WELCOME

EPA EURO
EPA EURO IIII ENGINE
ENGINE
HPI/CRI SYSTEM
HPI/CRI SYSTEM

Presented By
Presented By
KAP TRAINING
KAP TRAINING DEPARTMENT
DEPARTMENT
 COURSE PROGRAMME
Time Subjects
0900~1030 Introduction to EURO/TIER II
Engine ~CRI & HPI Fuel system

1045~1200 Common Rail Injection (CRI)

~S & F of Pump and Injector
~ Engine Controller System

1300~1500 High Pressure Injection (HPI)

~S & F Pump and Injector
~Engine Controller System
~Injector Adjustment

1515~1700 Engine Controller Overwriting

Procedures
Summary & Discussion
Joint-Venture Company
Joint-Venture Company
The Industrial Power Alliance (IPA) is a
joint-Venture company established by
Komatsu and Cummins, a world leader
in diesel engine manufacturer
Joint-Venture Company
Joint-Venture Company
IPA is a combination of the strength of
Komatsu and Cummins, and its mission
is to develop worldwide-standardized
products that meet requirements of the
highly competitive engine markets
Joint-Venture Company
Joint-Venture Company
IPA comprised of a group of experienced
engineers, who will engage in research
and development of industrial diesel
engines for the coming century
IPA OBJECTIVES
IPA OBJECTIVES

Countries today
are working
together to reach
global solutions
for
environmental
issues which the
world will be
facing in the
future.
IPA OBJECTIVES
IPA OBJECTIVES
IPA has set out to
develop high
performance engines for
meeting tomorrow’s ever
more stringent standards
of emission control.
As we approach the 21st
century, IPA seeks
innovations to enhance
diesel engines as the core
power unit of all equipment
and continuously explores
areas where the importance
of existing products may be
rediscovered.
IPA OBJECTIVES
IPA OBJECTIVES
IPA recognizes that
the value of an engine
lies in reliability and
efficiency.
Our engineers seek to
fulfill high customer
demands for diesel
engines installed in a
wide variety of
equipment used in the
industrial and
construction sectors
 EPA Non-Road
EPA Non-Road Diesel
Diesel Emission
Emission Standard
Standard

6D170 CRI
EU Emission
EU Emission Regulations
Regulations for
for
Off-Road Engines
Off-Road Engines

175
175to
to 750
750 HP
HP
 Japan Emission
Japan Emission Standards
Standards for
for
Construction Engines
Construction Engines

MCO = Japan Ministry of Construction

Sec 2
EPA EURO
EPA EURO IIII ~~ HPI
HPI System
System
The HPI 170E-3 meets the strict exhaust gas
regulations (USA: EPA regulations for the year
2001, EU: regulations for the year 2002, Japan:
construction equipment regulations for the year
2004).
At the same time, they are high performance,
high efficient engines which achieve low fuel
consumption, low noise, improved exhaust gas
colour, and improved acceleration.
These engines have been newly developed to
meet various purposes of use as the power unit
for construction equipment and industrial
machinery.
What is
What is HPI
HPI System?
System?

Uses the latest

generation of
Cummins
electronic controls,
provides precise
fuel management
and infinitely
variable injection
timing
EPA EURO
EPA EURO IIII ~~ CRI
CRI System
System
The 140E-3 &125E-3 both meet the strict exhaust
gas regulations (USA: EPA regulations for year
2001, EU: regulations for year 2002, Japan
construction equipment regulations for the year
2004)

At the same time, they are high performance, high

efficient engines which achieve low fuel
consumption, low noise, improved exhaust gas
colour, and improved acceleration

These engines have been newly developed to meet

various purposes of use as the power unit for
construction equipment and industrial machinery
What is
What is CRI
CRI System
System ??
Is an electronic controlled injection system
supplied by Denso. It provides optimum injection
to match engine speed and load.

Common Rail
Pressure
sensor

Max. 1200
injectors Kg/cm2
Controller

Cylinder No. Supply Pump

sensor

Throttle
EPA EURO
EPA EURO IIII ~~ Fuel
Fuel Standard
Standard
 Temperature above -12oC
ASTM Grade no 2-D diesel fuel with a
minimum Cetane number of 40
( Higher Cetane number may be
needed in high altitudes or extremely
low ambient temperatures)

 Temperature below -12oC

ASTM Grade no 1-D diesel fuel.
EPA EURO
EPA EURO IIII ~~ Fuel
Fuel Standard
Standard
 Low sulfur content fuel having a cloud
point that is at least 10 degrees below
the lowest expected fuel temperature.
Cloud point is the temperature at
which crystals begin to form in the
fuel.

 Viscosity of fuel must be kept above

1.3 cSt at 100oC to provide adequate
fuel system lubrication.
EPA EURO
EPA EURO IIII ~~ Oil
Oil Standard
Standard
Recommendation ~ CH-4
Designed to meet 1998 exhaust emission
standards. CH-4 oils are specifically
compounded for use with diesel fuels ranging in
sulfur content up to 0.5% weight. Can be used in
place of CD,CE,CF-4, and CG-4 oils

CH-4 has the ability to absorb contamination and

prevent piston ring sticking.

Note : New oil CH-6 will be introduced in end 2001

APPLICABLE MACHINE
APPLICABLE MACHINE MODELS
MODELS
ESTIMATED MACHINE
ESTIMATED MACHINE SHIPMENT
SHIPMENT
(EquivalentMachine
(Equivalent MachineModels
Modelsto
tobe
beFitted
Fittedwith
withCRI)
CRI)

Experienced machine delivery since 1993

: Not experienced yet
APPLICABLE
APPLICABLE MACHINE
MACHINE
MODELS
MODELS
(UP
(UP TO
TO 2001/JUNE
2001/JUNE PRODUCTION)
PRODUCTION)
• D155AX-5
• PC600-6, PC750-6, PC800-6
• WA500-3
• HD325-6, HD405-6
• HM400-1

ALL 140 SERIES ENGINES

Engine Application
Engine Application
CRI & HPI System Introduction Scheme
(Compliance to EPA, Emission regulation
TIER II from year 2001)

 125 series ~ PC400, WA470, HD255

 140 series ~ PC600,800, WA500, GD825,

PC1800,D155A, HD325, etc
 170 series ~ D375-3, WA600-3 m/c & others
in the ranges to meet Tier II &
EURO 2 emissions
KOMATSU vs
KOMATSU COMPETITOR
vs COMPETITOR

KOMATSU ~ CRI for 125 & 140 series

engines
HPI for 170 series engine

CATERPILLAR ~ uses HEUI unit

injection
system
KOMATSU SERVICE
KOMATSU SERVICE POLICIES
POLICIES
 AFTER-SALES SERVICE SHALL BE PROVIDED
BY KOMATSU NETWORK

 AUTHORIZATION SYSTEM SHALL BE

APPLIED TO;

OVERWRITING(*) OF CALIBRATION DATA

(Requires nomination and registration of
authorized person)

COMPONENT REPAIR

(*)Overwriting: Installation and rewriting calibration data

KOMATSU SERVICE
KOMATSU SERVICE POLICIES
POLICIES

 UTILIZE GLOBAL KOMATSU REMAN

CENTERS FOR COMPONENT REBUILDING

(Those countries supported by Komatsu

Reman Centers may request component
rebuilding.)
COMPONENT REPAIR
COMPONENT REPAIR
METHOD (( BY
METHOD BY DISTRIBUTORS)
DISTRIBUTORS)

 FUEL INJECTOR
Component Replacement for EPA
Regulation Applicable Area
Component Replacement or Nozzle
Chip Replacement for Non-EPA
Regulation Applicable Area
COMPONENT REPAIR
COMPONENT REPAIR
METHOD (( BY
METHOD BY DISTRIBUTORS)
DISTRIBUTORS)

 SUPPLY PUMP
Component Replacement or
Repair

 COMMON RAIL
Repair

 CONTROL BOX
Component replacement
AUTHORIZATION SYSTEM
AUTHORIZATION SYSTEM
~ Background
~ Background
 SAFETY
Failure of overwriting data may cause

serious damages to human and

machines.
 QUALITY
Repaired component should maintain

emission regulation standard

(Requires high level techniques/knowledge and

expensive facilities for Injector and Supply Pump

repairs. --- Same as PPM system)
This authorization system will be included in SPPM.
AUTHORIZATION SYSTEM
AUTHORIZATION SYSTEM
~~ Normination
Normination
Nominate one key person in the area, such as
USA, Europe, Asia, etc. for the following
functions of overwriting of data;

 To support Komatsu offices or distributors

in the same area for supporting overwriting
data.
(Extend network among Komatsu and distributors)

 To manage situation of overwriting of data.

 To provide information on overwriting of

data to Komatsu upon requests.
AUTHORIZATION SYSTEM
AUTHORIZATION SYSTEM
~~ Conditions
Conditions
 CALIBRATION DATA OVERWRITING
Nominate and register responsible persons
for CRI

 COMPONENT REPAIR AND CALIBRATION

DATA

 OVERWRITING
Own facilities/tools for repair & quality
assurance, and calibration data overwriting
Receive training
AUTHORIZATION SYSTEM
AUTHORIZATION SYSTEM
~~ Facilities
Facilities // Tools
Tools
FOR SUPPLY PUMP
- Disassembly and assembly tools
- Fuel pump test stand more than 11kw power
and some adapters, valves

CONTROLLER (Overwriting calibration data)

- Personal computer (OS: Windows 98)
- 24V power source(or battery mounted on
machine)
- Calibration data floppy disk, connectors and

cables
 AUTHORIZATION SYSTEM
AUTHORIZATION SYSTEM
~~ Training
Training

 CALIBRATION DATA OVERWRITING

– Training for authorization will be provided
in June and after that.
– Training duration will be 1-2 days
– Personal ID(4 digits) and installation
program will be given to trainees upon
completion of training and registration will
be made for that person
 AUTHORIZATION SYSTEM
AUTHORIZATION SYSTEM
~~ Training
Training
 SUPPLY PUMP REBUILDING
– FIRST TRAINING HAS COMPLETED ON
NOV. 2000 IN JAPAN AT DENSO
FACILITY FOR KOMATSU REMAN
CENTERS

– THE TRAINING FOR DISTRIBUTORS

WHO REQUIRE REBUILDING SHALL BE
ARRANGED CASE BY CASE BASIS
COMPONENT SUPPLY
COMPONENT SUPPLY &
&
REPAIR ROUTE
REPAIR ROUTE
(NEW CONTROLLER & OVERWRITING DATA)
COMPONENT OYAMA PARTS DIST.
PLANT D/CENTER
1 Controller Assembly
(with data) ORDER

2 White Controller
(without data)
3 Calibration Data Floppy SHIPMENT

Disk with Label

COMPONENT SUPPLY
COMPONENT SUPPLY &
&
REPAIR ROUTE
REPAIR ROUTE
(NEW & DAMAGED COMPONENTS)
COMPONENT CATE- DIST REMAN KT
GORY (1) CENTER (2)
INJECTOR 1 DENSO(3)
2 DENSO
SUPPLY PUMP
2
CONTROLLER 1 REFAB(4)
2 REFAB
(NOTE)
1) CATEGORY 1 : *Before starting remanufacturing at reman centers
*For countries not supported by Reman Centers
CATEGORY 2 : After starting remanufacturing at reman centers
2) (1) : Including Komatsu Subsidiaries and Liaison Offices
(2) : Komatsu Trading
(3) : Denso Corporation
(4) : Rebuilding center in Komatsu Electronics Division
3) Very similar system as current electronic component repair system
is applied.(Ref.ZSOD98-048, "Procedure Manual" December 1998)
PREPARATION SCHEDULE
PREPARATION SCHEDULE
~MACHINE
~ MACHINE PRODUCTION
PRODUCTION && INITIAL
INITIAL STOCK
STOCK
PARTS RECOMMENDATION
PARTS RECOMMENDATION LIST
LIST
MACHINE 2000 2001
MODEL 10 11 12 01 02 03 04 05 06
125 SERIES *
ENGINE *
140 SERIES *
ENGINE *
D155AX-5 *
*
PC600-6 *
*
PC750-6 *
*
PC800-6 *
*
WA500-3 *
*
HD325-6 *
*
HD405-6 *
*
HM400-1 *
*
*: Machine Production Schedule, *: Initial Stock Parts Recommendation List
PREPARATION SCHEDULE
PREPARATION SCHEDULE
~MATERIALS
~MATERIALS
(Applicable to the mach ines plann ed production start by June 2001)
MACHINE PRODUCTION SALES PRODUCT SPEC. OPE & MAINT PARTS
MODEL START CATALOG BULLETIN FILE MANUAL CATALOG
125 SERIES ENG 01/06 - - - - 000831
140 SERIES ENG 00/12 - - - - 010120
D155AX-5 00/12 001130 010202 010202 010130 001225
PC600-6 00/11 010201 010202 010202 010118 001130
PC750-6 01/05 010515 010515 010515 010515 010430
PC800-6 01/05 010515 010515 010515 010515 010430
WA500-3 01/05 010315 010315 010315 010330 010330
HD325-6A 00/12 001230 010210 010202 001225 001227
HD405-6A 00/12 001230 010210 010202 001225 001227
HM400-1 01/04 010313 010415 010415 010207 010215

MACHINE PRODUCTION SHOP MANUAL ASSEMBLY

MODEL START ST/FUNC T/SHOOT ASSEMBLY MANUAL
125 SERIES ENG 01/06 010601 010615 010815 -
140 SERIES ENG 00/12 010117 010119 010225 -
D155AX-5 00/12 010315 010330 010410 －
PC600-6 00/11 001225 010225 010330 －
PC750-6 01/05 001225 010225 010330 －
PC800-6 01/05 010430 010515 010715 010430
WA500-3 01/05 010330 010415 010615 -
HD325-6A 00/12 001225 010223 010410 -
HD405-6A 00/12 010330 010415 010615 -
HM400-1 01/04 010315 010510 010610 010301

(REMARKS) Completed
Not necessar Under the preparation
 PREPARATION SCHEDULE
PREPARATION SCHEDULE
~FACILITIES/TOOLS
~FACILITIES/TOOLS

COMPONENT SPECIAL TOOLS & FACILITIES SCHEDULE

JAN FEB MAR APR MAY JUN
INJECTOR Nozzle chip replacing tools ***

SUPPLY Disassembly & Assebly tools ***

PUMP
Test Bench related tools ***

CONTROLLER Cables and connectors for ***

Overwriting(*)
(Note) 1. Common rail can be repaired with ordinary tools
2. (*): PC and 24V-battery are additionally required
PREPARATION SCHEDULE
PREPARATION SCHEDULE
~~ ITEMS
ITEMS HANDLED
HANDLED BY
BY KOMATSU
KOMATSU

REMAN CENTERS
REMAN CENTERS

(1ST STAGE)
 INJECTORS (From DENSO)
 CONTROLLERS (From REFAB)
 SUPPLY PUMPS (By KOMATSU REMAN CENTERS)

(2ND STAGE)
INJECTORS (By KOMATSU REMAN CENTERS)
CONTROLLERS (From REFAB)
SUPPLY PUMPS (BY KOMATSU REMAN CENTERS)
PREPARATION SCHEDULE
PREPARATION SCHEDULE
~AUTHORIZATION
~AUTHORIZATION
OVERWRITING OF CALIBRATION DATA
(1ST STAGE)
- ALL OF KOMATSU SUBSIDIARIES AND LIAISON
OFFICES
- ALL OF KOMATSU REMAN CENTERS
- EXPERIENCED DISTRIBUTORS OF CUMMINS
QSK19 - QSK60 ENGINES

(2ND STAGE)
- ALL DISTRIBUTORS WHO REQUIRE
AUTHORIZATION WITH SATISFYING
CONDITIONS
PREPARATION SCHEDULE
PREPARATION SCHEDULE
~~ AUTHORIZATION
AUTHORIZATION

COMPONENT REBUILDING
(1ST STAGE):
2001/2002-
ALL OF KOMATSU REMAN CENTERS

(2ND STAGE):
ALL KOMATSU DISTRIBUTORS WHO REQUIRE
SUPPLY PUMP REBUILDING AND SATISFY
CONDITIONS
 PREPARATION SCHEDULE
PREPARATION SCHEDULE
~ACTIONS AT
~ACTIONS AT INITIAL
INITIAL STAGE
STAGE

INITIAL STOCK OF COMPONENTS AT KLTD

PDC AND DISTRIBUTORS ARE
INDISPENSABLE
(INJECTOR SET, SUPPLY PUMP , ONE WHITE
CONTROLLER AND DATA FLOPPY DISK FOR EACH
MACHNE MODEL)
 RECOMMEND SAME COMPONENTS TO BIG
CUSTOMERS & PROJECTS
 AUTHORIZATION OF OVERWRITING OF
CALIBRATION DATA BY DISTRIBUTOR
 TO BE ABLE TO OVERWRITE CALIBRATION
DATA BY ALL OVERSEAS SERVICE DEPT.
STAFF MEMBERS.
REQUESTS
REQUESTS
~SUBSIDIAIRES && LIAISON
~SUBSIDIAIRES LIAISON OFFICES
OFFICES
 Update information on customs clearance of
damaged components
(Ref. Separate material for investigation)
 Nomination of key person of overwriting of
calibration data
 Distributor authorization schedule for calibration
data overwriting and component
rebuilding.
 Rebuilding plan by each Komatsu Reman Center
 CRI COMPONENTS
CRI COMPONENTS ORDER
ORDER &
&
SHIPPING STATUS
SHIPPING STATUS
1.SHIPPED MACHINE STATUS
(As of end February)
D155AX-5 PC600-6 WA500-3 HD325-6
HD405-6
USA Y Y Y
KLC Y Y Y
KEISA Y Y Y
UK Y
ALGERIA Y
KSA Y
TURKEY Y
EGYPT Y
AUSTRALIA Y Y
CHINA
NEW CALEDONIA Y Y
 CRI COMPONENTS
CRI COMPONENTS ORDER
ORDER &
&
SHIPPING STATUS
SHIPPING STATUS
2. COMPONENTS ORDER & SHIPPING STATUS (As of March 7)
D155AX-5 PC600-6 WA500-3 HD325-6
HD405-6
INJECTOR 6218-11-3100
(pcs) 14/14
KAIC SUPLY PUMP 6217-71-1120 6218-71-1110
2/2
CONTROLLER 7872-10-3100 7872-10-4101 7872-10-5201 7872-10-2301
(WITH DATA) 1/1 1/1
INJECTOR 6218-11-3100
(pcs) 12/12
KEISA SUPLY PUMP 6217-71-1120 6218-71-1110
2/2 1/1
CONTROLLER 7872-10-3100 7872-10-4101 7872-10-5201 7872-10-2301
(WITH DATA)
* A/B : A-Order Q'ty, B-Shipped Q'ty
Komatsu Asia
Komatsu Asia &
& Pacific
Pacific Training
Training Centre
Centre