user who needs a memory card. If it is installed, however, have the machine monitor and VHMS controller recognize that it will execute the functions of the payload meter, by using rotary switch 2 of the transmission controller and VHMS initial setting tool. For setting procedure, see TESTING AND ADJUSTING, "Initial Setting of Payload Meter", and [Items related to VHMS controller] "Replacement of Parts".
HD465-7, HD605-7
•
PAYLOAD METER
The payload meter (having VHMS) cannot be installed to a dump truck which is not equipped with the VHMS controller or which is equipped with the VHMS controller and payload meter (card type).
10-221 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PAYLOAD METER
ELECTRIC CIRCUIT DIAGRAM See TROUBLESHOOTING, Troubleshooting of VHMS controller. Principle of measurement 1. Outline 2. Measurement of mass when empty (Calibration) • For measurement of mass when empty, see Payload meter II (card type). 3. Measurement of mass when full Load the dump truck and measure the mass at that time. When loading for this purpose, set the gearshift lever in the "N" position, set the dump control lever in the "FLOAT" position, turn the parking brake ON, and release the retarder brake and foot brake on a ground where the longitudinal inclination of the dump truck is ± 5° and the lateral inclination is ± 2°. 4. Correction on slope If the dump truck is loaded on a slope, the measured mass is different from the mass measured on a level ground. To solve this problem, the longitudinal inclination of the dump truck is measured and the measured mass is corrected according to the inclination angle. (Correction range of inclination angle: ± 5°) 5. Sensing of distance and travel speed The distance and travel speed are obtained from the signals of the travel signal sensor of the dump truck and the travel speed correction information. ★ Travel signal sensor: Transmission output shaft speed sensor
10-222 (6)
HD465-7, HD605-7
PAYLOAD METER
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
INITIAL SETTING OF PAYLOAD METER In the following cases, perform "setting of rotary switch 2 (SW2) of the transmission controller" and "setting with VHMS initial setting manual (tool)" according to the following table. 1. When the payload meter (having VHMS) or payload meter II (card type) is installed for the first time 2. When the payload meter (having VHMS) or payload meter II (card type) is removed 3. When the VHMS controller or transmission controller is replaced 4. When setting of VHMS controller is changed
Setting of payload meter
Payload meter function is not installed
Payload meter function is installed
VHMS controller
Not installed Installed
PLM-II (card type)
Not installed
Set position of rotary switch 2 (SW2) of transmission controller (*1) F
Setting with VHMS initial setting tool (*2)
Model
Serial No.
Variation code
Date Time Time difference Summer time
–
–
–
–
B
Payload meter function is installed VHMS
Installed
Not installed
9
PLM
Installed
Installed
B
PLM (Without VHMS)
Not installed
Installed
F
ST HD465 or HD605
–7
PV
Set properly
P2 –
–
–
–
(*1) See "TESTING AND ADJUSTING, Adjusting transmission controller". (*2) See "TESTING AND ADJUSTING, [Items related to VHMS controller], VHMS Initial Setting Manual (Tool)". When there is not a problem in installation and wiring of the payload meter but there are the following problems, check the above setting again. 1. Items related to the payload meter are not displayed on the machine monitor. "The payload is not displayed when the machine is loaded and stopped", "There are not the manus related to the payload meter on the match marks", etc. Wrong setting of rotary switch 2 (SW2) of transmission controller 2. While the payload meter (having VHMS) is not set, there are the menus related to the payload meter on the machine monitor. Wrong setting of rotary switch 2 (SW2) of transmission controller
4. The storage place of the data file made by the download software is not found. Wrong setting of the model and serial No. with the VHMS initial setting tool. 5. Data cannot be downloaded. Wrong setting of the model, serial No., and variation code with the VHMS initial setting tool. 6. Date and time of the downloaded data are wrong. Wrong setting of the date and time with the VHMS initial setting tool.
3. While the payload meter (having VHMS) is set, the payload does not match to the lighting condition of the red lamp of the outside indicator lamps. Wrong setting of the model and serial No. with the VHMS initial setting tool. HD465-7, HD605-7
10-223 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BASIC FUNCTIONS OF PAYLOAD METER
PAYLOAD METER
7. Setting of OFFSET range This function is used to adjust the calculated load mass by a set amount.
For details, see Operation Manual.
VARIOUS SETTING FUNCTIONS (SERVICE FUNCTIONS) 1. Setting of travel distance to recognize completion of loading When the dump truck travels 160 m from the loading area, the payload meter judges that the loading operation is finished. If the dump truck is unloaded before it travels 160 m, the payload meter does not judge that the dump truck is unloaded and the cycle data is not completed at this time. This function is used to change the travel distance to recognize completion of loading when the distance between the loading area and dump area is very short.
8. Selection of method of entering saved load mass This function is used to select either of the following methods of entering the hauled load mass. 1) Save the load mass when the dump lever is moved from the FLOAT position to another position in a dump area (This method is set when shipped). 2) Input and save the hauled load mass by statistically processing the data sampled during the travel from the loading area to the dump area.
2. Correction of calculation of calculation of load mass If the load mass indicated by the payload meter is different from that indicated by the user's load meter, measure the operating mass (when the truck is empty) and gross truck mass (when the truck is loaded with the rated load mass) with the user's load meter, then correct the relation table of the suspension pressure and load mass forcibly with the measured masses and this function. 3. Correction of level of inclination sensor This function is used to correct the level of the inclination sensor. 4. Setting of criterion of maximum travel speed This function is used to set a criterion of the maximum travel speed for the machine control system. 5. Setting of load mass to recognize start of loading The payload meter recognizes that loading is completed when the load mass changes by certain amount. This function is used to change that amount. Since an easy change can cause wrong recognition of loading, verify the machine condition thoroughly when changing. 6. Setting of indication range of outside indicator lamp This function is used to change the indication range of the outside indicator lamp. The condition for turning on the red lamp cannot be changed. If it is changed, the red lamp cannot warn of overloading.
10-224 (6)
HD465-7, HD605-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PAYLOAD METER
OPERATING METHOD Select "PLM" in Service Mode 1 on the machine monitor. For method of selection, see TESTING AND ADJUSTING, "Special functions of machine monitor (E MMS)".
HD465-7, HD605-7
10-225 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
1. Setting of travel distance to recognize completion of loading
Input a travel distance to recognize completion of loading by pressing the following buttons. The setting range is 0 – 255 m (0.0 – 0.158 miles). • [>] button: Number at cursor moves forward. • [], [] button: Select "YES". • [] •
• •
•
button: Number at cursor moves forward. [], []
button: Number at cursor moves forward. • [] button: Number at cursor moves forward. • [] button: Number at cursor moves forward. • [] button: Number at cursor moves forward. • [] button: Number at cursor moves forward. • [], [], [], [], [: Right, Next, Continue 4) ] button once to display the failure codes for the existing failures (Fig. 8: example). • [>] Button: Displays failure code ★ The failure codes detected in the past are divided into failures of the electrical system and the mechanical system and are recorded as trouble data. (For details, see Service mode 1.) ★ If more than one failure is occurring, press the [>] button once more to display the other failure codes. ★ After pressing the [>] button to display all the existing failures, press the [>] button once more to return to the service meter/odometer display screen. If the [>] button is pressed once more, the failure codes will be displayed again from the beginning. If the switch is not operated for 10 seconds, the display will switch automatically to the action code screen. ★ With the service code display function, the following data are displayed (Fig. 9). A: Failure code (4 digits for location code + 2 digits for problem code) B: Controller code (MON: Machine monitor) (ENG: Engine controller) (TM: Transmission controller) (BK: Retarder controller) C: System with problem ★ For details of the displayed failure codes, see FAILURE CODE TABLE. ★ With the failure code display function and trouble data display function (Service mode 1), the data that are displayed are partially different. ★ If no switch is operated on the failure code display screen for more than 30 seconds, the display automatically returns to the action code display screen.
HD465-7, HD605-7
20-167 ➄
SPECIAL FUNCTIONS OF MACHINE MONITOR
TESTING AND ADJUSTING
FAILURE CODES LIST Failure code
Failed section
Failure phenomenon (Phenomenon/Contents of failure)
Action code
TW
E03
TM
E03
1380MW
Lockup clutch
1500LO
Detection of double engagement
15B0NX
Clogging of steering oil filter
Clogging (NX)
TM
E01
15E0KM
R → F gear shifting abuse 1
Mistake in operation or setting (KM)
TM
15E7KM
R → F gear shifting abuse 2
Mistake in operation or setting (KM)
TM
15G0MW
R clutch
Slip (MW)
TM
E03
15H0MW
Hi clutch
Slip (MW)
TM
E03
15J0MW
Lo clutch
Slip (MW)
TM
E03
15K0MW
1st clutch
Slip (MW)
TM
E03
15L0MW
2nd clutch
Slip (MW)
TM
E03
15M0MW
3rd clutch
Slip (MW)
TM
E03
15N0MW
4th clutch
Slip (MW)
TM
E03
15SBL1
R clutch ECMV
TM
E03
15SBMA
R clutch ECMV
TM
E03
15SCL1
Hi clutch ECMV
TM
E03
15SCMA
Hi clutch ECMV
TM
E03
15SDL1
Lo clutch ECMV
TM
E03
15SDMA
Lo clutch ECMV
TM
E03
15SEL1
1st clutch ECMV
TM
E03
15SEMA
1st clutch ECMV
TM
E03
15SFL1
2nd clutch ECMV
TM
E03
15SFMA
2nd clutch ECMV
TM
E03
15SGL1
3rd clutch ECMV
TM
E03
15SGMA
3rd clutch ECMV
TM
E03
15SHL1
4th clutch ECMV
TM
E03
15SHMA
4th clutch ECMV
TM
E03
15SJL1
Lockup clutch ECMV
TM
E03
15SJMA
Lockup clutch ECMV
Malfunction (MA)
TM
E03
2F00KM
Parking brake
Mistake in operation or setting (KM)
TM
2G42ZG
Accumulator (Front)
Lowering of oil pressure (ZG)
BK
E03
2G43ZG
Accumulator (Rear)
Hydraulic tank filter
BK
E03
989AOO
Engine overrun prevention command signal
Operation (OO)
TM
E02
989AKZ
Engine overrun prevention command signal
Disconnection or short circuit (KZ)
TM
E01
989OO
Rear part tipping signal
Operation (OO)
BK
20-168 ➄
Slip (MW)
Controller
See separate list (L0)
See separate list (L1) Malfunction (MA) See separate list (L1) Malfunction (MA) See separate list (L1) Malfunction (MA) See separate list (L1) Malfunction (MA) See separate list (L1) Malfunction (MA) See separate list (L1) Malfunction (MA) See separate list (L1) Malfunction (MA) See separate list (L1)
HD465-7, HD605-7
TESTING AND ADJUSTING
Failure code
Failed section
SPECIAL FUNCTIONS OF MACHINE MONITOR
Failure phenomenon (Phenomenon/Contents of failure)
Controller
Action code
AA10NX
Air cleaner element
Clogging (NX)
TM
E01
AB00MA
Alternator
Malfunction (MA)
TM
E03
B@BCZK
Radiator water
Lowering of level (ZK)
TM
E01
B@C7NS
Rear brake oil
Overheating (NS)
MON
E02
B@CENS
Torque converter
Overheating (NS)
MON
E02
C111KT
Failure in controller memory
Internal defect of controller (KT)
ENG
E03
C112LK
Timing actuator defective
ENG
E03
C113KZ
Abnormal current in timing actuator
Disconnection or short circuit (KZ)
ENG
E03
C115KZ
Error in engine speed sensor 2 system
Disconnection or short circuit (KZ)
ENG
E03
C116KX
Abnormality in timing rail pressure sensor
Clogging (NX)
ENG
E03
C117KX
Abnormality in timing rail pressure sensor
Out of input signal range (KX)
ENG
E03
C118KX
Abnormality in fuel pump pressure sensor
Out of input signal range (KX)
ENG
E01
C119KX
Abnormality in fuel pump pressure sensor
Out of input signal range (KX)
ENG
E01
C121LC
Error in engine speed sensor 1 system
ENG
E03
C122KX
Abnormality in boost pressure sensor
Out of input signal range (KX)
ENG
E03
C123KX
Abnormality in boost pressure sensor
Out of input signal range (KX)
ENG
E03
C131KX
Abnormality in throttle sensor
Out of input signal range (KX)
ENG
E03
C132KX
Abnormality in throttle sensor
Out of input signal range (KX)
ENG
E03
C135KX
Abnormality in oil pressure sensor
Out of input signal range (KX)
ENG
E01
C141KX
Abnormality in oil pressure sensor
Out of input signal range (KX)
ENG
E01
C143ZG
Lowering of oil pressure (Engine protection)
Disconnection or short circuit (KZ)
ENG
E03
C144KX
Abnormality in water temperature sensor
Out of input signal range (KX)
ENG
E01
C145KX
Abnormality in water temperature sensor
Out of input signal range (KX)
ENG
E01
C148KX
Abnormality in FM throttle
Out of input signal range (KX)
ENG
E03
C151NS
Rise of water temperature (Engine protection)
Overheating (NS)
ENG
E02
C153KX
Abnormality in intake air temperature sensor
Out of input signal range (KX)
ENG
E01
C154KX
Abnormality in intake air temperature sensor
Out of input signal range (KX)
ENG
E01
C221KX
Abnormality in atmospheric pressure sensor
Out of input signal range (KX)
ENG
E03
C222KX
Abnormality in atmospheric pressure sensor
Out of input signal range (KX)
ENG
E03
C234N1
Engine over-speed
Overrun (N1)
ENG
E02
C254KZ
Abnormality in FSOV circuit
Disconnection or short circuit (KZ)
ENG
E03
C259FS
Abnormality in FSOV circuit
Fixing (FS)
ENG
E03
C261NS
Rise of fuel temperature (Engine protection)
Overheating (NS)
ENG
E02
C263KX
Abnormality in fuel temperature sensor
Disconnection or short circuit (KZ)
ENG
E01
HD465-7, HD605-7
See separate list (LK)
See separate list (LC)
20-169 ➄
TESTING AND ADJUSTING
Failure code
Failed section
SPECIAL FUNCTIONS OF MACHINE MONITOR
Failure phenomenon (Phenomenon/Contents of failure)
Controller
Action code
C265KX
Abnormality in fuel temperature sensor
Disconnection or short circuit (KZ)
ENG
E01
C316KZ
Abnormal current in fuel injection pump actuator Disconnection or short circuit (KZ)
ENG
E01
C318LK
Pump actuator defective
ENG
E01
C346KT
ECM power-down error
ENG
E03
C423L6
Timing rail pressure in-range error
See separate list (L6)
ENG
E03
C431L4
Abnormality in idling validation switch
See separate list (L4)
ENG
E01
C432L5
Idling validation process error
See separate list (L5)
ENG
E03
C441KK
Abnormality in battery voltage
Lowering of source/input voltage (KK)
ENG
E01
C442KG
Abnormality in battery voltage
High source voltage (KG)
ENG
E03
C451KX
Abnormality in fuel rail pressure sensor
Out of input signal range (KX)
ENG
E03
C452KX
Abnormality in fuel rail pressure sensor
Out of input signal range (KX)
ENG
E03
C455KZ
Abnormality in fuel rail actuator circuit
Disconnection or short circuit (KZ)
ENG
E03
C467LK
Timing actuator control error
See separate list (LK)
ENG
E03
C468LK
Rail actuator control error
See separate list (LK)
ENG
E03
C514LK
Rail actuator defective
See separate list (LK)
ENG
E03
C554L6
Fuel rail pressure sensor in-range error
See separate list (L6)
ENG
E03
D1B0KZ
Cut-out relay
Disconnection or short circuit (KZ)
TM
E03
D1C0KZ
Brake cut-out relay
Disconnection or short circuit (KZ)
BK
E03
D5ZMKZ
Disconnection/Grounding fault/Short circuit in engine output mode command line Failure in front brake cut-out output system (Disconnection, grounding fault, short circuit) (OPT)
Disconnection or short circuit (KZ)
TM
E01
Disconnection or short circuit (KZ)
BK
E01
DAF0KM
Monitor panel
Mistake in operation or setting (KM)
MON
E03
DAF9KM
Monitor panel
Mistake in operation or setting (KM)
MON
E03
DAFSKQ
Monitor panel
Disagreement of model selection signals (KQ)
MON
E03
DAQ0KK
Transmission controller
Lowering of source/input voltage (KK)
TM
E03
DAQ1KK
Transmission controller main power source line
Lowering of source/input voltage (KK)
TM
E03
DAQ2KK
Transmission controller load power source line
Lowering of source/input voltage (KK)
TM
E03
DAQ3KK
Transmission controller battery direct power source line
Lowering of source/input voltage (KK)
TM
E03
DAQ9KM
Transmission controller wiring harness
Mistake in operation or setting (KM)
TM
E03
DAQ9KQ
Transmission controller wiring harness
TM
E03
DAQAKQ
Transmission controller rotary switch
TM
E03
DAQSKR
Transmission controller S-NET line
Disagreement of model selection signals (KQ) Disagreement of model selection signals (KQ) Communication defective/Abnormality in objective component (KR)
MON
E03
DAQSMA
Transmission controller
Malfunction (MA)
TM
E03
DASRKR
COMMUNICATION ERROR ENG
Communication defective/Abnormality in objective component (KR)
MON
E03
DB10KK
Retarder controller
Lowering of source/input voltage (KK)
BK
E03
D5ZNKZ
20-170 ➄
See separate list (LK) Internal defect of controller (KT)
HD465-7, HD605-7
TESTING AND ADJUSTING
Failure code
Failed section
SPECIAL FUNCTIONS OF MACHINE MONITOR
Failure phenomenon (Phenomenon/Contents of failure)
Controller
Action code
DB11KK
Retarder controller main power source line
Lowering of source/input voltage (KK)
BK
E03
DB12KK
Retarder controller load power source line
Lowering of source/input voltage (KK)
BK
E03
DB13KK
Retarder controller battery direct power source line
Lowering of source/input voltage (KK)
BK
E03
DB19KM
Retarder controller wiring harness
Mistake in operation or setting (KM)
BK
E03
DB1SKR
Retarder controller S-NET line
MON
E03
DB1SKQ
Wrong information on model selection
BK
E03
DBBSKR
Communications error VHMS
Communication defective/Abnormality in objective component (KR) Disagreement of model selection signals (KQ) Defective communications, abnormality in target component system (KR)
MON
E01
DDD7KX
Failure in travel speed setting switch system (OP)
Out of input signal range (KX)
BK
E03
DDD8KA
Disconnection ARSC system switch (OP)
Disconnection (KA)
BK
E03
DDD8KB
Short circuit ARSC system switch (OP)
Short circuit (KB)
BK
E03
DDDAKA
Disconnection ASR system switch (OP)
Disconnection (KA)
BK
E01
DDDAKB
Short circuit ASR system switch (OP)
Short circuit (KB)
BK
E01
DDTGKA
Fill switch for lockup clutch
Disconnection (KA)
TM
E03
DDTHKA
Fill switch for Hi clutch
Disconnection (KA)
TM
E03
DDTJKA
Fill switch for Lo clutch
Disconnection (KA)
TM
E03
DDTKKA
Fill switch for 1st clutch
Disconnection (KA)
TM
E03
DDTLKA
Fill switch for 2nd clutch
Disconnection (KA)
TM
E03
DDTMKA
Fill switch for 3rd clutch
Disconnection (KA)
TM
E03
DDTNKA
Fill switch for R clutch
Disconnection (KA)
TM
E03
DDTPKA
Failure in flow sensor valve for 4th clutch
Disconnection (KA)
TM
E03
DF10KA
Gear shift lever
Disconnection (KA)
TM
E03
DF10KB
Gear shift lever
Short circuit (KB)
TM
E03
DGF1KX
Transmission valve oil temperature sensor
Out of input signal range (KX)
TM
E03
dGR2L8
Failure in retarder oil temperature sensor system
See separate list (L8)
BK
E03
DGR2L8
Brake oil temperature sensor (Rear)
See separate list (L8)
BK
E01
DGT1KX
Torque converter oil temperature sensor
Out of input signal range (KX)
TM
E01
dHP4KX
Failure in suspension pressure sensor (FR) system (OPT)
Out of input signal range (KX)
BK
E03
DhP4KX
Suspension pressure sensor (FR)
Out of input signal range (KX)
PLM
E01
DHP4KX
Failure in suspension pressure sensor (FR) system (OPT) Failure in suspension pressure sensor (FL) system (OPT)
Out of input signal range (KX)
BK
E01
Out of input signal range (KX)
BK
E03
DhP5KX
Suspension pressure sensor (FL)
Out of input signal range (KX)
PLM
E01
DHP5KX
Failure in suspension pressure sensor (FL) system (OPT)
Out of input signal range (KX)
BK
E03
DHP6KX
Suspension pressure sensor (RR)
Out of input signal range (KX)
PLM
E01
DHP7KX
Suspension pressure sensor (RL)
Out of input signal range (KX)
PLM
E01
dHP5KX
HD465-7, HD605-7
20-171 ➄
TESTING AND ADJUSTING
Failure code
Failed section
SPECIAL FUNCTIONS OF MACHINE MONITOR
Failure phenomenon (Phenomenon/Contents of failure)
Action code
TM
E01
TM
E01
DHT5KX
Torque converter oil pressure sensor
DHT5L6
Torque converter oil pressure sensor
DHU2KX
Accumulator oil pressure sensor (Front)
Out of input signal range (KX)
BK
E01
DHU3KX
Accumulator oil pressure sensor (Rear)
Out of input signal range (KX)
BK
E01
DJF1KA
Fuel level sensor
Disconnection (KA)
TM
E01
DK11KX
Throttle angle sensor
Out of input signal range (KX)
TM
E03
dK11KX
Failure in acceleration sensor system (OPT)
Out of input signal range (KX)
BK
E03
Dk11KX
Failure in acceleration sensor system (OPT)
Out of input signal range (KX)
BK
E01
DK30KX
Failure of steering angle potentiometer (OP)
Out of input signal range (KX)
BK
E01
DK51L5
Retarder lever potentiometer
BK
E03
DK52KX
Dump lever potentiometer 1
BK
E03
DK53L8
Dump lever potentiometer 2
BK
E03
DK54KX
Body positioner sensor
BK
E03
DKD0L6
Failure in steering speed sensor (OPT)
BK
E01
DKH1KX
Abnormality in angle sensor
Out of input signal range (KX)
PLM
E01
DLE2KA
Engine speed sensor
Disconnection (KA)
TM
E03
DLE2LC
Engine speed sensor
TM
E03
DLF1KA
Transmission input shaft speed sensor
TM
E03
DLF1LC
Transmission input shaft speed sensor
TM
E03
DLF2KA
Transmission intermediate shaft speed sensor
TM
E03
DLF2LC
Transmission intermediate shaft speed sensor
TM
E03
DLF8KA
Disconnection in wheel speed sensor (RR) (OP)
BK
E01
DLF8LC
Failure in wheel speed sensor (RR) system (OP)
BK
E01
DLF9KA
Disconnection in wheel speed sensor (RL) (OP)
BK
E01
DLF9LC
Failure in wheel speed sensor (RL) system (OP)
BK
E01
DLT3KA
Transmission output shaft speed sensor
Disconnection (KA)
TM
E03
dLT3KA
Disconnection in transmission output shaft speed sensor Disconnection in transmission output shaft speed sensor
Disconnection (KA)
BK
E01
Disconnection (KA)
BK
E01
dLt3KA
Out of input signal range (KX)
Controller
See separate list (L6)
See separate list (L5) Out of input signal range (KX) See separate list (L8) Out of input signal range (KX) See separate list (L6)
See separate list (LC) Disconnection (KA) See separate list (LC) Disconnection (KA) See separate list (LC) Disconnection (KA) See separate list (LC) Disconnection (KA) See separate list (LC)
DLT3LC
Transmission output shaft speed sensor
See separate list (LC)
TM
E03
DLT3LC
Transmission output shaft speed sensor
See separate list (LC)
BK
E01
dLT3LC
Failure in transmission output shaft speed sensor
Disconnection (LC)
BK
E01
DV00KB
Short circuit in buzzer output
Short circuit (KB)
MON
E01
DW35KZ
Failure in auto suspension solenoid 1 output system (Disconnection, grounding fault, short circuit) (OPT) Failure in auto suspension solenoid 2 output system (Disconnection, grounding fault, short circuit) (OPT)
Disconnection or short circuit (KZ)
BK
E01
Disconnection or short circuit (KZ)
BK
E01
DW36KZ
20-172 ➄
HD465-7, HD605-7
TESTING AND ADJUSTING
Failure code
Failed section
SPECIAL FUNCTIONS OF MACHINE MONITOR
Failure phenomenon (Phenomenon/Contents of failure)
Controller
Action code
Disconnection or short circuit (KZ)
BK
E01
DW73KZ
Failure in kick-out solenoid output system (D_OUT3) (Disconnection, grounding fault, short circuit) Failure in hoist select valve output system (D_OUT5) (Disconnection, grounding fault, short circuit)
Disconnection or short circuit (KZ)
BK
E03
DWNBK4
Shutt-off valve
Not control (K4)
BK
E01
DWNBKA Disconnection in shutt-off valve system
Not control (KA)
BK
E01
DWNBKB Grounding fauit in shutt-off valve system
Short circuit (KB)
BK
E01
DWNBKY Short circuit in shutt-off valve system
Short circuit with power line (KY)
BK
E01
DWNBMA Shutt-off valve
Malfunction (MA)
BK
E01
Electromagnetic proportional pressure reducing valve Disconnection in output circuit of rear wheel electromagnetic proportional pressure reducing valve (A_OUT2) Short circuit in output circuit of rear wheel electromagnetic proportional pressure reducing valve (A_OUT2) Grounding fault in output circuit of rear wheel electromagnetic proportional pressure reducing valve (A_OUT2) Electromagnetic proportional pressure reducing valve Disconnection in output circuit of hoist EPC valve (A_OUT3) Grounding fault in output circuit of hoist EPC valve (A_OUT3) Short circuit in output circuit of hoist EPC valve (A_OUT3) ASR proportional solenoid pressure reducing valve (Right) Disconnection in output circuit of ASR proportional solenoid pressure reducing valve (Right) (OP) Short circuit in output circuit of ASR proportional solenoid pressure reducing valve (Right) (OP) Grounding fault in output circuit of ASR proportional solenoid pressure reducing valve (Right) (OP) ASR proportional solenoid pressure reducing valve (Right) ASR proportional solenoid pressure reducing valve (Left) Disconnection in output circuit of ASR proportional solenoid pressure reducing valve (Left) (OP) Short circuit in output circuit of ASR proportional solenoid pressure reducing valve (Left) (OP) Grounding fault in output circuit of ASR proportional solenoid pressure reducing valve (Left) (OP) Grounding fault in output circuit of ASR proportional solenoid pressure reducing valve (Left) (OP)
Disconnection (K4)
BK
E03
Disconnection (KA)
BK
E03
Short circuit (KB)
BK
E03
Short circuit with power line (KY)
BK
E03
Malfunction (MA)
BK
E03
Disconnection (KA)
BK
E03
Short circuit (KB)
BK
E03
Short circuit with power line (KY)
BK
E03
Not control (K4)
BK
E03
Disconnection (KA)
BK
E01
Short circuit (KB)
BK
E01
Short circuit with power line (KY)
BK
E01
Malfunction (MA)
BK
E01
Not control (K4)
BK
E01
Disconnection (KA)
BK
E01
Short circuit (KB)
BK
E01
Short circuit with power line (KY)
BK
E01
Malfunction (MA)
BK
E01
DXH1KA
Disconnection in output circuit of lockup clutch solenoid
Disconnection (KA)
TM
E03
DXH1KB
Short circuit in output circuit of lockup solenoid
Short circuit (KB)
TM
E03
DXH2KA
Disconnection in output circuit of H clutch solenoid
Disconnection (KA)
TM
E03
DXH2KB
Short circuit in output circuit of H clutch solenoid
Short circuit (KB)
TM
E03
DXH3KA
Disconnection in output circuit of L clutch solenoid
Disconnection (KA)
TM
E03
DXH3KB
Short circuit in output circuit of L clutch solenoid
Short circuit (KB)
TM
E03
DXH4KA
Disconnection in output circuit of 1st clutch solenoid
Disconnection (KA)
TM
E03
DXH4KB
Short circuit in output circuit of 1st clutch solenoid
Short circuit (KB)
TM
E03
DW72KZ
DX11K4 DX11KA DX11KB DX11KY DX11MA DX13KA DX13KB DX13KY DX17K4 DX17KA DX17KB DX17KY DX17MA DX18K4 DX18KA DX18KB DX18KY DX18MA
HD465-7, HD605-7
20-173 ➄
TESTING AND ADJUSTING
Failure code
Failed section
DXH5KA
Disconnection in output circuit of 2nd clutch solenoid
DXH5KB
SPECIAL FUNCTIONS OF MACHINE MONITOR
Failure phenomenon (Phenomenon/Contents of failure)
Controller
Action code
Disconnection (KA)
TM
E03
Short circuit in output circuit of 2nd clutch solenoid
Short circuit (KB)
TM
E03
DXH6KA
Disconnection in output circuit of 3rd clutch solenoid
Disconnection (KA)
TM
E03
DXH6KB
Short circuit in output circuit of 3rd clutch solenoid
Short circuit (KB)
TM
E03
DXH7KA
Disconnection in output circuit of R clutch solenoid
Disconnection (KA)
TM
E03
DXH7KB
Short circuit in output circuit of R clutch solenoid
Short circuit (KB)
TM
E03
DXHHKA
Disconnection in output circuit of 4th clutch solenoid
Disconnection (KA)
TM
E03
DXHHKB
Short circuit in output circuit of 4th clutch solenoid
Short circuit (KB)
TM
E03
★ For details of the VHMS controller related failure codes not displayed on the machine monitor, see Troubleshooting VHMS control system. ★ Separate table: Detailed phenomena of L Series problem codes (L ) Problem code
Nature
L0
Fill signals on 2 or more channels for clutches not forming a set are input at same time
L1
Fill signal is ON when command current to ECMV is OFF
L2
Fuel pressure is higher than maximum set pressure
L3
Corresponding component cannot be controlled
L4
ON/OFF signals for 2 systems do not match
L5
Potentiometer signal and switch signal do not match
L6
Engine speed signal, terminal C signal, signals for oil pressure switch, water temperature switch, etc. do not match operating condition or stopped condition of machine
L8
Analog signals for 2 systems do not match
LC
Speed signals for 2 systems do not match
LH
Fill signal is OFF when command current to ECMV is ON
★ Failure codes with ( ) These failure codes are not recorded as trouble data for either the electrical system or the mechanical system. ★ Controller codes and troubleshooting mode names The controller code name shown in the Controller column and the troubleshooting mode name in the troubleshooting section are linked, so check the controller code for the failure code displayed, then go to the applicable troubleshooting mode. ENG: Troubleshooting of engine controller system (ENG MODE) TM: Troubleshooting of transmission controller system (TM MODE) BK: Troubleshooting of retarder controller system (BK MODE) MON: Troubleshooting of machine monitor system (MON MODE) VHMS: Troubleshooting for VHMS controller system (including payload meter system in VHMS) (VHMS mode)
20-174 ➄
HD465-7, HD605-7
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MACHINE MONITOR
9. Electrical system trouble data display function (ELECTRIC FAULT) The machine monitor retains the data for problems that occurred in the electrical system in the past as failure codes. They can be displayed as follows. 1) Menu selection Select the display function for trouble data on the menu screen of Service mode 1 (Fig. 1). ★ The total number of trouble data items recorded in memory is displayed in the [ ] portion. 2) Trouble data display With the menu selected, press the [ ] button and display the trouble data recorded in memory (Fig. 2: example). • [ ] button: Runs menu 3) Displayed trouble data With the display function for trouble data of the electrical system, the following data can be displayed (Fig. 3). 1: Record number (recorded up to a maximum of 20 items) A: Failure code (4-digit location code + 2-digit problem code) 2: Number of occurrences (number of occurrences of same code in past) 3: Elapsed time 1 (time elapsed on service meter since first occurrence) 4: Elapsed time 2 (time elapsed on service meter since last occurrence) ★ Failure codes for problems that are still existing are shown on a flashing display. ★ For details of the failure codes displayed, see FAILURE CODE TABLE in the explanation for the failure code display function. ★ Note that with the trouble data display function and failure code display function for the electrical system, the displayed data are partially different. ★ If no trouble data are recorded, [0] is displayed on the display portion for 1, and [–] is displayed on the display portion for A, 2, 3, and 4.
HD465-7, HD605-7
20-177 ➄
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MACHINE MONITOR
10. Mechanical system trouble data display function (MACHINE FAULT) The machine monitor retains the data for problems that occurred in the electrical system in the past as failure codes. They can be displayed as follows. 1) Menu selection Select the display function for trouble data on the menu screen of Service mode 1 (Fig. 1). ★ The total number of trouble data items recorded in memory is displayed in the [ ] portion. 2) Trouble data display With the menu selected, press the [ ] button and display the trouble data recorded in memory (Fig. 2: example). • [ ] button: Runs menu 3) Displayed trouble data With the display function for trouble data of the mechanical system, the following data can be displayed (Fig. 3). 1: Record number A: Failure code (4-digit location code + 2digit problem code) 2: Number of occurrences (number of occurrences of same code in past) 3: Elapsed time 1 (time elapsed on service meter since first occurrence) 4: Elapsed time 2 (time elapsed on service meter since last occurrence) ★ Failure codes for problems that are still existing are shown on a flashing display. ★ For details of the failure codes displayed, see FAILURE CODE TABLE in the explanation for the failure code display function. ★ Note that with the trouble data display function and failure code display function for the mechanical system, the displayed data are partially different. ★ If no trouble data are recorded, [0] is displayed on the display portion for 1, and [–] is displayed on the display portion for A, 2, 3, and 4.
HD465-7, HD605-7
20-179 ➄
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MACHINE MONITOR
11. Machine data monitoring function (REALTIME MONITOR) The machine monitor can monitor the condition of the machine in real time through the signals from the sensors installed to various parts of the machine. In the machine data monitoring function, the following 2 types of display can be shown. • 1st item independent display (for each controller) • 2nd item simultaneous display (code input) 1) Menu selection Select the machine data monitoring function on the menu screen of Service mode 1 (Fig. 1). 2) Display sub menu With the menu selected, press the [ ] button and display the initial screen of the sub menu (Fig. 2). • [ ] button: Runs menu 3) Select sub menu If the [>] button or [] button: Goes on to next menu • [] or [] button: Goes on to next item • [] button: Number at cursor moves forward. • [], [] button: Number at cursor moves forward. • [] button: Select "YES". • [], [] button: Number at cursor moves forward. • [] button: Select "YES". • [] button: Select "YES". • [] button: Number at cursor moves forward. • [] button: Number at cursor moves forward. • [] button: Number at cursor moves forward. • [] button: Number at cursor moves forward. • [], [] button: Select "YES". • [] button: Number at cursor goes up • [] button: Number at cursor goes up • [] button: Number at cursor goes up • [
