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RETURN

RETURN

ISUZU INDUSTRIAL DIESEL ENGINE


6WG1X Tier3

ISUZU MOTORS LIMITED HITACHI CONSTRUCTION MACHINERY CO.,Ltd


Off-highway Powertrain Operation Dept. Planning Technical Training Center
& Service Group
RETURN
Table 1. Differences between Tier2 engine and Tier3 engine.
of   ① Differences between Tier2 engine and Tier3 engine.
      Off Road Emission Regulation
contents       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
  a ECM                 
     b SUPPLY PUMP
     c COMMON RAIL                         
     d INJECTOR             
     e HARNESS INJECTOR
  f SENSORS
g COOLED EGR
2. Maintenance Schedule
3. Introduction of SST
4. Trouble Shooting
   ① Trouble Shooting Procedure
② How to use Trouble Shooting Manual
5. DTC code
① 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 
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 Regulation
CLASS ENGINE 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015

450 - 560 kW int erim


EP A − ▼ T ier2 ▽ T ier3
(600 - 750hp) NOx+HC 6.4 T ier4
CO 3.5
NOx+HC 4.0 Nox+NMHC 4.0
225 - 450 kW PM 0.2 int erim
6W,6S ▼ T ier2 ▽ T ier3 CO 3.5 CO 3.5
(300 - 600hp) T ier4
PM 0.2 P M 0.03
130 - 225 kW NOx+HC 6.6 int erim
6H ▼ T ier2 ▽ T ier3
(175 - 300hp) CO 3.5 / P M 0.2 T ier4

75 - 130 kW NOx+HC 6.6 NOx+HC 4.0 Nox+NM HC 4.0


4H ▼ T ier2 ▽ T ier3 CO 5.0 / P M 0.03
(100 - 175hp) CO 5.0 / P M 0.3 CO 5.0 / P M 0.3 int erim
T ier4
NOx+HC 7.5 NOx+HC 4.7
37 - 75 kW
4J,4LE ▽ T ier2 CO 5.0 / P M 0.4 ▽ T ier3 CO 5.0 / P M 0.4 int erim NOx + HC 4.7
(50 - 100hp) 56kw
T ier4 CO 5.0 / P M 0.03

NOx 6.0 / HC 1.0 NOx+HC 4.0 NOx+HC 4.0


EC 130 - 560 kW 6W,6S,6H ▼ St age2 ▽ St age3-A ▽St age3-B
CO 3.5 / PM 0.2 CO 3.5 / PM 0.2 CO 3.5 / P M 0.025

NOx 6.0 / HC 1.0 NOx+HC 4.0 NOx+HC 4.0


75 - 130 kW 4H ▼ St age2 ▽ St age3-A ▽ St age3-B CO 5.0 / P M 0.025
CO 5.0 / P M 0.3 CO 5.0 / P M 0.3

NOx 7.0 / HC 1.3 NOx+HC 4.7


37 - 75 kW 4J,4LE ▽ St age2 CO 5.0 / P M 0.4 ▽ St age3-A CO 5.0 / P M 0.4 ▽ St age3-B neary same as EPA

NOx 8.0 / HC 1.5 NOx+HC 7.5


19 - 37 kW L ▼ St age2 ▽ St age3-A CO 5.5 / P M 0.6 No proposal as St age3-B
CO 5.5 / P M 0.8

NOx 6.0 / HC 1.0 NOx 3.6 / HC 0.4


JP N 130 - 560 kW 6W,6S,6H      ▽ T ier-2 ▽ T ier-3 ▽T ier-4
CO 3.5 / PM 0.2 CO 3.5 / P M 0.17
Aft er t reat ment
(DP F) basis
NOx 6.0 / HC 1.0 NOx 3.6 / HC 0.4
75 - 130 kW 4H      ▽ T ier-2 ▽ T ier-3
CO 5.0 / PM 0.3 CO 5.0 / P M 0.2

NOx 4.0 / HC 0.7


56 - 75 kW 4J ▽ T ier-3 CO 5.0 / PM 0.25
NOx 7.0 / HC 1.3
CO 5.0 / PM 0.4 NOx 4.0 / HC 0.7
37 - 56 kW 4LE      ▽ T ier-2 ▽ T ier-3 CO 5.0 / PM 0.3

NOx 8.0 / HC 1.5 Nox 6.0 / HC 1.0


19 - 37 kW L T ier-2 ▽ T ier-3
CO 5.5 / P M 0.8     ▽ CO 5.0 / 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 stage engines include lower noise level for customer's application.
RETURN

Tier3 Emission Regulation (130kW∼)

EPA/EC Tier-3
130kW∼(2006)
JPN Tier-3
130kW∼(2006) EPATier-2
130kW∼(2003)
0.3


PM
(g/kwhr)
0.2

EPA Tier-4
(2012)
0.1
EC StageⅢ-B
(2012)

2.0 4.0 6.0 8.0


NOx+ HC (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 = Exhaust Gas Re-circulation Total
Total engine
engine technology
technology
EGR Valve -Combustion
-Combustion chamber
chamber
EGR
EGR Technology -Turbo-charging
Technology -Turbo-charging etc.
etc.
Noise
Noise Technology
Technology

EG
R
Co
Inlet Manifold Base Total
Total Electronic
Electronic Control
Base Technology Control

ol
Technology

e
Friction
Friction Reduction

r
Injection Reduction
Injection System
Inter Cooler

System

EGR Gas
Fuel
Fuel Improvement
Improvement

Exhaust Manifold
Turbo-Charging
Turbo-Charging
Technology
Technology

Air
RETURN

Technologies and Emission Level (130kW∼)


0.4
Tier 3 trade-off
130MPa pressure
Cooled EGR
Tier 2 trade-off
PM g/kWh

Electronic control
0. 70MPa pressure
 Inter cooler

Tier 3
0.
Tier 2
JPN Tier-3
Engine Modification
0. Limit


0 1. 2. 3. 4. 5. 6.
NOx + HC g/kWh
RETURN

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)
RETURN

Basic Information of Tier 3 Engine

• Low Emission
• Low Noise → Electronic Controlled Engine
• High Power

1. Tier 2 Engine Comparison


2. Electronic Control
3. Common Rail System
4. Cooled EGR
RETURN

6WG1 Engine Specification


Model 6WG1TQA 6WG1XQA 6WG1XYSA-01
Item TIER2 TIER2 TIER3
Water cooled, 6-cycle, inline Water cooled, 6-cycle, inline Water cooled, 6-cycle, inline
Engine model 4-cylinder, OHC, 4-cylinder, OHC, 4-cylinder, OHC,
direct injection diesel direct injection diesel direct injection diesel
Rated output (kW/min-1) 235.4/1800 295/1800 260/1800
Maximum torque (Nm/min-1) 1275/1500 1540/1500 1580/1500
Cylinder arrangement
and number (mm) L6-φ147×154
– bore × stroke
Displacement (L) 15,681
Compression ratio 16.4 16

Compression pressure MPa(psi)/rpm 2.75(400)/200


Dimensions
(mm) 1462×1007×1287(with fan) 1741×1016×1340(with fan) 1462×1015×1422(with fan)
(length × width × height)
Weight (kg) 1125 1185 1153
Fuel injection order 1-5-3-6-2-4
Mechanical fuel injection pump Mechanical fuel injection pump Electronic control fuel injection
Injection pump type (Inline fuel injection pump) (Inline fuel injection pump) system (common rail type)
BOSCH PE-P-S3S BOSCH PE-P-S3S Denso HP0
Injection pressure 17.7/22.1 17.7/22.1 180MPa
Governor type RSV type RSV type Electronic type
Timer type Equipped Equipped Electronic type
2Stage Nozzle 2Stage Nozzle Injector
Nozzle type Multi-hole type(8xφ0.24mm) Multi-hole type(8xφ0.24mm) Multi-hole type(8xφ0.19mm)
Bosch KBL2.4 Bosch KBL2.4 Denso G2
Exhaust gas recirculation device (EGR) No No Installed
RETURN

6WG1 Engine Specification


Model 6WG1TQA 6WG1XQA0* 6WG1XYSA-0*
Item TIER2 TIER2 TIER3

Fuel filter type Cartridge(Filter paper type) Cartridge(Filter paper type) Filter paper type

Oil filter type Full flow filter(Remote) Full flow filter(Remote) Full flow filter(Remote)
Oil pump type Gear type Gear type Gear type

Oil cooling type Water-cooling

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 system method Water-cooled controlled circulation type
Cooling water full
(L) 36
capacity
Water pump type Centrifugal, belt type
Thermostat type 2 wax-type units
Air cleaner type  To be supplied by OEM

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 24-5.0


Turbocharger type RHC9(IHI) RHC9(IHI) TD08H-31M (MHI)
Intercooler type Not Equipped Equipped Equipped
Thermostat valve open
(℃) 83(95)
temperature(10mm)
RETURN

Engine
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
プー リー 比 −
日立建機(株)殿向け 361型45t
搭載AH-6WG1XY
Performance
ク‐リングファン 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 ゾー ス トサ イレンサ ー 付(13.3kPa)


 )内ISUZU目標値
2000
1380Nm以上/約1500min-1
1370±69Nm/1000min-1)
( 1800

軸トル ク(Nm)
(1580±47)
1600
1400
1200
1000

300

260±4kW/
1800min-1
250
POWER OUTPUT(kW)

200

150

100

50

1900±30rpm

260
237±13.6g/kWh以下 /

SFC(g/kWh)
2000min-1 240

220

200
214±13.6g/kWh@1800mi
n-1
180
500 1000 1500 2000 2500
ENGINE SPEED(min-1)
RETURN

Engine Layout /Main Parts


EGR Valve Main Fuel Filter
(Tandem)

Common Rail
EGR Cooler
(Tandem)

Supply Pump
(G Sensor)
RETURN

Engine Layout /Main Parts

Turbocharger

Remote Oil Filter Port


RETURN

Characteristics of Main Structure Components


Cooled EGR
OHC 4VALVE
High Rigidity of Maximum
Cyl. Head Inj.Pressure
130MPa
Electronic Cont.
Common Rail
High Efficiency
Turbocharger High Rigidity
(no Waste Gate) Rudder Frame

Symmetry
High High
Rigidity Rigidity
C.Block C. Shaft
RETURN
High Rigidity
(Rudder Frame)
RETURN

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


SOUND PRESSURE LEVEL ENG.TYPE AH−6WG1X
*** AVERAGE *** 6WG1X-Tier2と
Comparisonの比較
with TierF
2AN無

●――――●
100 6WG1X-Tier3
SPL-AVE (FULLLOAD) dB(A)

Fan : none
FAN: 無
98

96

94 ×- - - - -×
6WG1X-Tier2
92 FAN:
Fan 無
: none
90
36WG1X-Tier2比
db(A) lower
約3dB(A)の
88 低騒音ホ ゚テ ンシ
Than Tier 2 ャル
86

84
600 800 1000 1200 1400 1600 1800 2000 2200
ENGI
NE SPEED (r
pm)
RETURN

Sensor Layout

Refer to
6WG1 Engine Troubleshooting
Name Manual (NM1J1-E-ENG-T)  1E-98
1.Pressure Control Valve
2. Fuel Temperature Sensor 7. EGR Valve
3. G Sensor (Cam speed) 8. Boost Pressure Sensor
4. Boost Temperature Sensor 9. CKP Sensor (Crank speed)
5. Common Rail Pressure Sensor 10. Engine Oil Pressure sensor
6. Engine Coolant Temp. Sensor 11. Overheating Switch
RETURN

System Schematic (6WG1)


Common Rail Pressure Sensor Pressure Limiter

Common Rail

Supply Pump

Injector

ECM

CKP Sensor
RETURN

Comparison with Conventional System


TWV: Two Way Valve
RETURN

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.
RETURN

Fuel Injection Rate Control

6WG1X Tier3 apply Main & Pilot Injection only


RETURN

Fuel Injection Rate Control


Conventional
ConventionalInjection
Injection Pilot
PilotInjection
Injection

Injection rate

Small mixed
Large mixed combustion
combustion
(NOx, noise)

Generation
rate of heat

Crank angle (°) Crank angle (°)

Pilot Injection reduce NOx and Noise


RETURN

ECM Diagram (6WG1X)

 Refer to
Trouble Shooting
Manual
 (NM1J1-E-ENG-T)

  1E−108
RETURN
 Refer to
Control System Trouble Shooting Manual
   1E−88

Sensors Actuator

Accelerator position
Accelerator position
Accelerator position Injector
Injector
sensor
sensor
Engine speed ・Injection amount control
Crankshaft
Crankshaft ・Injection timing control
position
positionsensor
sensor
Common rail
Cylinder identifying Common rail
pressure sensor
Camshaft signal pressure sensor
Camshaftposition
position
sensor,
sensor,
GGsensor
sensor
Supply
Supplypump
pump
Other
Othersensors,
sensors,
Switches ・Injection pressure control
Switches
RETURN

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)
 EGR
 Another Engine Control
All control is calculated and set by
   Idling control the on-boad control module, 
   QOS using the performance map and
according to the detected engine
   Self-diagnostic function and ambient conditions.  
   CAN communication
RETURN

ECM Engine Data Map


ENG SPEED rpm
y¥x 0 400 550 600 700 950 975 1020 1030 1070 1090 1200 1300
FUEL 0 50 30 30 40 50 65 80 80 85 85 90 90 90
QUONTITY 10 50 30 30 40 50 50 80 80 85 85 90 90 90
MM3/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 90
45 50 40 40 40 50 65 80 80 ECM
85 has85several
90 Engine
90 90 Control
75 50 50 50 50 50 65 80 80 85Data85Map90 90 90
85 50 50 50 50 50 65 80 80 85 85 90 90 90
95 50 50 50 50 50 65 80 80 ①Base
85 Map−Engine Speed
85 90 90 90 v.s.
Rail
120 50 50 50 50 50 65 80 80 85 85 90 90 90
  Pressure, Fuel Quantity etc
②Compensation Map−Coolant
Temp. Atmospheric Pressure
150 etc

Rail
100 100-150
Pressure
(MPa) 50-100
50 0-50
230
0 95 Fuel Quontity
Rail Pressure
0
700

(mm3/st)
1030
1300
1450

0
2000
3500

Engine speed (rpm)


RETURN

Fuel Injection at Starting

Injection amount at cranking


At low temperature
Engine starting mode

Starter signal ON
Less than "N1"
speed (rpm) At high temperature

Engine speed

6WG1X N1=950rpm
RETURN

Startig Fuel Quantity Adjust

Starting始動燃料流量補正
Fuel Quantity
(mm3/st)

ECM adjust Starting Fuel Quantity by Coolant Temperature Sensor signal

(deg C)
Engine エンジンクーラント 温度
Coolant Temp.
RETURN

High Altitude Correction


Maximum Fuel
Quantity

ECM adjust maximum Fuel Quantity by Atmospheric Pressure Sensor signal

Atmospheric Pressure
High Altitude
RETURN

Over Heat Control


In addition Alarm raise above105℃,
Fuel Quantity decrease above 100℃
100℃

Fuel Quantity

105℃
Engine Coolant
Engine Temp.
Coolant Temp.
RETURN

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.
RETURN

Pre-Heat Time

Engine Coolant Temp.


RETURN

CANCommunication Circuit
All ECU on Vehicle connected through CAN Communication Circuit
○MC:Main Controller
Satellite Dr.ZX
Communicatio
○ECM:Engine Control Module n

ICF
○ICF:Information Controller
Monitor Unit
   CAN Bus

○Monitor Unit

MC
CAN(Controller Area Network)
communicate
・Target Engine Speed CAN Bus
・Engine and Vehicle Trouble Code ECM
・Monitoring Engine and Vehicle Operating
Condition Tech2
RETURN

ECM Connect
orRemoval

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

Common Rail System(


PCV)
Common Rail Pressure Sensor Pressure Limiter

Common Rail

Supply Pump
(PCV)

Injector

ECM

CKP Sensor
RETURN

Common Rail System Main Parts


Common Rail Injector

Injector Hole Diameter


ZX450-3: 8-Φ0.19 
ZX650/800-3: 8-Φ0.21

PCV : Pressure Control Valve


Supply Pump
ECM
G Sensor (Cam speed)
RETURN

Supply Pump(PCV type)

(Pressure Control Valve)

Feed Pump   GSensor Gear    


RETURN

Supply Pump (PCV) operation


Intake Stroke Pumping Stroke

Can Lift

Open Valve

PCV Operation Close Valve

Close Valve

To Common Rail

Delivery Valve
Plunger
RETURN

PCV Circuit
PCVRelay
RETURN

Common Rail
Flow damper

Common rail
pressure sensor
Pressure limiter
RETURN
Pressure Limiter opens to release the pressure
Pressure Limiter 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)
Fuel Quantity (mm3/st)

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

Flow damper Reduce the pressure pulsations in the pressurized


line and also prevent abnormal discharge of fuel
Flow damper

Common rail Injector

Piston Ball Spring


RETURN

Flow Damper Operation (at Stop)

Common rail Injector

Piston Ball Spring


RETURN

Flow Damper Operation


(at Damping)
Common rail Injector

Piston Ball Spring


RETURN

Flow Damper Operation


(at Abnormal Discharge)
Seat
Common rail Injector

Piston Ball Spring


RETURN

Injector
Orifice 1

Orifice 2

Nozzle Hydraulic piston Orifice Solenoid


RETURN

Injector Outline

Common
Common railrail
pressure Leak
pressure sensor
sensor

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 Operation
-- No Signal --
Outer valve
Inner valve

Orifice 1
Return
Orifice 2

Common rail No signal


No signal
Hydraulic piston
RETURN

Injector Operation
-- Signal Input --
Outer valve
Inner valve

Valve open
Orifice 1
Return
Orifice 2

Common rail
Hydraulic piston
Signal
Signalinput
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
-- Signal Stop --
Outer valve

Orifice 1 Valve closed


Orifice 2 Return

Common rail
Hydraulic piston

Signal stop
Signal stop
RETURN

Injector Operation
-- Injection Stop --
Outer valve
Inner valve

Orifice 1
Return
Orifice 2

Common rail
Hydraulic piston

Injection
Injectionstop
stop
RETURN

Injector Terminal

High Voltage applied on the


Injector (above118V)
Battery cable must be disconnected
during Injector related work.

1. Injector
2. Injector Harness
3. Injector Terminal Nut

4HK1
RETURN

Injector Current and Voltage


15A or more

Max. 130V
RETURN

CKP(Crank Position) Sensor


G(Pump Position) Sensor

Amp回路 G sensor detects the G sensor Gear


rotation and identifies the cylinder.

G Sensor

Amp回路

CKP sensor detects the engine


speed.
CKPSensor
RETURN

CKP Sensor Waveform


RETURN

G Sensor Waveform
G Sensor

No.1 cylinder TDC


Recognition pulse
G Sensor Waveform
RETURN

G(CMP), CKP(NE) Sensor


Diagram (6 Cylinders)
No.6 cylinder No.1 cylinder
TDC standard pulse No.1 cylinder TDC TDC standard pulse
Recognition pulse

No.1 cylinder No.6 cylinder No.1 cylinder


NE standard pulse NE standard pulse NE standard pulse
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

Engine Coolant Temperature Sensor

Engine coolant temperature

Fail-safe:
Fail-safe:Changes
Changesto
to80℃
80℃inincase
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

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
EGR stands for ”Exhaust Gas Recirculation”.
This equipment lowers burning temperature by
mixing some of the emitted exhaust gas with To intercooler

the intake air to control oxygen concentration Turbo


in the combustion chamber slowing down
combustion. From air cleaner To silencer
This enables reduction of nitrogen oxide
or ”NOx”which is produced during high- Exhaust manifold
temperature combustion. Cooled EGR system
is a system which equips cooling system in the Coolant out

EGR gas passages.


Engine EGR cooler
This system contributes reduction of NOx by
further lowering the burning temperature than Coolant in
normal EGR with cooling down the heated
EGR gas with cooler before mixing with the Intake manifold

intake air.
Moreover, by cooling down the high EGR valve
temperature EGR gas, intake air concentration Reed valve
is increased resulting in more air capacity. From intercooler
ECM
This brings close to the perfect combustion
resulting in reduction of PM and other graphite
as well as better fuel consumption.
RETURN

EGR Layout
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)

EGR VALVE ASM

1.EGR Pipe
2.EGR Cooler
3.EGR Adapter
4.EGR Valve & REED VALVE
RETURN

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%.
RETURN

EGR Gas Flow Control


EGR gas enter into the intake side when intake air pulsation higher than exhaust gas pulsation

Exhaust Gas Pulsation


Intake Air Pulsation

REED VALVE prevent Intake Air enter into Exhaust Gas Side
RETURN

EGR Control
ECM provides 5 V to the EGR position
sensor U, V, and W through 5-V power
supply circuit and grounds to the inside
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 in
SENSOR OUTPUT polarity.

UVW INPUT
RETURN

Fuel Filter,Fuel Pump


Priming Pump

Main Filter
Pre. Filter 6WG1X : Tandem

Filter Wrench
(Pre, Main common)
RETURN

Improve Engine Oil Drain Method


(OIL PAN)

Drain Cock

Drainer
(On Vehicle)
RETURN

How to Replace Parts


1
z Never replace the pressure limiter, fuel temperature
sensor, flow damper alone.If faulty, replace the
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.
Change sealing line
(Not Reuse)
For SCV pump, the pump unit cannot be replaced itself
because the fuel temperature sensor is installed on it.
Be sure to replace it as supply pump ASSY.

Name
2
4 1. Injector pipe
2. Flow damper
5
3. Common rail pressure sensor
4. Fuel temperature sensor
5. Pressure limiter
3
RETURN
World Fuel Map for Off-road Machine
2005.4.14
Level of Consideration

Danger Need Care Good Unkown


・Sulfur contents ;   1000∼3000ppm / above 3000ppm
・Water contents
・Dust contents
・Fuel viscosity ;   HFRR 460∼560 / above 600
・Additive  

N.Europe
Sulfur
Water
Dust
Viscosity
W.Russia E.Russia
CANADA
Additive Sulfur Sulfur
Sulfur Water Water
Water Dust Dust
Dust EU Viscosity Viscosity
Viscosity Additive Additive
Additive Sulfur
Water
M.East
Dust China,E.Asia
N.America Viscosity Sulfur JAPAN
Sulfur
Additive Water
Water Sulfur
Sulfur Dust
Dust Water
Water N.Africa Viscosity
Viscosity Dust
Dust Additive
Sulfur Additive Viscosity
Viscosity
Water Additive
Additive
Dust
S.E.Asia
Viscosity Sulfur
S.America Additive Water Oseania
Sulfur Sulfur Dust
Water Water Viscosity Sulfur
Dust Dust Additive Water
Viscosity Viscosity Dust
Additive
S.Africa Viscosity
Additive
Sulfur Additive
Water
Dust
Viscosity
Additive
RETURN

Tier-3 Engine major specification and


Maintenance point
1.High pressure fuel injection control by common rail system. AGAIN
→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

List of Special Service Tools (1/3)


RETURN

List of Special Service Tools (2/3)


RETURN

List of Special Service Tools (3/3)


RETURN

 Detect Failure
SCAN Tool

Dr.ZX Monitor
ZX
ZX-3

Dr.ZX
 Tech2

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.
¾Isuzu prepare Tech2 for Isuzu service network 
RETURN

(Special Tool) Breaker Box(Harness Checker )


Breaker Box is a tool to easily check open or short circuit in connector pin
and harness between ECM and each sensor or actuator

Refer to

6WG1X Engine
Troubleshooting
Manual
(NM1J1-E-ENG-T)

  1E-85
RETURN

(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 to
6WG1X Engine Troubleshooting
Manual (NM1J1-E-ENG-T)
  1E-78
RETURN

  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 (Notice) ECM Power OFF


The power supply inside the ECM does not go off for about 10 seconds
after turning the key switch OFF.
C. Check 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.
RETURN
Check list for engine control system Inspector's company name
Inspector's name

User User's name


Address
Confirm Machine
userapplication
complain using Questionnaire sheet
Machine Date of delivery Date of trouble occurrence
Operating period
Machine model name Machine No.
Engine Engine model name Engine No.

Engine does not start □ □ □ □


Difficult starting of engine□ □ □ □
Trouble symptom

Unstable idling □ □ □ □
Drivability is low. □ □ □ □
□ □ When accelerator □ □
Engine stall pedal (lever) is released
□ When gear is shifted up □ At certain operation □ □
 When operating at full load mode
Vibration at idling

Trouble occurrence data


Frequency of trouble □ □ □ □
Refer to
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
Location


Spring
Outdoor
Summer
□ □

Autumn
General road


Winter
Rough road
6WG1X Engine
□ Construction field (Type
□ Indoor □ Roadworks field (Type ) □ Expressway □ Slope (grade degree )
Troubleshooting
Trouble condition

□ In mountain □ Harbor □ On the sea □ Height ( m above sea level)


Others ( )
Manual

Engine temperature □ Cold □ During warming-up □ After warmed-up □ Others ( )
Oil/coolant temperature □ Engine coolant temperature □ Oil temperature ( ℃)
Operating condition □ □ □ □ (NM1J1-E-ENG-T)
□ □ □ □
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 ( )   1E-13、14
□ 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 on


DTC Current trouble □(         ) □(         ) □(         ) □(         )
□(         ) □(         ) □(         ) □(         )
Past trouble □(         ) □(         ) □(         ) □(         )
□(         ) □(         ) □(         ) □(         )
Past trouble history □ Year Month Date (Content ) [Measure: ]
□ Year Month Date (Content ) [Measure: ]
RETURN

   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.    
RETURN

Translate Hitachi DTC Code to Isuzu Code


Translate 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) I


E−571

DTC Code Reference Sheet for Hitachi and Isuzu


Trouble display
SPN FMI P Code DTC description
on monitor
91 2 P1271 Ac celerator sebsor ○
1-2 comparison fault
91 3 P1277 Ac celerator sebsor 1 ○
fau lt (low voltage)
91 3 P1277 Ac celerator sebsor 1 ○
fau lt (high voltage)
RETURN

Detail of DTC (Diagnostic Trouble Code)


Isuzu DTC code detail, refer to Trouble Shooting Manual 1E-170∼181
Hitachi unique DTC code, refer to 1E−575∼578
List of diagnostic trouble code
List of diagnostic trouble codes
On some machines, the diagnosis lamp comes on instead of trouble display monitor on the machine.
 I
E−170
6WG1X
Preconditions Fault
Flash DTC Item to be DTC set Behavior when Diagnos
DTC when DTC is judgment
code description detected condition trouble occurs is lamp
set period
P0088 118 Common rail Common rail ・Key switch Rail pressure Approx. Increase engine ON
pressure pressure input voltage is more than 5 sec vibration, rough
fault abnormal is 16V or 150Mpa idling, output
(1st stage) increase more. (21756psi) lowering, blow up
・DTC P0088, fault, black smoke
P0192,P0193 emitted, and
or P1635 is excessive output
not detected. are possible.
Back-up:
Description of DTC Code(P0088, Refer to  Limited injection
1E-183∼187 amount 3 (multi-
injection stopped)
Target RP upper
Recovery from failure, refer to I
E−182 limit(80 Mpa
{11603 psi})
RETURN

Recovery from Failure


Wait 10 Pattern
Pattern
Pattern 11 seconds Pattern 22

Trouble occurs Recovery Trouble occurs Inspection and repair,


from failure
Inspection and repair, or temporary
or temporary recovery from
recovery from failure failure
Recovery from failure
RETURN

Recovery from Failure


Pattern
Pattern 33 Engine is
recovered from
failure, but
trouble code
exists and lamp
remains on.

DTC Clear Action Required

Trouble occurs Inspection and repair,


or temporary
recovery from failure

Recovery from failure


RETURN

Trouble Shoot Process from Phenomenon


Confirm failure phenomenon and read detail description of each failure

Refer to 6WG1X Engine Trouble Shooting Manual(NM1J1-E-ENG-T)


1E-539∼569

Electronic control fuel injection system(Common rail type) I


E−539
List of trouble symptom
Symptom Description
Engine start failure Crank speed is slow.
Crank speed is normal but engine does not start. (not
first combustion).
Engine start (first combustion exists) but can not
maintain 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.
RETURN

About Tech2 (I
suzuS Tool)

1) Display of Diagnostic Trouble Codes


Performs Reading, confirmation and clearing of DTC
2) Data Display
Displays the current data recognized and controlled by ECM
3) Snapshot
Records and plots data when trouble occurs
4) Programming
Enables to confirm the history of data when
ECM is replaced
5) Actuator Test
Checks operation and function at each test
and confirms abnormality
RETURN

Trouble Diagnosis Results of Tech2

• Past Trouble
Diagnostic 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 Trouble
Diagnostic 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 Past
Trouble code.
RETURN

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 near
position of ECM.
RETURN

Injector QRCode Programming

Tech2

Dr
.ZX

Injector QR code
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)
RETURN

What is Injector QR Code


QR (Quick Response) codes have been adopted to enhance correction
precision. The QR code, which contains the correction data of the injector,
is written in the engine ECM. QR codes have resulted i nsubstantial increase
in the number of fuel injection quantity correction points, greatly improving
injection quantity precision.

QR Code Correction Point


RailPressur

Parameter

Injection
Quantity

.ZX or Tech2
Dr

Actuating Pulse Width TQ


RETURN

Injector ; QR Code

Injector QR Code
RETURN
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