CASE CX180 Crawler Excavator Service Repair Manual SET

INDUSTRIAL DIESEL ENGINE AA-4BG1T, AA-6BG1 BB-4BG1T, BB-6BG1T MODELS ISUZU MOTORS LIMITED WORKSHOP MANUAL

ISUZU WORKSHOP MANUAL INDUSTRIAL DIESEL ENGINE AA-4BG1T, AA-6BG1 BB-4BG1T, BB-6BG1T MODELS 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. TABLE OF CONTENTS SECTION NAME 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 GENERAL INFORMATION MAINTENANCE ENGINE ASSEMBLY I (DISASSEMBLY) ENGINE ASSEMBLY II (INSPECTION & REPAIR) ENGINE ASSEMBLY III (REASSEMBLY) LUBRICATING SYSTEM COOLING SYSTEM FUEL SYSTEM TURBOCHARGER AIR COMPRESSOR ENGINE ELECTRICALS TROUBLESHOOTING SPECIAL TOOL LIST REPAIR STANDARD CONVERSION TABLE

GENERAL INFORMATION 1–1 SECTION 1 GENERAL INFORMATION TABLE OF CONTENTS ITEM PAGE General repair instructions ............................................................................... 1– 2 Notes on the format of this manual ..................................................................... 1– 2 Main data and specifications ............................................................................. 1– 6 External view ............................................................................................... 1– 9 Tightening torque specifications ........................................................................ 1–15 Angular nut and bolt tightening method ............................................................... 1–17 Major parts fixing nuts and bolts ........................................................................ 1–19 Identifications .............................................................................................. 1–30

1–2 GENERAL INFORMATION NOTES ON THE FORMAT OF THIS MANUAL This Workshop Manual is applicable to the 4BG1, 4BG1T, 6BG1, and 6BG1T family of industrial diesel engines. Unless otherwise specified, these engines have common parts and components as well as data and specifications. Illustrations used in this Workshop Manual are based on the AA-6BG1 and BB-6BG1T engines. The AA-4BG1T engine and the BB-4BG1T engine are turbocharged. 1. Find the applicable section by referring to the Table of Contents at the beginning of the Manual. 2. Common technical data such as general maintenance items, service specifications, and tightening torques are included in the "General Information" section. 3. Each section is divided into sub-sections dealing with disassembly, inspection and repair, and reassembly. The section ENGINE ASSEMBLY is an exception. This part is divided into three sections to facilitates quick indexing. 4. When the same servicing operation is applicable to several different units, the manual will direct you to the appropriate page. 5. For the sake of brevity, self-explanatory removal and installation procedures are omitted. More complex procedures are covered in detail. 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 com- pletely 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.

GENERAL INFORMATION 1–3 6. Each service operation section in this Workshop Manual begins with an exploded view of the applicable area. A brief explanation of the notation used follows. ENGINE ASSEMBLY ( 1 ) Disassembly Steps - 2 1. Water by-pass hose 2. Thermostat housing 3. Water pump ▲ 4. Injection nozzle holder 5. Glow plug and glow plug connector 6. Cylinder head cover ▲ 7. Rocker arm shaft and rocker arm 8. Push rod ▲ 9. Cylinder head 10. Cylinder head gasket ▲ 11. Crankshaft damper pulley with dust seal 12. Timing gear case cover (Option) 13. Timing gear cover 14. Timing gear oil pipe 15. Idler gear “B” and shaft ▲ 16. Idler gear “A” 17. Idler gear shaft Inverted Engine Parts marked with an asterisk (*) are included in the repair kit. Parts within a square frame are to be removed and installed as a single unit. All parts within an irregularly shaped frame form a single assembly. They are considered a "major component". Individual parts within the irregularly shaped frame are considered "minor components". The number tells you the service operation sequence. Removal of unnumbered parts is un- necessary unless replacement is required. The "* Repair Kit" indicates that a repair kit is available. The parts listed under "Reassembly Steps" or "Installation Steps" are in the service operation sequence. The removal or installation of parts marked with a triangle (▲) is an important operation. Detailed information is given in the text. • • • • • • • •

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CASE CX180 Crawler Excavator Service Repair Manual SET

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