Electrical System

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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

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Monitor panel

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Processing in monitor panel (Common to all specifications)

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Processing in monitor panel (Common to all specifications)

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Engine control

7. Neutral safety relay Input and output signals

1. Battery
2. Starting switch 8. Safety relay
9. Limit switch a. Battery power supply
3. Engine b. Engine start signal
4. Starting motor 10. Parking brake lever
11. Electric lever c. Starting switch "ACC" signal
5. Monitor panel d. Parking brake signal
6. HST controller 12. Steering and directional and gear shift lever
(PCCS lever) e. Neutral signal
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Engine control system

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)
d. Starting switch ACC signal
e. Controller power supply
f. Engine speed signal
g. Coolant temperature signal
h. Engine oil pressure signal
j. Sensor signal
k. Monitor display signal

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Cooling control system
1. Battery
2. Battery relay
3. HST controller
4. Engine controller
5. Monitor panel
6. Cooling fan motor
7. Work equipment and fan pump
8. Fan rotation selector switch
9. Control valve
10. Fan EPC valve
11. Fan speed sensor
12. Hydraulic oil temperature
sensor
13. Engine
14. Engine speed sensor
15. Coolant temperature sensor
16. Aftercooler temperature sensor

Input and output signals

a. Controller power supply
b. Fan rotation selector signal
c. Fan speed signal
d. Hydraulic oil temperature signal
e. Engine speed signal
f. Coolant temperature signal
g. Aftercooler temperature signal
h. CAN signal
j. Fan speed control signal
k. Fan reverse signal

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Cooling control system
Fan speed control
 Based on the monitoring results of the temperature from the coolant,
hydraulic oil and aftercooler temperature sensors, the HST controller
controls the flow rate to the cooling fan motor to obtain appropriate
fan speed.

Fan rotation mode selection

 When the starting switch is set to "ON" position and the engine is not
running, fan rotation mode can be selected by operating the fan
rotation selector switch.

Fan rotation mode consists of:

1) Normal rotation mode
2) Cleaning mode

The HST controller selects the direction of fan by operating the cooling
fan motor reverse solenoid valve according to the mode selected.

Interlocking at mode selection

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HST control system 1/2
 PCCS: Abbreviation for Palm Command Control System

1. Battery
2. Battery relay
3. Engine controller
4. Fuse box
5. HST controller
15. R.H. HST pump forward EPC valve
6. Decelerator pedal potentiometer
16. L.H. HST pump reverse EPC valve
7. Brake pedal potentiometer
17. R.H. HST pump reverse EPC valve
8. PCCS lever (for steering)
18. L.H. HST circuit oil pressure sensor
9. Fuel control dial potentiometer
19. R.H. HST circuit oil pressure sensor
10. Monitor panel
20. L.H. HST motor speed sensor
11. Reverse travel speed setting switch
21. R.H. HST motor speed sensor
12. Shift mode switch
22. L.H. HST motor EPC valve
13. Engine speed sensor
23. R.H. HST motor EPC valve
14. L.H. HST pump forward EPC valve

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HST control system 2/2

Input and output signals
a. Controller power supply
b. CAN signal
c. Reverse travel speed setting signal
d. Shift mode signal
e. Decelerator pedal stroke signal
f. Brake pedal stroke signal
g. Steering and directional and gear shift signal
h. Fuel control dial stroke signal
j. Engine speed signal
k. HST circuit oil pressure signal
m. HST motor speed signal
n. HST pump EPC valve drive signal
p. HST motor EPC drive signal

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Gear shift control system
Gear shifting by operator

 The operator can select the quick shift mode or the variable shift mode with the
shift mode switch.
 If the steering and directional and gear shift lever is leaned forward (for forward
travel), a set travel speed is decided according to the gear speed of broken line
(B) in the above graph.
 If the steering and directional and gear shift lever is leaned backward (for reverse
travel), a set travel speed is decided according to the gear speed of set (A) to (E)
of the reverse travel speed switch in the above graph.
 When the steering and directional and gear shift lever is in the neutral position, the
set travel speed is 0 km/h.
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Set travel speeds corresponding to gear speeds

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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.
Example)
 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.
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Brake command map

 If the brake pedal is operated, a brake command is lowered according to the

brake command map.
 The brake command means the ratio to the set travel speed.
Example)
 When the brake pedal is pressed halfway:
The travel speed is limited according to the formula of Command travel speed
= Brake command x Set travel speed/100.

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Changing travel speed according to change of engine speed

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Straight-travel correction control system
 The HST controller monitors the operating conditions of each lever and each
pedal and constantly controls the swash plate angle of the HST pump, or the
delivery of the HST pump, so that the output speed of the right and left
HST motors will be the same.

 While the machine is traveling straight forward, if the right HST motor speed
is higher than the left HST motor speed, the HST controller lowers the control
signal of the right forward HST pump EPC valve so that the machine will
always travel straight.

 Conditions for resetting straight travel correction control system

1. When the steering and directional and gear shift lever is set to the Right
or Left swing position.
2. When the steering and directional and gear shift lever is set to the Neutral
position.
3. When a pedal or the fuel control dial is operated and the travel speed
sensed by the HST motor speed sensor is 0.15 km/h or lower.
4. When the HST motor speed sensor is judged faulty because of disconnection,
etc.
Straight travel is secured when none of the above condition applies.

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Parking brake control system

Input and output signals

a. Controller power supply d. Solenoid valve drive signal
b. Parking brake lever LOCK signal e. Brake oil pressure signal
c. Brake pedal stroke signal
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Parking brake control system
 Parking brake limit switches 1 and 2 are installed interlocked with
parking brake lever so that parking brake will be released only when
parking brake lever is in the FREE position.
 Center brake proximity switch is installed, which is interlocked with
brake pedal so that when brake pedal is pressed fully, center brake
relay will be turned OFF and slow brake solenoid valve will be de-
energize and parking brake will be applied.

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Component equipment of system
Monitor panel

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Monitor panel
Input and output signals

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Monitor panel display

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Engine controller

 The signal category of the following

terminal table shall be as below.
A: Power supply
B: Input
C: Grounding/Shield/Return
D: Output
E: Communication

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Engine controller

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Engine controller

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Engine controller

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HST controller

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HST controller

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HST controller

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PCCS lever (for steering)
 PCCS: Abbreviation for Palm Command Control System
 Do not disassemble the electric lever.
If it is disassembled, the output voltage
characteristics and operating effort
characteristics will need to be adjusted.

1. Boot
2. Bracket
3. Plate
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PCCS lever (for steering)

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PCCS lever (for steering)
2. Output voltage characteristics

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Sensor

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Sensor
Brake oil pressure sensor
(HST charge oil pressure sensor)

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Sensor
Hydraulic oil temperature sensor

1. Thermistor
2. Plug
3. Connector

Air cleaner clogging sensor

1. Boss
2. Switch 4. Wire
3. Conduit 5. Connector

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Sensor
HST circuit oil pressure sensor

1. Sensor
2. Connector

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Sensor
Decelerator pedal potentiometer
Brake pedal potentiometer

1. Potentiometer
2. Connector

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Sensor
Fuel control dial

1. Knob
2. Dial
3. Spring
4. Ball
5. Potentiometer
6. Connector

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Sensor
Fuel level sensor

1. Connector
2. Float
3. Arm
4. Body
5. Spring
6. Contact
7. Spacer

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Sensor
Charge filter clogging sensor

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.

Coolant temperature sensor

1. Sensor
2. O-ring
3. Connector

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Sensor
Engine oil pressure switch

1. Connector
2. Sensor
3. O-ring

Engine speed sensor

1. Connector
2. Sensor
3. O-ring

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Sensor
Boost pressure and temperature sensor

1. Connector
2. Sensor
3. O-ring

Water-in-fuel sensor

1. Connector 3. Sensor
2. Tube 4. O-ring

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 The End

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