100% found this document useful (1 vote)
399 views17 pages

6WG1 Tanıtım

This document is a shop manual for the Isuzu 6WG1 diesel engine used in Kawasaki 95Z7 and 115Z7 wheel loaders. It provides general information, troubleshooting information, maintenance information, and diagrams of the engine systems including the fuel system, cooling system, turbocharger, and exhaust system. The maintenance section describes each engine system and components in detail.

Uploaded by

Halil Kara
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
100% found this document useful (1 vote)
399 views17 pages

6WG1 Tanıtım

This document is a shop manual for the Isuzu 6WG1 diesel engine used in Kawasaki 95Z7 and 115Z7 wheel loaders. It provides general information, troubleshooting information, maintenance information, and diagrams of the engine systems including the fuel system, cooling system, turbocharger, and exhaust system. The maintenance section describes each engine system and components in detail.

Uploaded by

Halil Kara
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 17

93215-00620

6WG1 (95Z7/115Z7) SHOP MANUAL


July 2012

For Service Training

SHOP MANUAL

ISUZU DIESEL ENGINE

Troubleshooting Information
General Information
6WG1
General Information
Troubleshooting Information

93215-00620

(For Kawasaki Wheel Loader 95Z7, 115Z7)

©2012 KCM Corporation. All rights reserved. Printed in Japan (K) Serial No. 97J1-5001 and up
( アメリカ用 ) Serial No. 11J1-5001 and up
0DLQWHQDQFH,QIRUPDWLRQ :* %

SIDE VIEW
For Service Trainning 2
%0DLQWHQDQFH,QIRUPDWLRQ :*

 )XHOV\VWHP )XHOV\VWHPGLDJUDP

TOP VIEW

For Service Trainning 3


0DLQWHQDQFH,QIRUPDWLRQ :* %

 &RPPRQUDLO  3UHIXHOILOWHU
 )XHOILOWHU  )HHGSXPS
 ,QMHFWRU  6XSSO\SXPS
 )XHOWDQN

&DXWLRQ㸸 Fuel System


࣭ 'RQRWGLVDVVHPEOHWKHVXSSO\SXPSFRPPRQ
࣭ 6LQFHWKHKLJKSUHFLVLRQIXHOV\VWHPKDVEHHQ UDLORULQMHFWRU
DGRSWHGWDNHFDUHWRSUHYHQWDQ\IRUHLJQ
&RPPRQUDLO
PDWWHUIURPHQWHULQJWKHIXHOV\VWHP

For Service Trainning 4


0DLQWHQDQFH,QIRUPDWLRQ :* %

 &03VHQVRU  3XPSFRQWUROYDOYH 3&9


 $LUEOHHGHU
 2YHUIORZYDOYH

,QMHFWRU
Fuel Pump

For Service Trainning 5


0DLQWHQDQFH,QIRUPDWLRQ :* %
 3ULPLQJSXPS
 $LUEOHHG
 &DVH
 'UDLQSOXJ

 &RROLQJV\VWHP
7KHFRROLQJV\VWHPLVDIRUFHGFLUFXODWLRQV\VWHPDQGLWV
PDLQFRPSRQHQWVDUHWKHZDWHUSXPSWKHUPRVWDWDQG
UDGLDWRU,WFRROVWKHLQVLGHRIWKHHQJLQHRLOFRROHU(*5
JDVHWF

Fuel Filter

 6XEWDQN  9DOYH

For Service Trainning 6


%0DLQWHQDQFH,QIRUPDWLRQ :*

 3UHVVXUHOLPLWHU  )ORZGDPSHU
 3UHVVXUHVHQVRU

Common Rail
)XHOVXSSO\SXPS

For Service Trainning 7


%0DLQWHQDQFH,QIRUPDWLRQ :*

 ,QMHFWRUDVVHPEO\  2ULQJ
 *DVNHW

)XHOILOWHU
Injector

For Service Trainning 8


0DLQWHQDQFH,QIRUPDWLRQ :* %

 &RPPRQUDLO  )HHGSXPS
 (&0  )HHGOLQH
 ,QMHFWRU  5HWXUQOLQH
 )XHOSUHVVXUHVHQVRU  +LJKSUHVVXUHSLSH
 )XHOILOWHU  6XSSO\SXPS
 3UHIXHOILOWHU  3&9
 )XHOWDQN

Fuel System
)XHOILOWHUFORJJLQJDODUPIXQFWLRQDQGURWDWLRQVSHHG 7KHVHFRQGVWDJH
UHVWULFWLRQIXQFWLRQ 7KHVHFRQGVWDJHDODUPLVLVVXHGZKHQWKHRXWSXWYDOXH
:KHQWKHFORJJHGIXHOILOWHUFRQWLQXHVWREHXVHGWKH IURPWKHIXHOILOWHUSUHVVXUHVHQVRUIDOOVEHORZWKH
(&0GHWHFWV'7&3DQGRXWSXWUHVWULFWLRQLV WKUHVKROGYDOXHHYHQDIWHUWKHILUVWVWDJHDODUPRFFXUV
LPSRVHG 7KHVHFRQGVWDJHDODUPUHPDLQVDVLVVXHGXQWLOWKH
LJQLWLRQVZLWFKLVWXUQHG2))
7KHILUVWVWDJH
$WWKHVDPHWLPHDVWKHLVVXHRIWKHVHFRQGVWDJHDODUP
,QRUGHUWRQRWLI\WKDWDILOWHULVFORJJHGEHIRUH'7&
WKHWDUJHWHQJLQHVSHHGLVUHGXFHGJUDGXDOO\DWDFRQVWDQW
3LVGHWHFWHGWKHILUVWVWDJHDODUPLVLVVXHGZKHQWKH
UDWH:KHQWKHRXWSXWYDOXHIURPWKHVHQVRUH[FHHGVWKH
RXWSXWYDOXHIURPWKHIXHOILOWHUSUHVVXUHVHQVRUIDOOV
VSHFLILHGWKUHVKROGYDOXHUHGXFWLRQRIWKHUHVWULFWHG
EHORZWKHVSHFLILHGWKUHVKROGYDOXH7KHDODUPVWRSV
HQJLQHVSHHGLVVWRSSHGDQGWKHFRQWUROLVFRQWLQXHG
ZKHQWKHRXWSXWYDOXHH[FHHGVWKHWKUHVKROGYDOXH

For Service Trainning 9


%0DLQWHQDQFH,QIRUPDWLRQ :*

Injection Pressure Control


)XHOV\VWHP VXSSOLHGWRWKHFRPPRQUDLO$WWKLVWLPHWKHIXHODPRXQW
7KHFRPPRQUDLOV\VWHPLVFRPSULVHGRIWZRIXHO WREHVXSSOLHGWRWKHFRPPRQUDLOLVFRQWUROOHGE\
SUHVVXUHV\VWHPVFRQVLVWLQJRIWKHVXFWLRQSLSLQJEHWZHHQ FRQWUROOLQJWKH3&9EDVHGRQWKHVLJQDOIURPWKH(&0
WKHIXHOWDQNDQGWKHVXSSO\SXPSDQGWKHKLJKSUHVVXUH
SLSLQJEHWZHHQWKHVXSSO\SXPSDQGWKHLQMHFWRU
7KHIXHOLVVXFNHGLQWRWKHVXSSO\SXPSIURPWKHIXHO
WDQNDQGWKHQLWLVERRVWHGE\WKHSXPSEHIRUHEHLQJ

For Service Trainning 10


%0DLQWHQDQFH,QIRUPDWLRQ :*

 ([KDXVWJDVLQOHW  7XUELQHZKHHO
 $FWXDWRU  1R]]OHYDQH
 &RQWUROURG
 ([KDXVWJDVRXWOHW

(QJLQHRSHUDWLRQFRQWURO
VGS Turbocharger
7KHIROORZLQJW\SHVRIRSHUDWLRQFRQWUROLQVWUXFWLRQV
H[LVWDQGWKHVHOHFWLRQYDULHVGHSHQGLQJRQHDFK
VSHFLILFDWLRQ
9ROWDJHLQSXWE\$369
$FFHOHUDWRURSHQLQJDQJOHLQVWUXFWLRQFRQWUROOHGWKURXJK
&$1FRPPXQLFDWLRQ5RWDWLRQVSHHG
LQVWUXFWLRQ
5RWDWLRQVSHHGLQVWUXFWLRQFRQWUROOHGWKURXJKWKHPRGH
PDSVZLWFK5RWDWLRQVSHHGLQVWUXFWLRQDQGFKDQJH
LQVWUXFWLRQJLYHQE\WKH$36
,QFUHDVHDQGGHFUHDVHLQVWUXFWLRQVIRUHDFKURWDWLRQJLYHQ
E\WKHLGOHVZLWFK
0RGHPDSVZLWFK
7KHPRGHPDSVZLWFKKDVURWDWLRQFRQWUROPRGHW\SHV
FRQVLVWLQJRI+6/%,DQG/0
7KHURWDWLRQVHWWLQJVDUH+!6!/!%,!/0
)RU+6/DQG%WKHURWDWLRQVSHHGFDQEHGHFUHDVHGE\
:KHQWKHUHJXODWLRQPRGHVZLWFKLQSXWLVSUHVHQWLQ
WKH$36
DGGLWLRQWRWKHPRGHPDSVZLWFKWKHIROORZLQJW\SHVRI
EXWFKDQJHVFDQQRWEHPDGHIURPWKH$36IRU,DQG/0
FRQWUROPHWKRGVDUHDYDLODEOH

For Service Trainning 11


0DLQWHQDQFH,QIRUPDWLRQ :* %

 9*6DFWXDWRU  6KDIW
 7XUELQHKRXVLQJ  7XUELQHZKHHO
 &RPSUHVVRUKRXVLQJ
 &RPSUHVVRUZKHHO

 ([KDXVWV\VWHP
VGS Turbocharger
WKHILOWHUZKHQWKHSUHVVXUHGLIIHUHQFHEHWZHHQWKHIURQW
DQGEDFNRIWKH'3'LVGHWHFWHGDQGZKHQWKHRSHUDWLRQ
7KH'3'ERG\FRQVLVWVRIWKHILOWHUSRUWLRQR[LGDWLRQ
LVSHUIRUPHGIRUDFHUWDLQSHULRGRIWLPH
FDWDO\VWSRUWLRQDQGVLOHQFHUSRUWLRQDQGFOHDQVWKH
H[KDXVWJDV7KHWUDSSHG30LVFRPEXVWHGWRUHJHQHUDWH

For Service Trainning 12


0DLQWHQDQFH,QIRUPDWLRQ :* %

 (OHFWULFDOV\VWHP ,QDGGLWLRQVPDOOGLRGHVWKDWDUHUHIHUUHGWRDVDWULR

EGR
GLRGHDUHXVHGWRVXSSO\WKHILHOGFXUUHQW
&KDUJLQJV\VWHP
7KLVJHQHUDWRUKDVWHUPLQDOVFRPSULVHGRIWKH%
7KHPDLQFRPSRQHQWVRIWKHFKDUJLQJV\VWHPDUHWKH
WHUPLQDO GLUHFWFXUUHQWRXWSXWWHUPLQDO /WHUPLQDODQG
EDWWHU\JHQHUDWRUDQGEDWWHU\GLVFKDUJHLQGLFDWRUOLJKW
5WHUPLQDO
FLUFXLW7KHJHQHUDWRULVDVHOIUHFWLILHUW\SHZLWKD
6LQFHWKH/WHUPLQDOLVFRQQHFWHGWRWKHILHOGFRLOLW
UHJXODWRUEXLOWLQ
ZRUNVDVDQLQSXWWHUPLQDOIRUWKHLQLWLDOH[FLWDWLRQ
*HQHUDWRU FXUUHQWDORQJZLWKWKH5WHUPLQDOXQWLOWKHJHQHUDWRU
7KHJHQHUDWRULVDEUXVKOHVVW\SH VWDUWVJHQHUDWLQJSRZHU
7KHPDLQFRPSRQHQWVDUHWKHUROOHUVWDWRUUHFWLILHU $OVRLWIXQFWLRQVDVDQRXWSXWWHUPLQDO FXUUHQWFDSDFLW\
DVVHPEO\IURQWEUDFNHWUHDUEUDFNHW,&UHJXODWRU LV$ :KHQWKH/WHUPLQDOYROWDJHUHDFKHVWKHEDWWHU\
EHDULQJSXOOH\HWF YROWDJHWKHFKDUJHOLJKWWXUQVRII
7KHPRYLQJSDUWVDUHWKHUROOHUDQGSXOOH\7KHILHOGFRLO 6LQFHERWKEHDULQJVDUHVHDOHGSHULRGLFOXEULFDWLRQVDUH
LVIL[HGWRWKHUHDUEUDFNHW QRWUHTXLUHG
PDLQGLRGHVDQGDGGLWLRQDOGLRGHVDUHXVHGWRFKDQJH 7KH,&UHJXODWRUFDQQRWEHGLVDVVHPEOHGVRLWVKRXOGEH
WKHWKUHHSKDVHDOWHUQDWLQJFXUUHQWJHQHUDWHGLQWKHVWDWRU KDQGOHGDVDQDVVHPEO\
FRLOWRDGLUHFWFXUUHQW
RXWRIWKHPDLQGLRGHVDUHUHIHUUHGWRDVSRVLWLYH
GLRGHDQGWKHUHVWLVUHIHUUHGWRDVQHJDWLYHGLRGH

For Service Trainning 13


%0DLQWHQDQFH,QIRUPDWLRQ :*

 ([KDXVWJDVWHPSHUDWXUHVHQVRU  'LIIHUHQWLDOSUHVVXUHSLSH
 ([KDXVWJDVWHPSHUDWXUHVHQVRU  %UDFNHW
 ([KDXVWGLIIHUHQWLDOSUHVVXUHVHQVRU  )LOWHUDVVHPEO\
 'LIIHUHQWLDOSUHVVXUHVHQVRUKRVH  2[LGDWLRQFDWDO\VWDVVHPEO\
 6LOHQFHU

 (PLVVLRQFRQWUROGHYLFH DPD 7KH(*5RSHUDWHVZKHQWKHHQJLQHVSHHGHQJLQHFRRODQW


WHPSHUDWXUHLQWDNHWHPSHUDWXUHDQGEDURPHWULFSUHVVXUH
(*5
VDWLVI\FHUWDLQFULWHULD7KHQWKHYDOYHRSHQLQJDQJOHLV
7KH(*5V\VWHPUHFLUFXODWHVDSDUWRIWKHH[KDXVWJDVWR
FDOFXODWHGEDVHGRQHQJLQHVSHHGDQGWKHWDUJHWIXHO
WKHLQWDNHPDQLIROGWRUHGXFHQLWURJHQR[LGHHPLVVLRQV
LQMHFWLRQDPRXQW7KHFDOFXODWHGYDOYHRSHQLQJDQJOHLV
%\FRQWUROOLQJWKH(*5V\VWHPKLJKRSHUDELOLW\DQG
XVHGWRGHWHUPLQHWKHPRWRUGULYHGXW\DQGWKHYDOYHLV
H[KDXVWJDVUHGXFWLRQDUHERWKDFKLHYHG$FRQWURO
GULYHQDFFRUGLQJO\7KHLQWDNHWKURWWOHYDOYHFORVHVZKHQ
FXUUHQWIURPWKH(&0RSHUDWHVDVROHQRLGWRFRQWUROWKH
WKH(*5RSHUDWHVWRHQVXUHDQDSSURSULDWHLQWHUQDO
OLIWDPRXQWRIWKH(*5YDOYH$OVRWKH(*5SRVLWLRQ
SUHVVXUHRIWKHLQWDNHPDQLIROG
VHQVRUGHWHFWVWKHDFWXDOYDOYHOLIWDPRXQWDQGWKHGDWDLV
XVHGIRUSUHFLVHFRQWURORIWKH(*5DPRXQW

For Service Trainning 14


%0DLQWHQDQFH,QIRUPDWLRQ :*

 (QJLQH  6LOHQFHU
 0$)VHQVRU  )LOWHU
 $LUFOHDQHU  2[LGDWLRQFDWDO\VW
 9DULRXVVHQVRUV  ([KDXVWJDVWHPSHUDWXUHVHQVRU
 (&0  ([KDXVWGLIIHUHQWLDOSUHVVXUHVHQVRU
 '3'VZLWFK

(&0
(&0IXQFWLRQV
DPD System
RXWSXWFLUFXLWE\FRQWUROOLQJWKHJURXQGRUSRZHUVXSSO\
FLUFXLWYLDRQHRIWKHGHYLFHV
7KH(&0FRQVWDQWO\PRQLWRUVWKHLQIRUPDWLRQVHQWIURP
1RWH㸸
YDULRXVVHQVRUVDQGFRQWUROVWKHYDULRXVV\VWHPVRIWKH
SRZHUWUDLQ7KH(&0SHUIRUPVWKHGLDJQRVWLFIXQFWLRQV ࣭ $VIRUWKH(&0LQVWDOODWLRQSRVLWLRQUHIHUWR
RIWKHV\VWHPGHWHFWVRSHUDWLRQDOSUREOHPVRIWKHV\VWHP WKHPDQXDORIWKHPDFKLQH
ZDUQVWKHRSHUDWRUYLDWKHGLDJQRVLVOLJKWDQGUHFRUGVWKH
'7&7KH'7&LGHQWLILHVWKHDUHDZKHUHWKHSUREOHPKDV
RFFXUUHGWRDVVLVWWKHUHSDLURSHUDWLRQSHUIRUPHGE\D
VHUYLFHWHFKQLFLDQ
7KH(&0RXWSXWVYROWDJHV HJ9 WRVXSSO\SRZHUWR
YDULRXVVHQVRUVDQGVZLWFKHV7KH(&0FRQWUROVWKH

For Service Trainning 15


%0DLQWHQDQFH,QIRUPDWLRQ :*

 0$)VHQVRU  (*5YDOYH
 (*5YDOYH  2LOSUHVVXUHVHQVRU
 ,07VHQVRU  &.3VHQVRU
 %RRVWWHPSHUDWXUHVHQVRU  )XHOWHPSHUDWXUHVHQVRU
 %RRVWVHQVRU  &03VHQVRU
 3&9  (QJLQHFRRODQWWHPSHUDWXUHVHQVRU
 )XHOSUHVVXUHVHQVRU

6XSSO\SXPS
Sensor Location
7KHVXSSO\SXPSKLJKO\SUHVVXUL]HVWKHIXHOXVLQJWKH
HQJLQHWRUTXHDQGIRUFHIHHGVWKHIXHOWRWKHFRPPRQ
UDLO$OVRWKH3&9&03VHQVRUDQGIHHGSXPSDUH
LQVWDOOHGRQWKHVXSSO\SXPS

For Service Trainning 16


%0DLQWHQDQFH,QIRUPDWLRQ :*

SLQFRQQHFWRU

ECM

For Service Trainning 17

You might also like