New generation KOMATSU Engines

Marketing & Service Principles

October 2000

Kenji OKUMURA
Service Technology Development
Customer Support Division
KOMATSU Limited , Japan

2018/7/25 Common Rail Service2000_10 1

 KOMATSU 125 & 140 bore Engines

Common Rail Fuel Injection(CRI) System

Introduction schedule
Compliance to EPA, Emission regulation
TIER II ( from year 2001 )
for
major KOMATSU middle size models
– 125 bore : (PC400),WA470,HD255
– 140 bore : PC600,800, WA500,GD825,
PC1800,D155A,HD325 etc.

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 Competitor & KOMATSU

It is not a pure competition but we must have

engines which meet TIER II of EPA , which will
starts from 2001
– CAT has HEUI, a kind of unit injection
– We, KOMATSU adopted CRI, Common Rail
Injection for 125 and 140 bore engines and HPI,
High Pressure Injection for 170 engine.
– CRI is supplied by DENSO and HPI is supplied
by CUMMINS.

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 CRI ( Common Rail Injection )
system image diagram

Common Rail
P ressure
sensor

Max. 1200
injectors Kg/cm2
Controller

Cylinder No. Supply Pump

sensor

Throttle

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 Our situation & what to do
• CRI and its service network
– CRI is an electronic controlled unit injection system and 120 M
Pa high pressure injection with microns clearance
components, injector and pump.
– CRI is supplied by DENSO and their service network is not
covered on all countries in the world, only for some high-way
trucks in US at the moment , October 2000.
• Same as we repair KP21, current KOMATSU electronic controlled
fuel pump, we , KOMATSU should have our own service network
to repair CRI by ourselves globally and establish to provide
reasonable repair cost to our customers even we adopted new
system.
• Difficult countries ( Attachment 1. )
There are several countries where re-exportation is impossible or
very difficult to send failed parts to outside for repair. Local repair
is indispensable like nozzle chip replacement or some way to
make the machine run.
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 CRI and KOMATSU equipment
• The machines equipped with CRI engines are of
middle size and they are sold for any categories
customers like construction, quarry, mining and
so on.
• Population and countries
( Attachment 2. )
US, Canada, Europe,Japan, Middle-east, Africa, Asia,
Russia, China and south American countries. They are
running mainly far from civilization and its support is very
different from the high-way trucks’ one. We can not expect
DENSO’s support so far even in US and Europe.

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 Repair Cost & its target
• Entire engine
– At least we should keep same cost level with the current 125
and 140 engines. Major parts are almost same other than CRI
related parts.
• CRI repair cost
– 30% of new one or maximum 40% of new one for replacement
parts cost in total.
– Injector : nozzle chip can be replaced and DENSO guaranteed
its variance ±6.7% against current BOSCH type ±8%
– SUPPY PUMP : All inner parts are supplied except plunger &
barrel sub-assembly.
– All other sensors, solenoid valve, actuators are to be replaced
with new one.

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 Repair contents & country
• No emission regulation countries
– injector: nozzle chip replacement
( Attachment 3. )
– SUPPLY pump: repair & test on stand
( Attachment 4. )
• Emission regulation countries
– injector : nozzle chip replacement for emergency repair
– SUPPLY pump: repair & test on stand

• Centralized repair of injectors ( in DENSO Japan )

– Failed injectors are to be returned to Komatsu Japan
and ship it back after repair in DENSO. 500K $ factory
facility is required for flow check. DENSO Nishio plant
will repair failed ones with 60% price of new one.
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 Controller & SUPPLY pump test &
Engine dynamo test
• Engine Controller(EC)
EC is developed by System Development Center of Komatsu
Japan same as other controllers and different from HPI Cummins
controller.
• SUPPLY pump test
11KW test bench is required for testing and adjustment of SUPPLY
pump and electronic control is simulated by the engine
controller(EC). An empty EC or each model EC is available and
calibrated to SERVICE mode. The software is supplied as a spare
parts together with uploading software.
• Dynamo test
Entire engine test is carried out on a dynamo test bench and its
electronic circuit is prepared with the EC , in which Dynamo test
mode is built-in. Only throttle signal is required to do the test. The
EC can be re-calibrated to any other model one.

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 Supply pump - bench test

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 Distribution of CRI parts
• KOMATSU spare parts route
Each subsidiaries can control it like limited supply of PPM
repair. Komatsu must do repair by ourselves but it is
business chance for Komatsu to keep it in our REMAN
center because too many repair points does not make profit
with its business volume.

• Purchasing & Supply

– Oyama plant purchases CRI parts from
DENSO in Japan and supplies from Japan.
– REMAN injector is available from DENSO.
Its logistic system is to be set up through
REMAN route.
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 Training & repair points establishment
( plan )
• Now to 2001/March
– preparation of tool , facility & manuals
– parts No. and pricing
• 2001/April to September
Japan, USA,UK. Japan covers Asia,USA covers
south America and UK covers Europe, Africa and
Middle-East.
• 2001/October to December
Australia and Indonesia
• And then we expand network to distributors level
by KOMATSU branch and subsidiaries

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 Controller system design

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 Troubleshooting/On-board diagnosis
• On-board diagnosis is available
- 7 segment character type(current type
monitor) : conventional coding like user code,
E15 and service code,E957….
- Failure code memory is available
• CYLINDER CUT-OUT mode
To find out failed injector
cutting fire one by one
RPM change indicates
a wrong one.(no RPM change)

The photo chows No.2

and 3 are cut and engine
speed is 674 r.p.m..

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 Attachment 1. Difficult countries
Difficult countries for re-exporting failed parts(including electronic devices)

subsidiaries ,offices country how difficult

DUBAI YEMEN impossible Export license takes lot of time and impossible actually
ISTANBUL LIBYA impossible same above
KAP NEPAL impossible same above
KEISA TUNISIA impossible Export license takes lot of time and impossible actually
KEISA MOROCCO impossible same above
ACCRA NIGERIA very difficult imported one with duty free is impossible
it looks OK, but it must be tried
MOSCOW CIS very difficult no legal restriction , but it is very difficult to re-export.
no distributor
KAP THAILAND difficult document is required severely
KAP INDIA difficult document is required severely
KBI BRAZIL difficult possible but tax is same with a new one.
ISTANBUL LEBANON unknown no experience , it must be tried.
ISTANBUL SYRIA unknown no experience , it must be tried.

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 Attachment 2. Population
COMMON RAIL
MODEL 1995 1996 1997 1998 1999 before 95 TOTAL
WA470 35 59 65 92 83 1143 1477
WA500 250 247 271 338 332 1544 2982
PC750 0 3 23 20 9 44 99
PC800 0 1 6 22 12 14 55
HD255 0 0 1 4 4 37 46
HD325 21 47 28 47 70 642 855
HD405 0 0 0 23 30 42 95
PC1600 8 4 0 1 0 26 39
PC400 137 112 101 96 75 952 1473
PC450 137 112 101 96 75 952 1473
D155AX 89 69 102 104 119 172 655
TOTAL 677 654 698 843 809 5568 9249

HPI
MODEL 1995 1996 1997 1998 1999 before 95 TOTAL
WA600 116 93 83 121 116 594 1123
WA700 6 9 11 10 7 69 112
HD465 43 45 82 30 73 304 577
PC1100 0 0 0 23 45 35 103
D375A 78 71 93 83 104 479 908
TOTAL 243 218 269 267 345 1481 2823

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 Attachment 3. Repair of injector
injector

solenoid valve

flow test
centralized repair
orifices(2) at DENSO Nishio Plant
in Japan (planned)

command piston
matching (2.5±0.5 μｍ）
nozzle chip
can be replaced in KOMATSU ｄｉｓｔ．shop
(variance: ±6.7%)

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 Attachment 4. Repair of SUPPLY pump
SUPPLY pump PCV
replacement with
priming pump
a assembly
valve plate

delivery valve

barrel
plunger overflow valve

replacement
with a set
cylinder NO.sensor
matching (2.5±0.5μｍ）

feed pump

tappet spring camshaft

tappet

roller bearing
(inside of the housing)
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