Technical Presentation Kit

SAA6D140/125-CRI Engines

Testing & Adjusting

Overwriting Of Calibration In CRI
Comptroller

Section 4.1

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ECM Calibrations are

machine specific

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CRI engine Controller
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CRI enginecontroller
W hitecontroller isavailableandaspecificoneisalsoabletobere-calibrated.
All softwaresareavailablesthroughSparePartsRoute. But re-calobrationm ust
bedonebyonlyauthorisedplacesandperson.

PDC ( image)
Prats 1. Specificmodel controller
Distribution Ass'ypartsNo. label
Center for specifcmodel (s)
tobesupplied
1. Specificmodel controller 2. Whitecontroller 3. Sofware
2. Em ptycontroller,whitecontroller softwarem edia sticker
3. Specificmodel Software -specificmodel data -m odel
4. Servicetest m odefor SUPPLYPUM P -ServiceDynam otestmode

or
Servicepoint partsNo.
REM ANCENTER (sticker)
PDC
eachsofthasonesticker
re-calibrationcanbedone
4. Servicetest modefor SUPPLYPUMP
REMANCENTER
re-calibrationcanbedone or

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Overwriting of calibration data in the CRI controller translated by K. Okumura

CS Division

1. Outline
1) Applicable to CRI ( Common Rail Injection ) engine controller

2) WHITE CONTROLLER
* A controller without any calibration data to be provided as " WHITE CONTROLLER "
* WHITE CONTROLLER to be ordered as a spare parts by the parts number
* WHITE CONTROLLER is sticked with the parts No. seal and serial No. seal
( See Fig. 1 )
* A WHITE CONTROLLER can be overwrited to a controller of a specific model
with its calibration data using by an overwriting software. ( The detail is explained later .)

* A specific model controller is shipped with the parts

No. sticker as the conventional way.
Par t s No. WHI TE Here is the Prtas No. sticker.
CONTROLLER * In case it is overwrited by Service, paste the specific
sticker here.

WHI TE CONTROLLER
manuf act ur i ng s er i al No.

Fi g.
1

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3) Calibration data software, spare parts kit

* A specific model software ( PC600, HD325 … ect. ), to be provided with each parts No.
* The spare parts kit to be provided with a floppy disc , a parts No. seal and an instruction
* The kit is able to be ordered as a spare parts with the kit parts No.

Spare parts kit Parts No. A floppy disc………… 1 pce

calibration data software (a model)
Parts No. seal …………. 1 pce software

( model ass'y No. ) Parts No. seal

I ns t r uct i on of overwriting……1 pce Instruction

( 2 languages, Japanese & English )

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4) Spare parts ordering

* The following three (3) items are available:
(1)model ass'y parts No. controller ( same as before )
A specific model calibration data is written in it from factory.
The specific model ass'y parts No. seal and serial No. seal are sticked on it.
(2)WHITE CONTROLLER
(3)A specific model calibration data software, spare parts kit

5) Description on parts catalogue (book)

All necessary elements are described on parts catalogue (book)
Overwriting is allowed only to an authorised person by Customer Support Division after a specific training.
( Policy & Procedure are explained in details later. )

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Policy & Procedure for Overwriting Calibration TPK

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1) Authorization of persons who can overwrite calibration data

* Nominate suitable persons in main service points and parts distribution centers (PDC)
* Customer Support Division ( hereinafter CS Div. ) carry out necessary training and
control the authorized persons keeping the list.
* Only this autorized person is allowed to overwrite calibration data with the software.
* Select a leader in each area
The leader works as the area represenrative who grasp status of overwrting jobs done
?????????????????????????????????????????
in the area, question handling or gather other related information. These leaders in each
??????????????????????????????????
area exchange information each other and manage this operation smoothly overcoming
??????????????????????????????????????????
the world time differences.
???????????????

2) Job description of the authorized service points and parts distribution centers
* To stock WHITE CONTROLLER
* To stock calibration data software
* When order entering a specific model controller, to overwrite it with the specific model
calibration data and ship it. ( Overwriting is to be done by the authorized person. )
* Overwriting histories are to be gathered by the leader who keep them with him.
The overwriting histories are generated automatically in a software of overwriting, which
is explained later. The leader gathers them and submits when requested from Komatsu.
( To grasp status of overwriting results , CS Division gathers them periodically such as
twice a year or annually. )

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Policy & Procedure for Overwriting Calibration TPK

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3) Responsibility of the authorized service point and PDC

* Job quality of overwriting calibration data correctly
* Job quality of overwriting correct model data
If the above jobs are done incorrectly , all related risk is taken by themselves.

4) Hardware restriction for spare parts

* When a specific model controller is ordered through spare parts route, overwriting is
allowed only to WHITE CONTROLLER. This is to be described on Policy & Procedure
Manual as a prohibited item.
< Reason >
Overwriting is not a reconditioning of the hardware of the controller.
Overwriting is to be done only to the hardware whose quality is confirmed.
For example , in case of the controller which was on a submerged machine or the controller
cannibalized from a scrapped machine, the hardware quality can not be guaranteed.
And also even a controller were being used for long time without any problem on a machine
, it has some unused circuits and they may be rusted. When it is converted to other
machine one, we can not guaranteed that it is in good condition. This is the reason why
only WHITE CONTROLLER is allowed to be overwrited as a new spare parts.

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Policy & Procedure for Overwriting Calibration TPK

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5) Special note
* As a principle of quality assurance, the overwrited calibration data software and the parts
No. seal must be coincident.
* When the software and the seal are not coincident, the controller can not be warranted
due to the judgement that the overwriting job was not done correctly.

6) Remanufacturing ( repair by REFAB of Electronics Division ) of the controller

* REFAB will repair a model controller and it can be converted to WHITE CONTROLLER.
same model controller as
a model controller Electronics Division
returned
REFAB These both way is available.
( repair & overwrite) WHITE CONTROLLER

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Tooling & Setup TPK

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Tooling
power switch
personal computer (PC)

GND VB
key

+24V ? CRI controller Boot SW

battery or
power source

Overwriting model
software software
neces s ar y t ool
1) a s peci al har nes s es ( s er vi ce t ool No. t o be s et ) Soft Parts No. seal
2) a over wr i t i ng s of t war e ( s er vi ce t ool No. t o be s et )
Wi ndows 98, J apanes e and Engl i s h ver s i on Parts No. seal
3) Cal i br at i on dat a s of t war e, s par e par t s ki t ( Par t s No. s t o be
s et )
4) power s our ce 24 V DC ( bat t er y or power uni t )
5) per s onal comput er ( PC- AT compat i bl e, Wi ndows 98, RS232C por t ,
ot her det ai l i s expl ai ned l at er .
To be pr epar ed by t he aut hor i zed poi nt s
Not e :
Over wr i t i ng mus t be done bef or e i ns t al l i ng t he cont r ol l er on t he
machi ne
and not t o be done on t he machi ne.

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Tooling & Setup TPK

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PC 24 Volt Power
Supply
Boot
Switch

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Tooling & Setup TPK

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Overwrite Controller
Software Machine Label
Calibration

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How to Overwrite White Controller
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1) Floppy disc data

How to overwrite WHITE CONTROLLER DOC file, MOT file ( program )
?? Information of DOC file
PRODUCT_NO : Ass'y Parts No. (12 chara.)
HARDWARE_NO :hardware Parts No.(10chara.)
spare parts contents SOFTWARE_NO :software Parts No. (10 char.)
WHITE CONTROLLER ORGINAL_SOFT_NO:WHITE CONT.parts No.(10char.)
spare parts kit Floppy disc 1 pce
Parts No. seal 1 pce (1) input master password
overwriting manual (2) input operator ID
(3) input operator password (personal control)
(4) generate overwrite history database
How to overwrite (5) obtain ass'y Parts No. from floppy disc
1 Connect the harness from PC to controller (6) confirm Parts No.
" You will fabricate a controller , whose Parts No. is
2 Start overwriting software 7872-**-****. Confirm further more if it is surely
correct with the machine parts catalogue."
3 Confirm Parts No.

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Use Boot
Switch to
connect
controller
to PC

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(1) retrieve ID data from controller

4 connect harness and power to be turned on -hardware Parts No.
-hardware serial No.
5 confirm communication link to overwrite -software Parts No.
(2) Cofirm coincidence of the hardware Parts No.s in the floppy
6 Turn the boot switch on disc and controller. Check first 9 characters.
(3) If they are not coincident, the program ends with alarm
message , "The hardware types are different, overwriting can not
7 start program to overwrite be done."
(4) When controller ID data can not be retrieved, alam message
is on.
8A normally end OK is displayed ( overwrited correctly )
"Overwriting is failed before or this controller may be damaged.
8B abnormally end NG is displayed
Go to next ? "
(5) Check the parts No. of the controller if it is of WHITE
9 In case of 8A, normally end , turn on the boot SW again. CONTROLLER.
( reset controller CPU ) If it is not of WHITE CONTROLLER, alam message is on.
"This is not a WHITE CONTROLLER.
It is prohibited to use a machine controller to other machine. If it
is used after overwriting, it is not warranted and guaranteed any
more. Go to next?"
(6) Caution !!
Once overwriting has been started, the software
in this controller will be erased and restored any more.

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10 Confirm if the overwriting is completed correctly.

normally end OK is displayed ( overwrited correctly )
abnormally end NG is displayed

11 Paste the Parts No. seal on the controller.

Put it on the same place with the WHITE CONTROLLER one.

12 Turn off power.

(1) retrieve ID data from controller

13 The overwriting history to be sent to the area leader.
The area leader stores the history data.
Caution when install controller on the machine
1 Wrong controller installation
This error is same level with the current jobs. Service should be
responsible for correct controller installation.
2 Do not open any cover of controller
The controller may be destroyed without any good result.
-hardware Parts No.
-hardware serial No.
-software Parts No.
(2) check the software Parts No. is coincident with
the overwrited software one.
(3) If they are not coincident the program ends with
the alam message , " NG Overwriting is failed. This
controller can not be used on the machine. "
(4) In case of coincidence, message is indicated
Overwriting is completed and the fabricated controller Parts
No. is
7872-xx-xxxx
Paste the Parts No. seal on the same place.
(5) After the controller resets CPU, SUM check is
carried out.
If SUM chek is error, ends abnormally with NG
message without obtaining the Parts No..
(6) Generate overwriting history data
date, operator ID , hardware Parts No., serial No.,
the overwrited software Parts No, the results of
normal end or abnormal end

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