Chapter for the Air Over Hydraulic Type Brakes 03-10-22 03-11-28 03-12-22 04-01-08 04-01-20

1 Tanaka 2 Watase 3 Watase 4 Watase

Operation Manual for the Retarder on Komatsu Dump Trucks

- Chapter for the Air Over Hydraulic Type Brakes HD255-5/325-6/405-6/785-5/985-5

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Chapter for the Air Over Hydraulic Type Brakes

- CONTENTS I.
1. 2. 3.

Regarding the brakes

Concepts of the brakes Types of the braking operations and the braking mechanisms being activated Constructions and movements of the brakes -3 -4 -5 -8 -8

II.
1. 2.

What is a retarder brake ?

Basic concept of using the retarder brake What is the way of operating the retarder brake to cause overheating ?

III.

Safer downhill traveling

1. (1) (2) (3) 2. Setting the downhill traveling speed ( = speed stage) Measurement of the downhill traveling distance and gradient Calculation of the overall mass of the vehicle Determination of the permissible maximum speed when making a downhill travel Actual operations (when carrying out the dump truck operations) Decelerating the speed to the downhill traveling speed before reaching the starting point of the downhill inclination. Making the downhill travel at a certain speed after entering into the downhill inclination Adjusting the travel speed depending on existence of curves, road surface status and the variation of the gradient On a road surface with curves On a slipperly road surface In case the downhill gradient varies Do not turn on and off the retarder brake lever frequently. Do not use the service brake frequently. Do not make abrupt operations of the retarder lever. Do not use the retarder brake as a parking brake. Do not accelerate the speed while making a downhill travel by shifting up the speed stage. Do not make a downhill travel setting the shift lever to the "N" position. - 10 - 10 - 10 - 11 - 12 - 12 - 13 - 14 - 14 - 14 - 14 - 15 - 15 - 16 - 16 - 16 - 16

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(1) (2) (3)

IV.
1. 2. 3. 4. 5. 6.

Prohibitions when making braking operations

V.
1. 2. 3. 4.

Auto retarder operations

What is an auto retarder ? Regarding the auto retarder operations Precautions when operating the auto retarder Regarding Komatsu Auto Retarder (for reference) - 17 - 17 - 18 - 18
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Chapter for the Air Over Hydraulic Type Brakes

I.

Regarding the brakes

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1.Concepts of the brakes

When a vehicle is decelerated or stopped by a brake, the "kinetic energy" and the "potential energy" being possessed by the vehicle will be converted into the "thermal energy" to be discharged externally, but a portion of thermal energy will not be discharged and will remain on the vehicle side. To carry out safe operations with less burden to the equipment, it is important to fully understand the aforementioned fact before starting the operations. If such operations are carried out under erroneous understandings, equipment will be damaged and, at the same time, very hazardous circumstances will occur. In the meantime, functions of the brakes on dump trucks can be broadly categorized into the following three different functions.

(1) To decelerate or to stop a vehicle in travel.

* While a vehicle is in travel, kinetic energy is being possessed by the vehicle. * When the brake is activated, the kinetic energy will be converted into the thermal energy.

"Kinetic energy" will be converted ==> "Thermal energy"

(Key point)
Since the kinetic energy will increase in proportion to the square of the travel speed, the heat (= thermal energy) being generated when the brake is activated to stop traveling of the vehicle will become proportionally large.

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Energy Energy

When the travel speed becomes 2 times faster, the thermal energy being generated when stopping the vehicle will become 4 times more.

Travel speed

Energy Energy
Even when the travel speed is becoming 2 times faster, the occurring energy = heat becomes four times more.

Energy

The 3 key factors of the kinetic energy: Speed Inclination - (gradient - distance) - Load * To prevent occurrence of overheating by braking, do not accumulate the thermal energy. It means that early stage braking is important before the vehicle reaches unnecessarily higher travel speed. (2)To decelerate or stop a vehicle traveling on a downhill road and acceleration is occurring by the gravity.
When a dump truck travels on a downhill road, by the action of the gravity, the "potential energy" will be added to the kinetic energy to further increase the "thermal energy" being generated when decelerating or stopping the vehicle as compared with doing so on a level road. * The "potential energy" is an energy type being accumulated in a substance because of the existence of the substance at a "certain position".

(3)To hold a parking vehicle at the position

When storing a vehicle, a brake will be used not to let the vehicle move ( = to hold the vehicle at the position) by external factors. ( = Parking brake) At this time, if it is on a level ground, no energy accumulation is occurring in particular but if it is on an inclined surface, the "potential energy" is occurring.

Chapter for the Air Over Hydraulic Type Brakes

I.

Regarding the brakes

2/5

2.Types of the braking operations and the braking mechanisms being activated Using braking
Braking operations being conducted on the operator's seat Front Rear Parking Exhaust

Types of the braking Applications operations

Service brake Retarder brake
Emergency brake
To decelerate to stop a vehicle in travel at an optional time
To control traveling speed of a vehicle on a long downhill road at a certain level continuously.

mechanism

Operating methods

By depressing the pedal by a foot

* * * * * * * *

By adjustment of the lever By turning ON and OFF of a switch By turning ON and OFF of a switch
By turning ON and OFF of a switch (It will be activated when the accel pedal is released.)

Parking brake To park a vehicle

For emergency purpose
An auxiliary braking to be used when a vehicle is traveling on a downhill road (Interlocking with the retarder brake)

Exhaust brake

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This is an auxiliary braking to acquire a braking force by suppression of the engine revolution. - To be used when parking a vehicle. - To be also used when loading or dumping the cargo.

Exhaust brake

Parking brake

Front brake
- Dry type disc brake mechanism is being employed. - It will be activated in common with the rear brake when operating the service brake.

Rear brake
- Oil cooled wet type multi discs mechanism is being employed. - Different from the dry type brake mechanism, since this mechanism is being activated under constant oil cooling effect, less abrasion occurs with the discs.

Chapter for the Air Over Hydraulic Type Brakes

I.

Regarding the brakes

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3.Constructions and movements of the brakes

(1) Service brake (foot brake)
* The service brake is to be used when stopping a traveling vehicle and both of the front brake and the rear brake will be activated. However, since the front brake is not being equipped with the mechanism to cool the structure forcefully, avoid using the service brake while the vehicle is traveling on a continuous downhill road, except for emergency cases.

(2) Retarder brake

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Without retarder brake DANGEROUS

Zing !

Travel speed of the vehicle will be accelerated by the influence of gravity.

- Retarder brake is a device to control the travel speed corresponding to the gradient for safe and efficient downhill operations of a vehicle. - The rear brake, which is being equipped with a forced cooling mechanism, only will be activated.
Brake oil circuit

With retarder brake SAFE

The vehicle will make a downhill travel at a certain speed.

Engine cooling water circuit

Plates Radiator

Retarder

Pump

Engine

Discs

LH and RH rear brakes

Brake oil cooler Brake oil tank

The braking force can be adjusted by the pulling extent of the lever.

Chapter for the Air Over Hydraulic Type Brakes

I.

Regarding the brakes

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3.Constructions and movements of the brakes (continuation)

(3)Exhaust brake
When the exhaust brake switch is turned "ON"

- The exhaust brake makes use of the resistance occurring to the engine revolution when the flow of exhaust gas coming out from the engine is hindered. - The exhaust brake will be activated when the accel pedal is released while the exhaust brake switch positioned on the dashboard panel is being turned "ON".

- While the exhaust brake is being released - Since the butterfly valve being installed to the exhaust piping is being opened, the exhaust gas flows smoothly. - In this case, any power to resist to the engine revolution will not occur in particular. - While the exhaust brake is being activated

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- When the accel pedal is released, the butterfly valve being installed to the exhaust piping will be closed. - Under this status, the exhaust gas coming out from the engine will not be discharged smoothly and a large resistance will occur to the revolution of the engine. - The exhaust brake is making use of this resistance.

- Conditions to activate the exhaust brake

Torque converter lockup Exhaust brake switch Operations Retarder lever (When turned of f ) (When turned on)

ON ON
Foot brake

Activated Released Activated Released Released Released

Activated Released Activated Released Released Activated

OFF ON OFF
Accel pedal

ON OFF OFF
Retarder lever foot brake Accel pedal

ON&OFF

Released

Released

Chapter for the Air Over Hydraulic Type Brakes

I.

Regarding the brakes

5/5

3.Constructions and movements of the brakes (continuation)

(4)Parking brake
- The parking brake is to be used when parking a vehicle. - It is a lever controlled brake being positioned in front of the operator's seat. - It consists of a separate braking mechanism from the front brake or the rear brake.

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(5)Emergency brake

- The emergency brake is to be used at times of emergency like, for example, when the wheel brake becomes ineffective by some damage of the foot brake. - It is controlled by use of a lever being positioned beside the speed shift lever in front of the operator's seat. - When the emergency brake is applied, the front brake, the rear brake and the parking brake will be activated.

* When the vehicle is stopped by activation of the emergency brake, apply the chocks to the wheels immediately and be sure to repair the section where the failure is occurring and readjust the parking brake.

Chapter for the Air Over Hydraulic Type Brakes

II.

What is a retarder brake ?

The basic requirement is that Heat generation

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1.Basic concept of using the retarder brake

- The retarder will work to let a vehicle make a downhill travel at a certain speed by converting the potential energy of the vehicle which is working to let the vehicle travel downhill by the gravity into thermal energy occurring from friction. (Divergence of thermal energy) - The retarder thus heated up will be cooled down forcefully by the circulating oil and the oil will be cooled by the oil cooler. - The revolution rate of the engine will influence the cooling capacity. In consideration of the above, the important points when using the retarder brake should be the following three points.

<

Cooling effect

is to be always maintained.

1. Do not accumulate the thermal energy. ( = Let the retarder diverge the thermal energy efficiently.) 2. Do not generate excessive thermal energy. ( = By operations always in an earlier stage.) 3. Let the retarder diverge the thermal energy efficiently. ( = Maximize the cooling capacity of the device.)

(Proper use of the retarder brake)

Decelerate the speed gradually.

Suppress generation of the thermal energy by travel speed matching the gradient and the distance.

Operations always in an earlier stage. Thermal energy being generated by deceleration upto the starting point of a downhill inclination

Heat Heat

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Heat Heat

Cooling effect

Thermal energy being generated by the downhill travel

Since the generated heat is always smaller than the cooling capacity, overheating will not occur.

2.What is the way of operating the retarder brake to cause overheating ?

(1)The way of operating the retarder brake where the heat generation is too large
- Making an abrupt deceleration before reaching the starting point of a downhill inclination A large quantity of thermal energy will be generated Making an abrupt by the abrupt deceleration
deceleration

Do not make an abrupt deceleration !

Entering into the downhill inclination area at an excess speed Thermal energy being generated by deceleration upto the starting point of a downhill inclination

Heat
Heat Thermal energy being generated by the downhill travel

Heat
Heat

>

Cooling effect

If the vehicle enters into the downhill road accumulating a large quantity of thermal energy which has been generated by the abrupt deceleration made before entering into the downhill inclination area, the thermal energy being generated by the downhill travel of the vehicle will be added to the accumulated thermal energy to exceed the cooling capacity, thus resulting in overheating.

! Key point The thermal energy being generated by braking will increase in proportion to the square of the travel speed. Therefore: "When the travel speed becomes 2 times faster, the thermal energy being generated by braking will become 4 times more." Now, to prevent occurrence of overheating, it is important to suppress the thermal energy being generated by braking before reaching the starting point of a downhill inclination and not to enter into the downhill travel accumulating a large quantity of thermal energy.

Chapter for the Air Over Hydraulic Type Brakes

II.

What is a retarder brake ?

- Downhill travel with an excess load
Deceleration

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A large quantity of thermal energy will be generated by the excess load. Do not load excessively !
Furthermore, the thermal energy being generated while making a downhill travel with an excess load will be quite large.

Entering into a downhill road with an excess load Thermal energy being generated by deceleration of the vehicle upto the starting point of a downhill inclination ! Key point

Heat Heat Heat Heat

Thermal energy being generated by downhill travel of a vehicle

>

Cooling effect

The thermal energy being generated by braking will increase in proportion to the overall weight of the vehicle. Therefore: "When the overall weight of the vehicle becomes 1.2 times more, the thermal energy being generated by braking will also become 1.2 times more." Now, to prevent occurrence of overheating, it is necessary to suppress the thermal energy exceeding the cooling capacity to the minimum. It means, it is important not to load a vehicles excessively.

(2)The way of operating a vehicle to accumulate the thermal energy

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Making a downhill travel at a speed exceeding the cooling capacity to accumulate the thermal energy
Deceleration

- Making a downhill travel at a speed exceeding the cooling capacity

Make a downhill travel at an appropriate speed.

Heat

Thermal energy being generated by deceleration of the vehicle upto the starting point of a downhill inclination

Heat
Heat

Heat

>

Cooling effect

Thermal energy being generated by the downhill travel

If the vehicle makes a downhill travel at a speed exceeding the cooling capacity of the vehicle, accumulating a large quantity of thermal energy, overheating will occur.

(3)The way of operating a vehicle not to let the vehicle exhibit its cooling capacity sufficiently - Making a downhill travel at lower engine revolution rates
Deceleration

Since the engine revolution is low, the vehicle cannot exhibit its cooling capacity sufficiently. Make a downhill travel at appropriate engine revolution rates.

Thermal energy being generated by the downhill travel Even if generation of the thermal energy may be appropriate, the cooling capacity of the vehicle is being kept at a low level and overheating will occur. ! Key point Heat Heat
Cooling effect

Thermal energy being generated by deceleration of the vehicle upto the starting point of a downhill inclination

Heat

Heat

>

In order to let a vehicle exhibit its cooling capacity to the maximum, "maintain the engine revolution at 1,800 to 2,200rpm".

Chapter for the Air Over Hydraulic Type Brakes

III. Safer downhill traveling

Contents of the operations
Setting the downhill traveling speed ( = speed stage)

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Supplements
Calculate the permissible maximum speed at which overheat will not be occurring and, also, calculate the optimum speed stage to shift to. For that purpose, it is important to check the status of the downhill road before entering into the downhill travel and to know the actual vehicle status (the mass under the maximum load). If you have any question regarding the setting of the downhill traveling speed and the speed stage, contact a Komatsu agent in your neighborhood. An example: Traveling range measurement data Distance (m)
Block "1 - 2" Block "2 - 3"

Flow of setting the downhill traveling speed Step(1)

Check the status of the downhill road before entering into the downhill travel. <1> Distance of the downhill road <2> Gradient of the downhill road

Step(2)
Check the specifications of the vehicle. <1> Overall weight of the vehicle

Step(3)
Calculate the followings by use of the results of the above Step 1 and Step 2. <1> Downhill traveling speed <2> Speed stage

(1)Measurement of the downhill traveling distance and gradient

To calculate the downhill traveling speed, measure the distance of the downhill traveling range and the gradient. When making measurement, a distance of more than 30m should be regarded as one block.
Dista

Downhill gradient (%)

100m 400m

3.0 => 5.2% 4.0 => 7.0%

The equation of conversion from the angle ( ) to gradient (%): Gradient (%) = sin A downhill product should be indicated in a minus figure. (Dump truck traveling range measurement drawing)

nce

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3 500 m Gradient 4 deg.

Block Make out a layout drawing of the course for the dump truck to travel on as shown in the drawing indicated on the RH side and determine the optimum downhill traveling speed and speed stage to use for each gradient range so that an efficient traveling plan may be completed.

4 deg. 2 100 m
3deg.

4 1900m 1.5 deg. 5 3100m

Loading Area 1 0 m

* Regarding how to cope with the cases where gradient variations exceeding 30m occur, refer to the Section "Travel speed adjustment corresponding to curves, road surface state and gradient variations" being indicated on page 11.

2 deg.

6 3500m

Dumping Area 7 3800m

(2)Calculation of the overall mass of the vehicle

Calculate the overall mass of the vehicle while making a downhill travel. Overall mass of the vehicle = Mass of the vehicle* + Mass of the load For example, in case of an HD465-7 with a load of 46.0t with additional 6.0t of the body liner:

Overall mass of the vehicle = Mass of the empty vehicle 43.7t + Mass of the load 46.0t + Operator 0.75t + Options and others 9.0t = 98.775t

*The mass of the vehicle includes the mass of all the equipment being installed to the vehicle like, body liner, various options, etc.

If a vehicle makes a downhill travel exceeding the specified limit of the overall mass of the vehicle, the bearable limit of the vehicle will be exceeded to cause overheating and other failures and, moreover, the traveling safety will also be influenced. Therefore, be sure to restrict the setting within the specified limit of the overall mass of the vehicle.

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Chapter for the Air Over Hydraulic Type Brakes

III. Safer downhill traveling

Contents of the operations
(3)Determination of the permissible maximum speed when making a downhill travel

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Supplements

For selection of the permissible maximum speed and the speed stage when making a downhill travel, the following two methods can be used. (Determine the actual travel speed to employ in considerations of other factors like the road surface state, curves, road width, visibility, etc.) Guideline for selection of the downhill traveling speed using the retarder (A simplified table)
Appropriate speed stage and traveling speed can be selected from the downhill traveling distance and gradient using the simplified table indicated below.
Guide line for s e le ction of the dow nhill trave ling s pe e d us ing the re tar de r

If you have any question regarding the setting of the downhill traveling speed and the speed stage, contact a Komatsu agent in your neighborhood.

Vehicle model: HD465-7

Ov erall weight of the v ehicle

98,775 kg
43,700 kg 75 kg 9,000 kg 46,000 kg

Empty vehicle w eight

Operator Options and others

Weight of the load

Tire size

24.00-35

Transmission Continuous dow nhill 600m dow nhill Uppe r lim it trave l speed stage road Gradie nt (%) road Gradient (%) s pe e d (k m /h)

F1 F2 F3 F4 F5 F6

20.8 - 28.4 16.0 - 20.8 12.3 - 16.0 9.6 - 12.3 7.7 - 9.6 6.2 - 7.7 0 - 6.2

24.2 - 31.9 19.4 - 24.2 15.8 - 19.4 13.1 - 15.8 11.1 - 13.1 9.7 - 11.1 0 - 9.7

11.4 16.2 21.8 29.5 39.8

For example, in case of operating a dump truck of model HD465-7: for the downhill traveling distance: 600m on the traveling road gradient: -13% with the overall weight of the vehicle: 98,775kg, The appropriate downhill traveling speed and the optimum speed stage can be selected using the table indicated on the LH side of this page.

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53.9 F7 72.6

Transmission downhill600m downhill road Continuous 600m speed stage road Gradient (%) Gradient (%)

-The gradie nt has be e n calculate d on as s um ption of 2% of the rolling re s is tance . -Since the road s ur face re s is tance w ill influe nce and, als o, the re can be cas e s w he re the re tarde r m ay be turne d off te m porarily, re fe r to the Se ction

F5

Upper limit travel speed (km/h) (%) (%) (km/h) 7.7 - 9.6 13.1 7.7 9.6 11.1 11.1 13.1 39.8 39.8

"Brak e pe rfor m ance graph" in the Ope r ation and M ainte nance M anual for de tails . Whe n m ak ing a dow nhill trave l us ing the re tarde r , ope rate the re tarde r le ve r s o that the e ngine re volution rate m ay be k e pt w ithin the range of 1,800 to 2,200rpm to k e e p the r e tarde r oil te m pe rature gauge indication unde r 120 C. In cas e the re tarde r oil te m pe r ature gauge indication e xce e ds 120 C, low e r the trave l s pe d by s hifting dow n the s pe e d s tage , e tc. The e ngine re volution s hould not e xce e d 2,450rpm .

In the above case, the optimum speed stage becomes "F5" and the upper limit downhill travel speed becomes "39.8km/H". *since the vehicle weight and the specifications are being regarded as the same, use these selections on the simplified table as the reference values when determining actual travel speed to employ.

Performance curve of the retarder

For example, in case of operating a dump truck of model HD465-7, for the downhill traveling distance of 600m, with the traveling resistance (the gradient resistance of -13% and the rolling resistance of 2%) and with the overall mass of the vehicle of 98,775kg
<1> Use the brake performance graph for the downhill traveling distance of 600m. <2> Assuming the scale point corresponding to the overall mass of the vehicle as <1>, draw a perpendicular line from the point <1> downward. <3> Assuming the point of intersection of the above perpendicular line with the traveling resistance of -11% ( = the gradient resistance of -13% + the rolling resistance of 2%) as <2>, draw a horizontal line from the point <2>. <4> Assuming the point of intersection of the above horizontal line with the performance curve as <3>, draw a perpendicular line from the point <3> and assume the point of intersection of the above perpendicular line with the vehicle travel speed scale as <4>. <5> By the above, the permissible maximum speed will become 40kg/h as per the point <4> and the optimum speed stage will become "F5" as per the point <3>.

(1)

(2) (3)

(4)

On the basis of the distance, gradient and overall mass of the vehicle calculated as per the above Sections (1) and (2), determine the permissible maximum speed when making the downhill travel using the "Simplified table of the guideline for selection of the downhill traveling speed using the retarder" or the " Performance curve of the retarder" indicated above.

For example, in case of operating a dump truck of model HD465-7, the permissible maximum speed when making a downhill travel for a vehicle of the overall mass of 98,775kg will become

Distance Block "A"

Downhill gradient

Permissible maximum speed (Optimum speed stage)

600m

-13%

40km/h ("F5")

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Chapter for the Air Over Hydraulic Type Brakes

III. Safer downhill traveling

Contents of the operations Actual operations (when carrying out the dump truck operations)
(1) Decelerating the speed to the downhill traveling speed before reaching the starting point of the downhill inclination. - Before reaching the starting point of the downhill inclination, release the accel pedal <1> and operate the retarder lever <2> to decelerate the speed to the preset downhill traveling speed.

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Supplements

Abrupt operation of the retarder lever => is dangerous since the tires may slip. Operate the retarder lever slowly and at an earlier stage. => Refer to the Section "Prohibitions when making brake operations".

Deceleration

Travel speed

Actual travel speed

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0

Preset downhill traveling speed

Keep the shift lever at the "D" range. (When the travel speed is decelerated to the preset downhill traveling speed, automatic shift down will be made to the optimum speed stage.)

Frequent ON-OFF operations of the retarder lever when making a downhill travel => Large braking force will be produced intermittently and overheating may occur.

Keep the shift lever at the "D" range.

Do not make frequent ON-OFF operations of the retarder lever when making a downhill travel. => Refer to the Section "Prohibitions when making brake operations".

-In case downhill traveling at the "F1" speed stage becomes necessary as the result of surveys of the traveling road, select the "6" range other than the "D" range. - Confirm the preset downhill traveling speed and the speed stage on the shift indicator on the Operator's seat panel. Confirm the
preset downhill traveling speed.

Confirm the preset speed stage.

Use of the service brake (foot brake) when making a downhill travel => Since the front wheel discs are not equipped with the cooling mechanism, the brake may become ineffective by overheating. Do not use service brake (foot brake) when making a downhill travel except for emergency cases. => Refer to the Section "Prohibitions when making brake operations".

Travel speed

Speed stage

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Chapter for the Air Over Hydraulic Type Brakes

III. Safer downhill traveling

Contents of the operations
(2)Making the downhill travel at a certain speed after entering into the downhill inclination
After entering into the downhill inclination, make the downhill travel at a certain speed using the retarder brake.
Deceleration

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Supplements

Making a downhill travel while the engine revolution is at a lower range => The cooling capacity of the brake oil cooler is lowered and overheating may occur.

Travel speed

Actual travel speed

To cool down the disc brake efficiently, maintain the engine revolution rate within the range of 1,800 to 2,200rpm.
Preset downhill traveling speed Optimum range 1800 - 2200rpm

While making a downhill travel, keep monitoring of the retarder oil temperature, engine revolution rate and the current speed stage selection.
!KEY POINT! While making a downhill travel, always pay attention to the retarder oil temperature and the current speed stage selection.
()
130 120 110 90 70 50

Engine tachometer (rpm) - Making a downhill travel at a speed exceeding the retarder capacity - Overloading => The thermal energy generation will exceed the cooling capacity to cause overheating.

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Keep the retarder oil temperature indication within the green zone.

Keep the current travel speed and loading limit.

Zing !

Maintain the engine revolution rate within the range of 1,800 to 2,200rpm.

Confirm the current speed stage selection on the monitor.

"Accelerating the speed while making a downhill travel by shifting up the speed stage" and "making a downhill travel setting the shift lever to the "N" (neutral) position" => The engine revolution comes down and overheating may occur. Also, "making a downhill travel setting the shift lever to the "N" position" is very dangerous since the travel speed of the vehicle will be accelerated to an uncontrollable range.

- Do not accelerate the speed while making a downhill travel by shifting up the speed stage. - Do not make a downhill travel setting the shift lever to the "N" position.

!KEY POINT!
When the retarder oil temperature gauge indication enters into the red zone, the caution lamp will turn on and the alarm will sound. Then, promptly stop the vehicle at a safe place to cool down the retarder oil temperature.

Let us remember how far the retarder lever should be pulled.

While carrying out a trial travel of the vehicle, let us remember how far the retarder lever was pulled when the actual travel speed became the preset speed. While making a downhill travel, conduct fine adjustment of the retarder lever depending on the variation of the gradient, road surface status, existence of curves, etc., in order to maintain the appropriate and safe travel speed.

To cool down the retarder oil temperature, set the shift lever to the "N" position and keep the engine revolution rate within the range of 1,800 to 2,200rpm.

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Chapter for the Air Over Hydraulic Type Brakes

III. Safer downhill traveling

Contents of the operations
(3)Adjusting the travel speed depending on existence of curves, road surface status and the variation of the gradient

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Supplements
To operate the retarder lever midway while the vehicle is traveling on a curve => It is dangerous since the vehicle will slip sidewise. Make sufficient deceleration before the vehicle enters into the curved road.

<1> On a road surface with curves Pull the retarder lever before entering into a curve to lower the travel speed to a safe speed range.
<2> On a slipperly road surface
When making a downhill travel on a slipperly road surface like on a muddy road, wet mud and sand surface road, snowy road, gravel road, etc., make a trial travel at a speed where tire slips will not occur and preset a lower travel speed than when the road surfaces are dried up. On a slipperly road surface, deviated retarder effect (unsymmetrical retarder effect) may occur by the fine difference between the LH side and RH side braking forces.

To operate the retarder lever abruptly => It is dangerous since the tires will slip. Operate the retarder lever slowly. => Refer to the "Prohibitions when making braking operations".

<3> In case the downhill gradient varies

How to cope with when the gradient becomes steeper A.In case the gradient is returning to the original state within 30m Decelerate the travel speed using the retarder lever when the gradient becomes steeper and return the retarder lever to the original position when the gradient returns to the original state to restore the preset travel speed.
Decelerate the travel speed using the retarder lever.
Return the retarder lever to the original position when the gradient returns to the original state to restore the preset travel speed.

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Within 30m
B. In case a steep gradient continues more than 30m Preset a new downhill traveling speed corresponding to the gradient and decelerate the travel speed using the retarder lever. How to travel when the gradient becomes more gradua A. In case a gradual gradient returns to the original state within 30m
When the gradient becomes gradual, return the retarder lever and depress the accel pedal to adjust the travel speed at 2,000rpm or more of the engine revolution. Then, when the gradient returns to the original state, restore the preset speed using the retarder lever. Adjust the travel speed by acceleration work.
When the gradient returns to the original state, decelerate to restore the preset speed using the retarder lever.

To adjust the travel speed by depressing the accel pedal after returning the retarder lever in case a gradual gradient continues for more than 30m => It will cause overheating and will also worsen the per gallon mileage. Returning the retarder lever, preset a new downhill traveling speed.

B. In case a gradual gradient continues for more than 30m Preset a new downhill traveling speed corresponding to the gradient and decelerate the speed using the retarder lever.

Within 30m

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Chapter for the Air Over Hydraulic Type Brakes

IV. Prohibitions when making braking operations

Contents of the operations
1. Do not turn on and off the retarder brake lever frequently.
- Do not turn on and off the retarder brake lever frequently while making a downhill travel.

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Supplements

- If the retarder lever is turned on and off frequently, heat generation by decelerations will increase and, also, since the engine revolution drops, the brake oil cooling capacity will decrease to cause overheating in an earlier stage.
Retarder oil temperature (C) If the retarder brake is turned on and off frequently, the brake oil temperature also will rise and drop repetitively and effective cooling cannot be expected.

Working time

2. Do not use the service brake frequently.

- While making a downhill travel, do not use the service brake frequently except for emergencies. - Since the front brake is not equipped with forced cooling mechanism, frequent use of service brake while making a downhill travel will cause overheating to reduce the braking effect extremely and it is very dangerous to use the service brake frequently while making a downhill travel. Also, early stage wears of related parts will occur. - Make it a rule to use the retarder brake when making ordinary downhill travels.

(Failure examples by frequent use of the service brake) The service brake was used frequently while making downhill travels. Then, not only the braking effect has been decreased extraordinarily, but also the brake parts of the vehicle have been damaged greatly. Piston

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Brake pad

Brake pad (New parts)

With the front brake, the braking force is being acquired by the friction force occurring when the piston pushes the brake pad onto the brake disc. However, when the service brake is used frequently while making downhill travels, holes will open in the brake pad finally and the piston will then push the disc directly. In this state, necessary braking force cannot be acquired and it will be very dangerous to drive a vehicle with holes in the brake pad.

3. Do not make abrupt operations of the retarder lever.

- Do not make abrupt operations of the retarder lever and operate it gradually and in an earlier stage. - Also, it may cause tire slips. Moreover, it may result in generation of excessive thermal energy. Abrupt operation of the retarder lever => The tires will slip and it will be very dangerous.

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Chapter for the Air Over Hydraulic Type Brakes

IV. Prohibitions when making braking operations

Contents of the operations 4.Do not use the retarder brake as a parking brake.
When you leave the vehicle, be sure to apply the parking brake. In case of the retarder brake, if it is used as a parking brake, the air may leak out and the vehicle may start moving.

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Supplements

-When parking the vehicle on an inclined place from necessity, turn on the parking brake and, after that, apply chocks to the front wheels.

RELEASE

LOCK

Chocks

5. Do not accelerate the speed while making a downhill travel by shifting up the speed stage. - If the travel speed is accelerated while making a downhill travel by shifting up the speed stage, the engine revolution will drop and sufficient cooling capacity for the retarder cannot be obtained. Therefore, adjust the travel speed while making a downhill travel by use of the retarder lever.

The engine revolution will drop and sufficient cooling capacity for the retarder cannot be obtained and overheating may occur.

The flow rate of the retarder oil into the oil cooler will be decreased.

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6. Do not make a downhill travel setting the shift lever to the "N" position. - If the shift lever is set to the "N" position while making a downhill travel, the engine revolution will drop and sufficient cooling capacity for the retarder cannot be obtained. Also, if the shift lever is set to the "N" position while making a downhill travel, the travel speed of the vehicle will be accelerated to an uncontrollable range and very dangerous.

Brake oil cooler

Oil tank

Retarder brake disc

When the retarder oil temperature gauge indication enters into the red zone, the caution lamp will turn on and the alarm will sound. Then, promptly stop the vehicle at a safe place to cool down the retarder oil temperature. During the summer season when the atmospheric temperature is high, since the heat balance of the retarder oil will become worsened corresponding to the atmospheric temperature, operate the retarder brake in an earlier stage. (Operation of the retarder brake always in an earlier stage will be more effective.)

To cool down the retarder oil temperature, set the shift lever to the "N" position and keep the engine revolution rate at 2,000rpm or more.

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Chapter for the Air Over Hydraulic Type Brakes

V.

Auto retarder operations (an optional equipment)

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1. What is an auto retarder ?

Auto retarder is a system which functions to adjust the retarder brake effects automatically so that the operator may be able to complete a downhill travel at a certain speed preset freely by the operator. When the auto retarder is used, it becomes unnecessary to operate the retarder lever and the operator can concentrate to the steering wheel operations, thus improving the traveling safety. Set the auto retarder to the speed at this point. => After setting, the vehicle will make a
downhill travel at a certain speed. (It becomes unnecessary to operate the retarder lever to adjust the travel speed and the operator can concentrate to the steering wheel operations.)
At a certa in speed At a certa in speed

At a cert spee ain d

The auto retarder will maintain a certain downhill traveling speed automatically even when the gradient changes.

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2. Regarding the auto retarder operations
Regarding the auto retarder operations, when the travel speed reaches the preset downhill traveling while the vehicle is making a downhill travel with the "Auto Retarder Switch <1>" positioned on the dashboard panel being turned ON, make the "setting operation" of the "Auto Retarder Setting (Features of Komatsu Auto Retarder) Switch <2>" to activate the system. With Komatsu Auto Retarder (ARSC), since
(4)CAUTION lamp (Red) (5)READY lamp (Green) (3)Preset travel speed indication (1) ARSC system switch

When the auto retarder is used, it becomes possible to make downhill travels at a stable travel speed and the overall downhill traveling Temperature variation of the cooling oil for the auto retarder and manual retarder speed will be increased and the cycle time C for the dump truck will be shortened as the 140 Overheating result. 120 Furthermore, since the vehicle will make downhill travels at a stable travel speed, 100 cooling of the retarder oil will be carried out efficiently and overheating will not 80 occur frequently. Overheating (Refer to the diagram indicated on Manual retarder the RH side.) 60

Acceleration

Release

Set Deceleration

the travel speed settings can be made freely using the switch being installed to the steering column and, also, since the preset travel speed will be indicated in the upper section of the panel, it is very easy to use and quick to check the current setting for the convenience of the operator of the dump truck equipped with Komatsu Auto Retarder. - Even if speed stage setting error is made, there will be no fear of "occurrence of engine overrun or of seizure of the brake disc by excessive load". (Even when the preset speed is exceeding the maximum speed stage of the current shift lever position, the retarder brake will be activated before overrun occurs by the function of the overrun preventive function. In the meantime, there will be no possibility of application of excessive load to the brake at that time.)

(2) ARSC setting lever

Regarding the actual operations of the auto retarder, carefully read its instruction manual.

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Chapter for the Air Over Hydraulic Type Brakes

V.

Auto retarder operations (an optional equipment)

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3. Precautions when operating the auto retarder

- Even when making a downhill travel by use of the auto retarder, it is necessary to carry out the measurement work of the traveling course in advance. Using the measurement results, select the downhill traveling speed corresponding to the performance of the vehicle to carry out the operation of the dump truck. The engine revolution rate at that time should be 1,800rpm or more. - If a setting is made to a travel speed exceeding the permissible maximum speed when making downhill travels which can be obtained from the brake performance graph, overheating may occur to damage the retarder brake and it is dangerous to make such a setting. Be sure to set the travel speed within the range not exceeding the permissible maximum speed when making downhill travels. (When "Overheat caution" is issued while using the auto retarder, the travel speed is exceeding the permissible maximum speed and pull the retarder lever promptly to decelerate the travel speed and make the proper setting once again.) - On slippery road surfaces, the tires may lock while the auto retarder is in operation. In these cases, stop using the auto retarder. - If an abnormality occurs in the system and when it becomes unfeasible to carry out proper controls, the system operation will be turned "OFF" at the same time as issuance of an alarm and the auto retarder will then be released. When necessary, control the vehicle speed using the retarder control lever and brake pedal to park at a safe plate and turn "OFF" the auto retarder switch <1>.

4. Regarding Komatsu Auto Retarder (for reference)

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Comparisons of the basic functions of the auto retarder systems (Komatsu's system and the competing model)
Control method Komatsu Travel speed control
- Turn ON the ARSC system sw itch. - Af ter entering into the dow nhill road, adjust the dow nhill traveling speed using the retarder brake and w hen the actual speed reaches an appropriate level, push the set sw itch. - Af ter that, the retarder brake w ill be activated automatically so that the preset travel speed may be maintained. - The above setting w ill be released w hen the accel pedal is depressed or w hen the lever sw itch is moved tow ard the releasing direction. - Since the travel speed settings w ill be stored in the memory, it is not necessary to make settings each time w hen making dow nhill travels of the same dow nhill road.

<Regarding the differences in the auto retarder functions between the Komatsu Auto Retarder and the competing model> With the Komatsu's Auto Retarder System (ARSC), it is possible to set the travel speed freely within the range of 10 to 55km/h. Also, it is possible to make fine adjustment of the once preset downhill traveling speed within the range of 5km/h. On the other hand, with the competing model, it is not possible to make settings at the optional speed. (The downhill traveling speed is to be selected by positioning of the shift lever.) Also, it is not possible to make fine adjustments after presetting the downhill traveling speed.

Competing model Engine revolution control

- Turn ON the ARSC sw itch ON the dashboard panel. - Carry out gear shif ts to match the gradient of the dow nhill road to descend. - w hen the vehicles enters into the dow nhill road, release the accel pedal. A utomatic controls w ill be carried out to maintain the engine revolution at the proper level automatically. an orange indicator ON the panel w ill Turn on. - w hen releasing the control, activate the accel pedal, brake or manual lever. - the sw itch is NORMA LLY ON and the system is ready f or operation any time. (it is necessary to make the positioning change of the shif t lever each time.) Since the dow nhill traveling speed is selected by positioning of the shif t lever, it is not possible to make travel speed settings optionally.

Operating methods

Travel speed setting

Confirmation of the settings

It is possible to make the setting to optional travel speed. A lso, by moving the sw itch up and dow n, it is possible to make A lso, it is possible to make f ine adjustment of the once preset dow nhill traveling speed (w ithin the range of 5km/h) easily. Since the preset travel speed w ill be indicated on the display in the upper section of the panel, it is very easy to check the current setting. The alarm w ill be issued in assumption of occurrence of overheating detecting the extent of the rise of the retarder oil temperature.

Since the current shif t lever position w ill not be indicated on the panel, it becomes necessary to make visual conf irmation of the current shift lever position. The ordinary overheating alarm w ill be issued.

Overheating alarm

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