ISUZU Diesel Engine 6BG1 Instruction Manual

GENERAL INFORMATION 1-I SECTION 1 GENERAL INFORMATION TABLE OF CONTENTS ITEM PAGE General repair instructions ............................................................................... l- 2 Notes on the format of this manual ..................................................................... l- 2 Main data and specifications ............................................................................. l- 6 Tightening torque specifications I ........................................................................ 1- 8 Angular nut and bolt tightening method ............................................................... l-10 Major parts fixing nuts and bolts . ........................................................................ l-12 Identifications .............................................................................................. l-23

13 GENERAL INFORMATION 1 . 2 . 3 . 4 . 5 . 6 . 7 . 8 . 9 . 10 . 11 . 12 . GENERAL REPAIR INSTRUCTIONS 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. Always use the proper tool or tools for the job at hand. . mere specified, use the specially designed tool or tools. L Use genuine ISUZU parts referring ISUZU PARTS CATALOG for the engines surely. Never reuse cotter pins, gaskets, O-rings, lock washers, and self locking nuts. Discard them as you remove them. Replace them with new ones. 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. ‘ , ‘ . r. I-- 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. Rotating and sliding part surfaces should be lubricated with oil or grease before reassembly. If necessary, use a sealer on gaskets to prevent leakage. Nut and bolt torque specifications should be carefully followed. 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. Always check and recheck you work. No sewice operation is complete until you have done this. 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 Bo.ok should be considered applicable. z NOTES ON THE FORMAT OF THIS MANUAL This Workshop Manual is applicable to the 4BG1, 4BGlT, 6BG1, and 6BGlT family of industrial diesel engines. Unless otherwise specified, these engines have common parts and components as well as data and qqecifications. Illustrations used in this Workshop Manual are based on the 6BGl and 6BGlT engines. The 4BGlTengine and the 6BGlT engine are turbocharged. . 1 . 2 . 3 . 4 . 5 . Find the applicable section by referring to the Table of Contents at the beginning of the Manual. Cdmmon technical data such as general maintenance items, service specifications, and tightening torques are included in the “General Information” section. 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. When the same servicing operation is applicable to<--everal different units, the manual will direct you to the appropriate page. For the sake of brevity, self-explanatory removal and installation procedures are omitted. More complex procedures are covered in detail. ,

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. o&sumblystaps-2 -. 1. W8terby-passho8e 2. ThwmosUtfiou8ing .3. WatDrpfJmp A 4. l~rKuzleholder 5. Glow plug and gJow plug connector 6. cylllherdcowr A 7. Rocbrarmshaftandrockerrrm S. fbhrod A 9. c-w 10. Cylinder he8d gultet A 11. Crankshaftdamper pulley with dust seal 12. liming gear cue cutter 13. liming gmr cover 14. Tf gear oil pipe 15. ldktr gear 3. rnd shaft 16. ldbr war -A’ l?. Mkr gear shaft I lnvwted Engine I- 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 ti “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 unne- cessary unless replacement is required. The ‘ I* 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 (A) is an important operation. Detailed information is given in the text.

I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I II I I I I I I&!.- 1 , 1” GENERAL INFORMATION 7. Below is a sample of the text of the Workshop Manual. This is the item shown in the illus- 4 tration. It is marked with a triangle (A) on the Major Components page. Special tools are identified by the from the upper face of the cylinder head. Letters and numbers contained in a circle refer to the illustration. set. guides. Symbols indicate the type of service or step to be per- formed. A detailed explanation of these symbols follows. Y Service data and specifications are given in this table. 8. The following symbols appear throughout this Workshop Manual. They tell you the type of service operation or step to perform. q CI) . . . 0 *+ l ** III +$+ . . . cl $+ l l l ltrl . . . 0 * . . . El aB ... . . l!!il . . . . B!l . . . Removal Installation Disassembly Reassembly Alignment (Marks) Directional Indication Inspection Measurement Sealant Application - El D II) . .. l5l .. . V ? 0. . . m . . . El bl . . . cl 0 . . . 0 qy5 l l l cl -b ... Adjustment Cleaning Important Operation Requiring Extra Care Specified Torque (Tighten) Special Tool Use Required or Recommended (lsuzu Tool or Tools) Commercially Available Tool Use Required or Recommended Lubrication (Oil) (2 Lubrication (Grease)

I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I II I I I I I I II I‘ GENERAL INFORMAiiON l-5 9 . 10 . II . Measurement criteria are defined by the terms “standard” and “limit”. A measurement falling within the “standard” range indicates that the applicable part or parts are ser- vicea ble. “Limit” should be thought of as an absolute value. A measurement which is outside the “limit” indicates that the applicable part or parts must be either repaired or replaced. Components and parts are listed in the singular form throughout the Manual. Directions used in this Manual are as follows: Front The cooling fan side of the engine viewed from the flywheel. Right The injection pump side of the engine. Left The exhaust manifold side of the engine. Rear The flywheel side of the engine. Cylinder numbers are counted from the front of the engine. The front most cylinder is No. 1 and rear most cylinder is No. 4 or No. 6. The’engine’s direction of rotation is counterclockwise viewed from the flywheel. . - b Front t Right Rear W Left +

I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I II I I I I I I II f=. - 1 l-6 GENERAL INFORMATION MAIN DATA AND SPECIFICATIONS Engine Model Item A-4BGl A-4BGlT - Engine type Water cooled, four cycle, vertical in-line overhead valve Combustion chamber type Direct injection Cylinder liner type Dry No. of cylinders - bore x stroke mm (in) 4 - 105 x 125 (4.13 x 4.92) Total piston displacement cm3 (cid) 4,329 (464) Compression ratio 17.0 to I f Engine dimensions mm (in) 842x645~775 878 x 702 x 883 Length x width x height (33.1 x 25.4 x 30.5) (34.6 x 27.6 x 34.8) ’ Engine weight (Dry) kg (lb) 325 (716) 361 (796) Fuel injection order I-3-4-2 Specified fuel Diesel fuel (ASTM D975 No. 2D) Injection pump In-line plunger, Bosch A type Governor Mechanical, RSV type Injection nozzle Multi hole injection starting pressure kg/cm2( psi) 150 (2,134) I 185 (2,630) Fuel filter type Center bolt or cartridge (spin-on) Water sedimentor (If so equipped) Sediment/water level indicating type Compression pressure kg/cm2 (psi) 31 (441) at 200 rpm at sea level (At warm) Valve clearances (At cold) Intake mm (in) 0.40 (0.016) Exhaust mm (in) 0.40 (0.016) Lubrication method Pressurized circulation Oil pump Gear type Main oil filter type Full flow, cartridge (spin-on) )cLubricating oil volume lit. (US gal) 13.2 (3.5) Oil cooler Water cooled integral type Cooling method Pressurized forced circulation Coolant volume (engine only) lit. (US gal) 8.5 (2.25) Water pump Belt driven impeller type i Thermostat type Wax pellet type * Generator V-A 24-40 * Starter V-KW 24-4.5 * Turbocharger manufacturer MITSUBISHI * Turbocharger model TDO4H Note: 1. These specifications are based on the standareengine. I :’ ! c- \.?, ‘L .@- jJ I *‘ I c .Tp’ t,. / . r-pa. ‘ i‘ tJ k ._ 2. Specifications for items marked with an asterisk (*) will vary according to the type of equipment on which the engine is installed. If you are unable to locate the data applicable to these specifications, please contact lsuzu Motors LTD through your machine supplier.

GENERAL INFORMAnON 1-7 MAIN DATA AND SPECIFICATIONS Engine Model Item A-6BGl A-6BG1T Engine type Water cooled, four cycle, vertical in-line overhead valve Combustion chamber type Direct injection Cylinder liner type Dry No. of cylinders - bore x stroke mm (in) 6 - 105.0 x 125.0 (4.13 x 4.92) Total piston displacement cm3 (cid) 6,494 (396) Compression ratio 17.5 to 1 Engine dimensions mm (in) 1122x648~775 1193X739X949 Length x width x height (44.2 x 25.5 x 30.5) (47.0 x 29.1 x 37.4) Engine weight (Dv) kg (lb) 458 (1009) \ 489 (1078) Fuel injection order l-5-3-6-2-4 Specified fuel Diesel fuel (ASTM 0975 No. 20) injection pump . In-line plunger, Bosch AD type Governor Inject& nozzle Mechanical, RSV type Multi hole injection starting pressure kg/cm2 (psi) 185 (2,630) Fuel filter type Cartridge (spin-on) Water sedimentor (if so equipped) Sedimenter/water level indicating type Compression pressure kg/cm* (psi) 31 (441) at 200 rpm, at sea level . .(At warm) Valve clearances (At cold) Intake mm (in) 0.40 (0.016) Exhaust mm (in) 0.40 (0.016) Lubrication method Pressurized circulation Oil pump Gear type Main oil filter type Centerbolt, fullflow or cartridge (spin-on) Partial oil filter Equipped by OEM ’Lubricating oil volume lit. (US gal) 21.5 (5.68) a Oil cooler Water cooled integral type Cooling method Pressurized forced circulation Coolant volume (engine only) lit. (US gal) 12 (3.2) Water pump Belt driven impeller type Thermostat type Wax pellet type t Generator V-A 24-40 e Starter V-KW 24-4.5 e Turbocharger manufacturer IHI t Turbocharger model ’ - (yJ RHE6 Note: 1 . These specifications are based on the standard engine. 2. Specifications for items marked with an asterisk (*) will vary according to the type of equipment on which the engine is installed. If you are unable to locate the data applicable to these specifications, please contact lsutu Motors LTD through your machine supplier.

I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I II I I I I I 1pr -4 1 I :. 1-8 GENERAL INFORMATION TIGHTENING TORQUE SPECIFICATIONS The tightening torque values given in the table below are applicable to the bolts unless otherwise specified. STANDARD BOLT kg.m (I b.ft/N.m) 4.8 (4T) (7-n 88 0 9.8 (9T) Refined Non-Refined @I @@@I @ 0 77 No mark -@@$I @ . M6 x1.0 0.4-0.8 0.5-1.0 (2.9-5.813.9-7.8) (3.6-7.2/4.9-9.8) M8 xl.25 0.8-1.8 1.2-2.3 x7-3.1 (5.8~~13.OjT.8-17.7) (8.7~16.6/11.8-22.6) (12.3-22.4/16.7-30.4) Ml0 x 1.25 2.1-3.5 2.8-4.7 3.8-6.4 (15.2-25.3/20.6-34.3) (20.3434.0/27.5-46.1) (27.5~46.3/37.3-62.8) M72 x 1.25 5.0-7.5 6.2-9.3 7.7-11.6 (36.2-54.2/49.0-73.6) (44.8~67.3/60.8-91.2) (55.7~83.9/75.5-113.8) M34 x 1.5 7.8-11.7 9.5-14.2 11.6-17.4 (56.4-84.6178.5-114.7) (68.7-102.7/93.2-139.3) . (83.9~125.6/113.8-170.6) Ml6 x 1.5 10.6-16.0 . 13.8-20.8 16.3-24.5 (76.7~115.7/103.0--156.9) (99.8-150.4/135.3-204.0) (118.9-177.2/159.9-240.3) Nil8 x 1.5 15.4-23.0 19.9-29.9 23.4-35.2 . (lll.l-166.4/151.0-225.6) (143.9-216.3/195.2-391.3) (169.34254.6/229.5-345.2) nmxl.5 21.0-31.6 27.5-41.3 32.3-48.5 , (151.9-228.6/205.9-307.9) (198.9-298.7/269.7-405.0) (233.6~350.8/316.8-475.6) M22xl.5 25.6-42.2 37.0-55.5 43.3-64.9 (185.2-305.2/251.1-413.8) (267.6-401.4/362.9-544.3) (313.2-469.4/424.6-636.5) M24 x 2.0 36.6-55.0 43.9-72.5 56.5-84.7 (264.7-397.8/358.9-539.4) (317.5~523.9/430.5-711.0) (408.7-612.6/554.1-830.6) *Ml0 x 1.5 2.0-3.4 2.8-4.6 3.7-6.1 (14.5-24.6/19.6-32.4) (20.3-33.3127.5-45.1) (26.8-44.1/36.3-59.8) I *Ml2 x 1.5 4.6-7.0 5.8-8.6 7.3-10.9 (33.3-50.6/45.1-68.7) (42.0~62.2/56.9-84.3) (52.8-78.8/7X6-106.9) *Ml4 x 2.0 7.3-10.9 9.0-13.4 10.9-16.3 (52.8-78.8/77.6-106.9) (65.1~96.9/88.3-131.4) (78.8~118.9/106.9-159.9) 10.2-15.2 *Ml6 x 2.0 173.8~110.0/100.0-149.1; 13.2-19.8 15.6-23.4 I (95.5~143.2/129.5-194.2) (112.8-169.3/162.8-229.5) r J ,I ‘\ i - &~ ,a- ,<. ‘C A _-- r,.- ‘3 ,Tc-\ : 3 \ An asterisk (*) indicates that *he bolts are used for female threaded parts that are made of soft materials such as casting. Those shown in parentheses in the strength class indicate the classification by the old standard.

ISUZU Diesel Engine 6BG1 Instruction Manual

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