Isuzu Hitachi 6BG1 Tier 2 Engine Manual EDCD-EN-00 PDF

Description

Isuzu Hitachi 6BG1 Tier 2 Engine Manual EDCD-EN-00 – PDF DOWNLOAD

FILE DETAILS:

Isuzu Hitachi 6BG1 Tier 2 Engine Manual EDCD-EN-00 – PDF DOWNLOAD 

Language : English
Pages : 234
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Isuzu Hitachi 6BG1 Tier 2 Engine Manual EDCD-EN-00 – PDF DOWNLOAD 

ESS-166A 1
GENERAL INFORMATION 3
General repair instructions 4
Notes on the format of this manual 4
Main data and specifications 8
Performance curve 9
External view 11
Tightening torque specifications 13
Angular nut and bolt tightening method 15
Major parts fixing nuts and bolts 17
Identifications 28
MAINTENANCE 29
Lubricating system 30
Fuel system 31
Cooling system 35
Valve clearance adjustment 35
Injection timing 37
Compression pressure measurement 42
Turbocharger inspection 43
Engine repair kit 44
Recommended lubricants 45
Engine oil viscosity chart 45
ENGINE ASSEMBLY I 47
External parts disassembly steps 48
Major components 52
Rocker arm and rocker arm shaft disassembly steps 57
Cylinder head disassembly steps 58
Piston and connecting rod disassembly steps 59
ENGINE ASSEMBLY II 61
Cylinder head 62
Valve guide 63
Valve spring 66
Tappet 67
Push rod 68
Rocker arm shaft and rocker arm 68
Idler gear and idler gear shaft 69
Camshaft 70
Cylinder body and liner 71
Piston and piston ring 77
Piston pin 79
Connecting rod 80
Crankshaft 82
Flywheel 89
Timing gear case cover 89
ENGINE ASSEMBLY III 91
Piston and connecting rod reassembly steps 92
Cylinder head reassembly steps 94
Rocker arm and rocker arm shaft reassembly steps 97
Major component reassembly steps I 98
Major component reassembly steps II 103
External parts reassembly steps (Left-Hand Side) 108
External parts reassembly steps (Right-Hand Side) 111
Engine tuning operation 115
LUBRICATING SYSTEM 117
General description 118
Oil pump 119
Oil cooler 121
COOLING SYSTEM 123
General description 124
Thermostat 125
FUEL SYSTEM 127
General description 128
Injection nozzle 129
Injection pump calibration data 134
TURBOCHARGER 137
General description 138
Turbocharger identification 139
Troubleshooting 141
Inspection and repair 143
ENGINE ELECTRICALS 145
Starter identification 146
Starter main data and specifications 147
Starter sectional view 148
Performance 148
Disassembly 149
Inspection and repair 152
Reassembly 156
Adjustment 157
Performance test 158
Alternator identification 159
Main data and specifications 160
Alternator sectional view 161
Charging curcuit 161
Structure 162
Disassembly 163
Inspections 166
Reassembly 168
Bench test 169
Current output test 170
Fault finding 171
Specifications 171
TROUBLESHOOTING 173
Hard starting 174
Starter inoperative 174
Starter operates but engine does not turn over 175
Engine turns over but does not start fuel is being delivered to the injection pump 176
Engine turns over but does not start 177
Unstable low idling 178
Insufficient power 180
Excessive fuel consumption 183
Excessive oil consumption 185
Overheating 186
White exhaust smoke 188
Dark exhaust smoke 189
Oil pressure does not rise 190
Abnormal engine noise 192
SPECIAL TOOL LIST 195
Special tool list 196
REPAIR STANDARDS 199
CONVERSION TABLE 223
LENGTH 223
AREA 225
VOLUME 225
MASS 227
PRESSURE 228
TORQUE 229
TEMPERATURE 230

DESCRIPTION:

Isuzu Hitachi 6BG1 Tier 2 Engine Manual EDCD-EN-00 – PDF DOWNLOAD 

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 07/01/2025