RETURN

RETURN

ISUZU INDUSTRIAL DIESEL ENGINE 6WG1X Tier3

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

HITACHI CONSTRUCTION MACHINERY CO.,Ltd Technical Training Center

Table of contents

1.Differences between Tier2 engine and Tier3 engine. Differences between Tier2 engine and Tier3 engine. Off Road Emission Regulation Engine Specifications Engine Layout /Main Parts Engine Layout /Sensors Out Line of Common Rail System Common Rail System Comparison with Conventional System System Component ECM a SUPPLY PUMP b c COMMON RAIL INJECTOR d HARNESS INJECTOR e 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 DTC code Scan Tool EMPS How to use scan tool 6. Point to notice on service Parts replace procedure 7. Trouble Shooting on actual machine

RETURN

RETURN

Tier-3 Engine major specification and Maintenance point

1.High pressure fuel injection control by common rail system. Prohibit teardown and re-adjustment of injector. Prohibit re-use of injector pipe and high pressure fuel pipe. Must be keep ISUZU fuel requirement. Keep observe strictly the maintenance schedule. 2.Electronic control module. notice : A battery cable must be disconnect at the time of welding work for ECM protection. 3.Cooled EGR Must be keep ISUZU fuel requirement. Must be keep ISUZU Engine oil requirement and maintenance. Observe engine strictly of Maintenance.

Off-Road Future Emission Regulation

Off-Road Future Emission Regulation
CLASS EP A 450 - 560 kW (600 - 750hp) 225 - 450 kW (300 - 600hp) 130 - 225 kW (175 - 300hp) 75 - 130 kW (100 - 175hp) ENGINE 2001 2002 T ier2 2003 2004 2005 2006 T ier3
NOx+HC 4.0 CO 3.5 PM 0.2

RETURN

2007

2008

2009

2010

2011 int erim T ier4 int erim T ier4 int erim T ier4

2012

2013

2014

2015

6W,6S

T ier2

NOx+HC 6.4 CO 3.5 PM 0.2

T ier3

Nox+NMHC 4.0 CO 3.5 P M 0.03

6H

T ier2

NOx+HC 6.6 CO 3.5 / P M 0.2

NOx+HC 6.6 CO 5.0 / P M 0.3

T ier3
NOx+HC 4.0 CO 5.0 / P M 0.3
NOx+HC 4.7 CO 5.0 / P M 0.4

4H

T ier2

T ier3

int erim T ier4

Nox+NM HC 4.0 CO 5.0 / P M 0.03

37 - 75 kW (50 - 100hp)

4J,4LE

T ier2

NOx+HC 7.5 CO 5.0 / P M 0.4

T ier3

56kw

int erim NOx + HC 4.7 T ier4 CO 5.0 / P M 0.03

EC

130 - 560 kW

6W,6S,6H

St age2

NOx 6.0 / HC 1.0 CO 3.5 / PM 0.2

NOx 6.0 / HC 1.0 CO 5.0 / P M 0.3

St age3-A

NOx+HC 4.0 CO 3.5 / PM 0.2

NOx+HC 4.0 CO 5.0 / P M 0.3
NOx+HC 4.7 CO 5.0 / P M 0.4

St age3-B

NOx+HC 4.0 CO 3.5 / P M 0.025

75 - 130 kW

4H

St age2

St age3-A

NOx+HC 4.0 St age3-B CO 5.0 / P M 0.025

37 - 75 kW

4J,4LE

St age2
NOx 8.0 / HC 1.5 CO 5.5 / P M 0.8

NOx 7.0 / HC 1.3 CO 5.0 / P M 0.4

St age3-A

St age3-B neary same as EPA

19 - 37 kW

St age2

NOx+HC 7.5 St age3-A CO 5.5 / P M 0.6

NOx 3.6 / HC 0.4 CO 3.5 / P M 0.17
NOx 3.6 / HC 0.4 CO 5.0 / P M 0.2

No proposal as St age3-B

JP N

130 - 560 kW

6W,6S,6H

NOx 6.0 / HC 1.0 T ier-2 CO 3.5 / PM 0.2

NOx 6.0 / HC 1.0 T ier-2 CO 5.0 / PM 0.3

T ier-3

T ier-4 Aft er t reat ment (DP F) basis

75 - 130 kW

4H

T ier-3

56 - 75 kW

4J
NOx 7.0 / HC 1.3 CO 5.0 / PM 0.4 T ier-2
NOx 8.0 / HC 1.5 T ier-2 CO 5.5 / P M 0.8

T ier-3

NOx 4.0 / HC 0.7 CO 5.0 / PM 0.25

37 - 56 kW

4LE

T ier-3

NOx 4.0 / HC 0.7 CO 5.0 / PM 0.3

19 - 37 kW

T ier-3

Nox 6.0 / HC 1.0 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

/EC Tier-3 130kW 2006) JPN Tier-3 130kW(2006) g/kwhr) EPA Tier-4 (2012) EC Stage-B (2012)

(130kW)

Tier-2 130kW(2003)

(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 EGR Valve EGR EGR Technology Technology Noise Noise Technology Technology Inlet Manifold Inter Cooler Injection Injection System System Base Base Technology Technology Friction Friction Reduction Reduction
R EG

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

EGR Gas

Co e ol r

Total Total Electronic Electronic Control Control

Fuel Fuel Improvement Improvement

Exhaust Manifold Turbo-Charging Turbo-Charging Technology Technology Air

RETURN

Technologies and Emission Level (130kW)

. Tier 3 trade-off
130MPa pressure Cooled EGR Electronic control

PM g/kWh

Tier 2 trade-off
70MPa pressure Inter cooler

Tier 3 Tier 2 JPN Tier-3 Engine Modification

Limit

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:8-0.21,45t:8-0.19)

RETURN

Basic Information of Tier 3 Engine

Low Emission Low Noise Electronic Controlled Engine High Power

1. 2. 3. 4.

Tier 2 Engine Comparison Electronic Control Common Rail System Cooled EGR

6WG1 Engine Specification

Model Item Engine model Rated output Maximum torque Cylinder arrangement and number bore stroke Displacement (kW/min-1) (Nm/min-1) (mm) (L) 16.4 2.75(400)/200 146210071287(with fan) 1125 Mechanical fuel injection pump (Inline fuel injection pump) BOSCH PE-P-S3S 17.7/22.1 RSV type Equipped 2Stage Nozzle Multi-hole type(8x0.24mm) Bosch KBL2.4 No 174110161340(with fan) 1185 1-5-3-6-2-4 Mechanical fuel injection pump (Inline fuel injection pump) BOSCH PE-P-S3S 17.7/22.1 RSV type Equipped 2Stage Nozzle Multi-hole type(8x0.24mm) Bosch KBL2.4 No 146210151422(with fan) 1153 Electronic control fuel injection system (common rail type) Denso HP0 180MPa Electronic type Electronic type Injector Multi-hole type(8x0.19mm) Denso G2 Installed 6WG1TQA TIER2 Water cooled, 6-cycle, inline 4-cylinder, OHC, direct injection diesel 235.4/1800 1275/1500 6WG1XQA TIER2 Water cooled, 6-cycle, inline 4-cylinder, OHC, direct injection diesel 295/1800 1540/1500 L6-147154 15,681 16 6WG1XYSA-01 TIER3 Water cooled, 6-cycle, inline 4-cylinder, OHC, direct injection diesel 260/1800 1580/1500

RETURN

Compression ratio Compression pressure MPa(psi)/rpm Dimensions (mm) (length width height) Weight (kg) Fuel injection order Injection pump type Injection pressure Governor type Timer type Nozzle type Exhaust gas recirculation device (EGR)

6WG1 Engine Specification

Model Item Fuel filter type Oil filter type Oil pump type Oil cooling type Amount of engine oil (L) Total 42-52 (37-47 Oil Pan) 6WG1TQA TIER2 Cartridge(Filter paper type) Full flow filter(Remote) Gear type 6WG1XQA0* TIER2 Cartridge(Filter paper type) Full flow filter(Remote) Gear type Water-cooling Total 42-52 (37-47 Oil Pan) Total 42-57 (37-52 Oil Pan) 6WG1XYSA-0* TIER3 Filter paper type Full flow filter(Remote) Gear type

RETURN

Cooling system method Cooling water full capacity Water pump type Thermostat type Air cleaner type Generator capacity (V-A) MITSUBISHI 24-50 MITSUBISHI 24-7.0 RHC9(IHI) Not Equipped (L)

Water-cooled controlled circulation type 36 Centrifugal, belt type 2 wax-type units To be supplied by OEM MITSUBISHI 24-50 MITSUBISHI 24-7.0 RHC9(IHI) Equipped 83(95) MITSUBISHI 24-50 MITSUBISHI 24-5.0 TD08H-31M (MHI) Equipped

Starter (V-kW) Turbocharger type Intercooler type Thermostat valve open temperature(10mm) ()

RETURN

Engine Performance

30Hr 3.4 13.3

36145 AH-6WG1X

ISUZU (Nm) SFC(g/kWh)

137069Nm1000min-1 1380Nm1500min-1 158047 2000 1800 1600 1400 1200 1000 300

2604kW 1800min-1
250

POWER OUTPUT

200

150

100

50 190030rpm 0 260

23713.6g/kWh 2000min-1

240 220 200 21413.6g/kWh1800 -1 180 2500

500

1000

1500

2000

ENGINE SPEED(min-1)

RETURN

Engine Layout /Main Parts

EGR Valve Main Fuel Filter (Tandem)

EGR Cooler (Tandem)

Common Rail

Supply Pump (G Sensor)

RETURN

Engine Layout /Main Parts

Turbocharger

Remote Oil Filter Port

RETURN

Characteristics of Main Structure Components

Cooled

OHC 4VALVE High Rigidity of Cyl. Head

High Efficiency Turbocharger no Waste Gate

Maximum Inj.Pressure a Electronic Cont. Common Rail High Rigidity Rudder Frame

Symmetry High Rigidity C.Block

High Rigidity C. Shaft

High Rigidity
Rudder Frame

RETURN

RETURN

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

*** AVERAGE ***
-

Comparison with Tier 2 6WG1X-Tier2

100 98 96 94 92 90 88 86 84 600 800 1000 1200 1400 1600 1800 2000 2200
6WG1X-Tier2 3 db(A) lower B A) Than Tier 2

6WG1X-Tier3 Fan : none

- - - - -

6WG1X-Tier2 Fan : none

RETURN

Sensor Layout

Name 1.Pressure Control Valve 2. Fuel Temperature Sensor 3. G Sensor (Cam speed) 4. Boost Temperature Sensor 5. Common Rail Pressure Sensor 6. Engine Coolant Temp. Sensor

Refer to 6WG1 Engine Troubleshooting Manual (NM1J1-E-ENG-T) -

7. EGR Valve 8. Boost Pressure Sensor 9. CKP Sensor (Crank speed) 10. Engine Oil Pressure sensor 11. Overheating Switch

RETURN

System Schematic (6WG1)

Common Rail Pressure Sensor Common Rail Pressure Limiter

Supply Pump

Injector ECM CKP Sensor

Comparison with Conventional System

TWV: Two Way Valve

RETURN

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
Injection rate

Pilot PilotInjection Injection

Large mixed combustion (NOx, noise)

Small mixed combustion

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)

Control System
Sensors
Accelerator position Accelerator position Accelerator position sensor sensor Crankshaft Crankshaft position positionsensor sensor Camshaft Camshaftposition position sensor, sensor, GGsensor sensor Other Othersensors, sensors, Switches Switches

Refer to Trouble Shooting Manual

RETURN

Actuator

Injector Injector Engine speed Injection amount control Injection timing control Common rail Common rail pressure sensor pressure sensor

Cylinder identifying signal

Supply Supplypump pump Injection pressure control

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 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.

ECM Engine Data Map

yx FUEL QUONTITY MM3/ST 0 10 15 40 45 75 85 95 120 ENG SPEED rpm 0 400 550 50 30 30 50 30 30 50 30 30 50 30 30 50 40 40 50 50 50 50 50 50 50 50 50 50 50 50 600 40 40 40 40 40 50 50 50 50 700 50 50 50 50 50 50 50 50 50 950 65 50 50 65 65 65 65 65 65 975 1020 1030 1070 1090 1200 1300 80 80 85 85 90 90 90 80 80 85 85 90 90 90 80 80 85 85 90 90 90 80 80 85 85 90 90 90 Engine 80 80 ECM 85 has 85several 90 90 90 Control 80 80 85 85 Data Map90 90 90 80 80 85 85 90 90 90 80 80 Base 85 85 90 90 90 MapEngine Speed v.s. 80 80 85 85 90 90 90

RETURN

150
Rail 100 Pressure (MPa)

Rail Pressure, Fuel Quantity etc Compensation MapCoolant Temp. Atmospheric Pressure etc
100-150 50-100 0-50

50
230

700

95

1030

1300

1450

2000

Engine speed (rpm)

3500

Fuel Quontity (mm3/st)

Rail Pressure

RETURN

Fuel Injection at Starting

Injection amount at cranking

Engine starting mode Starter signal ON Less than "N1" speed (rpm)

At low temperature

At high temperature

Engine speed

6WG1X N1=950rpm

RETURN

Startig Fuel Quantity Adjust

Starting Fuel Quantity

mm3/st

ECM adjust Starting Fuel Quantity by Coolant Temperature Sensor signal

Engine Coolant Temp.

(deg C)

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 Temp. Engine 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.

 Communication Circuit
All ECU on Vehicle connected through CAN Communication Circuit
MC Main Controller
Satellite Communicatio n

RETURN

Dr.ZX

ECM Engine Control Module

ICF

ICF Information Controller

Monitor Unit

CAN Bus

Monitor Unit
MC

CAN Controller Area Network communicate Target Engine Speed Engine and Vehicle Trouble Code Monitoring Engine and Vehicle Operating Condition
Tech2 CAN Bus ECM

RETURN

Push the Button

Lift up the Lever

Pull down the Lever until sound coming

RETURN

Common Rail System )

Common Rail Pressure Sensor Common Rail Pressure Limiter

Supply Pump (PCV)

Injector ECM CKP Sensor

Common Rail System Main Parts

Common Rail Injector
Injector Hole Diameter ZX450-3: 8-0.19 ZX650/800-3: 8-0.21

RETURN

PCV : Pressure Control Valve

Supply Pump ECM

G Sensor (Cam speed)

RETURN

Supply Pump PCV type

(Pressure Control Valve)

Feed Pump

Sensor 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

Circuit
Relay

RETURN

Common Rail
Flow damper

Common rail pressure sensor

Pressure limiter

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.

RETURN

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
900RPM

1800RPM

Engine Speed

RETURN

Flow damper
Flow damper

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

Common rail

Injector

Piston

Ball

Spring

RETURN

Flow Damper Operation (at Stop)

Common rail Injector

Piston

Ball

Spring

Flow Damper Operation (at Damping)

Common rail Injector

RETURN

Piston

Ball

Spring

Flow Damper Operation (at Abnormal Discharge)

Seat Common rail Injector

RETURN

Piston

Ball

Spring

RETURN

Injector
Orifice 1

Orifice 2

Nozzle

Hydraulic piston

Orifice

Solenoid

RETURN

Injector Outline
Common rail Common rail pressure pressure sensor sensor Leak

Orifice Common rail Control chamber Hydraulic piston

Nozzle Supply pump Injection pressure control

RETURN

Injector Circuit
Constant current circuit Constant current circuit

Charge circuit

Injector Operation -- No Signal -Outer valve Inner valve Orifice 1 Orifice 2 Common rail Hydraulic piston

RETURN

Return No signal No signal

Injector Operation -- Signal Input -Outer valve Inner valve Valve open Orifice 1 Orifice 2 Common rail Hydraulic piston Signal Signalinput input Return

RETURN

Injector Operation -- Injection Start -Outer valve Inner valve Orifice 1 Orifice 2 Common rail Hydraulic piston

RETURN

Return

Injection Start Injection Start

Injector Operation -- Signal Stop -Outer valve Orifice 1 Orifice 2 Common rail Hydraulic piston Valve closed Return

RETURN

Signal stop Signal stop

Injector Operation -- Injection Stop -Outer valve Inner valve Orifice 1 Orifice 2 Common rail Hydraulic piston

RETURN

Return

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

Injector Current and Voltage

15A or more

RETURN

Max. 130V

RETURN

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

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

G Sensor

CKP sensor detects the engine speed.

Sensor

RETURN

CKP Sensor Waveform

RETURN

Sensor Waveform
G Sensor

No.1 cylinder TDC Recognition pulse

G Sensor Waveform

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

RETURN

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

Boost Pressure Sensor

Electronic circuit

Silicon chip

Vacuum chamber

Filter Intake air pressure Boost pressure

RETURN

Engine Coolant Temperature Sensor

Engine coolant temperature

Fail-safe: Fail-safe:Changes Changesto to80 80 in incase caseof ofabnormality. abnormality.

RETURN

Fuel Temperature Sensor

Fuel temperature ()

Fail-safe: Fail-safe:Takes Takesthe thevalue valueof ofthe thewater watertemperature temperaturesensor sensorin incase case of abnormality. of abnormality.

RETURN

Intake Air Temperature Sensor

Intake air temperature (C)

Fail-safe: Fail-safe:Takes Takesthe thevalue valueof ofthe thewater watertemperature temperaturesensor sensorin incase case of abnormality. of abnormality.

RETURN

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 hightemperature 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
Coolant in

Intake manifold

EGR valve Reed valve

From intercooler

ECM

RETURN

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%.

 Gas Flow Control

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

RETURN

Intake Air Pulsation

Exhaust Gas 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 polarity.

SENSOR OUTPUT

UVW INPUT

Fuel Filter Fuel Pump

Priming Pump

RETURN

Main Filter Pre. Filter 6WG1X : Tandem

Filter Wrench
(Pre, Main common

Improve Engine Oil Drain Method

OIL PAN

RETURN

Drain Cock

Drainer On Vehicle

RETURN

How to Replace Parts

1
z z

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

4 5

1. 2. 3. 4. 5.

Injector pipe Flow damper Common rail pressure sensor Fuel temperature sensor Pressure limiter

Level of Consideration

World Fuel Map for Off-road Machine 2005.4.14

Danger above 3000ppm Need Care Good Unkown

RETURN

Sulfur contents 10003000ppm / Water contents Dust contents Fuel viscosity ; HFRR 460 560 / Additive

above 600
N.Europe
Sulfur Water Dust Viscosity Additive

CANADA
Sulfur Water Dust Viscosity Additive

W.Russia
Sulfur Water Dust Viscosity Additive

E.Russia
Sulfur Water Dust Viscosity
Additive

EU
Sulfur Water Dust Viscosity Additive

M.East
Sulfur Water Dust Viscosity Additive

China E.Asia
Sulfur Water Dust Viscosity Additive

N.America
Sulfur Water Dust Viscosity Additive

JAPAN
Sulfur Water Dust Viscosity
Additive

N.Africa
Sulfur Water Dust Viscosity Additive

S.E.Asia
Sulfur

S.America
Sulfur Water Dust Viscosity Additive

Sulfur
Water Dust Viscosity Additive

Water Dust Viscosity

Additive

Oseania
Sulfur Water Dust Viscosity
Additive

S.Africa
Sulfur Water Dust Viscosity Additive

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.

AGAIN

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)

 Detect
SCAN Tool

Failure

RETURN

ZX ZX-3
Dr.ZX
As

Dr.ZX

Monitor

Tech2

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 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) -

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) -

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 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.

Check list for engine control system

User Machine User's name Address Date of delivery Operating period Machine model name Engine model name

RETURN
Inspector's company name Inspector's name

Confirm Machine userapplication complain using Questionnaire sheet

Date of trouble occurrence Machine No. Engine No. When accelerator pedal (lever) is released At certain operation mode

Engine

Engine does not start Difficult starting of engine Unstable idling Drivability is low. Engine stall When gear is shifted up When operating at full load Vibration at idling

Trouble symptom

Trouble occurrence data Frequency of trouble Weather

Ambient temperature Season Location Engine temperature Oil/coolant temperature Operating condition Condition when trouble o Oil Fuel type

Fine Cloudy After lightening Others ( ) 30 or more Around 20 - 30 C Spring Summer Outdoor Construction field (Type Indoor Roadworks field (Type ) In mountain Harbor Others ( ) Cold During warming-up Engine coolant temperature Oil temperature ( ) After oil is replaced After oil filter is replac After operating on slope After out of gas Light oil Krosene Diesel fuel Special No. 3 Diesel fuel No. 2

Rain Around 10 - 15 C Autumn General road Expressway On the sea After warmed-up

Snow

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

Trouble condition

0 or less ( ) Winter Rough road Slope (grade degree ) Height ( m above sea level) )

Others (

After replenishment of After washing with high A heavy oil Diesel fuel No. 1

After sedimenter is drained Others ( ) Others ( ) Diesel fuel Special No. 1

Diagnosis lamp DTC Current trouble Past trouble Past trouble history

ON Year Month Year Month

Sometimes comes on Not come on Date (Content ) [Measure: Date (Content ) [Measure:

] ]

 How to use Trouble Shooting Manual

J

RETURN

Confirmation process from DTC code.(DTC;Diagnostic Trouble Code) Confirm DTC code by or 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

Translate Hitachi DTC code to Isuzu DTC code , Read detail description of each DTC code Refer to 6WG1X Engine Trouble Shooting Manual NM1J1-E-ENG-T) -
Electronic control fuel injection system Common rail type

RETURN

DTC Code Reference Sheet for Hitachi and Isuzu

Code description Ac celerator sebsor 1-2 comparison fault Ac celerator sebsor 1 fau lt (low voltage) Ac celerator sebsor 1 fau lt (high voltage) Trouble display on monitor

Detail of DTC
List of diagnostic trouble codes

RETURN

(Diagnostic Trouble Code)

Isuzu DTC code detail, refer to Trouble Shooting Manual - Hitachi unique DTC code, refer to List of diagnostic trouble code
On some machines, the diagnosis lamp comes on instead of trouble display monitor on the machine.

WG
P0088 Flash code 118 description Common rail pressure fault (1st stage) Item to be detected Common rail pressure abnormal increase Preconditions when DTC is set Key switch input voltage is 16V or more. DTC P0088, P0192,P0193 or P1635 is not detected. set condition Rail pressure is more than 150Mpa (21756psi)

Description of DTC Code P , Refer to - Recovery from failure, refer to

Fault Behavior when Diagnos judgment trouble occurs is lamp period Approx. Increase engine ON 5 sec vibration, rough idling, output lowering, blow up fault, black smoke emitted, and excessive output are possible. Back-up: Limited injection amount 3 (multiinjection stopped) Target RP upper limit(80 Mpa {11603 psi})

Recovery from Failure

Pattern Pattern 1 1
Wait 10 seconds

RETURN

Pattern Pattern 2 2

Trouble occurs Inspection and repair, or temporary recovery from failure

Recovery from failure

Trouble occurs

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

Recovery from Failure

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

RETURN

DTC Clear Action Required

Trouble occurs

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

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) -

RETURN

Electronic control fuel injection system Common rail type

List of trouble symptom

Symptom Engine start failure Description 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 cranks but take long time before start. It operates eventually, or starts but stops immediately.

Engine stall

RETURN

About Tech2 S Tool)

1) Display of Diagnostic Trouble Codes 2) Data Display 3) Snapshot
Records and plots data when trouble occurs Performs Reading, confirmation and clearing of DTC Displays the current data recognized and controlled by ECM

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

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)

RETURN

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 Q Code Programming

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

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 substantial increase in the number of fuel injection quantity correction points, greatly improving injection quantity precision. QR Code Correction Point
Parameter

RETURN

Injection Quantity

or

Actuating Pulse Width TQ

Injector ; QR Code

RETURN

Injector QR Code

Engine Label

RETURN

Label

Label

Engine Production serial NO. Injector QR Code

Engine Model / Production Month Month/Year) / month/ year JPN Label