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Engine Overview 2
Table of Contents
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
4 Turbo
5 EGR valve
l
6 EGR cooler
Engine Overview 6
Overall Appearance Diagram
4 Turbo
5 S
Starter motor
6 EGR valve
Engine Overview 7
Overview of Interim Tier IV engine system
Engine Overview 8
Full electric control
Engine Overview 9
Engine System Diagram
5 VGR turbo
b 15 F l ttankk
Fuel
10 Common rail
Engine Overview 10
ECM (engine control module)
Engine Overview 11
ECM (engine control module)
Engine Overview 12
ECM (engine control module)
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
3
Engine Overview 15
Supply Pump / SCV (Fuel Temperature sensor)
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)
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
Pressure Sensor
Engine Overview 22
Common Rail / Pressure Sensor / Pressure Limiter
Pressure Limiter
Engine Overview 23
Injector
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
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
The Engine Coolant Temperature sensor detects the engine coolant temperature and
sends it to the ECM.
Engine Overview 29
Engine Oil Pressure Sensor
4HK1X
6HK1X
Engine Overview 30
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)
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)
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
Engine Overview 39
Atmospheric pressure sensor
Engine Overview 40
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)
Engine Overview 43
Dropping Resister for Air Intake (MAF) Sensor
4HK1X
6HK1X
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.
6HK1X
1 Motor Actuator
Engine Overview 46
VG Turbocharger
High load
Vane open : large
Relative flow : slow
Low load
Vane open : small
Relative flow : fast
Engine Overview 47
VG Turbo Controller (4HK1X)
4HK1X
Engine Overview 48
VG Turbo Controller (6HK1X)
6HK1X
Engine Overview 49
Boost Pressure Sensor
4HK1X
6HK1X
Engine Overview 50
Boost Pressure Sensor
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
Engine Overview 52
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
Engine Overview 55
Fuel Filter (Main
4HK1X
6HK1X
Engine Overview 56
Fuel Filter (Main)
4HK1X
Engine Overview 57
Fuel Filter Sensor
4HK1X
6HK1X
Engine Overview 58
Fuel Filter Sensor
Engine Overview 59
Fuel Filter Sensor
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
Engine Overview 61
Fuel Filter Sensor
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
6HK1X
Engine Overview 65
EGR Valve (EGR Position Sensor)
4HK1X
6HK1X
Engine Overview 66
EGR Valve (EGR Position Sensor)
4HK1X
6HK1X
Engine Overview 67
EGR Intake Temperature Sensor
4HK1X
6HK1X
Engine Overview 68
EGR Intake Temperature Sensor
Engine Overview 69
Battery Relay
4HK1X
6HK1X
Engine Overview 70
Battery Relay
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
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
Engine Overview 83
DPD (Diesel Particulate Diffuser)
4HK1X
6HK1X
Engine Overview 84
DPD (Diesel Particulate Diffuser)
4HK1X 6HK1X
Engine Overview 85
DPD Differential Pressure Sensor
4HK1X
6HK1X
Engine Overview 86
DPD Differential Pressure Sensor
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
Engine Overview 89
Intake Throttle
Engine Overview 90