02.
Engine Control System Small Bulldozer
(D21EX-22)
Jakarta, Januari 2016 Technical Training Departement
Engine Control
1. Battery
2. Starting switch
3. Engine
4. Starting motor
5. Monitor panel
6. HST controller
7. Neutral safety relay
8. Safety relay
9. Limit switch
10. Parking brake lever
11. Electric lever
12. Steering and directional
and gear shift lever
(PCCS lever)
Input and output signals Function
a. Battery power supply A limit switch is installed to the parking brake and the HST
b. Engine start signal
controller controls the engine with it so that the engine can start
c. Starting switch "ACC" signal
d. Parking brake signal only when the parking brake lever is in the LOCK position and the
e. Neutral signal PCCS lever is in the N (Neutral) position.
Engine Control
1. Battery
2. Starting switch
3. Engine controller
4. HST controller
5. Monitor panel
6. Fuel control dial
7. Decelerator pedal
8. Engine
9. Engine speed sensor
10. Coolant temperature sensor
11. Engine oil pressure switch
12. Injector
13. Fuel supply pump valve
Input and output signals
a. Throttle No. 1 signal (fuel dial signal)
b. Throttle No. 2 signal (decelerator pedal
signal)
c. Throttle No. 3 signal (controller control
signal)
Engine speed control system d. Starting switch ACC signal
When the engine controller receives throttle No. 1 signal (fuel dial signal) and e. Controller power supply
throttle No. 2 signal (decelerator signal), it selects either one of the two f. Engine speed signal
whichever shows lower engine speed as the command signal to control the g. Coolant temperature signal
fuel supply pump and the injectors. h. Engine oil pressure signal
The engine controller information is shared by and sent to other controllers j. Sensor signal
on network to optimize relations between the engine and machine body. k. Monitor display signal
Engine stop system
Setting the starting switch to "OFF" cuts off ACC signal from the starting switch to the engine controller.
The engine controller stops fuel supply to the engine, and lowers the engine speed until it stops.
Engine Controller
Input and output signals
The following is the list of the symbols
used for signal classification in the
input/output signal chart.
A: Power supply
B: Input
C: Ground/shield/return
D: Output
E: Communication
Engine Controller
Engine Controller
HST Controller
HST Controller
Monitor System
1. Sensors
2. HST controller
3. Engine controller
4. KOMTRAX terminal
5. Battery
6. Alarm buzzer
7. Display panel A
8. Display panel B
a. Sensor signal
b. CAN signal
c. Power supply
d. Alarm buzzer signal
The monitor system notifies the operator of the machine condition. It monitors the machine condition with the
sensors installed to the machine and processes and displays the obtained information on the monitor panel
immediately. The content of panel display can be mainly classified into the following:
1. Travel direction, gear speed, shift mode (Display panel A)
2. Coolant temperature, hydraulic oil temperature, and fuel level (Gauge section)
3. Machine trouble alarm (Monitor section)
4. Current and voltage of each sensor and solenoid, action code and failure code (Display panel B)
• The monitor system consists of the monitor panel, controllers, sensors, alarm buzzer, and power supply.
The component parts are connected by wiring harnesses and the monitor panel is powered by the battery.
• If the machine has any trouble (and a sensor detects it), the monitor and alarm lamp flash and the alarm
buzzer sounds to protect the machine. The alarm buzzer can be turned OFF temporarily with the buzzer
cancel switch.
Decelerator Pedal Potentiometer
1. Potentiometer
2. Connector
Function
The potentiometer is connected to the decelerator pedal and brake pedal. Its shaft rotates
according to the working angle of the pedals.
Shaft movements cause the internal variable resistor to function, which changes the 5 V
supply voltage according to the working angle to generate the signal voltage.
Fuel Control Dial
1. Knob
2. Dial
3. Spring
4. Ball
5. Potentiometer
6. Connector
Function
Fuel control dial is installed to the left side of operator seat.
Turning knob (1) rotates the shat of potentiometer (5). This
changes resistance of the variable resistor, and the throttle
signal is sent accordingly to the engine controller via HST
controller.
The shaded portions in the graph below indicate the
abnormality detection range. Within these ranges, the
engine speed drops to onehalf.
Deceleration Command map
If the fuel control dial or decelerator pedal is operated, a
deceleration command is issued according to the
deceleration command map.
The deceleration command of fuel control dial is higher than
that of the decelerator pedal. Accordingly, even if the fuel
control dial is returned from the "Full" speed position, higher
output is secured.
The deceleration command means the ratio to the set
travel speed.
When the fuel control dial is at the "Full" speed position and the decelerator pedal is
not pressed: The deceleration command is 100%, and the command travel speed is
equal to the set travel speed.
When the fuel control dial or the decelerator pedal is set in the Medium speed position:
The travel speed is limited according to the formula of Command travel speed =
Deceleration command x Set travel speed/100.
Fuel Level Sensor
1. Connector
2. Float
3. Arm
4. Body
5. Spring
6. Contact
7. Spacer
Function
The fuel level sensor is installed to the side of the fuel tank. The float moves up
and down according to the fuel level. The float movement actuates the variable
resistor through the arm. As the result, a signal is generated by the resistor as the
change in resistance.
Charge Filter Clogging Sensor
Function
Installed to the charge filter, the contact of charge filter clogging sensor detects the pressure
before and after the filter. When the difference in the pressure before and after the filter
exceeds the set level, the switch is turned ON.
Air Cleaner Clogging Sensor
1. Boss
2. Switch
3. Conduit
4. Wire
5. Connector
Coolant Tempoerature Sensor
1. Sensor
2. O-ring
3. Connector
Engine Oil Pressure Switch
1. Connector
2. Sensor
3. O-ring
Engine Speed Sensor
1. Connector
2. Sensor
3. O-ring
Boost Pressure & Temperature Sensor
1. Connector
2. Sensor
3. O-ring
Ambient Pressure Sensor
