Engine Akl

8/6/2019 Engine Akl

http://slidepdf.com/reader/full/engine-akl 1/56

D375A-5 Electronic Training Part 1

Structure & Function Overview

Ayman Akl

D375A-5

8/6/2019 Engine Akl


Contents� Sensors Types

� Engine electronic control

� HPI Engine control system

� PCCS (Palm command control system)

� Transmission and steering Control systems� Monitor system

� Special function of EMMS

8/6/2019 Engine Akl


Sensor typesThe signal from the sensors are input to the panel directly .either side of a sensor contact

type is always connected to the chassis ground

Name of sensor Type of sensor When normal When abnormal

Engine oil pressure Contact OFF (open) ON (closed)

Engine water Temperature Resistor __ __

Fuel level Resistor __ __

Torque converter oil temperature Resistor __ __

Hydraulic oil temperature Contact ON (closed) OFF (open)

Radiator water level Contact ON (closed) OFF (open)

8/6/2019 Engine Akl


If the engine oil pressure is the same or higher

than the specif ied pressure , it is OF F (open contacts)

and if the pressure is below the specif ied pressure

it is ON ( closed contacts)

(open ) (closed)

8/6/2019 Engine Akl


8/6/2019 Engine Akl


(CLOSED)

In the normal time switch is On ( closed contacts)

In the Up normal time switch is OFF (open contacts)

(open)

8/6/2019 Engine Akl


When cooling water drops below the specified

level float goes down and sensor goes off

(closed) (open)

In the normal time switch is On ( closed contacts)

In the Up normal time switch is OFF (open contacts)

8/6/2019 Engine Akl


Move up and down of the f loat according to the f uel level

Will actuates signals , sends to the panel

8/6/2019 Engine Akl


8/6/2019 Engine Akl


The Decelerator potentiometer moved according to decelerator pedal actuation

This will generate a variable voltage signal between contact B&C send to the engine control

8/6/2019 Engine Akl


Engine Electronic Control

Fuel Cooler Fuel Cooler

8/6/2019 Engine Akl


The Throttle signal of the throttle

Dial enters the steering controller

And the transmission controller

And is processed together with

Another information ,then sent to

The engine controller as a throttle

Command .

The engine controller controls the

Control valve unit and the fuelPump in accordance with the

Throttle command

Engine Control

8/6/2019 Engine Akl


Engine control System

The engine controller receives theManual signal of the second throttle

(decelerator pedal) and the third throttle

signal .

The third throttle control signal includes the

following:-

1-Frist throttle signal ( Dial signal)

2-SSC (Shoe slip control) control) signal

3-Auto decelerators (F3,R3,R2) signal

8/6/2019 Engine Akl


*The Steering controller selects the lowest

engine speed from information 1,2,3 andSends it to the engine controller as a third

Throttle.

*The information of the engine controller

is used commonly by the all controllers through

networks for the optimum control of the

Engine and the machine body.

*The automatic decelerator function sets the

engine speed to 1000 rpm temporarily when

the travel direction is changed from F3,R3 or

R2( To protect the transmission clutch).

Engine control System

8/6/2019 Engine Akl


HPI Engine Control SystemHPI is an abbreviation of high pressure injection

*The signals detected by various sensors

are input to the engine controller.

*The input signals are operated arithmetically by the controller

signal is issued to each Actuator and controls a fuel injection level

and fuel injection timing .

8/6/2019 Engine Akl


8/6/2019 Engine Akl


Injector

8/6/2019 Engine Akl


HPI FUEL Injection system

8/6/2019 Engine Akl


HPI SensorsHPI is an abbreviation of high pressure injection

EngineController

Sensors

Sensors

8/6/2019 Engine Akl


Item Function Location

Atmospheric pressure sensor Detects the atmospheric pressure Installed to the control valve unit

Boost pressure sensor Detects the turbocharger boost pressure( intake pressure) Installed to the intake manifold

Intake air temperature sensor Detects the intake air temperature Installed to the intake manifoldOil pressure sensor Detects the oil pressure in the lubrication circuits Installed to the cylinder block

Fuel temperature sensor Detects the fuel pressure supplied f rom the fuel pump Instal led to the control valve unit

Cooling water temperature

sensor Detects the temperature of the cooling water Installed to the thermostat housing

Engine speed sensor Detects the speed of the flywheel Installed to the flywheel housing

Fuel pump pressure sensor Detects the discharge pressure of the fuel pump Installed to the fuel pump

Fuel rail pressure sensor Detects the pressure of the fuel rail( fuel injection amount circuit) Installed to the control valve unit

Timing rail pressure sensor Detects the pressure of the timing rail( fuel injection timing circuit) Installed to the control valve unit

Throttle sensor Detects the angle of the accelerator on the machine Installed to the control valve unit

Engine controller It controls the overall system Installed to the control valve unit

Fuel pump actuator Control the output pressure of the fuel pump Installed to the fuel pump

Fuel shut-off valve Control the operation or the stop of the fuel supply circuit Installed to the control valve unit

Fuel rail actuator

Receive the output signal from the controller and adjusts the

pressure of the fuel rail (fuel injection amount circuit) to control thefuel injection amount Installed to the control valve unit

Timing rail actuator

Receive the output signal from the controller and adjusts the

pressure of the timing rail (fuel injection timing circuit) to controlthe fuel injection timing Installed to the control valve unit

8/6/2019 Engine Akl


Fuel dial

RH.steeringLH.steering

FWDREV

N

SHIFT UP BUTTON

SHIFT DOWN BUTTON

N

D375A-5

PCCS Lever

PCCS Lever (Palm Command Control System)

8/6/2019 Engine Akl


Transmission Control

Saf ety lever

Saf ety switch

Engine does not start unless saf ety lever in Lock 2

position

8/6/2019 Engine Akl


Transmission ECMVTransmission ECMV

8/6/2019 Engine Akl


8/6/2019 Engine Akl


PCCS

8/6/2019 Engine Akl


Steering ,Brake Control

8/6/2019 Engine Akl


Steering ,Brake Control

8/6/2019 Engine Akl


Steering ECMV

8/6/2019 Engine Akl


Monitor System

*The monitor system monitors the

machine condition with the sensors

installed to various parts of the machine

and processes and displays the obtained

information the panel Quickly to notify

the operator of the machine Condition.

*The main display sections and functions

of the panel are as follows:-

1-Monitor unit which turns on the alarmwhen the machines has a trouble.

2-Function of displaying error codes .

3-Function of monitoring the current and

Voltage of the sensors solenoid.

8/6/2019 Engine Akl


Monitor System*In the monitor panel , there are various

mode selector switches of the SSC which are

Used to operate the machine control system.

*The monitor panel has function of displaying

Data and functions of displaying data and

selecting the SSC mode.

*The CPU (Central Processing Unit) in itProcesses ,displays, and outputs the

information. The display unit is LCD (liquid

Crystal Display ) and the Switches are seat

switches.

8/6/2019 Engine Akl


Monitor Panel

1 Display plate (speed range display) 8 Power train oil temp. caution lamp

2 Power Train temp.gauge 9 Hydraulic oil temp. caution lamp

3 Engine water temp.gauge 10 Preheat pilot lamp

4 Charge lamp 11 Dual tilt display lamp

5 Fuel level caution lamp 12 Radiator water level check lamp

6 Engine oil pressure caution 13 Fuel gauge

7 Engine water temp.caution lamp 14 Service meter

8/6/2019 Engine Akl


Monitor Panel

8/6/2019 Engine Akl


8/6/2019 Engine Akl


8/6/2019 Engine Akl


8/6/2019 Engine Akl


Special function of the Monitor Panel EMMSEMMS : Equipment Management Monitoring System

8/6/2019 Engine Akl


If the user code indicates a serious problems occurs , the warning lamp f lashes and alarm buzzer sounds at same time.

8/6/2019 Engine Akl


8/6/2019 Engine Akl


8/6/2019 Engine Akl


Details see 375A-5 shop manual page 20-161

MonitoringMode

Monitor singles coming f rom sensors to the panel

8/6/2019 Engine Akl


8/6/2019 Engine Akl



8/6/2019 Engine Akl


8/6/2019 Engine Akl



8/6/2019 Engine Akl


8/6/2019 Engine Akl


8/6/2019 Engine Akl


Engine oil pressure sensor (3-dimensional drawing)

8/6/2019 Engine Akl


Engine oil pressure sensor ( M circuit diagram ,K-3)

8/6/2019 Engine Akl


Service code EC135 (Abnormal high level engine oil pressure )

8/6/2019 Engine Akl


8/6/2019 Engine Akl


8/6/2019 Engine Akl


8/6/2019 Engine Akl


Troubleshooting when service code is display

8/6/2019 Engine Akl


Troubleshooting of electrical system (E-mode)


Troubleshooting of hydraulic and mechanical system

8/6/2019 Engine Akl


Troubleshooting of hydraulic and mechanical system

(H-mode)

8/6/2019 Engine Akl


Troubleshooting of the engine body (S-mode)

Documents

Engine Akl