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instrumentation
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Functional Training
Geometric Dimensioning and Tolerancing (GD&T) Training Kit World Class Manufacturing Solutions (WCMS) GD&T, Version:1, Nov 2003 Day – 1 Agenda Introduction to GD&T Concept of Function a…Descripción completa
USMC Training
CLSS
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OUTLINE OF CLSS
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B A SIC PRIN PRINCIP CIPL LE 1) Contro Contro ontrol ont roll of o f pump pum p swash plate
7. Variable type pressure compensation valve (for service valve)
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5. Pressure compensation valve
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8. Boom regeneration circuit
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8. Boom regeneration circuit
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Pump merge-divider valve
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LS SELECT VALVE
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Swing and Travel System
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SWING MOTOR KMF125ABE-5
B : From swing lock solenoid valve valve S : From control valve T : To tank MA: From control valve MB : From control valve
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Swing moto r 1. Brake spring 2. Drive shaft 3. Spacer 4. Case 5. Disc 6. Plate 7. Brake piston 8. Housing 9. Piston 10. Cylinder block 11. Valve plate 12. Reverse prevention valve 13. Center shaft 14. Center spring 15. Safety valve 16. Check valve 17. Check valve spring 18. Shuttle valve 19. Shuttle valve spring 20
OPERATION OF SWING LOCK 1) When swing lock solenoid valve is deactivated
2) When swing lock solenoid valve is excited
spring piston
disc plate
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OPERATION 1. When starting swing
2. When stopping swing
Relief valve Check valve
Shuttle valve
Check valve
Shuttle valve
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REVERSE PREVENTION VALVE
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Reverse prevention valve
Operation 1) When brake pressure is being generated at port MB
2) After motor stops
Spool Spring
Spring
Spool
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1. Cover 2. Body 3. Slipper seal 4. OO-ring 5. Shaft A1. To L.H. travel motor port PB A2. From control valve port A5 C1. To R.H. travel motor port PA B2. From control valve port B5 D1. To R.H. travel motor port PB E. To L.H. and R.H. travel motors port P T2. To tank T1. From L.H. and R.H. travel motors port T D2. From control valve port B2 B1. To L.H. travel motor port PA C2. From control valve port A2
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TRAVEL MOTOR HMV110-2
P : From travel speed solenoid valve T : To tank PA : From control valve PB : From control valve MA: MA pressure pickup port MB: MB pressure pickup port
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Travel motor 1. Regulator piston 2. Spring 3. Regulator valve 4. Spring 5. Motor case 6. Suction safety valve spring 7. Suction safety valve 8. Check valve 9. Check valve spring 10. Output shaft 11. Rocker cam 12. Retainer guide 13. Pin 14. Piston 15. Retainer 16. Cylinder 17. Valve plate 18. Counterbalance valve 19. Ring 20. Spool return spring 21. Brake piston 22. Plate 23. Disc 24. Ball
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Rocker cam
Check valve
Piston
Spring
Regulator valve
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Travel motor
Rocker cam
Check valve
Piston
Regulator valve
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OPERATION OF PARKING BRAKE When starting to travel
When stopping to travel
Counterbalance valve
spring disc plate piston 30
Operation when pressure oil is supplied
Suction safety valve Suction safety valve
Spool
31
Operation of brake when traveling downhill
spring
spool 32
2) Safety valve function 1. When travel is stopped (or when travailing down hill rotatin g to right) downhill 2. when rotating to left
spring
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2) When starting tr avel (or d uring normal travel )
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TRAVEL JUNCTION VALVE
OPERATION When pilot pressure is turned “ ON” Controller PST > Spring
spring s p o o l
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TRAVEL JUNCTION VALVE
OPERATION When pilot pressure is turned “ OFF” controller
s p r i n g
s p o o l
36
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TRAVEL PPC SHUTTLE VALVE OPERATION 1. When travel lever is in neutral
O r i f i c e
S p o o l
Operation Travel + boom raise + arm in and out + bucket curl and dump
P si ot n
P i s t o n
O ri f ci e
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TRAVEL PPC SHUTTLE VALVE OPERATION 1. When travel lever is operated
o r i fi c e p si t o n
Operation Travel + boom raise + arm in and out + bucket curl and dump
o ri f i c e
p si t o n
s p o o l
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Valve Control
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VALVE CONTROL
1. Travel PPC valve 2. Service PPC valve 3. Service pedal 4. L.H. travel lever 5. R.H. travel lever 6. R.H. PPC valve 7. R.H. work equipment control lever 8. Solenoid valve 9. Accumulator 10. Control valve 11. Hydraulic pump 12. Junction box 13. L.H. work equipment control lever 14. L.H. PPC valve Lever po sitions (1) Hold (2) Boom "RAISE" (3) Boom "LOWER" (4) Bucket "DUMP" (5) Bucket "CURL" (6) Hold (7) Arm "IN" (8) Arm "OUT" (9) Swing "RIGHT" (10) Swing "LEFT" (11) Neutral (12) Travel "REVERSE" (13) Travel "FORWARD"
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WORK EQUIPMENT • SWING PPC VALVE
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WORK EQUIPMENT • SWING PPC VALVE
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PPC valve Operation 1)At neutral
2) During fine control (Neutral → Final control)
piston retainer metering spring
spool
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3) During fine control (when control lever is returned)
4) At full stroke
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TRAVEL PPC VALVE P : From main pump T : To tank P1 : Left reverse P2 : Left forward P3 : Right reverse P4 : Right forward P5 : Travel signal P6 : Steering signal
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TRAVEL PPC VALVE
1. Plate 2. Body 3. Piston 4. Collar 5. Metering spring 6. Centering spring 7. Val v e 8. Damper 9. Steering signal 10. Steering signal valve spring
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2. Travel signal/ Steering function 1) When in neutral
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2) While traveling straight
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3) When steered or pivot -turned
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4) When pivot -turned
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Travel PPC shuttle valve
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Solenoid valve
1. PPC lock solenoid valve 2. Travel junction solenoid valve 3. Merge-divider solenoid valve 4. Travel speed solenoid valve 5. Swing brake solenoid valve 6. 2-stage relief solenoid valve T : To tank A1 : To PPC valve A2 : To main valve (Travel junction valve) A3 . To main valve (Merge-divider valve) A4 : To both travel motors A5 : To swing motor A6 : To main valve (2(2-stage relief valve) P1 : From main pump ACC: To accumulator
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Solenoid valve
WHEN SOLENOID IS TURNED OFF
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Solenoid valve WHEN SOLENOID IS TURNED ON
solenoid
spool spring
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FOR BREAKER
1. Drain plug 2. Element 3. Case 4. Head cover 5. Relief valve
BOOM HYDRAULIC DRIFT PREVENTION VALVE When boom control valve is at RAISE
spring
poppet
spool
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BOOM HYDRAULIC DRIFT PREVENTION VALVE When boom control valve is at NEUTRAL
Pilot valve
POPPET SPRING
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BOOM HYDRAULIC DRIFT PREVENTION VALVE When boom lever is in “lower” position
POPPET
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BOOM HYDRAULIC DRIFT PREVENTION VALVE When abnormally high pressure is generated
C H E C K V A L V E
S a f e t y v a lv e
V A L V E
C H E C K
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LIFT CHECK CHECK VALVE 1. While engine is stopped
SPRING VALVE
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L IFT IFT CHEC CH ECK K VALVE VAL VE LIFT CHECK 2. While engine is running
PA = { ( Area of - d) x PR + Force of spring (2)} / (Area of - d1)
spring
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ATTA A TTACHMENT CHMENT CIRCUIT SELECTOR SEL ECTOR VAL VA L VE
OPERATION 1. When attachment other than breaker is installed
spool spring
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ATTACHMENT CIRCUIT SELECTOR VALVE 2. When breaker is installed
spool spring
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67
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ENGINE CONTROL
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Engine control Starting engine
Engine speed control
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Engine control Stopping engine
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1. COMPONENT Fuel control dial
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Engine control Governor motor
1. Potentiometer 2. Cover 3. Shaft 4. Dust seal 5. Bearing 6. Motor 7. Gear 8. Connector
Operation While motor is stopped • Electric power is applied to both phases A and B of the motor.
While motor is running • The engine throttle and pump controller supplies a pulse current to phases A and B, and the motor revolves, synchronizing to the pulse.
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ENGINE CONTROL Engine throttle and pump controller
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Engine throttle and pump controller (Input (Input and output signals) CN-2
CN-3
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Engine throttle and pump controller
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Engine throttle and pump controller (Input and output signals)
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Engine throttle and pump controller contro ller (Input (Input and and output signals) signals)
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Types of Networks Komatsu controllers and controllers used by Komatsu communicate using one or more of the following network structures: 1. Komatsu S-Net (RS-232) 2. SAE J1587/1708 3. CAN SAE 1939
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Shortcomings of RS-232 RS-232 Is Simple, Universal, Well Understood and Supported, but RS-232 Has Some Serious Shortcomings As a Data Interface. The Standards for RS-232 and Similar Interfaces Usually Restrict RS 232 to 256kbps or Less and Line Lengths of 15M (50 Ft) or Less. The Rule of Thumb for the Length a Data Cable Depends on Speed of the Data & Quality of the Cable.
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Controller Area Network (S NET)
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Data Link What is a data link? J1587/J1708/J1939/ CAN. Information line for the computer to communicate with other devices or computers, i.e., J1587 and J1939.
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Data Links Can Work With Various Data Sources A communication link between various sources of data on a vehicle or equipment, following can be transmitted – Engine/Transmission /vehicle control – Change programmable parameters – Service info (faults, performance data, history data, etc.) 84
SAE J1939/CAN • Faster, more robust data transfer for the control system • Vehicle integration Vehicle information (not only engine) Multiplexing
Multiple modules • Single point service tool connection
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Example of Vehicle Integration Typical Machine Wiring
Machine Wiring With CAN/ J1939
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Co ntr nt olle rea a Net wo worr k ont on tr ol olller l er A re (CAN) Co n t r o l l er A r ea Netw Net w o r k i s an adv ad v anc an c ed • A Con seria se riall bus bu s syste sys tem m that effic efficie iently ntlyy suppor sup ports ts serial ientl distr di stribu ibuted, ted, rea contro l.. dist stri ribut bute ed, real real -time tim e control. control cont rol. rig inally lly deve developed loped for use in auto automobi mobile les s by by •Origina Bosc Bo sch h GmbH Gmb H, Ge Germa rm any, ny , in the th e late late 19 1980s. in ternatio tionally nally standa s tandard rdiz ize ed by b y the t he •CAN is interna rdize ized Inte nt erna rn ation ti ona al Standardiz tandardi zation ti on Orga rg aniz ni zation ti on (ISO 11898) and the th e Society oc iety of o f Aut A utom omot otiv ive e Engin ng ine eers (SAE (SA E J193 J 1939). 9). 87
CAN J1939 Network Terminating Resistor
Terminating Resistor
Engine Controller
Other Controller
VHMS Controller
A=Data
Terminating Resistor
B=Data
C =Grounded Shield
Terminating Resistor
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Backbone - Troubleshooting • Cannot monitor voltage on data link with Digital Multi -meter, must use a oscilloscope • Check continuity in each line • Check for 55-65 ohms resistance lines A&B with 120 ohm resistors • Insure proper grounding of line” C” shield 89
CAN J1939 Network 60.00 OHMs
With 120 Ohm terminating resistors there should be 55-65 Ohms between A & B Data lines.
A=Data
Terminating Resistor
B=Data C =Grounded Shield
Terminating Resistor
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CAN J1939 Network 0.00 OHMs
Each data line should have low Ohms Resistance between the ends of the data line.
A=Data
Terminating Resistor
B=Data
C =Grounded Shield
Terminating Resistor
91
CAN J1939 Network High OHMs
There should be high Ohms between data line and shield/ground .
A=Data
Terminating Resistor
B=Data
C =Grounded Shield
Terminating Resistor
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CAN J1939 Network 0.00 OHMs
There should be low Ohms between shield and ground.
