PRESENTASI

No. : PRS/BPN/TC/PKGM-02
Revisi : 00
Tanggal : 01 Januari 2024

ZX470-7G Series
Technical product & Maintenance
PKGM-03-I

Presented by Hexindo
16-19 JULI 2024

1
ENGINE
2
CONTENTS

1. Perfomance
2. Specification

3. New Parts Detail

4. Engine Circuit

5. Control System

3
 ZX490

Perfomance

4
ZAXIS HISTORY

Turbo,

ZX-5G ZX-5A ZX-7G

（Stage2,Tier2 equivalent) （Stage3A, GB3） （Stage2)
Turbo, Mechanical Turbo, Common rail, Turbo, Common rail, Electronic control,
governor, EC motor, EGR Electronic control EGR less, No aftertreatment system
less Cooled EGR system
5
ZAXIS Large by Region

5 5

5 5
5 1 5 5A

5 5

ZX-5G (Afr / Ru / Asia / Middle East) ZX-5A (Turkey / Oceania)

HIOSⅢ HIOSⅢ

7 7

7 7
7
Kayaba 7 7
Kayaba 5A＋

7 7

ZX-7 (Europe) ZX-7G (Afr / Asia / Middle East)

HIOSⅤ HIOSⅤ
6
 Perfomance
Productivity and Fuel consumption comparison on each mode of 5G ZX490
5G

e.g. ECO mode of

Productivity +1% 5G and 7G
ECO mode comparison
Fuel
consumption -24%

Productivity +10%
ZX490-7G PWR mode
Fuel consumption -14%

Productivity +7%
HP mode
Fuel consumption -2%

50% 60% 70% 80% 90% 100% 110% 120%

7
※ Note that the efficiency depends on the work condition
Perfomance
ZX490
ZX490 class: Saving 9 274 liter per year with PWR mode

9 274
liter 21 197
1 year liter

66 240 56 966 45 043

liter liter liter

ZX-5G ZX-7G ZX-7G

PWR mode PWR mode ECO mode

Calculation estimate:
Fuel consumption :276L / per day (field data from Global e-Service)
Working hour : 8 hours/day, 20 days / month
* Comparison at total fuel consumption (May be varied depending on work mode/ work 8
condition)
 Perfomance
ZX490
New New engine with enhanced reliability and durability

✓EGR-less for higher durability

✓Improved engine cooling circuit with
expansion tank

Isuzu 6WG1 engine

Mesin ini memiliki rekam jejak yang terbukti di pasar Cina. Selain
itu, langkah-langkah telah diambil untuk meningkatkan daya tahan.

Less engine trouble.

9
 Perfomance
ZX490
New Increasing engine output

Isuzu 6WG1 engine

Unit: kW

ZX470-5G ZX470-7G ZX670-5G ZX670-7G ZX870-7G ZX870-7G

Engine output
ISO 14396: 2002
235 296 312 345 360 377

Higher productivity.
10
 ZX-7G vs ZX-3
7G Engine vs ZX-3 ZX490

Mesin dasarnya adalah mesin 5A dengan EGR lebih sedikit dan peningkatan kekokohan
Agar lebih andal, 7G melakukan peningkatan di bawah ini

Blue box: Applied to 5A generation

Orange box：Applied to 7G Installed turbo with wastegate
Turbine was broken
Low ENG output
Piston crack No EGR system
Crank shaft crack
Broken EGR and reed valve
Set Air bleeding line
Mounted expansion tank Improve injector
Cylinder head crack Injector malfunction
EGR cooler was broken (Clog/wear/inferior fuel)

Changed fuel circuit Improve supply pump

Injector was broken Supply pump was broken

11
 Engine System
Electronic control fuel injection system - Common rail system function ZX490

・ Fuel bertekanan tinggi yang disuplai oleh supply pump diakumulasikan di common rail
・ Fuel didistribusikan ke setiap injector.
・ Sistem ini menghadirkan optimalisasi pembakaran, peningkatan penghematan Fuel, dan
pengurangan PM・ Jumlah NOx

Fuel Filter Rail Pressure sensor Pressure

Supply Common rail limiter
pump

Flow damper
Injector
Fuel tank
Cam ECM
position Crank angle Other sensors(Boost pressure,
sensor sensor Thermo ,etc)
12
 Engine System
Electronic control fuel injection system function ZX490

Common rail system 1）Engine controller（ECM）

・ Berdasarkan sinyal sensor yang dipasang pada ENGINE,
Fuel Filter
ECM mengontrol tekanan & jumlah injeksi yang dioptimalkan,
Rail Pressure sensor
Pressure
Supply Common rail limiter
Flow supply pump, waktu & panjang energi injector
pump

Flow damper
2) Supply pump
・High pressurized fuel
・Send it to common rail

3) Common rail
・Mengirim fuel bertekanan tinggi ke setiap
Injector injektor
Fuel tank

Cam ECM 4）Injector

position
sensor
Crank angle
sensor
Other sensors(Boost pressure,
Thermo ,etc)
・ Menyemburkan fuel bertekanan tinggi yang
berasal dari common rail

Harap perhatikan hal berikut jika menggunakan fuel dengan kualitas yang tidak memuaskan, hal ini dapat
menyebabkan tidak hanya kegagalan injector dan supply pump tetapi juga kerusakan mesin yang serius
13
Engine System
Mechanical governor system VS Common rail system ZX490
ZX-7G
Mechanical governor ZX-5G Common rail ZX-7G
Piping Common rail
TWV
changing
System high pressure
constant pressure
Governor

Timer Nozzle
Pump Supply pump Injector
Injection Pump(Governor) ECU, Injector
amount

Injection
Pump(Timer) ECU, Injector
Timing
Pressure Pump Supply pump
Increase
Distribution Pump Common rail
Injection Based on rotation speed
pressure And injection amount Supply pump

14
Specification

15
 Engine Specification
6WG1 Spec comparison ZX490
ZX870/670/470-7G ZX870/670-5G ZX470-5G
Manufacturer ISUZU ISUZU ISUZU
Model 6WG1XWSA 6WG1XQA 6WG1TQA
Displacement 15.681L 15.681L 15.681L
Cyl.No.-Bore×Stroke（mm) 6-147×154 6-147×154 6-147×154
Compression ratio 16 16.4 16.4
Output(No fan) ZX870 377kW@1800min-1 360.4kW@1800min-1 -
ZX670 345kW@1800min-1 312kW@1800min-1 -
ZX470 296kW@1800min-1 - 235.4kW@1800min-1
Size(mm) L1462×W952×H1443 L1462×W1005×H1432 L1642×W1005×H1432
Dry weight 1065kg 1185kg 1125kg
Exhaust-turbocharger（MHI；
Turbocharger Exhaust-turbocharger（IHI；RHC9） ←
TD08H）
Fuel system DENSO common rail BOSCH governor inline ←
Injection Nozzle DENSO G3AM​ BOSCH 8xφ0.24mm ←
Cooling fan → Φ1120 hybrid φ850
→ （Hydraulic drive） （Belt drive）
Starter → 24V-7kW ←
Alternator 24V-60A 24V-50A ←
Oil cooler Water cooling 8 steps Water cooling 6 steps ←
Oil capacity（Oil pan
MAX52L MIN37L MAX47L MIN37L ←
capacity）
16
 Engine Specification
New Electrical Parts ZX490

ZX870/670/470-7G ZX870/670-5G ZX470-5G

Engine electric parts ECM*(Baromatric sensor included) - -
(*dipasang pada engine)​ Crank position sensor - -
Cam position sensor - -
Common rail pressure sensor - -
Fuel temp. sensor - -
Fuel press. sensor - -
Boost pressure/Boost temp. sensor - -
Intake air temp. sensor*​ - -
Engine coolant temp. sensor - -
→ Overheat switch ←
→ Hydraulic press. sensor ←
→ Oil level switch ←
Battery relay*​ Battery relay*​ ←
Starter relay*​ - -
Glow relay*​ - -
- Safety relay *​ ←
- QOS engine coolant temp. switch ←
- QOS controller​*​ ←

17
 Layout Engine Parts
Newly added Oil Level Gauge ZX490
Or improved parts
Upper maintenance type Oil Filler Cap
（ZX670/470-7G）

Turbocharger

Oil Cooler Common Rail

Starter

Alternator
（60A） Supply Pump

Oil Filler Cap Oil Level Gauge

Oil Filter Side maintenance type Side maintenance type
(remote type) （Only ZX870-7G） （Only ZX870-7G）
18
 Layout Engine Parts
Newly added
Or improved parts
Boost Pressure ZX490
Water Temperature &Temperature Sensor
Sensor Fuel Pressure Sensor

Overheat Common Rail

Switch Pressure Sensor
Crank
Position
Sensor Oil Pressure
Sensor

Fuel Temperature Sensor

Oil Level Switch

19
Engine Control
Engine control ZX490

Change engine speed ECO and HP mode

Eco mode P mode HP mode
5G 1580 1700 1800
7G-470 1400 1600 1800
7G-670 1500 1700 1700
7G-870 1580 1700 1700

・Change E mode engine speed. 470

⇒Achieve workload reduction and work efficiency at the same time
・ Change E mode engine speed. 670
⇒Reduce noise
・Change HP mode engine speed. 670, 870
⇒Reduce fuel consumption. When traveling, engine speed is increased
20
New Part Detail

21
 New Part Detail
ECM function ZX490

ECM(Engine control module) mengontrol jumlah injeksi fuel, waktu injeksi,

dan rpm idle dari fase injeksi ke fase masuk/buang

6HK1
6HK1

6WG1
6WG1

22
 New Part Detail

Supply pump PCV Fuel temperature sensor ZX490

Menyuplai fuel bertekanan ECM mengontrol jumlah fuel ECM mensuplai 5V melalui resistance.
tinggi ke common rail system dengan memberi enerhizing Lower resistance = Higher temp.
time ke PCV Higher resistance = Lower temp.
PCV1 PCV2 ECM menghitung temp. berdasarkan
perubahan pada voltage

Note: bila ditemukan kelainan pada

CMP sensor sensor, maka ganti supply pump
assembly
PCV = Pump control valve
CMP = Cam position
Supply pump
23
 New Part Detail
Flow damper ZX490

Secara normal, hal ini mengurangi

pulsation pada pipa bertekanan
tinggi. Dalam keadaan tidak normal
seperti kebocoran bahan bakar dari Rail
injektor atau pipa, hal ini dapat
mengurangi tumpahan bahan bakar

Common rail pressure sensor Pressure limiter

6WG
1
Valve open

Valve close Abnormal high

pressure
Common rail pressure

Mendeteksi tekanan fuel di dalam Ketika tekanan common rail sangat tinggi, katup
common rail untuk diubah menjadi sinyal ini terbuka. Setelah tekanan kembali ke tekanan
voltage dan mengirimkannya ke ECM yang disetel, katup ini tertutup
24
 New Part Detail
Injector ZX490
Two way valve is On
TWV
Orifice 1 Orifice 2
Common rail Leak off
Press. sensor
Orifice 2

Orifice 1

Common Control room

rail
Piston

Nozzle Piston Orifice TWV Solenoid

(Two way valve) Nozzle
Supply
pump

25
Injector Operational Principle
No signal Input signal ZX490

Outer valve Outer valve

Outer valve Inner valve Inner valve
Inner valve
Valve open
Orifice 1 Orifice1
Orifice 1 Orifice 2 Return Orifice2 Return
Return
Orifice 2
Common rail Common rail Common rail
Piston Piston Piston

Nozzle

Signal stops Injection stops

Outer valve Outer valve
Inner valve Inner valve

Orifice 1 Valve close Orifice 1

Orifice 2 Return Return
Orifice 2
Common rail Common rail
Piston
Piston

26
 New Part Detail
Check here
Injector QR Code ZX490

Setelah pergantian injector,

Mohon masukkan kode ke
dalam MPDr.
- Gambar yang menunjukkan
kode lokasi

MPDr. Screen

Please exclude 00 0000 when you put injector

code on MPDr.

27
New Part Detail
ZX490
CMP sensor CKP sensor
Ketika bagian komponen cam shaft
melewati sensor, sinyal dihasilkan. Ketika bagian fly wheel yang
ECM menilai nomor silinder dan bergelombang melewati sensor, sinyal
crank angle berdasarkan sinyal ini. Ini dihasilkan. ECM mengontrol injeksi dan
memiliki fungsi cadangan untuk CKP kecepatan engine dengan sinyal ini.
sinyal
CKP sensor pulse
CMP sensor pulse
(NE pulse)
(G pulse)
G sensor

CYL.#1 identification reference pulse

G pulse

28
New Part Detail
ZX490
CKP and CMP sensor identify cylinder number

CYL.#1 G reference pulse

CYL.#6 G reference pulse CYL.#1 identification reference pulse

When additional chipped teeth

Chipped teeth signal of G and NE pulse signal is received, determine
At the same time = cyln.#1 or #6 here is CYL #1.

CYL.#1 NE reference pulse CYL.#6 NE reference pulse

CYL.#1 NE reference pulse

CKP = Crank Position Sensor

CMP = Cam Position Sensor
29
 New Part Detail

Engine coolant temperature sensor ZX490

・ Terpasang di cylinder head

・ Mengukur temperatur engine coolant
・ Spesifikasi 5V
・ Engine coolant temp. is low = sensor resistance is high
・ Nilai sensor digunakan untuk mengontrol injeksi bahan
bakar, dll.

30
New Part Detail

IAT sensor（Intake air temperature） ZX490

・ Terpasang pada saluran antara air cleaner and

turbocharger
・ Mengukur temperature udara yang masuk ke engine.
・ Intake air temp. is low = sensor resistance is high

31
 New Part Detail
ZX490
Barometric pressure sensor (Only 6HK1)
ECM of 6WG1 memiliki fungsi Barometric press. sensor

・ Terpasang pada sisi mesin

・ Ganti tekanan barometrik dengan sinyal voltage
・ ECM menghitung tekanan barometrik dari tegangan yang
dikonversi
・ ECM menggunakan nilai sensor untuk mengoreksi jumlah injeksi
bahan bakar

Untuk memeriksa posisi pemasangan sensor tekanan barometrik,

silakan merujuk ke manual

32
 New Part Detail

Boost pressure/temperature sensor ZX490

・ Gabungan fungsi dari boost pressure sensor dan boost temperature sensor
・ Mendeteksi boost pressure pada intake manifold dan mengkonversikan nya
menjadi sinyal voltage
・ The pressure is high = voltage is high
・ ECM menghitung boost pressure valve berdasarkan voltage
・ ECM menggunakan nilai sensor untuk mengoreksi jumlah injeksi bahan bakar,
dll

33
Circuit Engine

34
Intake/Exhaust Circuit
ZX490
：Intake
：Exhaust
Air cleaner

Silencer
Turbocharger
Engine
Inter cooler

Combustion
room

35
Fuel Circuit

Ketika pergantian fuel filter, hati-hati agar tidak masuk kontaminasi ZX490

Negative
Positive ENGINE
High pressure
Return

Fuel cooler

Common Rail
MainFilter
Block PCV

High pressure
pump
Electric solenoid pump Feed
Fuel Tank
Ketika Key-ON, Pump Gauze μm
Pre Filter Pump akan di Supply Pump
diperasikan untuk
proses bleeding udara

36
 Fuel Filter
Pre filter(with water separator) Main filter Electrical solenoid pump
■Cartridge ■Cartridge
…Spin on type …Spin on type
reduces risk contamination reduces risk contamination 6HK1
6HK1 6WG1
6WG1
is coming in is coming in
…Element(with water
separator)

Water level sensor

・Mesh size：5.5μ ・Mesh size：2μ-2 layers ・Flow rate：3.0L/min ・Flow rate：1.7L/min

・Pre filter with water separator（against bio fuel） ・Filter less ・Filter：100μ
・Water level sensor (Alarm amount is 100mL)
・Recirculate function

(ZX-5G) Mesh size: 20μ (ZX-5G) Mesh size: 20μ ー ー

37
Engine Oil Lubrication Circuit
ZX490

38
Coolant Circuit
ZX490

39
 Expantion Tank
Purpose: Expansion tank yang terpasang menurunkan risiko masuknya gelembung udara ke cooling system

Expansion tank-dua fungsi

・Mempertahankan internal pressure
・Memisahkan gas dan liquid
Air Bleeding
From Radiator Expansion Tank Mempertahankan internal pressure
Cooled coolant
- Udara terkompresi membuat efek bantalan dan
Heated coolant
menstabilkan tekanan dalam cooling system

Level Switch Jalur air bleeding

Campuran coolant dan
gelembung mengalir
Make up

Ke dalam tank
Thermostat
Water Jacket
Radiator Water
Pump
Engine
Memisahkan gas(udara) dan liquid
- setiap kali melewatinya
compartments, gelembung yang Jalur Make up
masuk coolant dihilangkan Coolant tanpa gelembung
mengalir ke jalur make up
40
Control System

41
Control System
ZX490
Standard Engine Speed
Performance Reference
Performance Test Designation Unit Remarks
Standard Page
Engine Speed T4-3-1
Slow Idle Speed (Slow Idle) minˉ¹ 900±50 Control lever: Neutral position
Fast Idle Speed (Relief Operation) minˉ¹ 1838±4 Boom raise relief operation
(Maximum FanSpeed) (Cutoff Cut)
Fast Idle Speed (HP Mode) minˉ¹ 1838±50 Arm roll-in relief operation
Fast Idle Speed (HP Mode) minˉ¹ 1750±50 Control lever: Neutral position
(when 1 second or more have
passed after returning to
neutral)
Fast Idle Speed (HP Mode) (with minˉ¹ 1850±50 Control lever: During operation
ECO Deactivated)
Fast Idle Speed (PWR Mode) minˉ¹ 1650±50 Control lever: Neutral position
Fast Idle Speed (ECO Mode) minˉ¹ 1450±50 Control lever: Neutral position
42
Control System
ZX490

Performance Reference
Performance Test Designation Unit Remarks
Standard Page
Auto-Idle Speed (Auto-Idle Switch: minˉ¹ 1180±50 Control lever: Neutral position
ON) (when 3.5 seconds or more
have passed after returning to
neutral)
Warming-UP Speed minˉ¹ 1400±50 Hydraulic oil temperature
of less than 0°C or coolant
temperature of 55°C or less

43
Control System

• Engine Protection Control

• Engine Control Dial Control
• Eco Control
• Power Mode (ECO/PWR/HP Mode) Switch Control
• ECP, PWR Mode Travel Speed Increase Control
• Auto-Idle Control
• Engine Speed Slow Down Control
• One-Touch Idle Control (Option)

44
 Control System
Engine Protection Control Engine
ZX490
Control Dial
Purpose
Mengontrol peningkatan kecepatan engine dan meningkatkan
sirkulasi oli mesin segera setelah engine hidup. Oleh karena itu,
Engine (turbocharger) terlindungi dari kerusakan

Key switch

Engine oil
Hydraulic oil pressure sensor
temperature
sensor

Coolant
temperature
sensor

45
 Control System
Engine Control Dial Control Engine
ZX490
Control Dial
Purpose
Mengatur kecepatan enigine sesuai dengan sudut putaran
engine control dial

46
 Control System
Power
Eco Control Mode
Switch
Engine
ZX490
Control Dial
Purpose Mpdr

Mengurangi kecepatan engine sebesar 100 Rpm dari kecepatan

engine idle cepat ketika semua control lever dalam keadaan
netral. Oleh karena itu, konsumsi bahan bakar dan tingkat
kebisingan dapat dikurangi.
Pressure Sensor
Pilot :

- Boom raise
Conditions - Boom down
- Bucket in
✓ Lever Position : Netral - Bucket out
✓ Power : HP Mode - Arm in
- Arm out
✓ Engine Control Dial : Fast Idle - Swing LH
- Swing RH
- Travel LH
- Travel RH

47
 Control System
Power
Power Mode Switch Control Mode
Switch ZX490
Purpose Mpdr

Mengatur pergerakan power mode (ECO/PWR/HP) melalaui

operating mode switch

Monitor
Power Mode Power Mode When Key Power Mode When Key Switch is Turned ON Next Time
Selection Switch is Turned OFF
Power Mode Memory Power Mode Memory
Selection: OFF Selection: ON
ECO, PWR, HP ECO ECO ECO
mode selection
(Default) PWR PWR PWR

HP PWR HP

- ECO ECO

- PWR PWR

- HP HP

ECO, PWR mode ECO ECO ECO

selection PWR PWR PWR
48
 Control System
Power Mode
ECO/PWR Mode Travel Speed Increase Control Switch
ZX490
Purpose
Meningkatkan kecepatan engine dan meningkatkan kecepatan
travel saat single operation dalam mode ECO/PWR

Conditions
✓ Travel pilot pressure : Output
✓ ECO : + 50 Rpm
✓ PWR : + 200 Rpm
Travel Pilot
Pressure Sensor

49
 Control System
Power
Auto Idle Mode
Auto Idle Control Switch Switch
Engine
ZX490
Control Dial
Purpose Mpdr

Mengurangi kecepatan engine saat semua control lever berada

dalam kondisi netral. Oleh karena itu, konsumsi bahan bakar dan
tingkat kebisingan dapat dikurangi.

Conditions Pressure Sensor

Pilot :
Aktif :
✓ Auto Idle Sw : ON - Boom raise
- Boom down
✓ All Control lever : Netral selama 3.5 detik - Bucket in
- Bucket out
Non-aktif : - Arm in
✓ All Control lever : dioperasikan - Arm out
✓ Power mode : dioperasikan - Swing LH
- Swing RH
✓ Control Dial : dioperasikan - Travel LH
- Travel RH

50
 Control System
Engine Speed Slow Down Control Engine
ZX490
Control Dial
Purpose

Mengatur penurunan kecepatan engine ke kecepatan slow idle

secara bertahap saat auto shut-down diaktifkan. Dengan
demikian beban engine dan aktuator hidrolik dapat dikurangi.

Auto Shut-
down Signal

51
 Control System
One-Touch Idle Control (option) Engine ZX490
Control Dial
Purpose
Mengurangi kecepatan engine ketika audio mute/one-touch
ditekan. Sehingga kebisingan dapat dikurangi

Conditions Pressure Sensor Audio mute/

Pilot : one touch
Aktif :
✓ Audio mute/one touch : ditekan - Boom raise
- Boom down
Non-aktif : - Bucket in
✓ All Control lever : dioperasikan - Bucket out
- Arm in
✓ Control Dial : dioperasikan - Arm out
✓ Audio mute/one touch : ditekan kembali - Swing LH
- Swing RH
- Travel LH
- Travel RH

52
THANK YOU
53