Isuzu AA-4BG1T, AA-6BG1 BB-4BG1T, BB-6BG1T Diesel Engine Workshop Manual PDF

Description

Isuzu AA-4BG1T, AA-6BG1 BB-4BG1T, BB-6BG1T Diesel Engine Workshop Manual – PDF DOWNLOAD

FILE DETAILS:

Isuzu AA-4BG1T, AA-6BG1 BB-4BG1T, BB-6BG1T Diesel Engine Workshop Manual – PDF DOWNLOAD 

Language : English
Pages : 222
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Isuzu AA-4BG1T, AA-6BG1 BB-4BG1T, BB-6BG1T Diesel Engine Workshop Manual – PDF DOWNLOAD 

INDUSTRIAL DIESEL ENGINE AA-4BG1T, AA-6BG1 BB-4BG1T, BB-6BG1T MODELS 1
SECTION 1 3
GENERAL INFORMATION 3
GENERAL REPAIR INSTRUCTIONS 4
NOTES ON THE FORMAT OF THIS MANUAL 4
MAIN DATA AND SPECIFICATIONS 8
EXTERNAL VIEW 10
TIGHTENING TORQUE SPECIFICATIONS 13
ANGULAR NUT AND BOLT TIGHTENING METHOD 15
MAJOR PART FIXING NUTS AND BOLTS 17
IDENTIFICATIONS 28
SECTION 2 29
MAINTENANCE 29
LUBRICATING SYSTEM 30
FUEL SYSTEM 31
COOLING SYSTEM 35
VALVE CLEARANCE AND ADJUSTMENT 35
INJECTION TIMING 37
COMPRESSION PRESSURE MEASUREMENT 43
TURBOCHARGER INSPECTION 44
ENGINE REPAIR KIT 45
RECOMMENDED LUBRICANTS 47
ENGINE OIL VISCOSITY CHART 47
SECTION 3 49
ENGINE ASSEMBLY I (DISASSEMBLY) 49
EXTERNAL PARTS DISASSEMBLY STEPS 50
MAJOR COMPONENTS 55
ROCKER ARM, AND ROCKER ARM SHAFT DISASSEMBLY STEPS 60
CYLINDER HEAD DISASSEMBLY STEPS 61
PISTON AND CONNECTING ROD DISASSEMBLY STEPS 62
SECTION 4 65
ENGINE ASSEMBLY II (INSPECTION & REPAIR) 65
CYLINDER HEAD 66
VALVE GUIDE 67
VALVE SPRING 70
TAPPET 71
PUSH ROD 72
ROCKER ARM SHAFT AND ROCKER ARM 72
IDLER GEAR AND IDLER GEAR SHAFT 73
CAMSHAFT 74
CYLINDER BODY AND LINER 75
PISTON AND PISTON RING 81
PISTON PIN 83
CONNECTING ROD 84
CRANKSHAFT 86
FLYWHEEL AND FLYWHEEL HOUSING 93
TIMING GEAR CASE COVER 93
SECTION 5 95
ENGINE ASSEMBLY III (REASSEMBLY) 95
PISTON AND CONNECTING ROD REASSEMBLY STEPS 96
CYLINDER HEAD REASSEMBLY STEPS 98
ROCKER ARM AND ROCKER ARM SHAFT REASSEMBLY STEPS 102
MAJOR COMPONENT REASSEMBLY STEPS I 103
MAJOR COMPONENT REASSEMBLY STEPS II 108
EXTERNAL PARTS REASSEMBLY STEPS (Left-hand side) 113
EXTERNAL PARTS REASSEMBLY STEPS (Right-hand Side) 117
ENGINE TUNING OPERATION 121
ENGINE SECTIONAL VIEW 123
SECTION 6 125
LUBRICATING SYSTEM 125
GENERAL DESCRIPTION 126
OIL PUMP 127
OIL COOLER 129
SECTION 7 131
COOLING SYSTEM 131
GENERAL DESCRIPTION 132
THERMOSTAT 133
SECTION 8 135
FUEL SYSTEM 135
GENERAL DESCRIPTION 136
INJECTION NOZZLE 137
INJECTION PUMP CALIBRATION DATA 142
SECTION 9 145
TURBOCHARGER 145
GENERAL DESCRIPTION 146
TURBOCHARGER IDENTIFICATION 147
INSPECTION AND REPAIR 148
SECTION 10 149
AIR COMPRESSOR 149
GENERAL DESCRIPTION 150
DISASSEMBLY STEPS 151
INSPECTION AND REPAIR 152
REASSEMBLY STEPS 154
SECTION 11 157
ENGINE ELECTRICALS 157
STARTER IDENTIFICATION 158
STARTER MAIN DATA AND SPECIFICATIONS 159
STARTER MOTOR SECTIONAL VIEW 160
PERFORMANCE 160
ALTERNATOR IDENTIFICATION 161
MAIN DATA AND SPECIFICATIONS 162
ALTERNATOR SECTIONAL VIEW 163
CHARGING CURCUIT 163
SECTION 12 165
TROUBLESHOOTING 165
HARD STARTING 166
1) STARTER INOPERATIVE 166
2) STARTER OPERATES BUT ENGINE DOES NOT TURN OVER 167
3) ENGINE TURNS OVER BUT DOES NOT START 168
4) ENGINE TURNS OVER BUT DOES NOT START 169
UNSTABLE LOW IDLING 170
INSUFFICIENT POWER 173
EXCESSIVE FUEL CONSUMPTION 176
EXCESSIVE OIL CONSUMPTION 178
OVERHEATING 179
WHITE EXHAUST SMOKE 181
DARK EXHAUST SMOKE 182
OIL PRESSURE DOES NOT RISE 183
ABNORMAL ENGINE NOISE 185
SECTION 13 189
SPECIAL TOOL LIST 189
SPECIAL TOOL LIST 190
SECTION 14 193
REPAIR STANDARDS 193
SECTION 15 213
CONVERSION TABLE 213
LENGTH 214
AREA 215
VOLUME 215
MASS 217
PRESSURE 218
TORQUE 219
TEMPERATURE 220

DESCRIPTION:

Isuzu AA-4BG1T, AA-6BG1 BB-4BG1T, BB-6BG1T Diesel Engine Workshop Manual – PDF DOWNLOAD 

FOREWORD:

• This Workshop Manual is designed to help you perform necessary maintenance, service, and repair procedures on applicable Isuzu industrial engines. Information contained in this Workshop Manual is the latest available at the time of publication.
• Isuzu reserves the right to make changes at any time without prior notice.
• The Table of Contents at the right hand side of this page shows you the general arrangement of the material in this Workshop Manual. A more detailed Table of Contents precedes each individual section.
• The black spot at the right hand side of some pages indicates the first page of a given section.
• This Workshop Manual is applicable to 1999 and later models.

GENERAL REPAIR INSTRUCTIONS:
1. Before performing any service operation with the engine mounted, disconnect the grounding cable
from the battery.
This will reduce the chance of cable damage and burning due to short circuiting.
2. Always use the proper tool or tools for the job at hand.
Where specified, use the specially designed tool or tools.
3. Use genuine ISUZU parts referring ISUZU PARTS CATALOG for the engines surely.
4. Never reuse cotter pins, gaskets, O-rings, lock washers, and self locking nuts. Discard them as you
remove them. Replace them with new ones.
5. Always keep disassembled parts neatly in groups. This will ensure a smooth reassembly operation.
It is especially important to keep fastening parts separate. These parts vary in hardness and design,
depending on their installation position.
6. All parts should be carefully cleaned before inspection or reassembly.
Oil ports and other openings should be cleaned with compressed air to make sure that they are completely
free of obstructions.
7. Rotating and sliding part surfaces should be lubricated with oil or grease before reassembly.
8. If necessary, use a sealer on gaskets to prevent leakage.
9. Nut and bolt torque specifications should be carefully followed.
10. Always release the air pressure from any machine-mounted air tank(s) before dismounting the engine
or disconnecting pipes and hoses. To not do so is extremely dangerous.
11. Always check and recheck you work. No service operation is complete until you have done this.
12. Information contained in the “Main Data and Specifications” of the Workshop Manual and the
Instruction Book may differ. In this case, the information contained in the Instruction Book should be
considered applicable.

S.V 05/01/2025