Oct.

17,2003 1
CRI (Common Rail Injection)
System
INJECTOR
CONTROLLER Electronically controlled on the
amount and the time of injection

Bar Filter
Fuel Filter

Fuel Tank
The flow of fuel Injection of fuel into the cylinder

Strainer

Gauze Filter

COMMON
RAIL
(Feed Pump) SUPPLY PUMP
 Oct.17,2003 2

Comparison with the conventional in-line type pump

In-line type pump injection system Common Rail Injection system

Injector
Nozzle （ electronic controlled ）
（ mechanical ）
Solenoid valve

Common Rail 2-way valve

Drain

Injection pump

Supply Pump

Injection of fuel into the cylinder
（ The highest injection pressure ： 500-800kg/cm2)
Features
・ Injection pressure depends on the engine rpm.
・ It becomes high pressure only at the time of high rpm.
　　　　 Injection of fuel into the cylinder
(The highest injection pressure ： 1200-1400kg/cm2)
Features
・ Injection pressure doesn’t depend on the engine rpm.

・ Injection pressure control of the nozzle side is limited by the ・ Always store uniform and high pressure fuel in the common rail.

　 fixed mechanical valve. ・ Optimum amount and timing of fuel injection can be set by the

・ Injection timing is fixed. electronic control of solenoid valve.

 Oct.17,2003 3

Comparison of CRI and conventional injection

system to foreign substances (dirt)
In-line type injection pump
system CRI
Clearance of nozzle needle
valve
５～６μm
Injection system 2-way valve N/A Important parts on fuel control
comparison
Maximum injection pressure 500-800kg/cm2 1200-1400kg/cm2
Permissible size of foreign
The permissible amount substance ２０μm ５μm
of foreign substances
Permissible amount of foreign
(dirt)
substances ５mg/L １mg/L
Capture size of mesh ２０μm ５μm
Fuel Filter Performance
Filtration efficiency 95% 95%

2-way valve which directly controls the information on the amount and the
timing of injection received from controller has been adopted on injector of CRI
system.
The maximum injection pressure of CRI is about two times as much as
conventional injection system, and it will have problems on the small dirt which
was under 20μm, although it may not have any problems to the conventional
injection system.
 Oct.17,2003 4

The necessity of the using Genuine Fuel Filter

Komatsu has adopted CRI system which is a high-pressure electronic control
injection system in order to correspond to severe exhaust gas regulation of every
country in the world.
Compared with the conventional injection system, it is necessary to pay a special
attention to the foreign substance such as dirt mixed in the fuel from the
outside by the reason explained in the previous pages.

Therefore, please do not use other fuel filters instead of genuine

high efficiency fuel filter.

【 Filtration ability improvement to the foreign substance in CRI system 】

Feed
Fuel Tank Supply Pump Common Rail Injector
Pump

Gauze Filter High Efficiency Bar Filter

Strainer
（ 30 mesh ： Fuel Filter （ capture over ３０ μ ）
（ 60
mesh ： equal to （ capture over ５
Equal to 500μm ） μ, 95% ）
250μm ）
（ improved from 15μto ５ μ ）
 Oct.17,2003 5

The difference from the conventional fuel filter

Conventional Type Filter New Type Filter for CRI and HPI
 Oct.17,2003 6

An Extract from Operation & Maintenance Manual

Maintenance in every ５００ hours.

Exchange of fuel filter cartridge.

　（ NOTE ） Please use the Komatsu genuine filter as fuel

filter cartridge. The common rail fuel injection system
used on this machine consists of more precise parts than
the conventional injection pump and nozzle. If any part
other than a genuine Komatsu filter cartridge is used, dust
or dirt may get in and cause problems with the injection
system. Always avoid using substitute parts.
 Oct.17,2003 7

Notes for exchange of a fuel filter cartridge

Dirty Side

CAP
Clean Side

★ According to the Operation & Maintenance Manual, pour the fuel in the dirty side
when you fill the fuel into the fuel filter. However, it will be possible to put it
into the clean side due to the structure. (It may cause fuel injection system trouble
in the case that the dirt in the fuel gets into the clean side.)
We added a cap which covers the clean side in order to prevent such a trouble. The
next page shows the way to exchange the filter with cap (spare parts have a cap).

Without Cap With Cap

P/No. 600-311-xxxx P/No. 600-319-xxxx
(*P/No. printed on filter itself is 600-311-xxxx)
 Oct.17,2003 8
When replacing the fuel filter cartridge, fill the filter
How to fill the fuel with the clean fuel by the following procedures.

(A) (A)
① Before filling ② With cap (A) on,
the fuel, ensure fill the filter with
that cap (A) is the clean fuel.
installed.

(A)
④ After thinly coating the
③ After filling the engine oil to the packing
filter with the fuel, surface of the fuel filter,
remove cap (A) install it to the filter head,
and dispose it. and contact the packing
surface to the seal surface
of filter head. After that,
tighten ½ to ¾ turns.
 Oct.17,2003 9

Filter comparison with other makers

Filtration performance：the mesh size （μ) which captures 95% or more
Strainer （Mesh) Main filter (μm)
Fuel tank Feed pump
Makers Engine Injection System Inlet Outlet Inlet Outlet
Cat 3116,3126,3412 C/R (Common Rail) - 150 15→2
3176,3406,3500 U/I (Unit Injector)
Detroit S4000 C/R 30 8
(Option）
Cummins QSX,QSK U/I 5

Isuzu ６ＨＫ、６ＷＧ１ C/R - produced by ND Strainer 20

Mitsubishi 8M22 C/R - produced by ND Strainer 20

6M22 C/R -produced by Bosch Strainer 10
Nissan Diesel GE13B U/I - produced by Bosch Strainer 8

Komatsu 125/ WA470, C/R - produced by ND 400 5

WA480, HM300 Strainer
140/ HD325, HM350 C/R - produced by ND 400 5
HM400, WA500 Strainer
140/ D155,PC600 C/R - produced by ND 400 290 5
PC750, PC800 Strainer Strainer
170/ D375 U/I (HPI) - Produced by 400 290 5
CUMMINS Strainer Strainer

Most makers have adopted 5- 8μm fine mesh for the fuel filters of the high
pressure injection system such as CRI and UI (HPI).