Structure and Function

Large class CRI

Structure and Function

Large Class CRI Engine

1
 Structure and Function
Machine installing 125Engine Large class CRI

SAA6D125E-5

PC450-8

HM300-2
2
 Structure and Function
Machine installing 140Engine Large class CRI

SAA6D140E-3

PC800-6,7,8

HD325-6,7

3
 Structure and Function
Machine installing 140 Engine Large class CRI

PC2000-8
SAA12V140E-3

HD785-7

D475-5E0

Tier2 　
4
 Structure and Function
Machine installing 170 Engine Large class CRI

SAA6D170E-5

HD465/605-7

With Electronic Lift Pump PC1250-8

5
 Structure and Function
Large class CRI

Solenoid Injector
Engine
Controller

Common Rail

Supply pump

Ex) SAA6D125E-5 for HM300-2

6
 Structure and Function
Outline of Denso Common rail system Large class CRI
Common Rail
Flow Dumper
Pressure Sensor
ECM

Common
Rail

PCV

Pressure
Control
Valve

Ne G Injector
Supply
Sensor Sensor
Pump
7
 Structure and Function
Large class CRI

from Pre
Fuel filter Injector

Common Rail
Supply Pump

return to
Fuel Tank

return to Fuel
Tank
8
 Structure and Function
Fuel circuit of Large class (140E-5) Large class CRI

ECM Injector Fuel Cooler

Flow
Damper

Fuel Tank
Common
Rail
Priming
Pump
Pressure
Limiter

ECM
Supply
Cooling
Pump
plate

※ 　 With EGR Main Filter Pre Filter

9
 Structure and Function
Supply Pump Large class CRI

PCV
(Pressure Control Valve) Delivery
Valve

Priming Pump

Over Flow
Valve

Feed Pump

10
 Structure and Function
Supply Pump Large class CRI

Open Close

Control PCV Close Timing Control output amount of fuel

11
 Structure and Function
Supply Pump － Feed Pump Large class CRI

Feed Pump （ Trochoid Pump)

Pressure
Chamber
Rotor

Drive Shaft
To Main Filter
From pre Filter

12
 Structure and Function
Common Rail Large class CRI

Common Rail Pressure Senso

Flow Damper

Pressure Limiter

Common Rail

Stores and distributes the high pressure fuel fro

m the supply pump to each injectors
13
 Structure and Function
Common Rail Large class CRI

Operation Pressure
Pressure Limiter
Ex.) 220 MPa (170E-5)
Open

Close
30 MPa
Rail Pressure

Acts as safety valve in the common

rail. If abnormal high pressure is
generated, the pressure will release
the pressure back14to the tank.
14
 Structure and Function
Common Rail Large class CRI

Flow Damper

Common Injector
Rail Side Side

Flow Damper
• Dampens fuel pressure pulsation
• Stabilizes fuel supply pressure for injector
• Acts as safety device if leakage or breakage in the pipe happens

15
 Structure and Function
Common Rail Large class CRI

Flow Damper
Fuel is not Injected
The piston is pushed by the spring to left hand side
and it is stopped by the stopper. Fuel flows through
the orifice going to the outlet of the flow damper.

1. Stopper
Fuel is Injected 2. Piston
3. Spring
Pressure after the piston is a little lower than the a. Orifice

pressure before the spool when injecting fuel thus

compressing the spring, pushing the spool to the
right side. Forces acting before and after spool is
balanced, enough to allow the fuel to flow through.
The spring absorbs the change in pressure thus
dampening the pressure pulsation.

Fuel is Stopped
If there is a big difference in pressure after the
spool, the spool moves on the right end side and
blocks the fuel flow. For example, a breakage of
injector piping.

16
 Structure and Function
Injector Large class CRI

Solenoid Injector
TWV
(Two Way Valve)

17
 Structure and Function
ECM Cooling Plate Large class CRI

ECM Cooling Plate

ECM is cooled by Fuel

18
 Structure and Function
Large Capacity Priming Pump Large class CRI

Engine with EGR .

Large capacity
Priming Pump

Engine without EGR .

Electronic Priming
Pump

19
Structure and Function
Large class CRI

20
 Structure and Function
125E-5 Engine CRI Components Large class CRI

from Pre
Fuel filter Injector

Common Rail

return to
Fuel Tank

return to Fuel Supply

Tank Pump Ex) SAA6D125LE-5 for HM300-2
21
 Structure and Function
125E-5 Fuel Circuit Diagram Large class CRI

Engine Injector Fuel Cooler

Controller

Flow
Fuel Tank
Damper

Common
Rail

Pressure
Limiter
Large Capacity
Priming Pump
Supply
Pump

Engine Controller Pre Filter

Cooling plate Main Filter
22
 Structure and Function
140E-5 Engine CRI Components Large class CRI

23
 Structure and Function
140E-5 Fuel Circuit Diagram Large class CRI

ECM Injector Fuel Cooler

Flow
Dumper

Fuel Tank
Common
Rail
Priming
Pump
Pressure
Limiter

ECM
Supply
Cooling
Pump
plate

※ 　 With EGR Main Filter Pre Filter

24
 Structure and Function
170E-5 Engine CRI Components Large class CRI

25
 Structure and Function
170E-5 Fuel Circuit Diagram Large class CRI

Engine
Controller Injector

Flow
Dumper
Fuel Tank
Common Electric
Rail Priming
Pump
Pressure
Limiter

Supply
Pump Engine Controller
Cooling plate
Main Filter Pre Filter
26
 Structure and Function
12V140E-3 Engine CRI Components Large class CRI

27
 Structure and Function
12V140E-3 Fuel Circuit Diagram Large class CRI
Engine Controller
(Parents) Injector

Flow Dumper
Electric
Common Rail Priming Pump

Pressure
Limiter

Supply
Pump
Injector Fuel Tank
Engine Controller
(Child)

Flow Dumper Electric

Priming Pump
Common Rail

Pressure
Limiter

Supply
Pump

Main Filter Pre Filter

28
 Structure and Function
Sensors & Actuators on 125 Engine Large class CRI

Ambient Press.
Injector Sensor

Intake Manifold
Coolant Temp. Sensor Press. Sensor

EGR Valve & Position Sensor

Intake Manifold
(EGR Bypass Valve & Position Sensor) Temp. Sensor

Oil Press. Sensor Rail Press. Sensor

PCV G Sensor Engine Controller Ne Sensor Fuel Temp. Sensor

29