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CX_C Engine Orientation

2011-03-08 Engine Overview 1


Notes

Engine Overview 2
Table of Contents

Overall Appearance Diagram 6


Overview of Interim Tier IV engine system 8
Full electric control 10
Engine System Diagram 11
ECM (engine control module) 12
Supply Pump / SCV (suction control valve) 14
(supply pump) 15
(Fuel Temperature sensor) 16
(suction control valve) 17
Common Rail 18
Flow Dampener 19
Pressure Sensor / Pressure Limiter 20
Injector 24
Glow Plugs 26
Engine Coolant Temperature Sensor 28
Engine Oil Pressure Sensor 30
Cam Position Sensor (CMP sensor) 32
Crank Position Sensor (CKP sensor) 34
Radiator 36
Reserve Tank – Level Switch 38
Atmospheric pressure sensor 40
Air Intake (MAF) Sensor (Mass & Temperature) 42
Dropping Resister for Air Intake (MAF) Sensor 44
VG Turbocharger 45
VG Turbo Controller (4HK1X ) 48
VG Turbo Controller (6HK1X) 49
Boost Pressure Sensor 50
Boost Temperature Sensor 52
Fuel Level Sensor 54
Fuel Filter ((Main 56
Fuel Filter Sensor 58

Engine Overview 3
Table of Contents (cont.)

EGR Cooler 64
EGR Valve (EGR position sensor) 66
EGR Intake Temperature Sensor 68
Battery Relay 70
Starter Relay 72
Glow Relay 76
Starter Motor 78
Alternator 80
Air Cleaner (Vacuum) Switch 82
DPD (Diesel Particulate Diffuser) 84
DPD Differential Pressure Sensor 86
DPD Exhaust Temperature Sensor 88
Intake Throttle 90

Engine Overview 4
Notes

Engine Overview 5
Overall Appearance Diagram

Engine Summary – Overall Appearance Diagram

1 Engine oil fill port 7 Starter motor

2 Air breather 8 Supply pump (SCV)

3 Alternator 9 Common rail

4 Turbo

5 EGR valve
l

6 EGR cooler

Engine Overview 6
Overall Appearance Diagram

Engine Summary – Overall Appearance Diagram

1 Engine oil fill port 7 EGR cooler

2 Air breather 8 Supply pump (SCV)

3 Alternator 9 Common rail

4 Turbo

5 S
Starter motor

6 EGR valve

Engine Overview 7
Overview of Interim Tier IV engine system

Engine Summary – Overview of Interim Tier IV engine system

Engine Overview 8
Full electric control

Engine Summary – Full electric control

Engine Overview 9
Engine System Diagram

Engine Summary – Engine System Diagram


1 Air cleaner 11 Supply pump

2 Fuel cooler 12 EGR cooler

3 Inter cooler 13 DPD

4 Radiator 14 Fuel main filter

5 VGR turbo
b 15 F l ttankk
Fuel

6 Compressor side 16 Fuel pre filter

7 Turbine side 17 Charge fuel pump

8 Engine 18 Intake throttle

9 Injector 19 EGR valve

10 Common rail

Engine Overview 10
ECM (engine control module)

Engine Summary – Detailed Parts Diagrams


1 ECM (engine control module)
1.

Engine Overview 11
ECM (engine control module)

Engine Summary – Detailed Parts Diagrams


1. ECM (engine control module)

Three roles of the ECM


[1] The ECM constantly monitors information sent from the various sensors and
controls the power train systems.
[2] The ECM executes system function diagnosis, detects problems in system
operation, issues trouble alarms 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 technician.
[3] The ECM puts out 5 V 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.

Engine Overview 12
ECM (engine control module)

Engine Controller Schematic

Engine Overview 13
Supply Pump / SCV (suction control valve)

4HK1X

6HK1X

Engine Overview 14
Supply Pump / SCV (supply pump)

Supply pump
The supply pump uses the force of the engine rotation to raise the fuel pressure
and send fuel to the common rail
rail. The SCV
SCV, fuel temperature sensor
sensor, and feed
pump are installed on the supply pump.

4HK1X

1
1 Fuel temperature sensor

2 SCV (suction control valve)

3 Feed pump (supply)


6HK1X

2
3

Engine Overview 15
Supply Pump / SCV (Fuel Temperature sensor)

4HK1X and 6HK1x

1 F
1. Fuell ttemperature
t sensor

The fuel temperature sensor is installed on the supply pump, and the thermistor
changes the resistance value according to the temperature change.

The resistance value becomes lower when the fuel temperature is high, and it
becomes higher when the fuel temperature is low.

The ECM applies 5 V to the fuel temperature sensor through the pull-up resistor, and
it calculates the fuel temperature from changes in the voltage and uses it for
controlling the supply pump, etc.

The voltage becomes lower when the resistance is lower, and it becomes higher
when the resistance is higher.

Engine Overview 16
Supply Pump / SCV (suction control valve)

4HK1 and 6HK1X

SCV (suction
( ti control
t l valve)
l )
The SCV is installed on the supply pump and controls the sending of fuel to the
common rail (discharge volume). The ECM controls the electrified time to the
SCV and controls the fuel discharge.

Engine Overview 17
Common Rail

4HK1x

6HK1x

Engine Overview 18
Common Rail / Flow Dampener

6HK1X 1

1 Common rail

6HK1X 2

1 Common rail
2 Flow damper

The common rail receives the fuel from the supply pump, holds the common rail (fuel)
pressure and distributes the fuel to each cylinder
pressure, cylinder. The common rail pressure sensor
sensor,
flow dampeners (only on the 6HK1X engine) and pressure limiter are installed on
the common rail.

Engine Overview 19
Common Rail / Pressure Sensor / Pressure Limiter

4HK1x

6HK1X

Engine Overview 20
Common Rail / Pressure Sensor / Pressure Limiter

4HK1X

Common rail
2 1
pressure sensor
2 Pressure limiter

6HK1X

Common rail
1
pressure sensor
1
2 Pressure limiter

Engine Overview 21
Common Rail / Pressure Sensor / Pressure Limiter

4HK1X and 6HK1X

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.

Engine Overview 22
Common Rail / Pressure Sensor / Pressure Limiter

4HK1X and 6HK1X

Pressure Limiter

(2) Pressure limiter


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

Engine Overview 23
Injector

4HK1X and 6HK1X

Injector
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 injectors. By controlling the injector electrified time, the ECM
controls the fuel injection, injection timing, etc.

Engine Overview 24
Injector

4HK1X

6HK1X

Engine Overview 25
Glow Plugs

4HK1X

6HK1X

Engine Overview 26
Glow Plugs

4HK1X and 6HK1X

There are 4 glow plugs on the 4HK1X engine and 6 glow plugs on the 6HK1X engine.

Engine Overview 27
Engine Coolant Temperature Sensor

4HK1X

6HK1x

Engine Overview 28
Engine Coolant Temperature Sensor

4HK1X and 6HK1X

Engine Coolant Temperature Sensor

The Engine Coolant Temperature sensor detects the engine coolant temperature and
sends it to the ECM.

The Engine Coolant temperature sensor is installed on the engine block


block, and the
thermistor changes the resistance value according to the temperature change.
The resistance value becomes smaller when the engine coolant temperature is high,
and the value becomes larger when the engine coolant temperature is low.
The ECM applies 5 V to the water temperature sensor through the pull-up resistor,
and calculates the engine coolant temperature from changes in the voltage.
This value is used in various control mechanisms, such as for fuel injection control,
Q i kO
Quick On Start
St t (QOS) control,
t l etc.
t
The voltage becomes higher when the resistance is higher, and it becomes lower
when the resistance is lower.

Engine Overview 29
Engine Oil Pressure Sensor

4HK1X

6HK1X

Engine Overview 30
Engine Oil Pressure Sensor

4HK1X and 6HK1X

Engine Oil Pressure Sensor

The engine
Th i oilil pressure sensor iis iinstalled
t ll d near the
th cylinder
li d block
bl k starter
t t motor.
t It
detects the engine oil pressure, converts this pressure into an electrical signal, and
sends that signal to the ECM.
The voltage becomes higher when the pressure is higher, and it becomes lower when
the pressure is lower.

Engine Overview 31
Cam Position Sensor (CMP sensor)

4HK1X

6HK1X

Engine Overview 32
Cam Position Sensor (CMP sensor)

4HK1X and 6HK1X

Cam Position Sensor (CMP sensor)

The camshaft
Th h ft position
iti sensor is
i installed
i t ll d b
behind
hi d th
the cylinder
li d h head,
d and
d generates
t a
CMP signal when the camshaft cam passes by it.
The ECM determines the cylinder and specifies the crank angle using the CMP signal
input from the camshaft position sensor, and uses the information for the fuel
injection control and calculation of the engine RPM.
While this control is usually performed using the CKP signal, the CMP signal is used
i t d when
instead h ththe crankshaft
k h ft position
iti sensor is
i faulty.
f lt

Engine Overview 33
Crank Position Sensor (CKP sensor)

4HK1X

6HK1X

Engine Overview 34
Crank Position Sensor (CKP sensor)

4HK1X and 6HK1X

Crank Position Sensor (CKP sensor)


The crankshaft position sensor is installed on the flywheel housing and the CKP
signal is generated every time when the protruding section of the flywheel passes the
sensor.
The ECM determines the cylinder and specifies the crank angle using the CMP signal
input from the camshaft position sensor, and uses the information for the fuel
injection control and calculation of the engine RPM.
While this control is usually performed using the CKP signal, the CMP signal is used
instead when the crankshaft position sensor is faulty.

Engine Overview 35
Radiator

4HK1X

6HK1X

Engine Overview 36
Radiator

4HK1x

6HK1X

Engine Overview 37
Reserve Tank – Level Switch

4HK1X

6HK1X

Engine Overview 38
Reserve Tank – Level Switch

Reserve Tank – Level Switch

Engine Overview 39
Atmospheric pressure sensor

4HK1X and 6HK1X

Located next to main computer

Engine Overview 40
Atmospheric pressure sensor

4HK1X and 6HK1X

Atmospheric pressure sensor

The atmospheric pressure sensor is installed in the cab. The ECM converts the
atmospheric pressure into an electric signal and calculates the atmospheric pressure
from this voltage signal and corrects the fuel injection quantity according to the
atmospheric pressure.

Engine Overview 41
Air Intake (MAF) Sensor (Mass & Temperature)

4HK1X

6HK1X

Engine Overview 42
Air Intake (MAF) Sensor (Mass & Temperature)

4HK1X and 6HK1X

Air Intake ((MAF)) Sensor ((Mass &


Temperature)

Intake air temperature sensor


The intake air temperature sensor is installed
on the duct between the air cleaner and
turbocharger. The intake air temperature
sensor is variable resistance inside the mass
air flow sensor to measure the temperature
of air taken into the engine. When the intake
air temperature sensor is cold, the resistance
of the sensor is high. When the air
temperature rises, the resistance of the
sensor becomes low. For high sensor
resistance, the ECM detects a high voltage of
the signal circuit. For low sensor resistance,
the ECM detects a low voltage of the signal
circuit.

Mass air flow sensor


The mass air flow sensor measures the
amount of air taken into the engine, and it is
installed on the duct between the air cleaner
and turbocharger. The mass air flow sensor
consists of the mass air flow sensor and
intake air temperature sensor to measure
some of air flowing in the duct. A small
amount of air taken into the engine indicates
deceleration or idle RPM. A large amount of
air indicates acceleration or high load.

Engine Overview 43
Dropping Resister for Air Intake (MAF) Sensor

4HK1X

6HK1X

Located next to main computer

Dropping Resister for Air Intake (MAF) Sensor

The voltage for Air Intake Sensor is 12V. To get 12V, a Dropping Resistor is needed.

24V power supply at ECM is connected to Dropping Register, and back to ECM than
ECM checks the voltage.
g Then 12V ppower supply
pp y at ECM g
goes to Air Intake sensor.

Engine Overview 44
VG Turbocharger

4HK1X

6HK1X

Engine Overview 45
VG Turbocharger

VG Turbocharger
VG Turbo is able to change the angle of 4HK1X
the exhaust turbine wing g to raise a
supercharge effect. It is used for exhaust
gas performance enhancements such as
PM restraint.

The turbocharger has an actuator with


built-in control unit installed. The opening
angle of the turbocharger variable nozzle 1
is driven by the motor actuator.

The built-in control unit performs CAN


communication, and the ECM performs
control that changes the boost
pressure by adjusting the nozzle opening
1 M t Actuator
Motor A t t
angle in accordance with the load
requirement for the engine.

6HK1X

1 Motor Actuator

Engine Overview 46
VG Turbocharger

Variable Geometry Turbo Charger ((VGT


VGT))

Because of emission control measurement changes; overall


factors such as boost pressure, fuel injection volume, exhaust
gas regeneration amount, etc. need to be controlled in various
modes.
The VGT controls the boost pressure by opening and closing the
vane which enables EGR to work more efficient. This results in
NOx decreasing.

High load
Vane open : large
Relative flow : slow

Low load
Vane open : small
Relative flow : fast

Engine Overview 47
VG Turbo Controller (4HK1X)

4HK1X

4HK1X VG Turbo Controller


The turbo controller for the 4HK1X
engine
i iis llocated
t d iinside
id th
the cab
b near th
the
fuse panel.

Engine Overview 48
VG Turbo Controller (6HK1X)

6HK1X

6HK1X VG Turbo Controller


The VG Turbo Controller for
the 6HK1X engine is located
on the turbocharger.

Engine Overview 49
Boost Pressure Sensor

4HK1X

6HK1X

Engine Overview 50
Boost Pressure Sensor

4HK1X and 6HK1X

Boost Pressure Sensor


The boost sensor detects the boost using the pressure hose between the boost
sensor and intake pipe to convert into the voltage signal and sends it to the ECM
ECM.
The voltage becomes higher when the pressure is higher, and it becomes lower when
the pressure is lower.

The ECM calculates the boost from the voltage signal sent from the sensor, and uses
it to control the fuel injection, etc.

Engine Overview 51
Boost Temperature Sensor

4HK1X

6HK1X

Boost Temperature Sensor


The boost temperature sensor is installed to the EGR valve upstream side of the
i t k manifold.
intake if ld Th
The sensor iis th
the th
thermistor
i t ttype, and
d th
the resistance
i t value
l iinside
id th
the
sensor changes in accordance with the change in the temperature.

Engine Overview 52
Boost Temperature Sensor

4HK1X and 6HK1X

Boost Temperature Sensor

Detects the boost temperature and sends it to the ECM. Used for fuel injection
control etc.

Engine Overview 53
Fuel Level Sensor

4HK1X

6HK1X

Engine Overview 54
Fuel Level Sensor

4HK1X and 6HK1X

Engine Overview 55
Fuel Filter (Main

4HK1X

6HK1X

Engine Overview 56
Fuel Filter (Main)

4HK1X

Fuel Filter (Main)

Engine Overview 57
Fuel Filter Sensor

4HK1X

6HK1X

Engine Overview 58
Fuel Filter Sensor

4HK1X and 6HK1X

Fuel Filter Sensor


Overview: The purpose of the Main Fuel Filter Pressure Transducer is to
protect the engine. If the engine is run with a restricted fuel filter,
cavitation may occur resulting in engine damage.

Engine Overview 59
Fuel Filter Sensor

Warning Message on Monitor

Notification of restricted fuel filter and requirement of fuel filter replacement will occur.
A Warning Message will be displayed
displayed, and engine rpm will be reduced according to
this situation.

If a restriction in the main fuel filter occurs the information is sent to the ECM to
inform the monitor display that the fuel filter is clogged.
Detects the negative pressure inside the main fuel filter and send it to the ECM.

Engine Overview 60
Fuel Filter Sensor

Main Fuel Filter Pressure Transducer


The main fuel filter pressure transducer is monitoring negative pressure on the fuel
line.
This system works 3 sec after engine start,
start and more than 0 C of fuel temperature
temperature.
(1)
When the fuel pressure reaches –30 kPa, for 60 seconds, the warning message will
be displayed on the monitor, and the alarm will sound for 5 seconds.
After replacing the main fuel filter, the controller recognizes the fuel pressure is now
over –5 kPa, the warning message will be cancelled.
(2)
If the fuel filters are not replaced at –30 kPa pressure condition and engine continues
to be run than ECM will signal to reduce engine rpm. If the fuel pressure goes to –38
kPa, for 30 seconds, the ECM signals to reduce engine rpm until the fuel pressure
becomes –30 kPa again.
(3)
If the engine continues to be run without fuel filter replacement treatment, and the
pressure
p essu e reaches
eac es too –38kPa
38 a aga
again,, the
e ECM
C will ssignal
g a to
o reduce
educe e
engine
g e rpm
p aga
again.
But the maximum reducing rpm this time will be 300 rpm from Rated RPM.

Engine Overview 61
Fuel Filter Sensor

Main Fuel Filter Pressure Transducer


The main fuel filter pressure transducer is monitoring negative pressure on the fuel
line.
This system
y works 3 sec after engine
g start,, and more than 32 F of fuel temperature.
p
(1)
When the fuel pressure reaches –4.4 psi, for 60 seconds, the warning message will
be displayed on the monitor, and the alarm will sound for 5 seconds.
After replacing the main fuel filter, the controller recognizes the fuel pressure is now
over –0.72 psi, the warning message will be cancelled.
(2)
If th
the ffuell filt
filters are nott replaced
l d att –4.4
4 4 psii pressure condition
diti and
d engine
i continues
ti
to be run than ECM will signal to reduce engine rpm. If the fuel pressure goes to –5.5
psi, for 30 seconds, the ECM signals to reduce engine rpm until the fuel pressure
becomes –4.4 psi again.
(3)
If the engine continues to be run without fuel filter replacement treatment, and the
pressure reaches to –5.5 psi again, the ECM will signal to reduce engine rpm again.
But the maximum reducing rpm this time will be 300 rpm from Rated RPM RPM.

Engine Overview 62
Notes

Engine Overview 63
EGR Cooler

4HK1X

6HK1X

EGR Cooler

The cooled EGR (cooling unit installed in the path) uses the engine coolant to cool
exhaust gas at high temperature (about 700 °C) down to (about 150 °C), to drop
the combustion temperature
temperature, and to reduce Nox
Nox.

Engine Overview 64
EGR Cooler

4HK1X

The 4HK1X engine uses 2 EGR coolers stacked in series

6HK1X

The 6HK1X engine used 3 EGR coolers stacked in series.

Engine Overview 65
EGR Valve (EGR Position Sensor)

4HK1X

6HK1X

EGR Valve(EGR position sensor)


(Exhaust Gas Recirculation)
Re-circulates 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 NOx.

Engine Overview 66
EGR Valve (EGR Position Sensor)

4HK1X

6HK1X

EGR Valve (EGR position sensor)


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

Engine Overview 67
EGR Intake Temperature Sensor

4HK1X

6HK1X

Engine Overview 68
EGR Intake Temperature Sensor

4HK1X and 6HK1X

Engine Overview 69
Battery Relay

4HK1X

6HK1X

Engine Overview 70
Battery Relay

4HK1X and 6HK1X

Engine Overview 71
Starter Relay

4HK1X

6HK1X

Engine Overview 72
Starter Relay

4HK1X

6HK1X

Engine Overview 73
Starter Relay

Engine Overview 74
Notes

Engine Overview 75
Glow Relay

4HK1X

6HK1X

Engine Overview 76
Glow Relay

Glow Relay 4HK1X and 6HK1X

The ECM determines the glow time according to


the engine coolant temperature, and activates the
glow relay and the QOC (Quick on Start) indicator
light.
The QOS system is a system to facilitate engine
start in a low temperature as well as reducing the
amount of white smoke and noise generated
immediately after engine start.
start
When the starter switch is turned ON, the ECM
detects the temperature of the engine coolant
based on the signal sent from the water
temperature sensor to change the glow time, so
the engine can be always started under the
optimum conditions
conditions.
Also, the after-glow function can stabilize the idling
immediately after engine start.

Engine Overview 77
Starter Motor

4HK1X

6HK1X

Engine Overview 78
Starter Motor

4HK1X

6HK1X

Engine Overview 79
Alternator

4HK1X

6HK1X

Engine Overview 80
Alternator

6HK1X
4HK1X

Engine Overview 81
Air Cleaner (Vacuum) Switch

4HK1X

6HK1X

Engine Overview 82
Air Cleaner (Vacuum) Switch

4HK1X and 6HK1X

Engine Overview 83
DPD (Diesel Particulate Diffuser)

4HK1X

6HK1X

DPD (Diesel Particulate Diffuser)


Built inside a special filter and oxidation catalyst.
catalyst Capture PM by filter
mainly, to burn in the combustion exhaust gas.

Engine Overview 84
DPD (Diesel Particulate Diffuser)

4HK1X 6HK1X

DPD (Diesel Particulate Diffuser)


DPD the oxidation catalyst for purifying HC and NOX,
DPD, NOX the exhaust from the engine,
engine a
special filter for the PM system to complement the collection. PM is deposited on the
filter, it is regeneration. The regeneration has the auto play and manual view.
Differential pressure sensor detects the state PM deposition, and in order to optimize
the combustion temperature, the temperature sensor to detect.

Note: refer to the DPD section in your training


manual for more information on the DPD system.

Engine Overview 85
DPD Differential Pressure Sensor

4HK1X

6HK1X

Engine Overview 86
DPD Differential Pressure Sensor

4HK1X and 6HK1X

DPD Differential Pressure Sensor

The DPD differential pressure sensor is installed near DPD.


The DPD differential p
pressure sensor varies the signal
g voltage
g accordingg to changes
g
of the exhaust gas differential pressure between in front and rear of DPD filter.

The ECM detects a lower signal voltage when the differential pressure is small due to
a small amount of accumulated PM. The ECM detects a higher signal voltage when
the differential pressure is large due to a large amount of accumulated PM.

The ECM uses this voltage signal for controlling DPD regeneration and determining
purification after regeneration. It also uses the signal voltage to detect filter failures
such as a too low differential pressure.

Engine Overview 87
DPD Exhaust Temperature Sensor

4HK1X

6HK1X

Engine Overview 88
DPD Exhaust Temperature Sensor

DPD Exhaust Temperature Sensor


The exhaust gas temperature sensors are variable resistors 4HK1X and 6HK1X
that are installed at 2 locations on the DPD housing One
sensor is installed in front of the DPD oxidation catalyst, and
the other sensor is installed in front of the filter.

The exhaust gas temperature sensor 1 that is located in


front of the filter measures the temperature of the exhaust
gas before entering the DPD filter, and the exhaust gas
temperature sensor 2 that is located in front of the
oxidation catalyst measures the temperature of the exhaust
gas before entering the oxidation catalyst.

When the exhaust gas temperature sensor is cold, the


resistance of the sensor is high. When the exhaust
temperature rises
rises, the resistance of the sensor decreases
decreases.

The ECM detects a high voltage in the signal circuit when


the sensor resistance is high. Also, the ECM detects a low
voltage in the signal circuit when the sensor resistance is
low. The ECM uses this voltage signal for temperature
control during the DPD regeneration.

Engine Overview 89
Intake Throttle

The intake throttle valve is installed on the 4HK1X and 6HK1X


inlet of the inlet manifold.
The ECM controls the opening angle of
the intake throttle valve according to the
condition of engine operation.
The motor inside the intake throttle valve
is controlled based on the duty ratio
signals sent from the ECM.
The opening angle of the intake throttle
valve is adjusted when the duty ratio is
changing from 0 % to the appropriate
ratio.
The valve closes when the duty signal
increases, and the valve opens when the
duty signal decreases.
The opening angle of the intake throttle
valve is detected by the position sensor.
The position sensor outputs the signal
representing the intake throttle valve
opening angle.
The ECM detects a low signal voltage
when the opening angle is small or the
valve is at the closed position
position.
Also, the ECM detects a high signal
voltage when the opening angle is large.

Engine Overview 90

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