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SAA6D140 CRI Controller Calibration Guide

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This document discusses overwriting calibration data in CRI (Common Rail Injection) engine controllers. It describes: 1) White controllers that are provided without calibration data and can…

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  • Cover Page
  • Overwriting Calibration in CRI Controller
  • CRI Engine Controller
  • Overwriting Calibration Data
  • Tooling & Setup
  • How to Overwrite White Controller
  • Computer Screens
  • The End

Technical Presentation Kit

SAA6D140/125-CRI Engines

Testing & Adjusting


Overwriting Calibration In CRI Controller

SAA6D140/125-CRI
KT900201
February 2001 Menu Exit
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Overwriting Calibration In CRI Controller TPK


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ECU Calibrations are machine


specific

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SAA6D140/125-CRI

CRI Engine Controller TPK


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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.
Parts No. WHITE Here is the Prtas No. sticker.
CONTROLLER * In case it is overwrited by Service, paste the specific
sticker here.

WHITE CONTROLLER
manufacturing serial No.

Fig.
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

Instruction 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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g
personal computer (PC)
power switch

GND VB
key

+24V ? CRI controller Boot SW


battery or
power source

Overwriting model
necessary tool software software
1) a special harnesses ( service tool No. to be set ) Soft Parts No. seal
2) a overwriting software ( service tool No. to be set )
Windows 98, Japanese and English version Parts No. seal
3) Calibration data software, spare parts kit ( Parts No.s to be
set )
4) power source 24 V DC ( battery or power unit )
5) personal computer ( PC-AT compatible, Windows 98, RS232C port ,
other detail is explained later.
To be prepared by the authorized points
Note :
Overwriting must be done before installing the controller on the
machine
and not to be done on the machine.

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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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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 [Link] 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. -hardware Parts No.
The area leader stores the history data. -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. "
Caution when install controller on the machine (4) In case of coincidence, message is indicated
1 Wrong controller installation Overwriting is completed and the fabricated controller Parts
This error is same level with the current jobs. Service should be No. is
responsible for correct controller installation. 7872-xx-xxxx
Paste the Parts No. seal on the same place.
2 Do not open any cover of controller (5) After the controller resets CPU, SUM check is
The controller may be destroyed without any good result. 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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Common questions

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The document stipulates that overwriting can only be performed by authorized individuals who have undergone specific training conducted by the Customer Support Division. Overwriting involves security measures such as requiring a master password and operator ID/password to access the functionality needed to generate an overwrite history database and to confirm Parts No. details .

The Parts No. seal is crucial for identifying the specific model calibration data programmed into a CRI controller. It serves both as a documentation and verification tool, ensuring that the controller aligns with its intended machine application post-overwriting. The seal also reflects any overwriting activity by replacing the WHITE CONTROLLER seal, thereby maintaining a clear record of the controller's configuration history .

The personal computer acts as a critical interface in the overwriting process by running the necessary software tools used to upload the new calibration data onto the CRI controller. It connects to the controller via special harnesses and must be equipped with specific operating system features (Windows 98, RS232C port) to support the software's requirements for data transfer and verification of parts and serial numbers .

The overwriting process ensures correctness by confirming the Parts No. at multiple stages: Initially, the operator inputs the master password, ID, and password to generate an overwrite history database. Later, the process retrieves the Ass'y Parts No. from a floppy disc and verifies its accuracy against a machine parts catalogue . Additional checks involve confirming the coincidence of the hardware and software Parts No. with the data on the floppy disc to prevent mismatches .

The Boot Switch facilitates the connection between the controller and the personal computer, enabling the overwriting software to interact with the CRI controller. Activation of the Boot Switch is part of the setup process that allows for the smooth execution of the software necessary to overwrite the existing controller data with specific calibration information .

If a hardware Parts No. mismatch is identified, the program immediately terminates the overwriting process with an alarm message indicating that the hardware types are different, rendering overwriting impossible. This step is critical for maintaining data integrity and ensuring the controller's compatibility with the intended machine .

The WHITE CONTROLLER is a type of controller without pre-installed calibration data, designed to be overwritten with specific model calibration data using dedicated overwriting software. It serves as a flexible component that can be customized for various engine models by importing the corresponding software from a spare parts kit .

In case of communication failure during the overwrite process, an alarm message indicates that the controller either failed to overwrite previously or may be damaged. The system prompts for a decision on whether to proceed, emphasizing the need for careful recovery steps and possibly initiating a review or repair of the controller's hardware or software components .

Overwriting must occur pre-installation to prevent conflicts between the controller's software and the machine's existing configuration. This protocol ensures that the controller is appropriately programmed and ready for seamless integration with the machine, avoiding potential issues that could arise if adjustments were made post-installation when the controller is already engaging with the system .

Incorrect controller installation can lead to critical errors. The controller might fail to function properly, and in severe cases, it could be destroyed if internal components are tampered with. Inappropriate installation makes the service liable for these issues, and errors at this level are considered equivalent to current issues faced during jobs, emphasizing the gravity of proper installation practices .

Technical Presentation Kit Engines Exit Menu SAA6D140/125-CRI KT900201 February 2001 SAA6D140/125-CRI Testing & Adjusting Ove
KT900201 - Testing & Adjusting SAA6D140/125-CRI TPK 02/00 Page 4-2 Exit Menu Overwriting Calibration In CRI Controller ECU Ca
KT900201 - Testing & Adjusting SAA6D140/125-CRI TPK 02/00 Page 4-3 Exit Menu CRI Engine Controller
KT900201 - Testing & Adjusting SAA6D140/125-CRI TPK 02/00 Page 4-4 Exit Menu Overwriting Calibration In CRI Controller Overwr
KT900201 - Testing & Adjusting SAA6D140/125-CRI TPK 02/00 Page 4-5 Exit Menu Overwriting Calibration In CRI Controller 3
KT900201 - Testing & Adjusting SAA6D140/125-CRI TPK 02/00 Page 4-6 Exit Menu Overwriting Calibration In CRI Controller 4
KT900201 - Testing & Adjusting SAA6D140/125-CRI TPK 02/00 Page 4-7 Exit Menu Tooling & Setup g personal computer (PC) power s
KT900201 - Testing & Adjusting SAA6D140/125-CRI TPK 02/00 Page 4-8 Exit Menu Tooling & Setup PC Boot Switch 24 Volt Power S
KT900201 - Testing & Adjusting SAA6D140/125-CRI TPK 02/00 Page 4-9 Exit Menu Tooling & Setup Overwrite Software Controller
KT900201 - Testing & Adjusting SAA6D140/125-CRI TPK 02/00 Page 4-10 Exit Menu How to Overwrite White Controller spare parts

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