ISUZU MOTORS LIMITED Off-highway Powertrain Operation Dept. Planning & Service Group
HITACHI CONSTRUCTION MACHINERY CO.,Ltd Technical Training Center April 2007
Table of contents
1. Differences between Tier2 engine and Tier3 engine. Differences between Tier2 engine and Tier3 engine. •‡ @
•@ •@
Off Road Emission Regulation Engine Specifications Engine Layout /Main Parts Engine Layout /Sensors •@ A• ‡ @Out @Out Line of Common Rail System Common Rail System •@ Comparison with Conventional System •@ ‡B• B@System @ • System Component @ • a@ • ECM@ • •@ •@ b•@SUPP SUPPLY LY PUMP PUMP •@ •@ c CO COMM MMON ON RAIL RAIL•@ • @ • •@ •@d•@INJECTOR•@ •@ @ • e•@HARNES HAR NESS S INJECTOR INJE CTOR @ • f SENSORS g COOLED•@EGR 2. 3. 4. •@
Maintenance Schedule Introduction of SST Trouble Shooting ‡ @ • Trouble Shooting Procedure
A• ‡ @How @How to use Trouble Shooting Manual 5. DTC code ‡ @ • DTC code
A• •@ ‡@ •@ B• ‡ B@ • •C• @ ‡ C@ •
Scan Tool EMPS How to use scan tool@ •
j 6. Point to notice notice on service service i• Parts replace procedure• 7. Trouble Shooting on actual machine
Table of contents
1. Differences between Tier2 engine and Tier3 engine. Differences between Tier2 engine and Tier3 engine. •‡ @
•@ •@
Off Road Emission Regulation Engine Specifications Engine Layout /Main Parts Engine Layout /Sensors •@ A• ‡ @Out @Out Line of Common Rail System Common Rail System •@ Comparison with Conventional System •@ ‡B• B@System @ • System Component @ • a@ • ECM@ • •@ •@ b•@SUPP SUPPLY LY PUMP PUMP •@ •@ c CO COMM MMON ON RAIL RAIL•@ • @ • •@ •@d•@INJECTOR•@ •@ @ • e•@HARNES HAR NESS S INJECTOR INJE CTOR @ • f SENSORS g COOLED•@EGR 2. 3. 4. •@
Maintenance Schedule Introduction of SST Trouble Shooting ‡ @ • Trouble Shooting Procedure
A• ‡ @How @How to use Trouble Shooting Manual 5. DTC code ‡ @ • DTC code
A• •@ ‡@ •@ B• ‡ B@ • •C• @ ‡ C@ •
Scan Tool EMPS How to use scan tool@ •
j 6. Point to notice notice on service service i• 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 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 CLASS EPA
EC
JP N
450 - 560 kW (600 - 750hp)
ENGINE
2001
2002 ¥ • Tier2
•|
2003
2004
2005
6W,6S
130 - 225 kW (175 - 300hp)
6H
•¥ Tier2
NOx+HC 6.6 CO 3.5 / P M 0.2
75 - 130 kW (100 - 175hp)
4H
•¥ Tier2
NOx+HC 6.6 CO 5.0 / P M 0.3
37 - 75 kW (50 - 100hp)
4J,4LE
130 - 560 kW
6W,6S,6H
75 - 130 kW
4H
37 - 75 kW
4J,4LE
19 - 37 kW
L
130 - 560 kW
6W,6S,6H
NOx 6.0 CO 3.5
/ HC 1.0 @ •@ •@ • / P M 0.2
¤ • T ier-2
75 - 130 kW
4H
NOx 6.0 CO 5.0
/ HC 1.0 @ •@ •@ • / P M 0.3
¤ • T ier-2
56 - 75 kW
4J
•¤ Tier2
•¥ St age2
•¥ Stage2
NOx 7.0 CO 5.0 37 - 56 kW
4LE
19 - 37 kW
L
NOx 8.0 CO 5.5
NOx 8.0 CO 5.5
•¤ Tier3
/ HC 1.0 / P M 0.2
•¥ Stage2
NOx 6.0 CO 5.0
/ HC 1.0 / P M 0.3
•¤ Stage2
NOx 7.0 CO 5.0
/ HC 1.5 •@ •@ • / P M 0.8@
¤ • T ier-2
2009
2010
NOx+HC 4.0 CO 3.5 PM 0.2
2011
2013
2014
2015
Nox+NMHC 4.0 CO 3.5 PM 0.03
interim Tier4 NOx+HC 4.0 CO 5.0 / PM 0.3
•¤ Tier3
interim Tier4
NOx+HC 4.7 CO 5.0 / PM 0.4
•¤ Tier3
•¤ Stage3-A
NOx+HC 4.0 CO 3.5 / PM 0.2
•¤ St age3-A
/ HC 1.3 / P M 0.4
56kw
NOx+HC 4.0 CO 5.0 / PM 0.3
•¤ Stage3-B
NOx+HC 4.7 CO 5.0 / PM 0.4
•¤ Stage3-A
NOx 3.6 CO 3.5
•¤ T ier-3
•¤ T ier-3
/ HC 0.4 / P M 0.17 NOx 3.6 CO 5.0
/ HC 0.4 / P M 0.2
• Tier-4 ¤ After treatment (DPF) basis
/ HC 0.7 / PM 0.25
•¤ Tier-3
NOx 4.0 CO 5.0
/ HC 0.7 / PM 0.3
LOW NOISE REQUIRMENT of EC STAGE-III
HC 1.0 PM 0.4
NOx+HC 4.0 CO 5.0 / PM 0.025
No pr opo sal as St age3-B
NOx 4.0 CO 5.0
/ /
interim NOx + HC 4.7 Tier4 CO 5.0 / PM 0.03
•¤ St age3-B neary same as EPA
•¤ Tier-3
Nox 6.0 CO 5.0
Nox+NM HC 4.0 CO 5.0 / PM 0.03
NOx+HC 4.0 CO 3.5 / PM 0.025
•¤ Stage3-B
NOx+HC 7.5 •¤ St age3-A CO 5.5 / PM 0.6
•¤ Tier-3
2012
interim Tier4
•¤ Tier3
/ HC 1.5 / P M 0.8
¤ • T ier-2
2008
interim Tier4
NOx+HC 7.5 CO 5.0 / P M 0.4
NOx 6.0 CO 3.5
/ HC 1.3 / P M 0.4 @ •@ •@ •
2007
•¤ Tier3
NOx+HC 6.4 CO 3.5 PM 0.2
225 - 450 kW (300 - 600hp)
•¥ Tier2
2006
NOx + HC: 40% reduction, PM: Same with Tier-2 from Y2006 JPN Government Proposal: PM 30% lower than EPA, EC T-3
K ey Technolog ies of Dies el E ng ine E G R = E xhaus t G as R e-circulation E G R V alve
EEGGRR Technology Technology
Nois Noisee Technolog Technology y Inlet Manifold r e l o o C r e t n I
Injection Injection SSys ystem tem
Total Total eng engine ine technolog technology y -Combus tion chamber -Combus tion chamber -Turbo-charging -Turbo-charging etc. etc.
BBas asee Technolog Technology y Friction Friction RReduction eduction
E G R C o o l e r s a G R G E
Exhaust Manifold Turbo-Charging Turbo-Charging Technology Technology A ir
Tier 3 applied New Technology
Total Total EElectronic lectronic CControl ontrol
Fuel Fuel Improvement Improvement
.
h W k / g @ • M P
Tier 2 trade-off
Tier 3 trade-off 160MPa pressure Cooled EGR Electronic control
Tier 3
70MPa pressure Inter cooler
Tier 2
JPN Tier-3 (plan) Engine Modification Limit
NOx + HC g/kWh
4JJ1X Exhaust Emission and Fuel Consumption
Basic Information of Tier 3 Engine
•¨ Electronic Controlled Engine
1. 2. 3. 4.
Tier 2 Engine Comparison Electronic Control Common Rail System Cooled EGR
4JJ1X Engine Specifications
Performance Performanceof of 4J 4JJJ1X 1X vs vs.. 4B 4BGG1TC 1TC
Model Item
4HK1X
Engine model Rated output Maximum torque Cylinder arrangement and number – bore × stroke Displacement Compression ratio Compression pressure Dimensions (length × width × height) Weight Fuel injection order Injection pump type Governor type Timer type Nozzle type
(kW/min-1) (Nm/min-1)
Water cooled, 4-cycle, inline 4-cylinder OHC, direct injection diesel 147/2100, 12.6/2000 686/1500, 677/1500
Model Item
4HK1X
Fuel filter type Filter paper type Oil filter type Oil pump type Oil cooling type
Full flow filter Gear type
L4-ƒÓ 115×125 (mm) (L)
5,193 17.5
MPa (psi)/rpm (mm) (kg)
3.23 (468)/200 1043.2×829×1011.8 478 1-3-4-2 Electronic control fuel injection system (common rail type) Electronic type Electronic type Multi-hole type
Water-cooling Amount of engine oil Cooling system method Cooling water full capacity Water pump type
(L)
(L)
14 Centrifugal, belt type
Thermostat type Air cleaner type Generator capacity Starter Turbocharger type Intercooler type
Oil pan•F13.0-20.5 Water-cooled controlled circulation type
2 wax-type units Filter paper type (V-A) (V-kW)
Thermostat valve open temperature (•Ž ) Exhaust gas recirculation device (EGR)
24-50 24-5.0 RHF-55 (IHI) Aluminium tube and end plate type 82 Installed
Model Item
6HK1X
Engine model Rated output Maximum torque Cylinder arrangement and number – bore × stroke Displacement Compression ratio Compression pressure Dimensions (length × width × height) W eight Fuel injection order Injection pump type Governor type Timer type Nozzle type
(kW/min-1) (Nm/min-1)
W ater cooled, 6-cycle, inline 4-cylinder, OHC, direct injection diesel 208/1900 1125/1500
Model Item
6HK1X
Fuel filter type Filter paper type Oil filter type Oil pump type Oil cooling c ooling type type
Full flow filter Gear type
L6-ƒ L6-Ó ƒ 115×125 (mm) (L)
7,790 17.5
MPa (psi)/rpm (mm) (kg)
304(441)/200 1356.5×995.4×1178 650 1-5-3-6-2-4 Electronic control fuel injection system (common rail type) Electronic type Electronic type Multi-hole type
Water-cooling Amount of engine oil Cooling system method Cooling water full capacity Water pump type
(L)
(L)
14.5 Centrifugal, belt type
Thermostat type Air cleaner type Generator capacity Starter Turbocharger type Intercooler type
28-38 W ater-cooled controlled circulation type
2 wax-type units Filter paper type (V-A) (V-kW )
Thermostat valve open temperature (•Ž ) Exhaust Exhaust gas recirculation device (EGR)
24-120 24-5.0 RHG6(IHI) Aluminium tube and endplate type 82 Installed
6WG1 Engine Specification Model Item Engine model Rated output Maxim um torque Cylinder arrangement and number – bore bore × stroke Dis plac ement
(kW /m in-1) (Nm /min-1)
6 WG1TQA
6WG1 XQA
TIER2 Water cooled, 4-cycle, inline 4-cylinder, OHC, direct injection diesel 235.4/1800 1275/1500
TIER2 Water cooled, 4-cycle, inline 4-cylinder, OHC, direct injection diesel 295/1800 1540/1500
(mm)
L6L6-ƒ Ó 147×154
(L)
15,681
Compression ratio
16.4
Compr Compressi ession on pressu pressure re MPa(p Pa(psi)/ si)/rp rpm m Dimensions (m m ) (length × width × height) W eight (kg) Fuel injection order Injection pump type Injection pressure press ure Governor type Timer type Nozzle type
6WG1XYSA-01 TIER3 Water cooled, 4-cycle, inline 4-cylinder, 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
1153
Mechanical fuel injection pump (Inline fuel injection pump) BOSCH PE-P-S3S 1 7.7/ 2 2.1 RSV type Equipped
1185 1-5-3-6-2-4 Mechanical fuel injection pump (Inline fuel injection pump) BOSCH PE-P-S3S 1 7 .7/ 2 2.1 RSV type Equipped
2Stage Nozz Nozzle le Multi-hole type(8xƒ type(8xƒ 0.24mm)) Ó 0.24mm Bosch KBL2.4
2Stage Nozzle Multi-hole type(8xƒ type(8xƒ 0.24mm)) Ó 0.24mm Bosch KBL2.4
Electronic control c ontrol fuel fuel injection system (common rail type) Denso HP0 18 0MPa Elec tronic type Elec tronic type Injector Denso G2 Multi-hole type(8xƒ type(8xƒ Ó 0.19mm)ZX450 Multi- hole type(8xƒ Ó 0.21mm)ZX600/800
6WG1 Engine Specification Model Item
6WG1TQA
6WG1XQA0*
TIER2
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 Amou Amount nt of engi engine ne oil oil
Water-cooling (L)
Total Total 42-52 42-52 (37-47 (37-47 Oil Pan) Pan)
Cooling Cooling system syst em method m ethod Cooling water full capacity
Total Total 42-52 42-52 (37-47 (37-47 Oil Pan) Pan)
Water-coole Water-c ooled d control c ontrolled led circulatio circ ulation n type
(L) (L)
36
Water pump type
Centrifugal, belt type
Thermostat type Air Air cleane cleanerr type type
2 wax-type units @ • To be sup supp plied lied by by OEM OEM
Generator capacity
(V-A)
Starter (V-kW) Turbocharger type Intercooler type Thermostat valve open temperature(10mm)
(Ž • )
Tota Totall 42-5 42-57 7 (37 (37-52 -52 Oil Pan) 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)
4JJ1X 4JJ1X Right Right Side Side View View Charged Air Outlet Exh Gas Outlet
(to Inter Cooler) Turbocharger
Built in Oil Cooler
SAE #3 HSG
Alternator
Oil Filter
4JJ1X 4JJ1X Left Left Side Side View View Multiple Injection Common Rail Oil Filler Cap
Confidential Aluminum Cylinder Head Charged Air Inlet (from Inter Cooler)
Water Outlet Common Rail Bell Mouth Fan Shroud (Opt.) Water Inlet Big Capacity Oil Pan
Starter Common Rail Supply Pump
TURBO CHARGER
COOLED EGR
INJECTOR (Inside of HD COV)
Common Rail Supply Pump
Remote Oil Filter
EGR Valve
Main Fuel Filter (Tandem)
EGR Cooler
Common Rail
(Tandem)
Supply Pump (G Sensor)
Turbocharger
Remote Oil Filter Port
4BG1T 4BG1T vs vs 4JJ1X 4JJ1X base base structure structure
DOHC 4 Valves Roller Follower
Multiple Injection Common Rail
(EGR Cooler) (Electronic Control EGR Valve) Built in Oil Cooler Aluminum Cylinder Head
4JJ1X SECTION VIEW
TIMING CHAIN (EGR PORT)
TIMING GEAR
4JJ1X SECTION VIEW
4JJ1X TIMING TRAIN CAM SHAFT ; EXHAUST
CAM SHAFT ; INLET
TIMING CHAIN
Oil Drain speed improved
FUEL SUPPLY PUMP
VACUUM PUMP (For Vehicle Use Only) CRANK
P/S PUMP (For Vehicle Use Only)
OIL PUMP
Crank case removal needs to remove Cyl Head Cyl Head
Cyl Body
Gear Case Assy
Crank Case Oil Pan
(Lubrication for improv ed abrasion resistance) (High rigidity of cylinder head) (Improved combustion, High power, High rigidity)
Ê Roughness 5ƒ
Roughness 3ƒÊ (Reduced oil consumption)
/ /
80/64
6BG1TC
(High rigidity, High power)
4/6HK1TC
82/73
(High pow er)
6WG1X
Nois Noiseecomparis comparison on 4J 4JJJ1X 1X vs vs.. 4B 4BGG1TC 1TC
9 5
dB 3 Reduct
4JJ1X
9 0
•œ•\
\• •œ
ion
8 5
4BG1TC
8 0
7 5 J un.17.'0 5
7 0 6 0
8 0
10 0
12 0
140 0
160 0
18 0 0
2 0 0
20 0
2400
26 0
Lubrication Lubrication cons consumption umption of of oil oil 4J 4JJJ1X 1X vs vs.. 4B 4B1TC 1TC
4BG1TC 4JJ1X
4JJ1X oil consumption
30% reduction in ISUZU test
-
4JJ1X Sensor/Actuator layout
4HK1X Sensor Locations Boost pressure sensor G (cam) sensor Crank sensor Coolant temperatur e sensor Common rail pressure sensor Boost temperature sensor Oil pressure sensor
Fuel temperature sensor •kVehicle equipment•l E Ambient temperature sensor •@ E Atmospheric pressure sensor •@
Ambient Temperature Sensor
Vehicle Front Side Atmospheric Pressure Sensor Air Cleaner
Coolant Temperature
Engine LH
Engine Rear
6H
Common Rail Pressure
Boost Temperature
Fuel Temperature
Boost Pressure
Oil Pressure
4H
Crank Position
Cam Position
6WG1X 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
Engine Control •@
Basic Injection Control •i Injection Quantity• AInjection Pressure• AInjection Timing• AInjection Rate• j
•@ Fuel Injection Compensation AAltitude Compensation• AOver Heat• j •i Starting Fuel Compensation•
•@EGR •@Another Engine Control •@
Idling control
•@
QOS
•@
Self-diagnostic function
@
CAN communication
mm3/st• j
ECM adjust Starting Fuel Quantity by Coolant Temperature Sensor signal
G ƒ “ƒ W ƒ “ƒ N ƒ [• ‰ ƒ “ƒ gƒ‰ · “x
(deg C)
ECM adjust maximum Fuel Quantity by Atmospheric Pressure Sensor signal
In addition Alarm raise above 105 , Fuel Quantity decrease above 100 100
105
6H/4HK1/4JJ1
Q Trim
Torque 1000RPM
1500RPM
RPM
2000RPM
Satellite Communicatio n
ICF CAN Bus
MC
CAN Bus ECM
Dr.ZX
Common Rail
Supply Pump
Injector
ECM
Common Rail
Injector
Supply Pump ECM )
Exploded View
SCV
IN
Filter Fuel temperature sensor Feed pump Regulating valve
Pump body Ring cam Camshaft
OUT
Injector
Common Rail
Injector Hole Diameter ZX 450-3: 8-ƒ³0.19•@ ZX 650/800-3: 8-ƒ³0.21
Supply Pump ECM
Can Lift Open Valve PCV Operation Close Valve Close Valve
To Common Rail
Delivery Valve Plunger
Flow damper
Common rail pressure sensor
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
Sample of Rail Pressure
j •i Rail Pressure Sensor•
) t s / 3 m m (
160MPa
y t i t n a u Q l e u F
100 – 150MPa
70 – 90MPa
30 – 60MPa
Rail Pressure Sensor Engine Speed (rpm)
6HK1
Approx. 160MPa
Q
Approx. 30MPa 2000RPM
900RPM
RPM
Flow damper
Reduce the pressure pulsations in the pressurized line and also prevent abnormal discharge of fuel
CMP sensor detects the camshaft rotation and identifies the cylinder.
CKP sensor detects the engine speed.
‚df‚ ‚q
Layout
4.
Negative Positive High Press. Over Flow
Engine
Fuel Cooler
Fuel Tank
Common Rail
Pre. Filter
Main Filter
Feed Pump
Fuel Pumo
Plunger Regulator Supply Pump
Fuel Pump Pre. Filter
Filter Wrench (Pre, Main common
Main Filter Priming Pump
OIL PAN• j
Drain Cock
Drainer i
hicl j
Change sealing line Not Reuse
