Training Engine Isuzu PDF

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

POWERTRAIN BUSINESS DEPT.
SERVICE GROUP
Off-highway Powertrain Operation Dept. Planning & Service Group
Training　Goal
GOAL
• Learning the approach for fault
diagnosis and part replacement on the
machine 6HK1/6WG1.
• Participants will be proficient in

instructing the course about the
approach for fault diagnosis on the
machine to the followings: OEM,
distributors, dealers, etc in Japan and
abroad.
Tier-3 Engine major 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.
　　　・
　　　・Must be keep ISUZU fuel requirement.
　　　・
　　　・Keep observe strictly the maintenance schedule.
　　2.Electric
　　 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.
Regulation
and
Effects of New Engine system
Off Road Emission Regulation

Off-Road Future Emission Regulation Interim T ier-4
CLASS ENGINE 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013
450 - 560 kW
EPA
(600 - 750hp) － ▼ T ier2 ▽ T ier3
NOx+HC 6.4
CO 3.5 NOx 0.40
225 - 450 kW PM 0.2 NOx+HC 4.0 HC 0.19
6W,6S ▼ T ier2 ▽ T ier3 CO 3.5 CO 3.5
(300 - 600hp) PM 0.2 PM 0.02
130 - 225 kW NOx+HC 6.6

(175 - 300hp)
6H ▼ T ier2 ▽ T ier3
CO 3.5 / PM 0.2
75 - 130 kW NOx+HC 6.6 NOx+HC 4.0 NOx 0.40 / HC 0.19

(100 - 175hp)
4H ▼ T ier2 CO 5.0 / PM 0.3 ▽ T ier3 CO 5.0 / PM 0.3 CO 5.0 / PM 0.02
56kw
37 - 75 kW NOx+HC 7.5 NOx+HC 4.7
4J,4LE ▽ T ier2 CO 5.0 / PM 0.4 ▽ T ier3 CO 5.0 / PM 0.4 Tier4
(50 - 100hp)
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 / 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 ▼ St age2 ▽ St age3-A ▽ St age3-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 NOx+HC

37 - 75 kW 4J,4LE ▽ Stage2 CO 5.0 / PM 0.4 ▽ St age3-A CO 5.0 / PM 0.4 ▽ St age3-B CO 5.0 / PM
NOx 8.0 / HC 1.5 NOx+HC 7.5

19 - 37 kW L ▼ Stage2 CO 5.5 / PM 0.8 ▽ St age3-A CO 5.5 / PM 0.6 No proposal as Stage
NOx 6.0 / HC 1.0 NOx 3.6 / HC 0.4 ▽Tier-4

JPN 130 - 560 kW 6W,6S,6H 　　　　　▽ T ier-2 ▽ T ier-3
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
CO 5.0 / PM 0.3 　　　　　▽ ▽ T ier-3
75 - 130 kW 4H T ier-2
CO 5.0 / PM 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 / PM 0.8 　　　　　▽ ▽ T ier-3
19 - 37 kW L T ier-2
CO 5.0 / PM 0.4
Tier3 Emission Regulation

ＥＰＡ/
ＥＰＡ/EC Tier-
Tier-3
75～
75～130kW
130kW（
kW（2007)
JPN Tier-
Tier-3
75～
75～130kW(2007)
130kW(2007) ＥＰＡ Tier-
Tier-2
75～
75 ～130kW(2003)
０．３
　
ＰＭ
（g/kw/hr)
０．２
JPN On-
On-Road
New Short Term
(Over 2.5t, 2003)
０．１
JPN On-Road
New Long Term
(Over 2.5t, 2003) JPN On-Road
Long Term
(over 2.5t, 1999)
２．０４．０６．０８．０
ＮＯｘ＋ＨＣ (g/kw/hr)
NOx + HC: 40% reduction, PM: Same with Tier-2 from Y2006
JPN Government Proposal: PM 30% lower than EPA, EC T-3
Regulation and Effect

Internal EGR + CA Fuel
retard consumption
0.350 240
Exhaust gas
0.300 230 PM; g/kWh

Fuel consumption
rate; g/kWh
Rated fuel consumption; g/kWh

0.250 220
Regulated value of PM: 0.20 Cooled EGR rate: 10 - 15%
PM; g/kWh
0.200 210
0.150 200
Internal EGR + CA
retard
0.100 190
Cooled EGR rate: 10-

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
NOx+HC; g/kWh
Applied Tech and Exh. Emission Level(75-130KW)

０.４
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
０１．０２．０３．０４．０５．０６．０
NOx + HC g/kWh
Tier3,
Tier3, Tier4
Tier4
Total
Total Engine
Engine Technologies
Technologies
EGR=Exhaust Gas Re-circulation -Combustion
-Combustion Chamber
Chamber
EGR valve -Turbo-charging
-Turbo-charging etc.
etc.
EGR
EGR
Noise
Noise reduction
reduction
EGR cooler
Inlet manifold
Base
Base technology
technology
friction
friction reduction
reduction Full
Full Electronic
Electronic Control
Control
High pressure injection
High pressure injection
Inter cooler Commonrail
Commonrail system
system
EGR gas
Mileage
Mileage
Exhaust manifold
Turbo-charging
Turbo-charging Catalyst
Catalyst technology
technology
technology
technology
NOX catalyst
Air DPD
DPD
DPD
DPD=Diesel Particulate Diffuser
:For Tier-2 :For Tier-3 :For Tier-4

Keys
Keysfor
forSuper
SuperClean/Fuel
Clean/FuelEconomy/High
Economy/HighPower
Power
The stringent emission regulations already established for Tier 2 and 3 require massive investment in R&D if
Compliant engines are to enter series production. This will be an extremely heavy burden for most vehicle
OEMs, resulting in difficulties being encountered in updating and replacing in-house engine designs within the
Laid-down timeframe. Isuzu will be able to accept both the R&D burden and produce compliant products within
The time available.
Electronic Control
Precision Control& Feedback Control
Sensor Technology
Integration of
Key Technology
Optimum Combustion After Treatment
Fuel Injection System
Diesel Particulate Filter(DPF)
Combustion System
De-Nox Catalyst
High Charge
Summary
Summary of
of New
New System
System
Using Common Rail System
New
Newsystem
system Using EGR System (130kW over)
Added following parts
1) Engine Control Unit

2) Common rail
3) EGR valve and cooler (Cooled EGR required engine)
4) Sensors (add about 10 sensors)
ex. Common rail pressure sensor
Ambient air pressure sensor
Cam angle sensor
5) Closed ventilation
）Engine harness
6）
Tier 3 Engine Main System

1. Electrical control Engine System
2. Commonrail System
3. Cooled EGR System
Clean Exhaust gas

Silent Engine
High Power
Easy maintenance
Doosan　Engine Specification
Engine New Mechanism

Fuel Filter (main)
Injector
EGR
PM Reduction
NOx Reduction
Common Rail
ACG Belt
PM Reduction
NOx Reduction
Fuel Filter (pre)

P.T.O.
For Cooling Fan Supply Pump Cooling Fan(w/o ENG)
*View 6WG1 model
Doosan　6WG1 Engine Specifications Table

Model 6WG1X Model 6WG1X
Item Item
Engine model Water cooled, 4-cycle, inline Fuel filter type
6-cylinder, 24 valve OHC, Filter paper type
direct injection diesel
Rated output -1 Oil filter type
(kW/min ) 345/1800 Filter paper type
Maximum torque -1 Oil pump type
(Nm/min ) 1980/1500 Gear type
Cylinder arrangement Oil cooler type
and number – bore × L6-φ147×154 Water cooling type
stroke (mm)
Displacement (L) 15,681 Amount of engine oil (L) Oil pan：37-52
Compression ratio Cooling system method Water-cooled controlled
16
circulation type
Compression pressure kPa Cooling water full
2 2750(28)/200 36
(kgf/cm )/rpm capacity (L)
Dimensions (length × Water pump type
1462×1017×1422 Centrifugal gear type
width × height) (mm)
Weight (kg) 1165 Thermostat type OEM
Fuel injection order 1-5-3-6-2-4 Air cleaner type OEM
Injection pump type Electronic control fuel injection Generator capacity
OEM
system (common rail type) (V-A)
Governor type Electronic type Starter (V-kW) 24-7.0
Timer type Electronic type Turbocharger type TD08H (Made by Mitsubishi)
Nozzle type DLL-P Intercooler type OEM
Intake/exhaust valve Thermostat valve open
0.4 80-84(82)
clearance (while cool) (mm) temperature (℃)
Intake valve opening and Thermostat all open
closing time 21 degree (BTDC) temperature/ amount of 10mm lift when at 95 °C
(Open) lift (℃/mm)
Intake valve opening and Oil thermostat all open
closing time 27 degree (ABDC) temperature/ amount of 8 mm lift when at 110 °C
(Closed) lift (℃/mm)
Exhaust valve opening Exhaust gas recirculation device
and closing time 52 degree (BBDC) (EGR) Installed
(Open)
Exhaust valve opening
17.5 degree (ATDC)
and closing time (Closed)
条件 conditions 仕様値 rating
大気状態 atmospheric condition 標準状態 standard
ｽﾘｱﾜｾ運転時間 braking time 30Hr
f o r h y d ra u l i c e x c a v a t o r Pulley Ratio ―
Doosan AH-6WG1X Cooling Fan 無 Not included
全負荷性能曲線図 Air Cleaner 付 Included

p e r f o rm a n c e c u r v e ※m a r k is j ust r e fer ence Alternator 付 Included
EXH. Silencer 付 Included
2200
1650±116 Nm / 1000min-1 2000
1800
1600
※ 1540 Nm / 850min -1 1400

1200
400
※ 313kW / 1850min -1
and over
※ 313kW / 1870min -1
300
200
100
1870±10min-1
0
240
燃料消費率/ＳＦＣ（g/kWh）
220
200
180
500 1000 1500 2000 2500

ENGINE SPEED (min-1 )
６WG１
１　Noise Level　
　Tier-２
２ｖｓTier-３
ｖｓ３
ＳＯＵＮＤ　ＰＲＥＳＳＵＲＥ　ＬＥＶＥＬＥＮＧ．ＴＹＰＥＡＨ－６
ＡＨ－６ＷＧ１
ＷＧ１Ｘ
***　
***　AVERAGE　
AVERAGE　*** 6WG1X
WG1X--Tier2 Comparison: ＦＡＮLess
ＦＡＮLess
●――――●
100 6WG1X-
WG1X-Tier3
ＦＡＮ：Les
ＦＡＮ：Les
98
96
-ＡＶＥ（ＦＵＬＬＬＯＡＤ）ｄＢ（Ａ）
94 ×- - - - -×
6WG1X-
WG1X-Tier2
92 ＦＡＮ：Less
ＦＡＮ：Less
90
6WG1X-
WG1X-Tier2
88 About ３ｄB（A)
86 Low Noise
84
ＳＰＬ-
ＳＰＬ
600 800 1000 1200 1400 1600 1800 2000 2200

ＥＮＧＩＮＥＳＰＥＥＤ（ｒｐｍ）
New
New 6WG1X
6WG1X Noise
Noise
100 Mean sound level in four direction.
Measured 1meter from engine.
98
Engine noise without cooling fan,
96 FULL LOAD Intake and exhaust.
94
NOISE LEVEL{dB(A)}
92
90
NO LOAD
88
86
84
82
80
600 800 1000 1200 1400 1600 1800 2000 2200
ENGINE SPEED (min-1)
6WG1 Engine Right Side View
Turbocharger
Oil Port
: Remote Oil Filter
6WG1 Engine Left Side View

EGR Valve
EGR Cooler
Fuel Filter –(2)
Common Rail
Supply Pump
Engine main Parts　

Cooled ＥＧＲ
High rigidity
OHC 4VALVE MAX Injection
Pressure１６０ＭＰ
１６０ＭＰa
Electronic Control
Turbocharger
（Without Westgate）
Westgate） High Rigidity
Ladder type
Crankcase
High
rigidity High rigidity
Cylinder 8-Balancer
Crankshaft
Block
High Rigidity
Ladder Frame
Ladder Frame
Piston
Configuration
Doosan　６WG1X　Engine
Emission　Parts
Supply Pump（PCV Type）

Supply Pump（Denso:ＨＰ０ Type）

ＰＣＶ Circuit
Motion of ＰＣＶ(Pressure Control Valve)

Feed stroke Pressure stroke
Cam lift
ＰＣＶの作動
PCV Open
ＰＣＶ
PCV Close
Common Rail
Delivery Valve
Plunger
Common Rail
Flow damper
Common rail
pressure sensor
Pressure limiter
Pressure Limiter
Pressure limiter
Valve open
Valve closed Abnormally

high pressure
Common rail pressure

Flow damper
Flow damper
Common rail Injector
Piston Ball Spring

Injector ;Out side configuration
Injector ID Code
Injector
Orifice 1
Orifice 2
Nozzle Hydraulic piston Orifice Solenoid

Injector Outline
Common
Common railrail
pressure Leak
pressure sensor
sensor
Orifice
Common rail Control chamber
Hydraulic piston
Nozzle
Supply pump
Injection pressure control
Injector Operation
-- No Signal --
Outer valve
Inner valve
Orifice 1
Return
Orifice 2
No
Common rail Nosignal
signal
Hydraulic piston
Injector
charge
ＥＧＲ　ＶＡＬＶＥ
Cooled EGR
EGR stands for ”Exhaust Gas
”.
Recirculation”
This equipment lowers burning
temperature by mixing some of the To intercooler
emitted exhaust gas with the intake air to
Turbo
control oxygen concentration in the
combustion chamber slowing down
combustion. From air cleaner To silencer
This enables reduction of nitrogen oxide

or ”NOx”” which is produced during high- Exhaust manifold
temperature combustion. Cooled EGR Coolant out
system is a system which equips cooling
system in the EGR gas passages. Engine EGR cooler
This system contributes reduction of
Coolant in
NOx by further lowering the burning
temperature than normal EGR with
Intake manifold
cooling down the heated EGR gas with
cooler before mixing with the intake air.
EGR valve
Moreover, by cooling down the high Reed valve
temperature EGR gas, intake air
concentration is increased resulting in From intercooler
ECM
more air capacity.
This brings close to the perfect
combustion resulting in reduction of PM
and other graphite as well as better fuel
consumption.
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 that the valve lift amount is
large, and the darkest color area
shows that the valve lift amount is
almost 100%.
EGR valve position learning
Installation of ECM
Install the ECM in the reverse order of removal.
EGR valve position learning is required after replacing
the ECM.
1. Turn the key switch to “ON”.
2. Turn the key switch to “OFF”.
3. Leave as it is for 10 seconds.
Failure to perform the EGR valve position learning may
result in detection of DTC for EGR.
6WG1
120-140Mpa
50 MPa
900RPM
RPM
Engine Control system
System（６ＷＧ１）
Common Rail System

Fuel Injection Rate Control

Conventional
ConventionalInjection
Injection Pilot
PilotInjection
Injection
Injection rate
Small mixed
Large mixed combustion
combustion
(NOx, noise)
Generation
rate of heat
Crank angle (°) Crank angle (°)

Comparison with Conventional System

Fuel Injection Amount Control

Fuel Injection at Starting
Injection amount at cranking

At low temperature
Engine starting mode
Starter signal ON
Less than "N1"
speed (rpm) At high temperature
Engine speed
InInthe
theengine
enginestarting
startingmode
modeatatlow
lowtemperature,
temperature,control
controllever
lever
(accelerator
(acceleratorpedal)must
pedal)mustbe
bedepressed
depressedmore
more
Starting Correction
Starting Q
Correction
3
mm /st
Engine Coolant Temp. (℃)

Threshold Cranking as Hint

6HK1/4HK1/4JJ
Release ;Starting Correction　

RPM
550RPM
Engine starting RPM

60RPM
ECM starting RPM 30RPM

High Altitude Correction

Various Correction
Buzzer of Machine more than
105deg, fault log is recorded
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 to stabilize idling immediately after starting.
System Off waiting period
5 Sec
Ign Off System Off

ON
OFF
Wait for 5 sec after Ignition key off

Electric control Sensor
Engine Sensors
Boost temp Sensor

Boost press Sensor
Rail press Sensor

Water Temp Sensor
NE(CKP) Sensor
Oil press Sensor
G(CAM) Sensor
〔Machine equipment〕
Fuel Temp Sensor
　・Ambient temp Sensor
　・Atmospheric press Sensor
CKP(NE) Sensor,
G(CMP) Sensor
Amp circuit
Pump position
G sensor
Amp circuit
Crank position
NE sensor
Wave of G-Sensor
CKP Sensor Waveform

G(CMP), CKP(NE) Sensor,

Diagram (6 Cylinders)
No.6 cylinder No.1 cylinder
G standard pulse No.1 cylinder G standard pulse
Standard pulse
No.1 cylinder No.6 cylinder

NE standard pulse NE standard pulse
Common Rail Pressure Sensor
Common rail pressure

Boost Pressure Sensor
Electronic circuit Silicon chip
Vacuum chamber
Filter
Intake air pressure
Boost pressure
Engine Coolant Temperature Senso
Engine coolant temperature
Fail-safe:
Fail-safe:Changes
Changesto
to80℃
80℃inincase
caseof
ofabnormality.
abnormality.
Intake Air Temperature Sensor
Intake air temperature (°C)
Fail-safe:
Fail-safe:Takes
Takesthe
thevalue
valueofofthe
thewater
watertemperature
temperaturesensor
sensorinincase
case
ofofabnormality.
abnormality.
Fuel Temperature Sensor
Fuel temperature (℃)
Fail-safe:
Fail-safe:Takes
Takesthe
thevalue
valueofofthe
thewater
watertemperature
temperaturesensor
sensorinincase
case
ofofabnormality.
abnormality.
Engine Control Module
Electronic　Control　System
　⇒ Full Electronics Controlled Engine
Sensor for Tier3 Engine　
ECM(Engine Control Module) have been monitored operation condition through various sensors.
ECM issue instruction for actuators.
Sensors Actuator
Accelerator
position
Accelerator
Accelerator Injector
position sensor Injector
position sensor
Engine speed ・ Injection amount control
Crankshaft
Crankshaft ・ Injection timing control
position sensor
position sensor
Cylinder Common
identifying Commonrail
rail
pressure
Camshaft pressuresensor
sensor
Camshaftposition
position signal
sensor,
sensor,
GGsensor
sensor Supply
Supplypump
pump
Other 　　　（ＳＣＶ）
　　　（ＳＣＶ）
Othersensors,
sensors, 　　　（ＳＣＶ）
　　　（ＳＣＶ）
Switches ・ Injection pressure control
Switches
EGR
EGRValve
Valve
ＥＣＭ　Diagram（６ＷＧ１）
ECM
ECM Diagram
Diagram forTier-3
forTier-3
Control Diagram
Signal from machine
ACCEL. POSITION SENSOR → → SUPPLY PUMP Injection Quantity Control

ENGINE SPEED SENSOR → → INJECTOR Injection Timing Control
CAM ANGLE SENSOR → High Land Revision Control
WATER TEMP. SENSOR →
FUEL TEMP. SENSOR → ENGINE → EGR VALVE → Emission Control
RAIL PRESSURE SENSOR →
CONTROL
BOOST PRESSURE SENSOR → → STARTER → Start Control
INTAKE AIR TEMP. SENSOR → MODULE → GLOW PLUG → Start Assist Control
BAROMETER SENSOR →
EGR POSITION SENSOR → → DIAGNOSIS LAMP → Self Diagnos
OIL PRESSURE SENSOR → → OIL PRESS. WARNING LAMP
BOOST TEMP. SENSOR → → BOOST TEMP. WARNING LAMP
KWP2000 CAN
Interface Interface
SERVICE TOOL OTHER CONTROLLER
CAN interface can be used,

instead of accel. position sensor.
ECU
ECU Failsafe
Failsafe function
function for
for Tier-III
Tier-III
FAILSAFE CLASSIFICATION DETECTION ITEMS

CAM SENSOR ERROR
CPU ERROR
COMMON RAIL PRESSURE ERROR (SECOND STAGE)
ENGINE SHUT DOWN INJECTOR DRIVE SYSTEM ERROR
CHARGE DIAGRAM ERROR
FUEL LEAK
INJECTOR DRIVE WIRE BREAKING
ACCELERATOR SENSOR 2ND SYSTEM ERROR
IDLE SPEED RUNNING CAN BUS ERROR
CAN TIME-OUT ERROR
ACCELERATOR SENSOR 1ST SYSTEM ERROR
BOOST PRESSURE SENSOR ERROR
HIGH BOOST PRESSURE ERROR
SUB CPU ERROR
LIMP HOME MODE COMMON RAIL PRESSURE ERROR (1ST STAGE)
SUPPLY PUMP OVER-PRESSURE
SUPPLY PUMP NO-PRESSURE
COMMON RAIL PRESSURE SENSOR ERROR
SCV DRIVE SYSTEM WIRE BREAKING OR SHORT CIRCUIT
System Off waiting period
5 Sec
Ign Off System Off

ON
OFF
Wait for 5 sec after Ignition key off

CAN Communication
Revolution control, axle control
Load signal
MCX Required engine speed
Required accelerator position
Engine stopped
Address 228
CAN BUS Line
Revolution
limit
Shift
ECM TCM
Control
Address 0 Address 5
Address 3
Fuel System
6U,6W FUEL　
FUEL　CIRCUIT　
CIRCUIT　DIAGRAM
Q leak
・max.140℃
・0≦P3 ≦40kPa
ENGINE
Suction　
Suction　Line
Pressure Line
High Pressure
Q return
Leak Line ・0～20kPa
Qinjection
φ10
Q suction
・-30kPa≦P1
φ10
Common Rail
φ14 φ14 Q suction
Feed Pump 980kPa≧P２
φ14
φ10
Regulator　
Regulator　 Po=0.3MPa
OEM Parts PCV
Pre Filter(RACOR）
Filter(RACOR）高圧Pump
高圧Pump
8980142540
2 Supply Pump ；HP0
・95%保証粒径10μm菊折ｴﾚﾒﾝﾄ、0.78m φ10
・可視Sedimenter一体
・水位警報Switch付 Supply Pump In
・250hr交換 -30≦T1 ≦60℃
or
Pre Filter(Fleetgurad
Filter(Fleetgurad）
Fleetgurad） Main Filter(和興
Filter(和興）
和興）
FS20000
・95%保証粒径5μm菊折ｴﾚﾒﾝﾄ
8980139861　
8980139861　×2本
2
・潤滑剤Cup付・Priming Pump付き 0.54m
250hr or 6ヶ月交換・95%保証粒径5μm、菊折ｴﾚﾒﾝﾄ
Fuel Tank ・可視Sedimenter一体
・ｴﾚﾒﾝﾄｴｺ化
・500hr交換（Std)
or 250hr交換（粗悪燃料地域）
Maintenance
Service parts ５００１０００１５００
hours hours hours
Fuel pre-
pre-filter ○ ○ ○
With Electromagnetic
○ ○ ○
pre-
pre-filter pump filter
Fuel main filter ○ ○ ○
Electromagnetic
pump filter ○ ○ ○
Without
pre-
pre-filter
Fuel main filter ○ ○ ○
Engine oil ○ ○ ○
* After 1500 hours, perform inspection and service every 500 hours.
* Use "ISUZU genuine parts" for engine oil and filters.
Be sure to perform proper maintenance at

specified intervals !!
Method to drain engine oil: The machine with

monitor has cock to drain.
Filter Wrench
Isuzu Parts
Only
Description (Part No.) Description (Part No.)

Pre-Filter Wrench (N/A) Main Filter Wrench (N/A)
Fuel System Air Bleeding

Priming Pump
The entry of air into the fuel system will cause hard engine
starting or engine malfunction.
When once the servicing such as emptying the fuel tank,
draining for the water sedimenter, and the fuel filter element
change is done, be sure to conduct air bleeding.
Float
Drain Plug
Air bleeding procedure:

1) Loosen the air bleeding plug of fuel filter.
2) Operate the priming pump of supply pump to bleed air from fuel filter and secure the
priming pump.
3) Operate the priming pump of fuel filter to bleed remaining air.
4) Tighten the air bleeding plug of fuel filter.
5) Loosen the air bleeding plug of supply pump and operate the priming pump until no
bubbles are visible.
6) Tighten the air bleeding plug of supply pump.
7) After tightening all the air bleeding plugs, operate the priming pump until resistance is felt.
8) Secure the priming pumps at the original position and then start the engine. If the engine
does not Start, repeat the procedure from step 7).
2005.4.14
Level of Consideration World Fuel Map for Off-road Machine
Danger Need Care Good Unkown
・Sulfur contents ；　　　1000～3000ppm / above 3000ppm
・Water contents
・Dust contents
・Fuel viscosity ; 　 HFRR 460～560 / above 600
・Additive　　
N.Europe
Sulfur
Water
Dust
Viscosity
W.Russia E.Russia
CANADA
Additive Sulfur Sulfur
Sulfur Water Water
Water Dust Dust
Dust EU Viscosity Viscosity
Viscosity Additive Additive
Additive Sulfur
Water
M.East
Dust China，E.Asia
N.America Viscosity Sulfur JAPAN
Sulfur
Additive Water
Water Sulfur
Sulfur Dust
Dust Water
Water N.Africa Viscosity
Viscosity Dust
Dust Additive
Sulfur Additive Viscosity
Viscosity
Water Additive
Additive
Dust
S.E.Asia
Viscosity Sulfur
S.America Additive Water Oseania
Sulfur Sulfur Dust
Water Water Viscosity Sulfur
Dust Dust Additive Water
Viscosity Viscosity Dust
Additive
S.Africa Viscosity
Additive
Sulfur Additive
Water
Dust
Viscosity
Additive
Maintenance
1
How to Replace Parts
z Do not reuse the “high-pressure pipe” and
“injector pipe” of the fuel system.”
Replace with new one if it is removed.
z Never replace the “pressure limiter”,” fuel
temperature sensor”,” flow damper” alone.”
If faulty, replace the common rail assembly and
all the fuel pipes.
For SCV pump, the fuel temp sensor cannot be replaced itself
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
3 5. Pressure limiter
Scan Tools
Ｏｎ＆Ｏｆｆ Board Diag
CAN
Monitor on the machine DTC

Controller on the On Board Diag Data parameter
machine
--ECU 　Service Master
JCB　
Snapshot
Off Board Diag
Trouble
Diagnostic
CAN Injector checker
Actuator test Procedure
Communication
Software to
Engine control Tool to rewrite (EMPS)
( ) rewrite
module
-- ECM
EEPROM
Tech2
Unique Data
Off Board Diag
KWP2000
Resistance Check Practice
Engine Harness
Breaker Switch
ECM Box Box
Engine
Machine Harness Sensor,

Actuator
6HK1;Sample of DTC Setting Condition

Fuel Pump
w/filter
Supply
Pump
Pre-Filter ?? Main
Filter
More than 900RPM More than 1200RPM

FRP
About 5sec = P1093
About 3sec = P0087

Target R.P.
15Mpa
50Mpa
Actual R.P.
0Mpa
over15A
MAX 130 V
Copyright: ISUZU MOTORS LIMITED

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What is the training goal discussed in the document?

What is the training goal discussed in the document?

What are some of the major maintenance points discussed for Tier-3 engines?

What are some of the major maintenance points discussed for Tier-3 engines?

Off-highway Powertrain Operation Dept.

Planning & Service Group

ISUZU MOTORS LIMITED

• Participants will be proficient in

Tier-3 Engine major Maintenance point

Off Road Emission Regulation

130 - 225 kW NOx+HC 6.6

75 - 130 kW NOx+HC 6.6 NOx+HC 4.0 NOx 0.40 / HC 0.19

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

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

NOx 7.0 / HC 1.3 NOx+HC 4.7 NOx+HC

NOx 8.0 / HC 1.5 NOx+HC 7.5

NOx 6.0 / HC 1.0 NOx 3.6 / HC 0.4 ▽Tier-4

NOx 4.0 / HC 0.7

NOx 8.0 / HC 1.5 Nox 6.0 / HC 1.0

Tier3 Emission Regulation

Regulation and Effect

0.300 230 PM; g/kWh

Rated fuel consumption; g/kWh

Cooled EGR rate: 10-

Regulated value of NOx+HC: 4.0

Applied Tech and Exh. Emission Level(75-130KW)

:For Tier-2 :For Tier-3 :For Tier-4

Added following parts

1) Engine Control Unit

Tier 3 Engine Main System

Clean Exhaust gas

Engine New Mechanism

Fuel Filter (pre)

Doosan 6WG1 Engine Specifications Table

Doosan AH-6WG1X Cooling Fan 無 Not included

全負荷性能曲線図 Air Cleaner 付 Included

※ 1540 Nm / 850min -1 1400

500 1000 1500 2000 2500

600 800 1000 1200 1400 1600 1800 2000 2200

6WG1 Engine Right Side View

6WG1 Engine Left Side View

Engine main Parts

Supply Pump（PCV Type）

Supply Pump（Denso:ＨＰ０ Type）

Motion of ＰＣＶ(Pressure Control Valve)

Valve closed Abnormally

Common rail pressure

Common rail Injector

Piston Ball Spring

Injector ;Out side configuration

Nozzle Hydraulic piston Orifice Solenoid

Common rail Control chamber

This enables reduction of nitrogen oxide

ECM operates the motor

Common Rail System

Fuel Injection Rate Control

Crank angle (°) Crank angle (°)

Comparison with Conventional System

Fuel Injection Amount Control

Doosan　6WG1 Engine Specifications Table

Engine main Parts　

Release ;Starting Correction　