power mode bypass controller to suit komatsu hd785 …

PRODUCT MANUAL POWER MODE BYPASS CONTROLLER TO SUIT KOMATSU HD785-5 AND HD785-7 VEHICLES

Part No. 11337 | 12731

2 | 16 M0698.docx | Rev 2.4 | Modified on 26/03/2021 | © Remote Control Technologies Pty Ltd

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M0698.docx | Rev 2.4 | Modified on 26/03/2021 | © Remote Control Technologies Pty Ltd 3 | 16

Contents

GENERAL SAFETY WARNINGS 4

PRODUCT OVERVIEW 5

FEATURES AND FUNCTIONS 5

OPERATION AND USE 5

CONTROLLER STATUS INDICATOR OPERATION 6

INSTALLATION GUIDE 7

INSTALLATION FOR KOMATSU HD785-5 7

- WIRING CONNECTIONS 7 INSTALLATION FOR KOMATSU HD785-7 8

- WIRING CONNECTIONS 8 DIAGRAMS 9

- WIRING DIAGRAM TO SUIT KOMATSU HD785-5 (519c) 9 - WIRING DIAGRAM TO SUIT KOMATSU HD785-7 (519d) 10 - WIRING DIAGRAM TO SUIT KOMATSU HD465 AND HD605 (590a) 11

CALIBRATION 12

SERVICE INFORMATION 12

SERVICE SCHEDULE 12 SERVICE PROCEDURE 12

PARTS LIST 13

TECHNICAL SPECIFICATIONS 13

COMPLIANCE AND STANDARDS 14

TROUBLESHOOTING 14

GLOSSARY 15

WARRANTY 15


GENERAL SAFETY WARNINGS

PERSONAL SAFETY

■ Everyone is responsible for safety.

■ The installer/service personnel should be trained and authorized to complete the required work.

■ Ensure that the machine is safely isolated during installation and testing to protect all personnel.

■ Complete all required risk assessments and job safety analysis (JSA) before commencing work.

■ Observe all site specific and machine OEM procedures regarding the following:

– working at heights

– working in heat

– working in confined spaces

– all other site specific occupational health and safety (OH&S) procedures

MACHINE ■ Carry out all prestart operations as per site and machine OEM procedures.

■ Ensure the machine is safely isolated during installation and testing to protect the machine and other equipment in the area.

■ Do not operate any machine with a known fault and report all findings to the supervisor in writing.

■ Test and operate machine as per machine OEM and site procedures.

■ Read and understand machine and site specific operational and testing instructions.

PRODUCT Before applying power to the equipment, the user/repairer/ installer must read all product instructions. If in doubt, seek assistance. ■ Ensure electrical connections are made as per RCT’s recommendations. Test circuits prior to connecting

power to any component.

■ The equipment contains no user serviceable parts inside. Return the unit to RCT for repairs.

■ Retain product and installation instructions for future use.

■ Ensure that RCT’s recommended service procedures are included in the machine’s service routine.

■ Observe all machine, site and RCT product warnings.

■ Follow all machine, site and RCT product operating procedures at all time.

The application of safety should not be limited to the above recommendations.


PRODUCT OVERVIEW

The Muirhead® Power Mode Bypass Controller, part number 11337, is designed to automatically select either standard mode or power mode based on whether or not the tray is loaded.

FEATURES AND FUNCTIONS ■ Multi-voltage 12-24 V

■ Environmentally sealed – IP65

■ Simple to install ■ No ongoing maintenance ■ Power boost switch available as an option

OPERATION AND USE When no load is detected, the Muirhead® Power Mode Bypass Controller will automatically select standard mode. When a heavy load is detected, the controller will automatically select power mode. The controller automatically filters the payload input to eliminate the controller falsely changing states. An optional momentary switch or key-switch can be fitted to manually place the vehicle into power mode. This may be used for servicing of the vehicle or where a boost of power from the vehicle is required. By default, the override switch will turn power mode on for 30 seconds


CONTROLLER STATUS INDICATOR OPERATION

STATE INDICATOR SEQUENCE

Battery Power-up ■ All indicators will turn on.

■ All indicators will turn off.

■ After power-up, the controller will revert to normal operation.

Status Indicator in Operation

RED – Fault.

■ If outputs have problems, this will turn on.

■ Outputs 1 & 2 – high current outputs: checked for over current.

■ Output 3 – not checked as it is a low side driver.

■ Output 4 – checked for correct output voltage.

■ Temperature – checked for board temperature exceeding 80 °C.

YELLOW – Pulses during normal operation, indicates system OK.

■ Flashes on and off at one-second intervals (on for one second, off for one second).

GREEN – On for normal operation.

Alarm Indication

System Status

Power Indication


INSTALLATION GUIDE 1. Install the controller in a suitable location, preferably in the cabin.

2. Refer to the wiring table below and the wiring diagram in this manual to connect the controller.

It is recommended that the wiring is installed alongside the OEM wiring ensuring that it is secured at regular intervals; this will provide protection from heat and abrasion, and any other excess damage that may occur with extended vehicle operation. When securing the wiring to the OEM wiring, ensure that the loom is away from moving vehicle parts which could lead to loom damage.

3. If you are using an optional LED, mount the LED in a suitable location that is visible to the operator. If you

are using the optional bypass switch, mount the switch in an area that is easily accessible to the operator. 4. Splice in the yellow wire (pin 8) to the payload strut sensor signal wire.

5. If you are installing to an HD785-5, cut the OEM wire coming out of the power mode switch terminal 1, 4

and 5 (Ensure that pins 1, 4 and 5 of the vehicles OEM power mode switch have been isolated and made safe). Connect the green wire (pin 4) to the existing wire going to terminal 10 of the CNS connector and connect the black wire (pin 2) to the existing wire going to terminal 6 of the CNS connector.

If you are installing to an HD785-7, cut the OEM wires coming out of the PWM2_M switch terminals 3 and 6. Join the OEM wire that was going to terminal 3 of the PWM2_M switch to the red wire (pin 1) and join the OEM wire that was going to terminal 6 of the PWM2_M switch to the yellow/blue wire (pin 3). Splice in the black wire (pin 2) to the OEM wire going to terminal 5 of the PWM2_M switch. Ensure any loose wires are isolated and made safe.

6. If you are installing to an HD785-5, connect the blue wire (pin 9) to pin 3 of the power mode switch.

If you are installing to an HD785-7, connect the park brake input to the orange wire (pin 6) if the signal is negative, or the pink wire (pin 7) if the signal is positive.

INSTALLATION FOR KOMATSU HD785-5 Connect wiring as per drawing 519c and as follows: WIRING CONNECTIONS

NO. COLOUR FUNCTION DESCRIPTION

1 Red Battery +VE Connect to a protected 12–24 V battery

2 Black Ground Connect to ground/battery negative

3 Yellow/Blue Output 1 Not connected (spare)

4 Green Output 3 Connect to pin 10 of CNS connector

5 White (optional) Input 1 (Optional) connected to bypass switch/pushbutton

6 Orange Input 3 Not connected

7 Pink Input 4 Not connected

8 Yellow Input 2 Connect to the payload strut sensor

9 Blue Output 4 Connect to LED –ve. This LED will be ON when the vehicle is in economy mode.

10 Purple Output 2 Not connected

11 Black/white (optional) Bypass GND (Optional) connected to bypass switch/pushbutton

12 Red/white Battery + VE Connected to LED + VE

Ensure that pins 1, 4 and 5 of the vehicles OEM power mode switch have been isolated and made safe.


INSTALLATION FOR KOMATSU HD785-7 Connect wiring as per 519d and as follows: WIRING CONNECTIONS

NO. COLOUR FUNCTION DESCRIPTION

1 Red Battery +VE Connect to a protected 12–24 V battery

2 Black Ground Connect to ground/battery negative

3 Yellow/Blue

Output 1 Connect to the wire that was disconnected from pin 6 of the OEM power mode switch

4 Green Output 3 Not connected

5 White (optional) Input 1 (Optional) connected to bypass switch/pushbutton

6 Orange Input 3 Not connected

7 Pink Input 4 Not connected

8 Yellow Input 2 Connect to the payload strut sensor

9 Blue Output 4 Connect to LED –ve. This LED will be ON when the vehicle is in economy mode.

10 Purple Output 2 Not connected

11 Black/white (optional) Bypass GND (Optional) connected to bypass switch/pushbutton

12 Red/white Battery + VE Connected to LED +ve

Ensure that pins 3 and 6 of the vehicles OEM power mode switch (PWM2_M) have been isolated and made safe.


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CALIBRATION

SETTING NO. DESCRIPTION UNITS* DEFAULT

1** Override Time

The length of time the economy bypass switch will allow the unit to force power mode, adjustable between 0 and 3 minutes.

Seconds 30

2** Truck Load Time

The length of time the controller will wait to engage power mode once the correct weight has been sensed (this is used to stop false changes), adjustable between 0 and 30 seconds.

Seconds 2

3** Analogue On Weight

The weight at which the unit will engage power mode, a signal greater than this value will still trigger this effect, adjustable between 0 and 24 volts.

V 3.515 V

4** Analogue Off Weight

The weight at which the unit will engage economy mode, a signal smaller than this value will still trigger this effect, adjustable between 0 and 24 volts.

V 2.49 V

* Note: The units’ column indicates the value that setting will increase by with each increment.

**Note: These parameters can be changed through programming; however, this will require the use of the

programmable controller utility available from RCT.

The following diagram is a visual representation of how the controller reacts to changes in voltage sensed from

the sensor struts:

In reference to the diagram above:

A If the voltage is within this range, the device will trigger (or remain in) economy mode. By default, this range is 2.49 V or below.

B If the voltage is within this range, the device output will remain in whatever state it was in prior to entering this range, until the voltage moves outside of this range. By default, this range is 2.50 V - 3.514 V.

C If the voltage is within this range, the device will trigger (or remain in) power mode. By default, this range is 3.515 V or above.

D This point represents the analogue off weight, 2.49 V by default.

E This point represents the analogue on weight, 3.515 V by default.

SERVICE INFORMATION

SERVICE SCHEDULE

The manufacturer recommends that the following service procedure should be performed at each machine’s scheduled service interval.

SERVICE PROCEDURE

1. Perform a visual inspection; include the following:

a) Control unit.

b) Wiring connections and looms.

c) Check that all switches and solenoids are in good working condition.

2. Perform a system test as per the Operation and Use section of this manual for the operation of the controller.


PARTS LIST

12731 POWER ECONOMY BYPASS KIT

PART NO. DESCRIPTION

QUANTITY

INCLUDED PARTS

SUGGESTED SPARES

11337 Power mode bypass controller 1 1

11110 Green LED 1 -

11981 LED resistor 1 -

12731 Power economy bypass kit 1 -

12738 Generic loom 1 -

7919 Bypass switch 1 -

3214 Switch cover 1 -

13617 System override label 1 -

TECHNICAL SPECIFICATIONS

Dimensions, controller only Length: 119 mm | Width: 80 mm | Height/Depth: 65 mm

Dimensions, boxed for freight Length: 140 mm | Width: 140 mm | Height/Depth: 70 mm

Weight, controller only 255 g

Weight, including loom / packaging for freight

600 g

Input nominal voltage 12 to 24 V

Ignition output continuous current maximum

10 A

Auxiliary output continuous current maximum

0.7 A

Operating temperate range −40 °C to +85 °C

Connection types 12-pin receptacle

Inputs Ignition supply, battery supply, chassis ground

Min & max input voltage 9 to 35 V DC

Enclosure type ABS

Environmental protection IP rating IP65

Programming/adjustment Refer to Calibration section.


COMPLIANCE AND STANDARDS Remote Control Technologies Pty Ltd has an obligation as a manufacturer to comply with the regulations as required by the relevant regulatory bodies, depending on the market and location.

This product currently complies with the following:

ACMA ■ IEC 61000-6-1:2005 Electromagnetic Compatibility (EMC) – Part 6-1: Generic Standards – Immunity for

Residential, Commercial and Light Industrial Environments. ■ IEC 61000-6-3:2006, A1:2010 Electromagnetic Compatibility (EMC) – Part 6-3: Generic Standards –

Emissions for Residential, Commercial and Light Industrial Environments. EU ■ IEC 61000-6-1:2005 Electromagnetic Compatibility (EMC) – Part 6-1: Generic Standards – Immunity for

Residential, Commercial and Light Industrial Environments. ■ IEC 61000-6-3:2006, A1:2010 Electromagnetic Compatibility (EMC) – Part 6-3: Generic Standards –

Emissions for Residential, Commercial and Light Industrial Environments. ■ RoHS 2 Directive 2011/65/EU FCC This device is exempt from FCC regulations under 47 CFR 15.103 Exempted devices.

IC This device is exempt from IC regulations under ICES-003 — Information Technology Equipment (ITE) — Limits and Methods of Measurement.

TROUBLESHOOTING

FAULT POSSIBLE CAUSE

Device not working. Check wiring and connections.

Intermittent fault. Check wiring and connections.


GLOSSARY

WARRANTY Please see the RCT standard warranty, available on our website - www.rct-global.com.

A Amp (Ampere)

mW Milli Watts

AC Alternating Current

N/A Not Applicable

AMS Advanced Management System

N/C Normally Closed

Aux Auxiliary Output

N/O Normally Open

CAN Controller Area Network

OEM Original Equipment Manufacturer

CMIO Control Master Input Output PCB

O/P Outputs

CMR Control Master Receiver

Out Output

CMT Control Master Transmitter

PB Push Button

CM2200 Control Master 2200 Remote Set

PC Personal Computer

COMMS Communications

PCB Printed Circuit Board

CPU Central Processor Unit

PIN Personal Identification Number

DC Direct Current

PLC Programmable Logic Controller

E.G. For example

POT Potentiometer

ETR Energised To Run

PPM Pulses Per Metre

ETS Energised To Stop

PWM Pulse Width Modulation

ESD Engine Shutdown

PWR Power

FET Field Effect Transistor

Rev Revision

GND Ground

RF Radio Frequency

H Hours

RH Relative Humidity

HEX Hexidecimal Numbering System

RPM Revolutions per minute

ID Identity

RX Receiver

i.e That is

RS232 Recommended Standard (number 232) for serial data transfer

In Input

Source The output can supply/drive current out

IP Ingress Protection

SYS System

kg Kilogram

TOV Text On Video

Km/h Kilometres Per Hour

TX Transmitter

LCD Liquid Crystal Display

V Volts

LED Light Emitting Diode

°C Degrees Centigrade

LK Link

# Number

M Minutes

< Less Than

mA Milli Amps

> Greater Than

MAX Maximum

% Percentage

MCU Multi Control Unit

MFU Multi Function Unit

MHz Mega Hertz (million(s) cycles per second)

MIN Minimum

mm millimetres

http://www.rct-global.com./

Discover more: www.rct-global.com [email protected] AUSTRALIA: +61 (0) 8 9353 6577 AFRICA: +27 (0) 83 292 4246 CANADA: +1 705 590 4001 RUSSIA / CIS: +7 (910) 411 11-74 SOUTH AMERICA: +56 3 5229 9409 USA: +1 801 938 9214

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