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Catalog động cơ diesel ISUZU 6WG1X

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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
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
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

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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.


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Off-Road Future Emission Regulation
Off-Road Future Emission Regulation
CLASS
EP A

EC

JP N

ENGINE

2001

450 - 560 kW
(600 - 750hp)

2002
T ier2

2003

2004

2005

6W,6S

130 - 225 kW
(175 - 300hp)

6H

T ier2

NOx+HC 6.6
CO 3.5 / P M 0.2

75 - 130 kW
(100 - 175hp)

4H

T ier2

NOx+HC 6.6
CO 5.0 / P M 0.3

37 - 75 kW
(50 - 100hp)

4J,4LE

130 - 560 kW

6W,6S,6H

75 - 130 kW

4H

37 - 75 kW

4J,4LE

19 - 37 kW

L

130 - 560 kW

6W,6S,6H

NOx 6.0 / HC 1.0
CO 3.5 / PM 0.2

T ier-2

75 - 130 kW

4H

NOx 6.0 / HC 1.0
CO 5.0 / PM 0.3

T ier-2

56 - 75 kW

4J

37 - 56 kW

4LE

19 - 37 kW

L

T ier2

St age2

2008

2009

NOx+HC 4.0
CO
3.5
PM
0.2

int erim
T ier4

NOx+HC 4.7
CO 5.0 / P M 0.4

56kw

NOx+HC 4.0
CO 3.5 / PM 0.2

NOx 7.0 / HC 1.3
CO 5.0 / P M 0.4

St age3-B

NOx+HC 4.0
CO 5.0 / P M 0.3

St age3-A

2014

2015

NOx 3.6 / HC 0.4
CO 5.0 / P M 0.2

T ier-2

T ier-3

Nox+NM HC 4.0
CO 5.0 / P M 0.03

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

NOx+HC 4.0
CO 3.5 / P M 0.025
NOx+HC 4.0
CO 5.0 / P M 0.025

St age3-B neary same as EPA

NOx+HC 7.5
CO 5.5 / P M 0.6

NOx 3.6 / HC 0.4
CO 3.5 / P M 0.17

T ier-3

St age3-B

NOx+HC 4.7
CO 5.0 / P M 0.4

St age3-A

No proposal as St age3-B

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

T ier-3

NOx 4.0 / HC 0.7
CO 5.0 / PM 0.25

T ier-3

NOx 4.0 / HC 0.7
CO 5.0 / PM 0.3

NOx 7.0 / HC 1.3
CO 5.0 / PM 0.4

T ier-2

2013

Nox+NMHC 4.0
CO 3.5
P M 0.03

int erim
T ier4

NOx+HC 4.0
CO 5.0 / P M 0.3

T ier3

St age3-A

T ier-3

2012

int erim
T ier4

NOx+HC 7.5
CO 5.0 / P M 0.4

St age3-A

2011
int erim
T ier4

T ier3

NOx 8.0 / HC 1.5
CO 5.5 / P M 0.8

NOx 8.0 / HC 1.5
CO 5.5 / P M 0.8

2010

T ier3

NOx 6.0 / HC 1.0
CO 5.0 / P M 0.3

St age2

St age2

T ier3

NOx 6.0 / HC 1.0
CO 3.5 / PM 0.2

St age2

2007

T ier3

NOx+HC 6.4
CO
3.5
PM
0.2

225 - 450 kW
(300 - 600hp)

T ier2

2006

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.


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Tier3 Emission Regulation

(130kW

/EC Tier-3
130kW 2006)
JPN Tier-3
130kW (2006)
130kW

g/kwhr)

EPA Tier-4
(2012)

EC Stage -B
(2012)

(g/kwhr)

NOx + HC: 40% reduction, PM: Same with Tier-2 from Y2006
JPN Government Proposal: PM 30% lower than EPA, EC T-3

Tier-2
(2003)

)


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Key Technologies of Diesel Engine
EGR = Exhaust Gas Re-circulation

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

EGR Valve
EGR
EGR Technology
Technology

Air

EGR Gas

Inter Cooler

Total
Total Electronic
Electronic Control
Control

r

Exhaust Manifold
Turbo-Charging
Turbo-Charging
Technology
Technology

e
ol

Injection
Injection System
System

Base
Base Technology
Technology
Friction
Friction Reduction
Reduction

Co

Inlet Manifold

R
EG

Noise
Noise Technology
Technology

Fuel
Fuel Improvement
Improvement


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Technologies and Emission Level (130kW

)

.

PM g/kWh

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

Tier 2 trade-off
70MPa pressure
Inter cooler

Tier 3
Tier 2
JPN Tier-3
Engine Modification
Limit

NOx + HC g/kWh


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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)


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Basic Information of Tier 3 Engine
• Low Emission
• Low Noise
• High Power

1.
2.
3.
4.

Electronic Controlled Engine

Tier 2 Engine Comparison
Electronic Control
Common Rail System
Cooled EGR


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6WG1 Engine Specification
Model
Item
Engine model
Rated output
Maximum torque
Cylinder arrangement
and number
– bore × stroke
Displacement

(kW/min-1)
(Nm/min-1)

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-

(mm)
(L)

Injection pressure
Governor type
Timer type
Nozzle type
Exhaust gas recirculation device (EGR)

16

16.4

Compression pressure MPa(psi)/rpm

Injection pump type

147×154
15,681

Compression ratio

Dimensions
(mm)
(length × width × height)
Weight
(kg)
Fuel injection order

6WG1XYSA-01
TIER3
Water cooled, 6-cycle, inline
4-cylinder, OHC,
direct injection diesel
260/1800
1580/1500

2.75(400)/200
1462×1007×1287(with fan)

1741×1016×1340(with fan)

1462×1015×1422(with fan)

1125

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(8x 0.24mm)
Bosch KBL2.4
No

1153

Mechanical fuel injection pump
(Inline fuel injection pump)
BOSCH PE-P-S3S
17.7/22.1
RSV type
Equipped
2Stage Nozzle
Multi-hole type(8x 0.24mm)
Bosch KBL2.4
No

Electronic control fuel injection
system (common rail type)
Denso HP0
180MPa
Electronic type
Electronic type
Injector
Multi-hole type(8x 0.19mm)
Denso G2
Installed


6WG1 Engine Specification
Model
Item

6WG1TQA
TIER2

6WG1XQA0*
TIER2

6WG1XYSA-0*
TIER3

Fuel filter type

Cartridge(Filter paper type)

Cartridge(Filter paper type)

Filter paper type

Oil filter type
Oil pump type

Full flow filter(Remote)
Gear type

Full flow filter(Remote)
Gear type

Full flow filter(Remote)
Gear type

Oil cooling type
Amount of engine oil

Water-cooling
(L)

Total 42-52 (37-47 Oil Pan)

Cooling system method
Cooling water full
capacity

Total 42-52 (37-47 Oil Pan)

Water-cooled controlled circulation type

(L)

36

Water pump type

Centrifugal, belt type

Thermostat type
Air cleaner type

2 wax-type units
To be supplied by OEM

Generator capacity

(V-A)

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

(

Total 42-57 (37-52 Oil Pan)

)

MITSUBISHI 24-50

MITSUBISHI 24-50

MITSUBISHI 24-50

MITSUBISHI 24-7.0
RHC9(IHI)
Not Equipped

MITSUBISHI 24-7.0
RHC9(IHI)
Equipped

MITSUBISHI 24-5.0
TD08H-31M (MHI)
Equipped

83(95)

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Engine
Performance

30Hr

361

45

AH-6WG1X
3.4
13.3

ISUZU
2000

1500min-1

1800
1600

(Nm)

1380Nm
1580 47

1370 69Nm 1000min-1

1400
1200
1000
300

260 4kW
1800min-1

200

150

100

50
1900

30rpm

0
260

237 13.6g/kWh
2000min-1

240
220
200
214 13.6g/kWh 1800

500

1000

1500

ENGINE SPEED(min-1)

2000

-1
180
2500

SFC(g/kWh)

POWER OUTPUT

250


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Engine Layout /Main Parts
EGR Valve

Main Fuel Filter
(Tandem)

EGR Cooler

Common Rail

(Tandem)

Supply Pump
(G Sensor)


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Engine Layout /Main Parts

Turbocharger

Remote Oil Filter Port


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Characteristics of Main Structure Components
Cooled

OHC 4VALVE
High Rigidity of
Cyl. Head

High Efficiency
Turbocharger
no Waste Gate

Symmetry
High
Rigidity
C.Block

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

High
Rigidity
C. Shaft


High Rigidity
Rudder Frame

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

Comparison with Tier 2
6WG1X-Tier2

100

6WG1X-Tier3

Fan : none

98
96
94

-----

6WG1X-Tier2

92

Fan : none

90

36WG1X-Tier2
db(A) lower
B A)

-

88

Than Tier 2

86
84
600

800

1000

1200

1400

1600

1800

2000

2200


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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

-


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System Schematic (6WG1)
Common Rail Pressure Sensor

Pressure Limiter
Common Rail

Supply Pump

Injector
ECM
CKP Sensor


Comparison with Conventional System
TWV: Two Way Valve

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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.



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Fuel Injection Rate Control

6WG1X Tier3 apply Main & Pilot Injection only


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Fuel Injection Rate Control
Conventional
ConventionalInjection
Injection

Pilot
PilotInjection
Injection

Injection rate

Small mixed
combustion

Large mixed
combustion
(NOx, noise)

Generation
rate of heat

Crank angle (

)

Crank angle (

)

Pilot Injection reduce NOx and Noise


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