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Isuzu Zx 3engine Text
Text NO. TTLA-0728-EN

ISUZU INDUSTRIAL DIESEL ENGINE

4JJ1X/4・6HK1X/6WG1X Tier3

ISUZU MOTORS LIMITED HITACHI CONSTRUCTION MACHINERY CO.,Ltd

Off-highway Powertrain Operation Dept. Planning Technical Training Center
& Service Group April 2007
 Table 1.  Differences between Tier2 engine and Tier3 engine.
of   ① Differences between Tier2 engine and Tier3 engine.
      Off Road Emission Regulation
contents       Engine Specifications
Engine Layout /Main Parts
Engine Layout /Sensors
   ② Out Line of Common Rail System
Common Rail System
      Comparison with Conventional System
   ③ System Component
   a ECM                 
       b SUPPLY PUMP
       c COMMON RAIL                         
      d INJECTOR              
     e HARNESS INJECTOR
  f SENSORS
g COOLED EGR
2. Maintenance Schedule
3. Introduction of SST
4. Trouble Shooting
   ① Trouble Shooting Procedure
② How to use Trouble Shooting Manual
5. DTC code
① DTC code
   ② Scan Tool
   ③ EMPS
   ④ How to use scan tool 
6. Point to notice on service （Parts replace procedure）
7. Trouble Shooting on actual machine 
 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 ENGINE 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015

450 - 560 kW int erim

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

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

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

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

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

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

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

NOx 7.0 / HC 1.3 NOx+HC 4.7

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

NOx 8.0 / HC 1.5 NOx+HC 7.5

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

NOx 6.0 / HC 1.0 NOx 3.6 / HC 0.4

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

NOx 4.0 / HC 0.7

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

NOx 8.0 / HC 1.5 Nox 6.0 / HC 1.0

CO 5.5 / P M 0.8     ▽ ▽ T ier-3
19 - 37 kW L T ier-2 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.
 Tier3 Emission Regulation (75∼130kW)

ＥＰＡＴｉｅｒ３/ECStageⅢ-A
75∼130kW（2007)
JPNTier-3
75∼130kW(2007) ＥＰＡ Tier-2
75∼130kW(2003)
０．３

 
ＰＭ
（g/kwhr)
０．２

EPA Tier-4
(2012)
０．１
EC StageⅢ-B
(2012)

２．０ ４．０ ６．０ ８．０

ＮＯｘ ＋ ＨＣ (g/kwhr)

NOx + HC: 40% reduction, PM: Same with Tier-2 from Y2006
JPN Government Proposal: PM 30% lower than EPA, EC T-3
 Key Technologies of Diesel Engine
EGR = Exhaust Gas Re-circulation Total
Total engine
engine technology
technology
EGR Valve -Combustion
-Combustion chamber
chamber
EGR
EGR Technology -Turbo-charging
Technology -Turbo-charging etc.
etc.
Noise
Noise Technology
Technology

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

ol
Technology

e
Friction
Friction Reduction

r
Injection Reduction
Injection System
Inter Cooler

System

EGR Gas
Fuel
Fuel Improvement
Improvement

Exhaust Manifold
Turbo-Charging
Turbo-Charging
Technology
Technology

Air

Tier 3 applied
New Technology
 Applied Technologies and Emission Level(75∼130kW)
０.４
Tier 3 trade-off Tier 2 trade-off
160MPa pressure 70MPa pressure
Cooled EGR  Inter cooler
Electronic control
PM g/kWh

０．３

Tier 3 Tier 2

０．２
JPN Tier-3 (plan)

Engine Modification
０．１ Limit

０
０ １．０ ２．０ ３．０ ４．０ ５．０ ６．０
NOx + HC g/kWh
 Engine Model for Zaxis-1 and Zaxis-3
ZX120∼ZX180
ZX-1 4BG1TC （Mechanical Controlled)
     ZX-3 ４JJ1X  （Electronic Controlled, Common Rail, EGR）
 
ZX200∼ZX270
     ZX-1 ６BG1TC （Mechanical Controlled)
     ZX-3 ４HK1X  （Electronic Controlled, Common Rail, EGR）
  
ZX330, ZX350
     ZX-1 ６HK1TC （Mechanical Controlled)
     ZX-3 ６HK1X  （Electronic Controlled, Common Rail, EGR）

ZX450∼ZX870
     ZX-1 ６WG1T/TC （Mechanical Controlled)
     ZX-3 ６WG1X  （Electronic Controlled, Common Rail, EGR）
 75kW(100HP)-130kW(175HP)
0.45 240
約230g/kWh...91kW@2200rpm Spec Tier-2；37kW-75kW
0.4 約225g/kWh...73kW@2000rpm Spec 230
4JG1NA(In linePump)

SFC (g/kWh)
0.35 220
Tier-3；'07∼ Tier-2 ・Turbo化
0.3 210
Truck Long term
PM (g/kWh)

0.25 200
・TC
JPN 3次；'07/10∼ ・Common Rail
0.2 Truck Short term ；'04∼ 190
・Nozzle centered
・4 valves
・Turbo Matching
0.15 Traget 180
・External EGR added

Truck New Long Term；'06∼

0.1 Vehicle Euro3；'01∼
170
4HK1X current

0.05 Vehicle Euro5 Vehicle Euro4；'06∼ 160

0 150
0 1 2 3 4 5 6 7 8
NOx+HC (g/kW・h)

4JJ1X Exhaust Emission and Fuel Consumption

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Isuzu Zx 3engine Text
4HK1X Emission and Fuel Consumption(130kW∼）
Fuel
HOT EGR + CA retard CA(Crank Angle) retard consumption
0.350 240
Exhaust gas

0.300 230 PM ; g/kWh

COOLED EGR RATE 10∼15%
Fuel consumption
rate; g/kWh
0.250 220
Regulated value of PM: 0.20

Fuel Consumption Rate ; g/kWh

PM ; g/kWh

0.200 210

0.150 200
HOT EGR + CA retard
CA(Crank Angle) retard
0.100 190

COOLED EGR RATE 10∼15%

0.050 180

Regulated value of
NOx+HC: 4.0
0.000 170
2.00 2.50 3.00 3.50 4.00 4.50 5.00 5.50 6.00
Cooled EGR rate: 10-15% NOx+HC ; g/kWh