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ISUZU INDUSTRIAL DIESEL ENGINE 6WG1X Tier3 1. chọn động cơ 6 xi lanh, 6 xilanh inline, direct injection diesel, Mechanical fuel injection pump (Inline fuel injection pump) BOSCH PEPS3S MITSUBISHI 2450MITSUBISHI
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 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 Maintenance Schedule Introduction of SST Trouble Shooting Trouble Shooting Procedure How to use Trouble Shooting Manual DTC code DTC code Scan Tool EMPS How to use scan tool Point to notice on service Parts replace procedure 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 RETURN 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 RETURN 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) ) RETURN 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 RETURN Technologies and Emission Level (130kW ) PM g/kWh Tier trade-off 130MPa pressure Cooled EGR Electronic control Tier trade-off 70MPa pressure Inter cooler Tier Tier 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 Engine • Low Emission • Low Noise • High Power Electronic Controlled Engine Tier Engine Comparison Electronic Control Common Rail System Cooled EGR Check list for engine control system RETURN Inspector's company name Inspector's name User Machine Trouble symptom Engine Confirm Machine userapplication complain using Questionnaire sheet User's name Address Date of delivery Operating period Machine model name Engine model name Date of trouble occurrence Machine No Engine No 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 When accelerator pedal (lever) is released At certain operation mode Vibration at idling Trouble occurrence data Frequency of trouble Weather Trouble condition Ambient temperature Season Location Engine temperature Oil/coolant temperature Operating condition Condition when trouble o Oil Fuel type Diagnosis lamp DTC Current trouble Refer to Fine After lightening 30 or more Spring Outdoor Indoor In mountain Others ( ) Cold Engine coolant temperature Cloudy Others ( ) Around 20 - 30 C Summer Rain Around 10 - 15 Autumn General road Expressway On the sea Construction field (Type Roadworks field (Type ) Harbor During warming-up Oil temperature ( Snow C or less ( ) Winter Rough road Slope (grade degree ) Height ( m above sea level) After warmed-up Others ( ) ) After oil is replaced After operating on slope After oil filter is replac After out of gas After replenishment of After washing with high After sedimenter is drained Others ( ) Light oil Diesel fuel Special No Krosene Diesel fuel No A heavy oil Diesel fuel No Others ( ) Diesel fuel Special No ON Sometimes comes on Not come on Past trouble Past trouble history 6WG1X Engine Troubleshooting Manual (NM1J1-E-ENG-T) Year Year Month Month Date Date (Content (Content ) [Measure: ) [Measure: ] ] - How to use “Trouble Shooting Manual” J 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 RETURN 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 DTC Code Reference Sheet for Hitachi and Isuzu Code description Ac celerator sebsor 1-2 comparison fault Ac celerator sebsor fau lt (low voltage) Ac celerator sebsor fau lt (high voltage) Trouble display on monitor RETURN Detail of DTC RETURN (Diagnostic Trouble Code) Isuzu DTC code detail, refer to Trouble Shooting Manual Hitachi unique DTC code, refer to List of diagnostic trouble code - List of diagnostic trouble codes On some machines, the diagnosis lamp comes on instead of trouble display monitor on the machine WG Flash code P0088 118 description Common rail pressure fault (1st stage) Item to be detected Common rail pressure abnormal increase Description of DTC Code P Recovery from failure, refer to Preconditions when DTC is set Key switch input voltage is 16V or more DTC P0088, P0192,P0193 or P1635 is not detected , Refer to set condition Rail pressure is more than 150Mpa (21756psi) Fault Behavior when Diagnos judgment trouble occurs is lamp period Approx Increase engine ON sec vibration, rough idling, output lowering, blow up fault, black smoke emitted, and excessive output are possible Back-up: Limited injection amount (multiinjection stopped) Target RP upper limit(80 Mpa {11603 psi}) Recovery from Failure Pattern Pattern 11 Trouble occurs Inspection and repair, or temporary recovery from failure Wait 10 seconds Recovery from failure Pattern Pattern 22 Trouble occurs Inspection and repair, or temporary recovery from failure Recovery from failure RETURN Recovery from Failure Pattern Pattern 33 Engine is recovered from failure, but trouble code exists and lamp remains on DTC Clear Action Required Trouble occurs Inspection and repair, or temporary recovery from failure Recovery from failure RETURN 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) - Electronic control fuel injection system Common rail type List of trouble symptom Symptom Description Engine start failure 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 stall Engine cranks but take long time before start It operates eventually, or starts but stops immediately RETURN RETURN About Tech2 S Tool) 1) Display of Diagnostic Trouble Codes Performs Reading, confirmation and clearing of DTC 2) Data Display Displays the current data recognized and controlled by ECM 3) Snapshot Records and plots data when trouble occurs 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 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) • 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 RETURN How to Clear DTC Connect the harness (shown left) to data link connector Turn the key switch to ON Short (connect) the probe Turn the key switch to OFF (DTC memory will be cleared simultaneously) 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 RETURN 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 Injection Quantity or Actuating Pulse Width TQ RETURN Injector ; QR Code Injector QR Code RETURN Engine Label Label Label Engine Production serial NO Injector QR Code Engine Model JPN Label / Production Month / month/ Month/Year) year