Improvement activity of HM400-3 ECMV fill switch error

<Date>
June 13～19

<Member>
Komatsu: Yasuta, Sonobe
KMSI: Ganjar
UT: Priyantoro, Nurcholis,
M Afrah, Imam Buchori
1.Background
HM400-3 fill switch error happened frequently compared to HM400-2.
<Result of investigation>

Contact point

HM400-3 HM400-2 Oil sediments (Calcium Carbonate)

Transmission thicker than HM400-2
controller Small ( Half) Large
HM400-3:0.20μm
resistance
HM400-2:0.08μm
Fill Switch
Large ( Twice ) Small
Current

<Estimation mechanism>
Heated Resistance
Change Fill-SW Oil
contact Sediments on contact Error
resistance Current sediments
point increase point happening
in controler （Twice） (C, Ca)
（Art, etc.） increase
2.Improvement

<Improvement 1> Changing the current flowing along the fill switch

TM controller
Fill switch
internal
current
resistance
Current Small Large
Improvement Large Small

Change the connection between transmission controller and the fill switch to equalize the circuit with HM400-2.

CAN COMMUNICATION
TM
PANEL
MONIT

CONTROLLER
OR

FILL SWITCH

Adding new wire

Changing software Changing software

<Improvement 2> Changing caution level when fill switch disconnection error occurs

Warning
Action level Alarm buzzer Transmission control
lamp
L03 SHIFT HOLD
Current ON ON
(Stop operation) (Unable to change shift)
L01 Not applied
Improvement OFF OFF
(Able to operate) (Shift is changeable)

The action level is able to be change because fill SW error in ECMV of HM400 need not be shift hold.
3.Activity

Countermeasure has been implemented start on Friday, 13-Jun-14

SERIAL CODE MODIFICATION LATEST ABNORMALITY *

REMARK
NUMBER NUMBER DATE SMR ODO CODE DATE SMR
8015 DT1623 13-Jun-14 2199.3 22698.2 COMPLETED DDTHKA 4-Jun-14 2065.6
8017 DT1624 18-Jun-14 2197.4 23099.1 COMPLETED DDTJKA 15-Jun-14 2152.4
8018 DT1625 17-Jun-14 2176.6 21104.4 COMPLETED DDTHKA 8-Jun-14 2052.1 #8015 / DT1623

8019 DT1626 14-Jun-14 2175.2 23374.3 COMPLETED DDTJKA 13-Jun-14 2162.7

8020 DT1627 19-Jun-14 2203.8 22964.6 COMPLETED DDTJKA 12-Jun-14 2081.1
8021 DT1628 16-Jun-14 2212.8 23035.1 COMPLETED DDTJKA 14-Jun-14 2179.6

NOTE (*):
• Latest abnormality before modification is performed. #8019 / DT1626

• Data is recorded by KOMTRAX as 15-Jun-14

6 vehicles is operated without ECMV fill switch error.

Monitoring will be continued for about 1 month by Komtrax.
<Actual activity>
1.Adding wiring harness
･In cab (From X direction) ･Under cab (From Y direction)
From transmission controller From J09 connecter
to J09 connecter to fill SW of transmission ECMV X
WIRING ROUTE
J09 connecter

WIRING ROUTE

J09 connecter
Y
2nd, Lo, 1st, Hi,
Transmission
Fill SW Fill SW Fill SW Fill SW
controller

2.Rewriting program of transmission controller and monitor controller

3.Replacement ECMV
2nd 3rd 1st Hi
6 new ECMV is installed
to make clean oil sediments
on fill SW contact point
: Hi, Lo, Rev, 1st, 2nd and 3rd

Rev Lo
END