14 - Treinamento Do Motor 6WG1

6WG1 Engine Training Handbook
Research Institute of Large-scale Excavator
编制： Writing: 审核：

Check: Approval: 批准：
1
SANY HEAVY MACHINE CO.,LTD
Catalogue
1. Introduction
2. Engine Overall Dimensions
3. Engine Specifications & Main Parameters
4. Common Rail System
5. Common Rail System's Components
6. Low-temperature EGR
7. 6WG1 Tier 3 Engine's Adaptability Improvement by ISUZU
8. Error Code & Symptom
2
1. Introduction
 6WG1 Engine Characteristics
 Common rail
 EGR with cooler
 Excellent function improvement; Lower fuel

consumption rate; Larger backup power and torque.
 Special improvement in order to adapt Chinese fuel;

Enhanced adaptability.
3
2. Engine Overall Dimensions
 6WG1 Engine Overall Dimensions and Main Components
Fuel Filter
(High Filtration Function)
4
2. Engine先做人
Overall
后做事Dimensions
品质改变世界
5
3. Engine Specifications & Characteristic
先做人后做事品质改变世界Curve
Type 6WG1XY
Emission Tier 3
Water Cooling, 6 Cylinders, In-line Arrangement, 4 Strokes,
Engine Type
Top-installed Cam Shaft, Direct Injection Diesel Engine
Max. Output Power (KW/min-1) 260/1800
Max. Torque (Nm/min-1) 1580/1500
Cylinder & Size (mm) 6 Cylinders, 147×154
Displacement (L) 15.681
Compression Ratio 16
Compression Pressure MPA (psi)/rpm 2.75(400)/200
L*W*H（mm） 1462×1015×1422(with fan)
Weight (kg) 1153
Firing Order 1-5-3-6-2-4
Injection Pump DENSO HP0 Electrical Controlled Fuel Injection System
Injection Pressure 130MPA
Speed Regulation Method Electrical Full Speed Control
Timing Method Electric Control
Nozzle Porous (8xφ0.19mm) DENSO G3
Fuel Filter Filter Paper
Engine Oil Filter Whole-current Filter Paper
Engine Oil Pump Gear
Engine Oil Cooler Water Cooling
Cooling System Water Cooling Circulate
Cooling Water Capacity 36L
Water Pump Impeller
Thermostat 2 , Wax-wrapped Pill
Thermostat Opening Temp. 83℃~95℃
Air Filter OEM 6
 Engine Torque-speed Characteristic Curve
7
 Engine Altitude Power Characteristic Curve
Altitude Characteristics No.:
Power (W)
Altitude (m)
8
4. Common Rail
先做人后做事 System
品质改变世界
 6WG1 uses Japan DENSO 2nd generation common rail system. Its
max. rail pressure is 1300bar with multiple injection.
Supple Pump Outlet Temp
Bellow 140℃
Feed Pump
Inlet Pressure
-30kPa
Hope to add boost pump
9
4. Common
先做人后做事Rail System
品质改变世界
Negative (-)
Positive (+)
High
Leak
Main Filter (Wako)

2µ x 2 layers
10
4. Common Rail
品质改变世界
 Common Rail System's Characteristics
11
4. Common Rail
品质改变世界
 Common Rail System's Characteristics:
1. High pressure in common rail is used to inject directly so it won’t

need boost structure in injector. And there’s continuous high
pressure in common rail chamber, so thrust in high pressure oil pump
required for is smaller than that in traditional oil pump.
2. By pressure adjusting solenoid valve on high pressure oil pump, oil

pressure in common rail chamber can change freely according to
engine’s load & economic & exhaust command, especially it can
improve engine’s low-speed function.
3. Control injection timing & quantity & speed via solenoid valve on
injector, and adjust the injection quantity of pre-injection & after-
injection and pre-injection & main injection’s gap in different
working conditions.
4. Injection pressure is decided by oil rail and does nothing with speed
attenuating the effect of injection quantity from speed.
12
4. Common Rail
品质改变世界
13
4. Common Rail
品质改变世界
 Injection Control
 6WG1 Tier3 only has main

injection and one pre-injection.
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4. Common Rail
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 Pre-injection’s Function & Principle
15
4. Common Rail
品质改变世界
 Electrical Control System
Sensor Controller Actuator
16
4. Common Rail
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 Electro-control Function
1. Engine Basic Control

① Basic Injection Control
Injection Quantity, Injection Pressure, Injection Timing etc.
② Injection Compensation
Starting Concentration Up, Atmosphere Pressure Adjusting,
Over-heat Protection etc.
2. Other Engine Control

① Engine Idling Control
② Warming-up Control
③ Engine Self-diagnosis
④ CAN Communication
17
4. Common Rail
品质改变世界
 Engine Fuel Injection Control Map
18
4. Common Rail
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 Fuel Injection Control Mode While Starting-up
19
4. Common Rail
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 Water Temperature Compensation Curve
20
4. Common Rail
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 Atmosphere Pressure Compensation Curve
21
4. Common Rail
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 Engine Over Heat Protection
 Excavator has its own

over-heat protection.
When temperature rises
above 105℃, engine
speed will reduce to
1100rpm.
22
4. Common Rail
品质改变世界
 ECM Principle Diagram
Connect to the negative terminal of battery.

Do not connect to negative terminal of ACG.
23
4. Common Rail
品质改变世界
 Sensor List & Function

No. Name Function Description
Calculate crank position exactly in order to calculate injection
1 Crank Sensor
timing, quantity, speed.
2 Cam Shaft Sensor Distinguish cylinders.
Measure inlet air temp to regulate injection quantity and
Inlet Temp Sensor
timing for over-heat protection.
3
Monitor inlet air pressure to regulate injection control
Boost Pressure Sensor
integrated with inlet air temp sensor.
Measure inlet air pressure & temp to regulate injection for
4 Engine Oil Temp. Sensor
engine protection.
Measure colling water's temp to calculate cold-start, target
5 Cooling Water Temp. Sensor idling etc, and regulate pre-injection angle, max power
protection etc.
Common Rail Pressure Measure common rail pipe's fuel pressure to stabilize fuel
6
Sensor pressure.
7 Throttle Position Sensor Transmit operator's intention to controller ECU.
8 Atmosphere Temp Sensor Calibrate control parameter integrated in ECU.
9 Atmosphere Pressure Sensor Calibrate control parameter integrated in ECU.
24
4. Common Rail
品质改变世界
 Actuator List & Function
No. Name Function Description
Control high pressure oil pump's oil inlet quantity to satisfy

1 Fuel Scale Valve
common rail's commands.
2 Injection Solenoid Valve Control pre-injection angle and injection quantity exactly.
3 Relay Control air compressor, exhaust brake and cold-start device.
4 Indicator Lamp Failure indicator lamp, cold-start indicator lamp.
5 Speed Output Use for excavator's tachometer.
25
5. Common Rail System's
先做人 Components
后做事品质改变世界
 5 Parts of Common Rail System

-- Rail, High Pressure Supply Pump, Injector, Sensor, ECM
Pre-filter
Fuel Filter Flow Damper
Fuel Tank
Various Sensors
(accelerator, foot pressure,
engine coolant temp etc.)
26
 Components of Common Rail System
27
五、高压共轨系统零部件
 Supply Pump
28
 Common Rail
– Store up high pressure and restrain fluctuation caused by oil pump’s oil supplying and injection.
29
 Pressure Limiter – Release pressure of common rail quickly when common rail’s
pressure becomes abnormally high.
30
 Rail Pressure Sensor – Detect Injection Pressure
Flow Damper
Pressure Limiter
31
 Liquid Flow Damper (Limiter) – Cut off oil supply to injector when injector leaks, and reduce
pressure fluctuation in common rail & high pressure hose.
32
 Injector – According to control signal from ECU, inject fuel in common rail into diesel
combustion chamber at the best timing & quantity & ratio by controlling solenoid valve open
and closed.
Structure of Solenoid Coil Injector
Full View Head Enlarged View Bottom Enlarged View
Solenoid
Coil Solenoid Control
Coil Joint Case of Low Piston
Pressure Side
Valve
Valve Solenoid
Mounting
Coil Nozzle
Valve Nut
Spring
Spring Inlet High Pressure
Control Filter Fuel Nozzle
Piston Valve Needle
Armature Groove
Flow Hole In/Out
Universal Nozzle
Low Pressure Body
Nozzle Fuel
Control Chamber
Case of Low (Control the front part Orifice of
Pressure Side of piston and hole Nozzle
clearance of low
Control
pressure case side)
Piston
33
喷油器工作原理
Injector’s Working Principle
Common rail
hydraulic
piston
无信号
No Signal 信号输入
Signal Input 喷油开始
Start to inject 信号停止
Signal Stop 喷油停止
Stop injecting
34
 Sensor Arrangement
35
EGR Valve & Boost Temp Sensor

EGR Position Engine Oil
Sensor Pressure Sensor
Boost Pressure Sensor
Crank Position
Water Temp Sensor
Sensor
Cam Shaft Position Sensor
Fuel Temp Sensor

36
6. Low-temperature
先做人后做事品质改变世界EGR
 Exhaust Gas Recirculation
A technology (method) by which internal-combustion engine can recirculate part of
exhaust gas into inlet side to ignite it once more.
Main Purpose: Reduce NOx in exhaust gas and improve fuel combustion availability。
37
6. Low-temperature
 EGR Components
38
6. Low-temperature
39
6. Low-temperature
 EGR Working Principle
Engine’s working conditions are different, so the demands to EGR are also
different. In order to make engine work more effectively, we should limit the
quantity of exhaust air.
1) While load is increasing, exhaust air quantity will also increase

appropriately to the best value.
2) While idling, being low-load, the concentration of NOx exhausted
becomes low, and in order to guarantee normal combustion it won't
recirculate exhaust gas.
3) Engine's temp and NOx concentration exhausted are low while warming
up, and it won't recirculate exhaust gas in order to prevent EGR from
burning out of control.
4) Engine won’t recirculate exhaust gas in a condition of high-load, high-
speed, or throttle full-opened in order to guarantee engine's dynamic
property.
5) In order to guarantee acceleration & necessary purification effect, EGR
will take effect in the process of transition while increasing speed.
40
7. 6WG1 Tier 3 Engine's Adaptability Improvement
先做人后做事 by ISUZU
品质改变世界
In order to adapt the poor quality fuel in Chinese market, ISUZU

improved engine's adaptability.
High Sulfur Fuel ▪ Foreign Matter ▪ Reducing
Durability Improvement
Corrosion Wear and Tear Heat-load
Improve Injector
(Add Special Coating / Increase Thrust / ●
Sludge Preventing Structure)
ECM Control Parameter Change ● ● ●
Fuel Filter
●
- Improve Filtering Function
EGR Valve
● ●
- Improve Durability
41
七、五十铃对6WG1国III发动机进行的适应性改进
品质改变世界
 Injector
Failure Portion & Appearance While Using Poor Quality Fuel
Poor Quality Fuel Fuel Injection Process
Solenoid (Many Foreign
Matters)
Coil Flow Hole Wear
and Tear
Valve
① Valve Open ① Valve Close
② Control Chamber ② Control Chamber

Poor Quality Fuel Pressure Down Pressure Up
(High Sulfur Fuel ▪
Heavy Oil etc.)
Control Sludge → Imperfect
Piston Slide
Nozzle Up Nozzle
Down
Nozzle
Poor Quality Fuel
(Many Foreign Matters)
Nozzle Wear and Tear
42
品质改变世界
 Injector Improvement
Valve Setting Load Up Valve Setting Load Up

Add DLC
Flow Decrease via Hole
Multi-hole Filtering
Add
DLC
Control Piston’s
Diameter to Be Smaller
Control Needle Groove’s Cancel Voltage-

Diameter to Be Smaller sharing Groove
Add
DLC
For Car
43
品质改变世界
Details of Improvement Misusing resistant function goes up by improving

valve’s control function. → Matter adhered resistant
function up → Poor quality fuel resistant function up
Improve abrasion resistant function by
decreasing flow via hole.
Content of Modification
Inner Unusual Wear and Tear
Valve Setting Load Up
Small Control Chamber →
Flow Decrease via Hole
Control Piston’s Diameter to
Be Smaller
Add DLC
Area of matter adhered decreases.
Add DLC
→Matter adhered resistant function goes up
→Wear and tear of nozzle seat decreases
Control Chamber
→ Don’t let foreign matters get in.
Grille Filter
44
品质改变世界
Details of Improvement
Content of Modification
Add DLC in Valve
Add DLC coating in 2 slip surfaces to prevent
Valve Setting Load Up matters from adhering to.
Add DLC in Control Piston
Misusing resistant function goes up by improving
valve’s control function. → Matter adhered resistant
Cancel Voltage-sharing Groove function up → Poor quality fuel resistant function up
Add DLC
→Matter adhered resistant function goes up
→Poor quality fuel resistant function up
Prevent slip resistance from increasing by

matters adhered in voltage-sharing groove.
(4J for Chinese car is completed.)
45
品质改变世界
Abstract of Improvement
No. G2→G3 Improvement Effect
1 Valve setting load up Improve matter adhered resistant function

2 Flow decreases via hole Improve foreign matter resistant function
3 Control diameter of piston/nozzle seat to be smaller Improve matter adhered resistant function
4 Multi-hole filtering Improve foreign matter resistant function
Improve foreign matter resistant function
5 Nozzle full DLC processing
Improve matter adhered resistant function
No. G2→G3AM Additional Improvement Effect
1 Valve setting load up: 60→70N Improve matter adhered resistant function
2 Add DLC to valve's slip portion Improve matter adhered resistant function
Improve matter adhered resistant function
3 Add DLC to valve's acting control portion
Improve foreign matter resistant function
4 Cancel voltage-sharing groove Improve matter adhered resistant function
46
品质改变世界
 EGR Improvement
From gas inlet/outlet side, you can see a lot of carbon matters adhered to the pipe.
47
品质改变世界
1. Market Failure Countermeasures: Specification Fluoro-vinyl Coating
Valve Block: Fluoro-vinyl Coating

Bottom Coating Quantity Control: 0.75±0.15
Valve
Case Block
Case: Fluoro-vinyl Coating
Specs & Effect of Improved Components

Current Improved Improving Effect
Toughness (Resistance to Impact)

Main Ingredient PTFE FEP
Fluororesin PTFE<FEP
Abrasion Coefficient 0.3 Below 0.1 Improve Abrasion Resistance
Bottom R’s Film

10µm 30µm Improve Corrosion Resisting of Bottom R
Thickness
Valve Block Blast Sanding +

Surfacing Cleaning Improve Bonding Degree
Bonderizing
Both Sides Both Sides
Coating Times Improve Bonding Degree
1time/side 3time/side
Improve Corrosion Resisting of Case;
Case Coating None F Resin
Improve Abrasion Resistance
48
品质改变世界
EGR Ratio – Fuel Sulfur Content VS Corrosion Resistance Reliability

Although sulfur content is 350 ppm while testing
Area of Engine’s Poor Corrosion effluent in China, we found fuel samples of 2000
Resistance Reliability ppm in Chinese market.
▪Continue to do a lot of improvements since 2006.
1) Improve water-proof function of EGR valve’s

Fuel Sulfur Content (ppm)
seat to deal with carbon blocking.

2) Replace engine oil from every 500hr to every
250hr
500hr rated
3) Improve efficiency of fuel filter by using larger
continuous
one.
4) Use larger sedimenter.
5) Replace parts attached to EGR on time (OEM).
Area of Engine’s Good
6) Add re-filtering system to fuel tank (OEM).
Corrosion Resistance Reliability
7) Use injector cleaning agent (OEM).
Turkey
EGR Ratio (%)

49
8. Error Code
先做人 & Symptom
 Check engine’s error code on display. Error code list is

attached below;
 Engine failures caused by engine sensor failures are also
attached below.
50
先做人后做事品质改变世界
THE END
51

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6WG1 Engine Training Handbook

Research Institute of Large-scale Excavator

编制： Writing: 审核：

2. Engine Overall Dimensions

3. Engine Specifications & Main Parameters

4. Common Rail System

5. Common Rail System's Components

7. 6WG1 Tier 3 Engine's Adaptability Improvement by ISUZU

8. Error Code & Symptom

 EGR with cooler

 Excellent function improvement; Lower fuel

 Special improvement in order to adapt Chinese fuel;

Supple Pump Outlet Temp

Hope to add boost pump

Main Filter (Wako)

 Common Rail System's Characteristics

 Common Rail System's Characteristics:

1. High pressure in common rail is used to inject directly so it won’t

2. By pressure adjusting solenoid valve on high pressure oil pump, oil

 6WG1 Tier3 only has main

 Pre-injection’s Function & Principle

 Electrical Control System

Sensor Controller Actuator

1. Engine Basic Control

2. Other Engine Control

 Engine Fuel Injection Control Map

 Fuel Injection Control Mode While Starting-up

 Water Temperature Compensation Curve

 Atmosphere Pressure Compensation Curve

 Engine Over Heat Protection

 Excavator has its own

 ECM Principle Diagram

Connect to the negative terminal of battery.

 Sensor List & Function

 Actuator List & Function

No. Name Function Description

Control high pressure oil pump's oil inlet quantity to satisfy

3 Relay Control air compressor, exhaust brake and cold-start device.

4 Indicator Lamp Failure indicator lamp, cold-start indicator lamp.

5 Speed Output Use for excavator's tachometer.

 5 Parts of Common Rail System

Fuel Filter Flow Damper

 Components of Common Rail System

 Rail Pressure Sensor – Detect Injection Pressure

EGR Valve & Boost Temp Sensor

Cam Shaft Position Sensor

Fuel Temp Sensor

1) While load is increasing, exhaust air quantity will also increase

In order to adapt the poor quality fuel in Chinese market, ISUZU

ECM Control Parameter Change ● ● ●

② Control Chamber ② Control Chamber

Valve Setting Load Up Valve Setting Load Up

Control Needle Groove’s Cancel Voltage-

Details of Improvement Misusing resistant function goes up by improving

Prevent slip resistance from increasing by

No. G2→G3 Improvement Effect

1 Valve setting load up Improve matter adhered resistant function

No. G2→G3AM Additional Improvement Effect

1. Market Failure Countermeasures: Specification Fluoro-vinyl Coating