Auto retarder system for BH50M-1

The dump trucks, while going downhill gain momentum as a result of which the Engine and other
power line components over speed beyond the specified limit. As soon as the operator notices the
over speeding, he will apply manual retarder to overcome the above problem. During applying
manual retarder certainly there may be a time lag. This results in serious and permanent damage to
all the mechanical components, thereby reducing their service life and leading to premature failure
of Engine and Power line components.
Auto retarder system has been developed to avoid engine and other power line components over
speed beyond the specified limit. The system involves engine speed sensing through transmission
controller (CEC1/CEC2 controls). The controller will actuate the proportional solenoid valve which
in turn will operate the retarder brake gradually in case engine over speed is detected. This is a add
on circuit the existing brake circuit.
Advantages:
a) Operator fatigue is eliminated.
b) Increase life of Engine and other power line components.
The Auto retarder system consist of following components.
1. Controller /Valve driver : The controller/valve driver is a small task oriented controller.
This unit is designed for ease of setup and weather resistance. The controller is a general
purpose unit that can control two bi-directional valve sections or two cartridge solenoids
simultaneously. The controller communicates with a variety of input and output devices. It
has current mode (current closed-loop) or PWM mode (voltage open-loop) output for valve
control. The controller/valve driver will monitor the engine over speed input from the
transmission controller. When input command goes high, current to valve coil jump to Imin
and ramp to Imax unless input command goes low. When input command goes low, current
will ramp to Imin, then shut off.
Supply voltage 9.0V DC min -36V DC max.
Supply current 40mA@14V(No load)
Minimum current adjustable up to maximum preset at 1.1Amp
Maximum current adjustable up to 2.0 Amp, preset at 1.6Amp
Ramp rate is adjustable

Current ramping details :

2. Valve(EBV-M-MS08N-D024-RN-90-20) : Electro hydraulic Brake Valve (EBV), is a full

power valve for modulating output pressures in proportion to the input current. The valve receives
signal from valve driver and actuate the rear brake/retarder brake in proportion to the input current.

2. Shuttle valve : A control valve that regulates the supply of fluid from more than one source
into a single area of the circuit. The connection details are shown in the hydraulic
schematic circuit.
3. Connector kit and connector : The connectors supplied along with the kit are mating
connector for valve driver and proportional control valve.
4. Hoses and other accessories : These items are required for installation of auto retarder
system on BH50M-1.

The scope of supply for auto retarder system as follows ----Table-1

Auto reatrder system Installation to P/no. 955-BR-02778
Sl.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31

Description
Hose Assy.
Hose Assy.
Hose Assy.
Fitting Tee
Hose Assy.
Connector
Connector
Connector
Elbow90
Elbow90
Valve(EBV-M-MS08N-D024-RN-90-20)-*
Shuttle Valve-*
Boss
Boss
Screw
S/Washer
Washer
O-Ring
O-Ring
O-Ring
O-Ring
Electronic Controller-*
Connector Kit-*
Connector-*
Kit, Auto Retarder system
Screw
Washer
Lock Nut
Screw
Washer
Wireharness(cables)

Part Number
955-BR-03141
955-BR-03117
955-BR-03125
955-HS-11644
955-BR-03133
955-HS-11685
955-HS-11693
955-HS-11717
955-HS-11588
955-BR-11477
955-EG-03174
955-EG-03206
CPW02-08016
CPW00-06012
CFS01-10860
CFW01-10825
CFW02-10616
WA3052
SV9812
WA3051
TL3995
955-EG-03182
955-EG-03199
955-EG-72843
955-EGB-0143
CFS02-10512
CFW02-10510
CFN02-10527
CFS01-10645
CFW01-10619
955-EG-03393

Qty/E

Remarks

1
1
1
2
1
2
1
2
1
1
1
1
2
2
1
2
2
9
10
2
1
1
1
1
1
1
1
1
2
2
1

Note : (*) marked items are part of Kit, Auto Retarder system to P/no. 955-EGB-0143
Kit, Auto Retarder system consists of following items

955-EGB-0143

set

a) Valve(EBV-M-MS08N-D024-RN-90-20)
b) Electronic Controller
c) Connector Kit
d) Shuttle Valve
e) Connector

955-EG-03174
955-EG-03182
955-EG-03199
955-EG-03206
955-EG-72843

01
01
01
01
01

Hydraulic and Electrical connection diagrams :

Electrical circuit diagram : Fig01

Hydraulic circuit diagram : Fig02

Line diagram for Hydraulic circuit connections : Fig03

Installation details : Fig04

Component location on the BH50M-1 equipment :

Shuttle valve

Valve driver in Cabin

Proportional control valve

Procedure for retro fitment of Auto retarder kit on BH50M-1 at field

1. The items are to be supplied as per 955-BR-02778 for retro fitment of Auto retarder
system.
2. Ensure all the items are received as per table.
3. Check all items are intact and no physical damage to the components.
4. Mount the controller box/Valve driver near the SBDR timer as shown in the Fig04 and
Photo using suitable hardwares.
5. The shuttle valve and proportional control valves are to be mounted below the cabin as
shown in the photo and Fig04.
6. Prepare wire harness to connect the controller and valve. The isolation connector to be
provided for controller to valve connection.
7. Tap the engine over speed signal from Engine over speed indication provided on the dash
board.
8. The 24V power supply for the controller to be tapped from Warning circuit breaker.
9. The hydraulic connections are to be made as per Fig03.
10. After installation of all components ensure the connections as per Fig01, 02 and 03.
11. Run the equipment in downhill position to check whether retarder actuating automatically
or not.
12. When the engine speed is more than 2350RPM or when Engine over speed indication is
turned ON the retarder brake has to be applied gradually depend on signal level and also
as explained in the controller portion.
13. To check the auto retarder function on normal roads, 24V signal can be given to controller
input(pin number 6 of controller) and the actuation of auto retarder can be ensured.