Technical Presentation Kit

SAA6D140/125-CRI Engines

Structure & Function

ECU & Controls

SAA6D140/125-CRI
KT900201
February 2001 Menu Exit
ECU - Location WA500-3 m/c
SAA6D140/125-CRI
TPK
02/01
Page 3-2
3-2

KT900201 - Structure & Function Menu Exit

ECU
SAA6D140/125-CRI
TPK
02/01
Page 3-3
3-3

Control system
The ECU (Engine Control Unit) carries out control by
calculating the length of time and the timing of sending
current to the injector by using the signals from the sensors
installed to the engine and various parts of the machine so
that it injects a suitable amount at the suitable injection
timing.
The control system and electrical components can be
broadly divided into the sensors, computer, and actuators.

KT900201 - Structure & Function Menu Exit

ECU
SAA6D140/125-CRI
TPK
02/01
Page 3-4
3-4

KT900201 - Structure & Function Menu Exit

ECU -Fault Codes - No active Codes
SAA6D140/125-CRI
TPK
02/01
Page 3-5
3-5

KT900201 - Structure & Function Menu Exit

ECU -Fault Codes - With Active Codes
SAA6D140/125-CRI
TPK
02/01
Page 3-6
3-6

CRI ECU With Stored Codes / With Active Codes

L 88 78 72 10 A4 00 Blank 99 -- 51 36
E All Stored Stored
D
lights Q rotary code code
Lights
D on for Display of controller program Number switch history history
off
i segmen settings not not
s t test active active
p 3- 3- 3- 3- 3-
l
second 1- second second second second
a
y
s Total 5 - seconds second s s s s
Note 1

77 E_ 51 E_ 77 E_ 51 …
Stored
code
Active Error
history Active Error Code Active Error Code Repeating
Code Repeating
not
active
3- 0.5- 3- 0.5 - 3- 0.5- 3-
second second second second second second second
s s s s s s s
Error History will be memorized and displayed in
order that faults have occurred.

KT900201 - Structure & Function Menu Exit

ECU Powers Injector Circuit
SAA6D140/125-CRI
TPK
02/01
Page 3-7
3-7

Voltage to Injectors
is 110 to 130 Volts

KT900201 - Structure & Function Menu Exit

Injector Circuit - Start of Injection
SAA6D140/125-CRI
TPK
02/01
Page 3-8
3-8

Charger or Pull
in current 11 to
12 Amps

KT900201 - Structure & Function Menu Exit

Injector Circuit - Injection
SAA6D140/125-CRI
TPK
02/01
Page 3-9
3-9

Constant or hold
in current 2 to 3
Amps

KT900201 - Structure & Function Menu Exit

Sensors
SAA6D140/125-CRI
TPK
02/01
Page 3-10
3-10

KT900201 - Structure & Function Menu Exit

NE & G Sensors
SAA6D140/125-CRI
TPK
02/01
Page 3-11
3-11

KT900201 - Structure & Function Menu Exit

NE Sensor
SAA6D140/125-CRI
TPK
02/01
Page 3-12
3-12

1) NE revolution sensor (crank angle sensor)

When the signal hole in the flywheel passes the
sensor, the line of magnetic force passing through the
coil changes and an AC voltage is generated in the
coil.
85~210

KT900201 - Structure & Function Menu Exit

NE Sensor
SAA6D140/125-CRI
TPK
02/01
Page 3-13
3-13

Signal holes are provided in the flywheel every 7.5

degrees, but there are 3 places where there is no hole,
so there is a total of 45 signal holes.
Therefore, for every 2 turns of the engine, 90 pulses
are output.
From this signal, the engine speed and the crank angle
for every 7.5 degrees is detected.

Flywheel alignment dowel

KT900201 - Structure & Function Menu Exit
G Sensor
SAA6D140/125-CRI
TPK
02/01
Page 3-14
3-14

G revolution sensor
(cylinder judgement
sensor)
In the same way as the
NE revolution sensor, the
change in the line of
magnetic force passing
through the coil is used
to generate an AC
voltage.

1.4~3.5 k

KT900201 - Structure & Function Menu Exit

G Sensor
SAA6D140/125-CRI
TPK
02/01
Page 3-15
3-15

The disc-shaped gear provided in the center of the camshaft of the

high-pressure pump has teeth cut (a notch is made) every 120
degrees , and in addition, there is an extra tooth at one point.
Therefore, for every 2 turns of the engine, 7 pulses are output.
The combination of the NE revolution sensor pulse and G revolution
sensor pulse is recognized as the No. 1 cylinder standard pulse.

KT900201 - Structure & Function Menu Exit

NE & G Sensors
SAA6D140/125-CRI
TPK
02/01
Page 3-16
3-16

Either sensors fail, engine output is

reduced & hunting.
75o x 2 = 150o
When subsequent sensor fails,
engine stops operation and not
able to start

Intake valve close

KT900201 - Structure & Function Menu Exit

Machine Speed Sensor
SAA6D140/125-CRI
TPK
02/01
Page 3-17
3-17

Engine Speed Sensor for Machine Controller, not

part of CRI Control system. Senses Flywheel Teeth.

KT900201 - Structure & Function Menu Exit

Throttle Position Sensor (TPS)
SAA6D140/125-CRI
TPK
02/01
Page 3-18
3-18

4.0 ~6.0 k

KT900201 - Structure & Function Menu Exit

TPS
SAA6D140/125-CRI
TPK
02/01
Page 3-19
3-19

KT900201 - Structure & Function Menu Exit

TPS
SAA6D140/125-CRI
TPK
02/01
Page 3-20
3-20

KT900201 - Structure & Function Menu Exit

TPS
SAA6D140/125-CRI
TPK
02/01
Page 3-21
3-21

KT900201 - Structure & Function Menu Exit

TPS
SAA6D140/125-CRI
TPK
02/01
Page 3-22
3-22

Faulty TPS - Engine fixed at high

idling

TPS with oil pressure switch fault -

Engine fixed at low idling

KT900201 - Structure & Function Menu Exit

Sensors - Water Temperature Sensor
SAA6D140/125-CRI
TPK
02/01
Page 3-23
3-23

Two different sensors One

for High Temperature and
One for Low Temperatures

Two different sensor

connectors are used to
prevent misconnection
KT900201 - Structure & Function Menu Exit
Sensors - Water Temperature Sensor
SAA6D140/125-CRI
TPK
02/01
Page 3-24
3-24

The water temperature sensor detects the temperature of

the engine cooling water and sends it to the ECM. The
sensor uses a thermistor which changes.
It applies voltage to the thermistor and detects with the
voltage divided into the resistance value inside the computer
and the resistance value of the thermistor.

ECM uses 90 degrees C for

calculation in the event of
sensor failure

KT900201 - Structure & Function Menu Exit

Sensors - Water Temperature Sensor
SAA6D140/125-CRI
TPK
02/01
Page 3-25
3-25

High Temperature Sensor

Provides engine protection at
90OC

Low Temperature Sensor

provides Low temperature
Start-up. Engine speed is
limited to 1000 rpm and split
injection is used, controls
white smoke at start up.
Faulty Low Temp Sensor
result in poor exhaust gas
colour & starting ability

KT900201 - Structure & Function Menu Exit

Sensors - Fuel Temperature Sensor
SAA6D140/125-CRI
TPK
02/01
Page 3-26
3-26

The fuel temperature sensor detects the temperature of the

fuel and sends it to the ECM.
The sensor uses a thermistor which changes the resistance
value according to the temperature. It applies voltage to the
thermistor and detects with the voltage divided into the
resistance value inside the computer and the resistance
value of the thermistor.

ECM uses 80 degrees C for

9k~0.3k
calculation in the event of
sensor failure

KT900201 - Structure & Function Menu Exit

Sensors - Fuel Temperature Sensor
SAA6D140/125-CRI
TPK
02/01
Page 3-27
3-27

As fuel temperature rises ECU derates fuel delivery

4-6 % between 50 degrees C and 70 degrees C.
Maximum Fuel Temperature is 80 degrees C
Faulty sensor will not result in engine operation

KT900201 - Structure & Function Menu Exit

Sensors - Boost
SAA6D140/125-CRI
TPK
02/01
Page 3-28
3-28

KT900201 - Structure & Function Menu Exit

Sensors - Boost
SAA6D140/125-CRI
TPK
02/01
Page 3-29
3-29

Denso Sensor Installed vertical to prevent fluid

collection.
ECU has connector to allow for high Altitude Operation
Faulty sensor will not affect engine operation

KT900201 - Structure & Function Menu Exit

Sensors - Oil Pressure
SAA6D140/125-CRI
TPK
02/01
Page 3-30
3-30

Low Oil pressure switch

closes at 0.5 kg/cm2
Faulty switch will not affect engine

operation

KT900201 - Structure & Function Menu Exit

Sensors - Oil Pressure
SAA6D140/125-CRI
TPK
02/01
Page 3-31
3-31

High Oil pressure switch

closes at 1.5 kg/cm2 and
ECM begins to monitor at
1300 rpm
Faulty switch will affect
engine operation

KT900201 - Structure & Function Menu Exit

Komatsu Asia & Pacific Training Centre
SAA6D140/125-CRI
TPK
02/01
Page 3-32
3-32

KT900201 - Structure & Function Menu Exit