ttlb0079

ISUZU INDUSTRIAL DIESEL ENGINE 6WG1X Tier3

ISUZU MOTORS LIMITEDOff-highway Powertrain Operation Dept. Planning

& Service Group

HITACHI CONSTRUCTION MACHINERY CO.,LtdTechnical Training Center

Tableof

contents

1.　Differences between Tier2 engine and Tier3 engine.　　①　Differences between Tier2 engine and Tier3 engine.　　　　　Off Road Emission Regulation　　　　　 Engine Specifications

Engine Layout /Main PartsEngine Layout /Sensors

　　②　Out Line of Common Rail SystemCommon 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　EGR2.　Maintenance Schedule3.　Introduction of SST4. Trouble Shooting　　①　Trouble Shooting Procedure②　How to use Trouble Shooting Manual

5.　DTC code①　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　

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 forECM 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 RegulationOff-Road Future Emission Regulation

CLASS ENGINE 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015

EPA450 - 560 kW(600 - 750hp) － ▼ T ier2 ▽ T ier3

interimTier4

225 - 450 kW(300 - 600hp)

6W,6S ▼ T ier2 ▽ T ier3interimTier4

130 - 225 kW(175 - 300hp)

6H ▼ T ier2 ▽ T ier3interimTier4

75 - 130 kW(100 - 175hp)

4H ▼ T ier2 ▽ T ier3

37 - 75 kW(50 - 100hp)

4J,4LE ▽ T ier2 ▽ T ier356kw

EC 130 - 560 kW 6W,6S,6H ▼ Stage2 ▽ Stage3-A ▽Stage3-B

75 - 130 kW 4H ▼ Stage2 ▽ Stage3-A ▽ Stage3-B

37 - 75 kW 4J,4LE ▽ Stage2 ▽ Stage3-A ▽ Stage3-B

19 - 37 kW L ▼ Stage2 ▽ Stage3-A

JPN 130 - 560 kW 6W,6S,6H 　　　　　▽ T ier-2 ▽ T ier-3

75 - 130 kW 4H 　　　　　▽ T ier-2 ▽ T ier-3

56 - 75 kW 4J ▽ T ier-3

37 - 56 kW 4LE 　　　　　▽ T ier-2 ▽ T ier-3

19 - 37 kW L 　　　　　▽ T ier-2 ▽ T ier-3

LOW NOISE REQUIRMENT of EC STAGE-IIIFrom 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.

NOx+HC 6.4CO 3.5PM 0.2 NOx+HC 4.0

CO 3.5PM 0.2

NOx+HC 6.6CO 3.5 / PM 0.2

NOx+HC 6.6CO 5.0 / PM 0.3

NOx+HC 4.0CO 5.0 / PM 0.3

NOx+HC 7.5CO 5.0 / PM 0.4

NOx+HC 4.7CO 5.0 / PM 0.4

NOx 6.0 / HC 1.0CO 3.5 / PM 0.2

NOx 6.0 / HC 1.0CO 5.0 / PM 0.3

NOx 7.0 / HC 1.3CO 5.0 / PM 0.4

NOx 8.0 / HC 1.5CO 5.5 / PM 0.8

NOx+HC 4.0CO 3.5 / PM 0.2

NOx+HC 4.0CO 5.0 / PM 0.3

NOx+HC 4.7CO 5.0 / PM 0.4

NOx+HC 7.5CO 5.5 / PM 0.6

No proposal as Stage3-B

NOx 6.0 / HC 1.0CO 3.5 / PM 0.2

NOx 6.0 / HC 1.0CO 5.0 / PM 0.3

NOx 7.0 / HC 1.3CO 5.0 / PM 0.4

NOx 8.0 / HC 1.5CO 5.5 / PM 0.8

NOx 3.6 / HC 0.4CO 3.5 / PM 0.17

NOx 3.6 / HC 0.4CO 5.0 / PM 0.2

NOx 4.0 / HC 0.7CO 5.0 / PM 0.3

Nox 6.0 / HC 1.0CO 5.0 / PM 0.4

▽Tier-4After treatment(DPF) basis

NOx 4.0 / HC 0.7CO 5.0 / PM 0.25

Nox+NMHC 4.0CO 3.5PM 0.03

Nox+NM HC 4.0CO 5.0 / PM 0.03interim

Tier4

interimTier4

NOx + HC 4.7CO 5.0 / PM 0.03

NOx+HC 4.0CO 3.5 / PM 0.025

NOx+HC 4.0CO 5.0 / PM 0.025

neary same as EPA

Tier3 Emission Regulation (130kW～)

ＥＰＡ/EC Tier-3

JPN Tier-3 ＥＰＡTier-2

130kW～(2003)

130kW～（2006)

130kW～(2006)

EC StageⅢ-B (2012)

EPA　Tier-4 (2012)

０．３

ＰＭ（g/kwhr)

０．２

０．１

２．０ ８．０４．０

ＮＯｘ＋ＨＣ (g/kwhr)

６．０

NOx + HC: 40% reduction, PM: Same with Tier-2 from Y2006JPN Government Proposal: PM 30% lower than EPA, EC T-3

Key Technologies of Diesel Engine

Noise TechnologyNoise Technology

Base TechnologyFriction Reduction

Base TechnologyFriction Reduction

Turbo-ChargingTechnology

Turbo-ChargingTechnology

Total Electronic ControlTotal Electronic Control

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

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

Exhaust Manifold

Air

EG

R G

as

EGR

Cooler

Inte

r C

oo

ler

EGR = Exhaust Gas Re-circulation

EGR Valve

Fuel ImprovementFuel Improvement

Injection SystemInjection System

EGR TechnologyEGR Technology

Inlet Manifold

Technologies and Emission Level (130kW～)

NOx + HC g/kWh

PM　

g/kW

h

Tier 3

Tier 2

０ １． ３． ４． ５．０

０．

０．

０．

２．

Tier 2 trade-off70MPa pressure　Inter cooler

Tier 3 trade-off130MPa pressureCooled EGRElectronic control

Engine ModificationLimit

０.４

６．

JPN Tier-3

Regulation and Effect(6WG1X）

Applied Tandem Cooled EGRHigh Injection Pressure

(80t:120Mpa,65t&45t:130Mpa)Noz.Hole Dia

(80t&65t:8-Φ0.21,45t:8-Φ0.19)

Basic Information of Tier 3 Engine

• Low Emission• Low Noise• High Power

→ Electronic Controlled Engine

1. Tier 2 Engine Comparison2. Electronic Control3. Common Rail System4. Cooled EGR

6WG1 Engine Specification6WG1TQA 6WG1XQA 6WG1XYSA-01

TIER2 TIER2 TIER3Water cooled, 6-cycle, inline

4-cylinder, OHC,direct injection diesel

Water cooled, 6-cycle, inline4-cylinder, OHC,

direct injection diesel

Water cooled, 6-cycle, inline4-cylinder, OHC,

direct injection dieselRated output (kW/min-1) 235.4/1800 295/1800 260/1800

Maximum torque (Nm/min-1) 1275/1500 1540/1500 1580/1500Cylinder arrangement

and number– bore × stroke

(mm)

Displacement (L)

16

Compression pressure MPa(psi)/rpm

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

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 injectionsystem (common rail type)

Denso HP017.7/22.1 17.7/22.1 180MPaRSV type RSV type Electronic typeEquipped Equipped Electronic type

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

Bosch KBL2.4

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

Bosch KBL2.4

InjectorMulti-hole type(8xφ0.19mm)

Denso G2No No Installed

ModelItem

Engine model

Compression ratio

Injection pump type

Governor type

Fuel injection order

L6-φ147×154

2.75(400)/200

Injection pressure

Nozzle type

Timer type

15,681

1-5-3-6-2-4

16.4

Exhaust gas recirculation device (EGR)

6WG1 Engine Specification6WG1TQA 6WG1XQA0* 6WG1XYSA-0*

TIER2 TIER2 TIER3

Cartridge(Filter paper type) Cartridge(Filter paper type) Filter paper type

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

Amount of engine oil (L) Total 42-52 (37-47 Oil Pan) Total 42-52 (37-47 Oil Pan) Total 42-57 (37-52 Oil Pan)

Cooling water fullcapacity

(L)

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 24-5.0RHC9(IHI) RHC9(IHI) TD08H-31M (MHI)

Not Equipped Equipped Equipped

Thermostat valve opentemperature(10mm)

(℃)

ModelItem

Cooling system method

Water pump type

Thermostat typeAir cleaner type

Fuel filter type

Oil filter typeOil pump type

Oil cooling type

Centrifugal, belt type

Water-cooled controlled circulation type

Water-cooling

36

　To be supplied by OEM2 wax-type units

Turbocharger typeIntercooler type

83(95)

EnginePerformance

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

ﾌﾟー ﾘｰ比 －

日立建機（株）殿向け　361型45ｔ搭載AH-6WG1XＹ ｸ‐ﾘﾝｸ ﾌ゙ｧﾝ 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

ｴｷｿﾞー ｽﾄｻ ｲﾚﾝｻ ｰ 付（13.3ｋＰａ）

0

50

100

150

200

250

300

100012001400160018002000

軸ﾄﾙｸ(

Nm)

237±13.6g/kWh以下 ／2000min-1

POW

ER O

UTPU

T（ｋＷ）

180

200

220

240

260

500 1000 1500 2000 2500ENGINE SPEED(min-1)

SFC(

g/kW

h)

1900±30rpm

260±4kW／1800min-1

1380Nm以上／約1500min-1（1580±47）

214±13.6g/kWh＠1800ｍｉｎ-1

（1370±69Nm／1000min-1）

（　）内ISUZU目標値

Engine Layout /Main Parts Main Fuel Filter

(Tandem)

EGR Cooler

(Tandem)

EGR Valve

Supply Pump

(G Sensor)

Common Rail

Engine Layout /Main Parts

Turbocharger

Remote Oil Filter Port

Characteristics of Main Structure Components

SymmetryHigh RigidityC.Block

High RigidityRudder Frame

Maximum Inj.Pressure１３０ＭＰaElectronic Cont.Common Rail

OHC 4VALVEHigh Rigidity ofCyl. Head

High RigidityC. Shaft

High EfficiencyTurbocharger（no Waste Gate）

Cooled ＥＧＲ

High Rigidity（Rudder Frame）

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

6WG1X-Tier2との比較 ＦＡＮ無

●――――●

6WG1X-Tier3ＦＡＮ：無

×- - - - -×

6WG1X-Tier2ＦＡＮ：無

ＥＮＧ．ＴＹＰＥ ＡＨ－６ＷＧ１ＸＳＯＵＮＤ　ＰＲＥＳＳＵＲＥ　ＬＥＶＥＬ***　AVERAGE　***

84

86

88

90

92

94

96

98

100

600 800 1000 1200 1400 1600 1800 2000 2200ＥＮＧＩＮＥ ＳＰＥＥＤ （ｒｐｍ）

ＳＰＬ

-ＡＶＥ

（ＦＵＬＬ

ＬＯＡＤ）

ｄＢ（Ａ）

6WG1X-Tier2比約３ｄB（A)の低騒音ﾎ ﾃ゚ﾝｼｬﾙ

Fan : none

Fan : none

Comparison with Tier 2

3 db(A) lower

Than Tier 2

Sensor Layout

Name1.Pressure Control Valve2. Fuel Temperature Sensor3. G Sensor (Cam speed)4. Boost Temperature Sensor5. Common Rail Pressure Sensor6. Engine Coolant Temp. Sensor

7. EGR Valve8. Boost Pressure Sensor9. CKP Sensor (Crank speed)

10. Engine Oil Pressure sensor11. Overheating Switch

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

System Schematic (6WG1)Common Rail Pressure Sensor Pressure Limiter

Common Rail

Injector

ECM

CKP Sensor

Supply Pump

Comparison with Conventional SystemTWV: Two Way Valve

Common Rail System Characteristic・The common rail system uses a type of accumulation chamber called a rail to store pressurized

fuel, and injectors that contain electronically controlled solenoid valves to inject the pressurized fuel into the cylinders.

・Because the engine ECM controls the injection system (including the injection pressure,injection rate, and injection timing), the injection system is independent and thus unaffectedby the engine speed or load.

・Because the engine ECM can control injection quantity and timing to a high level of precision, even multi-injection is possible.

・This ensures a stable injection pressure at all times, even in low engine speed range.

Fuel Injection Rate Control

6WG1X Tier3 apply Main & Pilot Injection only

Fuel Injection Rate Control

Conventional InjectionConventional Injection Pilot InjectionPilot Injection

Injection rate

Generation rate of heat

Crank angle (°) Crank angle (°)

Large mixed combustion (NOx, noise)

Small mixed combustion

Pilot Injection reduce NOx and Noise

ECM Diagram (6WG1X)

　Refer toTrouble ShootingManual　(NM1J1-E-ENG-T)

　　１Ｅ－１０８

　Refer toTrouble Shooting Manual　　　１Ｅ－８８

Control System

Other sensors,

Switches

Other sensors,

Switches

InjectorInjector

Cylinder identifying signalCamshaft position

sensor,

G sensor

Camshaft position sensor,

G sensor

Engine speed

Accelerator position

Accelerator position

sensor

Accelerator position

sensor

Sensors Actuator

・Injection amount control・Injection timing control

Common rail pressure sensor

Common rail pressure sensor

Supply pumpSupply pump

・Injection pressure control

Crankshaft

position sensor

Crankshaft

position sensor

Function of ECMEngine 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　　　Idling control　　　QOS　　　Self-diagnostic function　　　CAN communication

All control is calculated and set bythe on-boad control module,　using the performance map and according to the detected engine and ambient conditions.　　

ECM Engine Data MapENG SPEED rpm

y ¥ x 0 400 550 600 700 950 975 1020 1030 1070 1090 1200 1300FUEL 0 50 30 30 40 50 65 80 80 85 85 90 90 90QUONTITY 10 50 30 30 40 50 50 80 80 85 85 90 90 90MM3/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 9045 50 40 40 40 50 65 80 80 85 85 90 90 9075 50 50 50 50 50 65 80 80 85 85 90 90 9085 50 50 50 50 50 65 80 80 85 85 90 90 9095 50 50 50 50 50 65 80 80 85 85 90 90 90

120 50 50 50 50 50 65 80 80 85 85 90 90 90

070

010

3013

00

1450

2000

3500 0

95230

0

50

100

150

100-15050-1000-50

Engine speed (rpm)

Fuel Quontity (mm3/st)

RailPressure (MPa)

Rail Pressure

ECM has several Engine Control Data Map

①Base Map－Engine Speed v.s. Rail 　　Pressure, Fuel Quantity etc

②Compensation Map－Coolant Temp. Atmospheric Pressureetc

Fuel Injection at Starting

Engine starting mode

Starter signal ONLess than "N1" speed (rpm)

Engine speed

Inje

ctio

n am

ount

at

cran

king

At low temperature

At high temperature

6WG1X N1=950rpm

Startig Fuel Quantity Adjust

始動燃料流量補正（mm3/st）

エンジンクーラント温度 (deg C)

Starting Fuel Quantity

Engine Coolant Temp.

ECM adjust Starting Fuel Quantity by Coolant Temperature Sensor signal

High Altitude Correction

ECM adjust maximum Fuel Quantity by Atmospheric Pressure Sensor signal

Maximum Fuel Quantity

Atmospheric PressureHigh Altitude

Over Heat Control

100℃

105℃

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

Engine Coolant Temp.

Fuel Quantity

Engine Coolant Temp.

QOS (Quick On Start) System

The ECM determines the period required for glow (pre-glow, glow, after-glow), and operates the glow relay and QOS indicator lamp.QOS system allows to make the starting at cold weather easier and reduce white smoke and noise at starting.When turning the key switch to ON, the ECM detects the engine coolant temperature by signal from engine coolant temperature (ECT) sensor and changes the period for glow so that the proper starting conditions can be achieved all the time.Also, after-glow function allows stabilize idling immediately after starting.

Pre-Heat Time

Engine Coolant Temp.

ＣＡＮCommunication Circuit All ECU on Vehicle connected through CAN Communication Circuit

Monitor Unit　　

ICF

MC

ECM

SatelliteCommunication

Dr.ZX

CAN Bus

CAN Bus

Tech2

○MC：Main Controller

○ECM：Engine Control Module

○ICF：Information Controller

○Monitor Unit

CAN（Controller Area Network）communicate

・Target Engine Speed

・Engine and Vehicle Trouble Code

・Monitoring Engine and Vehicle Operating

Condition

ＥＣＭＣｏｎｎｅｃｔｏｒＲｅｍｏｖａｌ

Pull down the Lever until sound coming

Push the Button Lift up the Lever

Common Rail System（ＰＣＶ)Common Rail Pressure Sensor Pressure Limiter

Common Rail

Injector

ECM

CKP Sensor

Supply Pump (PCV)

Common Rail System Main PartsInjector

Injector Hole DiameterZX450-3: 8-Φ0.19　ZX650/800-3: 8-Φ0.21

Common Rail

Supply Pump

G Sensor (Cam speed)

PCV : Pressure Control Valve

ECM

Supply Pump（PCV type）

(Pressure Control Valve)

Feed Pump　　 ＧSensor Gear　　　　

Supply Pump (PCV) operation

Can Lift

PCV Operation Close Valve

Open Valve

Close Valve

To Common Rail

PlungerDelivery Valve

Intake Stroke Pumping Stroke

ＰＣＶRelay

ＰＣＶCircuit

Common RailFlow damper

Common rail pressure sensor Pressure limiter

Pressure Limiter

Valve open

Valve closed

Common rail pressure

Abnormally high pressure

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.

Engine Speed (rpm)

Fue

l Qua

ntity

(m

m3/

st)

30 – 60MPa

100 – 150MPa

160MPa

70 – 90MPa

（Rail Pressure Sensor）

Rail Pressure Sensor

Sample of Rail Pressure

Appx 130Mpa

6WG1X

Fuel Quantity

Appx 30MPa 1800RPM

900RPM

Engine Speed

Flow damper

Common rail Injector

SpringBallPiston

Flow damper

Reduce the pressure pulsations in the pressurized

line and also prevent abnormal discharge of fuel

Flow Damper Operation (at Stop)

Common rail Injector

SpringBallPiston

Flow Damper Operation (at Damping)

Common rail Injector

SpringBallPiston

Flow Damper Operation (at Abnormal Discharge)

Common rail Injector

SpringBallPiston

Seat

InjectorOrifice 1

Orifice 2

Nozzle OrificeHydraulic piston Solenoid

Injector Outline

Common rail pressuresensor

Common rail pressure sensor

Common rail

Nozzle

Supply pump

Injection pressure control

Hydraulic piston

Control chamber

Orifice

Leak

Injector Circuit

Charge circuit

Constant current circuit

Constant current circuit

Injector Operation-- No Signal --Outer valve

Orifice 1Orifice 2

Common railHydraulic piston

Return

Inner valve

No signalNo signal

Injector Operation-- Signal Input --

Outer valve

Orifice 1Orifice 2

Common railHydraulic piston

Return

Inner valve

Valve open

Signal inputSignal input

Injector Operation-- Injection Start --

Outer valve

Orifice 1Orifice 2

Common railHydraulic piston

Return

Inner valve

Injection StartInjection Start

Injector Operation-- Signal Stop --

Outer valve

Orifice 1Orifice 2

Common railHydraulic piston

ReturnValve closed

Signal stopSignal stop

Injector Operation-- Injection Stop --

Outer valve

Orifice 1Orifice 2

Common railHydraulic piston

Return

Inner valve

Injection stopInjection stop

1. Injector2. Injector Harness3. Injector Terminal Nut

High Voltage applied on the Injector (above118V)Battery cable must be disconnectedduring Injector related work.

Injector Terminal

4HK1

Injector Current and Voltage15A or more

Max. 130V

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

G Sensor

ＣＫＰSensor

Ａｍｐ回路

Ａｍｐ回路

G sensor detects the G sensor Gear

rotation and identifies the cylinder.

CKP sensor detects the engine

speed.

CKP Sensor Waveform

ＧSensor Waveform

G Sensor Waveform

No.1 cylinder TDCRecognition pulse

G Sensor

G(CMP), CKP(NE) Sensor Diagram (6 Cylinders)

No.6 cylinderTDC standard pulse No.1 cylinder TDC

Recognition pulse

No.1 cylinderNE standard pulse

No.6 cylinderNE standard pulse

No.1 cylinderTDC standard pulse

No.1 cylinderNE standard pulse

Common Rail Pressure Sensor

Common rail pressure

Boost Pressure Sensor

Boost pressure

Electronic circuit Silicon chip

Vacuum chamber

FilterIntake air pressure

Engine Coolant Temperature Sensor

Engine coolant temperature

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

Fuel Temperature Sensor

Fuel temperature (℃)

Fail-safe: Takes the value of the water temperature sensor in case of abnormality.

Fail-safe: Takes the value of the water temperature sensor in case of abnormality.

Intake Air Temperature Sensor

Intake air temperature (°C)

Fail-safe: Takes the value of the water temperature sensor in case of abnormality.

Fail-safe: Takes the value of the water temperature sensor in case of abnormality.

Cooled EGREGR stands for ”Exhaust Gas Recirculation”.This equipment lowers burning temperature by mixing some of the emitted exhaust gas with the intake air to control oxygen concentration in the combustion chamber slowing down combustion.This enables reduction of nitrogen oxide or ”NOx”which is produced during high-temperature combustion. Cooled EGR system is a system which equips cooling system in the EGR gas passages.This system contributes reduction of NOx by further lowering the burning temperature than normal EGR with cooling down the heated EGR gas with cooler before mixing with the intake air.Moreover, by cooling down the high temperature EGR gas, intake air concentration is increased resulting in more air capacity.This brings close to the perfect combustion resulting in reduction of PM and other graphite as well as better fuel consumption.

Engine

From intercooler

Turbo

To silencerFrom air cleaner

EGR cooler

Coolant out

Coolant in

EGR valveReed valve

ECM

Exhaust manifold

Intake manifold

To intercooler

1.Various Sensor Inputs2.Exhaust Gas Re-circulation (EGR) Valve3.EGR Cooler4.Engine Coolant 5.Intake Air6.Engine Control Module (ECM)

1.EGR Pipe2.EGR Cooler3.EGR Adapter4.EGR Valve & REED VALVE

ＥＧＲLayout

EGR VALVE ASM

EGR Control

ECM operates the motor according to engine speed, engine load, etc. to control amount of EGR valve lift.Amount of valve lift is detected by EGR position sensor.The dark color area in the figure shows the valve lift amount is large, and the darkest color area shows that the valve lift amount is almost 100%.

ＥＧＲGas Flow ControlEGR gas enter into the intake side when intake air pulsation higher than exhaust gas pulsation

REED VALVE prevent Intake Air enter into Exhaust Gas Side

Intake Air Pulsation Exhaust Gas Pulsation

EGR Control

SENSOR OUTPUT

UVW INPUT

ECM provides 5 V to the EGR positionsensor U, V, and W through 5-V powersupply circuit and grounds to the insideof 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 positionby counting the number of change inpolarity.

Fuel Filter，Fuel PumpPriming Pump

Main Filter

6WG1X : TandemPre. Filter

Filter Wrench

(Pre, Main common）

Improve Engine Oil Drain Method（OIL PAN）

Drain Cock

Drainer

（On Vehicle）

How to Replace Parts1

2

3

45

Change sealing line

（Not Reuse）

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.

For SCV pump, the pump unit cannot be replaced itselfbecause the fuel temperature sensor is installed on it.

Be sure to replace it as supply pump ASSY.

Name1. Injector pipe2. Flow damper3. Common rail pressure sensor4. Fuel temperature sensor5. Pressure limiter

2005.4.14

Danger Need Care Good Unkown・Sulfur contents ；　　　 1000～3000ppm / above 3000ppm・Water contents・Dust contents・Fuel viscosity ; 　 HFRR 460～560 / above 600・Additive　　

SulfurWaterDust

ViscosityAdditive

SulfurWaterDust

ViscosityAdditive

SulfurWaterDust

ViscosityAdditive

SulfurWaterDust

ViscosityAdditive

SulfurWaterDust

ViscosityAdditive

SulfurWaterDust

ViscosityAdditive

SulfurWaterDust

ViscosityAdditive

SulfurWaterDust

ViscosityAdditive

CANADA

S.America

N.Europe

N.Africa

M.East China，E.Asia

S.E.Asia

JAPAN

Level of Consideration

OseaniaSulfurWaterDust

ViscosityAdditive

SulfurWaterDust

ViscosityAdditive

E U

SulfurWaterDust

ViscosityAdditive

W.RussiaSulfurWaterDust

ViscosityAdditive

E.Russia

SulfurWaterDust

ViscosityAdditive

N.America

SulfurWaterDust

ViscosityAdditive

S.Africa

SulfurWaterDust

ViscosityAdditive

World Fuel Map for Off-road 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 forECM protection.

3.Cooled EGR

→Must be keep ISUZU fuel requirement.

→Must be keep ISUZU Engine oil requirement and maintenance.

→Observe engine strictly of Maintenance.

AGAIN

List of Special Service Tools (1/3)

List of Special Service Tools (2/3)

List of Special Service Tools (3/3)

　Detect Failure

Dr.ZX

Dr.ZX

　Tech2

ZXZX-3

Monitor

SCAN Tool

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

(Special Tool)　Breaker Box（Harness Checker ）

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

Refer to

6WG1X EngineTroubleshootingManual(NM1J1-E-ENG-T)

　　１Ｅ-８５

(Special Tool)　Injector Checker

Injector Checker is a tool to easily check the defect injector by cuttingthe current flow to a selected injector.(Same function will be applied on the Dr.ZX around Mar.’06)

Refer to6WG1X Engine TroubleshootingManual　（NM1J1-E-ENG-T)　　１Ｅ-７８

　　Trouble Shooting procedure

A. Diagnostic process with an interview1) Confirm user complain. (Use Questionnaire Sheet)

2) Carry out preparative inspection.3) Confirm service information.4) Confirm DTC code. (Translate to Isuzu Code)

5) Confirm phenomenon by visual observation.

B. Repair

C. Check

(Notice) ECM Power OFFThe power supply inside the ECM does not go off for about 10 secondsafter turning the key switch OFF. If the ECM power needs to be off such as for memory clear, wait for more than 10 seconds after turning the key switch OFF.

Check list for engine control system Inspector's company nameInspector's name

User User's name Machine applicationAddress

Machine Date of delivery Date of trouble occurrenceOperating periodMachine model name Machine No.

Engine Engine model name Engine No.

Engine does not start □ □ □ □

Difficult starting of engine□ □ □ □

Unstable idling □ □ □ □

Drivability is low. □ □ □ □

Engine stall□ □ When accelerator

pedal (lever) is released□ □

□ When gear is shifted up　When operating at full load

□ At certain operationmode

□ □

Vibration at idling

Trouble occurrence dataFrequency of trouble □ □ □ □

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 □ Spring □ Summer □ Autumn □ WinterLocation □ Outdoor □ Construction field (Type □ General road □ Rough road

□ Indoor □ Roadworks field (Type ) □ Expressway □ Slope (grade degree )

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

Engine temperature □ Cold □ During warming-up □ After warmed-up □ Others ( )Oil/coolant temperature □ Engine coolant temperature□ Oil temperature ( ℃)Operating condition □ □ □ □

□ □ □ □

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 ( )□ 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 onDTC Current trouble □（　　　　　　　　　） □（　　　　　　　　　） □（　　　　　　　　　） □（　　　　　　　　　）

□（　　　　　　　　　） □（　　　　　　　　　） □（　　　　　　　　　） □（　　　　　　　　　）

Past trouble □（　　　　　　　　　） □（　　　　　　　　　） □（　　　　　　　　　） □（　　　　　　　　　）

□（　　　　　　　　　） □（　　　　　　　　　） □（　　　　　　　　　） □（　　　　　　　　　）

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

Trou

ble s

ympt

omTr

ouble

con

dition

Confirm user complain using Questionnaire sheet

Refer to

6WG1X EngineTroubleshootingManual(NM1J1-E-ENG-T)

　　１Ｅ-１３、１４

　　　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.　　　　

Translate Hitachi DTC Code to Isuzu CodeTranslate 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）　ＩＥ－５７１

DTC Code Reference Sheet for Hitachi and Isuzu

ＳＰＮ ＦＭＩ Ｐ Code ＤＴＣ description Trouble displayon monitor

９１ ２ Ｐ１２７１ Accelerator sebsor1-2 comparison fault

○

９１ ３ Ｐ１２７７ Accelerator sebsor 1fault (low voltage)

○

９１ ３ Ｐ１２７７ Accelerator sebsor 1fault (high voltage)

○

Detail of DTC (Diagnostic Trouble Code)

List of diagnostic trouble codeList of diagnostic trouble codesOn some machines, the diagnosis lamp comes on instead of trouble display monitor on the machine.

６WG１Ｘ

ＤＴＣ Flashcode

ＤＴＣdescript ion

Item to bedetected

Precondit ionswhen DTC is

set

ＤＴＣ setcondit ion

Faultjudgment

period

Behavior whentrouble occurs

Diagnosis lamp

P0088 118 Common railpressure

fault(1st stage)

Common railpressureabnormalincrease

・Key switchinput voltage

is 16V ormore.

・DTC P0088,P0192,P0193or P1635 is

not detected.

Rail pressureis more than

150Mpa(21756psi)

Approx.5 sec

Increase enginevibration, roughidling, outputlowering, blow upfault , black smokeemitted, andexcessive outputare possible.Back-up:Limited injectionamount 3 (mult i-injection stopped)Target RP upperlimit(80 Mpa{11603 psi})

ON

　ＩＥ－１７０

Description of DTC Code（P００８８, Refer to　１Ｅ-１８３～１８７

Recovery from failure, refer to ＩＥ－１８２

Isuzu DTC code detail, refer to Trouble Shooting Manual １Ｅ-１７０～１８１Hitachi unique DTC code, refer to １Ｅ－５７５～５７８

Recovery from Failure

Trouble occurs Inspection and repair, or temporary recovery from failure

Recovery from failure

Trouble occurs

Recovery from failure

Inspection and repair, or temporary recovery from failure

Pattern 1Pattern 1 Pattern 2Pattern 2Wait 10 seconds

Recovery from Failure

Pattern 3Pattern 3 Engine is recovered from failure, but trouble code exists and lamp remains on.

DTC Clear Action Required

Inspection and repair, or temporary recovery from failure

Trouble occurs

Recovery from failure

Trouble Shoot Process from PhenomenonConfirm failure phenomenon and read detail description of each failure

Refer to 6WG1X Engine Trouble Shooting Manual（NM1J1-E-ENG-T)１Ｅ-５３９～５６９

List of trouble symptom

Symptom DescriptionEngine start failure Crank speed is slow.

Crank speed is normal but engine does not start. (notfirst combustion).Engine start (first combustion exists) but can notmaintain 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.

Electronic control fuel injection system（Common rail type）　ＩＥ－５３９

About Tech2　（ＩｓｕｚｕS Tool)

1) Display of Diagnostic Trouble CodesPerforms Reading, confirmation and clearing of DTC

Displays the current data recognized and controlled by ECM2) Data Display

3) SnapshotRecords and plots data when trouble occurs

5) Actuator TestChecks operation and function at each test and confirms abnormality

4) ProgrammingEnables to confirm the history of data when ECM is replaced

Trouble Diagnosis Results of Tech2

• Past TroubleDiagnostic 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 TroubleDiagnostic 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 PastTrouble code.

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 nearposition of ECM.

Injector QＲCode Programming

Injector QR code

Ｔｅｃｈ２

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）

Ｄｒ．ＺＸ

What is Injector QR Code

Actuating Pulse Width TQ

ＲａｉｌＰｒｅｓｓｕｒｅParameter

Injection Quantity

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

Ｄｒ．ＺＸ or Ｔｅｃｈ２

QR Code Correction Point

Injector ; QR Code

Injector QR Code

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