Structure & Function

Intake & EGR System

Section 2_4

Komatsu EGR System

Exhaust Gas Recirculation (EGR)

For Tier III EGR (Exhaust Gas Recirculation) is the primary method utilized
by Komatsu to comply with emissions requirements for the
6D125, 6D140, &6D170 Engines.

EGR Duct and Heat Exchanger

EGR
Control
Valve
Intake

Hot Exhaust Gas

Fresh Intake Air

EGR lowers O2 and reduces

peak temperatures and pressures

EGR gasses are cooled to

improve volumetric efficiency

Result is lower NOx

Diesel Engine Combustion Basics

Advancing or Retarding
Timing is a balance between
NOx, HC, and performance.

Courtesy of Cummins Engine Company

Function of EGR

Courtesy of Cummins Engine Company

Komatsu 6D140 EGR Cooler

EGR Concerns
Increased Corrosion
Cooled EGR leads to condensation and formation of higher acid levels
EGR creates sulfuric acid and nitric acid
Increased Soot
Increased levels of soot due to EGR
Higher Engine Temperatures
Engine coolant is used for
EGR cool EGR Gases
EGR COOLER Tube life is not measurable
Sulfur content is not easy to measure in the field
Component Accessibility is can be difficult due to heat shielding

EGR Valve Open Range

Peak Torque
Lift

Peak Torque

Max Lift : 10 mm

Torque / Boost

Fully Open

Rated Horsepower

Medium Lift
Fully Closed

Low Idle

High Idle

Engine Speed
Engine RPM

Komatsu EGR System Without By-Pass System

Turbocharger

Intake Air

Muffler

Cooled
Exhaust Out

Air to Air After Cooler

Cooler

Exhaust
Gas In

Exhaust Manifold

Fan

6D125
6D140
6D170
Valve

Intake Manifold

Venturi

 system With By-Pass

Turbo Charger
Air
Cleaner

Muffler

EGR Valve

EGR Cooler

Venturi
Intake Air
Temp

Intake Air
Pressure

By-pass
Valve
ECM (CM850)

Exhaust Manifold

EGR In Pressure
Sensor

Engine

EGR
Position
Sensor

Intake Manifold

Air to Air After cooler

Inlet Air
Temperature
Sensor

Engine
Coolant
Temperature

EGR / By-Pass Control Oil Flow

Control OIL In

Low Horsepower
EGR Only System

Return OIL Out

Coin Style Last

Chance Oil Filter

EGR and By-Pass Valves

By-Pass Valve
Position
Actuator

By-Pass Valve
Position Sensor
By-Pass Valve
EGR Valve
Position
Actuator

EGR Valve

EGR Valve
Position Sensor

Resorte Vlvula ERG

EGR Cooler
EGR Cooler uses a Waved Tube Design to
increase efficiency
Exhaust and Coolant Flow in the same direction
Contains 52 tubes each with an outside
diameter of 10 mm
Twin vent tube insure good venting

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Engine Driven EGR Oil Supply Pump

A EGR oil pump has been added to
supply pressurized oil to the EGR/ BP
actuators.

External EGR
Supply Pump
Output Line

Pressurized oil is routed thru internal oil

passages or external tubes
Pump contains two pressure relief
valves. Primary set @ 15 kg/cm
Secondary set at 18 kg/cm

6D140 EGR
Supply Pump

Internal EGR Supply

Pump Passage
6D125 EGR Supply Pump

EGR / BY Position Sensor

Tier 3 Komatsu Engine EGR System Component

Locations

6D125 Tier 3 Engine

Click on Image

6D140 Tier 3 Engine

Click on Image

6D170 Tier 3 Engine

Click on Image

Tier 3 6D125 Engine

EGR System
Component Locations

TIER III 6D125 for PC400 with EGR only

Komatsu KTR 90
Turbo Charger

Cooled EGR
Gas Out

EGR Coolant
Out
Hot EGR
Gas In
EGR Cooler

EGR
Coolant In

Tier III 6D125 for PC400 with EGR only

Cooled EGR
Gas In

EGR Control
Oil Supply In

EGR
Actuator
EGR Supply
Oil Pump

EGR Position
Sensor

EGR Valve

EGR Control
Oil Return

Tier III 6D125 for PC400 with EGR only

EGR Valve

EGR Control
Oil Supply In
EGR
Actuator
EGR Position
Sensor

EGR Control
Oil Return

Tier III 6D125 for PC400 with EGR only

EGR Hot
Gas In

EGR Pressure Sensor Location (not

required for EGR only System)

EGR Coolant Vent Line

(two required to insure correct coolant flow)

Cooled EGR Gas

Tier III 6D125 for HM300 with EGR & By-Pass

By-Pass
Valve

EGR Valve

Supply Oil

Oil Return

EGR Oil
Pump

Tier III 6D125 for HM300 with EGR & By-Pass

EGR Gas Venturi

EGR Pressure Sensor

Tier 3 6D125 Engine

EGR System
Component Locations

Return to Menu

Tier 3 6D140 Engine

EGR System Component Locations

Tier III 6D140 for PC700 with EGR & By-Pass

By-Pass
Valve

Heat Shield

EGR Valve

EGR Hot
Gas In
EGR Cooler
EGR Hot Gas In

EGR Hot
Gas In
EGR Hot
Gas In

Tier III 6D140 for PC700 with EGR & By-Pass

Vent Lines

Coolant In

Coolant Return

EGR Cooler

Tier III 6D140 for PC700 with EGR & By-Pass

By-Pass Valve

By-Pass Valve
Position Actuator

EGR Valve

EGR Valve
Position
Actuator

By-Pass Valve
Position Sensor

EGR Oil Supply

(in)

By-Pass Valve
Position Sensor

EGR Oil Return

(out)

Tier 3 6D140 Engine

EGR System Component
Locations

Return to Menu

Tier 3 6D170 Engine

EGR System Component
Locations

Tier III 6D170 for WA600 with EGR & By-Pass

Komatsu KTR 130
Turbo Charger

Hot EGR
Gas In

By-Pass

EGR Cooler

EGR Supply Oil Pump

Tier III 6D170 for WA600 with EGR & By-Pass

EGR Cooler

EGR
Valve

Inlet Air from After

Cooler

By-Pass
Valve

Tier III 6D170 for WA600 with EGR & By-Pass

EGR Valve
EGR Cooler

EGR Hot Gases

Cooler Vent
Collector

Tier 3 6D170 Engine

EGR System Component
Locations

Return to Menu

END OF
Structure & Function
Intake & EGR System
6D125 Tier 3
Engine

6D140 Tier 3
Engine

Section 2_4

6D170 Tier 3
Engine

EGR / By-Pass Sensor Voltage Signal

Signal
Voltage

5V

4.5 volt = EGR / BP Valve

Pos Sensor High Error

4V

3 volt = 12 mm
3V

2V

1V

.5 volt = EGR / BP Valve

Pos Sensor High Error

1 volt = 0 mm
0V
0mm

6mm

EGR / BP Valve Travel

12mm

EGR Actuator PWM Signal Vs Actuator Current

Full
Voltage

Larger Duty Cycle = Larger Current

100 % Current

90 % Duty
Cycle

50 %Current
10%Current

Zero
Voltage

Actuator Current Rise

Full
Voltage

Current Rise Lags Voltage Rise

100 % Current

50 % Duty
Cycle

50 %Current
10%Current

Zero
Voltage

Full
Voltage
100 % Current

10 % Duty
Cycle

50 %Current
10%Current

Zero
Voltage