Production Training Material 2015

Engine Control system

HD 785-7

Jakarta, April 2015 Technical Training Departement

1. Fuel System
Out Line CRI

- The CRI system checks the condition of the engine (engine speed, accelerator angle,
coolant temperature, etc.) with sensors.
- The microcomputer of the CRI system controls the fuel injection rate, fuel injection timing,
fuel injection pressure, etc. totally to operate the engine under the best condition.
- In addition, the CRI system has a failsafe function which stops the engine when a certain
parts fail and a backup function which continues the operation by changing the control
method in such a case.
Control System

- To the ECU (engine control unit), the signals are sent from the sensors installed
to the machine. Based on the signals, the ECU calculates and controls the
energizing timing and energizing period of the injector to inject proper quantity of
fuel in proper timing.
- The control system is roughly divided by the electric parts into the sensors,
computer, and actuators.
Various Control
3. Sensor & Switch
Accelerator Pedal Sensor
S/N 7001 - 7078
Function
This sensor is installed on the surface of the floor. It
outputs the accelerator signal or idle validation signal
depending on the accelerator pressing angle.
Accelerator Pedal Sensor
For S/N 7079 and up
Accelerator Pedal Sensor
For S/N 7079 and up

Accelerator signal
Magnitude of the accelerator pedal displacement
being detected by the potentiometer inside the sensor
is output in variable voltage from No. 2 pin.

Idle validation signal

The switch inside the sensor detects the accelerator
pedal operation. As the accelerator pedal is released,
it outputs the signal being entered to No. 5 pin from
No. 4 pin. And as the accelerator pedal is pressed, it
outputs the signal being entered to No. 6 pin from No.
4 pin.
Accelerator Pedal Sensor
Ne & Backup Ne Speed Sensor

Total 58 holes every 6°

2 holes missing for Top 1R or 6R

Ne & Backup Ne Speed Sensor

Ne

G
Common Rail Pressure Sensor

Outline
- The common rail fuel pressure sensor is installed to the
common rail to sense the fuel pressure.
- This sensor is a semiconductor pressure sensor, which
utilizes the phenomenon that the electric resistance of
silicon changes according to pressure applied to it.
PCV (Pressure Control Valve)

Outline
The PCV adjusts the fuel delivery from the fuel supply
pump to adjust the common rail fuel pressure. It
means that the delivery from the fuel supply pump to
the common rail is decided by the timing of energizing
the PCV.
 Injector

- The function of the injector is to inject the high pressure fuel from the common rail into each
combustion chamber of the engine in the optimum timing, by the optimum quantity, at the
optimum injection rate, and under the optimum spray condition.
- The TWV (2-way solenoid valve) controls the start and finish of fuel injection by controlling the
pressure in the control chamber.
Injector
Electric Feed Pump
Retarder / Retarder oil temperature sensor

1. Thermistor
2. Plug
3. Wiring harness
4. Connector

Function

- The retarder oil temperature sensor is installed on the retarder pipe. It converts a temperature
change into a change of thermistor resistance, and transmits a signal to the retarder controller. The
retarder controller transmits the signal via the network to the machine monitor panel, and the machine
monitor panel displays a temperature level. The temperature level displayed on the monitor panel
reaches a predetermined position, the lamp flashes and the warning buzzer sounds.

- The steering oil temperature sensor is installed to the steering and hoist piping. The sensor portion
detects the temperature, and when the oil temperature goes above the specified level, the warning
lamps lights up and a message is displayed on the character display of the monitor panel.
Fuel level secsor

Function
The fuel sensor is installed to the side face of the fuel
tank. The float moves up and down according to the
fuel level. This movement of the float is transmitted by
the arm and actuates a variable resistance. This
sends a signal to the monitor panel to indicate the
remaining fuel level. When the display of the monitor
panel reaches a certain level, a warning lamp
flashes.
Coolant level sensor

1. Float
2. Sensor
3. Connector

Function
This sensor is installed to the top of the radiator, and when the coolant level goes below the specified
level, the float goes down and the switch goes OFF. The maintenance caution lamp lights up and the
character display shows message to warn of abnormality.
Transmission oil filter clogging sensor

Function
1. Body This sensor are installed to each filter, and when the filter becomes
2. Tube clogged, and the difference in pressure between the low-pressure
3. Connector side and high-pressure side reaches the specified pressure, the
A : Low pressure pickup port switch goes OFF. The maintenance caution lamp lights up and the
B : High pressure pickup port character display shown message to warn of abnormality.

Actuating pressure: 275 kPa {2.8 kg/cm2}

Principle of switch: Pressure difference sliding piston type
Air cleaner clogging sensor

Function
The air cleaner clogging sensor is installed to the outward port
of the air cleaner. If the air cleaner becomes clogged and
reaches the set pressure (negative pressure), the maintenance
caution lamp lights up and character displayshows message to
warn of the abnormality.

1. Indicator
2. Spring
3. Adapter
Air cleaner clogging sensor
Body positioner sensor
Steering angle sensor (for ASR)

1. Bearing
2. Brush Assembly
3. Connector

Function
- The body position sensor is installed to the rear of the chassis. When the angle of the dump body
changes, the shaft rotates through the link installed to the dump body, and the dump body angle is
detected.
- The steering angle sensor is installed to the center lever and transmits voltage signals to the
controller according to the center lever angle.
Accumulator oil pressure sensor

1. Sensor
2. Connector

Function
The accumulator oil pressure sensor is installed to the accumulator
piping on the right side of the machine and its sensor section senses
the oil pressure. If the oil pressure lowers below the set level, the
warning lamp lights up and the message is indicated on the character
display of the monitor panel.
Steering oil pressure switch (For auto emergency
steering system)

1. Piston
2. Body
3. Switch
4. Connector

Function
The steering oil pressure switch is installed to the steering and hoist piping.
While the engine is running, if the steering circuit oil pressure lowers below
the set level, the steering oil pressure switch operates the electric pump to
secure the oil pressure for steering.
Tilt switch

1. Body
2. Connector

Function
When the machine tilts to the left or right and become into the roll-over danger range, If the dump lever
is operated to the RAISE position in this condition, the lamp lights up and the buzzer sounds to warn of
the danger.
Pressure sensor (For auto suspension system, for
ARSC, for ABS) Suspension oil pressure sensor

1. Sensor
2. Tube
3. Connector
Function
- The suspension oil pressure switch is installed to the suspension cylinder. If the pressure supplied
through the pressure inlet is applied to the diaphragm of the pressure sensor section, the diaphragm is
deflected and deformed. A bridge consisting of strain gauges is installed on the opposite side of the
diaphragm. If the diaphragm is deflected, the resistance of the strain gauges changes. A constant
voltage is applied to the strain gauges and the change of the resistance of the strain gauges is sent as a
change of voltage to the amplifier. The amplifier amplifies the change of the voltage and outputs it to the
controller.
- The pressure sensor for ABS is installed to the output line of each ABS control valve. If the pressure
supplied through the pressure inlet is applied to the diaphragm of the pressure sensor section, the
diaphragm is deflected and deformed. A bridge consisting of strain gauges is installed on the opposite
side of the diaphragm. If the diaphragm is deflected, the resistance of the strain gauges changes. A
constant voltage is applied to the strain gauges and the change of the resistance of the strain gauges is
sent as a change of voltage to the amplifier. The amplifier amplifies the change of the voltage and
outputs it to the controller.
Clinometer (For payload meter)

To carry out compensation on slopes, the clinometer measures the tilt angle of the chassis
in the front-to-rear direction.
The output characteristics of the clinometer are as
shown in the diagram. Voltage between clinometer
connector pin 1 (GND) and pin 2 (output) or voltage
of output (pin (3)) of clinometer when pin (9) of VHMS
controller connector (CN2B pin) is grounded
Blow-by pressure sensor (For VHMS)
Function
The blow-by sensor converts the pressure inside the engine crankcase into a voltage and inputs this into
the VHMS controller as the blow-by pressure.

Specifications
1. Voltage of power supply
2. Output voltage
3. Size: Mount (portion a)
: DC5V
: 0.5V(engine stopped) or more
: R 1/4
: Outside diameter of seat receiving pressure : 37 mm
: Length of cable : 1,110 mm
Engine oil temperature sensor (For VHMS)
Function
The engine oil temperature sensor is installed to the engine oil filter. It inputs the change in
temperature to the VHMS controller as a change in the resistance of the thermistor.

a : Heat sensing portion of sensor,

outside diameter of mount R 1/4

Specifications
1. Type of sensor : Thermistor
2. Range of measurement : 40 – 130 °C
: 80 – 130 °C (guaranteed precision ± 2 °C)
3. Max. power consumption : 0.5 mW
4. Pressure resistance : 4.9 MPa {50 kg/cm2}
5. Temperature range : --30 to 140 °C
6. Performance table
Exhaust temperature sensor (For VHMS)
Function
The exhaust temperature sensor is a thermoelectric type temperature sensor. It is installed to the
turbocharger inlet port and outputs the exhaust temperature data to the VHMS controller.

Specifications
1. Rated voltage : DC24V
2. Detection temperature range : 100 – 1,000 °C
: 300 – 800 °C
(guaranteed accuracy ± 10 °C)
3. Output voltage characteristics: See table below
4. Actuation temperature range : --40 to 110 °C
5. Consumption current : Max. 30 mA
a: Heat sensing portion of sensor, outside diameter of mount R 1/8
b: Amp
c: Connector (power source end)
d: Connector (sensor end)
Ambient temperature sensor (For VHMS)
Function
The ambient temperature sensor inputs the ambient temperature to the VHMS controller as a change in the
resistance of the thermistor.

a: Heat sensing portion of sensor, diameter of

mount 16 x 1.5

Specifications
1. Electricity consumption : Max. 0.5 mW
2. Pressure resistance : 0.98 MPa {10 kg/cm2}
3. Detected temperature range (surrounding) : --30 to 120°C
4. Retention temperature range : --30 to 140°C
5. Performance table below
Wheel speed sensor (For ABS/ASR)

1. Spring spacer
2. Tube
3. Connector

Function
This is non-condact sensor. A pulse voltage is generated by rotation of the teeth of the gear installed
to the outside of the pulse wheel, anda signal is sent to the controller.
Relay