Catalog động cơ diesel ISUZU 6WG1X

ISUZU INDUSTRIAL DIESEL ENGINE 6WG1X Tier3 1.　chọn động cơ 6 xi lanh, 6 xilanh inline, direct injection diesel, Mechanical fuel injection pump (Inline fuel injection pump) BOSCH PEPS3S MITSUBISHI 2450MITSUBISHI

ISUZU INDUSTRIAL DIESEL ENGINE

6WG1X Tier3

ISUZU MOTORS LIMITED Off-highway Powertrain Operation Dept Planning

& Service Group

HITACHI CONSTRUCTION MACHINERY CO.,Ltd

Technical Training Center

contents

  ① Differences between Tier2 engine and Tier3 engine.

      Off Road Emission Regulation       Engine Specifications

Engine Layout /Main Parts Engine Layout /Sensors   ② Out Line of Common Rail System

Common Rail System       Comparison with Conventional System   ③ System Component

   ① Trouble Shooting Procedure

② How to use Trouble Shooting Manual

① DTC code    ② Scan Tool    ③ EMPS    ④ How to use scan tool 

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 for

ECM 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 Regulation

Off-Road Future Emission Regulation

EC 130 - 560 kW 6W,6S,6H ▼ St age2 ▽ St age3-A ▽St age3-B

75 - 130 kW 4H ▼ St age2 ▽ St age3-A ▽ St age3-B

37 - 75 kW 4J,4LE ▽ St age2 ▽ St age3-A ▽ St age3-B

LOW NOISE REQUIRMENT of EC STAGE-III

From 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.

T ier4

int erim

T ier4 NOx + HC 4.7

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

Key Technologies of Diesel Engine

Noise Technology

Base Technology Friction Reduction

Base Technology Friction Reduction

Turbo-Charging

Technology

Turbo-Charging

Technology

Total Electronic Control

Total engine technology -Combustion chamber -Turbo-charging etc.

Total engine technology -Combustion chamber -Turbo-charging etc.

Exhaust Manifold

Air

EG R C o

EGR Technology

Inlet Manifold

Technologies and Emission Level (130kW∼)

Regulation and Effect (6WG1X）

Applied Tandem Cooled EGR High 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

1 Tier 2 Engine Comparison

2 Electronic Control

3 Common Rail System

4 Cooled EGR

6WG1 Engine Specification

Water cooled, 6-cycle, inline 4-cylinder, OHC, direct injection diesel

Water cooled, 6-cycle, inline 4-cylinder, OHC, direct injection diesel

Water cooled, 6-cycle, inline 4-cylinder, OHC, direct injection diesel

Mechanical fuel injection pump (Inline fuel injection pump) BOSCH PE-P-S3S

Electronic control fuel injection system (common rail type)

Denso HP0

2Stage Nozzle Multi-hole type(8xφ0.24mm)

Bosch KBL2.4

2Stage Nozzle Multi-hole type(8xφ0.24mm)

Bosch KBL2.4

Injector Multi-hole type(8xφ0.19mm)

Denso G2

Model Item Engine model

15,681

1-5-3-6-2-4 16.4

Exhaust gas recirculation device (EGR)

6WG1 Engine Specification

Cartridge(Filter paper type) Cartridge(Filter paper type) Filter paper type Full flow filter(Remote) Full flow filter(Remote) Full flow filter(Remote)

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 full

Thermostat valve open

temperature(10mm) (℃)

Model Item

Cooling system method

Water pump type

Thermostat type

Air cleaner type

Fuel filter type

Oil filter type Oil pump type

Oil cooling type

Centrifugal, belt type Water-cooled controlled circulation type

目標全負荷性能曲線図（ ＦＡＮ無） ｴ ｱ ｰ ｸﾘｰ ﾅ ｰ 付（ 3.4ｋＰａ）

ｴｷ ｿﾞｰ ｽ ﾄｻ ｲﾚﾝｻ ｰ 付（ 13.3ｋＰａ）

0 50 100 150 200 250

300

1000 1200 1400 1600 1800 2000

237±13.6g/kWh以下 ／ 2000min -1

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

Maximum Inj.Pressure １３０ＭＰa Electronic Cont.

High Rigidity

（ Rudder Frame ）

6WG1X Engine Noise (Tier 3 v.s Tier 2)

6WG1X-Tier2との比較 ＦＡＮ無

●――――●

6WG1X-Tier3 ＦＡＮ：無

×- - - - -×

6WG1X-Tier2 ＦＡＮ：無

ＥＮＧ．ＴＹＰＥ ＡＨ−６ＷＧ１Ｘ ＳＯＵＮＤ ＰＲＥＳＳＵＲＥ ＬＥＶＥＬ

Fan : none

Fan : none Comparison with Tier 2

3 db(A) lower Than Tier 2

Sensor Layout

Name

1.Pressure Control Valve

2 Fuel Temperature Sensor

3 G Sensor (Cam speed)

4 Boost Temperature Sensor

5 Common Rail Pressure Sensor

6 Engine Coolant Temp Sensor

7 EGR Valve

8 Boost Pressure Sensor

9 CKP Sensor (Crank speed)

10 Engine Oil Pressure sensor

11 Overheating Switch

Refer to6WG1 Engine TroubleshootingManual (NM1J1-E-ENG-T)  １Ｅ-９８

System Schematic (6WG1)

Common Rail

Injector ECM

CKP Sensor

Supply Pump

Comparison with Conventional System

TWV: 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 unaffected

by 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 Injection Pilot Injection

(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

・Injection amount control

・Injection timing control

Common rail pressure sensor

Common rail pressure sensor

Function of ECM

Engine 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）

ECM Engine Data Map

230 0

50 100

150

100-150 50-100 0-50

Engine speed (rpm)

Fuel Quontity (mm3/st)

Fuel Injection at Starting

Engine starting mode

Starter signal ON Less than "N1"

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 Pressure

High 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

Satellite Communicatio n

○ICF：Information Controller

○Monitor Unit

CAN（Controller Area Network）

communicate

・Target Engine Speed

・Engine and Vehicle Trouble Code

・Monitoring Engine and Vehicle Operating

Condition

ＥＣＭ Ｃｏｎｎｅｃｔ ｏｒＲｅｍｏｖａｌ

Pull down the Lever until sound coming Push the Button Lift up the Lever

Common Rail System（ＰＣＶ)

Common Rail

Injector ECM

CKP Sensor

Supply Pump

(PCV)

Common Rail System Main Parts

Injector

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)

Supply Pump (PCV) operation

ＰＣＶ Circuit

Pressure limiter

if abnormally high pressure is generated.

It resumes operation (closes) after the pressure falls a certain level.

Rail Pressure Sensor Sample of Rail Pressure

Appx 130Mpa 6WG1X

Fuel Quantity

900RPM

Engine Speed

Flow damper

Spring Ball

Piston

Flow damper

Reduce the pressure pulsations in the pressurized line and also prevent abnormal discharge of fuel

Flow Damper Operation (at Stop)

Spring Ball

Piston

Flow Damper Operation

(at Damping)

Spring Ball

Piston

Flow Damper Operation (at Abnormal Discharge)

Spring Ball

Piston

Seat

Injection pressure control

Hydraulic piston Control chamber Orifice Leak

Injector Circuit

Charge circuit

Constant current circuit

Constant current circuit

No signal

Injection Start

Injection stop

1 Injector

2 Injector Harness

3 Injector Terminal Nut

High Voltage applied on the Injector (above118V)

Battery cable must be disconnected during Injector related work.

Injector Terminal

4HK1

Injector Current and Voltage

15A or more

Max 130V

CKP(Crank Position) Sensor

G(Pump Position) Sensor

CKP Sensor Waveform

No.1 cylinder

NE standard pulse

Common Rail Pressure Sensor

Common rail pressure

Boost Pressure Sensor

Engine Coolant Temperature Sensor

Engine coolant temperature

Fail-safe: Changes to 80℃ in case of abnormality

Fuel Temperature Sensor

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 EGR

EGR 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 silencer From air cleaner

EGR cooler

Coolant out

Coolant in

EGR valve Reed valve

ECM

Exhaust manifold

Intake manifold

To intercooler

1.Various Sensor Inputs 2.Exhaust Gas Re-circulation (EGR) Valve 3.EGR Cooler

4.Engine Coolant 5.Intake Air

6.Engine Control Module (ECM)

1.EGR Pipe 2.EGR Cooler 3.EGR Adapter

4.EGR Valve & REED VALVE

ＥＧＲ Layout

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%

ＥＧＲ Gas Flow Control

EGR 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

of 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 position

by counting the number of change inpolarity

Fuel Filter，Fuel Pump

Priming Pump

Main Filter 6WG1X : Tandem Pre Filter

Filter Wrench

(Pre, Main common）

Improve Engine Oil Drain Method

Drain Cock

Drainer

How to Replace Parts

common rail assembly and all the fuel pipes

z 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

Name

1 Injector pipe

2 Flow damper

3 Common rail pressure sensor

4 Fuel temperature sensor

5 Pressure limiter

Danger Need Care Good Unkown

・Sulfur contents ；    1000∼3000ppm / above 3000ppm

Sulfur Water Dust Viscosity Additive

Sulfur Water Dust Viscosity Additive

Sulfur Water Dust Viscosity Additive

Sulfur Water Dust Viscosity Additive

Sulfur Water Dust Viscosity Additive

Sulfur Water Dust Viscosity Additive

Sulfur Water Dust Viscosity Additive

Sulfur Water Dust Viscosity Additive

E U

Sulfur Water Dust Viscosity Additive

W.Russia

Sulfur Water Dust Viscosity Additive

E.Russia

Sulfur Water Dust Viscosity Additive

N.America

Sulfur Water Dust Viscosity Additive

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 for

ECM 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)

¾As ZX-3 type machine scan tool, Dr.ZX add the new function of engine failure

detection ⇒ Main Scan Tool

¾Monitor also able to scan the failure of vehicle and engine and to monitor

operating condition.

(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 cutting

the 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 interview

1) 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