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  RETURN    
  RETURN ISUZU INDUSTRIAL DIESEL ENGIN E 6WG1X Tier3 ISUZU MOTORS LIMITED Off-highway Powertrain Operation
  RETURN ISUZU INDUSTRIAL DIESEL ENGIN E 6WG1X Tier3 ISUZU MOTORS LIMITED Off-highway Powertrain Operation
 

ISUZU INDUSTRIAL DIESEL ENGINE 6WG1X Tier3

  RETURN ISUZU INDUSTRIAL DIESEL ENGIN E 6WG1X Tier3 ISUZU MOTORS LIMITED Off-highway Powertrain Operation Dept.

ISUZU MOTORS LIMITED Off-highway Powertrain Operation Dept. Planning & Service Group

HITACHI CONSTRUCTION MACHINERY CO.,Ltd Technical Training Center

Table 1.   Differences between Tier2 engine and Tier3 engine. RETURN of     ①
Table 1.   Differences between Tier2 engine and Tier3 engine. RETURN of     ①

Table

1. Differences between Tier2 engine and Tier3 engine.

of

   Differences between Tier2 engine and Tier3 engine.

 

contents

      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   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     Trouble Shooting Procedure  How to use Trouble Shooting Manual 5. DTC code ① DTC code    ② Scan Tool    ③ EMPS     How to use scan tool  6. Point to notice on service Parts replace procedure7. Trouble Shooting on actual machine 

  RETURN Tier-3 Engine major specification and Maintenance point 1.High pressure fuel injection control by
  RETURN Tier-3 Engine major specification and Maintenance point 1.High pressure fuel injection control by
 

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
  RETURN Off-Road Future Emission Regulation   Off-Road Future Emission Regulation CLASS ENGINE 2001
 

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
CLASS
ENGINE
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011
2012
2013
2014
2015
450
- 560 kW
interim
EPA
▼ Tier2
Tier3
(600 - 750hp)
NOx+HC
6.4
Tier4
CO
3.5
NOx+HC
4.0
PM
0.2
Nox+NMHC 4.0
225
- 450 kW
interim
6W,6S
▼ Tier2
Tier3
CO
3.5
CO
3.5
(300 - 600hp)
Tier4
PM
0.2
PM
0.03
130
- 225 kW
NOx+HC 6.6
interim
6H
▼ Tier2
Tier3
(175 - 300hp)
CO
3.5
/
PM 0.2
Tier4
75
- 130 kW
NOx+HC 6.6
NOx+HC
4.0
Nox+NM
HC 4.0
4H
▼ Tier2
Tier3
(100 - 175hp)
CO
5.0
/ PM 0.3
CO
5.0 /
PM 0.3
CO
5.0
/
PM 0.03
interim
Tier4
NOx+HC
7.5
NOx+HC
4.7
37
- 75 kW
4J,4LE
Tier2
CO 5.0
/
PM
0.4
Tier3
CO
5.0 / PM
0.4
interim
NOx + HC 4.7
(50 - 100hp)
56kw
Tier4
CO 5.0
/
PM 0.03
NOx
6.0
/ HC 1.0
NOx+HC 4.0
NOx+HC 4.0
EC
130
- 560 kW
6W,6S,6H
▼ Stage2
▽ Stage3-A
▽ Stage3-B
CO
3.5
/ PM
0.2
CO 3.5 /
PM
0.2
CO 3.5 /
PM
0.025
NOx
6.0
/
HC 1.0
NOx+HC 4.0
NOx+HC
4.0
75
- 130 kW
4H
▼ Stage2
▽ Stage3-A
▽ Stage3-B
CO
5.0
/
PM
0.3
CO 5.0 / PM 0.3
CO 5.0 / PM
0.025
NOx
7.0
/ HC
1.3
NOx+HC
4.7
37
- 75 kW
4J,4LE
neary same as EPA
Stage2
Stage3-A
▽ Stage3-B
CO
5.0
/ PM
0.4
CO 5.0
/ PM 0.4
NOx
8.0
/ HC 1.5
NOx+HC 7.5
19
- 37 kW
L
▼ Stage2
▽ Stage3-A
No proposal as Stage3-B
CO
5.5
/ PM
0.8
CO 5.5 /
PM 0.6
NOx
6.0
/
HC
1.0
NOx
3.6
/
HC 0.4
JPN
130
- 560 kW
6W,6S,6H
▽ Tier-2
▽ Tier-3
▽ Tier-4
CO
3.5
/
PM
0.2
CO
3.5
/
PM
0.17
After treatment
(DPF) basis
NOx
6.0
/
HC
1.0
NOx
3.6
/
HC
0.4
75
- 130 kW
4H
▽ Tier-2
▽ Tier-3
CO
5.0
/
PM
0.3
CO
5.0
/
PM
0.2
NOx
4.0
/
HC
0.7
56
- 75 kW
4J
▽ Tier-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
▽ Tier-2
▽ Tier-3
CO
5.0
/
PM
0.3
NOx
8.0
/
HC
1.5
Nox
6.0
/ HC
1.0
19
- 37 kW
L
 ▽ Tier-2
▽ Tier-3
CO
5.5
/
PM
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 ~ )   0.3 PM ( g/kwhr) 0.2
  RETURN Tier3 Emission Regulation (130kW ~ )   0.3 PM ( g/kwhr) 0.2
 

Tier3 Emission Regulation (130kW)

 

0.3

PM

g/kwhr)

0.2

0.1

EPA/EC Tier-3 130kW~(2006) JPN Tier-3 130kW~(2006) EPATier-2 130kW~(2003)   EPA Tier-4
EPA/EC Tier-3
130kW~(2006)
JPN Tier-3
130kW~(2006)
EPATier-2
130kW~(2003)
 
EPA Tier-4
(2012)
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

EGR Cooler Key Technologies of Diesel Engine EGR = Exhaust Gas Re-circulation EGR Valve Total
EGR Cooler
Key Technologies of Diesel Engine
EGR = Exhaust Gas Re-circulation
EGR Valve
Total Total engine engine technology technology
-Combustion -Combustion chamber chamber
EGR EGR Technology Technology
-Turbo-charging -Turbo-charging
etc. etc.
Noise Noise Technology Technology
Inlet Manifold
Total Total Electronic Electronic Control Control
Base Base Technology Technology
Friction Reduction
Friction Reduction
Injection Injection System System
Fuel Fuel Improvement Improvement
Exhaust Manifold
Turbo-Charging Turbo-Charging
Technology Technology
Air
Inter Cooler
EGR Gas
 
0.4 Tier 3 trade-off 130MPa pressure Cooled EGR Electronic control Tier 2 trade-off 0. 70MPa
0.4
Tier 3 trade-off
130MPa pressure
Cooled EGR
Electronic control
Tier 2 trade-off
0.
70MPa pressure
 Inter cooler
Tier 3
0.
Tier 2
JPN Tier-3
Engine Modification
0.
Limit
1.
2.
3.
4.
5.
6.
PM g/kWh 
 

Technologies and Emission Level (130kW)

 

NOx + HC

g/kWh

Applied Tandem Cooled EGR High Injection Pressure (80t:120Mpa,65t&45t:130Mpa) Noz.Hole Dia
Applied Tandem Cooled EGR
High Injection Pressure
(80t:120Mpa,65t&45t:130Mpa)
Noz.Hole Dia
(80t&65t:8-Φ0.21,45t:8-Φ0.19)
 

Regulation and Effect(6WG1X

 
  RETURN Basic Information of Tier 3 Engine   • Low Emission • Low Noise
  RETURN Basic Information of Tier 3 Engine   • Low Emission • Low Noise
 

Basic Information of Tier 3 Engine

 

Low Emission

Low Noise

High

Power

Electronic Controlled Engine

1. Tier 2 Engine Comparison

2. Electronic Control

3. Common Rail System

4. Cooled EGR

6WG1 Engine Specification RETURN   Model 6WG1TQA 6WG1XQA 6WG1XYSA-01 Item TIER2 TIER2
6WG1 Engine Specification RETURN   Model 6WG1TQA 6WG1XQA 6WG1XYSA-01 Item TIER2 TIER2

6WG1 Engine Specification

 

Model

6WG1TQA

6WG1XQA

6WG1XYSA-01

Item

TIER2

TIER2

TIER3

Engine model

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

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 – bore × stroke

(mm)

 

L6-φ147×154

Displacement

(L)

 

15,681

Compression ratio

 

16.4

16

Compression pressure

MPa(psi)/rpm

 

2.75(400)/200

Dimensions (length × width × height)

(mm)

1462×1007×1287(with fan)

1741×1016×1340(with fan)

1462×1015×1422(with fan)

Weight

(kg)

1125

1185

1153

Fuel injection order

 

1-5-3-6-2-4

Injection pump type

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

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

Electronic control fuel injection system (common rail type) 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

Nozzle type

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

Exhaust gas recirculation device (EGR)

No

No

Installed

6WG1 Engine Specification RETURN   Model 6WG1TQA 6WG1XQA0* 6WG1XYSA-0* Item TIER2 TIER2
6WG1 Engine Specification RETURN   Model 6WG1TQA 6WG1XQA0* 6WG1XYSA-0* Item TIER2 TIER2

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 capacity

(L)

 

36

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

()

 

temperature(10mm)

 

83(95)

Engine           変更履歴   RETURN       条件  
Engine           変更履歴   RETURN       条件  

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 36145t搭載AH-6WG1X

ク‐リングファン

 

   

Performance

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

 

   
       

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±69Nm1000min-1

   

1580±47

 

1800

1600

軸トル ク(Nm)

 
           

1400

 
           

1200

 
           

1000

   
 

300

             
         

260±4kW

     
         

1800min-1

     
 

250

             

POWER OUTPUT(kW)

200

             

150

             

100

             
 

50

             
         

1900±30rpm

     
 

0

             
           

260

   
     

237±13.6g/kWh以下 /

         
     

2000min -1

   

240

SFC(g/kWh)

 
           

220

 
           

200

 
       

214±13.6g/kWh1800min-1

   
           

180

   
 

500

1000

1500

2000

 

2500

   
     

ENGINE SPEED(min-1)

         
  RETURN Engine Layout /Main Parts Main Fuel Filter (Tandem) EGR Valve EGR Cooler (Tandem)
  RETURN Engine Layout /Main Parts Main Fuel Filter (Tandem) EGR Valve EGR Cooler (Tandem)
 

Engine Layout /Main Parts

  RETURN Engine Layout /Main Parts Main Fuel Filter (Tandem) EGR Valve EGR Cooler (Tandem) Supply

Main Fuel Filter (Tandem)

EGR Valve

Engine Layout /Main Parts Main Fuel Filter (Tandem) EGR Valve EGR Cooler (Tandem) Supply Pump (G
EGR Cooler (Tandem) Supply Pump (G Sensor)
EGR Cooler
(Tandem)
Supply Pump
(G Sensor)

Common Rail

  RETURN Engine Layout /Main Parts Remote Oil Filter Port Turbocharger
  RETURN Engine Layout /Main Parts Remote Oil Filter Port Turbocharger
 

Engine Layout /Main Parts

Remote Oil Filter Port
Remote Oil Filter Port

Turbocharger

  RETURN Characteristics of Main Structure Components Cooled EGR OHC 4VALVE High Rigidity of Cyl.
  RETURN Characteristics of Main Structure Components Cooled EGR OHC 4VALVE High Rigidity of Cyl.
 

Characteristics of Main Structure Components

Cooled EGR
Cooled EGR
of Main Structure Components Cooled EGR OHC 4VALVE High Rigidity of Cyl. Head Maximum Inj.Pressure

OHC 4VALVE High Rigidity of Cyl. Head

Maximum Inj.Pressure 130MPa Electronic Cont. Common Rail

Inj.Pressure 130MP a Electronic Cont. Common Rail High Efficiency Turbocharger ( no Waste Gate ) High
Inj.Pressure 130MP a Electronic Cont. Common Rail High Efficiency Turbocharger ( no Waste Gate ) High
Inj.Pressure 130MP a Electronic Cont. Common Rail High Efficiency Turbocharger ( no Waste Gate ) High

High Efficiency Turbocharger no Waste Gate

Rail High Efficiency Turbocharger ( no Waste Gate ) High Rigidity Rudder Frame Symmetry High Rigidity

High Rigidity Rudder Frame

Symmetry

High

Rigidity

C.Block

High

Rigidity

C. Shaft

High Rigidity RETURN   ( Rudder Frame )  
High Rigidity RETURN   ( Rudder Frame )  

High Rigidity

 

Rudder Frame

 
  RETURN 6WG1X Engine Noise (Tier 3 v.s. Tier 2) SOUND PRESSURE LEVEL ***  
  RETURN 6WG1X Engine Noise (Tier 3 v.s. Tier 2) SOUND PRESSURE LEVEL ***  
 

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

SOUND PRESSURE LEVEL

*** AVERAGE ***

ENG.TYPE AH-6WG1X

6WG1X-Tier2との比較 FAN無

Comparison with Tier 2

100 98 96 94 92 90 6WG1X-Tier2比 3 db(A) lower 約3dB(A)の 88 低騒音ポテンシャル T han
100
98
96
94
92
90
6WG1X-Tier2比
3 db(A) lower
約3dB(A)の
88
低騒音ポテンシャル
T
han Tier 2
86
84
600
800
1000
1200
1400
1600
1800
2000
2200
SPL-AVE(FULLLOAD)dB(A)

ENGINESPEED (rpm)

●――――●

6WG1X-Tier3

FAN:無

Fan : none

×- - - - -×

6WG1X-Tier2

FAN:無

Fan : none

  RETURN Sensor Layout   Refer to 6WG1 Engine Troubleshooting Manual (NM1J1-E-ENG-T)  1E-98
  RETURN Sensor Layout   Refer to 6WG1 Engine Troubleshooting Manual (NM1J1-E-ENG-T)  1E-98
 

Sensor Layout

 
Refer to 6WG1 Engine Troubleshooting Manual (NM1J1-E-ENG-T)  1E-98 Name 1.Pressure Control Valve 2. Fuel
Refer to
6WG1 Engine Troubleshooting
Manual (NM1J1-E-ENG-T)  1E-98
Name
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
5. Common Rail Pressure Sensor 10. Engine Oil Pressure sensor 6. Engine Coolant Temp. Sensor 11.

6. Engine Coolant Temp. Sensor

11. Overheating Switch

  RETURN System Schematic (6WG1) Common Rail Pressure Sensor Pressure Limiter Common Rail Supply Pump
  RETURN System Schematic (6WG1) Common Rail Pressure Sensor Pressure Limiter Common Rail Supply Pump
 

System Schematic (6WG1)

Common Rail Pressure Sensor Pressure Limiter Common Rail Supply Pump Injector ECM CKP Sensor
Common Rail Pressure Sensor
Pressure Limiter
Common Rail
Supply Pump
Injector
ECM
CKP Sensor
Comparison with Conventional System RETURN   TWV: Two Way Valve
Comparison with Conventional System RETURN   TWV: Two Way Valve

Comparison with Conventional System

 

TWV: Two Way Valve

Comparison with Conventional System RETURN   TWV: Two Way Valve
  RETURN Common Rail System Characteristic ・ The common rail system uses a type of
  RETURN Common Rail System Characteristic ・ The common rail system uses a type of
 

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 6WG1X Tier3 apply Main & Pilot Injection only
 

Fuel Injection Rate Control

  RETURN Fuel Injection Rate Control 6WG1X Tier3 apply Main & Pilot Injection only

6WG1X Tier3 apply Main & Pilot Injection only

  RETURN Fuel Injection Rate Control Conventional Conventional Injection Injection Pilot Pilot Injection Injection
  RETURN Fuel Injection Rate Control Conventional Conventional Injection Injection Pilot Pilot Injection Injection
 

Fuel Injection Rate Control

Conventional Conventional Injection Injection Pilot Pilot Injection Injection Injection rate Small mixed Large mixed
Conventional Conventional Injection Injection
Pilot Pilot Injection 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

ECM Diagram (6WG1X) RETURN     Refer to Trouble Shooting Manual   (NM1J1-E-ENG-T)
ECM Diagram (6WG1X) RETURN     Refer to Trouble Shooting Manual   (NM1J1-E-ENG-T)

ECM Diagram (6WG1X)

 

 Refer to Trouble Shooting Manual

 (NM1J1-E-ENG-T)

  1E-108

Sensors Actuator Accelerator position Accelerator Accelerator position position sensor sensor Engine speed
Sensors
Actuator
Accelerator position
Accelerator Accelerator position position
sensor sensor
Engine speed
Crankshaft Crankshaft
・Injection amount control
・Injection timing control
position position sensor sensor
Cylinder identifying
signal
Camshaft sensor, Camshaft position position
sensor,
G G sensor sensor
Other Other sensors, sensors,
Switches Switches
・Injection pressure control
 

 Refer to

Control System

Trouble Shooting Manual    1E-88

 
  RETURN Function of ECM Engine Control System Configuration   Engine Control      
  RETURN Function of ECM Engine Control System Configuration   Engine Control      
 

Function of ECM

Engine Control System Configuration

 Engine Control    Basic Injection Control

Injection QuantityInjection PressureInjection TimingInjection Rate

   Fuel Injection Compensation

Starting Fuel CompensationAltitude CompensationOver 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.  

ENG SPEED rpm y ¥ x 0 400 550 600 700 950 975 1020 1030
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
ECM
has several Engine Control
45
50
40
40
40
50
65
80
80
85
85
90
90
90
75
50
50
50
50
50
65
80
80
85
85
90
90
90
Data Map
85
50
50
50
50
50
65
80
80
85
85
90
90
90
95
50
50
50
50
50
65
80
80
①Ba
85
se Map-Engin
85
90
90
e Speed v.s. Rail
90
120
50
50
50
50
50
65
80
80
85
85
90
90
90
  Pressure, Fuel Quantity etc
150
②Compensation Map-Coolant
Temp. Atmospheric Pressure
etc
Rail
100
100-150
Pressure
50-100
(MPa)
0-50
50
230
0
95
Fuel Quontity
Rail Pressure
(mm3/st)
0
0
700
1030
1300
1450
2000
3500
 

ECM Engine Data Map

 

Engine speed (rpm)

  RETURN Fuel Injection at Starting At low temperature Engine starting mode Starter signal ON
  RETURN Fuel Injection at Starting At low temperature Engine starting mode Starter signal ON
 

Fuel Injection at Starting

At low temperature Engine starting mode Starter signal ON Less than "N1" speed (rpm) At
At low temperature
Engine starting mode
Starter signal ON
Less than "N1"
speed (rpm)
At high temperature
Engine speed
6WG1X N1=950rpm
Injection amount at cranking
  RETURN Startig Fuel Quantity Adjust エンジンクーラント温度 (deg C) Engine Coolant Temp. Starting Fuel
  RETURN Startig Fuel Quantity Adjust エンジンクーラント温度 (deg C) Engine Coolant Temp. Starting Fuel
 

Startig Fuel Quantity Adjust

エンジンクーラント温度 (deg C)
エンジンクーラント温度 (deg C)

Engine Coolant Temp.

Starting Fuel Quanti

始動燃料流量補正

mm3/st

ty

ECM adjust Starting Fuel Quantity by Coolant Temperature Sensor signal

  RETURN High Altitude Correction Atmospheric Pressure High Altitude Maximum Fuel Quantity ECM adjust maximum
  RETURN High Altitude Correction Atmospheric Pressure High Altitude Maximum Fuel Quantity ECM adjust maximum
 
High Altitude Correction Atmospheric Pressure High Altitude
High Altitude Correction
Atmospheric Pressure
High Altitude

Maximum Fuel Quantity

ECM adjust maximum Fuel Quantity by Atmospheric Pressure Sensor signal

  RETURN Over Heat Control 100℃ 105℃ Engine Engine Coolant Coolant Temp. Temp. In addition
  RETURN Over Heat Control 100℃ 105℃ Engine Engine Coolant Coolant Temp. Temp. In addition
 

Over Heat Control

100℃ 105℃ Engine Engine Coolant Coolant Temp. Temp.
100℃
105℃
Engine Engine Coolant Coolant Temp. Temp.

In addition Alarm raise above105, Fuel Quantity decrease above 100

Fuel Quantity

  RETURN QOS (Quick On Start) System The ECM determines the period required for glow
  RETURN QOS (Quick On Start) System The ECM determines the period required for glow
 

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.

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 Pre-Heat Time       Engine Coolant Temp.  
   

Pre-Heat Time

   
 

Engine Coolant Temp.

 
CAN Communication Circuit RETURN   All ECU on Vehicle connected through CAN Communication Circuit ○
CAN Communication Circuit RETURN   All ECU on Vehicle connected through CAN Communication Circuit ○

CANCommunication Circuit

 

All ECU on Vehicle connected through CAN Communication Circuit

MCMain Controller

Satellite Dr.ZX Communicatio n ICF Monitor Unit CAN Bus    MC CAN Bus ECM
Satellite Dr.ZX
Communicatio
n
ICF
Monitor Unit
CAN Bus
  
MC
CAN Bus
ECM

Tech2

ECMEngine Control Module

ICFInformation Controller

Monitor Unit

CANController Area Networkcommunicate

Target Engine Speed

Engine and Vehicle Trouble Code

Monitoring Engine and Vehicle Operating

Condition

ECM ConnectorRemoval RETURN   Push the Button Lift up the Lever Pull down
ECM ConnectorRemoval RETURN   Push the Button Lift up the Lever Pull down

ECM ConnectorRemoval

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

Push the Button

Lift up the Lever

Pull down the Lever until sound coming

Common Rail Pressure Sensor Pressure Limiter Common Rail Supply Pump (PCV) Injector ECM CKP Sensor
Common Rail Pressure Sensor
Pressure Limiter
Common Rail
Supply Pump
(PCV)
Injector
ECM
CKP Sensor
 

Common Rail System(PCV)

 
Common Rail System Main Parts RETURN   Common Rail ECM Injector Injector Hole Diameter ZX450-3:
Common Rail System Main Parts RETURN   Common Rail ECM Injector Injector Hole Diameter ZX450-3:

Common Rail System Main Parts

 

Common Rail

Common Rail System Main Parts RETURN   Common Rail ECM Injector Injector Hole Diameter ZX450-3: 8-

ECM

Rail System Main Parts RETURN   Common Rail ECM Injector Injector Hole Diameter ZX450-3: 8- Φ
Rail System Main Parts RETURN   Common Rail ECM Injector Injector Hole Diameter ZX450-3: 8- Φ

Injector

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

PCV : Pressure Control Valve

Diameter ZX450-3: 8- Φ 0.19   ZX650/800-3: 8- Φ 0.21 PCV : Pressure Control Valve Supply

Supply Pump

G Sensor (Cam speed)

(Pressure Control Valve) Feed Pump   GSensor Gear    
(Pressure Control Valve)
Feed Pump  
GSensor Gear    

Supply PumpPCV type

 
  RETURN Supply Pump (PCV) operation Intake Stroke Pumping Stroke Can Lift Open Valve PCV
  RETURN Supply Pump (PCV) operation Intake Stroke Pumping Stroke Can Lift Open Valve PCV
 

Supply Pump (PCV) operation

Intake Stroke Pumping Stroke Can Lift Open Valve PCV Operation Close Valve Close Valve To
Intake Stroke
Pumping Stroke
Can Lift
Open Valve
PCV Operation
Close Valve
Close Valve
To Common Rail
Delivery Valve
Plunger
  RETURN PCV Circuit   PCV Relay  
  RETURN PCV Circuit   PCV Relay  
 

PCV Circuit

 

PCVRelay

 
  RETURN Common Rail Flow damper Common rail pressure sensor Pressure limiter
  RETURN Common Rail Flow damper Common rail pressure sensor Pressure limiter
 

Common Rail

Flow damper Common rail pressure sensor Pressure limiter
Flow damper
Common rail
pressure sensor
Pressure limiter
  Pressure Limiter opens to release the pressure RETURN Pressure Limiter if abnormally high pressure
  Pressure Limiter opens to release the pressure RETURN Pressure Limiter if abnormally high pressure
 

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 160MPa 100 – 150MPa 70 – 90MPa 30 –
  RETURN Sample of Rail Pressure 160MPa 100 – 150MPa 70 – 90MPa 30 –
 

Sample of Rail Pressure

  RETURN Sample of Rail Pressure 160MPa 100 – 150MPa 70 – 90MPa 30 – 60MPa
160MPa 100 – 150MPa 70 – 90MPa 30 – 60MPa Fuel Quantity (mm3/st)
160MPa
100 – 150MPa
70 – 90MPa
30 – 60MPa
Fuel Quantity (mm3/st)

Engine Speed (rpm)

Rail Pressure Sensor

Rail Pressure Sensor
Rail Pressure Sensor
  RETURN 6WG1X Appx 30MPa 1800RPM 900RPM Engine Speed Appx 130Mpa Fuel Quantity
  RETURN 6WG1X Appx 30MPa 1800RPM 900RPM Engine Speed Appx 130Mpa Fuel Quantity
 
6WG1X Appx 30MPa 1800RPM 900RPM
6WG1X
Appx 30MPa
1800RPM
900RPM
  RETURN 6WG1X Appx 30MPa 1800RPM 900RPM Engine Speed Appx 130Mpa Fuel Quantity

Engine Speed

Appx 130Mpa

Fuel Quantity

  RETURN Flow damper Reduce the pressure pulsations in the pressurized line and also prevent
  RETURN Flow damper Reduce the pressure pulsations in the pressurized line and also prevent
 

Flow damper

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

Flow damper Common rail Injector Spring Piston Ball
Flow damper
Common rail
Injector
Spring
Piston
Ball
Common rail Injector Spring Piston Ball
Common rail
Injector
Spring
Piston
Ball
 

Flow Damper Operation (at Stop)

 
Common rail Injector Spring Piston Ball
Common rail
Injector
Spring
Piston
Ball
 

Flow Damper Operation (at Damping)

 
Seat Common rail Injector Spring Piston Ball
Seat
Common rail
Injector
Spring
Piston
Ball
 

Flow Damper Operation (at Abnormal Discharge)

 
  RETURN Injector Orifice 1 Orifice 2 Nozzle Hydraulic piston Orifice Solenoid
  RETURN Injector Orifice 1 Orifice 2 Nozzle Hydraulic piston Orifice Solenoid
 

Injector

Orifice 1 Orifice 2 Nozzle Hydraulic piston Orifice Solenoid
Orifice 1
Orifice 2
Nozzle
Hydraulic piston
Orifice
Solenoid
  RETURN Injector Outline Leak Common Common rail rail pressure sensor pressure sensor Orifice Common
  RETURN Injector Outline Leak Common Common rail rail pressure sensor pressure sensor Orifice Common
 

Injector Outline

Leak Common Common rail rail pressure sensor pressure sensor Orifice Common rail Control chamber Hydraulic
Leak
Common Common rail rail pressure
sensor pressure 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 Circuit Constant current circuit Constant current circuit Charge circuit
 

Injector Circuit

Constant current circuit Constant current circuit Charge circuit
Constant current
circuit
Constant current
circuit
Charge circuit
Outer valve Inner valve Orifice 1 Return Orifice 2 Common rail Hydraulic piston No No
Outer valve
Inner valve
Orifice 1
Return
Orifice 2
Common rail
Hydraulic piston
No No signal signal
 

Injector Operation -- No Signal --

 
Outer valve Inner valve Valve open Orifice 1 Return Orifice 2 Common rail Hydraulic piston
Outer valve
Inner valve
Valve open
Orifice 1
Return
Orifice 2
Common rail
Hydraulic piston
 

Injector Operation -- Signal Input --

 
Outer valve Inner valve Orifice 1 Return Orifice 2 Common rail Hydraulic piston Injection Injection
Outer valve
Inner valve
Orifice 1
Return
Orifice 2
Common rail
Hydraulic piston
Injection Injection Start Start
 

Injector Operation -- Injection Start --

 
Outer valve Valve closed Orifice 1 Orifice 2 Return Common rail Hydraulic piston
Outer valve
Valve closed
Orifice 1
Orifice 2
Return
Common rail
Hydraulic piston
 

Injector Operation -- Signal Stop --

 
Outer valve Inner valve Orifice 1 Return Orifice 2 Common rail Hydraulic piston Injection Injection
Outer valve
Inner valve
Orifice 1
Return
Orifice 2
Common rail
Hydraulic piston
Injection Injection stop stop
 

Injector Operation -- Injection Stop --

 
  RETURN Injector Terminal High Voltage applied on the Injector (above118V) Battery cable must be
  RETURN Injector Terminal High Voltage applied on the Injector (above118V) Battery cable must be
 

Injector Terminal

  RETURN Injector Terminal High Voltage applied on the Injector (above118V) Battery cable must be disconnected

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

Injector Current and Voltage RETURN   15A or more   Max. 130V
Injector Current and Voltage RETURN   15A or more   Max. 130V

Injector Current and Voltage

 

15A or more

 
Injector Current and Voltage RETURN   15A or more   Max. 130V

Max. 130V

Injector Current and Voltage RETURN   15A or more   Max. 130V
  RETURN CKP(Crank Position) Sensor G(Pump Position) Sensor Amp回路 G Sensor Amp回路
  RETURN CKP(Crank Position) Sensor G(Pump Position) Sensor Amp回路 G Sensor Amp回路
 

CKP(Crank Position) Sensor G(Pump Position) Sensor

Amp回路 G Sensor Amp回路 CKPSensor
Amp回路
G Sensor
Amp回路
CKPSensor

G sensor detects the G sensor Gear rotation and identifies the cylinder.

CKP sensor detects the engine speed.

  RETURN CKP Sensor Waveform
  RETURN CKP Sensor Waveform
 

CKP Sensor Waveform

  RETURN CKP Sensor Waveform
  RETURN G Sensor Waveform G Sensor No.1 cylinder TDC Recognition pulse G Sensor Waveform
  RETURN G Sensor Waveform G Sensor No.1 cylinder TDC Recognition pulse G Sensor Waveform
 

Sensor Waveform

  RETURN G Sensor Waveform G Sensor No.1 cylinder TDC Recognition pulse G Sensor Waveform

G Sensor

No.1 cylinder TDC Recognition pulse

G Sensor Waveform

G(CMP), CKP(NE) Sensor RETURN Diagram (6 Cylinders)   No.6 cylinder TDC standard pulse No.1 cylinder
G(CMP), CKP(NE) Sensor RETURN Diagram (6 Cylinders)   No.6 cylinder TDC standard pulse No.1 cylinder

G(CMP), CKP(NE) Sensor

Diagram (6 Cylinders)

 

No.6 cylinder TDC standard pulse

No.1 cylinder TDC Recognition pulse

No.1 cylinder TDC standard pulse

 

No.1 cylinder NE standard pulse

No.6 cylinder NE standard pulse

No.1 cylinder NE standard pulse

 
  RETURN Common Rail Pressure Sensor Common rail pressure
  RETURN Common Rail Pressure Sensor Common rail pressure
 

Common Rail Pressure Sensor

Common rail pressure
Common rail pressure
  RETURN Boost Pressure Sensor Electronic circuit Silicon chip Filter Intake air pressure Boost pressure
  RETURN Boost Pressure Sensor Electronic circuit Silicon chip Filter Intake air pressure Boost pressure
 

Boost Pressure Sensor

Electronic circuit Silicon chip Filter Intake air pressure Boost pressure
Electronic circuit
Silicon chip
Filter
Intake air pressure
Boost pressure

Vacuum chamber

  RETURN Engine Coolant Temperature Sensor Engine coolant temperature Fail-safe: Fail-safe: Changes Changes to to
  RETURN Engine Coolant Temperature Sensor Engine coolant temperature Fail-safe: Fail-safe: Changes Changes to to
 

Engine Coolant Temperature Sensor

Engine coolant temperature Fail-safe: Fail-safe: Changes Changes to to 80℃ 80℃ in in case case
Engine coolant temperature
Fail-safe: Fail-safe: Changes Changes to to 80℃ 80℃ in in case case of of abnormality. abnormality.
  RETURN Fuel Temperature Sensor Fuel temperature (℃) Fail-safe: Fail-safe: Takes Takes the the value
  RETURN Fuel Temperature Sensor Fuel temperature (℃) Fail-safe: Fail-safe: Takes Takes the the value
 

Fuel Temperature Sensor

Fuel temperature (℃) Fail-safe: Fail-safe: Takes Takes the the value value of of the the
Fuel temperature (℃)
Fail-safe: Fail-safe: Takes Takes the the value value of of the the water water temperature temperature sensor sensor in in case case
of abnormality.
of abnormality.
  RETURN Intake Air Temperature Sensor Intake air temperature (°C) Fail-safe: Fail-safe: Takes Takes the
  RETURN Intake Air Temperature Sensor Intake air temperature (°C) Fail-safe: Fail-safe: Takes Takes the
 

Intake Air Temperature Sensor

Intake air temperature (°C) Fail-safe: Fail-safe: Takes Takes the the value value of of the
Intake air temperature (°C)
Fail-safe: Fail-safe: Takes Takes the the value value of of the the water water temperature temperature sensor sensor in in case case
of abnormality.
of abnormality.
  RETURN Cooled EGR EGR stands for ” Exhaust Gas Recirculation ” . This equipment
  RETURN Cooled EGR EGR stands for ” Exhaust Gas Recirculation ” . This equipment
 

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 NOxwhich 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.

To intercooler Turbo From air cleaner To silencer Exhaust manifold Coolant out Engine EGR cooler
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 EGR Layout 1.Various Sensor Inputs 2.Exhaust Gas Re-circulation (EGR) Valve 3.EGR Cooler 4.Engine
  RETURN EGR Layout 1.Various Sensor Inputs 2.Exhaust Gas Re-circulation (EGR) Valve 3.EGR Cooler 4.Engine
 

EGR Layout

  RETURN EGR Layout 1.Various Sensor Inputs 2.Exhaust Gas Re-circulation (EGR) Valve 3.EGR Cooler 4.Engine

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

5.Intake Air 6.Engine Control Module (ECM) EGR VALVE ASM 1.EGR Pipe 2.EGR Cooler 3.EGR Adapter 4.
5.Intake Air 6.Engine Control Module (ECM) EGR VALVE ASM 1.EGR Pipe 2.EGR Cooler 3.EGR Adapter 4.

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.
  RETURN EGR Control ECM operates the motor according to engine speed, engine load, etc.
 

EGR Control

  RETURN EGR Control ECM operates the motor according to engine speed, engine load, etc. to

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 RETURN   EGR gas enter into the intake side when intake
EGR Gas Flow Control RETURN   EGR gas enter into the intake side when intake

EGR Gas Flow Control

 

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

when intake air pulsation higher than exhaust gas pulsation Exhaust Gas Pulsation Intake Air Pulsation REED
Exhaust Gas Pulsation Intake Air Pulsation REED VALVE prevent Intake Air enter into Exhaust Gas
Exhaust Gas Pulsation
Intake Air Pulsation
REED VALVE prevent Intake Air enter into Exhaust Gas Side
  RETURN EGR Control SENSOR OUTPUT UVW INPUT ECM provides 5 V to the EGR
  RETURN EGR Control SENSOR OUTPUT UVW INPUT ECM provides 5 V to the EGR
 

EGR Control

SENSOR OUTPUT
SENSOR OUTPUT

UVW INPUT

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 polarity.

Fuel Filter , Fuel Pump RETURN   Priming Pump Pre. Filter Main Filter 6WG1X :
Fuel Filter , Fuel Pump RETURN   Priming Pump Pre. Filter Main Filter 6WG1X :

Fuel FilterFuel Pump

 

Priming Pump

Fuel Filter , Fuel Pump RETURN   Priming Pump Pre. Filter Main Filter 6WG1X : Tandem

Pre. Filter

, Fuel Pump RETURN   Priming Pump Pre. Filter Main Filter 6WG1X : Tandem Filter Wrench

Main Filter 6WG1X : Tandem

Filter Wrench

(Pre, Main common

Improve Engine Oil Drain Method RETURN   (OIL PAN) Drain Cock Drainer ( O n
Improve Engine Oil Drain Method RETURN   (OIL PAN) Drain Cock Drainer ( O n

Improve Engine Oil Drain Method

 
(OIL PAN) Drain Cock
(OIL PAN)
Drain Cock

Drainer On Vehicle

  RETURN How to Replace Parts 1 Never replace the pressure limiter, fuel temperature sensor,
  RETURN How to Replace Parts 1 Never replace the pressure limiter, fuel temperature sensor,
 

How to Replace Parts

1 Never replace the pressure limiter, fuel temperature sensor, flow damper alone.If faulty, replace the
1
Never replace the pressure limiter, fuel temperature
sensor, flow damper alone.If faulty, replace the
common rail assembly and all the fuel pipes.
Do not reuse the high-pressure pipe and injector
pipe of the fuel system.Replace with new one if it is
removed.
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
        World Fuel Map for Off-road Machine 2005.4.14 RETURN      
        World Fuel Map for Off-road Machine 2005.4.14 RETURN      
       

World Fuel Map for Off-road Machine

2005.4.14

         

Level of Consideration

           
       

Danger

Need Care

Good

 

Unkown

 

Sulfur contents

 

 10003000ppm /

above 3000ppm

         

Water contents

                 

Dust contents

                 

Fuel viscosity ;

   

HFRR 460560 /

above 600

         

Additive  

                 
       

N.Europe

         
       

Sulfur

         
       

Water

         
       

Dust

W.Russia

E.Russia

     
   

CANADA

Viscosity

         
       

Additive

Sulfur

Sulfur

     
   

Sulfur

 

Water

Water

     
   

Water

 

Dust

Dust

     
   

Dust

E

U

Viscosity

Viscosity

     
   

Viscosity

Additive

Sulfur

Additive

Additive

     
       

Water

M.East

       
       

Dust

ChinaE.Asia

 

JAPAN

   
     

N.America

Viscosity

Sulfur

Sulfur

   
     

Sulfur

Water

Dust

Viscosity

Additive

Additive

N.Africa

Sulfur

Water

Water

Dust

Viscosity

Additive

Water

Dust

Viscosity

Additive

S.E.Asia

 

Sulfur

Water

Dust

Viscosity

Additive

   
       

Dust

         
     

S.America

Viscosity

Sulfur

       
     

Additive

Water

Oseania

     

Sulfur

   

Sulfur

 

Dust

       

Water

   

Water

 

Viscosity

Sulfur

     

Dust

   

Dust

 

Additive

Water

     

Viscosity

   

Viscosity

S.Africa

 

Dust

     

Additive

   

Additive

 

Viscosity

     
       

Sulfur

 

Additive

     
       

Water

         
       

Dust

         
       

Viscosity

         
       

Additive

         
  RETURN Tier-3 Engine major specification and Maintenance point AGAIN 1.High pressure fuel injection control
  RETURN Tier-3 Engine major specification and Maintenance point AGAIN 1.High pressure fuel injection control
 

Tier-3 Engine major specification and Maintenance point

AGAIN

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 List of Special Service Tools (1/3)
  RETURN List of Special Service Tools (1/3)
 

List of Special Service Tools (1/3)

  RETURN List of Special Service Tools (1/3)
  RETURN List of Special Service Tools (1/3)
  RETURN List of Special Service Tools (2/3)
  RETURN List of Special Service Tools (2/3)
 

List of Special Service Tools (2/3)

  RETURN List of Special Service Tools (2/3)
  RETURN List of Special Service Tools (2/3)
  RETURN List of Special Service Tools (3/3)
  RETURN List of Special Service Tools (3/3)
 

List of Special Service Tools (3/3)

  RETURN List of Special Service Tools (3/3)
  RETURN List of Special Service Tools (3/3)
    Detect Failure     RETURN           SCAN Tool  
    Detect Failure     RETURN           SCAN Tool  
 

 Detect Failure

   
       
 

SCAN Tool

       

ZX

 

Dr.ZX

 

Monitor

 
   

ZX-3

     
 

Dr.ZX

       
     

 Tech2

   

As ZX-3 type machine scan tool, Dr.ZX add the new function of engine failure detection Main Scan Tool

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

operating condition.

Isuzu prepare Tech2 for Isuzu service network 

  RETURN (Special Tool)   Breaker Box ( Harness Checker ) Breaker Box is a
  RETURN (Special Tool)   Breaker Box ( Harness Checker ) Breaker Box is a
 

(Special Tool) Breaker BoxHarness 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

pin and harness between ECM and each sensor or actuator Refer to 6WG1X Engine Troubleshooting Manual

Refer to

6WG1X Engine Troubleshooting Manual

(NM1J1-E-ENG-T)

  1E-85

  RETURN (Special Tool)   Injector Checker   Injector Checker is a tool to easily
  RETURN (Special Tool)   Injector Checker   Injector Checker is a tool to easily
 

(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)

function will be applied on the Dr.ZX around Mar. ’ 06) Refer to 6WG1X Engine Troubleshooting

Refer to 6WG1X Engine Troubleshooting

Manual (NM1J1-E-ENG-T)

  1E-78

the Dr.ZX around Mar. ’ 06) Refer to 6WG1X Engine Troubleshooting Manual  ( NM1J1-E-ENG-T)   1E -
  RETURN    Trouble Shooting procedure A. Diagnostic process with an interview 1) Confirm user
  RETURN    Trouble Shooting procedure A. Diagnostic process with an interview 1) Confirm user
 

  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 OFF The power supply inside the ECM does not go off for about 10 seconds after 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.

Trouble symptomTrouble

Trouble symptomTrouble C heck list for engine control system I n s p e c t
Trouble symptomTrouble C heck list for engine control system I n s p e c t

C heck list for engine control system Inspector's company name

Inspector's name

User

User's name

Confirm user complain using Questionnaire sheet

Machine application

 

Address

Machine

Date of delivery Operating period Machine model name

Date of trouble occurrence

 

Machine No.

Engine

Engine model name

Engine No.

Engine does not start Difficult starting of engin Unstable idling Drivability is low.

□□□

 

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□□□

□□□

 

When accelerator

Engine stall

pedal (lever) is released

 

 

At certain operation

When gear is shifted up

Vibration at idling

 When operating at full load mode

 

Trouble occurrence data

   

Refer to

Frequency of trouble

□□□

   
 

Weather

Fine

Cloudy

Rain

Snow

   

After lightening

 

Others (

)

Ambient temperature

30or more

Around 20 - 30°C

Around 10 - 15°C Autumn General road

0or less ( Winter Rough road

)

Season

Spring

Summer

6WG1X Engine

Location

Outdoor

Construction field (Type

Indoor

Roadworks field (Type )

Expressway

Slope (grade

degree )

sea level)

Troubleshooting

condition

In mountain

 

Harbor

On the sea

Height ( m above

Others (

)

Man

ual

Engine temperature Oil/coolant temperature Operating condition

Cold

During warming-up

Others (

)

 

Engine coolant temperature Oil temperature (

After warmed-up )

   

(NM1J1-E-ENG-T)

□□□

 
 

□□□

Condition when trouble o

After oil is replaced

 

After oil filter is replac After replenishment o After sedimenter is drained

   

After operating on slope

After out of gas

After washing with hig Others (

)

Oil

□□□

  1

-13、14

Fuel type

Light oil

Krosene

A heavy oil Diesel fuel No. 1

Others (

)

Diesel fuel Special No. 3

Diesel fuel No. 2

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 ”    (NM1 J
  RETURN     How to use “ Trouble Shooting Manual ”    (NM1 J
 

   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.

To translate Hitachi DTC code to Isuzu DTC code

    To read/confirm the pages which described Table

of DTC code on trouble shooting manual.     To read detail description of each DTC code.  

Confirmation process from phenomenon.     Confirm failure phenomenon.  To read/confirm the pages which described Table of phenomenon.     To read detail description of each failure.    

Translate Hitachi DTC Code to Isuzu Code RETURN   Translate Hitachi DTC code (SPN+FMI) to
Translate Hitachi DTC Code to Isuzu Code RETURN   Translate Hitachi DTC code (SPN+FMI) to

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 ManualNM1J1-E-ENG-T) 1E-571,572

Electronic control fuel injection system(Common rail type) IE-571 DTC Code Reference Sheet for Hitachi
Electronic control fuel injection system(Common rail type) IE-571
DTC Code Reference Sheet for Hitachi and Isuzu
SPN
FMI
P Code
DTC description
Trouble display
on monitor
91
2 P1271
Accelerator sebsor
1-2 comparison fault
91
3 P1277
Accelerator sebsor 1
fault (low voltage)
91
3 P1277
Accelerator sebsor 1
fault (high voltage)
D e t a i l o f D T C (Diagnostic Trouble Code) RETURN
D e t a i l o f D T C (Diagnostic Trouble Code) 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.

 IE-170

 

WG1X

               
       

Preconditions

 

Fault

   

DTC

Flash

code

DTC

description

Item to be detected

when DTC is set

DTCset

condition

judgment

period

Behavior when

trouble occurs

Diagnos

is lamp

 

P0088

118

Common rail

Common rail

Key switch

P0192,P0193