130-5/ENGINE

130-5
Service material of Engine

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Main Data Table
(Difference between 130-5 and 130-3 engine）
）
SH130-5 (Tier 3) SH130-3 (Tier 2)
Engine Model Name ISUZU　AJ-4JJ1X ISUZU　BB-4BG1T
Model - 4-cycle,Water cooled,OHC 4-cycle,Water cooled,OHV,inline direct injection
Dry weight kg 328 365
Displacement cc 2999 4329
Cylinders-bore×stroke mm 4-95.4*104.9 4-105*125
Compression ratio - 17.5 18
Rated output kW/min -1 70.9 / 2000 75.0 / 2200
Maximum torque Nm/min-1 359 / 1600 367 / 1600
No load maximum speed min-1 2000 2200
-1
No load minimum speed (idling) min 1050 1000
Fuel consumption rate g/kW･hr 227.6 or below 258.0 or below
Fuel unit - DENSO,common rail type-HP3 BOSCH, line fuel injection pump type-ADS
Control device - Transtron (ECM) BOSCH (ECU)
Cooling fan - 8N-inhale-Dia.550　plastic 8N-inhale-Dia.540　plastic
Bell mouth type fan guide - installed installed
Fan belt - V shape ribbed belt (single) Type-B V belt, dual-drive
Alternator - NDTC electric　50A-24V MITSUBISHI　50A-24V
Starter - NDTC　4.0kW-24V NDTC　4.5kW-24V
Turbo - IHI　type-RHF55 IHI　type-RHG6
Preheat - QOS-II QOS-II
Inter cooler - Yes None
Fuel cooler - Yes None
Electromagnetic pump - Yes None
Fuel filter - 4micron, with water separator, remotive 20micron,with water separator,at engine
Fuel pre filter - 7micron,with water separator, remotive None
Oil filter - separate with engine
Oil pan L 11.0 - 15.0 11.0 - 13.2
Oil2013/4/15
pan drain cock - Yes None2＜１＞<1>＜

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 -
Engine Summary
Engine equipments layout
View from CTWT Side
Water temp.
Sensor Injectors

Boost Press.
Sensor
EGR Valve
Boost temp.
Sensor

SCV (Supply P) Engine Starter

Fuel Temp.
Sensor
Crack Position
Sensor
Common Rail (Back of Starter)

Engine Oil
Press. Sensor Common Rail
2013/4/15 Press. Sensor 3＜１＞<1>＜
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 -
Engine Summary
Engine equipments layout
View from C/V Side Oil Supply Port

Cam Position
EGR Cooler Sensor

Generator
Turbo Charger

Blow-bye hose

Bell mouth Fan

Guard
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 -
Engine Summary
Engine equipments layout
CTWT Side

Water temp.
Sensor

AC
Compressor

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 -
Engine Summary
Engine equipments layout
CTWT Side

Over heating Switch

(Not in use)

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 -
Engine Summary
Engine equipments layout
CTWT Side

Injector connectors guard

Injector

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 -
Engine Summary
Engine equipments layout
CTWT Side

Boost Press.
Sensor

Boost temp.
Sensor

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 -
Engine Summary
Cooling system compartment
Fuel cooler

Vacuum sensor A/C

condenser
Double air
cleaner Battery
Reserve relay box
tank

A/C Batteries
Receiver/dryer

Selector
valve

Wind washer
tank 2013/4/15 9＜１＞<1>＜
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 -
Engine Summary
3 parallel cooling system

Inter
Radiator Oil Cooler
Cooler

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Sensors
Differences between Tier2 and Tier3 sensors

ＴＩＥＲ２ ＴＩＥＲ３

TACHO SENSOR CRANK POSITON SENSOR

CMP SENSOR
ENGONE COOLANT TEMPERATURE SENSOR ENGINE COOLANT
TEMPERATURE SENSOR
FUEL
TEMPERATURE SENSOR
BAROMETIC SENSOR
COMMON RAIL
PRESSURE SENSOR
BOOST PRESSURE
SENSOR

OIL PRESSURE SENSOR OIL PRESSURE SENSOR

BOOST TEMPERATURE SENSOR
INTAKE AIR TEMPERATURE SENSOR
EGR POSITION SENSOR
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Sensors and Accessories layout
Left-side ①LLC temperature sensor
②Boost pressure sensor
③Common rail pressure sensor
④ＥＧＲ valve

⑤Boost temperature sensor

⑥Starter motor
⑦Oil pressure seonsor

⑧Suction control valve

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⑨Fuel temperature sencer 12＜１＞<1>＜
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Sensors and Accessories layout
Back-side

⑩Cam position
sensor

⑪Crank position
sensor

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Engine System Diagram
Air and combustion gas flow
Fuel flow
Air cleaner Coolant flow

Turboﾞ
compressor turbine
side side
Inter cooler
Fuel cooler

EGR cooler
Radiator

Engine

Muffler
Injector
Common rail
Supply pump

In

Fuel filter

Fuel pre Electro magnetic

Fuel tank filter pump

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Common Rail System(4JJ1)

Fuel filter

Common rail
pressure sensor Common rail Pressure limiter

Electromagnetic
pump

Supply pump

Pre filter
Fuel cooler

Injector

Fuel tank

Each sensor
Accelerator, Boost pressure,
CMP sensor CKP sensor Engine coolant temperature, etc

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ECM(Engine Control Module)

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Three roles of the ECM

1. The ECM constantly monitors information sent from the

various sensors and controls the engine systems.
2. The ECM executes system function diagnostics, detects
problems in system operation, issues trouble code to
warn the operator and stores the diagnostic trouble code
into memory.
The diagnostic trouble code identifies the area in which
the problem occurred and supports repair work by the
service engineer.
3. The ECM output ranges 5V and other voltages to supply
power to the various sensors and switches.
The ECM controls output circuits by controlling ground or
power supply circuits via one device or another.

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Supply Pump
②Fuel temperature sensor ①SCV（suction control valve）
③Feed pump

Supply pump SCV（suction control valve）

The supply pump is driven by the The SCV is installed on the supply pump and controls
engine to raise the fuel pressure and the sending of fuel to the common rail under pressure
sends it under pressure to the (discharge amount). The ECM controls the time during
common rail. The SCV, fuel which power is on to the SCV and controls the fuel
temperature sensor, and feed pump discharge amount.
are2013/4/15
installed on the supply pump. 18＜１＞<1>＜
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Common Rail

Common Rail

NOTES;
Make sure to keep 2 minutes after engine
stop for disassembling common rail.

Common Rail
The common rail receives the fuel from the supply pump, holds the common rail
(fuel) pressure, and distributes the fuel to each cylinder. The common rail
pressure sensor, flow dampers, and pressure limiter are installed on the common
rail.

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Common Rail

Pressure Limiter

Common Rail
Pressure Sensor

Common Rail Pressure Sensor

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 fuel injection control.
Pressure Limiter
If the pressure in the common rail becomes abnormally high, the pressure limiter
operates to return fuel to the tank and thus allow pressure within the common rail
to escape.

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Injector

The injectors are installed in the cylinder head. They are controlled by
the ECM and inject fuel. The injector drive voltage is boosted to 118v
inside the ECM and applied to the injectors. By controlling the time this
power to the injectors is on, the ECM controls the fuel injected, the
injection
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Detail view of parts
Engine coolant sensor Engine oil pressure sensor

Engine coolant sensor is mounted on the top

left of the Engine block.
A thermistor changes resistance value
depending on a change of temperature.

If the LLC temperature is high, then the

resistance value will be low, when LLC
temperature is low, then the resistance value
will be higher. The engine oil pressure sensor is
installed in the cylinder block near by
From the voltage variation, the ECM the starter motor, it detects the engine
calculates the engine coolant temperature oil pressure and converts it to an
from the change of the ECM voltage and electrical signal and send it to ECM.
uses 2013/4/15
the value for fuel injection control. 22＜１＞<1>＜
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Detail view of parts
Cam position sensor （CMP sensor）
） Crank position sensor（
（CKP sensor）
）

This sensor send a signal to ECM when a cam This sensor sends a signal to the ECM when
on engine camshaft passes a sensor . A convex part of the engine fly wheel passes
The ECM identifies a cylinder by the sensor the sensor.
input and determines the angle of the crank The ECM identifies a cylinder by the sensor
and uses the information for fuel injection input and determines the angle of the crank
control and calculation of the engine speed. and uses this information for fuel injection
In addition, This sensor is the backup function control and calculation of the engine speed.
when the CKP sensor fails. In addition, this sensor is the backup function
In this regard, if the CKP sensor fails while the for the CMP sensor if it fails.
engine is running it will continue to run, but
restarting after an engine shutdown becomes
difficult.
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Detail view of parts
Barometric pressure sensor Intake-air temperature sensor

The Barometric pressure sensor is

The intake air temperature sensor is
installed behind the cab, it converts air
installed in the middle of the air intake
pressure to a voltage signal. The ECM
duct so the ECM can optimize the
calculates the air pressure from the
quantity of fuel injected based on the
voltage signal and determines the
ambient air temperature.
quantity of fuel to be injected.
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Detail view of parts
Boost pressure sensor Boost temperature sensor

The boost pressure sensor detects boost The boost temperature sensor is
(manifold) pressure, using a hose installed on the upstream side of the
connected to the intake manifold. It EGR valve in the intake manifold.
converts the pressure into an electrical This sensor is the thermistor type,
signal and sends it to the ECM. and changes resistance value
depending on a change of
temperature.
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Detail view of parts
Electromagnetic Pump

Gauze filter (rock stopper) is added.

Size 150mesh 100micron meter

Locating the fuel filter and pre-filter to remote operation increased the
distance from the fuel tank to the feed pump.
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.
This pump always operates when the key switch is ON.
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Detail view of parts
EGR cooler Cooling water
inlet

A passage of A passage of cooling water

exhaust gas （The out side of an exhaust gas
passage）

Cooled EGR (equipped cooling system at passage) uses

cooling water for Engine and It does cooling down high
temperature exhaust gas around 700℃
700℃ to around 200℃
200℃.
It intents
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to redacting of NOx. 27＜１＞<1>＜
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Detail view of parts
EGR valve

The EGR valve controls the amount

of exhaust gas injected into the
intake manifold. The operation is
controlled by a signal from ECM.

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 Engine control Summary
Electronically controlled fuel injection system（（Common rail））
This is a system in which the engine speed, engine load, and
other information (signals from many sensors) are acquired
by the engine control module (ECM). Based on this
information, the ECM sends electrical signals to the supply
pump, the injectors, and fuel control valves to appropriately
control the fuel injection quantity and the timing for each
cylinder.

Injection quantity control

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

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 An Engine control outline
Injection pressure control
The injection pressure is controlled by controlling the fuel
pressure in the common rail. The appropriate pressure in the
common rail is calculated from the engine speed and fuel
injection quantity. By controlling the supply pump, the
pressure in the common rail is controlled by the amount of
fuel sent to the common rail.

Injection timing control

Instead of a timer function, primarily the appropriate fuel
injection timing is calculated from the engine speed, injection
quantity, etc. and the injectors controlled.

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An Engine control outline

Injection rate control

In order to improve the combustion in the cylinder, at
first only a small amount of fuel is injected (pre-injection),
the fuel is ignited, then once the fuel has ignited, a
second injection (main injection) is carried out. This
injection timing and quantity control is possible because
of the proportional solenoid valve in the injectors.

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Engine term explanation-1
The fuel is compressed by the supply pump and sent to the
Common Rail common rail, the pressure is maintained, and is distributedto
each injector.
When pressure in the common rail becomes abnormally high, it is
Pressure limiter
relieved by the pressure limiter.
Common rail The fuel pressure in a common rail is detected, it is converted to
pressure sensor voltage that is send to the ECM.
Electronically controlled by the ECM to inject fuel into the
Injector
cylinedrs by proportional solenoid valves.
The fuel is made high-pressure by using the rotation power of
Supply pump
the engine from there the fuel is sent to the common rail.
The fuel force feed (amount of the exhalation) to a common rail
SCV (Suction
is controlled. ECM controls the energizing time to SCV and has
control valve)
increased and decreased the amount of the fuel exhalation.

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 Engine term explanation-2
The SCV controls the pressure of the fuel feed to the common
SCV (Suction
rail. The ECM controls the energizing time to the SCV which will
control valve)
increase or decrease the amount of the fuel in the common rail.
Fuel temperature The temperature of the fuel is detected and the signal is sent to
sensor the ECM. It uses the information to control the supply pump.
A part of the engine exhaust emission is made to circulate again
into the intake manifold, and the combustion temperature is
EGR
lowered by mixing the EGR gas with the intake air, Nox is
decreased.
The Operation (opening and closing) time of the EGR valve is
EGR valve
controlled according to the signal from ECM.
The high temperature EGR gas is cooled by using the engine
EGR cooler
coolant.
Information from each sensor is always confirmed, and the
ECM
engine system is controlled.

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Engine term explanation-3
Information from each sensor is always confirmed, and the
ECM
engine system is controlled.
The time of Gros is decided in proportion to the temperature of
QOS (quick on the engine coolant and the Gros relay is operated. The Engine
start system) start at the low temperature is facilitated and white smoke and
the noise immediately after the start of the engine are decreased
The signal when the convex part of the engine flywheel passes
CKP sencer the sensor is sent to ECM. ECM distinguishes the cylinder by
(crank position the sensor signal input and decides the angle of the crank.
sensor) Then, it is used the fuel jet control and to calculate the engine
rotati
Engine oil The pressure of the engine oil is detected and it sends it to
pressure sensor ECM. It uses it for warning etc. when the oil low pressure.
Engine coolant The temperature of the engine coolant is detected and it sends
temperature it to ECM. It uses it for the fuel jet control and the QOS control,
sensor etc.
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Engine term explanation-4

CMP (Cam The signal when the cam of the engine camshaft passes the
position sensor) sensor is sent to ECM.
The atmospheric pressure is detected and it sends it to ECM.
Atmospheric
The fuel injection quantity is adjusted by the atmospheric
pressure sensor
pressure.
Air intake
The intake temperature is detected and it sends it to ECM. It
temperature
adjusts it to the best fuel oil consumption.
sensor
The boost (manifold air pressure) in the intake pipe is detected
Boost pressure
and it sends it to ECM. It uses it for the fuel jet control etc. by
sensor
the boost pressure.
Boost
The boost temperature is detected and it sends it to ECM. It
temperature
uses it for the fuel jet control etc.
sensor

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Common Rail System

High-
Common Rail
Pressure
Pump

Injector

Opening
& closing
ECM The high-pressure fuel for all
signal
cylinders is saved and supplied to
each injector uniformly.

Fuel tank
Electronically controlled system
Engine R.P.M.
The ECM Engine load ratio
monitors all Boost pressure
Common rail pressure
of these Barometric pressure The fuel injection pressure, the timing,
sensors Coolant temperature and the fuel injection quantity are
controlled by the ECM for ideal
combustion
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Multistage fuel injection
common rail
（pre-injection）
conventional injection

Start
injection
& Firing

It is a state of no jet with a model conventionally, but a

pre-jet is started with a common rail type, and firing
begins.
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Multistage fuel injection
common rail
conventional injection （pre-injection）

Combustion

As for the firing conventional model, a jet is started at this point in time, but
for common rail type, fired it already by pre-jet and start the second jet
(main injection). It will be becoming to create perfect combustion states in a
chamber, with a common rail type by dividing fuel injection of high pressure
into a lot of times and reduce the engine noise / vibration more.
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Inter-cooler
The air was cooled off, and became high-density

Intercooler

Radiator
Open air Engine

Intake air Exhaust air

The air was compressed, and became hot Turbo charger

The temperature of the intake air was raised when it was supercharged. Cooling makes the air
density higher and increases the oxygen content, hence the combustion efficiency of the engine
raises. This improves the fuel consumption, reduces CO/CO2, along with lower combustion
temperature which reduces NOx emissions.
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Cooled EGR
EGR stands for ”Exhaust Gas
Recirculation”.
This equipment lowers burning
temperature by mixing some of the
emitted exhaust gas with the intake air to
control oxygen concentration in the
combustion chamber, slowing down
To intercooler
combustion.
Turbo
This enables reduction of nitrogen oxide
or ”NOx” which is produced during high-
temperature combustion. The EGR From air cleaner To silencer
Cooler system is in the EGR gas
passages way. Exhaust manifold
This system contributes reduction of Coolant out
NOx by further lowering the burning
temperature. It cools down the heated Engine EGR cooler
EGR gas before mixing with the intake air.
Coolant in
Moreover, by cooling down the high
temperature EGR gas, intake air Intake manifold
concentration is increased resulting in
more air capacity.
EGR valve
This brings close to the perfect Reed valve
combustion resulting in reduction of PM
and other graphite as well as better fuel From intercooler
ECM
consumption.

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Cooled EGR
ECM controls EGR valve lift quantity by
motor, motor turns depending on states of the
engine revolutions and engine load etc,
and controls lift of an EGR valve. quantity of
lift of a valve is detected with an EGR position
sensor.
Engine load etc

In a part shown dark in a figure, quantity of

valve lift is large and the darkest part shown
quantity of lift is near to 100%.
It is no EGR control at the idol time.

Engineｴﾝｼﾞﾝ回転
revolutions

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Characteristics of Main Structure Components

Roller rocker
(Lubrication for
Over Head cam（
（DOHC）
） improved abrasion
2 valves Cam Flat （High rigidity of cylinder resistance)
OHV 4 valve
tappet head)
(Improved
High rigidity combustion,
Cylinder head High power,
High
rigidity)

Liner
less

High rigidity
Cylinder High rigidity
block
crank case

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4BG1 4JJ142＜１＞<1>＜
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 4BG1 4JJ1

High rigidity crank

case

Bearing cap
structure
High rigidity crank case (Reduce engine noise,
enhanced engine durability)
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Common Rail System

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Common Rail System
■従来の燃料噴射ポンプ
Convention fuel injection Common rail injection
ポンプ

Because the fuel is highly pressurized, the fuel mist can be spread into cylinder inside area
2013/4/15
and mixes 45＜１＞<1>＜
better with the air, that is, combustion efficiency gets better.
SUMITOMO (S.H.I) CONSTRUCTION MACHINERY MANUFACTURING CO.,LTD 45
Common Rail System

Sensors Actuator

Accelerator position
Accelerator position
Injector
sensor

Engine speed ・ Injection amount control

Crankshaft
・ Injection timing control
position sensor

Common rail
Cylinder identifying pressure sensor
Camshaft position signal
sensor,
G sensor

Supply pump
Other sensors,
Switches
・ Injection pressure control

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Comparison with Conventional System

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Injector operation explanation1
When there is not a signal
ＳｐｒｉｎｇA
Ｓｐｒｉｎｇ from ECM.（ （A state before
Outer an injection）
）
valve Inner valve

orifice1 The outer valve of the

Return
orifice2
Common rail
injector inside is pushed
No signal
Hydraulic piston
downward by power of
spring A and confines the
Control room
fuel in the control room.
Fuel in the control room
Spring B

Nozzle
pushes down on
piston/spring B, and the
Stroke length 0.35mm nozzle, therefore it is
closed.
Injection volume 0.1cc
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Injector operation explanation 2

solenoid When a signal from the

Spring A ECM is received.
Outer valve
Inner valve
A signal from the ECM
Orifice1
valve OPEN
to the solenoid turns it on,
Return
Orifice2
Common rail
then the outer valve
Hydraulic piston
pushes spring A and it
Signal input
moves up.
Control room
Because the outer
valve opened, fuel in the
Nozzle control room returns to
the tank via the return
line.
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Injector operation explanation 3

Outer State of an injection start.

valve Inner valve

orifice1
orifice2 Return
Because some of the
Common rail fuel in the control room
Hydraulic piston
Control room
flowed out through the
Jet start return line, the piston in
Spring B
the nozzle moves up and
Nozzle opens the nozzle.
Differential Fuel is injected by
pressure occurs
differential pressure with
the control room side.

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Injector operation explanation 4
Solenoid
When a signal from the
Spring A ECM is cut off.
Outer valve
Inner valve

Orifice1 valve OPEN Because of electricity to

Orifice2
Common rail
Return
the solenoid is cut off to
Hydraulic piston the injector, the outer valve
is pushed back to the lower
Signal STOP part by power of spring A.
The outer valve closes a
passage to the return line.

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Injector operation explanation 5

State of the injection stop

Outer valve
(The injection finished））
Inner valve

The control room is filled

Orifice1
Orifice2 Return

Common rail with fuel again because

Hydraulic piston Control
room the return line has been
Spring B
sealed.
Filled up fuel makes
Jet STOP
piston and spring B be
pushed downward, and
that closes the nozzle.
The injection is finished
by the above sequence.
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Cross section drawing

1. Fuel Tank
2. Fuel Filter
3. Suction
4. Fuel Inlet
5. Feed Pump
6. Regulating Valve
7. Suction Control Valve
(SCV)
8. Return Spring
9. Plunger
10. Suction Valve
11. Delivery Valve
12. Fuel Overflow
13. Return
14. Common Rail
15. Injector
16. Drive Shaft
17. Suction Pressure
18. Feed Pressure
19. High Pressure
20. Return Pressure
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4H・6HK1 Engine
The high pressure injection pump is mounted
on the engine accessory drive. The feed pump
(item 5) is mounted to the high pressure pump
and draws fuel from fuel tank.
Feed pump pulsation is dampened by the
regulating valve (item 6). Some of the fuel will
go to the suction control valve (item 7). The
balance of the fuel flow is used to lubricate the
plunger and cam and will be returned to fuel
tank by over flow valve (item 12).
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4H・6HK1 Engine
A signal from the ECM to the suction control
valve determines how much it will be opened
based on the current delivered to the valve.
A proportionate amount of fuel is fed to the
suction valve, and then compressed by plunger.
High pressure fuel which was compressed by
plunger is fed to the delivery valve of the
common rail.
Fuel is stored in the common rail and is
distributed
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Supply pump exploded view

①suction valve

②plunger
⑥feed pump

③cam ring ⑤suction control valve

⑦fuel temperature sensor
④delivery valve

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Supply pump exploded view
①
①Delivery Valve
②Fuel Temperature Sensor
② ③Feed Pump
④SCV
（Suction Control Valve）
⑥ ⑤Pump Housing
⑥Plunger
③
⑦Adjustment Valve
⑧Cam Ring
⑩
⑦ ⑨Eccentric Cam
⑩Cam Shaft
⑧ ⑤
⑥ ④
⑨

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 Pressure Limiter
When the pressure
within the common
rail reaches 200MPa,
for the sake of
safety, the pressure
Pressure limiter limiter opens and
returns fuel to the
tank. When the
pressure drops to
30MPa, the valve
Valve open
closes to return
operation to normal.
Valve
closed Abnormally
high pressure

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How to Replace
Parts
1

Do not reuse the “high-pressure pipe” and
“injector pipe” of the fuel system.”
Replace with new one if it is removed.

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
3
1. Injector pipe
4 2. Common rail pressure
sensor
3. Pressure limiter
4.Fuel temperature
sensor
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 Notes (maintenance)
Please, do not crack a line to check for a misfiring cylinder or to
attempt to remove air from the fuel line. This is not necessary since
there is a constant high pressure flow of fuel through those lines.
（Any high pressure fuel leak is dangerous. High Pressure Fuel
Spray can be injected into your skin and is an immediate emergency.
Please never do it. ） NOTES;
Make sure to keep 2 minutes after engine
stop for disassembling common rail system.

Please never loosen

these when the
engine starts.
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 Notes (maintenance)
The electrical voltage going to each injector is as high as
118V. Please detach the negative wire-harness side of the
battery cable when you adjust any injector.

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Engine control explanation 1
The Quantity of fuel injected varies according to the following;
The ECM calculates the quantity of the basic injection by the signals from the
throttle volume. At that time, it controls the SCV and the injector on time for the most
suitable injection timing and quantity of the fuel injected regarding to the conditions,
such as common rail pressure and engine coolant temperature.

Start Q revision
In addition, as for the ECM, if an engine speed is less than the system recognition
of the engine speed of 30rpm, it will not be able to adjust the start Q revision and start
the engine.
※A minimum engine start speed is 60rpm.

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Engine control explanation 2
QOS (Quick On Start) System
The ECM determines the time period required for the glow plug on (pre-glow,
glow, after-glow). It operates the glow relay and monitor display. The QOS
system makes starting in cold weather easier and reduces white smoke and
noise at starting. When the key is turned ON, the ECM detects the engine
coolant temperature signal from the engine coolant temperature (ECT)
sensor and sets the time for the glow plug on so that the proper starting
conditions can be achieved. Also, after-glow function stabilizes idling
immediately after starting.

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Engine control explanation 3

Barometric pressure revision (Highlands revision） ）

The ECM calculates the current altitude by the signal from the Barometric press
It controls the electrical timing for injector and the SCV by conditions such as
altitude for the most suitable fuel flow.
If the Barometric sensor fails, the ECM will fix the Barometric pressure to
80kPa (2,000m) altitude equivalency and cancel the control of the EGR.

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Engine control explanation 4
Overheat protection
The system contorls when the engine coolant temperature exceeds 100 ℃ for a engine protection.
If the temperature is raised up to 120℃, the engine will stop.

In addition, a protection function starts in one minute after the engine starts to detect
stable coolant water temperature.
Return
When coolant temperature sensor
Setting Judgment time Engine control condition is out of order, -20 degree Celsius
１００℃ ECM：Quantity of fuel
at engine starting and 80 degree
water injection decrease Celsius under operation will be
１０５℃ temperature dial Computer A：Normal water displayed on monitor.
8 dials temperature
ECM：Quantity of fuel dial　　7dials
１１０℃ 5s injection decrease and bellow Buzzer will ring for 5 seconds
Computer A：Idle when coolant temperature exceeds
ECM：Quantity of fuel key ON after 105degree Celsius.
１２０℃ 5s injection decrease a engine
Computer A：Stop shutdown
※A protection function does not apply at the time of the following error code displays
0117（water sensor low voltage）　0118（water sensor lhigh voltage）　2104（CAN bus abnormality）
2106（CAN timed out）　0090（CAN communication error）
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Engine control explanation 5
Overheat protection

100℃
Flow quantity restrictions start
100%

Fuel flow
quantity
110℃
It is controlled to an idling revolutions

0%
105℃ 120℃
overheat warning engine shutdown

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Engine control explanation 6
Function at the time of a boost temperature rise
When the boost temperature exceeds 80℃ the fuel flow restriction starts.
When the temperature becomes 90℃, engine stops.
In addition, a protection function starts in one minute after the engine starts to detect
stable coolant water temperature.

Judgment
Setting time Engine control Return condition
A state equal to or
ECM：Normal less than 70℃
８０℃ 5s Controller A：control continues for 30
Idle seconds
ECM：Normal key ON after a
９０℃ 5s Controller A：Engine engine
shutdown control shutdown
※A protection function does not act at the time of the following error code displays
1112（boost temp sensor low voltage）　1113（boost temp sensor high voltage）
2104（CAN bus abnormality）　2106（CAN timed out）　0090（CAN communication error）

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Engine control explanation 7
Function at the time of an engine oil pressure drop.
When the engine oil pressure drops down, it will stop the
engine to prevent engine damage.
In addition, it starts a protection function after the engine starts for 30 seconds, to detect
stable engine oil pressure.
Judgment
Setting time Engine control Return condition
ECM：Normal
key ON after a
Controller A：
40kPa 5s engine
Engine shutdown
shutdown
control
※A protection function does not apply at the time of the following error code displays
0522（Oil pressure sensor low voltage）　0523（Oil pressure sensor high voltage）
2104（CAN bus abnormality）　2106（CAN timed out）　0090（CAN communication error）
1633（5V power supply 3voltage abnormality/power supply for sensor）

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Engine control explanation 8
Controls at engine start time
Start control（
（ Water temperature monitor）
１
）
( )Purpose
When water temperature equal or less than 0 ℃, It secures engine start characteristics at the
time of low temperature by performing the fuel injection which accepted water temperature.

Long cranking control

１
( )Purpose
It aims for black smoke reduction at the time of the engine start, when enough initiationQ
(Fuel injection) cannot inject, such as at the time of injector abrasion, then backup, it will inject
when the time progress that is appointed after cranking start, only predetermined quantity
increases initiationQ in quantity and improves start characteristics.
cranking time cranking time
is usual is more than 1s
STRT
Key ON
switch OFF
ｽｲｯﾁ 1s
Engine Idle
revolutions cranking
0
UP-Q
ST-Q
initiation NL-Q
Q ０

※ST-Q：standard initiationQ　UP-Q：increased initiationQ　　NL-Q：No loadQ

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Engine control explanation 9
Start control whe n an inje ctor misfire s.
When the ECM has detected that there was an injector which stopped by a
trouble diagnosis, when an error code was detected, to secure
the engine start characteristics for an emergency escape, it controls
the quantity of fuel injection.
1） Iｔ divides the quantity of fuel for the failed injector, into the other
injectors. The total quantity of fuel injected is the same.
※A correction factor of the injector is as follows.

The number of the normal cylinders 4 3 2 1 0

Correction factor 1.0 1.33 2.0 1.0 1.0
Attention）
When more than three injectors fails or an injector breaks mechanically, the
ECM does not control it.
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Engine control explanation 10

Motion for key switch OFF

１） Turn off key switch

２） When the ECM recognizes key OFF, it performs 3,4 & 5 at the same time.
３） The quantity of injection calculation stop.
４） All close instructions to the Suction cotrol valve(SCV).
５） All close instructions of the EGR valve.
６） After 3, 4 & 5 instructions are finished, the trouble histories are written to an EEPROM in the
７） The power to the ECM is cut off.
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Engine control explanation 11
Engine start / stop judgment
Engine start and stop is judged based on the engine speed
sent from the ECM with CAN communications.

Judgment value Start ; 500min-1 Stop ; 200min-1

Start

Stop

Structure drawing

Computer A
CKP sensor signal

ENG. R.P.M.

CMP sensor signal

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Fuel quality analysis and status
The –5 models have Tier 3 engine,
and new fuel injection system.
The system is sensitive against the
fuel.
Requirements against diesel fuel for
Tier3 engine is to pay attention for
following fuel specification when
we select.
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Fuel quality analysis and status
Element Unit Standard Value
Sulfur ppm 2500 or less
Lubrication (HFRR) µm 460 or less
Residual carbon wt % 0.1 or less
Water wt % 0.05 or less
Dust ppm
Oxidation deterioration Keeping period Two months or less

HFRR ( High-Frequency Reciprocating

rig).
This is an index showing lubricating
properties of the fuel.
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Fuel quality analysis and status

In case of the diesel fuel will not meet

our specifications and requirements,
there are some possibilities that
engine function and performance will
not deliver correctly.

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Fuel quality analysis and status
We are investigating fuel quality for
all over the world.
Therefore, we would like to ask you to
cooperate to get fuel more sample
data in your country.
We especially want the data of the
north area.
Thank you for your cooperation.
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ENGINE Service Tool

Part Number ; WDB0164

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ENGINE Service Tool
Breaker Box (Image)

1.ECM
2.Connector
3.To connect Machine
Harness

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 END

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