RETURN
RETURN
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
RETURN
ISUZU INDUSTRIAL DIESEL ENGINE 6WG1X Tier3
ISUZU MOTORS LIMITED Off-highway Powertrain Operation Dept. Planning & Service Group
Table of contents
HITACHI CONSTRUCTION MACHINERY CO.,Ltd Technical Training Center
1. Differ Differenc ences es betwe between en Tier2 Tier2 engi engine ne and and Tier3 Tier3 engin engine. e. Differences between Tier2 engine and Tier3 engine. Off Road Emission Regulation Engine Specifications Engine Layout /Main Parts Engine Layout /Sensors Out Line of Common Rail System Common Rail System Comparison with Conventional System System Component a ECM b SUPPLY PU PUMP c COMMON RAIL d INJECTOR e HARN HARNES ESS S INJE INJECT CTOR OR f SENSORS g COOLED EGR 2. Main Mainte tena nanc nce e Sched Schedul ule e 3. Intro Introdu duct ctio ion n of of SST SST 4. Trouble Shooting Trouble Shooting Procedure How to use Trouble Shooting Manual 5. DTC code DTC code Scan Tool EMPS How to use scan tool 6. Point Point to notice notice on servic service e Parts replace procedure 7. Troubl Trouble e Shootin Shooting g on actu actual al machi machine ne
RETURN
RETURN
ISUZU INDUSTRIAL DIESEL ENGINE 6WG1X Tier3
ISUZU MOTORS LIMITED Off-highway Powertrain Operation Dept. Planning & Service Group
Table of contents
HITACHI CONSTRUCTION MACHINERY CO.,Ltd Technical Training Center
1. Differ Differenc ences es betwe between en Tier2 Tier2 engi engine ne and and Tier3 Tier3 engin engine. e. Differences between Tier2 engine and Tier3 engine. Off Road Emission Regulation Engine Specifications Engine Layout /Main Parts Engine Layout /Sensors Out Line of Common Rail System Common Rail System Comparison with Conventional System System Component a ECM b SUPPLY PU PUMP c COMMON RAIL d INJECTOR e HARN HARNES ESS S INJE INJECT CTOR OR f SENSORS g COOLED EGR 2. Main Mainte tena nanc nce e Sched Schedul ule e 3. Intro Introdu duct ctio ion n of of SST SST 4. Trouble Shooting Trouble Shooting Procedure How to use Trouble Shooting Manual 5. DTC code DTC code Scan Tool EMPS How to use scan tool 6. Point Point to notice notice on servic service e Parts replace procedure 7. Troubl Trouble e Shootin Shooting g on actu actual al machi machine ne
RETURN
Table of contents
1. Differ Differenc ences es betwe between en Tier2 Tier2 engi engine ne and and Tier3 Tier3 engin engine. e. Differences between Tier2 engine and Tier3 engine. Off Road Emission Regulation Engine Specifications Engine Layout /Main Parts Engine Layout /Sensors Out Line of Common Rail System Common Rail System Comparison with Conventional System System Component a ECM b SUPPLY PU PUMP c COMMON RAIL d INJECTOR e HARN HARNES ESS S INJE INJECT CTOR OR f SENSORS g COOLED EGR 2. Main Mainte tena nanc nce e Sched Schedul ule e 3. Intro Introdu duct ctio ion n of of SST SST 4. Trouble Shooting Trouble Shooting Procedure How to use Trouble Shooting Manual 5. DTC code DTC code Scan Tool EMPS How to use scan tool 6. Point Point to notice notice on servic service e Parts replace procedure 7. Troubl Trouble e Shootin Shooting g on actu actual al machi machine ne
RETURN
RETURN
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.
RETURN
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.
RETURN
Off- Road Future Emission Regulation Off-Road Future Emission Re gulation CLASS EP A
2002 T ier2
2003
2004
130 - 225 kW (175 - 300hp)
6H
T ier2
75 - 130 kW (100 - 175hp)
4H
T ier2
6W,6S,6H
75 - 130 kW
4H
37 - 75 kW
4J,4LE
19 - 37 kW
L
130 - 560 kW
6W,6S,6H
75 - 130 kW
4H
56 - 75 kW
4J
37 - 56 kW
4LE
19 - 37 kW
L
2006
T ier3
NOx+HC 6.6 CO 3.5 / PM 0.2
/ /
CO
5.0
St age2
St age2
NOx 6.0
NOx 8.0 CO 5.5
/ /
/
HC 1.0
3.5
/
PM 0.2
NOx 6.0 CO 5.0
/ /
HC 1.0 PM 0.3
NOx 7.0 CO 5.0
/ /
HC 1.3 PM 0.4
CO
St age3-A
/
HC 1.0 PM 0.3
NOx 7.0 CO 5.0
T ier-2
T ier3
/ /
HC 1.5 PM 0.8
T ier-2
2014
2015
Nox+NM HC 4.0
NOx+HC 4.7 CO 5 .0 / P M 0 .4
St age3-B
NOx+HC 4.0
St age3-A
NOx 3.6 CO 3.5
T ier-3
T ier-3
St age3-B
CO 5.0 / PM 0.3 NOx+HC 4.7 CO 5.0 / PM 0.4
St age3-A
NOx 3.6 CO 5.0
/ /
NOx+HC 4.0 CO 3.5 / PM 0.025 NOx+HC 4.0 CO 5.0 / PM 0.025
No p rop osal as St age3-B
Tier-4
HC 0.4 PM 0.2
After treatment (DPF) basis
T ier-3
NOx 4.0 CO 5.0
/ HC 0.7 / PM 0.25
T ier-3
NOx 4.0 CO 5.0
/ HC 0.7 / PM 0.3
Nox 6.0 CO 5.0
interim NOx + HC 4.7 Tier4 CO 5 .0 / P M 0 .0 3
St age3-B neary same as EPA
NOx+HC 7.5 CO 5.5 / PM 0.6 / HC 0.4 / P M 0.17
CO 5.0 / PM 0.03
56kw
CO 3 .5 / P M 0 .2
HC 1.3 PM 0.4
T ier-3
2013
Nox+NM HC 4.0 CO 3.5 P M 0.03
interim Tier4
NOx+HC 4.0
T ier-2
NOx 8.0 CO 5.5
interim Tier4
CO 5.0 / PM 0.3
St age3-A
/ /
2012
NOx+HC 4.0
NOx+HC 7.5 CO 5 .0 / P M 0 .4
/
2011
interim Tier4
T ier3
HC 1.5 PM 0.8
T ier-2
2010
T ier3
HC 1.0 PM 0.2
NOx 6.0
St age2
2009
NOx+HC 4.0 CO 3.5 PM 0.2
CO 5.0 / PM 0.3
NOx 6.0 CO 3.5
2008
interim Tier4
NOx+HC 6.6
T ier2
St age2
2007
T ier3
T ier2
4J,4LE
130 - 560 kW
2005
NOx+HC 6.4 CO 3.5 PM 0.2
6W,6S
37 - 75 kW
JP N
2001
225 - 450 kW (300 - 600hp)
(50 - 100hp)
EC
ENGINE
450 - 560 kW (600 - 750hp)
/ HC 1.0 / PM 0.4
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 s tage e ngines include l ower noise level for customer's application.
RETURN
Off- Road Future Emission Regulation Off-Road Future Emission Re gulation CLASS EP A
2002 T ier2
2003
2004
130 - 225 kW (175 - 300hp)
6H
T ier2
75 - 130 kW (100 - 175hp)
4H
T ier2
6W,6S,6H
75 - 130 kW
4H
37 - 75 kW
4J,4LE
19 - 37 kW
L
130 - 560 kW
6W,6S,6H
75 - 130 kW
4H
56 - 75 kW
4J
37 - 56 kW
4LE
19 - 37 kW
L
2006
T ier3
NOx+HC 6.6 CO 3.5 / PM 0.2
/ /
CO
5.0
St age2
St age2
NOx 6.0
NOx 8.0 CO 5.5
/ /
/
HC 1.0
3.5
/
PM 0.2
NOx 6.0 CO 5.0
/ /
HC 1.0 PM 0.3
NOx 7.0 CO 5.0
/ /
HC 1.3 PM 0.4
CO
St age3-A
/
HC 1.0 PM 0.3
NOx 7.0 CO 5.0
T ier3
/ /
HC 1.5 PM 0.8
NOx 3.6 CO 3.5
T ier-3
T ier-2
2015
NOx+HC 4.0
T ier-3
St age3-B
CO 5.0 / PM 0.3
NOx+HC 4.0 CO 5.0 / PM 0.025
/ /
No p rop osal as St age3-B
Tier-4
HC 0.4 PM 0.2
After treatment (DPF) basis
T ier-3
NOx 4.0 CO 5.0
/ HC 0.7 / PM 0.25
T ier-3
NOx 4.0 CO 5.0
/ HC 0.7 / PM 0.3
Nox 6.0 CO 5.0
CO 3.5 / PM 0.025
St age3-B neary same as EPA
NOx+HC 7.5 CO 5.5 / PM 0.6
NOx 3.6 CO 5.0
interim NOx + HC 4.7 Tier4 CO 5 .0 / P M 0 .0 3
NOx+HC 4.0
NOx+HC 4.7 CO 5.0 / PM 0.4
/ HC 0.4 / P M 0.17
CO 5.0 / PM 0.03
56kw
St age3-B
St age3-A
T ier-2
NOx 8.0 CO 5.5
NOx+HC 4.7 CO 5 .0 / P M 0 .4
CO 3 .5 / P M 0 .2
St age3-A
T ier-2
2014
Nox+NM HC 4.0 interim Tier4
NOx+HC 4.0
HC 1.3 PM 0.4
T ier-3
2013
Nox+NM HC 4.0 CO 3.5 P M 0.03
interim Tier4
CO 5.0 / PM 0.3
St age3-A
/ /
2012
NOx+HC 4.0
NOx+HC 7.5 CO 5 .0 / P M 0 .4
/
2011
interim Tier4
T ier3
HC 1.5 PM 0.8
T ier-2
2010
T ier3
HC 1.0 PM 0.2
NOx 6.0
St age2
2009
NOx+HC 4.0 CO 3.5 PM 0.2
CO 5.0 / PM 0.3
NOx 6.0 CO 3.5
2008
interim Tier4
NOx+HC 6.6
T ier2
St age2
2007
T ier3
T ier2
4J,4LE
130 - 560 kW
2005
NOx+HC 6.4 CO 3.5 PM 0.2
6W,6S
37 - 75 kW
JP N
2001
225 - 450 kW (300 - 600hp)
(50 - 100hp)
EC
ENGINE
450 - 560 kW (600 - 750hp)
/ HC 1.0 / PM 0.4
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 s tage e ngines include l ower noise level for customer's application.
RETURN
g/ kwhr)
(g/ kwhr)
NOx + HC: 40% reduction, PM: Same with Tier-2 from Y2006 JPN Government Proposal: PM 30% lower than EPA, EC T-3
RETURN
g/ kwhr)
(g/ kwhr)
NOx + HC: 40% reduction, PM: Same with Tier-2 from Y2006 JPN Government Proposal: PM 30% lower than EPA, EC T-3
RETURN
Key Technologies of Diesel Engine EGR = E xhaust G as R e-circulation
Total Total engine engine technology technology -Combustion -Combustion chamber chamber -Turbo-charging -Turbo-charging etc. etc.
EGR Valve EGR EGR Technology Technology Noise Noise Technology Technology Inlet Manifold r e l o o C r e t n I
Injection Injection System System
Base Base Technology Technology Friction Friction Reduction Reduction
Exhaust Manifold Turbo-Charging Turbo-Charging Technology Technology Air
E G R C o o l e r s a G R G E
Total Total Electronic Electronic Control Control
Fuel Fuel Improvement Improvement
RETURN
Key Technologies of Diesel Engine EGR = E xhaust G as R e-circulation
Total Total engine engine technology technology -Combustion -Combustion chamber chamber -Turbo-charging -Turbo-charging etc. etc.
EGR Valve EGR EGR Technology Technology Noise Noise Technology Technology Inlet Manifold r e l o o C r e t n I
Injection Injection System System
Base Base Technology Technology Friction Friction Reduction Reduction
E G R C o o l e r
Total Total Electronic Electronic Control Control
s a G R G E
Fuel Fuel Improvement Improvement
Exhaust Manifold Turbo-Charging Turbo-Charging Technology Technology Air
RETURN
.
Tier 3 trade-off
h W k / g M P
130MPa pressure Cooled EGR Electronic control
Tier 2 trade-off 70MPa pressure Inter cooler
Tier 3 Tier 2 JPN Tier-3 Engine Modification Limit
NOx + HC g/kWh
RETURN
.
Tier 3 trade-off
h W k / g M P
130MPa pressure Cooled EGR Electronic control
Tier 2 trade-off 70MPa pressure Inter cooler
Tier 3 Tier 2 JPN Tier-3 Engine Modification Limit
NOx + HC g/kWh
RETURN
Applied Tandem Cooled EGR High Injection Pressure (80t:120Mpa,65t&45t:130Mpa) Noz.Hole Dia (80t&65t:8- 0.21,45t:8- 0.19)
RETURN
Applied Tandem Cooled EGR High Injection Pressure (80t:120Mpa,65t&45t:130Mpa) Noz.Hole Dia (80t&65t:8- 0.21,45t:8- 0.19)
RETURN
Basic Information of Tier 3 Engine Low Emission • Low Noise
Electronic Controlled Engine
• High Power
1. 2. 3. 4.
Tier 2 Engine Comparison Electronic Control Common Rail System Cooled EGR
RETURN
Basic Information of Tier 3 Engine Low Emission • Low Noise
Electronic Controlled Engine
• High Power
1. 2. 3. 4.
Tier 2 Engine Comparison Electronic Control Common Rail System Cooled EGR
RETURN
6WG1 Engine Specification Model Item Engine model Rated output Maximum torque Cylinder arrangement and number – bore × stroke Displacement
(kW/min-1) (Nm/min-1)
6WG1TQA TIER2 Water cooled, 6-cycle, inline 4-cylinder, OHC, direct injection diesel 235.4/1800 1275/1500
6WG1XQA TIER2 Water cooled, 6-cycle, inline 4-cylinder, OHC, direct injection diesel 295/1800 1540/1500 L6-
(mm) (L) 16.4
Compression pressure MPa(psi)/rpm
Injection pump type Injection pressure Governor type Timer type Nozzle type Exhaust gas recirculation device (EGR)
147×154 15,681
Compression ratio
Dimensions (mm) (length × width × height) Weight (kg) Fuel injection order
6WG1XYSA-01 TIER3 Water cooled, 6-cycle, inline 4-cylinder, OHC, direct injection diesel 260/1800 1580/1500
16 2.75(400)/200
1462×1007×1287(with fan)
1741×1016×1340(with fan)
1462×1015×1422(with fan)
1125
1185 1-5-3-6-2-4 Mechanical fuel injection pump (Inline fuel injection pump) BOSCH PE-P-S3S 17.7/ 22.1 RSV type Equipped 2Stage Nozzle Multi-hole type(8x 0.24mm) Bosch KBL2.4 No
1153
Mechanical fuel injection pump (Inline fuel injection pump) BOSCH PE-P-S3S 17.7/ 22.1 RSV type Equipped 2Stage Nozzle Multi-hole type(8x 0.24mm) Bosch KBL2.4 No
Electronic c ontrol fuel injection system (common rail type) Denso HP0 180MPa Electronic type Electronic type Injector Multi-hole type(8x 0.19mm) Denso G2 Installed
RETURN
6WG1 Engine Specification Model Item Engine model Rated output Maximum torque Cylinder arrangement and number – bore × stroke Displacement
(kW/min-1) (Nm/min-1)
6WG1TQA TIER2 Water cooled, 6-cycle, inline 4-cylinder, OHC, direct injection diesel 235.4/1800 1275/1500
6WG1XQA TIER2 Water cooled, 6-cycle, inline 4-cylinder, OHC, direct injection diesel 295/1800 1540/1500 L6-
(mm) (L)
6WG1XYSA-01 TIER3 Water cooled, 6-cycle, inline 4-cylinder, OHC, direct injection diesel 260/1800 1580/1500
147×154 15,681
Compression ratio
16.4
Compression pressure MPa(psi)/rpm Dimensions (mm) (length × width × height) Weight (kg) Fuel injection order Injection pump type Injection pressure Governor type Timer type Nozzle type Exhaust gas recirculation device (EGR)
16 2.75(400)/200
1462×1007×1287(with fan)
1741×1016×1340(with fan)
1462×1015×1422(with fan)
1125
1185 1-5-3-6-2-4 Mechanical fuel injection pump (Inline fuel injection pump) BOSCH PE-P-S3S 17.7/ 22.1 RSV type Equipped 2Stage Nozzle Multi-hole type(8x 0.24mm) Bosch KBL2.4 No
1153
Mechanical fuel injection pump (Inline fuel injection pump) BOSCH PE-P-S3S 17.7/ 22.1 RSV type Equipped 2Stage Nozzle Multi-hole type(8x 0.24mm) Bosch KBL2.4 No
Electronic c ontrol fuel injection system (common rail type) Denso HP0 180MPa Electronic type Electronic type Injector Multi-hole type(8x 0.19mm) Denso G2 Installed
6WG1 Engine Specification Model Item
6WG1TQA TIER2
6WG1XQA0* TIER2
6WG1XYSA-0* TIER3
Fuel filter type
Cartridge(Filter paper type)
Cartridge(Filter paper type)
Filter paper type
Oil filter type Oil pump type
Full flow filter(Remote) Gear type
Full flow filter(Remote) Gear type
Full flow filter(Remote) Gear type
Oil cooling type Amount of engine oil
Water-cooling (L)
Total 42-52 (37-47 Oil Pan)
Cooling system method Cooling water full capacity
Total 42-52 (37-47 Oil Pan)
Water-cooled controlled circulation type
(L)
36
Water pump type
Centrifugal, belt type
Thermostat type Air cleaner type
2 wax-type units To be supplied by OEM
Generator capacity
(V-A)
Starter (V-kW) Turbocharger type Intercooler type Thermostat valve open temperature(10mm)
(
Total 42-57 (37-52 Oil Pan)
)
MITSUBISHI 24-50
MITSUBISHI 24-50
MITSUBISHI 24-50
MITSUBISHI 24-7.0 RHC9(IHI) Not Equipped
MITSUBISHI 24-7.0 RHC9(IHI) Equipped
MITSUBISHI 24-5.0 TD08H-31M (MHI) Equipped
83(95)
RETURN
6WG1 Engine Specification Model Item
6WG1TQA TIER2
6WG1XQA0* TIER2
6WG1XYSA-0* TIER3
Fuel filter type
Cartridge(Filter paper type)
Cartridge(Filter paper type)
Filter paper type
Oil filter type Oil pump type
Full flow filter(Remote) Gear type
Full flow filter(Remote) Gear type
Full flow filter(Remote) Gear type
Oil cooling type Amount of engine oil
Water-cooling (L)
Total 42-52 (37-47 Oil Pan)
Cooling system method Cooling water full capacity
Total 42-52 (37-47 Oil Pan)
(L)
36 Centrifugal, belt type
Thermostat type Air cleaner type
2 wax-type units To be supplied by OEM (V-A)
Starter (V-kW) Turbocharger type Intercooler type Thermostat valve open temperature(10mm)
(
Total 42-57 (37-52 Oil Pan)
Water-cooled controlled circulation type
Water pump type
Generator capacity
RETURN
MITSUBISHI 24-50
MITSUBISHI 24-50
MITSUBISHI 24-50
MITSUBISHI 24-7.0 RHC9(IHI) Not Equipped
MITSUBISHI 24-7.0 RHC9(IHI) Equipped
MITSUBISHI 24-5.0 TD08H-31M (MHI) Equipped
)
83(95)
RETURN
Engine Performance
30Hr
3.4 13.3
ISUZU 1380Nm 1580 47
1370 69Nm 1000min- 1
2000
1500min- 1
1800 )
m
N 1600 ( 1400 1200 1000
300
260 4kW 1800min- 1 250
T 200 U P T U O R E W150 O P
100
50 1900 30rpm 0 260
237 13.6g/ kWh 2000min-1
) W k / g 220 ( C F S 240 h
200 214 13.6g/kWh 1800 500
1000
1500
ENGINE SPEED(min-1)
2000
-1 180 2500
RETURN
Engine Performance
30Hr
3.4 13.3
ISUZU 1380Nm 1580 47
1370 69Nm 1000min- 1
2000
1500min- 1
1800 )
m
N 1600 ( 1400 1200 1000
300
260 4kW 1800min- 1 250
T 200 U P T U O R E W150 O P
100
50 1900 30rpm 0 260
237 13.6g/ kWh 2000min-1
) W k / g 220 ( C F 200 S 240 h
214 13.6g/kWh 1800 500
1000
1500
2000
-1 180 2500
ENGINE SPEED(min-1)
RETURN
Engine Layout / Main Parts EGR Valve
Main Fuel Filter (Tandem)
EGR Cooler
Common Rail
(Tandem)
Supply Pump (G Sensor)
RETURN
Engine Layout / Main Parts EGR Valve
Main Fuel Filter (Tandem)
EGR Cooler
Common Rail
(Tandem)
Supply Pump (G Sensor)
RETURN
Engine Layou yout / Main Parts
Turbocharger
Remote Oil Filter Port
RETURN
Engine Layou yout / Main Parts
Turbocharger
Remote Oil Filter Port
RETURN
Characteristics of Main Structure Components
RETURN
Characteristics of Main Structure Components
High Rigidity Rudder Frame
RETURN
High Rigidity
RETURN
Rudder Frame
RETURN
6WG1X Engine Noise (Tier 3 v.s. Tier 2)
100 98 96 94 92 90 88 86 84 600
800
1000
1200
1400
1600
1800
2000
2200
RETURN
6WG1X Engine Noise (Tier 3 v.s. Tier 2)
100 98 96 94 92 90 88 86 84 600
800
1000
1200
1400
1600
1800
2000
2200
RETURN
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
RETURN
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
RETURN
System Schematic (6WG1)
RETURN
System Schematic (6WG1)
RETURN
Comparison with Conventional System TWV: Two Way Valve
RETURN
Comparison with Conventional System TWV: Two Way Valve
RETURN
Common Rail System Characteristic
RETURN
Common Rail System Characteristic
RETURN
Fuel Injection Rate Control
RETURN
Fuel Injection Rate Control Conventional ConventionalInjection Injection
Pilot PilotInjection Injection
Injection rate
Large mixed combustion (NOx, noise)
Small mixed combustion
Generation rate of heat
Crank angle ( )
Crank angle ( )
RETURN
Fuel Injection Rate Control Conventional ConventionalInjection Injection
Pilot PilotInjection Injection
Injection rate
Large mixed combustion (NOx, noise)
Small mixed combustion
Generation rate of heat
Crank angle ( )
Crank angle ( )
RETURN
ECM Diagram (6WG1X)
Refer to Trouble Shooting Manual (NM1J 1-E-ENG-T)
RETURN
ECM Diagram (6WG1X)
Refer to Trouble Shooting Manual (NM1J 1-E-ENG-T)
RETURN
Control System
Refer to Trouble Shooting Manual
Actuator
Sensors Accelerator position Accelerator position Accelerator position sensor sensor Crankshaft Crankshaft position sensor position sensor Camshaft position Camshaft position sensor, sensor, G sensor G sensor Other sensors, Other sensors, Switches Switches
Injector Injector Engine speed
Cylinder identifying signal
Injection amount control Injection timing control Common rail Common rail pressure sensor pressure sensor
Supply pump Supply pump Injection pressure control
RETURN
Refer to Trouble Shooting Manual
Control System
Actuator
Sensors Accelerator position Accelerator position Accelerator position sensor sensor Crankshaft Crankshaft position sensor position sensor Camshaft position Camshaft position sensor, sensor, G sensor G sensor
Injector Injector Engine speed
Injection amount control Injection timing control Common rail Common rail pressure sensor pressure sensor
Cylinder identifying signal
Supply pump Supply pump
Other sensors, Other sensors, Switches Switches
Injection pressure control
RETURN
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 by the on-boad control module, using the performance map and according to the detected engine and ambient conditions.
RETURN
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 All control is calculated and set by the on-boad control module, using the performance map and according to the detected engine and ambient conditions.
Idling control QOS Self-diagnostic function CAN communication
RETURN
y¥x FUEL 0 QUONTIT 10 MM3/ ST 15 40 45 75 85 95 120
ENG SPEED rpm 0 400 550 50 30 30 50 30 30 50 30 30 50 30 30 50 40 40 50 50 50 50 50 50 50 50 50 50 50 50
600 40 40 40 40 40 50 50 50 50
700 50 50 50 50 50 50 50 50 50
950 65 50 50 65 65 65 65 65 65
975 1020 1030 1070 1090 1200 1300 80 80 85 85 90 90 90 80 80 85 85 90 90 90 80 80 85 85 90 90 90 80 80 85 85 90 90 90 80 80 85 85 90 90 90 80 80 85 85 90 90 90 80 80 85 85 90 90 90 80 80 85 85 90 90 90 80 80 85 85 90 90 90
150 Rail 100 Pressure (MPa)
100- 150 50- 100 0- 50
50 230
0 0
0 0 0 3 0 0 7 0 0 5 0 0 1 3 1 4 1 0 2
Engine speed (rpm)
95 0 0 0 5 3
Fuel Quontity (mm3/ st)
Rail Pressure
RETURN
y¥x FUEL 0 QUONTIT 10 MM3/ ST 15 40 45 75 85 95 120
ENG SPEED rpm 0 400 550 50 30 30 50 30 30 50 30 30 50 30 30 50 40 40 50 50 50 50 50 50 50 50 50 50 50 50
600 40 40 40 40 40 50 50 50 50
700 50 50 50 50 50 50 50 50 50
950 65 50 50 65 65 65 65 65 65
975 1020 1030 1070 1090 1200 1300 80 80 85 85 90 90 90 80 80 85 85 90 90 90 80 80 85 85 90 90 90 80 80 85 85 90 90 90 80 80 85 85 90 90 90 80 80 85 85 90 90 90 80 80 85 85 90 90 90 80 80 85 85 90 90 90 80 80 85 85 90 90 90
150 Rail 100 Pressure (MPa)
100- 150 50- 100 0- 50
50 230
0 0
0 0 0 3 0 0 7 0 0 5 0 0 1 3 1 4 1 0 2
95 0 0
Fuel Quontity (mm3/ st)
Rail Pressure
0 5 3
Engine speed (rpm)
RETURN
Fuel Injection at Starting Engine starting mode Starter signal ON Less than "N1" speed (rpm)
g n i k n a r c t a t n u o m a n o i t c e j n I
At low temperature
At high temperature
Engine speed
6WG1X N1=950rpm
RETURN
Fuel Injection at Starting Engine starting mode Starter signal ON Less than "N1" speed (rpm)
g n i k n a r c t a t n u o m a n o i t c e j n I
At low temperature
At high temperature
Engine speed
6WG1X N1=950rpm
RETURN
mm3/st
ECM adjust Starting Fuel Quantity by Coolant Temperature Sensor signal
(deg C)
RETURN
mm3/st
ECM adjust Starting Fuel Quantity by Coolant Temperature Sensor signal
(deg C)
RETURN
ECM adjust maximum Fuel Quantity by Atmospheric Pressure Sensor signal
RETURN
ECM adjust maximum Fuel Quantity by Atmospheric Pressure Sensor signal
RETURN
In addition Alarm raise above105 , Fuel Quantity decrease above 100 100
105
RETURN
In addition Alarm raise above105 , Fuel Quantity decrease above 100 100
105
RETURN
RETURN
RETURN
RETURN
RETURN
Satellite Communicatio n
Dr.ZX
ICF CAN Bus
MC
CAN Bus ECM
Tech2
RETURN
Satellite Communicatio n
Dr.ZX
ICF CAN Bus
MC
CAN Bus ECM
Tech2
RETURN
RETURN
RETURN
Common Rail System
)
RETURN
Common Rail System
)
RETURN
Injector
Common Rail
Injector Hole Diameter ZX450-3: 8- 0.19 ZX650/ 800-3: 8- 0.21
Supply Pump ECM
RETURN
Injector
Common Rail
Injector Hole Diameter ZX450-3: 8- 0.19 ZX650/ 800-3: 8- 0.21
Supply Pump ECM
RETURN
RETURN
RETURN
Can Lift Open Valve PCV Operation Close Valve Close Valve
To Common Rail
Delivery Valve Plunger
RETURN
Can Lift Open Valve PCV Operation Close Valve Close Valve
To Common Rail
Delivery Valve Plunger
RETURN
Circuit Relay
RETURN
Circuit Relay
RETURN
Common Rail Flow damper
Common rail pressure sensor
Pressure limiter
RETURN
Common Rail Flow damper
Common rail pressure sensor
Pressure limiter
RETURN
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.
Pressure limiter
Valve open
Valve closed
Abnormally high pressure Common rail pressure
RETURN
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.
Pressure limiter
Valve open
Valve closed
Abnormally high pressure Common rail pressure
RETURN
Sample of Rail Pressure Rail Pressure Sensor ) t s / 3 m m (
y t i t n a u Q l e u F
160MPa
100 – 150MPa
70 – 90MPa
30 – 60MPa
Rail Pressure Sensor Engine Speed (rpm)
RETURN
Sample of Rail Pressure Rail Pressure Sensor ) t s / 3 m m (
y t i t n a u Q l e u F
160MPa
100 – 150MPa
70 – 90MPa
30 – 60MPa
Rail Pressure Sensor Engine Speed (rpm)
RETURN
6WG1X Appx 130Mpa Fuel Quantity
Appx 30MPa
1800RPM
900RPM Engine Speed
RETURN
6WG1X Appx 130Mpa Fuel Quantity
Appx 30MPa
1800RPM
900RPM Engine Speed
RETURN
Flow damper Flow damper
Reduce the pressure pulsations in the pressurized line and also prevent abnormal discharge of fuel
Common rail
Piston
Injector
Ball
Spring
RETURN
Flow damper Flow damper
Reduce the pressure pulsations in the pressurized line and also prevent abnormal discharge of fuel
Common rail
Piston
Injector
Ball
Spring
RETURN
Flow Damper Operation (at Stop) Common rail
Piston
Injector
Ball
Spring
RETURN
Flow Damper Operation (at Stop) Common rail
Piston
Injector
Ball
Spring
RETURN
Flow Damper Operation (at Damping) Common rail
Piston
Injector
Ball
Spring
RETURN
Flow Damper Operation (at Damping) Common rail
Piston
Injector
Spring
Ball
RETURN
Flow Damper Operation (at Abnormal Discharge) Seat Common rail
Piston
Injector
Ball
Spring
RETURN
Flow Damper Operation (at Abnormal Discharge) Seat Common rail
Piston
Injector
Spring
Ball
RETURN
Injector Orifice 1
Orifice 2
Nozzle
Hydraulic piston
Orifice
Solenoid
RETURN
Injector Orifice 1
Orifice 2
Nozzle
Hydraulic piston
Orifice
Solenoid
RETURN
Injector Outline Common Common railrail pressure pressure sensor sensor
Leak
Orifice Common rail
Control chamber Hydraulic piston
Nozzle Supply pump Injection pressure control
RETURN
Injector Outline Common Common railrail pressure pressure sensor sensor
Leak
Orifice Common rail
Control chamber Hydraulic piston
Nozzle Supply pump Injection pressure control
RETURN
Injector Circuit Constant current circuit Constant current circuit
Charge circuit
RETURN
Injector Circuit Constant current circuit Constant current circuit
Charge circuit
RETURN
Injector Operation -- No Signal -Outer valve Inner valve
Orifice 1 Orifice 2 Common rail Hydraulic piston
Return No signal No signal
RETURN
Injector Operation -- No Signal -Outer valve Inner valve
Orifice 1 Orifice 2 Common rail Hydraulic piston
Return No signal No signal
RETURN
Injector Operation -- Signal Input -Outer valve Inner valve Valve open Orifice 1 Orifice 2
Return
Common rail Hydraulic piston
Signal input Signal input
RETURN
Injector Operation -- Signal Input -Outer valve Inner valve Valve open Orifice 1 Orifice 2
Return
Common rail Hydraulic piston
Signal input Signal input
RETURN
Injector Operation -- Injection Start -Outer valve Inner valve
Orifice 1 Orifice 2
Return
Common rail Hydraulic piston
Injection Start Injection Start
RETURN
Injector Operation -- Injection Start -Outer valve Inner valve
Orifice 1 Orifice 2
Return
Common rail Hydraulic piston
Injection Start Injection Start
RETURN
Injector Operation -- Signal Stop -Outer valve
Orifice 1 Orifice 2
Valve closed Return
Common rail Hydraulic piston
Signal stop Signal stop
RETURN
Injector Operation -- Signal Stop -Outer valve
Orifice 1 Orifice 2
Valve closed Return
Common rail Hydraulic piston
Signal stop Signal stop
RETURN
Injector Operation -- Injection Stop -Outer valve Inner valve
Orifice 1 Orifice 2
Return
Common rail Hydraulic piston
Injection stop Injection stop
RETURN
Injector Operation -- Injection Stop -Outer valve Inner valve
Orifice 1 Orifice 2
Return
Common rail Hydraulic piston
Injection stop Injection stop
RETURN
Injector Terminal
1. Injector 2. Injector Harness 3. Injector Terminal Nut
4HK1
RETURN
Injector Terminal
1. Injector 2. Injector Harness 3. Injector Terminal Nut
4HK1
Injector Current and Voltage 15A or more
Max. 130V
RETURN
Injector Current and Voltage
RETURN
15A or more
Max. 130V
RETURN
G sensor detects the G sensor Gear rotation and identifies the cylinder. G Sensor
CKP sensor detects the engine speed. Sensor
RETURN
G sensor detects the G sensor Gear rotation and identifies the cylinder. G Sensor
CKP sensor detects the engine speed. Sensor
RETURN
CKP Sensor Waveform
RETURN
CKP Sensor Waveform
RETURN
Sensor Waveform G Sensor
G Sensor Waveform
RETURN
Sensor Waveform G Sensor
G Sensor Waveform
RETURN
G(CMP), CKP(NE) Sensor Diagram (6 Cylinders)
RETURN
G(CMP), CKP(NE) Sensor Diagram (6 Cylinders)
RETURN
Common Rail Pressure Sensor
Common rail pressure
RETURN
Common Rail Pressure Sensor
Common rail pressure
RETURN
Boost Pressure Sensor
Electronic circuit
Silicon chip
Vacuum chamber
Filter Intake air pressure
Boost pressure
RETURN
Boost Pressure Sensor
Electronic circuit
Silicon chip
Vacuum chamber
Filter Intake air pressure
Boost pressure
RETURN
Engine Coolant Temperature Sensor
Engine coolant temperature
Fail-safe: Fail-safe:Changes Changesto to80 80 in incase caseof ofabnormality. abnormality.
RETURN
Engine Coolant Temperature Sensor
Engine coolant temperature
Fail-safe: Fail-safe:Changes Changesto to80 80 in incase caseof ofabnormality. abnormality.
RETURN
Fuel Temperature Sensor
Fuel temperature ( )
Fail-safe: Fail-safe:Takes Takesthe thevalue valueofofthe thewater watertemperature temperaturesensor sensorinincase case ofofabnormality. abnormality.
RETURN
Fuel Temperature Sensor
Fuel temperature ( )
Fail-safe: Fail-safe:Takes Takesthe thevalue valueofofthe thewater watertemperature temperaturesensor sensorinincase case ofofabnormality. abnormality.
RETURN
Intake Air Temperature Sensor
Intake air temperature ( C)
Fail-safe: Fail-safe:Takes Takesthe thevalue valueofofthe thewater watertemperature temperaturesensor sensorinincase case ofofabnormality. abnormality.
RETURN
Intake Air Temperature Sensor
Intake air temperature ( C)
Fail-safe: Fail-safe:Takes Takesthe thevalue valueofofthe thewater watertemperature temperaturesensor sensorinincase case ofofabnormality. abnormality.
RETURN
Cooled EGR To intercooler
Turbo
From air cleaner
To silencer
Exhaust manifold Coolant out
Engine
EGR cooler Coolant in
Intake manifold
EGR valve Reed valve From intercooler
ECM
RETURN
Cooled EGR To intercooler
Turbo
From air cleaner
To silencer
Exhaust manifold Coolant out
Engine
EGR cooler Coolant in
Intake manifold
EGR valve Reed valve From intercooler
ECM
RETURN
Layout
4.
RETURN
Layout
4.
RETURN
EGR Control
.
RETURN
EGR Control
.
RETURN
Gas Flow Control
RETURN
Gas Flow Control
RETURN
EGR Control
SENSOR OUTPUT
UVW INPUT
RETURN
EGR Control
SENSOR OUTPUT
UVW INPUT
RETURN
Priming Pump
Main Filter Pre. Filter
6WG1X : Tandem
Filter Wrench (Pre, Main common
RETURN
Priming Pump
Main Filter Pre. Filter
6WG1X : Tandem
Filter Wrench (Pre, Main common
RETURN
OIL PAN
Drain Cock
Drainer On Vehicle
RETURN
OIL PAN
Drain Cock
Drainer On Vehicle
RETURN
How to Replace Parts 1
Change sealing line Not Reuse
Name
2
4 5
3
1. Injector pipe 2. Flow damper 3. Common rail pressure sensor 4. Fuel temperature sensor 5. Pressure limiter
