Technical Presentation Kit

SAA6D140/125-CRI Engines

Structure &
Structure & Function
Function
Injectors
Injectors

SAA6D140/125-CRI
KT900201
February 2001 Menu Exit
ECM Powers the Injectors
SAA6D140/125-CRI
TPK
02/01
Page 3-2
3-2

KT900201 - Structure & Function Menu Exit

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

The function of the injectors is to inject high-pressure fuel

from the common rail according to the signal from the ECU
into the injection chamber of the engine at the optimum fuel
injection timing, fuel injection amount, fuel injection ratio
and spray condition.

KT900201 - Structure & Function Menu Exit

ECM Powers Injector Circuit
SAA6D140/125-CRI
TPK
02/01
Page 3-4
3-4

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 3-5
3-5

Charger or Pull
in current 11 to
12 Amps

KT900201 - Structure & Function Menu Exit

Injector Circuit - Injection
SAA6D140/125-CRI
TPK
02/01
Page 3-6
3-6

Constant or hold
in current 2 to 3
Amps

KT900201 - Structure & Function Menu Exit

Outline
SAA6D140/125-CRI
TPK
02/01
Page 3-7
3-7

The TWV (Two-Way electromagnetic Valve) controls the

pressure in the control chamber in order to control the start
and finish of the fuel injection.
TWV Off TWV On

KT900201 - Structure & Function Menu Exit

Injector Assembly
SAA6D140/125-CRI
TPK
02/01
Page 3-8
3-8

Solenoid

Fuel inlet

Drain

KT900201 - Structure & Function Menu Exit

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

1. Inlet connector
2. Terminal
3. Upper body
4. Solenoid
5. Outer body
6. Inner valve Valve assembly
7. Valve body
8. OUT orifice
9. IN orifice
10. Control chamber
11. Command piston
12. Spring
13. Pressure pin
14. Nozzle assembly

KT900201 - Structure & Function Menu Exit

Injector - Components
SAA6D140/125-CRI
TPK
02/01
Page 3-10
3-10

Outer Valve Body

Command Pressure Pin

Nozzle Assy
Piston & spring

Solenoid Inner valve Assy

KT900201 - Structure & Function Menu Exit

Injector - Solenoid
SAA6D140/125-CRI
TPK
02/01
Page 3-11
3-11

Drain

Spring

KT900201 - Structure & Function Menu Exit

Injector - Inner Valve Body
SAA6D140/125-CRI
TPK
02/01
Page 3-12
3-12

KT900201 - Structure & Function Menu Exit

Injector - Valve Assembly
SAA6D140/125-CRI
TPK
02/01
Page 3-13
3-13

KT900201 - Structure & Function Menu Exit

Injector - Components
SAA6D140/125-CRI
TPK
02/01
Page 3-14
3-14

Command Piston

Pressure Pin & Spring

KT900201 - Structure & Function Menu Exit

Injector - Nozzle Assembly
SAA6D140/125-CRI
TPK
02/01
Page 3-15
3-15

KT900201 - Structure & Function Menu Exit

Injector Body
SAA6D140/125-CRI
TPK
02/01
Page 3-16
3-16

O-rings

Drain thru’
Cylinder head

KT900201 - Structure & Function Menu Exit

Cylinder Head - Fuel Drain
SAA6D140/125-CRI
TPK
02/01
Page 3-17
3-17

Drain port

KT900201 - Structure & Function Menu Exit

Cylinder head
SAA6D140/125-CRI
TPK
02/01
Page 3-18
3-18

Fuel Inlet
Connection
Drain
connection
Wire entry
connection

KT900201 - Structure & Function Menu Exit

Cylinder head ~ Injector wiring
SAA6D140/125-CRI
TPK
02/01
Page 3-19
3-19

Injector wire

KT900201 - Structure & Function Menu Exit

Cylinder head ~ Injector wiring
SAA6D140/125-CRI
TPK
02/01
Page 3-20
3-20

Fuel inlet piping

KT900201 - Structure & Function Menu Exit

Cylinder head
SAA6D140/125-CRI
TPK
02/01
Page 3-21
3-21

Fuel inlet
Solenoid connector

KT900201 - Structure & Function Menu Exit

Injector - Components TWV Off
SAA6D140/125-CRI
TPK
02/01
Page 3-22
3-22

The hydraulic
piston transmits
force to the TWV Off
Valve Closed
needle valve of
the nozzle
according to the
pressure in the
control chamber.

Injector Tip
Closed

KT900201 - Structure & Function Menu Exit

Injector - Components TWV On
SAA6D140/125-CRI
TPK
02/01
Page 3-23
3-23

TWV On
Valve Open

Injector Tip
Open

KT900201 - Structure & Function Menu Exit

Injector Tip replacement
SAA6D140/125-CRI
TPK
02/01
Page 3-24
3-24

Injector Tip Can Replaced But

Flow tolerance is +/- 6.7 %.
EPA & Euro II Maximum
Tolerance +/- 3 %, Therefore
injector must be replaced in
emission area.

KT900201 - Structure & Function Menu Exit

Fuel Injection Rate Control
SAA6D140/125-CRI
TPK
02/01
Page 3-25
3-25

Current design will

use split injection
for cold starts.
Komatsu engines
may use pilot
injection to meet
future emission
demands
KT900201 - Structure & Function Menu Exit
Wiring Installation
SAA6D140/125-CRI
TPK
02/01
Page 3-26
3-26

It is critical that
injector wiring does
not interfere with valve
train
KT900201 - Structure & Function Menu Exit
Komatsu Asia & Pacific Training Centre
SAA6D140/125-CRI
TPK
02/01
Page 3-27
3-27

KT900201 - Structure & Function Menu Exit