(004) Isuzu Engine

(1)

Engine Summary

RST-06-01-001 RST-06-01-001 Engine Summary Engine Summary Engine Summary Engine Summary SH200SH200

Main Data Table (changes from model 3)

CX210B (Tier 3) CX210B (Tier 3) (Exhaustgas third regulation) (Exhaustgas third regulation)

CX210 (Tier 2) CX210 (Tier 2)

(Exhaust gas second regulation) (Exhaust gas second regulation) E

Ennggiinne e mmooddeel l nnaammee -- IIssuuzzu u 4H4HKK11 CCAASSE E 66TTAAAA--55990044

M

Mooddeell

--4-cycle, water cooled, overhead 4-cycle, water cooled, overhead cam-shaft, vertical in-line, direct injection shaft, vertical in-line, direct injection type

type

4-cycle, water cooled, overhead valve, 4-cycle, water cooled, overhead valve, vertical in-line, direct injection type vertical in-line, direct injection type

D

Drry y wweeiigghhtt llb b ((kkgg)) 1, 1, 558 8 llb b ((448800)) ?? D

Diissppllaacceemmeenntt iinn³ ³ ((cccc)) 33117 7 ((55119933)) 33660 0 ((55990000)) Number of cylinders

Number of cylinders - bore X stroke

bore X stroke iin n ((mmmm)) 44--44..553 3 X X 44..992 2 ((44--11115 5 X X 112255)) 6 6 - - 44..002 2 X X 44..772 2 ((6 6 - - 11002 2 X X 112200)) C

Coommpprreessssiioonnrraattiioo -- 1717..55 1188..00

R

Raatteed d oouuttppuutt -- 157 hp / 1800 rpm157 hp / 1800 rpm (117 kW / 1800 rpm) (117 kW / 1800 rpm) 148 hp / 1950 rpm 148 hp / 1950 rpm (110.0 kW / 1950) rpm (110.0 kW / 1950) rpm M

Maaxxiimmuum m ttoorrqquuee NNm m / / rrppmm 463 lb ft / 1500 rpm463 lb ft / 1500 rpm (628 Nm / 1500 rpm) (628 Nm / 1500 rpm) 450 lb ft / 1400 rpm 450 lb ft / 1400 rpm (610 Nm / 1400 rpm) (610 Nm / 1400 rpm) No load maximum speed

No load maximum speed rpmrpm 18001800 19501950

No load minimum speed No load minimum speed

(idling)

(idling) rrppmm 11000000 990000

Rated fuel consumption Rated fuel consumption

ratio

ratio g g / / kkWW••hhrr 222299..3 3 mmaax x mmaaxx F

Fuueel l uunniitt -- HP3 model common rail from DensoHP3 model common rail from Denso Corp.

Corp. CDCCDC

C

Coonnttrrool l ddeevviiccee -- EECCM M mmaadde e bby y TTrraannssttrroon n IInncc.. CCDDCC C

Coooolliinng g ffaann -- 77N N ssuuccttiioonn φφ 6 6550 0 ppllaassttiicc 77N N ssuuccttiioonn φφ 600 plastic600 plastic B

Beelll l mmoouutth h ttyyppe e ffaan n gguuiiddee -- YYeess YYeess F

Faan n bbeelltt -- DDrriivve e bby y oonne e VV--rriib b bbeelltt DDrriivve e bby y ttwwo o BB--mmooddeel l V V bbeellttss

A

Alltteerrnnaattoorr -- 550 0 AA--224 4 VV, , mmaadde e bby y NNiikkkko o EElleeccttrriicc 50 A -24 50 A -24 VV, made by , made by Mitsubishi ElectricMitsubishi Electric Corp.

Corp. S

Sttaarrtteerr -- 55..0 0 kkWW--224 4 VV, , mmaadde e bby y NNiikkkko o EElleeccttrriicc 44..5 5 kkWW--224 4 VV, , mmaadde e bby y NNiikkkko o EElleeccttrriicc T

Tuurrbboo -- RRHHFF555 5 mmooddeel l mmaadde e bby y IIHHII P

Prreehheeaat t uunniitt -- QQOOSS--IIII MMaanniiffoolld d ggrriid d

IInntteerrccoooolleerr -- YYeess YYeess

F

Fuueellccoooolleerr -- YYeess NNoo

E

Elleeccttrroommaaggnneettiic c ppuummpp -- YYeess YYeess F

Fuueel l ffiilltteerr -- 44 μμ main unit remote type with main unit remote type with waterwater separator function

separator function

20

20 μμ with water s with water separator function eparator function WithWith engine

engine

F

Fuueel l pprree--ffiilltteerr -- 1010 μμ main unit remote type with main unit remote type with waterwater separator function

separator function

--O

Oiil l ffiilltteerr -- RReemmootte e ttyyppee WWiitth h eennggiinnee O

Oiil l ppaan n ccaappaacciittyy LL 1133..0 0 tto o 2200..55 O

Oiillppaanndrraaiind nccoocckk -- YYeess NNoo

Page 1 of 53 Page 1 of 53

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RST-06-01-001 RST-06-01-001

Engine Summary

Overall Appearance Diagram

1

1 EEnnggiinne e ooiil l ffiilll l poporrtt 66 EEGGR R ccoooolleerr 2

2 AAiir r bbrreeaatthheerr 77 BBeelll l mmoouutth h ttyyppe e ffaan n gguuiiddee 3

3 AAlltteerrnnaattoorr 88 SSttaarrtteer r mmoottoorr 4

4 TTuurrbboo 99 SSuupppplly y ppuummp p ((SSCCVV)) 5

5 EEGGR R vvaallvvee 1010 CCoommmmoon n rraaiill

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Engine Summary

RST-06-01-001 RST-06-01-001

Sensor and Auxiliary

Sensor and Auxiliary Equipment Layou

Equipment Layout (left)

t (left)

1

1 EEnnggiinne ce coooollaannt tt teemmppeerraattuurre se seennssoorr 66 SSttaarrtteer mr moottoorr 2

2 BBoooosst t pprreessssuurre e sseennssoorr 77 OOiil l pprreessssuurre e sseennssoorr 3

3 CCoommmmoon n rraaiil l pprreessssuurre e sseennssoorr 88 SSuuccttiioon n ccoonnttrrool l vvaallvve e ((SSCCVV)) 4

4 EEGGR R vvaallvvee 99 FFuueel l tteemmppeerraattuurre e sseennssoorr 5

5 BoBoosost tet tempmpererataturure see sensnsoror

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RST-06-01-001 RST-06-01-001

Engine Summary

Sensor and Auxiliary

Sensor and Auxiliary Equipment Layo

Equipment Layout (rear)

ut (rear)

Engine System Diagram

1

1 CrCranank pk pososititioion sn senensosorr 2

2 CCam am poposisitition on sesensnsoror

1

1 AAiir r cclleeaanneerr 77 TTuurrbbiinne e ssiiddee 1133 MMuufffflleerr 2

2 FFuueellccoooolleerr 88 EEnnggiinnee 1144 FFuueellmmaaiinnffiilltteerr 3

3 IInntteerrccoooolleerr 99 IInnjjeeccttoorr 1155 FFuueellttaannkk 4

4 RRaaddiiaattoorr 1100 CCoommmmoon n rraaiill 1166 FFuueel l pprreeffiilltteerr 5

5 TTuurrbboo 1111 SSuupppplly y ppuummpp 1177 EElleeccttrroommaaggnneettiic c ppuummpp 6

6 CCoommpprreessssoor r ssiiddee 1122 EEGGR R ccoooolleerr

Flow of air and combustion gas Flow of air and combustion gas Flow of fuel Flow of fuel Flow of coolant Flow of coolant In In Page 4 of 53 Page 4 of 53

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Engine Summary

RST-06-01-001 RST-06-01-001

Fuel System Diagram

1

1 EElleeccttrroommaaggnneettiic c ppuummpp 66 FFlloow w ddaammppeerr 1111 CCMMP P sseennssoorr 2

2 FFuueel l mmaaiin n ffiilltteerr 77 FFuueel l pprreeffiilltteerr 1122 CKCKP P sseennssoorr 3

3 CCoommmmoon n rraaiil l pprreessssuurre e sseennssoorr 88 SSuupppplly y ppuummpp 1133 IInnjjeeccttoorr 4

4 CCoommmmoon n rraaiill 99 FFuueel l ccoooolleerr 5

5 PPrreessssuurre e lliimmiitteerr 1100 FFuueel l ttaannkk

ECM

Sensors

Engine coolant, atmospheric pressure, others

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RST-06-01-001 RST-06-01-001

Engine Summary

Detailed Parts Diagrams

1. 1. ECM (e

ECM (engine

ngine contro

control modu

l module)

le)

Three roles of the ECM Three roles of the ECM

[1]

[1] The ECM The ECM constanconstantly montly monitors initors informatformation senion sent from tht from the varie various sensous sensors and ors and controcontrols thels the power train systems.

power train systems. [2]

[2] The ECM eThe ECM executxecutes system fues system function dnction diagnoiagnosis, detsis, detects proects problemblems in system ops in system operatieration, issuon, issueses trouble alarms to warn the

trouble alarms to warn the operator and stores the diagnostic trouble code intoperator and stores the diagnostic trouble code into memory.o memory. The diagnostic trouble code identifies the area in which the problem occurred and supports The diagnostic trouble code identifies the area in which the problem occurred and supports repair work by the ser

repair work by the service engineer.vice engineer. [3]

[3] The ECM The ECM puts ouputs out 5 V and ot 5 V and other vther voltageoltages to supps to supply powly power to ther to the varioe various sensous sensors andrs and switches.

switches.

The ECM controls output circuits

The ECM controls output circuits by controlling ground or power supply circuits via one deviceby controlling ground or power supply circuits via one device or another.

or another.

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Engine Summary

RST-06-01-001 RST-06-01-001

2. 2. Suppl

Supply Pump / SCV (suction con

y Pump / SCV (suction control val

trol valve)

ve)

Supply pump Supply pump

The supply pump uses the force of the engine rotation to raise the fuel pressure and send it to the The supply pump uses the force of the engine rotation to raise the fuel pressure and send it to the common rail.The SCV

common rail.The SCV, fuel t, fuel temperature sensor, and feed pump are installed emperature sensor, and feed pump are installed on the supply on the supply pump.pump. SCV (suction control valve)

SCV (suction control valve)

The SCV is installed on the supply pump and controls the sending of fuel to the common rail under The SCV is installed on the supply pump and controls the sending of fuel to the common rail under pressure (discharge amount). The ECM controls the time during which power is on to the SCV and pressure (discharge amount). The ECM controls the time during which power is on to the SCV and controls the fuel discharge amount.

controls the fuel discharge amount.

3. 3. Commo

Common Rail

n Rail / Flow

/ Flow Dampe

Damperr

[1

[1]] CCoommmmoon n rraailil

The common rail receives the fuel from the supply pump, holds the common rail (fuel) The common rail receives the fuel from the supply pump, holds the common rail (fuel) pres-sure, and distributes the fuel to each cylinder. The common rail pressure sensor, flow sure, and distributes the fuel to each cylinder. The common rail pressure sensor, flow damp-ers, and pressure limiter are installed

ers, and pressure limiter are installed on the common rail.on the common rail. [2

[2]] FFlloow w ddaammppeerr

The flow dampers are installed on the discharge port

The flow dampers are installed on the discharge port of each injector of the common rail. Theyof each injector of the common rail. They suppress pressure pulses in the common rail and prevent excess fuel injection from the suppress pressure pulses in the common rail and prevent excess fuel injection from the injec-tors.

tors.

When a flow damper operates, the fuel supply

When a flow damper operates, the fuel supply to the injector stops.to the injector stops.

1

1 FuFuel tel temempeperaratuture sre senensosorr 2

2 SCSCV (V (susuctctioion cn conontrtrol ol vavalvlve)e) 3 3 FFeeeed pd puummpp 1 1 FFlloow w ddaammppeerr 2 2 CCoommmmoon rn raaiill Page 7 of 53 Page 7 of 53

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RST-06-01-001 RST-06-01-001

Engine Summary

4. 4. Commo

Common Rail Press

n Rail Pressure Senso

ure Sensor / Pressure Limit

r / Pressure Limiter

er

[1

[1]] CoCommommon ran rail pil preressussure sre senensosorr

Sends the pressure inside the common rail to the ECM as a voltage signal. From the signal Sends the pressure inside the common rail to the ECM as a voltage signal. From the signal sent, the ECM calculates the actual common rail pressure (fuel pressure) and uses this for sent, the ECM calculates the actual common rail pressure (fuel pressure) and uses this for fuel injection control.

fuel injection control. [2

[2]] PrPresessusure re lilimimiteterr

If the pressure in the common rail becomes abnormally high, the pressure limiter relieves the If the pressure in the common rail becomes abnormally high, the pressure limiter relieves the pressure, and excess fuel is returned to the tank.

pressure, and excess fuel is returned to the tank.

5. 5. In

Inje

ject

ctor

or

The injectors are installed on the cylinder head sections. They are controlled from the ECM and The injectors are installed on the cylinder head sections. They are controlled from the ECM and inject fuel. The injector drive voltage is boosted (to 118 V) inside the ECM and applied to the inject fuel. The injector drive voltage is boosted (to 118 V) inside the ECM and applied to the injec-tors. By controlling the time this power to the injectors is on, the ECM controls the fuel injection, tors. By controlling the time this power to the injectors is on, the ECM controls the fuel injection, injection timing, etc.

injection timing, etc.

1

1 CoCommmmon on rarail il prpresessusure re sesensnsoror 2

2 PrPresessusure re lilimimiteterr

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Engine Summary

RST-06-01-001 RST-06-01-001

6. 6. Engine

Engine Coolant T

Coolant Temperature

emperature Sensor

Sensor

The engine coolant temperature sensor is installed on the engine block. The resistance of its The engine coolant temperature sensor is installed on the engine block. The resistance of its ther-mistor varies with the temperature.

mistor varies with the temperature.

The resistance is low when the engine coolant temperature is high and high when the coolant The resistance is low when the engine coolant temperature is high and high when the coolant tem-perature is low

perature is low. From the ECM voltage variation, the ECM calc. From the ECM voltage variation, the ECM calculates the engine coolant temperatureulates the engine coolant temperature and uses this for fuel injection control etc.

and uses this for fuel injection control etc.

7. 7. Engin

Engine Oil

e Oil Pressu

Pressure Sen

re Sensor

sor

The engine oil pressure sensor is installed near the cylinder block starter motor. It detects the The engine oil pressure sensor is installed near the cylinder block starter motor. It detects the engine oil pressure, converts this pressure into an electrical signal, and sends that signal to the engine oil pressure, converts this pressure into an electrical signal, and sends that signal to the ECM.

ECM.

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RST-06-01-001 RST-06-01-001

Engine Summary

8. 8. Cam P

Cam Positio

osition Sensor (C

n Sensor (CMP sensor

MP sensor))

This sensor sends a signal to the ECM when the engine camshaft cam section passes this sensor. This sensor sends a signal to the ECM when the engine camshaft cam section passes this sensor. The ECM identifies the cylinders through this sensor input, determines the crank angle, and uses The ECM identifies the cylinders through this sensor input, determines the crank angle, and uses this information to control the fuel injection and to calculate the engine speed.

this information to control the fuel injection and to calculate the engine speed.

The CMP sensor also provides a back-up function in case of trouble in the CKP sensor. However, if The CMP sensor also provides a back-up function in case of trouble in the CKP sensor. However, if there is trouble in the CMP sensor s

there is trouble in the CMP sensor system, there is no cystem, there is no change in the behavior while the engine runs,hange in the behavior while the engine runs, but after it stops, the engine cannot start.

but after it stops, the engine cannot start.

9. 9. Cran

Crank Posi

k Position Senso

tion Sensor (CKP sensor)

r (CKP sensor)

This sensor sends a signal to the ECM when the projection section of the engine flywheel passes This sensor sends a signal to the ECM when the projection section of the engine flywheel passes this sensor.

this sensor.

The ECM identifies the cylinders through this sensor input, determines the crank angle, and uses The ECM identifies the cylinders through this sensor input, determines the crank angle, and uses this information to control the fuel injection and to calculate the engine speed.

this information to control the fuel injection and to calculate the engine speed. In case of trouble in t

In case of trouble in the CKP sensor, the CMP sensor provides a back-up functhe CKP sensor, the CMP sensor provides a back-up function.ion.

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Engine Summary

RST-06-01-001 RST-06-01-001

10.Atmospheric Pressure Sensor

The atmospheric pressure sensor is installed in the cab. The ECM converts the atmospheric The atmospheric pressure sensor is installed in the cab. The ECM converts the atmospheric pres-sure into an electric signal and calculates the atmospher

sure into an electric signal and calculates the atmospheric pressure from this voltage signal and cor-ic pressure from this voltage signal and cor-rects the fuel injection quantity according to the atmospheric pressure.

rects the fuel injection quantity according to the atmospheric pressure.

11.Suction Air Temperature Sensor

The suction air temperature sensor is installed midway through the suction air duct. It detects the The suction air temperature sensor is installed midway through the suction air duct. It detects the suction air temperature in order to optimize

suction air temperature in order to optimize the fuel injection quantity.the fuel injection quantity.

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RST-06-01-001 RST-06-01-001

Engine Summary

12.Boost Pressure Sensor

The boost pressure sensor uses a pressure hose between the boost pressure sensor and intake The boost pressure sensor uses a pressure hose between the boost pressure sensor and intake pipe to detect the boost (suction air pressure), converts this pressure into an electrical signal, and pipe to detect the boost (suction air pressure), converts this pressure into an electrical signal, and sends that signal to the ECM.

sends that signal to the ECM.

13.Boost Temperature Sensor

The boost temperature sensor is installed on the upstream side of the EGR valve of the intake The boost temperature sensor is installed on the upstream side of the EGR valve of the intake man-ifold.

ifold.

This sensor is the thermistor type. The internal resistance of the sensor changes with the This sensor is the thermistor type. The internal resistance of the sensor changes with the tempera-ture.

ture.

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Engine Summary

RST-06-01-001 RST-06-01-001

14.Electromagnetic Pump

Converting the fuel filter and pre-filter to remote operation increased the distance from the fuel tank Converting the fuel filter and pre-filter to remote operation increased the distance from the fuel tank to the feed pump.

to the feed pump.

Therefore, this new pump was added to assist in drawing the fuel from the tank and to make it easy Therefore, this new pump was added to assist in drawing the fuel from the tank and to make it easy to bleed out air during maintenance.

to bleed out air during maintenance.

This pump always operates when the key switch is ON. This pump always operates when the key switch is ON.

15.EGR Cooler

The cooled EGR (cooling unit installed in the path) uses the engine coolant to cool exhaust gas at The cooled EGR (cooling unit installed in the path) uses the engine coolant to cool exhaust gas at high temperature (about 700

high temperature (about 700 °°C) down to (about 200C) down to (about 200 °°C), to drop the combustion temperature, andC), to drop the combustion temperature, and to reduce NOx. to reduce NOx. Coolant inlet Coolant inlet Coolant path Coolant path (outside of exhaust gas path) (outside of exhaust gas path) Exhaust gas path

Exhaust gas path

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Engine Summary

16.Reed V

16.Reed Valve (check

alve (check valve)

valve)

The reed valve is installed between the EGR valve outlet and the inlet manifold. It suppresses EGR gas back The reed valve is installed between the EGR valve outlet and the inlet manifold. It suppresses EGR gas back flow and allows the EGR gas to

flow and allows the EGR gas to only flow in one direction.only flow in one direction.

17.EGR Valve

The operation of the EGR valve (lift

The operation of the EGR valve (lift amount) is controlled by signals from the ECM.amount) is controlled by signals from the ECM.

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Engine Summary

Engine Control Summary

Electronic control fuel injection system (common rail Electronic control fuel injection system (common rail type)type)

This is a system in which the engine speed, engine load, and other information (signals from many sensors) is This is a system in which the engine speed, engine load, and other information (signals from many sensors) is acquired by the engine control mod

acquired by the engine control module (ECM). ule (ECM). Based on this information, the ECM sends elBased on this information, the ECM sends electrical signals toectrical signals to the supply pump, injectors and fuel control vales to appropriately control the fuel injection quantity and timing the supply pump, injectors and fuel control vales to appropriately control the fuel injection quantity and timing for each cylinder.

for each cylinder.

Injection quantity control Injection quantity control

To provide the optimum injection quantity, the ECM controls the injectors based on the engine speed and the To provide the optimum injection quantity, the ECM controls the injectors based on the engine speed and the instructed information from computer A and

instructed information from computer A and controls the fuel injection quantity.controls the fuel injection quantity. Injection pressure control

Injection pressure control The injection pressure is contro

The injection pressure is controlled by controlling the fuel presslled by controlling the fuel pressure in the common rail. ure in the common rail. The appropriate pressureThe appropriate pressure in the common rail is calculated from the engine speed and fuel injection quantit

in the common rail is calculated from the engine speed and fuel injection quantity. y. By controlling the supplyBy controlling the supply pump, the pressure in th

pump, the pressure in the common rail is controllee common rail is controlled by the amount of fuel send by the amount of fuel sent to the common rail.t to the common rail. Injection timing control

Injection timing control

To provide the optimum injection quantity, the ECM controls the timeing of the fuel injection pulses based To provide the optimum injection quantity, the ECM controls the timeing of the fuel injection pulses based mainly on the

mainly on the engine speed and the engine speed and the instructed speed from the instructed speed from the excavator controllerexcavator controller.. Injection rate control

Injection rate control

In order to improve the combustion in the cylinder, at first only a

In order to improve the combustion in the cylinder, at first only a small amount of fuel is injected (pre-injection),small amount of fuel is injected (pre-injection), the fuel is ignited, then once

the fuel is ignited, then once the fuel has ignited, a the fuel has ignited, a second injection (main injection) is carried out.This injectionsecond injection (main injection) is carried out.This injection timing and quantity control is possible because

timing and quantity control is possible because of the proportional solenoid valve in of the proportional solenoid valve in the injectors.the injectors.

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Explanation of Engine Terms

Function Explanation Table

Name

Name FunctionFunction

1

1 CCoommmmoon n rraaiill RReecceeiivvees s tthhe e hhiigghh--pprreessssuurre e ffuueel l sseennt t uunnddeer r pprreessssuurre e ffrroom m tthhe e ssuupppplly y ppuummpp,, holds the fuel pressure, and distributes the fuel to each injector.

holds the fuel pressure, and distributes the fuel to each injector. 2

2 PPrreessssuurre le limimititeer r

(common rail component part) (common rail component part)

Operates to allow pressure within the common rail to escape if the pressure in Operates to allow pressure within the common rail to escape if the pressure in the common rail becomes abnormally high.

the common rail becomes abnormally high. 3

3 FFlloow w ddaammppeer r

(common rail component part) (common rail component part)

Installed on the discharge port of

Installed on the discharge port of each injector. Suppress pressure pulses in theeach injector. Suppress pressure pulses in the common rail and prevent fuel supply to the injectors when there is pipe common rail and prevent fuel supply to the injectors when there is pipe dam-age.

age. 4

4 CoCommmmon on rarail il prepressssurure e sesensnsor or (common rail component part) (common rail component part)

Detects the pressure inside the common rail,

Detects the pressure inside the common rail, converts it to a voltage, and sendsconverts it to a voltage, and sends that voltage to the ECM.

that voltage to the ECM. 5

5 IInnjjeeccttoorr CCoonnttrroolllleed d bby y tthhe e EECCM M aannd d iinnjjeecctts s tthhe e ffuueell.. 6

6 SSuupppplly y ppuummpp RRaaiisse e tthhe e ffuueel l pprreessssuurre e aannd d sseennd d iit t uunnddeer r pprreessssuurre e tto o tthhe e ccoommmmoon n rraaiil l bby y uussiinngg the force of the engine rotation.

the force of the engine rotation. 7

7 SCSCV (sV (sucuctition con conontrtrol vol valalveve)) (supply pump component part) (supply pump component part)

Controls the fuel pressure (discharge quantity) sent to the common rail. Controls the fuel pressure (discharge quantity) sent to the common rail. The ECM controls the time during which power is on to the SCV to increase The ECM controls the time during which power is on to the SCV to increase or decrease the amount of fuel discharged.

or decrease the amount of fuel discharged. 8

8 FuFuel el tetempmpererataturure se senensosor r (supply pump component part) (supply pump component part)

Detects the fuel temperature and sends it to the ECM. Detects the fuel temperature and sends it to the ECM. Used for supply pump control etc.

Used for supply pump control etc. 9

9 EEGGR R

(Exhaust Gas Recirculation) (Exhaust Gas Recirculation)

Recirculates part of the exhaust gas in the intake manifold and mixes the EGR Recirculates part of the exhaust gas in the intake manifold and mixes the EGR gas with the suction air to reduce the combustion temperature and reduce gas with the suction air to reduce the combustion temperature and reduce NOx.

NOx. 1

100 EEGGR R vvaallvvee

(EGR position sensor) (EGR position sensor)

The EGR valve operation (open and close) timing and the lift amount are The EGR valve operation (open and close) timing and the lift amount are con-trolled by signals from the ECM. (The valve lift amount is detected by the trolled by signals from the ECM. (The valve lift amount is detected by the EGR position sensor)

EGR position sensor) 1

111 EEGGR R ccoooolleerr CCoooolls s tthhe e hhiigghh--tteemmppeerraattuurre e EEGGR R ggaas s bby y uussiinng g tthhe e eennggiinne e ccoooollaanntt.. 1

122 RReeeed d vvaallvvee IInnccrreeaassees s tthhe e aammoouunnt t oof f EEGGR R bby y ssuupppprreessssiinng g bbaacck k fflloow w oof f tthhe e EEGGR R ggaas s aannd d letting it flow only in one direction.

letting it flow only in one direction. 1

133 EECCMM

(engine control module) (engine control module)

Constantly monitors the information from each sensor and controls the engine Constantly monitors the information from each sensor and controls the engine system.

system. 1

144 QQOOSS

(quick on start system) (quick on start system)

Determines the glow time according to the engine coolant temperature, Determines the glow time according to the engine coolant temperature, oper-ates the glow relay, and makes starting at low temperatures easy and also ates the glow relay, and makes starting at low temperatures easy and also reduces white smoke and noise immediately after the engine starts.

reduces white smoke and noise immediately after the engine starts. 1

155 CCKKP P sseennssoor r

(crank position sensor) (crank position sensor)

Sends a signal to the ECM when the projection section of the engine flywheel Sends a signal to the ECM when the projection section of the engine flywheel passes this sensor

passes this sensor..

The ECM identifies the cylinders through this sensor input, determines the The ECM identifies the cylinders through this sensor input, determines the crank angle, and uses this information to control the fuel injection and to crank angle, and uses this information to control the fuel injection and to cal-culate the engine speed.

culate the engine speed. In case of trouble in t

In case of trouble in t he CKP sensor, the CMP sensor provides a back-up func-he CKP sensor, the CMP sensor provides a back-up func-tion.

tion. 1

166 OOiil l pprreessssuurre e sseennssoorr DDeetteecctts s tthhe e eennggiinne e ooiil l pprreessssuurre e aannd d sseenndds s iit t tto o tthhe e EECCMM.. Used for oil pressure drop alarms etc.

Used for oil pressure drop alarms etc. 17

17 EnEngigine cne coooolalant tnt temempeperaratuture sre senensosorr DeDetetectcts ths the ene engigine cne coooolalant tnt temempeperaratuture are and snd senends ids it to tt to the Ehe ECMCM.. Used for fuel injection control, QOS control, etc.

Used for fuel injection control, QOS control, etc.

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RST-06-02-001 RST-06-02-001

Explanation of Engine Terms

1

188 CCMMP sP seennssoorr

(cam position sensor) (cam position sensor)

Sends a signal to the ECM when the engine camshaft cam section Sends a signal to the ECM when the engine camshaft cam section passes this

passes this sensor.sensor.

The ECM identifies the cylinders through this sensor input, determines The ECM identifies the cylinders through this sensor input, determines the crank angle, and uses this information to control the fuel injection the crank angle, and uses this information to control the fuel injection and to calculate the engine speed.

and to calculate the engine speed. Also provides a back-up function in

Also provides a back-up function in case of trouble in the case of trouble in the CKP sensor.CKP sensor. However, if there is trouble in the CMP sensor system, there is no However, if there is trouble in the CMP sensor system, there is no change in the behavior while the engine

change in the behavior while the engine turns, but after it stops, restart-turns, but after it stops, restart-ing is difficult.

ing is difficult. 19

19 AtAtmomospspheheriric pc preressssurure se senensosorr DeDetetectcts ts the he atatmomospspheheriric pc preressssurure ae and nd sesendnds is it tt to to the he ECECM. M. ThThe ie injnjec ec--tion quantity is corrected according

tion quantity is corrected according to the atmospheric pressure.to the atmospheric pressure. 20

20 SuSuctctioion ain air tr temempeperaratuture sre senensosorr DeDetetectcts ts the he susuctctioion an air ir tetempmpererataturure ae and nd sesendnds is it tt to to the he ECECM. M. OpOptitimimizezess the fuel injection quantity.

the fuel injection quantity. 2

211 BBoooosst t pprreessssuurre e sseennssoorr DDeetteecctts ts thhe be boooosst (t (ssuuccttiioon an aiir pr prreessssuurree) i) innssiidde te thhe ie innttaakke pe piippe ae anndd sends it to the ECM. Used to control fuel injection with the boost sends it to the ECM. Used to control fuel injection with the boost pres-sure.

sure. 22

22 BoBooost st tetemmpeperrataturure e ssenensosorr DDetetecectts s ththe e boboosost t ttemempeperraatuturre ae and nd ssenendds is it t tto o ththe e EECMCM. . UsUsed ed ffor or ffueuell injection control etc.

injection control etc. N

Naammee FFuunnccttiioonn

(18)

Explanation of Engine Structure

18

18 RST-06-03-001RST-06-03-001

Explanation of Engine Structure Explanation of Engine Structure Explanation of Engine Structure

Explanation of Engine Structure SH200SH200

Technology for Exhaust Gases

1. 1. Com

Common Ra

mon Rail Sys

il System

tem

1

1 SSuupppplly y ppuummpp 2

2 CCoommmmoon rn raaiill 3

3 IInnjjeeccttoorr 4 4 FFuueel l ttaannkk ECM ECM Open / close Open / close signal signal

Electronic control system Electronic control system

Engine speed Engine speed Engine load ratio Engine load ratio Boost pressure Boost pressure Common rail pressure Common rail pressure Atmospheric pressure Atmospheric pressure Coolant temperature Coolant temperature These are These are detected detected by sensors. by sensors.

High-pressure fuel is accumulated High-pressure fuel is accumulated forfor all cylinders and fed uniformly to each all cylinders and fed uniformly to each injector.

injector.

The fuel injection pressure, injection timing, The fuel injection pressure, injection timing, and injection quantity are controlled and injection quantity are controlled elec-tronically to attain ideal combustion. tronically to attain ideal combustion. ECM ECM Open / close Open / close signal signal

Electronic control system Electronic control system

Engine speed Engine speed Engine load ratio Engine load ratio Boost pressure Boost pressure Common rail pressure Common rail pressure Atmospheric pressure Atmospheric pressure Coolant temperature Coolant temperature These are These are detected detected by sensors. by sensors.

High-pressure fuel is accumulated High-pressure fuel is accumulated forfor all cylinders and fed uniformly to each all cylinders and fed uniformly to each injector.

injector.

The fuel injection pressure, injection timing, The fuel injection pressure, injection timing, and injection quantity are controlled and injection quantity are controlled elec-tronically to attain ideal combustion. tronically to attain ideal combustion.

1 1 Page 18 of 53

(19)

19 19

RST-06-03-001 RST-06-03-001

Explanation of Engine Structure

2. 2. Multi-Stage

Multi-Stage Fuel Inj

Fuel Injection

ection (multiple

(multiple injection)

injection)

With conventional models, there is the no-injection s

With conventional models, there is the no-injection state, but with common rail models, pre-injectiontate, but with common rail models, pre-injection is started and ignition starts.

is started and ignition starts.

Conventional models start injection at this point in time, but common rail models have already Conventional models start injection at this point in time, but common rail models have already ignited with pre-injection and now start the second injection (main injection).

ignited with pre-injection and now start the second injection (main injection). Start of injection

Start of injection

Ignition Ignition

Conventional type injection

Conventional type injection Common rail modelsCommon rail models (pre-injection) (pre-injection)

Common rail models Common rail models (main injection start) (main injection start) Conventional type injection

2 2 Page 19 of 53

(20)

Explanation of Engine Structure

20

20 RST-06-03-001RST-06-03-001

Common rail models divide the high-pressure fuel injection over many times to make it possible to Common rail models divide the high-pressure fuel injection over many times to make it possible to create a uniform, complete combustion state in the combustion chamber and also to reduce the create a uniform, complete combustion state in the combustion chamber and also to reduce the engine noise and vibration.

engine noise and vibration. Combustion

Combustion

Common rail models Common rail models

(main injection) (main injection) Conventional type injection

3 3 Page 20 of 53

(21)

RST-06-03-001 RST-06-03-001

Explanation of Engine Structure

3. 3. Int

Inter

er Coo

Cooler

ler

1

1 IInntteer r ccoooolleerr 2

2 RRaaddiiaattoorr 3

3 EEnnggiinnee

Air cooled and brought to high-density (to engine) Air cooled and brought to high-density (to engine)

Exhaust gas Exhaust gas Suction air Suction air Turbo charger Turbo charger Outside air Outside air

By cooling intake air that had

By cooling intake air that had reached high temperature due to reached high temperature due to turbo-charging, the air density risesturbo-charging, the air density rises and the charging efficiency rises.

and the charging efficiency rises. This raises the engine fuel

This raises the engine fuel efficiency and improves fuel efficiency (CO / COefficiency and improves fuel efficiency (CO / CO22 reduction) and also reduction) and also has the effect of lowering the

has the effect of lowering the combustion temperaturcombustion temperature that reduces NOe that reduces NOXX..

Air that has been compressed Air that has been compressed and become hot

and become hot

(22)

Explanation of Engine Structure

4. 4. EGR (

EGR (exhaus

exhaust gas

t gas recir

recirculati

culation)

on)

EGR (exhaust gas recirculation) EGR (exhaust gas recirculation)

EGR system is an abbreviation for "exhaust gas recirculation" system. The EGR system recirculates part of EGR system is an abbreviation for "exhaust gas recirculation" system. The EGR system recirculates part of the exhaust gas in the intake

the exhaust gas in the intake manifold and mixes inactive gases with the suction air to manifold and mixes inactive gases with the suction air to reduce the combustionreduce the combustion temperature and suppress the generation of nitrogen oxides (NOx).The EGR quantity is controlled by the temperature and suppress the generation of nitrogen oxides (NOx).The EGR quantity is controlled by the operation (opening and closing) of the EGR valve, which is installed between the exhaust manifold and the operation (opening and closing) of the EGR valve, which is installed between the exhaust manifold and the intake manifold.

intake manifold.

The ERG quantity is determined from the engine speed and engine load rate (fuel injection quantity) and the The ERG quantity is determined from the engine speed and engine load rate (fuel injection quantity) and the EGR amount is controlled.A cooling device (EGR cooler) is installed in the EGR gas path to cool the EGR amount is controlled.A cooling device (EGR cooler) is installed in the EGR gas path to cool the high-temperature EGR gas with this EGR cooler. This cooled EGR gas is mixed with new air intake to make the temperature EGR gas with this EGR cooler. This cooled EGR gas is mixed with new air intake to make the combustion temperature lower than with normal EGR, which contributes to the reduction of NOx. (Cooled combustion temperature lower than with normal EGR, which contributes to the reduction of NOx. (Cooled EGR)

EGR)

Furthermore, a reed valve is

Furthermore, a reed valve is used in the EGR system to suppress EGR gas used in the EGR system to suppress EGR gas back flow and allow the EGR gas back flow and allow the EGR gas toto only flow in one direction.

only flow in one direction.

1

1 EEGGR R ccoooolleerr 66 BoBooosst t pprreessssuurre e sseennssoor r 2

2 RReeeed d vvaallvvee 77 SSuuccttiioon n aaiir r tteemmppeerraattuurre e sseennssoor r 3

3 EEGGR R vvaallvvee 88 EEnnggiinne e ssppeeeed d 4

4 EEGGR R ppoossiittiioon n sseennssoorr 99 EEnnggiinne e ccoooollaannt t tteemmppeerraattuurree 5

5 BBoooosst t tteemmppeerraattuurre e sseennssoorr 1100 EEnnggiinne e llooaad d

Co Coololanant out outt CoCoololanant int in Exhaust gas Exhaust gas ECM ECM Suction air Suction air Page 22 of 53 Page 22 of 53

(23)

RST-06-03-001 RST-06-03-001

Explanation of Engine Structure

The ECM operates the motor according to such engine states as the speed and load and controls The ECM operates the motor according to such engine states as the speed and load and controls the EGR valve lift amount.

the EGR valve lift amount.

The valve lift amount is detected by the EGR position sensor. The sections shown in darker color in The valve lift amount is detected by the EGR position sensor. The sections shown in darker color in the diagram have larger valv

the diagram have larger valve lift amount. The e lift amount. The darkest color indicates a darkest color indicates a lift amount near 100%.lift amount near 100%.

E

E n n

g

i

i n n e e

l

l o o a a

d d e e t t c c . .

No EGR control during idling No EGR control during idling

Engine speed Engine speed

(24)

Explanation of Engine Operation

RST-06-04-001 RST-06-04-001

Explanation of Engine Operation Explanation of Engine Operation Explanation of Engine Operation

Explanation of Engine Operation SH200SH200

Engine Overall

1. 1. Compa

Comparison o

rison of 6BG1

f 6BG1 and 4

and 4HK1

HK1

With the ladder frame structure, the crank shaft bearing is supported as one piece by the frame. With the ladder frame structure, the crank shaft bearing is supported as one piece by the frame. (increased engine rigidity and reduced noise)

(increased engine rigidity and reduced noise)

1

1 _{Liner chrome plating roughness 5}_{Liner chrome plating roughness 5} 66 _{Liner phosphate film roughness 3}_{Liner phosphate film roughness 3} (reduced oil consumption) (reduced oil consumption) 2

2 CCaam m ffllaat t ttaappppeett 77 OOvveerrhheeaad d ccaam m ((hhiigghh--rriiggiiddiitty y ccyylliinnddeer r hheeaadd)) 3

3 Crank Crank / / journal journal pin pin diameter diameter 80 80 / / 6464 88 HiHighgh-r-rigigididitity cyy cylilindnderer 4

4 RRool ll leer rr roocckkeerr

(increases ability of lubricant to withstand wear)

(increases ability of lubricant to withstand wear) 99 BlocBlock & ladk & ladder fder framrame (hie (high righ rigidigidityty, hig, high outh outputput)) 5

5 4 4 vvaallvveess

(combustion improvement, high output, high rigidity)

(combustion improvement, high output, high rigidity) 1010 Crank Crank / (high output)(high output)/ journal journal pin pin diameter diameter 80 80 / / 7373

1

1 BeBeararining cg cap ap ststruructctururee 2

2 LaLadddder fer frarame sme strtrucuctuturere

2 valves OHV

6

6 B

B

G

1

4

4 H

H

K

1

6

6 B

B

e

n

g

i

n

e

4

4 H

H

e

n

g

i

n

e

(25)

RST-06-04-001 RST-06-04-001

Explanation of Engine Operation

Fuel Unit

1. 1. Commo

Common Rai

n Rail Sys

l System Su

tem Summary

mmary

The common rail system pressurizes the fuel to high pressure and injects the fuel mist widely into The common rail system pressurizes the fuel to high pressure and injects the fuel mist widely into the cylinder to increase the

the cylinder to increase the surface of contact with the surface of contact with the air and improve the combustion state.air and improve the combustion state. Injection pressure Injection pressure P P a a r r t t i

i c c u u

l l a a t t e e m m a a t t t t e e r r I I n n j j e e c c t t i

i o o n n

p p r r e e s s s s u u r r e e I I n n j j e e c c t t i

i o o n n

p p r r e e s s s s u u r r e e F F u u e e l l i i n n j j e e c c t t i

i o o n n

r r a a t t i

i o o

N N O O x x Pump speed Pump speed Conventional Conventional pump pump Conventional Conventional pump pump Pilot injection Pilot injection Common rail system

Common rail system Common rail systemCommon rail system

Split injection Split injection Pump speed Pump speed Crank angle Crank angle

High pressure injection

Pressure control

Fuel injection Fuel injection rate control rate control

Common rail system

Timing flexibility

Conventional model Conventional model Image diagram Image diagram Common rail Common rail C

Coonnvevennttiioonnaal fl fuueel il innjjeectctioion pn puummpp CCoommmmoon rn raaiil tl tyyppe he hiigghh-p-prreessssuure re fufueel il innjejeccttiioon sn sysystteemm

S S t t a a r r t t o o f f i i n n j j e e c c t t i

i o o n n

I I n n j j e e c c t t i

i o o n n

p p e e a a k k Page 25 of 53 Page 25 of 53

(26)

Explanation of Engine Operation

RST-06-04-001 RST-06-04-001

Relationship between ECM and sensor actuators

2. 2. Change P

Change Points for Injection

oints for Injection Method (governor

Method (governor, common rail)

, common rail)

1

1 TThhrroottttlle e vvoolluumme e ((ccoommppuutteer r AA)) 55 IInnjjeeccttoorr 2

2 CCrraannk k sshhaafft t ppoossiittiioon n sseennssoorr 66 CCoommmmoon n rraaiil l pprreessssuurre e sseennssoorr 3

3 CCaammsshhaafft t ppoossiittiioon n sseennssoorr 77 SSuupppplly y ppuummpp 4

4 OOtthheer r sseennssoorrss 88 EEGGR R vvaallvvee

System System

IInnlliinne e ttyyppee CCoommmmoon n rraaiil l ssyysstteemm

Injection Injection quan-tity adjustment

tity adjustment PPuummp p ((ggoovveerrnnoorr)) EECCMM, , iinnjjeeccttoorr Injection timing

Injection timing adjustment

adjustment PPuummp p ((ttiimmeerr)) EECCMM, , iinnjjeeccttoorr P

Prreessssuurre e bboooosstt PPuummpp SSuupppplly y ppuummpp Distribution

Distribution method

method PPuummpp CCoommmmoonnrraaiill

Injection Injection pres-sure adjustment sure adjustment

According to engine speed and injection According to engine speed and injection quantity

quantity Supply pump (SCV)Supply pump (SCV)

1

1 PPiippee 55 NNoozzzzllee 2

2 TTiimmeerr 66 CCoommmmoonnrraaiill 3

3 SSuupppplly y ppuummpp 77 IInnjjeeccttoorr 4

4 GGoovveerrnnoorr

Injection quantity control Injection quantity control Injection timing control Injection timing control

Injection pressure control Injection pressure control Throttle signal Throttle signal Engine speed Engine speed Correction signal Correction signal Actuator Actuator Sensor Sensor

Engine control module Engine control module

E

C

M

Cylinder identification Cylinder identification signal signal

Fluctuating high pressure Fluctuating high pressure

Constant high pressure Constant high pressure

(27)

RST-06-04-001 RST-06-04-001

Explanation of Engine Operation

3. 3. Expla

Explanatio

nation of Injecto

n of Injector Operat

r Operation

ion

(1)When there is no signal from the ECM (state before injection) (1)When there is no signal from the ECM (state before injection)

The outer valve in the injector is pushed down by the force of the spring A and seals the fuel into The outer valve in the injector is pushed down by the force of the spring A and seals the fuel into the control c

the control chamberhamber..

The hydraulic piston and spring B are pushed down by the fuel in the control chamber and the The hydraulic piston and spring B are pushed down by the fuel in the control chamber and the nozzle is in the closed state.

nozzle is in the closed state.

(2)When there is a signal from the ECM (2)When there is a signal from the ECM

When the signal from the ECM passes power through the injector solenoid, the outer valve When the signal from the ECM passes power through the injector solenoid, the outer valve com-presses the spring A

presses the spring A and moves it up.and moves it up.

The outer valve opening allows the fuel in the control chamber to return to the tank via the return The outer valve opening allows the fuel in the control chamber to return to the tank via the return line. line. No signal No signal Common rail Common rail Return Return 1 1 OOuutteer vr vaallvvee 2 2 OOrriiffiicce e 11 3 3 OOrriiffiicce e 22 4

4 HHydydrrauaulilic c pipiststonon 5 5 SSpprriinng g AA 6 6 IInnnneer vr vaallvvee 7 7 CCoonnttrrool c hl c haammb eb err 8 8 SSpprriinng g BB 9 9 NNoozzzzllee Signal input Signal input Common rail Common rail Return Return 1 1 OOuutteer vr vaallvvee 2 2 OOrriiffiicce e 11 3 3 OOrriiffiicce e 22 4

4 HHydydrrauaulilic c pipiststonon 5 5 SSoolleennooiidd 6 6 SSpprriinng g AA 7 7 IInnnneer vr vaallvvee 8 8 CCoonnttrrool c hl c haammb eb err 9 9 NNoozzzzllee 1 100 VVaal vl ve oe op ep enn Page 27 of 53 Page 27 of 53

(28)

Explanation of Engine Operation

RST-06-04-001 RST-06-04-001 (3)Injection start state

(3)Injection start state

The pressure difference between the control and the nozzle chamber, which is caused by the The pressure difference between the control and the nozzle chamber, which is caused by the control chamber opening to return line, opens the nozzle, then fuel is injected.

control chamber opening to return line, opens the nozzle, then fuel is injected.

(4)When the signal from the ECM is cut off (4)When the signal from the ECM is cut off

Because the power to the injector solenoid is cut off, the outer valve is pushed back down by the Because the power to the injector solenoid is cut off, the outer valve is pushed back down by the force of the spring A and the outer valve closes the return line path.

force of the spring A and the outer valve closes the return line path. Start of injection Start of injection Common rail Common rail Return Return Pressure difference Pressure difference generated generated 1 1 OOuutteer vr vaallvvee 2 2 OOrriiffiicce e 11 3 3 OOrriiffiicce e 22 4

4 HHydydrrauaulilic c pipiststonon 5 5 IInnnneer vr vaallvvee 6 6 CCoonnttrrool c hl c haammb eb err 7 7 SSpprriinng g BB 8 8 NNoozzzzllee Signal stop Signal stop Common rail Common rail Return Return 1 1 OOuutteer vr vaallvvee 2 2 OOrriiffiicce e 11 3 3 OOrriiffiicce e 22 4

4 HHydydrrauaulilic c pipiststonon 5 5 SSoolleennooiidd 6 6 SSpprriinng g AA 7 7 IInnnneer vr vaallvvee 8 8 VVaallvve e cclloossee 9 9 NNoozzzzllee Page 28 of 53 Page 28 of 53

(29)

RST-06-04-001 RST-06-04-001

Explanation of Engine Operation

(5)Injection stop state (injection end) (5)Injection stop state (injection end)

Because the fuel is sealed into the return line, fuel fills the control chamber again. Because the fuel is sealed into the return line, fuel fills the control chamber again.

The hydraulic piston and the spring B are compressed down by the filled fuel and the nozzle is The hydraulic piston and the spring B are compressed down by the filled fuel and the nozzle is closed.

closed.

This ends the injection. This ends the injection.

Injection stop Injection stop Common rail Common rail Return Return 1 1 OOuutteer vr vaallvvee 2 2 OOrriiffiicce e 11 3 3 OOrriiffiicce e 22 4

4 HHydydrrauaulilic c pipiststonon 5 5 IInnnneer vr vaallvvee 6 6 CCoonnttrrool c hl c haammb eb err 7 7 SSpprriinng g BB 8 8 NNoozzzzllee Page 29 of 53 Page 29 of 53

(30)

Explanation of Engine Operation

RST-06-04-001 RST-06-04-001

4. 4. Expla

Explanatio

nation of Supply Pu

n of Supply Pump Opera

mp Operation

tion

The drive shaft is dr

The drive shaft is driven by the force of engine rotation.iven by the force of engine rotation. The feed pump is turned by the

The feed pump is turned by the power of the drive shaft and draws up fuel from power of the drive shaft and draws up fuel from the fuel tank.the fuel tank.

The fuel pressurized by the feed pump has feed pressure pulse stabilized by the adjustment valve. The fuel pressurized by the feed pump has feed pressure pulse stabilized by the adjustment valve. Part of this fuel remains at the suction control valve to lubricate the plunger and cam and is returned Part of this fuel remains at the suction control valve to lubricate the plunger and cam and is returned to the fuel tank

to the fuel tank via the over flow.via the over flow.

The signal from the ECM is input to the suction control valve and the opening stroke varies The signal from the ECM is input to the suction control valve and the opening stroke varies accord-ing to the quantity

ing to the quantity of power passed through.of power passed through.

The quantity of fuel corresponding to the stroke is sent to the suction valve under pressure and is The quantity of fuel corresponding to the stroke is sent to the suction valve under pressure and is compressed to high pressure at t

compressed to high pressure at the plunger.he plunger.

The fuel raised to high pressure at the plunger is sent under pressure from the delivery valve to the The fuel raised to high pressure at the plunger is sent under pressure from the delivery valve to the common rail.

common rail.

The fuel temporarily built up in

The fuel temporarily built up in the common rail is distrthe common rail is distributed to the injectors for each cyliibuted to the injectors for each cylinder.nder.

1

1 FFuueellttaannkk 88 RReettuurrnnsspprriinngg 1155 IInnjjeeccttoorr 2

2 FFuueellffiilltteerr 99 PPlluunnggeerr 1166 DDrriivveesshhaafftt 3

3 SSuuccttiioonn 1100 SSuuccttiioon n vvaallvvee 1177 SSuuccttiioon n pprreessssuurree 4

4 FFuueel l iinnlleett 1111 DDeelliivveerry y vavallvvee 1188 FFeeeed d pprreessssuurree 5

5 FFeeeed d ppuummpp 1122 OOvveer r ffllooww 1199 HHiiggh h pprreessssuurree 6

6 AAddjjuussttiinng g vavallvvee 1133 RReettuurrnn 2200 RReettuurrn n pprreessssuurree 7

7 SSuuccttiioon n ccoonnttrrool l vvaallvvee 1144 CCoommmmoon n rraaiill

(31)

RST-06-04-001 RST-06-04-001

Explanation of Engine Operation

5. 5. Suppl

Supply Pump Disass

y Pump Disassemb

embly Diagr

ly Diagram

am

1

1 SSuuccttiioon n vvaallvvee 55 SuSuccttiioon n ccoonnttrrool l vvaallvvee 2

2 PPlluunnggeerr 66 FFeeeeddppuummpp 3

3 CCaammrriinngg 77 Fuel temperature sensorFuel temperature sensor 4

4 DDeelli vi veer y r y vvaallvvee

1

1 DDeelliivveerry y vvaallvvee 66 PPlluunnggeerr 2

2 Fuel temperature sensorFuel temperature sensor 77 AdAdjujuststining g vvalalvvee 3

3 FFeeeeddppuummpp 88 CCaammrriinngg 4

4 SCV (suction control valve)SCV (suction control valve) 99 EEcccceennttrriic cc caamm 5 5 PPuummp p hhoouussiinngg 1100 CCaammsshhaafftt

2 valves OHV

6BG1

4HK1

(32)

Explanation of Engine Operation

RST-06-04-001 RST-06-04-001

6. 6. Expla

Explanatio

nation of Flow Dampe

n of Flow Damper Operati

r Operation

on

Internal structure diagram Internal structure diagram

[1

[1]] WhWhen en enengigine ne is is stostoppppeded

When the engine is stopped, the ball and piston are pressed to the common rail side by the When the engine is stopped, the ball and piston are pressed to the common rail side by the tension of the spring.

tension of the spring. [2

[2]] WhWhen een engnginine ste startarts (ds (damampipingng))

When the engine starts, the fuel pressure from the common rail side is applied and the piston When the engine starts, the fuel pressure from the common rail side is applied and the piston and ball move to the injector side.

and ball move to the injector side.

The fuel pulses (damping) are absorbed by the

The fuel pulses (damping) are absorbed by the spring.spring.

1 1 PPiissttoonn 2 2 BBaallll 3 3 SSpprriinngg 1 1 PPiissttoonn 2 2 BBaallll 3 3 SSpprriinngg 1 1 PPiissttoonn 2 2 BBaallll 3 3 SSpprriinngg C Coommmmoon n rraaiil l ssiiddee IInnjjeeccttoor r ssiiddee C Coommmmoon n rraaiil l ssiiddee IInnjjeeccttoor r ssiiddee C Coommmmoon n rraaiil l ssiiddee IInnjjeeccttoor r ssiiddee Page 32 of 53 Page 32 of 53

(33)

RST-06-04-001 RST-06-04-001

Explanation of Engine Operation

[3

[3]] FFauaultlty fuy fuel oel oututflflowow

When there is faulty fuel outflow from the injection pipe etc. on the injector side, the injector When there is faulty fuel outflow from the injection pipe etc. on the injector side, the injector side pressure drops drastically, so the piston and ball are pushed out by the pressure side pressure drops drastically, so the piston and ball are pushed out by the pressure differ-ence with the common rail side to seal the flow damper with the ball and prevent fuel outflow ence with the common rail side to seal the flow damper with the ball and prevent fuel outflow from the common rail side.

from the common rail side.

7. 7. Pre

Pressu

ssure Lim

re Limite

iterr

When the pressure within the common rail reaches 200 MPa, for the sake of safety, the pressure When the pressure within the common rail reaches 200 MPa, for the sake of safety, the pressure limiter opens and returns fuel to the tank.

limiter opens and returns fuel to the tank. When the pressure drops to 30 MPa, the

When the pressure drops to 30 MPa, the valve closes to return operation to norvalve closes to return operation to normal.mal.

1 1 PPiissttoonn 2 2 BBaallll 3 3 SSpprriinngg Adhering Adhering C Coommmmoon n rraaiil l ssiiddee IInnjjeeccttoor r ssiiddee

Common rail pressure Common rail pressure Valve close

Valve close Valve open

Valve open 200 MPa200 MPa

30 MPa

30 MPa AbnormallyAbnormally

high pressure

(34)

Explanation of Engine Operation

RST-06-04-001 RST-06-04-001

8. 8. Cauti

Cautions f

ons for Mai

or Maintena

ntenance

nce

(1)Cautions concerning fuel used (1)Cautions concerning fuel used

With common rail engines, the supply pump and injector are lubricated by the fuel running With common rail engines, the supply pump and injector are lubricated by the fuel running through them.

through them.

Therefore, if any fuel other than diesel is used, this leads to engine trouble, so use of Therefore, if any fuel other than diesel is used, this leads to engine trouble, so use of non-speci-fied fuel is strictly prohibited.

fied fuel is strictly prohibited.

Please be aware that troubles resulting from the use of non-specified fuel are not covered by the Please be aware that troubles resulting from the use of non-specified fuel are not covered by the warranty.

warranty. Specified fuel Specified fuel JIS No. 2 diesel, JI

JIS No. 2 diesel, JIS No. 3 diesel, special S No. 3 diesel, special No. 3 diesel, or SUMITOMO approval fuel (Please con-No. 3 diesel, or SUMITOMO approval fuel (Please con-tact to your dealer about details

tact to your dealer about details of SUMITOMO Approval fuel.)of SUMITOMO Approval fuel.)

The parts of the fuel system (injector internal part etc.) and the holes and gaps that form the fuel The parts of the fuel system (injector internal part etc.) and the holes and gaps that form the fuel path are made with extremely high precision

path are made with extremely high precision

Therefore, they are extremely sensitive to foreign matter

Therefore, they are extremely sensitive to foreign matter. Foreign matter in the fuel . Foreign matter in the fuel path can dam-path can dam-age it, so use

age it, so use great care to keep out foreign matter.great care to keep out foreign matter. [1]

[1] Clean aClean and care fnd care for the fueor the fuel line and itl line and its surrous surroundingndings befos before starting otre starting other mainher maintenanctenance.e. [2]

[2] Those wThose working oorking on the fuel ln the fuel line musine must havt have hands cle hands clean of diean of dirt and dust.Wrt and dust.Wearing earing glovgloves whilees while working is strictly prohibited.

working is strictly prohibited. [3]

[3] After reAfter removinmoving fuel hoseg fuel hoses and fuel pis and fuel pipes, alwpes, always seaays seal the hoses anl the hoses and pipes bd pipes by covey covering thering the open sections with plastic bags or the like.

open sections with plastic bags or the like. [4]

[4] When rWhen replacineplacing parts, do nog parts, do not open the pt open the packinacking for thg for the new pe new parts until it is tiarts until it is time to instame to installll them.

them. [5]

[5] Do Do not not reuse reuse any any gaskgaskets oets or O-r O-ringsrings. . ReplaReplace thce them wem with nith new ew onesones..

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RST-06-04-001 RST-06-04-001

Explanation of Engine Operation

•• Do not reuse fuel Do not reuse fuel system high-pressure pipes or system high-pressure pipes or injector pipes.If they are injector pipes.If they are removed, repremoved, replacelace them with new parts.

them with new parts.

•• Do not replace a Do not replace a pressure limiter, pressure limiter, fuel temperature sensor or fuel temperature sensor or flow damper aloneflow damper alone.If there is.If there is any problem, replace the common rail assembly and all

any problem, replace the common rail assembly and all the fuel pipes.the fuel pipes. (2)Unreusability of high puressured fuel line.

(2)Unreusability of high puressured fuel line.

The SCV pump alone cannot be replaced because the fuel temperature sensor is inst

The SCV pump alone cannot be replaced because the fuel temperature sensor is installed on thealled on the pump main unit.

pump main unit. Always replace the supply Always replace the supply pump assemblypump assembly..

1

1 IInnjje ce cttoor r ppi pi peess

1

1 FFlloow w ddaammppeerr 33 FFuueel l tteemmppeerraattuurre e sseennssoorr 2

2 CCoommmmoon n rraaiil l pprreessssuurre e sseennssoorr 44 PPrreessssuurre e lliimmiitteerr

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Explanation of Engine Operation

RST-06-04-001 RST-06-04-001

(3)If there is engine trouble, it is strictly prohibited to judge individual cylinders as OK or NG by (3)If there is engine trouble, it is strictly prohibited to judge individual cylinders as OK or NG by start-ing up the engine and loosenstart-ing the injection pipes.(Never do this. The high-pressure fuel sprays ing up the engine and loosening the injection pipes.(Never do this. The high-pressure fuel sprays out dangerously.)

out dangerously.)

(4)Be careful. High voltage of 118 V or higher is applied to the injectors.Disconnect the batt

(4)Be careful. High voltage of 118 V or higher is applied to the injectors.Disconnect the batt ery cableery cable ground before replacing injectors.

ground before replacing injectors.

1

1 LooLoosensening wing when ehen enginngine stae starts srts stritrictlctly proy prohibhibitedited

1

1 IInnjjeeccttoorr 2

2 InInjejecctotor r haharnrnesesss 3

3 IInnjjeeccttoor r nnuutt Page 36 of 53