Embed Size (px)
Citation preview
ISUZU INDUSTRIAL DIESEL ENGINE 6WG1X Tier3
ISUZU MOTORS LIMITEDOff-highway Powertrain Operation Dept. Planning
& Service Group
HITACHI CONSTRUCTION MACHINERY CO.,LtdTechnical Training Center
Tableof
contents
1. Differences between Tier2 engine and Tier3 engine. ① Differences between Tier2 engine and Tier3 engine. Off Road Emission Regulation Engine Specifications
Engine Layout /Main PartsEngine Layout /Sensors
② Out Line of Common Rail SystemCommon Rail System
Comparison with Conventional System ③ System Component
a ECM b SUPPLY PUMP c COMMON RAIL d INJECTOR e HARNESS INJECTOR f SENSORS
g COOLED EGR2. Maintenance Schedule3. Introduction of SST4. Trouble Shooting ① Trouble Shooting Procedure② How to use Trouble Shooting Manual
5. DTC code① DTC code
② Scan Tool ③ EMPS ④ How to use scan tool 6. Point to notice on service（Parts replace procedure）7. Trouble Shooting on actual machine
Tier-3 Engine major specification and Maintenance point
1.High pressure fuel injection control by common rail system.
→Prohibit teardown and re-adjustment of injector.
→Prohibit re-use of injector pipe and high pressure fuel pipe.
→Must be keep ISUZU fuel requirement.
→Keep observe strictly the maintenance schedule.
2.Electronic control module.
→notice : A battery cable must be disconnect at the time of welding work forECM protection.
3.Cooled EGR
→Must be keep ISUZU fuel requirement.
→Must be keep ISUZU Engine oil requirement and maintenance.
→Observe engine strictly of Maintenance.
Off-Road Future Emission RegulationOff-Road Future Emission Regulation
CLASS ENGINE 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015
EPA450 - 560 kW(600 - 750hp) － ▼ T ier2 ▽ T ier3
interimTier4
225 - 450 kW(300 - 600hp)
6W,6S ▼ T ier2 ▽ T ier3interimTier4
130 - 225 kW(175 - 300hp)
6H ▼ T ier2 ▽ T ier3interimTier4
75 - 130 kW(100 - 175hp)
4H ▼ T ier2 ▽ T ier3
37 - 75 kW(50 - 100hp)
4J,4LE ▽ T ier2 ▽ T ier356kw
EC 130 - 560 kW 6W,6S,6H ▼ Stage2 ▽ Stage3-A ▽Stage3-B
75 - 130 kW 4H ▼ Stage2 ▽ Stage3-A ▽ Stage3-B
37 - 75 kW 4J,4LE ▽ Stage2 ▽ Stage3-A ▽ Stage3-B
19 - 37 kW L ▼ Stage2 ▽ Stage3-A
JPN 130 - 560 kW 6W,6S,6H ▽ T ier-2 ▽ T ier-3
75 - 130 kW 4H ▽ T ier-2 ▽ T ier-3
56 - 75 kW 4J ▽ T ier-3
37 - 56 kW 4LE ▽ T ier-2 ▽ T ier-3
19 - 37 kW L ▽ T ier-2 ▽ T ier-3
LOW NOISE REQUIRMENT of EC STAGE-IIIFrom 2006, EC stage-III request new noise level regulation to Construction equipment.
And Isuzu is developping next stage engines include lower noise level for customer's application.
NOx+HC 6.4CO 3.5PM 0.2 NOx+HC 4.0
CO 3.5PM 0.2
NOx+HC 6.6CO 3.5 / PM 0.2
NOx+HC 6.6CO 5.0 / PM 0.3
NOx+HC 4.0CO 5.0 / PM 0.3
NOx+HC 7.5CO 5.0 / PM 0.4
NOx+HC 4.7CO 5.0 / PM 0.4
NOx 6.0 / HC 1.0CO 3.5 / PM 0.2
NOx 6.0 / HC 1.0CO 5.0 / PM 0.3
NOx 7.0 / HC 1.3CO 5.0 / PM 0.4
NOx 8.0 / HC 1.5CO 5.5 / PM 0.8
NOx+HC 4.0CO 3.5 / PM 0.2
NOx+HC 4.0CO 5.0 / PM 0.3
NOx+HC 4.7CO 5.0 / PM 0.4
NOx+HC 7.5CO 5.5 / PM 0.6
No proposal as Stage3-B
NOx 6.0 / HC 1.0CO 3.5 / PM 0.2
NOx 6.0 / HC 1.0CO 5.0 / PM 0.3
NOx 7.0 / HC 1.3CO 5.0 / PM 0.4
NOx 8.0 / HC 1.5CO 5.5 / PM 0.8
NOx 3.6 / HC 0.4CO 3.5 / PM 0.17
NOx 3.6 / HC 0.4CO 5.0 / PM 0.2
NOx 4.0 / HC 0.7CO 5.0 / PM 0.3
Nox 6.0 / HC 1.0CO 5.0 / PM 0.4
▽Tier-4After treatment(DPF) basis
NOx 4.0 / HC 0.7CO 5.0 / PM 0.25
Nox+NMHC 4.0CO 3.5PM 0.03
Nox+NM HC 4.0CO 5.0 / PM 0.03interim
Tier4
interimTier4
NOx + HC 4.7CO 5.0 / PM 0.03
NOx+HC 4.0CO 3.5 / PM 0.025
NOx+HC 4.0CO 5.0 / PM 0.025
neary same as EPA
Tier3 Emission Regulation (130kW～)
ＥＰＡ/EC Tier-3
JPN Tier-3 ＥＰＡTier-2
130kW～(2003)
130kW～（2006)
130kW～(2006)
EC StageⅢ-B (2012)
EPA Tier-4 (2012)
０．３
ＰＭ（g/kwhr)
０．２
０．１
２．０ ８．０４．０
ＮＯｘ＋ＨＣ (g/kwhr)
６．０
NOx + HC: 40% reduction, PM: Same with Tier-2 from Y2006JPN Government Proposal: PM 30% lower than EPA, EC T-3
Key Technologies of Diesel Engine
Noise TechnologyNoise Technology
Base TechnologyFriction Reduction
Base TechnologyFriction Reduction
Turbo-ChargingTechnology
Turbo-ChargingTechnology
Total Electronic ControlTotal Electronic Control
Total engine technology-Combustion chamber-Turbo-charging etc.
Total engine technology-Combustion chamber-Turbo-charging etc.
Exhaust Manifold
Air
EG
R G
as
EGR
Cooler
Inte
r C
oo
ler
EGR = Exhaust Gas Re-circulation
EGR Valve
Fuel ImprovementFuel Improvement
Injection SystemInjection System
EGR TechnologyEGR Technology
Inlet Manifold
Technologies and Emission Level (130kW～)
NOx + HC g/kWh
PM
g/kW
h
Tier 3
Tier 2
０ １． ３． ４． ５．０
０．
０．
０．
２．
Tier 2 trade-off70MPa pressure Inter cooler
Tier 3 trade-off130MPa pressureCooled EGRElectronic control
Engine ModificationLimit
０.４
６．
JPN Tier-3
Regulation and Effect(6WG1X）
Applied Tandem Cooled EGRHigh Injection Pressure
(80t:120Mpa,65t&45t:130Mpa)Noz.Hole Dia
(80t&65t:8-Φ0.21,45t:8-Φ0.19)
Basic Information of Tier 3 Engine
• Low Emission• Low Noise• High Power
→ Electronic Controlled Engine
1. Tier 2 Engine Comparison2. Electronic Control3. Common Rail System4. Cooled EGR
6WG1 Engine Specification6WG1TQA 6WG1XQA 6WG1XYSA-01
TIER2 TIER2 TIER3Water cooled, 6-cycle, inline
4-cylinder, OHC,direct injection diesel
Water cooled, 6-cycle, inline4-cylinder, OHC,
direct injection diesel
Water cooled, 6-cycle, inline4-cylinder, OHC,
direct injection dieselRated output (kW/min-1) 235.4/1800 295/1800 260/1800
Maximum torque (Nm/min-1) 1275/1500 1540/1500 1580/1500Cylinder arrangement
and number– bore × stroke
(mm)
Displacement (L)
16
Compression pressure MPa(psi)/rpm
Dimensions(length × width × height)
(mm) 1462×1007×1287(with fan) 1741×1016×1340(with fan) 1462×1015×1422(with fan)
Weight (kg) 1125 1185 1153
Mechanical fuel injection pump(Inline fuel injection pump)
BOSCH PE-P-S3S
Mechanical fuel injection pump(Inline fuel injection pump)
BOSCH PE-P-S3S
Electronic control fuel injectionsystem (common rail type)
Denso HP017.7/22.1 17.7/22.1 180MPaRSV type RSV type Electronic typeEquipped Equipped Electronic type
2Stage NozzleMulti-hole type(8xφ0.24mm)
Bosch KBL2.4
2Stage NozzleMulti-hole type(8xφ0.24mm)
Bosch KBL2.4
InjectorMulti-hole type(8xφ0.19mm)
Denso G2No No Installed
ModelItem
Engine model
Compression ratio
Injection pump type
Governor type
Fuel injection order
L6-φ147×154
2.75(400)/200
Injection pressure
Nozzle type
Timer type
15,681
1-5-3-6-2-4
16.4
Exhaust gas recirculation device (EGR)
6WG1 Engine Specification6WG1TQA 6WG1XQA0* 6WG1XYSA-0*
TIER2 TIER2 TIER3
Cartridge(Filter paper type) Cartridge(Filter paper type) Filter paper type
Full flow filter(Remote) Full flow filter(Remote) Full flow filter(Remote)Gear type Gear type Gear type
Amount of engine oil (L) Total 42-52 (37-47 Oil Pan) Total 42-52 (37-47 Oil Pan) Total 42-57 (37-52 Oil Pan)
Cooling water fullcapacity
(L)
Generator capacity (V-A) MITSUBISHI 24-50 MITSUBISHI 24-50 MITSUBISHI 24-50
Starter (V-kW) MITSUBISHI 24-7.0 MITSUBISHI 24-7.0 MITSUBISHI 24-5.0RHC9(IHI) RHC9(IHI) TD08H-31M (MHI)
Not Equipped Equipped Equipped
Thermostat valve opentemperature(10mm)
(℃)
ModelItem
Cooling system method
Water pump type
Thermostat typeAir cleaner type
Fuel filter type
Oil filter typeOil pump type
Oil cooling type
Centrifugal, belt type
Water-cooled controlled circulation type
Water-cooling
36
To be supplied by OEM2 wax-type units
Turbocharger typeIntercooler type
83(95)
EnginePerformance
変更履歴条件 仕様値
大気状態 標準状態ｽﾘｱﾜｾ運転時間 30Hr
ﾌﾟー ﾘｰ比 －
日立建機（株）殿向け 361型45ｔ搭載AH-6WG1XＹ ｸ‐ﾘﾝｸ ﾌ゙ｧﾝ 無
目標全負荷性能曲線図（ＦＡＮ無） ｴｱｰｸﾘｰﾅｰ 付（3.4ｋＰａ）充電発電機 付
ｴｷｿﾞー ｽﾄｻ ｲﾚﾝｻ ｰ 付（13.3ｋＰａ）
0
50
100
150
200
250
300
100012001400160018002000
軸ﾄﾙｸ(
Nm)
237±13.6g/kWh以下 ／2000min-1
POW
ER O
UTPU
T（ｋＷ）
180
200
220
240
260
500 1000 1500 2000 2500ENGINE SPEED(min-1)
SFC(
g/kW
h)
1900±30rpm
260±4kW／1800min-1
1380Nm以上／約1500min-1（1580±47）
214±13.6g/kWh＠1800ｍｉｎ-1
（1370±69Nm／1000min-1）
（ ）内ISUZU目標値
Engine Layout /Main Parts Main Fuel Filter
(Tandem)
EGR Cooler
(Tandem)
EGR Valve
Supply Pump
(G Sensor)
Common Rail
Engine Layout /Main Parts
Turbocharger
Remote Oil Filter Port
Characteristics of Main Structure Components
SymmetryHigh RigidityC.Block
High RigidityRudder Frame
Maximum Inj.Pressure１３０ＭＰaElectronic Cont.Common Rail
OHC 4VALVEHigh Rigidity ofCyl. Head
High RigidityC. Shaft
High EfficiencyTurbocharger（no Waste Gate）
Cooled ＥＧＲ
High Rigidity（Rudder Frame）
6WG1X Engine Noise (Tier 3 v.s. Tier 2)
6WG1X-Tier2との比較 ＦＡＮ無
●――――●
6WG1X-Tier3ＦＡＮ：無
×- - - - -×
6WG1X-Tier2ＦＡＮ：無
ＥＮＧ．ＴＹＰＥ ＡＨ－６ＷＧ１ＸＳＯＵＮＤ ＰＲＥＳＳＵＲＥ ＬＥＶＥＬ*** AVERAGE ***
84
86
88
90
92
94
96
98
100
600 800 1000 1200 1400 1600 1800 2000 2200ＥＮＧＩＮＥ ＳＰＥＥＤ （ｒｐｍ）
ＳＰＬ
-ＡＶＥ
（ＦＵＬＬ
ＬＯＡＤ）
ｄＢ（Ａ）
6WG1X-Tier2比約３ｄB（A)の低騒音ﾎ ﾃ゚ﾝｼｬﾙ
Fan : none
Fan : none
Comparison with Tier 2
3 db(A) lower
Than Tier 2
Sensor Layout
Name1.Pressure Control Valve2. Fuel Temperature Sensor3. G Sensor (Cam speed)4. Boost Temperature Sensor5. Common Rail Pressure Sensor6. Engine Coolant Temp. Sensor
7. EGR Valve8. Boost Pressure Sensor9. CKP Sensor (Crank speed)
10. Engine Oil Pressure sensor11. Overheating Switch
Refer to6WG1 Engine TroubleshootingManual (NM1J1-E-ENG-T) １Ｅ-９８
System Schematic (6WG1)Common Rail Pressure Sensor Pressure Limiter
Common Rail
Injector
ECM
CKP Sensor
Supply Pump
Comparison with Conventional SystemTWV: Two Way Valve
Common Rail System Characteristic・The common rail system uses a type of accumulation chamber called a rail to store pressurized
fuel, and injectors that contain electronically controlled solenoid valves to inject the pressurized fuel into the cylinders.
・Because the engine ECM controls the injection system (including the injection pressure,injection rate, and injection timing), the injection system is independent and thus unaffectedby the engine speed or load.
・Because the engine ECM can control injection quantity and timing to a high level of precision, even multi-injection is possible.
・This ensures a stable injection pressure at all times, even in low engine speed range.
Fuel Injection Rate Control
6WG1X Tier3 apply Main & Pilot Injection only
Fuel Injection Rate Control
Conventional InjectionConventional Injection Pilot InjectionPilot Injection
Injection rate
Generation rate of heat
Crank angle (°) Crank angle (°)
Large mixed combustion (NOx, noise)
Small mixed combustion
Pilot Injection reduce NOx and Noise
ECM Diagram (6WG1X)
Refer toTrouble ShootingManual (NM1J1-E-ENG-T)
１Ｅ－１０８
Refer toTrouble Shooting Manual １Ｅ－８８
Control System
Other sensors,
Switches
Other sensors,
Switches
InjectorInjector
Cylinder identifying signalCamshaft position
sensor,
G sensor
Camshaft position sensor,
G sensor
Engine speed
Accelerator position
Accelerator position
sensor
Accelerator position
sensor
Sensors Actuator
・Injection amount control・Injection timing control
Common rail pressure sensor
Common rail pressure sensor
Supply pumpSupply pump
・Injection pressure control
Crankshaft
position sensor
Crankshaft
position sensor
Function of ECMEngine Control System Configuration Engine Control Basic Injection Control
（Injection Quantity、Injection Pressure、Injection Timing、Injection Rate）
Fuel Injection Compensation（Starting Fuel Compensation、Altitude Compensation、Over Heat）
EGR Another Engine Control Idling control QOS Self-diagnostic function CAN communication
All control is calculated and set bythe on-boad control module, using the performance map and according to the detected engine and ambient conditions.
ECM Engine Data MapENG SPEED rpm
y ¥ x 0 400 550 600 700 950 975 1020 1030 1070 1090 1200 1300FUEL 0 50 30 30 40 50 65 80 80 85 85 90 90 90QUONTITY 10 50 30 30 40 50 50 80 80 85 85 90 90 90MM3/ST 15 50 30 30 40 50 50 80 80 85 85 90 90 90
40 50 30 30 40 50 65 80 80 85 85 90 90 9045 50 40 40 40 50 65 80 80 85 85 90 90 9075 50 50 50 50 50 65 80 80 85 85 90 90 9085 50 50 50 50 50 65 80 80 85 85 90 90 9095 50 50 50 50 50 65 80 80 85 85 90 90 90
120 50 50 50 50 50 65 80 80 85 85 90 90 90
070
010
3013
00
1450
2000
3500 0
95230
0
50
100
150
100-15050-1000-50
Engine speed (rpm)
Fuel Quontity (mm3/st)
RailPressure (MPa)
Rail Pressure
ECM has several Engine Control Data Map
①Base Map－Engine Speed v.s. Rail Pressure, Fuel Quantity etc
②Compensation Map－Coolant Temp. Atmospheric Pressureetc
Fuel Injection at Starting
Engine starting mode
Starter signal ONLess than "N1" speed (rpm)
Engine speed
Inje
ctio
n am
ount
at
cran
king
At low temperature
At high temperature
6WG1X N1=950rpm
Startig Fuel Quantity Adjust
始動燃料流量補正（mm3/st）
エンジンクーラント温度 (deg C)
Starting Fuel Quantity
Engine Coolant Temp.
ECM adjust Starting Fuel Quantity by Coolant Temperature Sensor signal
High Altitude Correction
ECM adjust maximum Fuel Quantity by Atmospheric Pressure Sensor signal
Maximum Fuel Quantity
Atmospheric PressureHigh Altitude
Over Heat Control
100℃
105℃
In addition Alarm raise above105℃,Fuel Quantity decrease above 100℃
Engine Coolant Temp.
Fuel Quantity
Engine Coolant Temp.
QOS (Quick On Start) System
The ECM determines the period required for glow (pre-glow, glow, after-glow), and operates the glow relay and QOS indicator lamp.QOS system allows to make the starting at cold weather easier and reduce white smoke and noise at starting.When turning the key switch to ON, the ECM detects the engine coolant temperature by signal from engine coolant temperature (ECT) sensor and changes the period for glow so that the proper starting conditions can be achieved all the time.Also, after-glow function allows stabilize idling immediately after starting.
Pre-Heat Time
Engine Coolant Temp.
ＣＡＮCommunication Circuit All ECU on Vehicle connected through CAN Communication Circuit
Monitor Unit
ICF
MC
ECM
SatelliteCommunication
Dr.ZX
CAN Bus
CAN Bus
Tech2
○MC：Main Controller
○ECM：Engine Control Module
○ICF：Information Controller
○Monitor Unit
CAN（Controller Area Network）communicate
・Target Engine Speed
・Engine and Vehicle Trouble Code
・Monitoring Engine and Vehicle Operating
Condition
ＥＣＭＣｏｎｎｅｃｔｏｒＲｅｍｏｖａｌ
Pull down the Lever until sound coming
Push the Button Lift up the Lever
Common Rail System（ＰＣＶ)Common Rail Pressure Sensor Pressure Limiter
Common Rail
Injector
ECM
CKP Sensor
Supply Pump (PCV)
Common Rail System Main PartsInjector
Injector Hole DiameterZX450-3: 8-Φ0.19 ZX650/800-3: 8-Φ0.21
Common Rail
Supply Pump
G Sensor (Cam speed)
PCV : Pressure Control Valve
ECM
Supply Pump（PCV type）
(Pressure Control Valve)
Feed Pump ＧSensor Gear
Supply Pump (PCV) operation
Can Lift
PCV Operation Close Valve
Open Valve
Close Valve
To Common Rail
PlungerDelivery Valve
Intake Stroke Pumping Stroke
ＰＣＶRelay
ＰＣＶCircuit
Common RailFlow damper
Common rail pressure sensor Pressure limiter
Pressure Limiter
Valve open
Valve closed
Common rail pressure
Abnormally high pressure
Pressure limiter
Pressure Limiter opens to release the pressure
if abnormally high pressure is generated.
It resumes operation (closes) after the pressure
falls a certain level.
Engine Speed (rpm)
Fue
l Qua
ntity
(m
m3/
st)
30 – 60MPa
100 – 150MPa
160MPa
70 – 90MPa
（Rail Pressure Sensor）
Rail Pressure Sensor
Sample of Rail Pressure
Appx 130Mpa
6WG1X
Fuel Quantity
Appx 30MPa 1800RPM
900RPM
Engine Speed
Flow damper
Common rail Injector
SpringBallPiston
Flow damper
Reduce the pressure pulsations in the pressurized
line and also prevent abnormal discharge of fuel
Flow Damper Operation (at Stop)
Common rail Injector
SpringBallPiston
Flow Damper Operation (at Damping)
Common rail Injector
SpringBallPiston
Flow Damper Operation (at Abnormal Discharge)
Common rail Injector
SpringBallPiston
Seat
InjectorOrifice 1
Orifice 2
Nozzle OrificeHydraulic piston Solenoid
Injector Outline
Common rail pressuresensor
Common rail pressure sensor
Common rail
Nozzle
Supply pump
Injection pressure control
Hydraulic piston
Control chamber
Orifice
Leak
Injector Circuit
Charge circuit
Constant current circuit
Constant current circuit
Injector Operation-- No Signal --Outer valve
Orifice 1Orifice 2
Common railHydraulic piston
Return
Inner valve
No signalNo signal
Injector Operation-- Signal Input --
Outer valve
Orifice 1Orifice 2
Common railHydraulic piston
Return
Inner valve
Valve open
Signal inputSignal input
Injector Operation-- Injection Start --
Outer valve
Orifice 1Orifice 2
Common railHydraulic piston
Return
Inner valve
Injection StartInjection Start
Injector Operation-- Signal Stop --
Outer valve
Orifice 1Orifice 2
Common railHydraulic piston
ReturnValve closed
Signal stopSignal stop
Injector Operation-- Injection Stop --
Outer valve
Orifice 1Orifice 2
Common railHydraulic piston
Return
Inner valve
Injection stopInjection stop
1. Injector2. Injector Harness3. Injector Terminal Nut
High Voltage applied on the Injector (above118V)Battery cable must be disconnectedduring Injector related work.
Injector Terminal
4HK1
Injector Current and Voltage15A or more
Max. 130V
CKP(Crank Position) Sensor G(Pump Position) Sensor
G Sensor
ＣＫＰSensor
Ａｍｐ回路
Ａｍｐ回路
G sensor detects the G sensor Gear
rotation and identifies the cylinder.
CKP sensor detects the engine
speed.
CKP Sensor Waveform
ＧSensor Waveform
G Sensor Waveform
No.1 cylinder TDCRecognition pulse
G Sensor
G(CMP), CKP(NE) Sensor Diagram (6 Cylinders)
No.6 cylinderTDC standard pulse No.1 cylinder TDC
Recognition pulse
No.1 cylinderNE standard pulse
No.6 cylinderNE standard pulse
No.1 cylinderTDC standard pulse
No.1 cylinderNE standard pulse
Common Rail Pressure Sensor
Common rail pressure
Boost Pressure Sensor
Boost pressure
Electronic circuit Silicon chip
Vacuum chamber
FilterIntake air pressure
Engine Coolant Temperature Sensor
Engine coolant temperature
Fail-safe: Changes to 80℃ in case of abnormality. Fail-safe: Changes to 80℃ in case of abnormality.
Fuel Temperature Sensor
Fuel temperature (℃)
Fail-safe: Takes the value of the water temperature sensor in case of abnormality.
Fail-safe: Takes the value of the water temperature sensor in case of abnormality.
Intake Air Temperature Sensor
Intake air temperature (°C)
Fail-safe: Takes the value of the water temperature sensor in case of abnormality.
Fail-safe: Takes the value of the water temperature sensor in case of abnormality.
Cooled EGREGR stands for ”Exhaust Gas Recirculation”.This equipment lowers burning temperature by mixing some of the emitted exhaust gas with the intake air to control oxygen concentration in the combustion chamber slowing down combustion.This enables reduction of nitrogen oxide or ”NOx”which is produced during high-temperature combustion. Cooled EGR system is a system which equips cooling system in the EGR gas passages.This system contributes reduction of NOx by further lowering the burning temperature than normal EGR with cooling down the heated EGR gas with cooler before mixing with the intake air.Moreover, by cooling down the high temperature EGR gas, intake air concentration is increased resulting in more air capacity.This brings close to the perfect combustion resulting in reduction of PM and other graphite as well as better fuel consumption.
Engine
From intercooler
Turbo
To silencerFrom air cleaner
EGR cooler
Coolant out
Coolant in
EGR valveReed valve
ECM
Exhaust manifold
Intake manifold
To intercooler
1.Various Sensor Inputs2.Exhaust Gas Re-circulation (EGR) Valve3.EGR Cooler4.Engine Coolant 5.Intake Air6.Engine Control Module (ECM)
1.EGR Pipe2.EGR Cooler3.EGR Adapter4.EGR Valve & REED VALVE
ＥＧＲLayout
EGR VALVE ASM
EGR Control
ECM operates the motor according to engine speed, engine load, etc. to control amount of EGR valve lift.Amount of valve lift is detected by EGR position sensor.The dark color area in the figure shows the valve lift amount is large, and the darkest color area shows that the valve lift amount is almost 100%.
ＥＧＲGas Flow ControlEGR gas enter into the intake side when intake air pulsation higher than exhaust gas pulsation
REED VALVE prevent Intake Air enter into Exhaust Gas Side
Intake Air Pulsation Exhaust Gas Pulsation
EGR Control
SENSOR OUTPUT
UVW INPUT
ECM provides 5 V to the EGR positionsensor U, V, and W through 5-V powersupply circuit and grounds to the insideof the ECM through ground circuit.
EGR position sensor outputs polarity(ON, OFF) of any one of the EGR position sensors U, V, and W through respective signal circuit to the ECM.
ECM detects the EGR valve positionby counting the number of change inpolarity.
Fuel Filter，Fuel PumpPriming Pump
Main Filter
6WG1X : TandemPre. Filter
Filter Wrench
(Pre, Main common）
Improve Engine Oil Drain Method（OIL PAN）
Drain Cock
Drainer
（On Vehicle）
How to Replace Parts1
2
3
45
Change sealing line
（Not Reuse）
Never replace the pressure limiter, fuel temperature sensor, flow damper alone.If faulty, replace the common rail assembly and all the fuel pipes.Do not reuse the high-pressure pipe and injector pipe of the fuel system.Replace with new one if it is removed.
For SCV pump, the pump unit cannot be replaced itselfbecause the fuel temperature sensor is installed on it.
Be sure to replace it as supply pump ASSY.
Name1. Injector pipe2. Flow damper3. Common rail pressure sensor4. Fuel temperature sensor5. Pressure limiter
2005.4.14
Danger Need Care Good Unkown・Sulfur contents ； 1000～3000ppm / above 3000ppm・Water contents・Dust contents・Fuel viscosity ; HFRR 460～560 / above 600・Additive
SulfurWaterDust
ViscosityAdditive
SulfurWaterDust
ViscosityAdditive
SulfurWaterDust
ViscosityAdditive
SulfurWaterDust
ViscosityAdditive
SulfurWaterDust
ViscosityAdditive
SulfurWaterDust
ViscosityAdditive
SulfurWaterDust
ViscosityAdditive
SulfurWaterDust
ViscosityAdditive
CANADA
S.America
N.Europe
N.Africa
M.East China，E.Asia
S.E.Asia
JAPAN
Level of Consideration
OseaniaSulfurWaterDust
ViscosityAdditive
SulfurWaterDust
ViscosityAdditive
E U
SulfurWaterDust
ViscosityAdditive
W.RussiaSulfurWaterDust
ViscosityAdditive
E.Russia
SulfurWaterDust
ViscosityAdditive
N.America
SulfurWaterDust
ViscosityAdditive
S.Africa
SulfurWaterDust
ViscosityAdditive
World Fuel Map for Off-road Machine
Tier-3 Engine major specification and Maintenance point
1.High pressure fuel injection control by common rail system.
→Prohibit teardown and re-adjustment of injector.
→Prohibit re-use of injector pipe and high pressure fuel pipe.
→Must be keep ISUZU fuel requirement.
→Keep observe strictly the maintenance schedule.
2.Electronic control module.
→notice : A battery cable must be disconnect at the time of welding work forECM protection.
3.Cooled EGR
→Must be keep ISUZU fuel requirement.
→Must be keep ISUZU Engine oil requirement and maintenance.
→Observe engine strictly of Maintenance.
AGAIN
List of Special Service Tools (1/3)
List of Special Service Tools (2/3)
List of Special Service Tools (3/3)
Detect Failure
Dr.ZX
Dr.ZX
Tech2
ZXZX-3
Monitor
SCAN Tool
As ZX-3 type machine scan tool, Dr.ZX add the new function of engine failuredetection⇒Main Scan Tool
Monitor also able to scan the failure of vehicle and engine and to monitor
operating condition.
Isuzu prepare Tech2 for Isuzu service network
(Special Tool) Breaker Box（Harness Checker ）
Breaker Box is a tool to easily check open or short circuit in connector pinand harness between ECM and each sensor or actuator
Refer to
6WG1X EngineTroubleshootingManual(NM1J1-E-ENG-T)
１Ｅ-８５
(Special Tool) Injector Checker
Injector Checker is a tool to easily check the defect injector by cuttingthe current flow to a selected injector.(Same function will be applied on the Dr.ZX around Mar.’06)
Refer to6WG1X Engine TroubleshootingManual （NM1J1-E-ENG-T) １Ｅ-７８
Trouble Shooting procedure
A. Diagnostic process with an interview1) Confirm user complain. (Use Questionnaire Sheet)
2) Carry out preparative inspection.3) Confirm service information.4) Confirm DTC code. (Translate to Isuzu Code)
5) Confirm phenomenon by visual observation.
B. Repair
C. Check
(Notice) ECM Power OFFThe power supply inside the ECM does not go off for about 10 secondsafter turning the key switch OFF. If the ECM power needs to be off such as for memory clear, wait for more than 10 seconds after turning the key switch OFF.
Check list for engine control system Inspector's company nameInspector's name
User User's name Machine applicationAddress
Machine Date of delivery Date of trouble occurrenceOperating periodMachine model name Machine No.
Engine Engine model name Engine No.
Engine does not start □ □ □ □
Difficult starting of engine□ □ □ □
Unstable idling □ □ □ □
Drivability is low. □ □ □ □
Engine stall□ □ When accelerator
pedal (lever) is released□ □
□ When gear is shifted up When operating at full load
□ At certain operationmode
□ □
Vibration at idling
Trouble occurrence dataFrequency of trouble □ □ □ □
Weather □ Fine □ Cloudy □ Rain □ Snow□ After lightening □ Others ( )
Ambient temperature □ 30℃ or more □ Around 20 - 30°C □ Around 10 - 15°C □ 0℃ or less ( ℃)Season □ Spring □ Summer □ Autumn □ WinterLocation □ Outdoor □ Construction field (Type □ General road □ Rough road
□ Indoor □ Roadworks field (Type ) □ Expressway □ Slope (grade degree )
□ In mountain □ Harbor □ On the sea □ Height ( m above sea level)□ Others ( )
Engine temperature □ Cold □ During warming-up □ After warmed-up □ Others ( )Oil/coolant temperature □ Engine coolant temperature□ Oil temperature ( ℃)Operating condition □ □ □ □
□ □ □ □
Condition when trouble o□ After oil is replaced □ After oil filter is replac□ After replenishment of□ After sedimenter is drained□ After operating on slope □ After out of gas □ After washing with high□ Others ( )
Oil □ □ □ □
Fuel type □ Light oil □ Krosene □ A heavy oil □ Others ( )□ Diesel fuel Special No. 3 □ Diesel fuel No. 2 □ Diesel fuel No. 1 □ Diesel fuel Special No. 1
Diagnosis lamp □ ON □ Sometimes comes on □ Not come onDTC Current trouble □（ ） □（ ） □（ ） □（ ）
□（ ） □（ ） □（ ） □（ ）
Past trouble □（ ） □（ ） □（ ） □（ ）
□（ ） □（ ） □（ ） □（ ）
Past trouble history □ Year Month Date (Content ) [Measure: ]□ Year Month Date (Content ) [Measure: ]
Trou
ble s
ympt
omTr
ouble
con
dition
Confirm user complain using Questionnaire sheet
Refer to
6WG1X EngineTroubleshootingManual(NM1J1-E-ENG-T)
１Ｅ-１３、１４
How to use “Trouble Shooting Manual” （ＮＭ１J１－Ｅ－ＥＮＧ－Ｔ）
＊Confirmation process from DTC code.(DTC;Diagnostic Trouble Code)
① Confirm DTC code by Ｄｒ．ＺＸor Monitor.② To translate Hitachi DTC code to Isuzu DTC code
③ To read/confirm the pages which described Table of DTC code on trouble shooting manual.
④ To read detail description of each DTC code.
＊Confirmation process from phenomenon. ① Confirm failure phenomenon.② To read/confirm the pages which described Table
of phenomenon. ③ To read detail description of each failure.
Translate Hitachi DTC Code to Isuzu CodeTranslate Hitachi DTC code （ＳＰＮ＋ＦＭＩ）to Isuzu DTC code（ＰＣｏｄｅ）,Read detail description of each DTC code
Refer to 6WG1X Engine Trouble Shooting Manual（NM1J1-E-ENG-T)１Ｅ-５７１，５７２
Electronic control fuel injection system（Common rail type） ＩＥ－５７１
DTC Code Reference Sheet for Hitachi and Isuzu
ＳＰＮ ＦＭＩ Ｐ Code ＤＴＣ description Trouble displayon monitor
９１ ２ Ｐ１２７１ Accelerator sebsor1-2 comparison fault
○
９１ ３ Ｐ１２７７ Accelerator sebsor 1fault (low voltage)
○
９１ ３ Ｐ１２７７ Accelerator sebsor 1fault (high voltage)
○
Detail of DTC (Diagnostic Trouble Code)
List of diagnostic trouble codeList of diagnostic trouble codesOn some machines, the diagnosis lamp comes on instead of trouble display monitor on the machine.
６WG１Ｘ
ＤＴＣ Flashcode
ＤＴＣdescript ion
Item to bedetected
Precondit ionswhen DTC is
set
ＤＴＣ setcondit ion
Faultjudgment
period
Behavior whentrouble occurs
Diagnosis lamp
P0088 118 Common railpressure
fault(1st stage)
Common railpressureabnormalincrease
・Key switchinput voltage
is 16V ormore.
・DTC P0088,P0192,P0193or P1635 is
not detected.
Rail pressureis more than
150Mpa(21756psi)
Approx.5 sec
Increase enginevibration, roughidling, outputlowering, blow upfault , black smokeemitted, andexcessive outputare possible.Back-up:Limited injectionamount 3 (mult i-injection stopped)Target RP upperlimit(80 Mpa{11603 psi})
ON
ＩＥ－１７０
Description of DTC Code（P００８８, Refer to １Ｅ-１８３～１８７
Recovery from failure, refer to ＩＥ－１８２
Isuzu DTC code detail, refer to Trouble Shooting Manual １Ｅ-１７０～１８１Hitachi unique DTC code, refer to １Ｅ－５７５～５７８
Recovery from Failure
Trouble occurs Inspection and repair, or temporary recovery from failure
Recovery from failure
Trouble occurs
Recovery from failure
Inspection and repair, or temporary recovery from failure
Pattern 1Pattern 1 Pattern 2Pattern 2Wait 10 seconds
Recovery from Failure
Pattern 3Pattern 3 Engine is recovered from failure, but trouble code exists and lamp remains on.
DTC Clear Action Required
Inspection and repair, or temporary recovery from failure
Trouble occurs
Recovery from failure
Trouble Shoot Process from PhenomenonConfirm failure phenomenon and read detail description of each failure
Refer to 6WG1X Engine Trouble Shooting Manual（NM1J1-E-ENG-T)１Ｅ-５３９～５６９
List of trouble symptom
Symptom DescriptionEngine start failure Crank speed is slow.
Crank speed is normal but engine does not start. (notfirst combustion).Engine start (first combustion exists) but can notmaintain stable engine speed, or no blow up.
Engine stall Engine cranks but take long time before start. It ope-rates eventually, or starts but stops immediately.
Electronic control fuel injection system（Common rail type） ＩＥ－５３９
About Tech2 （ＩｓｕｚｕS Tool)
1) Display of Diagnostic Trouble CodesPerforms Reading, confirmation and clearing of DTC
Displays the current data recognized and controlled by ECM2) Data Display
3) SnapshotRecords and plots data when trouble occurs
5) Actuator TestChecks operation and function at each test and confirms abnormality
4) ProgrammingEnables to confirm the history of data when ECM is replaced
Trouble Diagnosis Results of Tech2
• Past TroubleDiagnostic test was completed at previous ignition cycle.Diagnostic test was accepted at current ignition cycle.Faults found by the diagnostic test do not currently exist.
DTC codes of Past Trouble are stored in the ECM until clear works have been done.(After 30 times ignition on and off, Past Trouble codes are eliminated automatically)
• Current TroubleDiagnostic test was completed at previous ignition cycle.The faults detected by the diagnostic test currently exist.The faults exist at the current engine cycle.
After Current Trouble has been accepted, the code is stored in the ECM as PastTrouble code.
How to Clear DTC
1. Connect the harness (shown left) to data link connector.
2. Turn the key switch to ON.
3. Short (connect) the probe.
4. Turn the key switch to OFF (DTC memory will be cleared simultaneously).
5. Disconnect the harness.
Hitachi Parts NO：3106414 Data Link Connector is located nearposition of ECM.
Injector QＲCode Programming
Injector QR code
Ｔｅｃｈ２
New Injector QR codes have to be input in the ECM by using Dr.ZX or Tech2, when Injectors are exchanged （Input using Dr.ZX wil be available around March ‘06）
Ｄｒ．ＺＸ
What is Injector QR Code
Actuating Pulse Width TQ
ＲａｉｌＰｒｅｓｓｕｒｅParameter
Injection Quantity
QR (Quick Response) codes have been adopted to enhance correctionprecision. The QR code, which contains the correction data of the injector,is written in the engine ECM. QR codes have resulted ｉｎsubstantial increasein the number of fuel injection quantity correction points, greatly improvinginjection quantity precision.
Ｄｒ．ＺＸ or Ｔｅｃｈ２
QR Code Correction Point
Injector ; QR Code
Injector QR Code
Engine Label
ＥＰＡLabel ＥＣLabel
Engine Production serial NO.Injector QR Code
ＡＨ－６ＷＧ１ＸＹＳＡ－０１（Engine Model）
ＢＢ/ＡＦ （Production Month： Month/Year)） Ａ，Ｂ，Ｃ，Ｄ，Ｅ，Ｆ＝０，１，２，３，４，５
ＢＢ/ＡＦ＝ １１month/０５year
JPN Label
