Isuzu 6RB1 6RB1T Workshop Manual by engineparts2

TABLE OF CONTENTS

ISUZU WORKSHOP MANUAL INDUSTRIAL DIESEL ENGINE 6RB1-6RB1T 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 1987 and earlier models.

SECTION

NAME

GENERAL INFORMATION

MAINTENANCE

ENGINE ASSEMBLY I (DISASSEMBLY)

ENGINE ASSEMBLY II (INSPECTION & REPAIR)

ENGINE ASSEMBlY Ill (REASSEMBLY)

LUBRICATING SYSTEM

COOLING SYSTEM

FUEL SYSTEM

TURBOCHARGER

AIR COMPRESSOR

ENGINE ELECTRICALS

TROUBlESHOOTING

SPECIAL TOOL UST

CONVERSION TABLE

NOTICE Before using this Workshop Manual to assist you in performÂ ing engine service and maintenance operations, it is recommended that you carefully read and throughly understand the information contained in Section - 1 under the headings "GENERAL REPAIR INSTRUCTION" and "NOTES ON THE FORMAT OF THIS MANUAL".

GENERAL INFORMATION 1 -1

SECTION 1

GENERAL INFORMATION TABLE Of CONTENTS ITEM

PAGE

General repair instructions ......................................................... 1- 2 Notes on the format on this manual ................................................. 1- 2 Main data and specifications ........................................................ 1- 6 Design features and general outline ................................................. 1- 8 Tightening torque specifications .................................................... 1- 9 Angular nut and bolt tightening method ............................................. 1-10 Major parts fixing nuts and bolts .................................................... 1-12 Identifications ..................................................................... 1-23

1-2 GENERAL INFORMATIONS

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. remove them. Replace them with new ones. 5. Always keep disassembled parts neatly in groups.

Discard them as you

This will ensure a smooth reassembly operation.

It is especially important to keep fastening parts separate. depending on their installation position.

These parts vary in hardness and design,

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足 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 your 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 Instruc足 tion Book may differ. In this case, the information contained in the Instruction Book should be considered applicable.

NOTES ON

THIS MANUAL

This Workshop Manual is applicable to the ISUZU industrial diesel engine model specified in the title of this Workshop Manual. Illustrations used in this Workshop Manual are based on the 6RB1TPA industrial standard model. The 6RB1 engine is non-turbocharged and the 6RB1TPA, which is abbreviated to 6RB1T in the descrip足 tions, is 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 reas足 sembly. The section ENGINE ASSEMBLY is an exception. quick indexing.

This part is divided into three sections to facilitates

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 INFORMATIONS 1-3 6. Each service operation section in this Workshop Manual begins with an explcded view of the applic able area. A brief explanation of the notation used follows. Parts within a frame are to be removed and installed as a single unit, and their disassembly steps or reassembly steps are shown in the illustrations respect ively.

. 1

The number tells you the service opera tion sequence. Removal of unnumbered parts is unne cessary unless replacement is required. The "* Repair Kit" indicates that a repair kit is available.

OiPJMmbly Step$ 2 1 2. 3 4 A. 5 6. A 7, a A. 9.

Weter by-pess hose The1mosta1 housing Waffir p-ump lnjnct1on Mule holdtir Glow plug 11nd glow plug cor,necto, Cylinder he.!ld cover Rocker arm aheft and rocker arm Push rod Cylinder head

10 A 1l 12 13 14 15 6 7

tt :•.

Cylinder head gaslt:o: Crt1nkshntt demp-01 pulley with dust seol Timing gaer case cover Timmg gear covur Timing ge11t ml pipe 1d!or gaar and shaft Idler QO-'lr •AIdler gear st.oft

·a•

The parts listed under "Disassembly Steps" or "Reassembly Steps" are in the service operation sequence. The removal or installation of parts marked with a triangle (A) is an import ant operation. Detailed information is given in the text.

1-4 GENERAL INFORMATION 7. Below is a sample of the text of the Workshop Manual. This is the item shown in the illus tration. It is marked with a triangle (.a.) on the Major Components page.

the valve guide outer face with engine oi1. 3, Use a hammer to drive the v from tho cylinder head upper face

Valve Guide Installer: 1 ·85220-00H,,.,.___ ·---'�D

4. Measure the height of the valve guide upper end from the upper face of the cylinder heed,

Note:

If the valve guide has bee removed, both the Ive and the valve guide must be re aced with new on as a set. Be absolutely sure to discard the guides.

Special tools are identified by the tool name and/or number. The illustration shows how the spe cial tool is to be used. Letters and numbers contained in a circle refer to the illustration. Symbols indicate the type of service operation or step to be per formed. A detailed explanation of these symbols follows. Service data and specifications are given in this table.

8. The following symbols appear throughout this Workshop Manual. operation or step to perform.

EJ . .

B 1�:•1 l•!·I . . g .. �--·· � .... � .... �--··

Removal

Installation

Disassembly

Reassembly

Alignment (Marks)

Directional Indication

Inspection

Measurement

Liquid Gasket Application

[E . .

ffi] . . �--·· �--··

B···

They tell you the type of service

Adjustment

Cleaning

Important Operation Requiring Extra Care

Specified Torque (Tighten)

Special Tool Use Required or Recommended (Isuzu Tool or Tools) Commercially Available Tool Use Required or Recommended

Lubrication (Oil)

Lubrication (Grease)

GENERAL INFORMATION 1-5 9. 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 serÂ viceable. "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. 10. Components and parts are listed in the singular form throughout the Manual. 11. 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 the final cylinder number of the engine. The engine's direction of rotation is counterclockwise viewed from the flywheel.

1-6 GENERAL INFORMATIONS

MAIN DATA AND SPECIFICATIONS Engine Model

Item

I I

6RB1

Water cooled, four cycle, vertical in-line, overhead valve

Engine type

Direct injection

Combustion chamber type

Dry

Cylinder liner type No. of cylinders - bore X stroke Total piston displacement

mm(in) cm3(in3)

6 - 135 X 160 (5.31 X 6.30) 13,741 (838) 16.5

Compression ratio (To 1) mm(in)

*Engine dimensions Length X width X height

kg(lb)

*Engine weight (Dry)

1,471 X 773 X 1,027 (57.9 X 30.4 X 40.4) 980 (2,163)

degrees

*Fuel injection timing (BTDC)

Mechanical, RSV type 650

rpm

*Low idle speed

750

Hole type (with multi orifices)

Injection nozzle kg/cm3(psi/kPa)

200 (2,844/19,620) or 225 (3,195/22,073) Center bolt or cartridge (spin-on) Optional equipment

kg/cm2(psi/kPa) Intake

mm(in)

29 (412/2,842) at 220 rpm at sea level 0.60 (0.024) 0.60 (0.024)

Exhaust mm(in)

Pressurized circulation

Lubrication method

Gear type

Oil pump

Center bolt, full flow or cartridge (spin-on)

Main oil filter type

Centrifugal type

Partial oil filter *Lubricating oil capacity

1,076 (2,375) 2-6-3-5

In-line plunger, Bosch P type

Governor

Valve clearances (At cold)

1,471 X 885 X 1,267 (57.9 X 34.8 X 49.9)

Diesel fuel (ASTM D975 No. 2D)

Specified fuel Injection pump

Compression pressure (At warm)

Fuel injection order

*Injection starting pressure Fuel filter type Water sedimentor

6RB1T

lit(US/UK gal)

19 (5.o/3.5)

45 (11.819.9)

Engine parts contact email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.Isuzu-6RB1.com www.HeavyEquipmentRestorationParts.com

GENERAL INFORMATION 1-7

Item

Engine Model

Oil cooler

Water cooled integral type Pressurized forced circulation

Cooling method Coolant capacity

lit(US/UK gal)

Thermostat type *Starter *Turbocharger manufacturer *Turbocharger model

30 (7.93/6.60) Belt driven impeller type

Water pump *Alternator

6RB1T

6RB1

Wax pellet type V-A

24 - 20 or 24 - 30

V-kW

24 - 7.4 or 24 - 11 GARRETT AUTOMOTIVE PRODUCTS COMPANY

TV61 or T51

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. Regarding the injection starting pressure and the injection timing crank angle of your engine, make sure the applicable data referring MAINTENANCE DATA PLATE affixed on your engine. If you are unable to locate the data applicable to the specifications, please contact to ISUZU MOTORS LIMITED through your machine suuplier.

1-8 GENERAL INFORMATION

DESIGN FEATURES AND GENERAL OUTLINES The ISUZU 6RB1 industrial diesel engine is a water-cooled, in-line six-cylinders having 13,741 liters (838 cubic inches) piston displacement. The model 6RB1 is the naturally aspirated engine and, model 6RB1 T is the turbocharged one. The combustion system is a direct fuel injection type. The valve configulation is four valves (two inlet and two exhaust valves) driven by the roller tappet (i.e. cam-follower), push rod, rocker arm and valve bridge. In order to level up the air intake efficiency and the combustion efficiency, a dual port type intake system is employed. One of the dual ports is a conventional swirl port, while the another one is a tangential swirl type. They act together to generate an optimum air swirls. However, the exhaust system is of a single-port with two-valve configulation and, the port sectional shape is designed to reduce the exhaust resistance. The water passages specially cross-drilled around the injection nozzle position contribute to reduce the local thermal-load at this cylinder head area. The fuel injection nozzles are located at the central position of the combustion chamber to give a better fuel combustion efficiency. The Bosch P type in-line fuel injection pump with the RSV type mechanical governor is equipped giving a high versatility for various industrial applications. A forced circulation type lubricating system with a fullÂ flow center bolt type oil filter or a spin-on type oil filter together with a partial-flow oil filter assures an improved durability and reliability.

GENERAL INFORMATION 1-9

TIGHTENING TORQUE SPECIFICATIONS ,�,

STANDARD BOlTS

The torque values given in the following table should be applied where a particular torque is not specified.

Bolt identification

...,�-

� Bolt diameter x pitch

kg-m(lb.ft/N-m)

<:I>/

4T (Low carbon steel)

(mm)

-·---,-

M 6 X 1.0

7T (High carbon steel)

9T (Alloy steel)

(

0.6 ±0.2 4.4± 1.4/ 5.88± 1.96)

(

1.3 ±0.5 0.4± 3.4/ 12.74± 4.90)

( 12.66±

1.75± 0.5 3.00/ 17.15±

4.90)

( 17.36±

2.0 ± 0.7 5.36/ 19.60±

2.8 ±0.7 ( 20.3± 5.2/ 27.44± 6.86)

( 27.20±

3.75± 0.9 7.2 I 36.75±

8.82)

( 36.88±

5.0 ± 1.3 9.88/ 49.00± 12.74)

M12 X 1.25

6.25±1.2 ( 45.2± 9.2/ 61.25±11.76)

7.75± 1.5 ( 56.03± 11.03/ 75.95± 14.70)

9.65± 1.9 ( 69.77± 13.77/ 94.57± 18.62)

M14 X 1.5

8.75±1.9 ( 70.5±14.5/ 85.75±18.62)

11.85± 2.3 ( 85.67± 16.6 /116.13± 22.54)

14.50± 2.9 (104.84± 20.83/142.1 ± 28.42)

M16 X 1.5

13.3 ±2.7 ( 94.0±17.0/130.34±26.46)

17.30± 3.5 (125.07± 25.07 /169.54± 34.30)

20.40± 4.1 (147.5 ± 29.49/199.92± 40.18)

M18 X 1.5

19.2 ±3.8 (138.9±27.9/188.16± 37.24)

24.90± 5.0 (180.03± 36.3 /244.02±

4.90)

29.30± 5.9 (211.84± 42.83/287 .14± 57.82)

M20 X 1.5

26.3 ±5,3 (190.2±38.2/257.74±51.94)

34.40± 6.9 (248.72± 49.7 /337.12± 67.62)

40.40± 8.1 (292.10± 58.09/395.92± 79.38)

M22 X 1.5

33.0 ±8.3 (245.1±60.1/323.40±81.34)

46.25± 9.2 (334.39± 66.38/453.25± 90.16)

54.10±10.8 (391.15± 78.14/530.18±105.84)

M24 X 2.0

45.8 ±9.2 (331.2±60.2/448.84±90, 16)

58.20±14.0 (420.70±102.78/570.36±137.20)

70.60±14.1 (510.44±101.44/691.88±138.18)

*M10 X 1.5

2.7 ±0.7 ( 19.6± 5.6/ 26.46± 6.86)

( 26.75±

*M12 X 1.5

5.8 ±1.2 ( 42.0± 9.0/ 56.84±11.76)

7.2 ± 1.4 ( 52.02± 10.05/ 70.56± 13.72)

9.1 ± 1.8 ( 65.80± 12.80/ 89.18± 17.64)

*M14 X 2.0

9.1 ±1.8 ( 65.8±12.8/ 89.18± 17.64)

11.2 ± 2.2 ( 80.97± 15.7 /109.76± 21.56)

13.6 ± 2. 7 ( 98.33± 19.33/133.28± 26.46)

12.7 ±2.5 ( 91.9±17.9/124.46±24.5 )

16.5 ± 3.3 (119.30± 24.3 /161. 70± 32.34)

19.5 ± 3.9 (140.99± 27.99/191.1 ± 38.22)

M 8 X 1.25 M10 X 1.25

*M16 X 2.0 '

5.43±

0.75± 0.2 1.43/ 7.35± 1.96)

3.7 ± 0.9 6.7 / 36.26±

8.82)

( 35.43±

6.86)

4.9 ± 1.2 8.42/ 48.02± 11.76)

Note: The asterisk (*) indicates that the bolts are used for female-threaded parts that are made of soft materials such as casting.

1-10 GENERAL INFORMATION

lÂ«I

ANGULAR NUT AND BOLT TIGHTENING METHOD

1. Carefully wash the nuts and bolts to remove all oil and grease.

2. Apply a coat of molybdenum disulfide grease to the threads and setting faces of the nuts and bolts.

3. Tighten the nuts and bolts to the specified torque (snug torque) with a torque wrench.

NUT OR BOLT Snug torque

Center line

4. Draw a line [A-BJ across the center of each bolt

GENERAL INFORMATION 1-11 5. Draw another line [C-D] on the face of each of the parts to be clamped. This line should be an exten sion of the line [A-BJ.

Line

6. Draw another line [F-G] on the face of each of the parts to be clamped. This line will be in the direc tion of the specified angle [Q] across the center [E] of the nut or bolt.

\ ) Specified angle (01 \

Coinciding line

7. Use a socket wrench to tighten each nut or bolt to the point where the line [A-B] is aligned with the line [F-G].

Example: Specified Angle and Tightening Rotation A

30°

180

° °

360

I I I !

i i

1/12 of a turn 1/6 of a turn

1/4 of a turn

1/2 of a turn

One full turn

1-12 GENERAL INFORMATION

l«I

MAJOR PARTS FIXING NUTS AND BOLTS

Cylinder Head Cover, Cylinder Head, Inlet Cover, and Exhaust Manifold kg.m(lb.ft/N.m)

4.0±0.5 (28.9±3.6/39.2±4.9)

3±0.5 (21.7±3.6/29.4±4.9)

3.3±0.5 (23.8±3.6/32.3±4.9) 3.3±0.5 (23.8±3.6/32.3±4.9)

Apply M0S2

15±1 19±1 --- 300+30• 0 (108.3±7.2/147.0±9.8) -- (137.4±7.2/186.4±9.8)

GENERAL INFORMATION 1-13

l«I

Cylinder Body, Crankshaft Bearing Cap, Tappet Cover, Oil Pan kg-m(lb.ft/N.m)

2.5±0.2 I (18.1±1.4/24.5±2.0) I 2±0.2 (14.5±1.4/19.6±2.0)

(lubricate with engine oil)

39±3 (282.0±21.6/382.6±29.4)

(lubricate with engine oil)

I 12.5±1.5 (90.4±10.8/122.6±14.7)

4.o+o.5 I I t28.9±3.6/39.2±4.9l

1-14 GENERAL INFORMATION Timing Gear Case and Flywheel Housing kg.m(lb.ft/N.m)

26.0±2 "±14.4/255.1±19.6)

L� /

(!%%�

�

2.8±0.3 . I 120.2±2.2121.4±2.9)

For ¢12 Bolt 7.0±1.5 . {50.6±10.8/68.7±14.7) For ¢0 Bolt 5.0±1.0 (36.2±7.2/49.1 ±9.8) 4.0±0.5 (29.0±3,6/39.2±4,9)

For ¢14 Bolt 11.0±2.3 (79.5±16.6/108.0±22.5) For ¢8 Bolt 2.6±0.3 (18.8±2.2/25.5±2.9)

GENERAL INFORMATION 1-15

l«I

Crankshaft, Connecting Rod, Flywheel and Pulley kg,m(lb.ft/N-m)

Apply M0S2 8.0±1.0 0 --- 30.�,s· o (57.8±7.2/78.5±9.8)- 60,�15"

7 (50.6/68.6)

10.0±0.5 (72.3±3.6/98.1±4.9)

lubricate with engine oil

5.0±1.0 I (36.2±7 .2/49.1±9.8)

lubricate with engine oil 9.0+1.0 (65.1±7.2/88.3±9.8) I lubricate with engine oil 80.0±10.0 (578.5±72.0/785.0±98.0) \ Apply M0S2

1-16 GENERAL INFORMATION Camshaft, Rocker Arm Shaft Bracket Camshaft Gear and Idler Gear kg-m(lb.ft/N-m) 8.0±0.5 · (57.8±3.6/78.5±4.9) Lubricate with engine oil 9.0±1.0 (65.1±7.2/88.3±9.8) Lubricate with engine oil

5.5±0.5 i • (39.7±3.6/53.9±4.9) • Lubricate with engine oil 3.0±0.5 (21.7±3.6/29.4±4.9)

17.0±2.0 ( 123.0±14.4/166.8±19.6)

3.5±0.5 (25.3±3.6/34.3±4.9)

4.0±0.5 (28.9±3.6/39.2±4.9) 15.0±1.5 (108.5±10.8/147.2±14.7)

GENERAL INFORMATION 1-17

l«I

Oil Pump and Oil Filter kg-m(lb.ft/N.m) 4.5±0.5

�I ·�

�

r)1 L) <I!)

�S>

0.75±0.2 (5.4±1.4/7.4±1.9)

4.5±0.5 (32.5±3.6/44.1±4.9) 2.0±0.2 (14.5±1.4/19.6±2.0)

2.0±0.2 (14.5±1.4/19.6±2.0)

4.0±0.5 (29.0±3.6/39.2±4.9)

OIL FILTER (CENTRIFUGAL)

�

OIL FILTER (MAIN)

1.8±0.2 (13.0±1.4/17.6±2.0J

1.0±0.2 (7.2±1.5/9.8±1.9)

ffi < 3.5±0.3 (25.2±2.2/34.3±3.0) 2.0±0.2 (14.5±1.4/19.6±2.0)

s.o±o.5 I (36.2±3.6/49.1±4.9)

4.0±0.5 (29.0±3.6/39.2±4.9)

1 18 GENERAL INFORMATION Water Pump, Thermostat Housing Air Compressor and Oil Cooler kg,m(lb.ft/N.m)

3.8±0.5 (27.4±3.6/37.2±4.9)

1.8±0.2 : (13.0±1.4/17.6±2.0) •

'�

27.0±3.0 (195.2±21.6/267.8±29.4)

�'l

.� • (13.0±1.4/17.6±2.0)

7.2±0.8 (52.0±5.8/70.6± 7.8) •

4.2±0.5 • (30.3±3.6/41.2±4.9)

GENERAL INFORMATION 1-19

l«I

Fan, Fan Belt Adjuster and Fan Center

-1

3.8±0.5 \ \ (27.4±3.6/37.2±4.9)

kg.m(lb. ft/N,m)

1.8±0.2 (13.0±1.4/17.6±2.0)

7.2±0.8 (52.0±5.8/70.6±7.8)

7.7±0.8 (55.4±5.8/75.5±7.8)

1 20 GENERAL INFORMATION

l�I

Injection Pump, Fuel Pipes and Fuel Filter

¢8 Bolt

1.2±0.2 (8.6±1.4/11.8±2.0)

kg.m(lb.ft/N.m)

2.5±0.2 (18.1±1.4/24.5±2.0) I

¢10 Bolt

2.8±0.3 (20.2±2.2/27,4±2.9)

2.8±0.2 (20.2±1.4/27.4±2.0) I

3.3±0.2 I 124.0±1.4/32.4±2.01

4.2±0.5 . (30.4±3.6/41.2±5.0) 4.2±0.5 (30.4±3.6/41.2±5.0)

>":>

<�

�-��)') �-----,--

2.8±0.8 I I . (20.2±2.2/27.4±2.9): 4.2+0.5 !� (30.4±3.6/41.2±5.0)

2.8±0.8 (20.2±2.2/27.4±2.9)

4.2±0.5 (30.4±3.6/41.2±5.0)

4.0±0.5 (28.9±3.6/39.2±5.0) =----.____

�

4.2±0.5 I • (30.4±3.6/41.2±5.6)

4.2±0.5 (30.4±3.6/41.2±5.0)

11.0±1.0 ! (80.0±7.2/107.8±9.8)

GENERAL INFORMATIONS 1-21 Turboc h arger an d Intake Duct kg-m(lb.ft/N,m)

1-22 GENERAL INFORMATIONS Air Compressor kg-m{lb.tt/N.m)

2.5-3 0 (18.1/24.5-2i. 7/29.4) 10-12 I â&#x20AC;¢ (72.3/98.1-86.8/117 .8)

2.5-3.0 (18.1/24.5-21.7/29.4)

2.3-2.6 (16.6/22.6-18.8/25.5)

0.6-7.5 (4.3/5.9-54.2/73.6)

GENERAL INFORMATION 1-23

IDENTIFICATIONS MODEL IDENTIFICATION Engine Serial Numbe_r The engine number is stamped on the front right hand side of the cylinder body.

INJECTION PUMP IDENTIFICATION Injection Pump Number

···•· ··· •••· Pump No. ·•• ·· ·• ·· • ·· ·· •••·· NP-PE ( LICENCE BOSCH>

@··· Identification number

Injection volume should be adjusted after referring to the adjustment data applicable to the injection pump installed. The injection pump identification number (A) is stamped on the injection pump identification plate. Note: Always check the identification number before beginn ing a service operation. Applicable service data will vary according to the ident ification number. Use of the wrong service data will result in reduced engine performance and engine damage.

MAINTENANCE DATA PLATE In the 6RB1 industrial engine, the valve clearance, injec tion nozzle opening pressure (i.e. injection starting pressure) and the injection timing crank angle vary depending on the engine applications, therefore, the data is stamped on the Maintenance Data Plate which is affixed on the cylinder head cover top. In the illustration, the figures indicate the following data respectively. 1. 2. 3. 4.

Firing Order Valve Clearance Injection Nozzle Opening Pressure Injection Timing Crank Angle

MEMO

..QUALITY PARTS YOU CAN TRUST ..

MAINTENANCE 2-1

SECTION 2

MAINTENANCE TABLE OF CONTENTS ITEM

PAGE

lubricating system ............................................................... . 2- 2 Fuel system ..................................................................... . 2- 3 Cooling system ................................................................... 2- 8 Valve clearance adjustment ....................................................... 2- 9 Injection timing ................................................................... 2-11 Compression pressure measurement ............................................... 2-13 Turbocharger inspection .......................................................... 2-14 Engine repair kit .................................................................. 2-15 Recommended lubricants ......................................................... 2-16 Engine oil viscosity chart .......................................................... 2-16

Note: Maintenance intervals such as fuel or oil filter changes should be referred to INSTRUCTION BOOK.

Engine parts contact email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.Isuzu-6RB1.com www.HeavyEquipmentRestorationParts.com

2-2 MAINTENANCE

LUBRICATING SYSTEM Main Oil Filter Replacement Center Bolt Type Removal 1. Loosen the drain plug CD to drain the engine oil from the oil filter. Place a receptacle beneath the drain port to contain the drained oil.

2. Remove the center bolt @ and the filter body @ from the filter cover along with the filter element@.

3. Discard the used filter element.

4. Wipe the oil filter fitting face clean with a rag. will allow the new oil filter to seat properly.

This

Installation 1. Install the three 0-rings ®, ©, (J) and new element ® and, check that they are correctly positioned.

2. Reassemble the filter body ® with the center bolt @. kg-m(lb.ft/N.m) I Center Bolt Torque 4.5 ± 0.5 (32.5 ± 3.6/44.1 ± 4.9) I 3. Check that the gasket is properly seated. prevent oil leakage.

This will

4. Start the engine and check for oil leakage from the oil filter.

5. Check the engine oil level and replenish to the spec ified level if required. Drain Plug Torque

kg.m(lb.ft/N.m)

• 1.8 ± 0.2 (13.0 ± 1.4/17.6 ± 2.0) I

Cartridge (Spin-On) Type Removal Remover and Installer: Filter Wrench

1. Loosen the used oil filter by turning it counterclock wise with the filter wrench. 2. Discard the used oil filter.

Installation 1. Wipe the oil filter mounting face with a clean rag. This will allow the new oil filter to seat properly.

2. Lightly oil the 0-ring.

3. Turn in the new oil filter until the sealing face is fit ted against the 0-ring.

4. Use the filter wrench to turn in the oil filter an addi tional 3/4 of a turn or one turn.

5. Start the engine and check for oil leakage from the oil filter.

6. Check the engine oil level and replenish to the spec ified level if required.

MAINTENANCE 2-3

FUEL SYSTEM Fuel Filter Replacement Center Bolt Type Removal 1. Loosen the drain plug CD to drain the fuel from the fuel filter.

2. Loosen the center bolt ® to remove the filter body @, the spring ©, the washer @, the gasket ®, and the filter element 0 and the 0-ring ®·

3. Discard the used element.

Installation 1. Wash the filter body and the other parts immersing them into clean diesel oil.

2. Reassemble the parts in reverse order. new element.

Use the

3. Check that the gaskets are properly seated. This will prevent fuel leakage.

kg,m(lb.ft/N-m) 5.8/41.2 ± 7.9) I

Drain Plug Torque

i 4.2

Center Bolt Torque

kg.m(lb.ft/N-m) '. 2.5 ± 0.5 (18.1 ± 3.6/24.5 ± 4.9) I

0.8 (30.3

Cartridge Type Removal 1. Loosen the fuel filter by turning it counterclockwise with the filter wrench or your hand. Discard the used filter. Filter Wrench

2. Wipe the fuel filter fitting face clean with a rag.

This will allow the new fuel filter to seat properly.

2-4 MAINTENANCE 0-ring

Installation 1. Apply a light coat of engine oil to the O-ring. 2. Supply fuel to the new fuel filter. This will facilitate air bleeding. 3. Turn in the new fuel filter until the filter O-ring is fit足 ted against the sealing face. 4. Use the filter wrench to turn in the fuel filter an ad足 ditional 1 /2 to 3/4 of a turn.

Overflow Valve Check the overflow valve for clogging. Check the ball side for suction leakage. Parts No. 1-13200-666-0 Overflow Valve Opening Pressure (Reference) Parts No. 1-13200-549-0 Overflow Valve Opening Pressure

kg/cm2 (psi/kPa) 2.5 (35.6/196.2) kg/cm 2 (psi/kPa) 1.5 (21.3/147.2)

Injection Nozzle Regarding the injection pipe and the nozzle holder rem足 oval and installation, refer to the section 3 DISASSEM足 BLY page 3-5 and the section 5 REASSEMBLY 5-28, 29.

Inspection Procedure 1. Clamp the injection nozzle holder in a vise. 2. Use a wrench to remove the injection nozzle holder cap. 3. Remove the injection nozzle holder from the vise.

MAINTENANCE 2-5 Adjusting Procedure Injection Starting Pressure Check

1. Attach the injection nozzle holder to the injection nozzle tester. 2. Loosen the adjusting screw CD. 3. Check the injection nozzle starting pressure and the spray condition by operating the injection nozzle tester. 4. Adjust the injection nozzle starting pressure. Turn the adjusting screw clockwise while operating the injection nozzle tester handle. kg/cm2 (psi/kPa) 200 (2844/19620) or Injection Nozzle Injection 225 (3199/22073) Starting Pressure

Note:

The applicable nozzle pressure is indicated on the MAIN TENANCE DATA PLATE affixed on the cylinder head cover. WARNING: TEST FLUID FROM THE NOZZLE TESTER WILL SPRAY OUT UNDER GREAT PRESSURE. IT CAN EASILY PUNCTURE A PERSON'S SKIN. KEEP YOUR HANDS AWAY FROM THE NOZZLE TESTER AT ALL TIMES.

Spray Condition Check (During Injection Nozzle Tes ter Operation)

1. Tighten the adjusting screw CD. 2. Check the injection nozzle starting pressure. 3. Check the injection nozzle spray condition.

(1)

Ill

�

" (2)

�

*. (3)

i ·.•.:

�'

111 :

Operate the injection nozzle tester hand lever 4 to 6 times a second while looking for abnormal injection noz zle spray conditions. Refer to the illustration for different spray conditions. (1) Good (2) Bad (Restrictions in orifice) (3) Bad (Dripping)

2-6 MAINTENANCE Water Sedimentor Non-Transperent Type The sedimented water must be drained every 250 oper ation hours. 1. Place a receptacle beneath the drain pipe to contain the drained water. 2. Loosen the drain plug to drain the water. The sedimenter water capacity is 410 cc (0.86 pints). 3. Tighten the drain plug after the water is drained

out

Water Sedimenter Drain Plug torque

kg-m(lb.ft/N-m) 4.2

0.8 (30.3 ± 5.7/41.2 ± 0.8) kg.m(lb.ft/N-m)

Water Sedimenter Center Bolt Torque

2.5 ± 0.5 (18.1 ± 3.6/24.5 ± 4.9)

Transparent Type Union Nut A Union Nut B

As a transparent shell is used in this type, the sedi mented water level is visible from the outside. 1. Drain the sedimented water when the water level came to the level mark on the transparent shell. 2. Place a receptacle beneath the drain pipe to contain the drained water. 3. Loosen the drain valve to drain the water.

Level Mark

4. Tighten the drain valve after the water is drained out.

Float

Drain Valve

Feed Pump Strainer 1 . Remove the joint bolt. 2. Use a screwdriver to remove the strainer. 3. Wash the strainer in clean diesel fuel.

MAINTENANCE 2-7

Strainer \

Air Bleeding 1. Loosen the priming pump cap G) on the injection pump. 2. Loosen the fuel filter fuel return eye bolt @. 3. Operate the priming pump until there are no more bubbles visible in the fuel being discharged from the fuel filter fuel return eye bolt. 4. Retighten the fuel filter fuel return eye bolt. 5. Operate the priming pump several times and check for fuel leakage around the injection pump and the fuel filter.

2-8 MAINTENANCE

COOLING SYSTEM Cooling fan Drive Belt 8.5-12mm

Thermometer Agitating rod

Wood piece

Adjustment

1. Check the cooling fan drive belt for cracking and other damage. 2. Check the drive belt tension by exerting a force of 10 kg (22 lb) midway between the water pump pul ley @ and the alternator pulley ®· 3. Adjust the belt tension by loosening the alternator mounting bolt and the alternator adjusting bolt and pivoting the alternator. Be sure to retighten the bolts after adjusting the belt tension. mm(in) Cooling Fan Drive 8.5 - 12 Belt Deflection (0.33 - 0.47)

Thermostat Inspection

Visually inspect the thermostat. Replace the thermostat if excessive wear or damage is discovered during inspection. Measure the valve lift. mm(in) Amount of Valve Lift 11.0 (0.43) at 95°C (203° F) °

Valve Opening Temperature

80 - 84 (176

C(° F)

183)

MAINTENANCE 2-9

VALVE CLEARANCE AND ADJUSTMENT Note:

The cylinder head bolts were previously tightened with the "Angular Tightening Method". Therefore, it is not necessary to retighten the cylinder head bolts before adjusting the valve clearance.

0K757

1. Remove the cylinder head covers. 2. Bring the piston in either the No. 1 cylinder or the No. 6 cylinder to Top Dead Center on the compresÂ sion stroke by turning the crankshaft until the TDC notched line on the flywheel or the crankshaft damper is aligned with the timing pointer. Check to see if there is play in the No. 1 intake and exhaust valve rocker arms. If the No. 1 cylinder intake and exhaust valve rocker arms have play, the No. 1 piston is at TDC on the compression stroke. If the No. 1 cylinder intake and exhaust valve rocker arms are depressed, the No. 6 piston is at TDC on the compression stroke.

When No. 1 Cylinder is in TDC compression stroke.

Front OK412

Do this adjustment on the valves indicated by arrows in the illustrations when the No. 1 cylinder or the No. 6 cylinder is in T.D.C. compression stroke respectively.

When No. 6 Cylinder is in TDC compression stroke.

Front -

0K412

2-10 MAINTENANCE Asjusting Screw A

Note:

For brevity of the description, the rocker arm adjusting screw is abbreviated as the screw A and, the bridge adjusting screw is also abbreviated as the screw B in this procedure. 1. Loosen the lock nuts of the screw A and B to permit the adjusting screws are turned freely.

2. Screw in the screw B to allow the bridge is lifted up. This will result to make no clearence condition between the valve stem and the screw B. 3. Lock the screw B by tightening the lock nut to fix the bridge position. 4. Insert a 0.6 mm (0.0024 in.) feeler gauge into the bridge and the rocker arm clearance.

5. Keep the filler gauge in the clearance and, tighten the screw A until the feeler gauge is bound. 6. Loosen the screw A slowly until the feeler gauge move in the clearance but feel a slight drag. This is the correct valve clearance of this engine.

Valve Clearance (Cold)

mm(in)

0.6 (0.024)

7. Tighten the lock nut of the screw A to the specified torque. (Apply a coat of engine oil.) Rocker Arm Screw Lock Nut Torque

Bridge Screw Lock Nut Torque

kg.m(lb.ft/1\J-m)

8.0 ± 1.0

]

(57.8 ± 7.2/78.5 ± 9.8) (39.7

5.5 ± 0.5 3.6/53.9

4.9)

Engine parts contact email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.Isuzu-6RB1.com www.HeavyEquipmentRestorationParts.com

MAINTENANCE 2-11

Take care to avoid entry of dust or foreign particles into the pump interior when the timing adjustment is made.

1. Injection timing checking procedure 1) Remove the cylinder head covers. Remove the flywheel timing mark cover if necessary.

INJECTION TIMING Note:

2) Bring the piston in either the No. 1 cylinder or the No. 6 cylinder to Top Dead Center on the compression stroke by turning the crankshaft until the TDC notched line on the flywheel or the crankshaft damper is aligned with the timÂ ing pointer.

Timing Marks on the Damper

2-12 MAINTENANCE 3) Check to see if there is play in the No. 1 intake and exhaust valve rocker arms. 4) Back the crankshaft to align the applicable tim ing notch line on the flywheel or the damper. 5) Check the injection pump notch line and the injection pump flywheel notched line for align ment. When the two notched lines are in alignment, the injection timing is correct. 2. Injection Timing Adjustment If the two notched lines are not in alignment or an injection timing change is necessary, do the injec tion timing adjustment referring page 2-23 - 2-28 in the section 5.

Note: The applicable injection timing crank angle of your engine is indicated on MAINTENANCE DATA PLATE affixed on the cylnder head cover top.

MAINTENANCE 2-13

COMPRESSION PRESSURE MEASUREMENT 1. Operate the engine to warm-up until the coolant ° ° temperature reachs to 75 C (167 F). 2. Remove all of the injection nozzles and the injection pipes. Nozzle Holder Replacer : 9-8523-2001-0 3. Attach a compression gauge to the No. 1 cylinder injection nozzle fitting hole. l\lote: Compression pressure may be measured starting at any cylinder and in no particular cylinder order. However, it is very important that the compression pressure be measured in each cylinder. Therefore, start at the !\Jo. 1 cylinder and work back. In this way, you will be sure to measure the compression pressure in each cylinder. Compression Gauge: Compression Gauge Adapter: 9-8543-1505-0 4. Crank the engine with the starter motor and take the compression gauge reading. kg/cm2 (psi/kPa) at 220 rpm at sea level Standard 29 (412/2842)

Limit 23 (370/2551)

5. Repeat the procedure (Steps 2 and 3) for the re maining cylinders. Compression pressure should be approximately the same for each cylinder. A variation exceeding 2.0 kg/cm2 (28.4 psi/19.6 kPa) is unacceptable. If the measured value exceeds the specified limit, the related parts must be checked.

2-14 MAINTENANCE

TURBOCHARGER INSPECTION 1. Check the air intake duct connections for air lea足 kage.

2. Check the intake manifold connections for air lea足 kage.

3. Check the exhaust duct connections for smoke lea足 kage. 4. Check the turbocharger mounting nuts for loose足 ness.

5. Check the oil feed pipe for oil leakage.

6. Check the oil return pipe joints for oil leakage.

MAINTENANCE 2-15

ENGINE REPAIR KIT All of the numbered parts listed below are included in the Engine Repair Kit. The gaskets marked with an asterisk(*) are also included in the Top Overhaul Kit.

1. 2. * 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Valve guide seal Cylinder head gasket Head cover gasket Tappet chamber cover gasket O-ring Tachometer flange O-ring Timing gear case gasket Timing gear cover gasket Oil pan drain plug gasket Oil pan gasket Partial-flow oil filter O-ring Fuel filter joint bolt gasket

13. 14. 15. 16. 17. 18. * 19. 20. 21. 22. 23. 24.

Oil pipe O-ring Oil pipe O-ring Water pump gasket Inlet pipe gasket Water outlet pipe gasket Oil-cooler gasket Water outlet pipe gasket Air inlet cover gasket Exhaust manifold gasket Injection nozzle gasket Injection pipe sleeve nut gasket Return pipe gasket

2-16 MAINTENANCE

RECOMMENDED LUBRICANTS ENGINE TYPE

TYPES OF LUBRICANTS

Without turbocharger

Diesel engine oil CC or CD grade

With turbocharger

Diesel engine oil CD grade

ENGINE OIL VISCOSITY CHART

ENGINE OIL VISCOSITY GRADE

AMBIENT TEMPERATURE

!Single grade] SAE 40,50 :�:�

r Ambient l-30 C l Temperature;(-22° F) [Multi-grade]

-15 C ° (0 F)

0 C ° (32 Fl SAE 10W--30 SAE 15W-40,20W-40,20W-50

30 C ° (90 F)

ENGINE ASSEMBLY I 3-1

SECTION 3

ENGINE ASSEMBLV (DISASSEMBLY)

TABLE OF CONTENTS ITEM

PAGE

General descreiption .............................................................. 3- 1 Disassembly 1st step ............................................................. 3- 3 Disassembly 2nd step ............................................................. 3- 6 Disassembly 3rd step ............................................................. 3- 9 Cylinder head disassembly step ................................................... 3-13 Piston and connecting rod disassembly step ....................................... 3-15 Rocker arm and shaft disassembly step ............................................ 3-17 Camshaft and gear disassembly step .............................................. 3-17 Crankshaft disassembly step ...................................................... 3-18

3-2 ENGINE ASSEMBLY I

ENGINE ASSEMBLY GENERAL DESCRIPTION For your reference:

Note: This sectional drawing is based on 6RB1 T standard engine.

In this engine, an oil jet piston cooling is provided to reduce the piston thermal-load. An oil jet nozzle is located at the crankcase lower position per cylinder, they are pointing the piston back side cavity to allow the oil hit the place exactly. The laminated steel sheet cylinder head gasket is very durable. This type of gasket eliminates cylinder head bolt retightening. The tufftrided crankshaft which has a long service life is used for the turbocharged model and, it cannot be reground because of it is a tufftrided one. A non-tufftrided normal type crankshaft is used for the naturally aspirated engine. The crankshaft main bearings and the connecting rod bearings are aluminum plated. These bearings are especially sensitive to foreign material such as metal scraps. It is very important that the oil ports and other related parts be kept clean and free of foreign material.

ENGINE ASSEMBLY I 3-3

DISASSEMBLY 1 ST STEP

13 4 r

23 ,ďż˝ ,s I ,2 20 2 1 39 40

Disassembly Steps 1. 2. A 3. 4. 5. 6. 7. 8. 9. 10. 11 12. 13. 14. 15. 16. 17. A 18. Âˇ 19. 20. A 21. A 22.

Cooling fan and spacer Fan drive belt Alternator and adjusting plate Engine stop device (if equipped) Air intake duct Cylinder head cover Fuel pipe ; filter to injection pump Fuel pipe ; filter to feed pump Fuel return pipe ; injection pump Fuel leak off pipe ; outer Fuel pipe ; intake heater Fuel filter Oil pipe ; cylinder block to head Oil pipe ; filter outlet Oil pipe ; filter inlet Water drain valve Oil filter Injection pipes with clip Oil pipe ; injection pump in and out Injection pump coupling cover Injection pump Tachometer drive elbow (if equipped)

A. 23. Bearing case or air compressor 24. Turbocharger oil pipe ; inlet and outlet 25. Turbocharger 26. Water inlet pipe 27. Water outlet pipe 28. Water inlet pipe (manifold type) 29. Intake cover 30. Exhaust manifold 31. Dipstick and guide tube 32. Oil pipe ; partial filter 33. Partial-flow oil filter 34. Fuel leak off pipe ; inner A 35. Injection nozzle 36. Engine hanger ; front and rear 37. Air breather 38. Tappet cover 39. Oil pipe ; oil cooler 40. Oil-cooler 41. Starter

3-4 ENGINE ASSEMBLV I W Important Operations 3. Alternator and Adjusting Plate

Loosen the generator fixing bolts A. Loosen the bolt B until the water pump drive belt can be easily removed.

18. Injection Pipes with Clip

Disconnect the injection pipes by loosening the nuts in the numerical sequence shown in the illustration. {CD,® and@) Keep the knurled nut CD with the mating injection pipe neatly in group. Discard the used gasket © and replace with new one.

21. Injection Pump

Use the shipping plugs (or something similar) to seal the injection pump delivery valve ports. This will prevent the entry of foreign material.

Remove the bolts on the injection pump side. Do not attempt to disassemble the injection pump drive gear side coupling. Not to observe this will lead miss alignment between the both coupling centers causing a coup ling breakage.

22. Tachometer Drive Elbow

Remove the tachometer drive elbow or the cover from the timing gear case.

ENGINE ASSEMBLV I 3-5

Mounting Bolt

Counter bore

23. Air Compressor 1) Remove the four air compressor mounting bolts and disconnect the air compressor water pipe. 2) Remove the injection pump gear fixing nut located at the air compressor crankshaft front end fixing the gear and the air compressor. In this condition, the air compressor is still being mounted on the original place being sup ported by the gear adapter in the timing gear case.

Fixing nut

3) Use the remover to push out the air compres sor from the adapter. Remover : 1-85210-036-0

Note: In this removal, take care not to fall the air compressor drive shaft key into the timing gear inside.

4) Loosen the coupling lock bolt and remove the coupling from the compressor. Do not attempt to disengage the coupling by removing the coupling bolts.

23. Bearing Case (For Non-Air Compressor Engine)

Before the injection pump gear removal, the nut CD must be removed from the bearing case shaft ® as shown in the illustration. 1) Remove the nut CD and washers from the bear ing case shaft® front end. 2) Remove the bearing case bolts ® and drive out the shaft with the air compressor remover. Remover : 1-85210-036-0

35. Injection Nozzle Holder Use the injection nozzle holder remover to remove the inj ection nozzle holder. Remover : 9-8523-2001-0

OK468.

3-6 ENGINE ASSEMBLY I

DISASSEMBLY 2ND STEP

1-------2-----ï¿½,

3 _______,...,

Disassembly Steps A 1. 2. 3. Jo. 4. 5.

Rocker arm and shaft Valve bridge Push rod Cylinder head Cylinder head gasket

Jo. 6. Crankshaft pulley with damper Jo. 7. Flywheel 8. Oil pan 9. Timing gear case cover

ENGINE ASSEMBLY I 3-7

w B

Important Operations 1. Rocker Arm Shaft Loosen the rocker arm shaft fixing bolts a little at a time in numerical sequence as specified.

4. Cylinder Head Loosen the cylinder head bolts a little at a time in the numerical order shown in the illustration.

OK410

Crankshaft Pulley

6. Crankshaft Pulley with Damper 1) Block the flywheel with a piece of wood to preÂ vent it from turning. Use an appropriate wrench to remove the crankshaft pulley nut.

Wrench

2) Use the taper bushing remover to remove the crankshaft end taper bushing. Remover : 9-8521-0123-0

Taper bush"ing I remover j

Pulley

7. Flywheel Loosen the flywheel bolt a little at a time in the numerical order as specified.

3-8 ENGINE ASSEMBly I Use the flywheel remover to remove the flywheel. Flywheel remover : 1-85230-006-0

ENGINE ASSEMBLY I 3-9

l+-!i+I

DISASSEMBLV 3RD STEP

Disassembly Steps 1. Oil pump and pipe A 2. Idler gear A 3. Piston and connecting rod 4. Flywheel housing A 5. Wear ring A 6. Crankshaft bearing cap and thrust bearing (Lower halves) A 7. Thrust bearing (Upper halves)

8. 9. A 10. A 11. A 12. 13. 14.

Crankshaft assembly Crankshaft bearing upper halves Camshaft assembly Roller tappet No. 7 camshaft bearing Oiling jet Timing gear case

3-10 ENGINE ASSEMBLY I W Important Operations 2. Idler Gear Measure the following points before disassembly. mm(in) Standard 0.003 (0.0001

Idler Gear End Play

0.10 0.0004)

Limit 0.20 (0.008) mm(in)

Timing Gears Backlash

Standard

Limit

0.125 0.200 (0.0049 - 0.0078)

0.25 (0.0010)

Includes the crankshaft gear, the camshaft gear, and the idler gear.

Measure the crankshaft end play at the thrust bearÂ ing on the crankshaft front end before disassembly. mm(in) Crankshaft End Play

Standard

Limit

0.04 - 0.19 (0.0016 - 0.0075)

0.3 (0.0018)

OK3110

3. Piston and Connecting Rod

Note: Remove any carbon deposits from the upper part of the cylinder bore. This will prevent the piston and the piston rings from damage when they are removed from the cylinder bore.

5. Wear Ring Use the wear ring remover to remove the wear ring. Remover : 1-85210-027-0

01(31121

ENGINE ASSEMBLY I 3-11 6. Crankshaft Bearing Cap and Thrust Bearing (lower halves)

Loosen the bearing cap bolts a little at a time in the numerical order in the illustration.

OK055

7. Thrust Bearing (Upper halves)

Use a wire or a screw driver to remove the thrust bearing.

10. Camshaft Assembly 1) Fully loosen the roller tappet guide bolt but hold the bolt on the bolt hole. 2) Do not alllow the roller tappet to come in conÂ tact with the camshaft.

3) Remove the camshaft bearing set screw from the cylinder body. 4) Carefully pull the camshaft out from the cylinder body. Note:

The cam gear thrust plate is incorporated within the No. 1 camshaft bearing assembly.

11. Roller Tappet

After the camshaft has removed out, remove the tappet guide bolt and pull the tappet out toward the oil pan. 0

01<3127

3-12 ENGINE ASSEMBLY I

12. No. 7 Camshaft Bearing

Remove the No. 7 camshaft bearing from the cylinÂ der body after the camshaft removal.

ENGINE ASSEMBLY I 3-13

lâ&#x20AC;¢!-+I

CYLINDER HEAD DISASSEMBL V STEP

Disassembly Steps .A. 1. Split collar 2. Valve spring upper seat 3. Valve spring

A. 4. Intake and exhaust valve A. 5. Valve stem oil seal 6. Valve spring lower seat

Engine parts contact email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.Isuzu-6RB1.com www.HeavyEquipmentRestorationParts.com

3-14 ENGINE ASSEMBLY I Important Operations 1. Split Collar 1) Place the cylinder head on a flat wooden sur face. 2) Use the spring compressor to remove the split collar. Do not allow the valve to fall from the cylinder head. Spring Compressor : 9-8523-1436-0

�)!

/,v-o

/ r-

L_C./f-f

�

--------------1

Ii.

4. Intake and Exhaust Valve If the intake and exhaust valves are to be rein stalled, mark their installation positions by tagging each valve with the cylinder number from which it was removed. If there is excessive valve wear or damage, the valve must be replaced. Refer to Page 4 of "Inspection and Repair" for the valve and valve seat insert procedure.

Note: If there is excessive valve guide wear or damage, the valve guide must be replaced. Refer to Page 4 of "Inspection and Repair" for the valve guide replacement procedure. The valve and the valve guides must be replaced as a set. never replace only one or the other.

5. Valve Stem Oil Seal Use a pair of plier to remove the valve stem oil seal.

ENGINE ASSEMBLY I 3-15

PISTON AND CONNECTING ROD DISASSEIVIBLV STEP

·�f0 \):!1J

Disassembly Steps A 1. Piston ring A 2. Snap ring A 3. Piston pin

4. Piston 5. Connecting rod 6. Bearing

3-16 ENGINE ASSEMBLV I Important Operations 1. Piston Rings Use a piston ring remover to remove the piston rings. Do not attempt to use some other tool. Piston ring stretching will result in reduced piston ring tension. Piston ring replacer : 1-85221-025-0 2. Snap Ring Use a pair of snap ring pliers to remove the snap ring.

3. Piston Pin Use your thumb to push out the piston pin. Piston heating is unnecessary in this engine.

ENGINE ASSEMBLY I 3-17

l+i!•I

ROCKER ARM AND SHAFT DISASSEIVIBLV STEP

Disassembly Steps .A. 1. Piston ring A 2. Snap ring .A. 3. Piston pin

l·!·I

4. Spring 5. Shaft

CAMSHAFT AND GEAR DISASSEIVIBL V STEP

Disassembly Steps 1. Gear 2. No. 1 bearing

3. No. 2-6 bearing 4. Camshaft

3-18 ENGINE ASSEMBLY I

CRANKSHAFT DISASSEMBLV STEP

Disassembly Steps A 1. Gear 2. Thrust collar

3. Crankshaft

Important Operation 1. Gear Use a gear remover to remove the crankshaft gear. Remover

ENGINE ASSEMBLY II 4-1

SECTION 4

ENGINE ASSEMBLV II (INSPECTION & REPAIR) TABLE OF CONTENTS ITEM

PAGE

Cylinder head ...................................................................... 4- 2 Valve guide ........................................................................ 4- 3 Valve and valve seat insert ......................................................... 4- 4 Valve spring ...... ..... ... ................ ........... .. ........... ... .. ........... .

Tappet ............................................................................ 4- 9 Push rod .......................................................................... 4-10 Rocker arm shaft and rocker arm .................................................... 4-10 Idler gear and idler gear shaft ....................................................... 4-11 Camshaft .......................................................................... 4-12 Cylinder body and liner ............................................................. 4-13 Piston and piston ring .............................................................. 4-21 Piston pin ......................................................................... 4-22 Connecting rod .................................................................... 4-23 Crankshaft and bearings ............................................................ 4-25 flywheel and flywheel housing ....... ........ ........... .. .............. .. ...... .. 4-33 Timing gear case cover ........ ...... ..... ... ........ ... ........ .. ... ... ..... ... .. 4-34

4-2 ENGINE ASSEMBLY II

IL'i'I INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is dis covered during inspection.

CYLINDER HEAD Cylinder Head lower Face Warpage 1. Use a straight edge and a feeler gauge to measure the four sides and the two diagonals of the cylinder head lower face. 2. Regrind the cylinder head lower face if the mea sured values are greater than the specified limit but less than the maximum allowable grinding stock. If the warpage amount exceeds the maximum allowable grinding stock, the cylinder head must be replaced. Cylinder Head Lower Face Warpage mm(in) Maximum Allowable Standard Limit I Grinding Stock 0

(0. 00 �) ;r less •

0 ·2 ( 0. 008)

Cylinder Head Height (Reference) Standard 146.9 - 147.1 (5.783 - 5.791)

0.3 ( 0. 012)

mm(in)

Limit 146.6 (5.772)

Note:

If the cylinder head lower face is reground, valve depression must be checked. H

1 Water Jacket Water Pressure Test Use the hydraulic gauge to check the water jacket water pressure. Apply water pressure to the water jacket at 5 kg/cm2 (71.1 psi/49.1 kPa) for three minutes. Check the entire cylinder head for water leakage. OK763

ENGII\IE ASSEMBLY 11 4-3

VALVE GUIDE Valve Stem and Valve Guide Clearance Measuring Method - I 1. With the valve stem inserted in the valve guide, set the dial indicator needle to "O". 2. Move the valve head from side to side. Note the total dial indicator reading {TIR). OK083

This value is the clearance between the valve stem and the valve guide. If the measured values exceed the specified limit, the valve and the valve guide must be replaced as a set. Valve Stem Clearance Intake Side TIR â&#x20AC;˘

Exhaust Side TIR

mm(in) Standard

Limit

0.05 - 0.10 (0.020 - 0.004)

0.2 (0.008)

0.08 - 0.10 (0.003 - 0.004)

0.25 (0.010)

Measuring Method - II 1. Measure the valve stem outside diameter. Refer to "Valve Stem Outside Diameter". 2. Use a caliper calibrator or a telescoping gauge to measure the valve guide inside diameter.

Valve Guide Replacement Valve Guide Removal Use a hammer and the valve guide remover to drive out the valve guide from the cylinder head lower face. Valve Guide Replacer : 9-8523-1222-0

OK435

Valve Guide Installation 1. Apply engine oil to the valve guide outer circumferÂ ence. 2. Attach the valve guide replacer to the valve guide. 3. Use a hammer to drive the valve guide into position from the cylinder head upper face. Valve Guide Replacer : 9-8523-1222-0

4-4 ENGII\IE ASSEM BlY II

� + . · . � r

i.•1�1 , i i

! i

i I.i

r-· L

I . I

4. Measure the height of the valve guide upper end from the upper face of the cylinder head. Valve Guide Upper End Height (H) (Reference)

mm(in)

25.0 (0.984) 29.5 (1.161)

Inlet Valve Exhaust Valve Note:

If the valve guide has been removed, both the valve and the valve guide must be replaced as a set.

VALVE AI\ID VALVE SEAT INSERT Valve Stem Outside Diameter

Measure the valve stem diameter at three points. If the measured value is less than the specified limit, the valve and the valve guide must be replaced as a set. mm(in)

Valve Stem Outside Diameter Standard Intake valve Exhaust valve

10.92 (0.4302 10.90 (0.4294

10.94 0.4310) 10.92 0.4302)

Limit

10.85 (0.4275)

Valve Thickness Measure the valve thickness

If the measured value is less than the specified limit, the valve and the valve guide must be replaced as a set. Intake and Exhaust Valve Thickness Standard Intake Valve Exhaust Valve

3.3 (0.130) 2.0 (0.079)

mm(in) Limit

2.8 (0.110) 1.5 (0.059)

Engine parts contact email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.Isuzu-6RB1.com www.HeavyEquipmentRestorationParts.com

ENGINE ASSEMBLV II 4-5 Valve Depression or Projection 1. Install the valve to the cylinder head. 2. Use a depth gauge or a straight edge with steel rule to measure the valve depression from the cylinder head lower surface.

Depression OKOSO

Projection OK419

If the measured value exceeds the specified limit, the valve seat insert and/or valve must be replaced, the valve guide must be also replaced. For Piston Type A Projection Depression

mm(in)

Valve

Standard

Limit

Intake

0.5 (0.020)

-1.5 (0.06) *(Depression)

Exhaust

1.0 (0.040)

3.0 (0.12)

* The projection will be a valve depression when the mating valve seat comes to wear off. For Piston Type B

mm(in)

Valve

Standard

Depression i Intake

1.8 (0.071)

Depression I Exhaust

1.6 (0.063)

I I

Limit 3.8 (0.150) 3.6 (0.142)

Refer the description in page 4-19 on the Piston Type A and 8.

Valve Contact Width 1. Inspect the valve contact faces for roughness and unevenness. Make smooth the valve contact surfaces. 2. Measure the valve contact width. Contact width

If the measured value exceeds the specified limit, the valve seat insert must be replaced. Valve

OKOSO

Valve Contact Width

Intake Exhaust i

Standard

mm(in) Limit

1.9 (0.075)

3.4 (0.134)

2.0 (0.079)

4.3 (0.169)

4-6 ENGINE ASSEMBLY II Valve Seat Insert Replacement Valve Seat Insert Removal

1. Arc weld the entire inside circumference CD of the valve seat insert®· 2. Allow the valve seat insert to cool for a few minutes. This will invite contraction and make removal of the valve seat insert easier. 3. Use a screwdriver ® to pry the valve seat insert free. Take care not to damage the cylinder head ©. 4. Carefully remove carbon and other foreign material from the cylinder head insert bore.

Valve Seat Insert Installation

1. Carefully place the attachment CD (having a smaller outside diameter than the valve seat insert) on the valve seat insert®· Note:

The smooth side of the attachment must contact the valve seat insert. 2. Use a bench press ® to gradually apply pressure to the attachment and press the valve seat insert into place. Note:

Press pressure required is 2,500 kg (5,512 lbs.). Do not apply an excessive amount of pressure with the bench press. Damage to the valve seat insert will result.

ENGINE ASSEMBLY II 4-7 Valve Seat Insert Correction 1. Remove the carbon from the valve seat insert sur face. °

2. Use a valve cutter (15 , 45 , and 75 blades) to mini mize scratches and other rough areas. This will bring the contact width back to the standard value. Remove only the scratches and rough areas. Do not cut away too much. Take care not to cut away unblemished areas of the valve seat surface. Valve Seat Angle

Note: Use an adjustable valve cutter pilot. Do not allow the valve cutter pilot to wobble inside the valve guide.

Angle Location

Standard

Intake Valve Seat Angle ®

30°

Exhaust Valve Seat Angle ®

45•

Note: Use an adjustable valve cutter pilot. Do not allow the cutter pilot to wobble inside the valve guide. 3. Apply abrasive compound to the valve seat insert surface. 4. Insert the valve into the valve guide. 5. Hand lap the valve and the valve seat with a lapp ing cup. This will provide optimum valve and valve seat con tact for effective gas sealing. 6. Check that the valve contact width is correct. OK081

7. Check that the valve seat insert surface is in contact with the entire circumference of the valve.

4-8 ENGINE ASSEMBLV II

VALVE SPRING Valve Spring Free length

Use a vernier caliper to measure the valve spring free length.

If the measured value is less than the specified limit, the valve spring must be replaced.

Valve Spring Free Length

Mating Piston Type A

mm(in)

Limit

Standard

66.4 (2.62)

62.0 (2.44)

73.6 (2.90)

69.0 (2.72)

66.4 (2.62)

Intake Valve Spring,

E = Exhaust Valve Spring

Refer to the description in page 4-19 on the Piston Type A and B.

Valve Spring Squareness

Squareness

Use a surface plate and a square to measure the valve spring squareness. If the measured value exceeds the specified limit, the valve spring must be replaced.

OK086

Valve Spring Squareness

Mating I Piston Type

Standard

1.50 (0.06)

Intake Valve Spring, I

2.0 (0.08) E

mm(in)

Limit

2.5 (0.10)

2.5 (0.10) 3.0 (0.12)

Exhaust Valve Spring

Refer to the description in page 4-19 on the Piston Type A and B.

ENGINE ASSEMBlV 11 4-9 Valve Spring Tension

Use a spring tester to measure the valve spring tension.

If the measured value is less than the specified limit, the valve spring must be replaced.

0K0£7

Spring Tension

Mating Piston Type B

A !

kg(lb)

H mm(in) • Standard I 53.1 (2.1)

53.1 (2.1)

Limit

39.o (86.o) 30.9 (68.1) I

39.0 (86.0) • 30.9 (68.1)

E I 58.1 (2.3) • 39.o (86.o) i 30.9 (68.1) I = Intake Valve Spring, E Exhaust Valve Spring

"H" refers to the spring compressed height.

Refer to the description in 4-19 on the Piston Type A and B.

Valve Bridge

Clearance between the valve bridge and valve bridge guide. Limit

Standard

0.02 -0.047 0.0019) (0.0008

mm(in)

0.10 (0.004)

TAPPET (Cam Follower or Valve litter)

Inspect the tappets for excessive wear, damage and any abnormalities.

Use a micrometer to measure the tappet diameter.

�

Tappet Diameter

0K769

Roller Height

Standard

29.94 - 29.97 (1.180 - 1.181) Standard

2.5 (0.099)

mm(in) Limit

29.9 (1,178)

mm(in) Limit

1.5 (0.059)

4-10 ENGINE ASSEMBLY II Use a dial indicator to measure the clearance between the tappet and cylinder body tappet travelling bore. mm(in) Limit Standard Tappet and Tappet 0.03 - 0.09 0.15 Travelling Bore (0.0012 - 0.0035) (0.0059) Clearance OK097

PUSH ROD Use a filler gauge to measure the valve push rod run out Roll the push rod along a smooth flat surface as illus trated. mm(in) Limit

Push Rod Run-Out

0.5 (0.02)

ROCKER ARM SHAFT AND ROCKER ARM Inspect all disassembled parts for wear, damage and any abnormalities.

Rocker Arm Shaft Outside Diameter

Use a micrometer to measure the rocker arm outside diameter. If the measured value is less than the specified limit, the shaft must be replaced. mm(in) Limit Standard 30.00 29.85 Rocker Arm Shaft 29.98 (1.176) Diameter (1.181 1.182) Rocker Arm Correction

Inspect the rocker arm valve stem contact surfaces for ridge (D and scoring ®· If the surfaces have light ridge or scoring, they may be honed with an oil stone. If the ridge or scoring is severe, the rocker arm must be replaced.

EI\JGINE ASSEMBLV II 4-11 Rocker Arm Shaft and Rocker Arm Clearance 1. Use a vernier caliper to measure the rocker arm bushing inside diameter.

: ' ::1 11

Standard Rocker Arm Bushing Inside Diameter

30.03 - 30.08 (1.182 1.185)

mm(in) Limit 30.10 (1.185)

2. Measure the rocker arm shaft outside diameter. Replace either the rocker arm or the rocker arm shaft if the clearance exceeds the specified limit.

mm(in) Rocker Arm Bushing and Rocker Arm Shaft Clearance

Standard

Limit

0.03 0.10 (0.012 - 0.004)

0.2 (0.008)

3. Check that the rocker arm oil port is free of obstrucÂ tions. If necessary, use compressed air to clean the rocker arm oil port

IDLER GEAR AND IDLER GEAR SHAFT 1. Use a micrometer to measure the idler gear shaft diameter. If measured diameter exceeds replace the idler gear shaft.

specified

Standard Idler Gear Shaft Diameter

75.93 - 75.96 (2.992 - 2.993)

limit,

mm{in) Limit

75.85 (2.998)

2. Use a dial indicator to measure the idler gear inside diameter. mm(in) Standard 1

Idler Gear and Idler I Gear Shaft Clearance

0.04 (0.0016

0.10 0.004)

Limit

0.2 (0.008)

4-12 ENGINE ASSEMBLY II

-4 '

��

CAMSHAFT

Inspect all disassembled parts for wear, damage or other abnormal conditions.

�

�. ®�' �J ��

��'

No. 1 Camshaft Bearing

OK063

Cam lobe Height and Camshaft Diameter

Use a micrometer to measure the cam lobe height and camshaft diameter. If the cam lobe height is less than the specified limit, the camshaft must be replaced. Cam Lobe Height {C-D)

Standard

7.53 {2.96)

mm(in)

Limit

7.03 {2.77)

Camshaft Diameter

No. 1 Journal No. 2-7 Journal

mm{in)

Standard

55.94 - 55.97 {2.204 - 2.205) 43.95 - 43.98 {1.732 - 1.733)

i :

Limit

55.91 {2.203)

43.92 {1.730)

Camshaft End Play

1. Before removing the camshaft gear CD, push the thrust plate ® as far as it will go toward the cam shaft@.

2. Use a feeler gauge to measure the clearance between the thrust plate and the camshaft gear. If the measured value exceeds the specified limit, the thrust plate must be replaced.

Camshaft End Play Standard

0.06 (0.002)

Limit

0.2 (0.008)

mm{in)

ENGINE ASSEMBLY II 4-13 7-@ a

1--...,, . ! i l j I

Thrust Plate Replacement Thrust Plate Removal 1. Use the universal puller G) to remove the camshaft gear@. Universal Puller : 5-8840-0086-0

� G)

2. Remove the thrust plate (No. 1 camshaft bearing) ®·

IJ E]

Thrust Plate Installation 1. Install the I\Jo. 1 camshaft bearing (combined with a camshaft gear thrust plate) to the front most cam shaft journal.

2. Apply engine oil to the bolt setting face and the bolt threads.

�

3. Install the camshaft gear. Camshaft Gear Torque

kg-m(lb.ft/N-m)

15.o ± 1.5 (108.5 ± 10.81147.2 ± 14.7)

CYLINDER BODY AND Ul\!ER Note: The cylinder liner of the 6RB1 and 6RB1T engines have two cylinder liner types depending on the engines. The types are: A.

Press Fit Type adopted on the engine serial number 501436 and the earlier ones. In these engines, the cylinder liner must be installed in a press-in method.

Loose Fit Type adopted on the engine serial number 501437 and the later ones. In these engines, the cylinder liner may be installed in a manually inserting.

Cylinder liner Bore Measurement

Use a cylinder indicator to measure the cylinder liner bore at measuring point CD in the lateral X-X and axial Y-Y directions of the crankshaft. Measuring Point : CD; 25 mm(1.0 in),@; 130 mm(5.1 in), ®; 230 mm(9.1 in)

4-14 ENGINE ASSEMBLY II mm(in)

Cylinder Liner Bore Diameter Nominal

Limit

135.0 (5.319)

136.5 (5.378)

Note: If the cylinder liner bore is scored or scorched, the cylin足 der liner must be replaced. If the measured value exceeds the specified limit, the cylinder liner must be replaced. Cylinder liner Projection Inspection 1. Hold a straight edge G) along the top edge of the cylinder liner to be measured. Or, use a dial indicator to measure the cylinder liner projection. 2. Use a feeler gauge 速 to measure each cylinder liner projection. Cylinder Liner Projection

mm(in)

Standard 0.05 - 0.10 (0.002 - 0.0039)

The difference in the cylinder liner projection height between any two adjacent cylinders must not exceed 0.02 mm (0.0008 in).

Cylinder Liner Replacement Cylinder liner Removal 1. Set the cylinder liner remover to the cylinder liner. 2. Check that the remover shaft ankle is firmly gripp足 ing the cylinder liner bottom edge. 3. Slowly turn the remover shaft handle counterclock足 wise to pull the cylinder liner free. Cylinder Liner Remover: 9-8523-1186-0 Note: Take care not to damage the cylinder body upper face during the cylinder liner removal procedure.

ENGINE ASSEMBLY II 4-15 Cylinder liner Grade Selection The term "grade" refers to the cylinder body inside diameter and the cylinder liner outside diameter combi nation. Measure the cylinder body bore diameter and select the appropriate cylinder liner grade.

Cylinder Body Bore Measurement Wy � X

-+----H

Y I

1. Take measurements at measuring point CD across the positions W-W, X-X, Y-Y, and Z-Z. Measuring Point CD: 130 mm (5.118 in) 2. Calculate the average value of the four measure ments to determine the correct cylinder liner grade.

�xi"-

Cylinder liner Outside Diameter Measurement 1. Take measurements at measuring points CD, @, and @. Measuring Points mm(in): CD 20 (0.984) @ 130 (5.118) @ 230 (9.055) 2. Calculate the average value of the 6 measurements to determine the correct cylinder liner grade. Press Fit Type mm(in) 0.006 - 0.046 (0.0002 - 0.0018)

Cylinder Liner Fitting Clearance (Interference) Standard

Cylinder Bore and Cylinder liner Outside Diameter Combinations mm(in)

(Reference) Grade

Cylinder Bore

141.000 - 141.020 (5.5512 - 5.5520)

141.021 (5.5520

141.040 5.5528)

Cylinder Liner Outside Diameter 141.026 (5.5522

141.046 5.5530)

141.066 141.047 (5.5530 - 5.5538)

Engine parts contact email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.Isuzu-6RB1.com www.HeavyEquipmentRestorationParts.com

4-16 ENGINE ASSEMBLY II Loose Fit Type mm(in) 0.016 (0.0006

Cylinder Liner Clearance Standard

0.045 0.0018)

Cylinder Bore and Cylinder Liner Outside Diameter Combinations mm(in)

(Reference) Grade

Cylinder Bore

Cylinder Liner Outside Diameter

141.000-141.015 5.5518) (5.5512

140.970 - 140.984 (5.5500 -5.5506)

141.016-141.030 (5.5518 -5.5524)

140.985 -141.000 (5.5506 5.5512)

Cylinder Liner Installation 1. Carefully wipe away any foreign material from the cylinder liner inside and outside surfaces and the cylinder bore. 2. Use new kerosene or diesel oil to thoroughly clean the cylinder liner and bore surfaces. 3. Use a clean rag to remove all traces of kerosene or diesel oil from the cylinder liner and bore surfaces.

Installation Steps for Press Fit Type Cylinder Liner 4. Insert the cylinder liner into the cylinder body from the top of the cylinder. No specific installation direction required. 5. Set the cylinder liner installer to the top of the cylinÂ der liner. Cylinder Liner Installer : 9-8522-0043-0 6. Check that the cylinder liner is set perpendicular to the cylinder. Check that the cylinder liner does notwobble. 7. Use a bench press to press in the cylinder liner into the cylinder body. 8. After installing the cylinder liners, measure the cylinder liner projection. Refer to "Cylinder Liner Projection Inspection".

ENGINE ASSEMBLY II 4-17 Installation Steps for Loose Fit Type Cylinder Liner Insert the cylinder liner into the cylinder body. As this liner is of a loose fit type, the liner may be inserted smoothly without exerting any forcing power. There is no specific liner installation direction.

Piston Grade Selection for Press Fit Type Cylinder Liner The term "piston grade" refers to the piston diameter and cylinder liner bore combination. Selection of the proper piston grade will ensure efficient engine operation, free from cylinder liner and piston problems. Measure the cylinder liner bore after installing the cylin der liner. Then select the appropriate piston grade for the installed cylinder liner. Cylinder Liner Bore Measurement

1. Locate the two measuring points. Cylinder Liner Measuring Point CD: 25 mm (0.984 in) Cylinder Liner Measuring Point@: 130 mm (5.122 in) 2. Measure the cylinder liner bore at measuring point CD and @ in four different directions (W-W, X-X, Y-Y, and Z-Z). 3. Calculate the average value of the eight measure ments. mm(in) 134.970 135.069 Cylinder Liner Bore Total (5.3138 5.3177) Indicator Reading Note:

It is most important that the correct piston grade be used. Failure to select the correct piston grade will result in piston seizure. Always measure the cylinder bore and select the appro priate piston grade.

4-18 ENGINE ASSEMBLY 11 Piston Outside Diameter

Measure the piston outside diameter at the measuring position L shown in the illustration. Piston Grade Grade K

I 134.763 (5.3056

Measuring Position L

134.747 134.766 (5.3050 - 5.3058)

134.803 - 134.822 (5.3072 - 5.3080)

134.787 - 134.806 (5.3066 5.3073)

71.15 (2.80)

[ 134.823 134.842 (5.3080 - 5.3088) i

6RB1T

134.782 5.3064)

134.783 - 134.802 (5.3064 - 5.3072)

6RB1

134. 767 - 134. 786 (5.3058 - 5.3066)

134.826 134.807 (5.3073 - 5.3081)

Cylinder liner Bore and Piston Clearance 6RB1

Cylinder Liner 0.208 Bore and (0.0082 Piston Clearance

Note:

mm(in)

6RB1T

0.227 0.224 - 0.243 0.0089) I (0.0088 - 0.0096)

Cylinder liner piston kit clearances are preset. HowÂ ever, the cylinder liner installation procedure may result in slight decreases in cylinder liner bore clearances. Always measure the cylinder liner bore clearance after installation to be sure that it is correct.

ENGINE ASSEMBLY II 4-19 Piston Grade Selection for Loose Fit Type Cylinder Liner

Cylinder Liner Bore Measurement 1. Locate the two measuring points. Cylinder Liner Measuring Point CD: 25 mm (0.984 in) Cylinder Liner Measuring Point®: 130 mm (5.122 in) 2. Measure the cylinder liner bore at measuring point CD and ® in four different directions (W-W, X-X, Y-Y, and Z-Z). 3. Calculate the average value of the eight measure ments. Cylinder Liner Bore Total Indicator Reading

mm(in) 134.990 - 135.059 (5.3146 - 5.3173)

Note: It is most important that the correct piston grade be used. Failure to select the correct piston grade will result in piston seizure. Always measure the cylinder bore and select the appro priate piston grade. Note: In the 6RB1 and 6RB1T engines later than the serial number 501437, a two types of pistons might be used depending on the engines.

The piston types are:

Piston Type A

Type 8

The type having a square shape combustion cham ber at the piston crown.

The type having a round shape combustion chamber at the same place.

In the cylinder liner and piston grade selection, they have a different grade dimensions, therefore, take care not to confuse the respective grade dimensions. For the brebity of the description, the respective piston type is called hereinafter Piston Type A for the item A and, Piston Type B for the item B.

4-20 ENGINE ASSEMBLY II Piston Outside Diameter

Measure the piston outside diameter at the measuring position L shown in the illustration. Piston Grade

Piston Type A

6RB1T

134.783-134.795 134.767-134.779 134.777-134.789 (5.3064-5.3069) (5.3058-5.3063) (5.3062-5.3067)

Piston Type B

6RB1T

6RB1

mm(in)

134.796-134.808 134.780-134.792 134.790-134.802 (5.3069-5.3074) (5.3063-5.3068) (5.3067-5.3072)

• 134.809-134.821 134.793-134.805 134.803-134.815 (5.3074-5.3079) (5.3068-5.3073) I (5.3072-5.3077)

Measuring Position L I

71 .15 (2.80)

•

Cylinder Liner Bore and Piston Clearance Cylinder Liner Bore and Piston Clearance 6RB1

Piston Type A

0.206-0.230 (0.0081-0.0091) Note:

I I

6RB1T

66.15 (2.60)

mm(in)

Piston Type B 6RB1T

0.212-0.236 0.222-0.246 I (0.0081-0.0091) I (0.0083-0.0093)

Cylinder liner piston kit clearances are preset. How ever, the cylinder liner installation procedure may result in slight decreases in cylinder liner bore clearances. Always measure the cylinder liner bore clearances after installation to be sure that it is correct.

ENGINE ASSEM BlY II 4-21

PISTON AND PISTON RING Piston Ring and Piston Ring Groove Clearance Use a feeler gauge to measure the clearance between the piston ring and the piston ring groove. Do this at several points around the piston. If the clearance between the piston ring and the piston ring groove exceeds the specified limit, the piston ring must be replaced. Piston Ring and Piston Groove Clearance Standard 0.10 0.13 • 1st compression ring (0.0039 0.0051) 0.05 -0.08 2nd compression ring (0.0020 -0.0032) . 0.02 -0.06 Oil ring I (o.ooos 0.0024)

mm(in) Limit I 0.20 (0.0079) 0.15 (0.0059) 0.15 (0.0059)

Piston Ring Gap 1. Insert the piston ring horizontally (in the position it would assume if it were installed to the piston) into the cylinder liner. 2. Use an inverted piston to push the piston ring into the cylinder liner until it reaches· either measuring point CD or measuring point ®· Cylinder liner diameter is the smallest at these two points. Do not allow the piston ring to slant to one side or the other. It must be perfectly horizontal. Cylinder Liner Measuring Point CD: 10 mm (0.39 in) Cylinder Liner Measuring Point®: 130 mm (5.12 in) 3. Use a feeler gauge to measure the piston ring gap. If the measured value exceeds the specified limit, the piston ring must be replaced. mm(in) Standard Limit 1.5 1st Compression 0.3 -0.5 (0.059) (0.012 -0.020) Ring Gap 0.45 0.65 1.5 2nd Compression (0.059) Ring Gap (0.018 0.026) 1.5 0.35 0.55 Oil ring Gap (0.014 0.022) I (0.059) i

Engine parts contact email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.Isuzu-6RB1.com www.HeavyEquipmentRestorationParts.com

4-22 ENGINE ASSEMBLY II

PISTON PIN Piston Pin Diameter Use a micrometer to measure the piston pin outside diameter at several points. If the measured piston pin outside diameter exceeds the specified limit, the piston pin must be replaced. The "Combination" refers to the piston combustion chamber type and the relative parts combination. See the page 4-19. mm(in) Mating Limit Standard Piston Type •

Piston Pin Diameter

A B

50.0 (1.970) 52.0 (2.049)

49.97 (1.969) 51.97 (2.04s)

Refer to the description in the page 4-19 on the Piston Type A and B.

Piston Pin and Pin Hole Clearance Determine the clearance between the piston pin and the piston pin hole by calculating the difference between the piston pin hole diameter and the piston pin diame ter. mm(in) Limit Standard 0.05 0.007 - 0.020 Piston Pin and Piston (0.0003 - 0.0008) (0.002) Pin Hole Clearance Piston Pin Fitness Lubricated piston pin should fit snugly into the piston or connecting rod small end at normal workshop tempera ture when a finger pressure is exerted.

0K076

0K768

ENGII\IE ASSEMBLY II 4-23

CONNECTING ROD Connecting Rod Alignment

Use a connecting rod aligner to measure the parallelism between the connecting rod big end hole and the conÂ necting rod small end hole. If either the measured parallelism exceeds the specified limit, the connecting rod must be replaced. Connecting Rod Alignment (Per Length of 100 mm (3.94 in)) mm(in) Standard Limit I I Less than 0.10 Parallelism 0.05 (0.002) (0.004) Less than 0.15 Twist 0.05 (0.002) (0.006) i I

Piston Pin and Connecting Rod Small End Bushing Clearance

Use a caliper calibrator and a micrometer to measure the piston pin and connecting rod small end bushing clearance. If the clearance between the piston pin and the connectÂ ing rod small end bushing exceeds the specified limit, replace either the piston pin or the connecting rod bushing. mm(in) I Standard ! Limit I I Piston Pin and Connec-1 0.020 - 0.037 0.10 ting Rod Small End (0.004) (0.0008 - 0.0015) Bushing Clearance I

Connecting Rod Bushing Replacement Connecting Rod Bushing Removal

1. Clamp the connecting rod in a vise. 2. Use the remover and a bench press or hammer to remove the connecting rod bushing. Remover : 9-8522-0042-0

4-24 ENGINE ASSEMBLY II Connecting Rod Bushing Installation

Use the connecting rod bushing installer to install the connecting rod bushing. Connecting Rod Bushing Installer : 9-8522-0042-0

Note:

The Connecting rod bushing oil port must be aligned with the connecting rod oil port. Use a piston pin hole grinder CD fitted with a reamer @ or an adjustable pilot reamer to ream the piston pin hole. I

•

Connecting Rod Bushing Inside Diameter

Mating Piston Type

;

mm(in)

A B

Standard

50.020 - 50.032 (1.9708 - 1.9713)

52.020 - 52.032 i (2.0496 - 2.0501)

Refer to the description in the page 4-19 on the Piston Type A and B. Connecting Rod Bearing Inspection

1. Inspect the connecting rod bearing for excessive wear and damage.

2. Fit the connecting rod bearing lower half into the connecting rod bearing cap. 3. Check the connecting rod bearing lower half ten sion.

If the tension is insufficient, the bearing must be replaced.

4. Tighten the connecting rod and the bearing cap to the specified torque.

Connecting Rod and Bearing Cap Bolt Tightening Torque

1st Step

kg-m(lb.ft/N-m)

7 (50.6/68.6)

2nd Step

10 ± 0.5 (72.3 ± 3.6/ 98.1 ± 4.9)

5. Use an inside dial indicator to measure the connect ing rod inside diameter. Connecting Rod Bearing Nominal Diameter

mm(in)

89.96 - 90.00 (3.5444 - 3.5460)

ENGINE ASSEMBLY II 4-25

CRANKSHAFT AND BEARINGS •

The 6RB1 (naturally aspirated) engine has a normal type crankshaft but, the 6RB1T (turbocharged) engine has the Tafftride Type crankshaft. The two type of engines have different crankshaft repair method respectively.

•

The 6RB1 engine's crankshaft can be repaired by regrinding and the use of undersize main bearings and the connecting rod bearings.

•

However, the 6RB1T engine's crankshaft (Tafftride type) cannot be repaired by the above method. The tafftride type crankshaft must be replaced with a new one when it has excessively worn than the specified wear limit.

Summarization of the Basic Dimension Measurement Steps B

Main Bearing Inside Diameter A Crankshaft Journal Diameter B Crankshaft Journal-to-Main Bearing Clearance

A-8

To obtain C, A and B is measured. Also measure the crankpin-to-connecting rod bearing clearance (C') in similar way. The clearances C or C' are a base to determine a way of repair. Further the descriptions cover the way of repair as sum marized below. 1) Replace the bearings with of standard sized ones when the crankshaft journal wear amount and/or crankpin wear amount is within an allowable extent but the bearing wear amount is close to the speci fied limit. 2) Regrind the crankshaft journal surfaces and/or crankpin surfaces and, replace the bearings with of undersized ones when the crankshaft journal wear and crankpin wear are exceeding the specified limit. Crankshaft and Bearings Inspection 1. Inspect the crankshaft journal surfaces and the crankpin surfaces for excessive wear and damage. 2. Inspect the oil seal fitting surfaces of the crankshaft front and rear ends for excessive wear and damage. 3. Replace or repair the crankshaft if any excessive wear or damage is discovered. 4. Inspect the crankshaft oil ports for obstructions. 5. Use high pressure air to clean the oil ports if neces sary.

4-26 ENGINE ASSEMBLY II Crankshaft Journal and Crankpin Outside Diameter Measurement 1. Use a micrometer to measure the crankshaft journal diameter across points CD - CD and ® - ®· 2. Use the micrometer to measure the crankshaft jour nal diameter at the two points (® and ©). 3. Repeat steps 1 and 2 to measure the crankpin out side diameter. mm(in) Standard Crankshaft Journal 99.880 - 99.905 (3.9353 3.9363) Diameter mm(in) Standard 89.895 - 89.925 (3.5419 - 3.5430)

Crankpin Diameter ;

Crankshaft Journal Main Bearing and Connecting Rod Bearing Clearances If the bearing clearance exceeds the specified limit, the crankshaft must be reground (except 6RB1T engine) and/or the bearing must be replaced. mm(in) Standard i Position at! I Limit Crankshaft Journal All and Main Bearing Bearings Clearance

Crankpin and Connecting Rod Bearing Clearance

0.045-0.120 0.14 (0.0018-0.005) (0.006) j

Standard 0.035-0.105 (0.0014-0.0041)

mm(in) Limit 0.13 (0.005)

•

Engine parts contact email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.Isuzu-6RB1.com www.HeavyEquipmentRestorationParts.com

ENGINE ASSEMBLY 11 4-27 Crankshaft Journal Bearing Inside Diameter Measure ment 1. Install the main bearing cap with bearings to the cylinder body with the specified torque and facing the arrow mark on the bearing cap toward front, and place them in order of punched cylinder num bers. kg-m(lb.ft/N.m) Crankshaft Main Bearing Cap Bolt Torque

(282.0

39.0 ± 3.0 ± 21.6/382.6 ± 29.4)

2. Use an inside dial indicator to measure the main bearing diameters. mm(in) Main Bearing Nominal Diameter

100 (3,937)

Connecting Rod Bearing Inside Diameter Measure ment 1. Lubricate the connecting rod bearing cap nut setting face and the bolt threads with a coat of engine oil. 2. Tighten the connecting rod bearing cap nuts to the specified torque in two steps with working up a little at a time in the numerical order as illustrated.

OK446

1st Step Connecting Rod Bearing Nut Torque

7 (50.6/68.6)

kg-m(lb.ft/N-m) 2nd Step 10.0 ± 0.5 (72.3 ± 3.6/ 98.1 ± 4.9)

3. Use an inside dial indicator to measure the connect ing rod bearing inside diameter. kg-m(lb.ft/N-m) Connecting Rod Bearing Nominal Diameter

90 (3.546)

4-28 ENGINE ASSEMBLY II Crankshaft Run-Out 1. Mount the crankshaft on a set of V-blocks. 2. Set a dial indicator to the center of the crankshaft journal. 3. Gently turn the crankshaft in the normal direction of engine rotation. Read the dial indicator (TIR) as you turn the crankÂ shaft. If the measured value exceeds the specified limit, the crankshaft must be replaced. mm(in) Crankshaft Run-Out

Standard

Limit

0.05 (0.020)

0.30 (0.012)

If the crankshaft generated a crack after repair, replace the crankshaft. Crankshaft for 6RB1T engine can not be bench pressed, because it is finished with tufftride method.

Main Bearing and Connecting Rod Bearing Tension Check to see if the bearing has enough tension, so that good finger pressure is needed to fit the bearing into position.

Crankshaft Regrinding To ensure crankshaft reliability, pay close attention to the following items during and after the crankshaft grinding procedure. mm(in) Undersize Bearing Availability

0.25 (0.010)

0.50 (0.020)

Note: Crankshaft for 6RB1T can not be reground because it is finished with TUFFTRIDE method. Therefore, the undersize bearings are not prepared for this model engines.

ENGINE ASSEMBLY 11 4-29 Crankshaft Regrinding Procedure 1. Regrind the crankshaft journals and the crankpins. 2. Fillet the crankshaft journal and the crankpin sur faces fillet position respectively shown in the illustration to the following measurement. mm(in) Position

No. 1 Journal

® @ ©

I I

Specified Radius

± 0.2 (0.204 ± 0.008) 5.8 ± 0.3 (0.229 ± 0.012) 4.8 ± 0.3 (0.189 ± 0.012) 5.2

The fillet curve surfaces and the journal surfaces must be blended smoothly keeping free of ridge or step condition at the blending zone.

3. Finish the crankshaft journal and crankpin oil port corners to a smooth surface having a chamfer radius of 1 mm (0.04 in). Crankshaft Journal and Crankpin Surface Roughness

0.4 µ or less

4. Measure the crankshaft journal and crankpin clear ance. Refer to "Crankshaft Journal Clearance" and "Crank pin and Clearance" on Page 4-26. 5. Measure the crankshaft run-out. Refer to "Crankshaft Run-Out" on Page 4-28.

4-30 ENGINE ASSEMBLV 11 Crankshaft Grinding limit

mm(in) Limit 99.38 (3.916)

Crank Journal Diameter Crankpin Diameter

Isuzu 6RB1 6RB1T Engine Parts contact: Email: engineparts2@gmail.com Phone: 269 673 1638 Website: www.Isuzu-6RB1.com

89.40 (3.522)

Undersize bearings 0.25 mm (0.010 in) and 0.50 mm (0.020 in) are available to compensate for excessive clearance between the crankshaft journal bearing and the crankshaft. Regrinding of the crankshaft to fit the undersize bearings is required. mm(in) Limit Position at I Standard Crankshaft Journal All and Main Bearing Bearings Clearance

0.045-0.120 (0.002-0.005) I

•

0.14 (0.005)

Undersize bearings 0.25 mm (0.010 in) and 0.50 mm (0.020 in) are available to compensate for excessive clearance between the crankpin bearing and the crank shaft. Regrinding of the crankshaft to fit the undersize bearings is required. mm(in) Limit Standard Crankpin and Connecting Rod Bearing Clearance

0.035-0.105 (0.0014-0.041)

0.13 (0.0051)

Plastigage Clearance Measurements

This is another method to measure the crank journal bearing clearance. Crankshaft Journal Bearing Clearance

1. Clean the cylinder body, the journal bearing fitting portions, the bearing cap, and the inside and out side surfaces of the bearing. 2. Install the new journal bearing to the cylinder body. 3. Carefully place the crankshaft on the bearing. 4. Rotate the crankshaft approximately 30° to seat the bearing. 5. Place the Plastigage (arrow) over the crankshaft journal across the full width of the bearing. Apply engine oil to the Plastigage to keep it from falling. 6. Install the bearing cap with the bearing. 7. Tighten the bearing cap to the specified torque. Do not allow the crankshaft to turn during bearing cap installation and tightening.

ENGINE ASSEMBLY II 4-31 8. Remove the bearing cap. 9. Compare the width of the plastigage attached to either the crankshaft or the bearing against the scale printed on the plastigage container. If the measured value exceeds the limit, perform the following additional steps. 1) Use a micrometer to measure the crankshaft outside diameter. 2) Use an inside dial indicator to measure the bearing inside diameter. 3) Replace the crankshaft and/or the bearing if the measured value(s) exceed the limit.

Engine parts contact email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.Isuzu-6RB1.com www.HeavyEquipmentRestorationParts.com

Crankshaft Pin Bearing Clearance 1. Clean the crankshaft, the connecting rod, the bearÂ ing cap, and the bearings. 2. Install the bearing to the connecting rod. Do not allow the crankshaft to move when installing the bearing cap. 3. Hold the connecting rod (with the bearing installed) against the crankshaft pin. 4. Attach the plastigage to the crankshaft pin. Apply engine oil to the plastigage to keep it from falling. 5. Install the connecting rod bearing cap and tighten it to the specified torque. Do not allow the connecting rod to move when installing and tightening the bearing cap. 6. Remove the bearing cap. 7. Compare the width of the plastigage attached to either the crankshaft or the bearing against the scale printed on the plastigage container. If the measured value exceeds the limit, perform the following additional steps. 1) Use a micrometer to measure the crankshaft outside diameter. 2) Use an inside dial indicator to measure the bearing inside diameter. 3) Replace the crankshaft and/or the bearing if the measured value(s) exceed the limit.

4-32 ENGII\IE ASSEMBLY II Crankshaft Tufftriding Inspection (For 6RB1T only) Ammoniun cuprous chloride Face in contact : with crank pin--..___ or journal

Test liquid should not be applied to area around oil port

1. Use an organic cleaner to thoroughly clean the crankshaft. There must be no traces of oil on the surfaces to be inspected. 2. Prepare a 5 - 10% solution of ammonium cuprous chloride (dissolved in distilled water). 3. Use a syringe to apply the solution to the surface to be inspected. Hold the surface to be inspected perfectly horizontal to prevent the solution from running. Note:

Do not allow the solution to come in contact with the oil ports and their surrounding area. Judgement

1. Wait for thirty to forty seconds. If there is no discoloration after thirty or forty sec onds, the crankshaft is useable. If dicsoloration appears (the surface being tested will become the color of copper), the crankshaft must be replaced. 2. Steam clean the crankshaft surface immediately after completing the test. Note:

The ammonium cuprous chloride solution is highly cor rosive. Because of this, it is imperative that the surfaces being tested be cleaned immediately after completing the test.

Crankshaft Timing Gear Replacement Crankshaft Timing Gear Removal

1. Use the crankshaft gear remover CD to remove the crankshaft gear®· 2. Remove the crankshaft feather key. Crankshaft Timing Gear Remover.

Crankshaft Timing Gear Installation

1. Install the crankshaft gear. 2. Use the crankshaft gear installer CD to install the crankshaft gear®· The crankshaft gear timing mark ("X-X") must be facing outward. Crankshaft Gear Installer : 9-8522-0025-0

ENGINE ASSEMBLY II 4-33

FLYWHEEL AND FlYWHEEl HOUSING (REAR Oil SEAL} Ring Gear Inspection Inspect the ring gear. If the ring gear teeth are broken or excessively worn, the ring gear must be replaced. Ring Gear Replacement Ring Gear Removal Strike around the edges of the ring gear with a hammer and chisel to remove it. Ring Gear Installation 1. Heat the ring gear evenly with a gas burner to invite thermal expansion. Do not allow the temperature of the ring gear to ° exceed 200 c (390°F). 2. Use a hammer to install the ring gear when it is suf ficiently heated.

Flywheel Housing Oil Seal Replacement Inspect oil seal for wear, damaged or other abnormal conditions. Replacement of Oil Seal To remove the oil seal without disassembling the engine, proceed as follows. Remove the flywheel and pry off the oil seal using a conventional screw driver. 1. Install setting tool CD to rear end of the crankshaft using flywheel fixing bolt. 2. Install the setting tool® to the tool CD.

Note: The tool® serves as a guide for locating the oil seal.

01(3120

3. Insert the setting tool ® with oil seal ® into the setting tool ©. The tip end of the tool © should preferabily in light contact with the oil seal. 4. Insert these parts into the setting tool CD. 5. Install the oil seal ® into place between the wear ring ® and flywheel housing © by turning in the nut@. Installer: 1-85220-035-0

4-34 ENGINE ASSEMBLY 11

TIMING GEAR CASE COVER Crankshaft Front Oil Seal Replacement Removal Use an adapter and a hammer to remove the crankshaft front end oil seal. Check the timing gear oil jet for clogging. Clean the oil jet port with compressed air if necessary. Installation Use the crankshaft front oil seal installer to install the crankshaft front oil seal. Crankshaft Front Oil Seal Installer : 9-8522-0034-0

Oil port

ENGINE ASSEMBLY 111 5-1

SECTION 5

ENGINE ASSEMBLV (REASSEMBLY}

Ill

TABLE OF CONTENTS ITEM

PAGE

Piston and connecting rod reassembly step .......................................... 5- 2 Cylinder head reassembly step ...................................................... 5- 5 Rocker arm and rocker arm shaft reassembly step ................................... 5- 7 Reassembly 1st step ............................................................... 5- 9 Reassembly 2nd step ............................................................... 5-18 Reassembly 3rd step ............................................................... 5-31 Reassembly 4th step ............................................................... 5-34 Engine tuning operation ........ .. ... ... ........ ..... ... ..... ........ ... ... ..... ... 5-37

5-2 ENGINE ASSEMBLV Ill

1-.:..1

PISTON AND COI\INECTING ROD REASSEIVIBLY STEP

Reassembly Steps

A 1. Connecting-rod and bolt A 2. Piston A 3. Piston pin

A 4. Snap ring A 5. Piston ring A 6. Bearing

ENGINE ASSEMBLV Ill 5-3

PISTON AND CONNECTING ROD Important Operations 1. Connecting Rod and Bolt Use a hammer or a bench press to install the con necting rod bolts •into the bolt hole.

2. Piston Install the connecting rod to the piston with setting the marks as illustrated.

Front mark

3. Piston Pin As this piston pin installation is done by a finger push fit, the piston heating is unnecessary.

ISUZU mark

Refer the description of piston pin in page 4-22. OK770

1) Lubricate the piston pin with the engine oil. 2) Use a finger or thumb to fit the piston pin into the piston pin hole.

OK766

4. Piston Pin Snap Ring 1) Use a pair of snap ring pliers to install the pis ton pin snap ring. 2) Check that the piston moves smoothly on the piston pin.

5-4 ENGINE ASSEMBLY 111 5. Piston Ring

1) Use a piston ring installer to install the three piston rings. Piston Ring Installer : 1-8522-1025-0 Install the piston rings in the following order. (1) Oil ring (2) 2nd compression ring (3) 1st compression ring The marked side of the two compression rings must be facing up. As the oil ring has no any facing mark, it may face in either direction. 2) Lubricate the piston ring surfaces with engine oil. 3) Check that the piston rings rotate smoothly in the piston ring grooves.

2nd compression ring

Oil ring

1st comÂ pression ring OK109

6. Connecting Rod Bearing

1) Install the connecting rod bearings to the conÂ necting rod large-end and the connecting rod cap. 2) Install the bearing cap to the connecting rod with semi-tightening the cap bolts. 3) Lubricate the bearing with the engine oil.

Engine parts contact email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.Isuzu-6RB1.com www.HeavyEquipmentRestorationParts.com

ENGINE ASSEMBLY 111 5-5

l•!·I

CYLINDER HEAD REASSEMBLY STEP

Reassembly Steps 1. Valve spring lower seat A 2. Valve stem oil seal 3. Valve

A 4. Intake and exhaust valve spring 5. Valve spring upper seat A 6. Split collar

5-6 ENGINE ASSEMBLY Ill

0K436

Important Operations

(If it is removed in the disassembly step) 1. Nozzle Sleeve 1) Check the nozzle sleeve hole for presence of remaining sealant. Clean the hole inside if necessary. 2) Apply a coat of LOCTITE TL290 on the nozzle sleeve position A in the illustration. 3) Lubricate the nozzle sleeve O-ring with engine oil and, install it into the groove B. 4) Press in the nozzle sleeve into the sleeve hole.

2. Valve Stem Oil Seal Use a hammer and the valve stem oil seal installer to install the oil seal. Valve Stem Oil Seal Installer : 9-8522-1289-0

OK437

4. Intake and Exhaust Valve Springs Install the valve springs with their painted end (the close pitched end) facing down.

0K43a

6. Split Collar 1) Use a spring compressor to push the valve sprÂ ing into position. 2) Install the spring seat split collar. 3) Set the split collar by tapping lightly around the head of the collar with a rubber hammer. Valve Spring Compressor : 9-8523-1436-0

ENGINE ASSEMBl Y Ill 5-7

ROCKER ARM AND ROCKER ARM SHAFT REASSEMBLY STEP

-,....Front

4 I

� -·· i�':

�n. »1 � ,�i, I lir�,·

A and B mark /

,.,J

OK441

Reassembly Steps A

1 A 2.

A 3.

4. 5. A 6. 7. 8.

Rocker arm shaft Rocker arm shaft bracket Rocker arm (8) Waving washer Snap ring Rocker arm (A) Spring Rocker arm (B}

10.

11. 12. 13. 14. 15. 16.

Rocker arm shaft bracket Rocker arm (A) Spring Rocker arm (8) Rocker arm shaft bracket Rocker arm (A) Waving washer Snap ring

5-8 ENGINE ASSEMBLY Ill W

- Front

Important Operation 1. Rocker Arm Shaft

Oil port

The rocker arm shaft must be installed with the oil ports facing rear.

OKOBB

2. Rocker Arm Shaft Bracket Install the rocker arm shaft bracket ÂŽ to the rocker arm shaft with aligning the oil ports Q) as illustrated.

OK111

3. Rocker Arm (B) 6. Rocker Arm (A) Install the rocker arm (A) and (8) so that the rocker arm tip facing toward respective bracket side as illustrated.

Rocker arm end

OK441

ENGINE ASSEMBlV Ill 5-9

l·!•I

REASSEMBLY 1 ST STEP

3 13

Reassembly Steps A 1. A 2. 3. A 4. A 5. A 6. A 7. A 8.

Oiling jet Timing gear case and oiling jet No. 7 camshaft bearing Roller tappet Injection pump gear and adapter Camshaft assembly Crankshaft upper bearing Crankshaft assembly

A 9. Thrust bearing (Upper half) A 10. Crankshaft bearing cap and thrust bearing (Lower half) A 11. Wear ring A 12. Flywheel housing A 13. Piston and connecting rod assembly A 14. Idler gear A 15. Oil pump and pipe

5-10 ENGINE ASSEMBLY Ill

Important Operations 1. Oil Jet Install the oil jets taking care not to damage the oil spray nozzles and, keep them to spray the oil tow ard the piston inside cavity.

Front OK114

Oil Jet Torque

kg.m(lb.ft/N-m) 2 ± 0.2 (14.5 ± 1.4/19.6 ± 2.oi

(Lubricate with engine oil) 2. Timing Gear Case and Oiling Jet

Install the oiling jet on the timing gear case so that the oil jet faces downward. kg-m(lb.ft/N-m) Timing Gear Case 3.0 ± 0.3 (21.6 ± 2.2/29.4 ± 2.9) Oil Jet Torque

�mp gearo !

(

Oil pan facing direc,ion �ar

OK116

Oil pipe joim for cylinder head

kg.m(lb.ft/N-m) Timing Gear Bolt Torque

<1>10 • 4.0±0.5 (29.0± 3.6/39.2± 4.9) <1>12 I

1.5 (50.6±10.8/68.7±14.7)

3. No. 7 Camshaft Bearing The oil port of No. 7 camshaft bearing is a part of the lubricating circuit coming from the cylinder body oil gallery to the valve rockers. Install the No. 7 camshaft bearing with aligning the oil port and the cylinder body oil outlet port as illus trated.

OK115

4. Roller Tappet 1) Fill the tappet roller with the engine oil from the oil filling port as illustrated until the oil flow out from the roller part. 2) Lubricate the entire tappet surfaces with the engine oil. 3) Fit the lock spring into the tappet groove and insert the tappet into the tappet setting tool as illustrated. Tappet Setting Tool: 1-88430-154-0

ENGINE ASSEMBLY Ill 5-11 )' � 1...l--

(./

4) Insert the roller tappet into the cylinder block's tappet travelling bore with gently tapping the setting tool by a plastic hammer or alike, while hold the lock spring by your hand as illustrated.

(

--�-\ .

01<3126

5) Align the tappet guide hole with the guide bolt and fit the guide bolt with semi-tighten one by one for all tappets. 6) Tighten the guide bolts to the specified torque. 7) Make sure that the tappets travell up and down smoothly. kg,m(lb.ft/N-m) Tappet Guide Bolt Torque

3.0

0.3 (21.7

2.2/29.4

2.9)

mm(in) Tappet Roller Free Bolt Torque

. Timing Gear Case

8 - 9 (0.31

0.39)

5. Injection Pump Gear 1) Place the injection pump gear to the original location as illustrated. In this work, the gear timing mark must be fac ing front.

Rear.--Adapter

-- Front Injection Pump Gear

2) Install the injection pump gear adapter and, at the same time, fit the injection pump gear cen ter boss into the adapter bore.

5-12 ENGINE ASSEMBLY Ill

6. Camshaft Bearing and Camshaft Gear Installation The camshaft bearing has a stamped cylinder num ber mark. The mark must be facing front when it is installed to the camshaft as illustration. Note: The No. 1 bearing which is unitized with the thrust plate has already been described in the section 4 INSPECTION AND REPAIR. 1) Lubricate the entire bearing surfaces with the engine oil. 2) Install the bearing to the camshaft as illustrated. The bearing halve's setting line must be in per pendicular to the crankcase lower surface.

Camshaft Installation 1) Keep the tappet roller at such position not to block up the camshaft when it is inserted. When the cylinder body is placed with the crankcase facing down, full way slide up and block them at the position with inserting a pin or something alike into the guide bolt groove.

2) Lubricate entire cam surfaces with the engine oil. 3) Insert the camshaft into the cylinder body cam shaft bore carefully with aligning the cam bearing bolt hole and the cylinder body side bolt hole. Do not tap the bearing in this work.

4) Tighten the No. 1 bearing set bolt to the speci fied torque. kg-m(lb.ft/N-m) Camshaft No.1 Bear ing Set Bolt Torque

4.0

0.5 (28.9

3.6/39.2

4.9)

ENGINE ASSEMBLV Ill 5-13 5) Make sure that all of the bearings are facing toward correct direction. The bearing set bolt holes are located as the illustration, therefore, take care not to mix up the oil hole and the bolt hole. 6) The bearing set bolts have different length depending on the used location as illus trated. Install them to the original position. Do not reuse the set bolt gaskets. 7) Tighten all of the bearing set bolts to the speci fied torque. kg-m(lb.ft/N-m) Camshaft Bearing Set Bolt Torque No.2,4,6

i 3.5 ± 0.5 (25.3 ± 3.6/34.3 ± 4.9)

No.3,5

i ill

No. 2 No. 3 No. 4 No. 5 No.6

7. 8. 9. 10.

Upper Halves

Journal No.

1. 2. 3. 5. 6.

Crankshaft Bearing Upper Half Crankshaft Thrust Bearing (Upper Half) Crankshaft Bearing Cap and Thrust Bearing (lower Half) The crankshaft main bearing identifications are as follows:

Lower Halves OK117

• All Bearing Upper Halves ... Have Oil Groove and Oil Hole • All Bearing Lower Halves ... No Oil Groove and Oil Hole e No. 4 and No. 7 Bearings ... Have different Size in Width

5-14 ENGINE ASSEMBLY Ill 1) Install the front and rear thrust bearing. --- Front

The bearing oil groove must be faced to front and rear respectively as illustrated. 2) Install the main bearing upper halves and lubric ate them with the engine oil. 3) Place the crankshaft on the main bearing upper halves. 4) Install the main bearing lower halves on the bearing cap. 5) Lubricate the bearing lower halves and the thrust bearing lower halves with a coat of engine oil. 6) Set the thrust bearing lower halves on the front most bearing cap and lubricate it with a coat of engine oil. 7) Install the bearing caps on the crankshaft main journal original position. The stamped mark must be facing front. OKl 19

8) Lubricate the main bearing cap bolt with a coat of engine oil. 9) Tighten the bearing cap bolts to the specified torque a little at a time in the numerical order shown in the illustration. kg,m(lb.ft/l'J.m) Crankshaft Bearing Cap Bolt Torque

39.0±3.0 (282.0±21.6/382.6±29.4)

(Lubricate with engine oil) 10) Check that the crankshaft turns smoothly by manually rotating it.

Lubricate with engine oil OK121

12. Wear Ring

1) Install the setting tool CD to rear end of the crankshaft using flywheel fixing bolt. 2) Install the wear ring ® into the setting tool CD, then install the wear ring to the crankshaft by applying a shock load with setting tool ®· Note:

Submerging wear ring in heated oil (90 - 1 oo•q for about 15 minutes will facilitate wear ring installation. OK3122

Installer: 1-85220-014-0

ENGINE ASSEMBLY Ill 5-15 13. Flywheel Housing 1) Apply a liquid gasket to the shaded area of the illustration.

2) Install the flywheel housing. Tighten the flywheel housing bolts to the speci fied torque a little at a time in the numerical order shown in the illustration. kg-m(lb.ft /N-m) 1 1·0± 2-3 i ¢14 Bolt 9 1 ( ± 5 7 Housing _ _ ._ Flywheel _ _ _ 6 _.6/1 ----+_ _ 0 _8_.0_±_ 2_2 _ ._5)---, Bolt Torque 2.6±0.3 ¢ 8 Bolt 2.9) (1 8.8± 2.2 / 14. Piston and Connecting Rod Position the piston ring gaps as shown in the illus tration. 1) Set the piston ring gaps as shown in the illus tration. 2) Lubricate the piston, the piston rings, and the connecting rod bearings with a coat of engine oiL 3) Position the piston front mark towards the front of the engine. 4) Use the piston ring compressor to compress the piston rings.

Piston Ring Compressor: 9-8 5 22-13 1 9-0 5 ) Use a hammer grip to push the piston in until it makes contact with the crankpin. At the same time, rotate the crankshaft until the crankpin reaches its highest point. In this work, take care not to damage the oiling jets in the crankcase. 6) Set the bearing cap cylinder number marks and the connecting rod cylinder number marks. The marks must be facing the exhaust manifold. 7) Lubricate the connecting rod bearing cap nut setting face and the bolt threads with a coat of engine oil.

Matching numbers 01(444

5-16 ENGINE ASSEMBlY 111 Tighten the connecting rod bearing cap nuts to the specified torque in two steps with working up a little at a time in the numerical order as illustrated. 1st Step Connecting Rod Bearing Nut Torque

kg.m(lb.ft/N.m) 2nd Step

7 10.0±0.5 (50.6/68.6) (72.3±3.6/98.1 ±4.9)

(Lubricate with engine oil)

OK446

13.ldler Gear 1) Install the idler gear thrust plate with the cuta way portion facing up and the cylinder block.

2) Lubricate the idler gear side surface and the thrust plate mating surface with the specified grease.

Lubricate with grease

3) Install the idler gear with setting the crankshaft gear timing marks (X and XX) and the camshaft gear timing marks (Y, YY) and the injection pump gear marks (Z, ZZ) as illustrated.

4) Install the idler gear spindle and tighten the gear with the idler gear bolt to the specified torque. kg.m(lb.ft/N-m) Idler Gear Bolt Torque

17.0±2.0 (123.0±14.4/166.8±19.6)

ENGINE ASSEMBLY Ill 5-17

14. Oil Pump Install the oil pump beneath the crankcase front most with meshing the oil pump idler gear and the crankshaft gear. I Oil Pump Bolt Torque \ 5.0

Oil Pipe Joint Torque \ 2.0

± 0.5 (36.2 ±

kg-m(lb.ft/N.m) 3.6/49.1 ± 4.9) \

kg,m(lb.ft/N.m)

± 0.2 (14.5 ± 1.4/19.6 ± 2.0)

5-18 ENGINE ASSEMBLY Ill

REASSEMBlY 2ND STEP �18

(' '1.

tJ----,s 12 -------.�

10--------

16 13-----14

Reassembly Steps .A. 1. Oil cooler A 2. Air compressor (or bearing case) 3. Timing gear case cover A 4. Oil pan A 5. Flywh'eel A 6. Crankshaft pulley 7. Tappet chamber cover A 8. Cylinder head gasket A 9. Cylinder head Note: The bearing case is equipped for non-air compressor engine.

10 Push rod A 11. Valve bridge

A 12. Rocker arm and rocker arm shaft A 13. Injection pump coupling A 14. Injection pump 15. Injection nozzle A 16. Injection pipe A 17. Injection nozzle holder flange 18. Leak off pipe A 19. Tachometer drive elbow or cover

ENGINE ASSEMBLY Ill 5-19 W

Important Operations 1. Oil Cooler

1) Apply a coat of liquid gasket on the cylinder block oil cooler mounting surface and also on the oil cooler gasket both faces. 2) Affix the oil cooler gasket on the cylinder block. 3) Install the oil cooler and tighten the oil cooler bolts. Start up from © and @ shown in the illustration alternately and work out to the arrow direction. kg-m(lb.ft/N-m) Oil Cooler Bolt 1.8 ± 0.2 (13.0 ± 1.4/17.6 ± 2.0) Torque

2. Air Compressor (If equipped)

1) Make sure that the key is securely fitted on the air compressor crankshaft front end. 2) Align the key and the mating key groove in the i njection pump drive gear center bore.

Note:

In this work, take care not to fall the key into the timing gear case.

Counterbore

:, Fixing Nut

3) Install the air compressor with pushing in the key and the crankshaft into the pump drive gear until the air compressor counterbore is fitted with the injection pump gear adapter com pletely. 4) Tighten the four bolts evenly to fix the air com pressor on the timing gear case. kg-m(lb.ft/N-m) Air Compressor 4.0 ± 0.5 (29.0 ± 3.6/39.2 ± 4.9) Bolt Torque 5) Connect the air compressor water pipes. kg-m(lb.ft/N-m) Water Pipe Nut 4.2 0.5 (30.3 ± 3.6/41.2 ± 4.9) Torque

5-20 ENGINE ASSEMBLY Ill 2. Bearing Case (For Non-Air Compressor Engine) 1) Install the key into the bearing case shaft key groove. 2) Push in the bearing case shaft end into the injection pump gear center bore. 3) Tighten the four bearing case fixing bolts evenly to the specified torque. kg-m(lb.ft/N.m) Bearing Case Bolt Torque

[ 4.0

± 0.5 (29.0 ± 3.6/39.2 ± 4.9)

Reference: The tachometer elbow is installed on the shaft front end via adapter. The injection pump coupling is installed on the shaft rear end.

4) Place the plane washer and the spring washer on the injection pump gear boss surface and, tighten the nut G) in the illustration to the speci fied torque. kg-m(lb.ft/N-m) Injection Pump Gear Fixing Nut Torque

26.0 ± 2.0 (188.0 ± 14.4/255.1

19.6)

3. Timing Gear Case Cover After the timing gear case cover has installed, fit the oil seal. 1) Apply a coat of engine oil on the entire oil seal ing lip faces. 2) Use the oil seal setting tool to install the oil seal to the timing gear case cover. Oil Seal Setting Tool : 1-85220-015-0

ENGINE ASSEMBLY Ill 5-21 4. Oil Pan 1) Wipe the crankcase oil pan mounting flange surface and oil pan flange surface to clean the surfaces before the liquid gasket coating. 2) Apply a coat of liquid gasket on the crankcase side flange surface in 1.5 mm (0.06 in) thick and 5.0 to 10 mm (0.2 to 0.4 inch) width. 3) Affix the oil pan gasket and install the oil pan. 4) Tighten the oil pan bolts to the specified torque starting from CD and ® alternately, as shown in the illustration and, work out toward arrow direction. kg-m(lb.ft/N.m) Oil Pan Bolt Torque 4.0 ± 0.5 (28.9 ± 3.6/39.2 ± 4.9) I 1

Lubricate with MOS, OK127

5. Flywheel 1) Apply a molybdenum disulfide grease to the fly wheel bolt threads and setting faces. 2) Install the flywheel with aligning the dowel. 3) Tighten the flywheel bolts by the Angular Tigh tening Method in the numerical order as illustrated. kg-m(lb.ft/N.m) I 2nd Step i Final Step 1st Step I I Apply MoS2 ° ±15" Flywhee I 300 ±15 Go 80 + 10 · o · o" Bolt Torque 7. 7 7 I (5 8± .2/ 8:5±9.8) I I

5-22 ENGINE ASSEMBLY Ill 6. Crankshaft Pulley

1) Use a plastic hammer to gently tap the dust thrower in to the pulley.

2) Do not lubricate the oil sealing surface of the pulley. 3) Apply MoS2 to the pulley fixing nut threads.

4) Install the pulley on the crankshaft front end and tighten the pulley nut to the specified torque.

Wrench : 55 mm Crankshaft Pulley Nut Torque

kg.m(lb.ft/N-m)

80.0 ± 10.0 (578.5 ± 72.0/785.0

98.0)

8. Cylinder Head Gasket 9. Cylinder Head

1) Carefully place the cylinder head gasket on the cylinder body upper surface. The gasket "TOP" mark must be facing up.

2) Align the cylinder body dowels and the cylinder head dowel holes.

0K448

3) Carefully place the cylinder head on the cylinder body.

4) Apply molybdenum disulfide grease to the cylinder head bolt threads and setting faces. 5) Use the Angular Tightening Method to tighten the cylinder head bolts in three steps.

Lubricate with MOS 1

Follow the numerical sequence shown in the illustration.

0K410

Refer to 'Torque Specifications" for the angular tightening method.

Cylinder Head Bolt Torque Isuzu 6RB1 6RB1T engine parts contact: Email: engineparts2@gmail.com Phone: 269 673 1638

Angular Tightening Method Head Bolt Torque

1st Step

15 ± 1 (108.3 ± 7.2/ I 147.0 ± 9.8)

Apply a coat of M0S2 grease

2nd Step

kg-m(lb.ft/N-m) • Final Step

19 ± 1 I (137.4 ± 7.2/ i 186.4 ± 9.8)

±30

ENGINE ASSEMBLV Ill 5-23 11. Valve Bridge 1) Lubricate the valve bridge arrow positions with the engine oil. 2) Install the bridge on the bridge guide.

j: I I

l I

� 12. Rocker Arm and Rocker Arm Shaft 1) Check that the rocker arm shaft bracket lower surface oil port is free from obstruction. 2) Install the rocker arm shaft with the bracket to the cylinder head.

3) Tighten the rocker arm bracket bolts to the specified torque a little at a time in the numeri cal order shown in the illustration. OK412

4) Lubricate the rocker arm and the rocker arm shaft with engine oil.

R ocker Arm S haft 9.0 + 1.0 (65.1 Bracket Bo lt Torque .I

kg-m(lb.ft/N-m)

± 7 .2/88.3 ± 9.8)

(Lubricate with engine oil)

5) Adjust the valve clearance.

R efer to MAINTENANCE for the valve clearance adjustment procedure.

13. Injection Pump Coupling

1) Install the coupling to the air compressor crank shaft rear end or the bearing case shaft rear end with aligning the key and the key groove. 2) Tighten the coupling lock bolt and nut to lock the coupling and the shaft end enijagement.

Injection Pump Side

Coupling Lock Bolt Nut Torque

kg-m(lb.ft/N-m)

6.5

± 0.5 (46.9 ± 3.6/63.7 ± 4.9)

To avoid the timing mark misaligment, do not loosen or remove the four coupling bolts shown in the illustration.

5-24 ENGINE ASSEMBLY Ill 14. Injection Pump

1) Install the injection pump brakcet to the cylinder block (If the bracket is removed in the disas sembly) with aligning the dowel. kg-m(lb.ft/N-m) Injection Pump Bra- ¢10 cket Bolt Torque ¢14

4±0.5 (28.9±3.6/ 39.2±4.9) 11±1.0 (80.0±7.2/107.8±9.8)

2) Place the injection pump on the bracket and semi-tighten the injection pump fixing bolts. 3) Bring the piston in either the No. 1 cylinder or the No. 6 cylinder to Top Dead Center on the compression stroke by turning the crankshaft until the TDC notched line on the flywheel or the crankshaft damper pulley is aligned with the pointer.

Timing Marks on the Damper

4) Reverse the crankshaft to the specified injection timing mark on the flywheel or the damper pul ley as illustrated.

Note: The specified injection timing crank angle of your engine is indicated on the MAINTENANCE DATA PLATE affixed on the cylinder head cover top.

5) Install the injection pump coupling and align the injection pump notched line and the automatic timing advancer notched line (or the injection pump flywheel notched line). 6) Tighten the coupling bolts to the specified torque.

Injection Pump Coupling Bolt Torque kg-m(lb.ft/N-m) ¢ 8 mm Bolt

3.3 ± 0.5 (23.8 ± 3.6/32.3 ± 4.9)

¢10 mm Bolt

4.8 ± 0.5 (34.7 ± 3.6/47.0 ± 4.9)

7) Tighten the four injection pump fixing bolts in the numerical order as illustrated. kg-m(lb.ft/N-m) Injection Pump Fixing Bolt Torque

4.0 ± 0.5 (28.9 ± 3.6/39.2 ± 5.0)

ENGINE ASSEMBLV Ill 5-25 Injection Timing Inspection Procedures 1) Align the timing pointer and the timing notched line on the flywheel or on the crankshaft damÂ per pulley with turning the crankshaft. Refer the procedure described in the page 2-11 of the section MAINTENANCE. 2) Check alignment of the injection pump flywheel (or the automatic timing advancer) notched line and the injection pump body notched line. When the two notched lines are in alignment, the injection timing is correct. Injection Timing Correction Procedures If a timing marks misaligment is discovered in the injecÂ tion timing inspection, do the following adjustment after all of the fuel system parts have installed.

1) Disconnect the injection pipe from the No. 1 plunger. This will allow you to visually check the fuel injection starting flow at No. 1 plunger.

2) Use a screw driver to remove the injection pump delivery valve cover fixing screw. 3) Remove the delivery valve cover.

4) Use the socket wrench shown in the illustration to loosen the delivery valve holder. Delivery Valve Holder Wrench : (Special Tool)

5-26 ENGINE ASSEMBLY Ill 5) Use the delivery valve holder extracter as shown in the illustration to remove the delivery valve holder. Delivery Valve Holder Extracter : (Special Tool)

�

6) Remove the delivery valve holder G), the valve seat @, valve spring ® and the delivery valve © from the No. 1 plunger.

---1

Reinstall the delivery holder G) and tighten it to the specified torque.

©-0

Do not reinstall the delivery valve spring, the valve seat and the delivery valve. These parts will be reinstalled later. kg-m(lb.ft/N-m) Delivery Valve Holder Tightening Torque

7) Hold the fuel control lever at the full fuel position.

Note: Take care to avoid entry of dust or foreign particles into the pump interior when the timing adjustment is made.

ENGINE ASSEMBLY Ill 5-27 8) Align the timing pointer on the damper pulley or the flywheel housing, whichever easily acces sible, to the specified injection starting timing line as illustrated.

INJECTION TIMING CRANK ANGLE of the engine Refer to the MAINTENANCE DATA PLATE affixed on the cylinder head cover top.

Timing Marks on rhe Damper

9) Loosen the two coupling bolts on the injection pump flywheel (or the automatic timing advan cer) to disengage the injection pump drive line. 10) Slowly turn the injection pump flywheel, at the same time, continue to feed the fuel to the No. 1 plunger with pumping the feed pump (i.e. priming pump). Fuel will flow out from the No. 1 delivery valve holder freely by the pumping.

11) The fuel flow will stop at some injection pump flywheel position when the No. 1 plunger start to fuel injection. This position is the injection starting timing.

12) Keep the engine timing condition made by procedure 4) and, engage the injection pump drive line by tightening the coupling bolts to the specified torque. 13) Do the Injection Timing Inspection Procedures to make sure that the injection timing is cor rected.

5-28 ENGINE ASSEMBLY Ill Delivery Valve Reinstallation 1) Remove the delivery valve holder to reinstall the delivery valve. Reinstall the delivery valve, valve seat and the spring on the plunger. 2) Lubricate the delivery valve holder 0-ring with a coat of grease. Do not reuse the 0-ring, replace it with the new one. 3) Use the socket wrench to tighten the valve hol der in the following order and the tightening torque. 1st Time 11 +01 (79.5 1�·2)

Loosen

2nd Time 11+10 (79.5 Tb 2)

Loosen

Final 11+10 79 ( .5 1b.2 l

Repeat two times tighten and loosen and, finally tighten to the specified torque. Install the delivery valve holder cover. 4) Reconnect the No. 1 injection pipe. The reinstallation procedure is described in the item 16. Injection Pipe.

Reference: To advance the timing Turn the injection pump flywheel (or timing advancer) toward out while the injection pump side coupling bolts are loosened condition. To retard the timing Turn the injection pump flywheel (or timing advancer) towred in (cylinder block side) in the injection pump coupling bolts same condition. The 1 mm misalignment between the two setting mark ° lines corresponds to about 2 in crank angle.

ENGINE ASSEMBLV Ill 5-29 16. Injection Pipe 17. Injection Nozzle Flange In this engine, the injection nozzle is located at the combustion chamber central position, therefore, an about 120 mm (4.7 inch) length sleeve nut is used as the pipe connection parts in order to facilitates the piping from the cylinder head outside.

Flange

Injection

Pump Side

1) Install the nozzle holder flange and tighten the fixing nuts in semi-tighten. 2) Before to connect the injection pipe to the noz zle holder, make sure that the gasket CD is fitted on the sleeve nut and the gasket @ is fitted on the nozzle holder inlet port threads as shown in the illustration.

3) Screw the sleeve nut ® full way in to the female threads ® and allow the nut ® reach to the threads®·

4) Screw in the nut ® to the nozzle holder threads ® along with the threads ® but keep them in semi-tighten.

1 ...c:J

�

5) Tighten the injection pump side sleeve nut ® in semi-tighten. 6) Make sure that the threads ® ® ® and the pipe line is in free of hard threading or misalignment conditions. 7) Tighten the two injection pipe sleeve nuts ® and® to the specified torque. 8) Tighten the nozzle holder flange fixing nuts to the specified torque.

5-30 ENGINE ASSEMBLY 111 kg,m(lb.ft/N.m) 2.8 ± 0.3 </l10 Bolt (20.2 ± 2.2/27.4 ± 2.9) Nozzle Holder Flange Fixing Nut Torque 1.2 ± 0.2 </l 8 Bolt ( 8.6 1.4/11.8 ± 2.0)

Injection Pump Side

Injection Pump Side Injection Pipe Sleeve Nut Torque

kg,m(lb.ft/N.m) 3.3 ± 0.2 (24.0 ± 1.4/32.4 ± 2.0)

Nozzle Holder Side Injection Pipe Sleeve Nut Torque

kg,m(lb.ft/N-m) 2.8 0.2 (20.2 ± 1.4/27.4 ± 2.0)

The gasket CD acts to seal the oil in the cylinder head cavity and, the nozzle holder gasket @) acts to seal the fuel leakage.

9) Finger tighten the knurled nut © to retain the gasket CD.

1 0) Install the injection pipe clips on the position illustrated.

No.6

01<7721

ENGINE ASSEMBLV Ill 5-31

REASSEMBLY 3RD STEP

Reassembly Steps

1. 2. .A. 3. 4. .A. 5. 6. 7.

Cylinder head cover Inlet cover Tachometer elbow Oil filter assembly and pipe Fuel filter Water pump Water inlet pipe

8. 9. 10. .A. 11. .A. 12. 13. 14.

Injection pump oil pipe Air compressor oil pipe Air compressor water pipe Air compressor air pipe Fuel pipe assembly Water outlet pipe Inlet duct

5-32 ENGINE ASSEMBLY Ill W

Important Operations 1. Tachometer Elbow

1) Install the tachometer adapter ® into the air compressor crankshaft end female threads CD.

Note:

In this work, take care not to damage the threads because the female threads are a left hand threads.

In the non-air compressor engine, this adapter is incor porated in the bearing case shaft. 2) Place the washer and the spring washer tighten the nut® to the specified torque.

and

kg-m(lb.ft/N-m) Injection Pump Drive Gear Fixing Nut Torque

( 188.0

26.0 ± 2 14.4/255.1

19.6)

3) Apply a coat of liquid gasket on the O-ring ® faces and affix it into the tachometer elbow's O-ring groove. 4) Install the tachometer elbow (J) to the timing gear case. 5) Place the washer and the spring washer and, tighten the nut® to the specified torque. kg-m(lb.ft/N.m)

Tachometer Elbow Nut Torque

(20.2

2.8 ± 0.3 2.2/27.4

± 2.9)

11. Air Compressor Air Pipe

Install the air pipe to the air compressor and tighten the nut to the specified torque. kg-m(lb.ft/N-m)

Air Pipe Nut Torque

(223.2

31.0 ± 8.5 61.4/303.8

83.3)

ENGINE ASSEMBLV Ill 5-33 6. Fuel Filter 12. Fuel Pipe 1) Install the fuel filter to the filter bracket but keep the fixing nuts in semi-tighten. 2) Connect the fuel pipes and tighten the eye bolts to the specified torque. 3) Tighten the filter fixing bolt's nuts to the speci fied torque. kg,m(lb.ft/N-m) Fuel Filter Fixing Nut Torque

2.8 ± 0.3 (20.2 ± 2.2/27.4 ± 2.9)

This installation procedures will secure the eye bolts from damage caused by a undue stress created by the eye bolt threads and the filter female threads misalig ment.

The eye bolts shown in the illustration are a hollow bolt incorporating a strainer. kg-m(lb.ft/N-m) Fuel Filter Eye Bolt Torque

4.2 ± 0.5 (30.4 ± 3.6/41.2 ± 5.0)

5-34 ENGINE ASSEMBLY Ill

REASSEMBLY 4TH STEP

Reassembly Steps Water outlet pipe Air breather Exhaust manifold Partial-flow oil filter and pipes Starter Dipstick guide tube Air inlet duct Turbocharger A 9. Turbocharger oil pipe ; outlet A 10. Turbocharger oil pipe ; inlet 1. 2. A 3. 4. A 5. 6. 7. A 8.

Water drain pipe Alternator and adjusting plate Fan belt Cooling fan Engine stop device (if originally equipped) 16. Fuel return pipe 17. Intake heater fuel pipe 18. Oil pipe for valve mechanism

11 . 12. A 13. 14. 15.

r;._"'" ·�"8>"�D

ENGINE ASSEMBLY 111 5-35 Important Operations 3. Exhaust Manifold 1) Install the seal rings setting the ring gaps in ° 120 evenly to the exhaust manifold connecting collar. 2) Install the exhaust manifold gasket and the exhaust manifold.

Seal Ring

3) Install the distance tube on the studs and seat the washer as illustrated and, tighten the nuts evenly to the specified torque. kg-m(lb.ft/N-m) Exhaust Manifold Nut Torque

(23.8

3.3 ± 0.5

± 3.6/32.3 ± 4.9)

5. Starter Motor Install the starter motor with tightening the starter fixing nuts to the specified torque. Starter Motor Nut Torque

kg-m(lb.ft/N-m) 11.9 ± 2.3 (86.0 ± 16.6/116.6 ± 22.5)

8. Turbocharger 9. Turbocharger Oil Pipe (Return Pipe) 10. Turbocharger Oil Pipe 1) Place the turbocharger gasket on the exhaust manifold outlet port. The gasket edged side must be facing turbo charger side.

2) Install the turbocharger and tighten the nuts to the specified torque. kg-m(Ib.ft/N-m) Turbocharger Fixing Nut Torque

4.0 ± 0.5 (28.9 ± 3.6/39.2 ± 4.9)

5-36 ENGINE ASSEMBLY Ill 3) Install the two oil pipes and tighten the eye bolts to the specified torque. kg,m(lb.ft/N-m)

Oil Return Pipe Eye Bolt Torque

3.8 ± 0.5 (27.5 ± 3.6/37.3 ± 4.9)

Oil Inlet Pipe Bolt Torque

2.6 0.3 (18.8 ± 2.2/25.5 ± 2.9)

kg,m(lb.ft/N.m)

Pre-lubricate the turbocharger with CD grade oil through the oil port shown by the arrow in the illustration.

OY014

I �

13. Fan Belt Install and adjust the fan belt tension. Refer to MAINTENANCE for the fan belt tension adjustment.

ENGINE ASSEMBLY Ill 5-37

ENGINE TUNING OPERATION After reassembly, the engine must be tuned. This will ensure that the engine operates at its maximum effi ciency. 1. Mount the engine on a test bench. 2. Fill the engine with the specified oil. 3. Connect the cooling pipes and the fuel pipes.

Reference

Starter switch

�--�o

PREHEAT OFF ON

OOOO�hGlow plug

START : Control resistor

0.85mm' Warning lump

5 i

1.25 Fuse box

--------,

I 0.85 i I

Oil pressure switch

Relay

0.85

N E E

Alternator

4. Connect the electrical wiring. Refer to the wiring diagram. 5. Connect the air intake line to the air cleaner. 6. Connect the exhaust pipe. 7. Manually operate the fuel feed pump to feed fuel to the engine. 8. Bleed the fuel lines of air. Refer to Page 2-7 of Section 2 MAINTENANCE for the air bleeding procedure.

5-38 ENGINE ASSEMBLY Ill 9. Crank the engine with the starter motor (non-igni tion operation) for about twenty seconds. This wil I prelubricate the engine internal compo nents. 10. Start the engine and allow it to run at 750 to 800 rpm for five minutes. 11. Remove the cylinder head cover while the engine is running. 12. Check that the engine oil is continuously circulating from the oil pump to the valve rockers through the cylinder head. If there is no oil circulation or if the oil circulation is sluggish, stop the engine and make the appropriate repairs or adjustments. Reinstall the cylinder head cover. 13. Increase the engine speed to 1,500 rpm to do the engine warming-up operation. 14. Check the engine for oil, fuel, coolant, and air intake leakage. 15. Check for abnormal noise and odor. 16. Check for abnormal electrical charging. 17. Check the engine fastening parts for looseness. 18. When the engine coolant temperature reached to 75°C (167° F) or more, increase the engine speed to 2,000 rpm and allow it to run for twenty minutes. This will give the engine the essential run-in operat ing time. 19. Adjust the engine operation speed to the specified value. 20. Stop the engine to complete the tuning procedure.

LUBRICATING SYSTEM 6-1

SECTION 6

LUBRICATING SYSTEM TABLE OF CONTENTS ITEM

PAGE

General description ................................................................ 6- 2 Oil pump .......................................................................... 6- 3

Main oil filter ...................................................................... 6- 5 Oil cooler .. ....................................................................... 6- 6 Partial-How oil filter ................................................................ 6- 7

6-2 LUBRICATING SYSTEM

GENERAL DESCRIPTION

Oil pres$ure gauge

Battery

Oil pressure switch

Cylinder body oil gallery

va,,.,,

opining

Camshaft bearing

1st oil

Timing gear oiling j1t

A1r compressor

Fan center

re!ief valve pressure 12 kg/cm' f------l Oil pump

Oil strainer

Partial flow: filter

Connecting ro d bearing

2nd oll relief valve Valve opening pressure 4, l kg/cm1

This engine family uses a normal forced circulation lubricating system. A gear type oil pump is driven by the crankshaft gear at the crankshaft front end via an idler gear. A center bolt type or a cartridge (spin-on) type main oil filter and a centrifugal type partial-flow filter assures a superior lubricating ability giving this engine a long service life.

LUBRICATING SYSTEM 6-3

lâ&#x20AC;¢!*I

OIL PUMP DISASSEMBLV 4

Disassembly Steps 1. Cover 2. Driven gear Ii. 3. Spindle

4. Idler gear 5. Relief valve

Important Operation 3. Spindle Use a bench press to remove the idler gear.

6-4 LUBRICATII\IG SYSTEM

I L'ii' I

INSPECTION AND REPAIR

Make necessary correction or parts replacement if wear, damage or any other abnormal conditions are found through inspection.

Use a feeler gauge to meausre the clearance between the gear teeth and the pump body inside surface. mm(in) Gear Teeth and Body Inside Surface Clearance

Standard

Limit

0.07 (0.0028)

0.15 (0.0059)

Use a feeler gauge to measure the clearance between the gear side surface and the pump cover. mm(in) Pump Cover and Gear Side Surface Clearance

lďż˝!+-1

REASSEMBLY

To assemble, follow the disassembly procedure in reverse order.

Standard

Limit

0.07 (0.0028)

0.15 (0.0059)

LUBRICATING SYSTEM 6-5

l+-!*I

MAIN OIL FILTER DISASSEMBly

----8

5 __

__,_ _ _ _ 3 _ __,_ 7 --

Disassembly Steps 1. Drain plug 2. Center bolt 3. O-ring 4. Oil filter element

5. 6. 7. 8.

Element gasket Spring seat Coil spring Oil filter body

Refer to Page 2-2 of the MAINTENANCE for information on the cartridge type (spin-on type) oil filter.

IL'ifl

INSPECTION AND REPAIR

l*!+-1

REASSEMBlv

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is disÂ covered during inspection.

To reassemble, follow the disassembly procedure in reverse order.

6-6 LUBRICATING SYSTEM

l•!*I

OIL COOLER DISASSEMBly

* Also included in

engine overhaul kit

Disassembly Steps 1. Baffle plate 2. Element

IL'ii'I

INSPECTION AND REPAIR

l*!•I

REASSEMBly

3. Oil cooler cover

Make necessary correction or parts replacement if wear, damage or any other abnormal conditions are found through inspection.

To reassembe, follow the disassembly procedure in reverse order.

LUBRICATING SYSTEM 6-7

l•!•I

PARTIAL-FLOW OIL FILTER

DISASSEMBly

1 ·�

.. ,0 ._____ 3 �t----5

Disassembly Steps 1. Cap nut 2. Filter cover 3. Thrust nut

I L1i'I

INSPECTION AND REPAIR

l•!•I

REASSEMBly

4. Rotor assembly 5. Nut

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is dis covered during inspection.

To reassembe, follow the disassembly procedure in reverse order.

6-8 LUBRICATING SYSTEM

Thrust nut

Knurled Nut Tightening Torque

Finger Tighten

Note: Take care not to screw in the knurled nut with an over torque or the filter cover distortion might take place. When the clearance A is 0.3 to 0.5 mm (0.012 to 0.20 in.) the nut torque is normal. Thrust Nut Torque

kg,m(lb.ft/N-m)

o.5-1.0 (3.6-7.2/4.9-9.8)

COOLING SYSTEM 7-1

SECTION 7

COOLING SYSTEM TABLE OF CONTENTS ITEM

PAGE

General description ................................................................ 7- 2 Water pump ....................................................................... 7- 3 Thermostat ........................................................................ 7- 8

7-2 COOLING SYSTEM

GENERAL DESCRIPTION Water outlet pipe Thermostat

- -

Water outlet pipe

Reserve tank

Cylinder body

water pump OK858

This family of engines uses a pressurized, forced circulation cooling system with a V-belt driven centrifugal water pump and a wax pellet thermostat.

COOLING SYSTEM 7-3

WATER PUMP

1.,:,.1

DISASSEMBLY

Disassembly Steps Cover Impeller Pulley center and pulley 4. Dust thrower

1. A 2. A 3.

A 5. A 6. 11,,.

Snap ring Spindle, bearing and spacer 7. Seal unit, washer and seal

1-4 COOLING SYSTEM

Important Operation 2. Impeller Use the remover to remove the impeller. Remover: 1-85210-028-0

OK300

3. Pulley Center and Pulley Use a bench press and a suitable rod to remove the pulley center.

,------ - - -----,

5. Snap Ring Use a pair of snap ring pliers to remove the snap ring.

6. Spindle, Bearing, and Spacer Use a bench press and a suitable remover to remove the spindle, bearing, and spacer.

7. Seal Unit, Washer and Seal Use a suitable remover to remove the seal unit, the washer, and the seal.

COOLING SYSTEM 7-5

IL--1

INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is disÂ covered during inspection.

Bearing Replacement Removal:

Use a bench press to remove two bearings and the spacer.

01(859

Installation:

Use a bench press to install two bearings and the spacer.

Use a micrometer to check the fitness at the three points shown in the illustrations.

Impeller

Shah

Fitness Pulley

Pulley center

Shaft to Pulley Center Fitness

Shaft to Impeller I Fitness

Shaft to Pulley Fitness

mm(in)

0.025 0.060 (0.001 - 0.0024) 0.035 - 0.065 (0.0014 - 0.0026)

7-6 COOLING SYSTEM

l*!â&#x20AC;¢I

REASSEMBly

Reassembly Steps A 1. A 2.

Spindle, bearing and spacer Snap ring 3. Dust thrower A 4. Seal unit, washer and seal

Impeller

6. Cover A 7. Pulley Center and pulley

COOLING SYSTEM 7-7 Important Operations

Lubricate with multipurpose type grease

1. Spindle, Bearing, and Spacer Lubricate the bearing with multipurpose grease. Use a bench press to install the spindle, the bearing and the spacer. Sealed side outward OK144

E] 2. Snap Ring Use a pair of snap ring pliers to install the snap ring.

4. Seal Unit, Washer and Seal 1) Apply a thin coat of liquid gasket to the seal unit outer periphery before installation.

Apply liquid gasket here 01<145

2) Use a bench press and a bar to install the seal unit into the pump body.

5. Impeller 1) Use a bench press to install the impeller to the spindle. 2) Use a feeler gauge to measure the clearance between the impeller and the pump body. mm(in} Clearance between Impeller and Pump Body

0.3-0.8 (0.0118-0.0315)

7-8 COOLING SYSTEM 7. Pulley Use a bench press and a bar to install the pulley.

I L'ii I

THERMOSTAT

INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is dis covered during inspection.

Visually inspect the thermostat function referring Sec tion 2 MAINTENANCE in page 2-8. Agitating rod

Wood piece

FUEL SYSTEM 8-1

SECTION 8

FUEL SYSTEM TABLE OF CONTENTS

ITEM General description .............................................................. . .

fuel filter .......................................................................... 8- 3 Injection nozzle .................................................................... 8- 5 Injection pump calibration data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2 FUEL SYSTEM

GENERAL DESCRIPTION

Nozzle holder

Fuel filter

Fuel tank

Water sedimentor

Injection pump

The fuel system consists of the fuel tank, the water sedimentor, the fuel filter, the injection pump, and the injection nozzle. The fuel from the fuel tank passes through the water sedimentor and the fuel filter where water particles and other foreign material are removed from the fuel. Fuel, fed by the injection pump plunger, is delivered to the injection nozzle in the measured volume at the optimum timing for efficient engine operation.

FUEL SYSTEM 8-3

FUEL FILTER

l•!*I

DISASSEMBLV

*--5

<el> ...

'ij..

* Element kit 01<362

Disassembly Steps 1. 2. 3. 4.

Drain plug Center bolt Fuel filter body Body cover gasket

5. Fuel filter element 6. Spring seat 7. Spring

Refer to Page 2-3 of the "Maintenance" for information on the cartridge type fuel filter.

IL• I

INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is dis covered during inspection.

l*!•I

REASSEMBLy

To reassemble the fuel filter, follow the disassembly procedure in the reverse order.

8-4 FUEL SYSTEM

FUEL FILTER

MAIN Oil FILTER WATER SEDIMENTOR Refer to "FUEL SYSTEM" on Page 2-6 of the "MAINTENANCE" Section of this Workshop Manual.

FUEL SYSTEM 8-5

l•!*l l*!•I

IN.JECTION NOZZLE DISASSEMBly AND REASSEMBLY

e------

..i--

--7

Reassembly Steps

Disassembly Steps

A 7. A 6.

Cap nut Lock nut Spring adjust screw Spring 5. Push rod 6. Nozzle nut 7. Nozzle assembly 1. 2. 3. 4.

-6

5. 4. A. 3. A 2. A 1.

Nozzle assembly Nozzle nut Push rod Spring Spring adjust screw Lock nut Cap nut

Important Operation 7. Nozzle Assembly Remove the nozzle from the nozzle body.

"-' I/

OK836

Keep the parts separately to maintain the proper needle valve to body combination.

8-6 FUEL SYSTEM

IL•I

INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is dis covered during inspection.

Push Rod Spring Check the push rod spring for wear, weakness, and cor rosion.

Nozzle Holder Push Rod 1. Check the nozzle holder push rod curvature. 2. Check the nozzle holder push rod and needle valve contact surfaces for excessive wear and poor con tact.

Injection Nozzle 1. Check the injection nozzle needle valve, the valve seat, and the injection nozzle hole for carbon depos its. If carbon deposits are present, the injection nozzle and the needle valve must be replaced. 2. Hold the nozzle body vertically. Pull the needle valve about one-third of the way out of the nozzle body. Release the needle valve. Check that the needle valve falls back into the noz zle body as far as the valve seat. If the needle valve does not fall back into the nozzle body as far as the valve seat, the injection nozzle and the needle valve must be replaced.

FUEL SYSTEM 8-7 Important Operations 7. Nozzle Assembly There must be no oil on the contact surfaces of the injection nozzle and the injection nozzle holder.

Clean these contact surfaces with diesel fuel before installation. The nozzle dowel pin must be aligned with the dowel hole in the nozzle holder body.

6. Nozzle Nut Nozzle Nut Torque

Correct

AA Incorrect

Restrictions in orifices

Incorrect

3. Spring Adjust Screw Injection Starting Pressure Adjustment The injection nozzle injection starting pressure can be adjusted after the adjusting screw is installed.

Refer to "FUEL SYSTEM" on Page 2-4, 5 of the "MAINTENANCE" Section of this Workshop Manual.

Dripping

OK024

1 ± 1 (50.6

kg-m(lb.ft/N-m) 1 .2/68.6 ± 9.8) 1

6RB1 Injection Starting Pressure

kg/cm3 (psi/kPa) 6RB1T

200 (2840/20410) 200 (2840/20410) or or 225 (3195/22073) 225 (3195/22073)

Note: The injection starting pressure might vary depending on the engine applications, therefore, refer to MAINTEN ANCE DATA PLATE affixed on the cylinder head cover top.

Cap nut

2. lock Nut

Lock nut

1. Cap Nut Nozzle Lock Nut Torque 5.5 ± 0.5 (39.7

kg-m(lb.ft/N-m)

± 3.6/53.9 ± 4.9) Nozzle Cap Nut Torque 4.5 ± 0.5 (32.5 ± 3.6/44.1 4.9)

8-8 FUEL SYSTEM

INJECTION PUMP CALIBRATION DATA

]

IDENTIFICATION PLATE AND PRODUCT SERIAL NUMBER 1. Injection pump adjustment and repair should be made by the nearest DKKC (Diesel Kiki Co., Ltd.) or ROBERT BOSCH Authorized Service Outlet

o 3RG I - - - -@ I o ---· -· -···-·

2. When you ask such authoriged service outlet the adjustment or repair, the Identification Plate and Product Serial Number will give them a necessary clue to get technical data distributed by the manu facturers previously.

Pump No.101··· •·· · • NP· PE 6A95 • • • • ·· · · • · · · · · · · ( LICENCE BOSCH )

®··· Identification number

Without this data, the Service Outlet will be unable to effectively service your injection pump. If you are unable to locate the data applicable to your injection pump, please contact ISUZU MOTORS LTD through your machine supplier. 3. Do not remove the Identification Plate and Product Serial Number from the injection pump. Keep the Identification Plate and Product Serial Number clean at all times. Do not allow it to rust or become illegible. Note: Examples of test conditions and calibration data are as follows.

TEST CONDITIONS REQUIRED FOR THE FUEL INJECTION AMOUNT ADJUSTMENT Injection Nozzle

*DKKC No.: 105780-0000 Bosch Type No.: DN12DS1 2T

Injection Nozzle Holder

DKKC No.: 105780-2080 Boshc Type No.: EF8511/9A

Injection Starting Pressure Injection Line Dimensions Inside Diameter

kg/cm2(psi)

175 (2488.5)

mm(in.)

2.0 {0.079)

Outside Diameter

6.0 (0.236)

Length

600.0 {23.6)

Transfer Pump Pressure Testing Diesel Fuel Operating Temperature Pump Rotation Direction

1.6 {22.75)

·crF)

ISO4113 or SAE Standard Test Oil {SAEJ967D) 40

45 {104 - 113)

Clockwise (Viewed from the drive side)

8-9

FUEL SYSTEM

INJ. PUMP CALIBRATION DATA ENGINE MODEL Injection pump

PES4A 000000-0000

Ass'y No.

000000-0000

Date: Company: ISUZU No. 0-00000-000-0

6BD1T

Timing device

Governor · EP/RSV 000000-0000

1. Test Conditions Pump rotation

clockwise (viewed from drive si.de)

Nozzle : 000000-0000 (BOSCH Type No. DN12SD12T) Nozzle opening pressure : 175 Kg/cm' Injection pipe

Inner Dia.

Nozzle H0 1 ,.,

•

·"

mm "

000000-0000 (BOSCH Type No. EF8511/9A) ressure : 1. 6 Kglcm'

Length

Test Oil: IS04113orSAE�

..,11(SAE J967d)

Overflow valve opening pressure

Kg_/cm'

600 mm

Oil Temp. · 40 +5 °C

2. Injection Timing : Pre-stroke

No. 1 Plunger

3. 4

±0.05mm mm

Note : Adjust with control rod position of

·+3 0'

(interval

Injection order

)

Plungers are numbered from the Drive side. Tappet clearance : Bolt adjustment type ; More than 0.3mm for all cylinders. : Shim adjustment type ; Manually rotate the camshaft 2~3 times and confirm that it rotates smoothly.

4. Injection Quantity : Adjusting Point A

·-

I I

Rod I Position {mm) 9.5

! Approx.

6.5

9.5

Pump Speed (r.p.m)

Injection Q'ty (cc/1000 strokes)

1, 100

71.1

74. 1

400

7.4

10.2

1,100

71.1

74. 1

Max. var bet. cyl (%)

Fixed

Remarks

Rod

. ±2 ±14

Basic

Rod Lever

Basic

•

5. Timing Advance Specificaiiun

Pump Speed (r.p.m) Advance Angle (deg.)

I DIESEL 1<11<1

DIESEL KIKI CO .. LTD. Service Department

3-6-7 SHIBUYA, SHIBUYA-Kl', TOKYO 150, JAPAN Tel. (03) 400-1551 · Fax: (03) 499-4115

8-10 FUEL SYSTEM 000000-0000

3. GOVERNOR ADJUSTMENT Recommended speed droop adjustment screw position :7 ( Notches from fully tightened position)

Above 14

Idle-Sub spring setting Main spring setting

Difference in control rack position between 1000 rpm and 750 rpm

� E E

q _, '.)-

6,5 5,5

I_\ I

+ - I

\ \

I I

\ I

300

\, L_

400

550±20

1 860±30

800±20

1200± 1 s

1100±5

PUMP SPEED(rpm)

SPEED LEVER ANGLE STOP LEVER ANGLE

TIV

SEHING ,

,lunger beginning of injection I

�--,s I

�o

gear mark "cc"

TURBOCHARGER 9-1

SECTION 9

TURBOCHARGER TABLE OF CONTENTS ITEM General description

PAGE 9- 2

Turbocharger identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 3 Rotor shaft play inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 4

Regarding the details of the turbocharger repair, refer the following workshop manual. Published by: AIR RESERCH INDUSTRIAL DIVISION (A Division of The Garett Corporation) Manual l\lo. of the manual: OVERHAUL MANUAL, Diesel Engine Turbochargers Series TV61 ; TP20-0101-1 Title TV61 INSTRUCTION MANUAL, T45 & T51 Series Turbocharger ; TP25-0107 Availability of the manual: ISUZU MOTORS LIMITED will send the manual upon request through your machine supplier.

9 2 TURBOCHARGER

GENERAL DESCRIPTION TV61

TV51

TURBOCHARGER 9-3

TURBOCHARGER IDENTIFICATION

The Turbocharger nameplate gives the date of manufacÂ ture and other important information required to identify the unit when service inquiries or part orders are made. The arrow in the illustration indicates the location of the Turbocharger nameplate.

The turbocharger nameplate has the following informaÂ tion stamped on it. Refer to the illustration at the left. (1) Model number (2) Pat number assigned by ISUZU MOTORS LIMITED Example : 1144001330 (3) Serial number assigned by GARRETT TURBO INCORPORATED (4) Part number assigned by AIRESEARCH INDUSTRIAL DIVISION Example : J467000 The model number (1) indicates the group to which the turbocharger belongs. Part numbers (2) and (4) indicate specific designs or configurations.

9-4 TURBOCHARGER

IL'ii'I

ROTOR SHAFT PLAY INSPECTION

Rotor Shaft Axial Play Measurement 1) Install a dial indicator on the turbine housing as illustrated. 2) Use the dial indicator to measure the rotor shaft axial play with moving the shaft push and pull. Read the total indicator reading (TIR). mm(in) Rotor Shaft Axial Play TIR

Model

Limit

TV61

0.25 (0.010)

TV51

0.18 (0.007)

3) If the measured value exceeds the specified limit the shaft must be replaced.

Rotor Shaft Radial Play Measurement 1) Turn over the turbocharger with the turbine exhaust inlet flange facing up. 2) Install a dial indicator to measure the rotor shaft radial play. 4) Use the dial indicator to measure the play. the TIR. Oil retun porr

Model

OY019 !

Rotor Shaft Radial Play

TV61 TV51

Read mm(in)

Limit 0.18 (0.007) 0.18 (0.007)

5) If the measured value exceeds the specified limit replace the shaft.

AIR COMPRESSOR 10-1

SECTION 10

AIR COMPRESSOR TABLE OF CONTENTS ITEM

PAGE

General description (Parts No. 1-19100-107-1) ...................................... 10- 2 Disassembly steps ............................................................... 10- 3 Inspection and repairs ................................................. , .......... 10- 5 Reassembly steps . . ....................... . ................. . .... . ........ . ... . .. 10- 7 General description (Parts No. 1-19100-113-2) ...................................... 10-11 Disassembly steps ......... . ..................................................... 10-12 Inspection and repairs ............ ................................................ 10-14 Reassembly steps ................................................................ 10-16

10-2 AIR COMPRESSOR

GENERAL DESCRIPTION AIR COMPRESSOR SECTIONAL VIEW

Parts No. 1-19100-107-1

Output port to air tank

Suction port

Main Data

for Air Compressor P<1rts No. 1-19100-107-1

Piston ring configuration Theoretical air delivery amount Cylinder bore X stroke Maximum operating speed Crankshaft rotating ratio to engine Weight

mm(in) rpm kg(lb)

Three compression rings and one oil ring 340 cc (20.8 in3)/rev. 85 (3.35) X 60 (2.36) 1400 0.5 11.7 (25.7)

AIR COMPRESSOR 10-3

DISASSEMBLY STEPS

Disassembly Steps 1. -'i. 2. 3. 4. 5.

6. Piston ring 7. Connecting rod and bearing 8. Bearing cover fixing bolt .& 9. Crankshaft and bearing

Cylinder head assembly Cylinder body Snap ring Piston pin Piston

Important Operation 2. Cylinder body 1) Remove the cylinder mounting flange bolts. 2) Remove the cylinder with tapping out from the crankcase.

10-4 AIR COMPRESSOR 9. Crankshaft and Bearing Use a soft hammer to tap the crankshaft rear end (key grooved side) with turning the crankshaft slowly. This will allow the bearing cover and the bearings to be removed along with the crankshaft from the crankcase.

AIR COMPRESSOR 10-5

IL•I

INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is dis covered during inspection.

Cylinder Measure the uneven wear of the cylinder bore at the piston skirt position.

Cylinder Bore Uneven Wear I

mm(in)

Limit

•

0.10 (0.004)

Measure the piston and the cylinder bore clearance. mm(in)

Limit

Standard Piston and Cylinder Bore Clearance

0.090 (0.0035

0.155 0.0061)

0.18 (0.0071)

Note:

The piston outside diameter must be taken at the piston skirt positions. Measure the piston ring grooves and the piston ring clearances. mm(in)

Standard Piston Ring and Piston Ring Groove Clearance

I:fEI

0.005 (0.0002

Limit

0.080 (0.0032)

0.040 0.0016)

Measure the piston ring gaps. Standard

mm(in)

Limit

Compression Ring Gap

0.1 (0.0040

0.3 0.0118)

1.0 (0.040)

Oil Ring Gap

0.3 (0.0118

0.9 0.0354)

1.0 (0.040)

10-6 AIR COMPRESSOR Measure the piston and the piston pin hole clearance. mm(in) Standard Piston Pin and Piston Pin Hole Clearance

0.012 (0.0005

0.016 0.0006)

Limit 0.080 (0.0032)

Measure the piston pin and the connecting rod smallÂ end clearance. mm(in) Standard Piston Pin and Connecting Rod Smallend Clearance

0.016 (0.0006

0.044 0.0017)

Limit 0.070 (0.0028)

Measure the air compressor crank pin and connecting rod large-end clearance. mm(in) Standard Crankpin and Connect0.083 0.Q17 ing Rod Large-end (0.0007 - 0.0033) Clearance I

Limit 0.1 (0.0039)

AIR COMPRESSOR 10-7

lâ&#x20AC;¢!+-1

REASSEMBLv STEPS

Reassembly Steps A 1. A 2.

Crankshaft and bearings Bearing cover fixing bolts A 3. Connecting rod A 4. Piston rings A 5. Piston

A 6. A 7. A 8. A 9.

Piston pin Snap ring Cylinder body Cylinder head assembly

10-8 AIR COMPRESSOR W Important Operations

Oil seal

1. Crankshaft and Bearings 1) Use an appropriate adapter and a bench press to install the couple of bearings to the crank shaft. Bearing cover

2) Use an appropriate pilot bar to press in the oil seal into the bearing cover bore. In this work, take care not to damage or distort the oil seal. 3) Install the crankshaft into the bearing cover bore.

Crankshaft rear end

Setting an adapter at the crankshaft rear end (key grooved side), as illustrated, will secure the oil seal lips from damage or distortion when the crankshaft is pressed in.

bearing cover

4) Fit the O-ring into the crankcase O-ring groove.

Oil seal

5) Lubricate the bearing and the crankshaft journal with a coat of engine oil. 6) Install the bearing cover with the crankshaft and bearings to the crankcase. Use a soft hammer to tap the crankshaft front end gently.

2. Bearing Cover Fixing Bolts Tighten the bearing cover fixing bolts to the speci fied torque evenly. Bearing Cover Fixing Bolt Torque

kg.m(lb.ft/N-m) 0.7 ± 0.1 (5.0 ± 0.7/6.9 ± 1.0)

AIR COMPRESSOR 10-9 3. Connecting Rod

Setting mark

The connecting rod large end and the bearing cap has a setting mark as illustrated. 1) Lubricate the connecting rod bearing with a coat of engine oil. 2) Install the bearing cap and the connecting rod to the crankshaft journal. 3) Seat the lock plate under the cap nut and tigh ten the nut to the specified torque. kg,m(lb.ft/1\J-m) 2.5 ± 0.2 Connecting Rod Cap Nut Torque (18 ± 1.5/24.5 ± 2.0) 4) Bend the lock plate tang to lock the nut.

4. Piston Rings

--�==�

s;,�

S.1de ring .

The piston ring stamped mark must be facing up, as illustrated, when it is installed. The side ring and the spacer must be installed to the oil ring groove before the oil ring installation. The piston ring gaps must be positioned as illus trated.

Spacer

Side ring gap

5. Piston 6. Piston Pin 7. Snap Ring

1) Lubricate the connecting rod and the bushing. Install the piston to the connecting rod. 2) Insert the piston pin into the piston hole and the connecting rod bushing bore. 3) Install the snap rings into the piston snap ring grooves.

10-10 AIR COMPRESSOR 8. Cylinder Body 1) Fit the O-ring to the crankcase bore edge. 2) Install the piston into the cylinder. 3) Insert the piston into the cylinder bore until the cylinder body securely come into contact the crankcase. 4) Tighten the cylinder body fixing bolts to the specified torque evenly. kg-m(lb.ft/N-m) Cylinder Body Fixing Bolt Torque

2.8 ± 0.2 (19.6 ± 1.4/27.4

2.0)

9. Cylinder Head Assembly 1) Fit The O-ring into the cylinder body top O-ring groove. 2) Place the cylinder head on the cylinder body. 3) Tighten the cylinder head bolt evenly to the specified torque. Cylinder Head Bolt Torque

kg-m(lb.ft/N-m) 2.8 ± 0.2 (19.6 ± 1.4/27.4 ± 2.0) kg-m(lb.ft/1\J.m)

CD Unloader Valve Tightening Torque @ Discharge Valve Tightening Torque

11.0 ± 1.0 (79.2 ± 7.2/107.8 ± 9.8) (79.2

11.0

1.0

± 7.2/107.8 ± 9.8)

AIR COMPRESSOR 10-11

GENERAL DESCRIPTION AIR COMPRESSOR SECTIONAL VIEW

Parts No. 1-19100-113-2

Unloader valve port

Main Data

for Air Compressor Parts No. 1-19100-113-2

Piston ring configuration Theoretical air delivery amount Cylinder bore X stroke Maximum operating speed Crankshaft rotating ratio to engine Weight

mm(in) rpm kg (lb)

Three compression rings and one oil ring 340 cc (20.8 in 3 )/rev. 85 (3.35) X 60 (2.36) 1450 0.5 10.8 (23.8)

10-12 AIR COMPRESSOR

l•!*I

DISASSEMBLY STEPS

,,----�\

Disassembly Steps 1. 2. 3. A 4. 5. 6.

Cylinder head Cylinder head gasket Cylinder body and 0-ring Piston pin snap ring Piston pin Piston

A 7. 8. .ii. 9. .ii. 10. 11.

Piston ring Connecting rod Bearing cover Crankshaft and bearing Crankcase

W Important Operations 4. Piston Pin Snap Ring Use a pair of snap ring pliers to remove the snap ring.

AIR COMPRESSOR 10-13 7. Piston Ring

Use a pair of piston ring pliers to remove the snap ring.

9. Bearing Cover Slowly turn the crankshaft while tapping out the bearing cover and the crankshaft with a hammer.

10. Crankshaft Bearing Use a bench press to remove the crankshaft bearÂ ing.

10-14 AIR COMPRESSOR

INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is disÂ covered during inspection.

Cylinder Measure the uneven wear of the cylinder bore at the piston skirt position. mm(in) Limit

0.10 (0.004}

Cylinder Bore Uneven Wear

Measure the piston and the cylinder bore clearance. Standard

0.10 (0.004

Piston and Cylinder Bore Clearance

0.16 I 0.006)

mm(in) Limit

0.20 (0.008)

Note: The piston outside diameter must be taken at the piston skirt positions. Measure the piston ring grooves and the piston ring clearances. mm(in)

Piston Ring and Piston Ring Groove Clearance

Standard

Limit

0.025 0.060 (0.001 - 0.002)

0.15 (0.006)

Measure the piston ring gaps. mm(in) i

Compression Ring Gap

Standard

0.1 (0.004

0.3 0.012)

Limit

1.0 (0.04)

AIR COMPRESSOR 10-15 Measure the piston and the piston pin hole clearance. mm(in) Limit Standard Piston Pin and Piston Pin Hole Clearance

0.002 (0.0001

0.1 (0.004)

0.023 0.001)

Measure the piston pin and the connecting rod smallÂ end clearance. mm(in) Standard Limit Piston Pin and ConÂ 0.006 0.022 i 0.1 necting Rod Smallend (0.004) (0.0002 0.0009) Clearance

Measure the air compressor crank pin and connecting rod large-end clearance. mm(in) Standard I Limit Crankpin and Connect0.02 ing Rod Large-end (0.0008 Clearance i

0.06 0.0024) I

0.15 (0.059)

10-16 AIR COMPRESSOR

lâ&#x20AC;˘!+-1

REASSEMBLY STEPS

Reassembly Steps 1. A 2. 3. A 4. 5. A 6.

Crankcase Crankshaft and bearing Bearing cover Connecting rod Piston Piston ring

7. Piston pin A 8. Piston pin snap ring A 9. Cylinder body and 0-ring 10. Cylinder head gesket A 11. Cylinder head

W Important Operations 2. Crankshaft and Bearings Use a brass hammer to force the bearing onto the crankshaft.

AIR COMPRESSOR 10-17 4. Connecting Rod

1) Fit the bearing into the connecting rod and the bearing cap. 2) Apply engine oil. kg,m(lb .ft/N.m) Connecting Rod Nut 2.5 ± 0.2 Torque (18 1.5/24.5 ± 2.0)

6. Piston Ring

1) The piston ring portion must be positioned as shown in the illustration. CD Front mark ® 1st Compression ring 2nd Compression ring © Oil ring lower side rail ® Oil ring expander ® Oil ring upper side rail 2) Lubricate the piston surface with a coat of engine oil. Piston Ring Installer:

8. Piston Pin Snap Ring

Use a pair of snap ring pliers to install the snap ring.

9. Cylinder Body and O-ring

kg,m(lb.ft/N.m) Cylinder Body Bolt Torque

( 19.6

2.8 ± 0.2 ± 1.4/27.4 ± 2.0)

10-18 AIR COMPRESSOR

l«I

11. Cylinder Head kg-m(lb.ft/N-m) CD Cylinder Head Bolt Torque ® Unloader Valve Torque ® Discharge Valve Torque

2.8 ± 0.2 (19.6 ± 1.4/27.4 ± 2.0) 11.0 ± 1.0 (79.2 ± 7.2/107.8 ± 9.8) 11.0 ± 1.0 (79.2 ± 7.2/107.8 ± 9.8)

ENGINE ELECTRICALS 11-1

SECTION 11

ENGIN

LECTRICALS

TABLE OF CONTENTS ITEM

PAGE

Starter motor identification ....................................................... 11- 2 Star:ter main data and specifications .............................................. 11- 3 Starter motor sectional view .......................................... . ........... 11- 4 ............,.,. motor exploded view ... . . . .. . ........ . ............. . ............ . ........ 11- 5 Alternator identification ............ . . ............. . ........ . ..................... 11- 6 Main data and specifications ...................................................... 11- 7 Alternator sectional view ............................................ . ............ 11- 8 Alternator exploded view . . ... . ................... . ............................... 11- 9 Intake heater .................................................................... 11-10

11-2 ENGINE ELECTRICALS

STARTER MOTOR IDENTIFICATION The starter motor identification plate is attached to the starter motor outside yoke. The ISUZU part number, the manufacturer's code number, and other important information are stamped on the plate. Refer to the identification plate together with the "Main Data and Specifications" Tables and accompanying charts in this Manual when requesting service assistance from a qualified electrical repair shop. If you are unable to locate the data applicable to your engine, please contact ISUZU MOTORS LIMITED through your machine supplier.

NIKKO IDENTIFICATION PLATE

A START I NG MOTOR B C

NIKKO ELEC. IND. CO.,LTD. A: B: C: D:

Isuzu part number Manufacturer's code number Rated output Manufacturer's production mark

HITACHI IDENTIFICATION PLATE

A: B: C: D:

Isuzu part number Manufacturer's code number Rated output Manufacturer's production mark

ENGINE ELECTRICALS 11-3

STARTER MOTOR

MAIN DATA AND SPECIFICATIONS Isuzu Part No. Manufacturer's code No. Rated voltage Rated output Rating Direction of rotation (Viewed from the pinion side) Clutch type Terminal voltage (No load) Maximum current (No load) Starter motor minimum operating speed (No load)

(V) (kW) (Sec)

(V) (A) (rpm)

1-81100-217-0

1-81100-180-0

0-23000-1070 (NIKKO)

S210-08 (HITACHI)

24 4.5 30

24 11 30

Clockwise Roller 24 120

Clockwise Roller 24 170

More than 2500

2000 3.5 11 48.8 (1.92) 1.64 (0.064)

Pinion gear Modules Number of teeth Outside diameter Travel distance

mm(in.) mm(in.)

3.5 11 48.8 (1.95) 1.64 (0.645)

Yoke outside diameter

mm(in.)

90 (3.55)

113 (4.45)

0.14 1.02

0.13 1.09

mm(in.)

21.0 - 22.0 (0.82 0.86) 12.0 (0.47)

22.0 (0.87) 14.0 (0.55)

kg/(lbs.)

4.5 (9.92)

3.5 (7.7)

mm(in.) mm(in.)

43.0 (1.69) 42.0 (1.65)

43.0 (1.69) 40.0 (1.57)

mm(in.) mm(in.)

0.015 (0.0006) 0.1 (0.004)

0.05 (0.002) 0.1 (0.004)

mm(in.)

0.5 0.8 0.031) (0.020 0.2 (0.008)

0.5 - 0.8 (0.020 - 0.03) 0.2 (0.008)

Number of poles Â°

Â°

Magnetic switch (at 20 C [68 F] ) Series coil resistance Shunt coil resistance Brush length Standard Limit Brush spring standard fitting load Commutator Outside diameter Standard Limit Difference between the largest and smallest diameters (Run-out) Standard Limit Depth of undercut mica Standard Limit

(f!) (H)

mm(in.)

-mm(in.)

11-4 ENGINE ELECTRICALS

STARTER MOTOR SECTIONAL VIEW

NIKKO-0-23000-6091

HITACHI-S210-108

ENGINE ELECTRICALS 11-5

STARTER MOTOR EXPLODED VIEW

NIKKO-0-23000-6091

HITACHI-S210-108

11-6 ENGINE ELECTRICALS

AlTERNATOR IDENTIFICATION The alternator identification plate is attached to the alternator rear bracket. The ISUZU part number, the manu facturer's code number, and other important information are stamped on the plate. Refer to the identification plate together with the "Main Data and Specifications" Tables and accompanying charts in this Manual when requesting service assistance from a qualified electrical repair shop. If you are unable to locate the data applicable to your engine, please contact ISUZU MOTORS LIMITED through your machine supplier.

NIKKO IDENTIFICATION PLATE

A ALTERNATOR I

'-----_D__I �

NIKKO ELEC. IND. CO.,LTD. A: B: C: D:

Isuzu part number Manufacturer's code number Rated output Manufacturer's production mark

HITACHI IDENTIFICATION PLATE

F7. �1 I �-------

�I

cf=1· _

� ®ID A: B: C: D:

Isuzu part number Manufacturer's code number Rated output Manufacturer's production mark

ENGINE ELECTRICALS 11-7

MAIN DATA AND SPECIFICATIONS ALTERNATOR Isuzu Part No. Manufacturer's code No. (V) (A) (rpm) (rpm)

Rated voltage Rated output Operating speed Rated speed Rated output at r.p.m. No-load output at O Amp. Direction of rotation as viewed from pulley side Polarity grounded Pulley diameter

1-81200-205-0

1-81200-146-1

0-33000-3700 (NIKKO)

LT220-14C (HITACHI)

24 25 1000 - 5000 5000

24 20 850 - 6000 3000

4 or more/27/1100 Less than 25/27/5000 28.5 ± 1/1000 or less

(Amp.Nolt/rpm) (Volt/rpm)

Clockwise

2 or more/28/ 900 18 or more/28/3000 28/850 or less Clockwise (-)

mm(in.)

80 (3.15)

14 0.34

13.8 0.36

15 (0.59) 4 (0.16)

14.5 (0.57) 7.5 (0.30)

350 ± 10%

Coil resistance at 20 C Rotor coil Stator coil [U-V-W] Brush length Standard Limit Brush spring standard fitting load

(n l ( .n)

mm(in.) mm(in.) (g)

Slip ring diameter Standard Limit

mm(in.) mm(in.)

33 (1.30) 32 (1.26)

34 (1.34) 17 (0.67)

Shaft diameter Front Rear

mm(in.) mm(in.)

25 (0.99) 17 (0.67)

1-81251-024-0 0-44000-0730

1-81251-002-0 TL2Z-18

Regulator's applicable Isuzu part No. Manufacturer's code No.

11-8 ENGINE ELECTRICALS

ALTERNATOR SECTIONAL VIEW

NIKKO-0-33000-3700

HITACHI-L T220-14C

ENGINE ELECTRICALS 11-9

ALTERNATOR EXPLODED VIEW

NIK K 0-0-33000-3700

ï¿½ \::!J)

HITACHI-LT220-14C

11-10 ENGINE ELECTRICALS

INTAKE HEATER GENERAL DESCRIPTION

Return=========� Needle Valve

Fuel Tank

Switch

�___,...-o-�l Intake Cover

Fuel Filter

Type A

Intake Air

Switch Solenoid Valve

Intake Heater

Type B *The minimum required height H is approximately 100mm (4in.)

In these engines, a two types of intake heaters are provided, depending on the engine, as an engine start ing aid. Type A : Ball Valve Type Intake Heater with an intake heater fuel tank. Type B : Orifice Type Intake Heater with a fuel control solenoid valve. The respective function of the two types are as follows. Type A The fuel is fed from the tank to the ball valve in the intake heater by the gravity. When the starter switch is operated, the intake heater coil is energized heating the ball valve barrel thereby invite a thermal expansion to the barrel permitting the barrel to create a clearance between the ball and the barrel. This results to introduce and ignite the fuel. The fuel burns and flames heating the intake air in the engine intake cover to facilitates the engine starting. Type B In this type, a fuel control solenoid valve is equipped instead of the fuel tank in the type A. When the starter switch is operated, the solenoid valve is energized opening the fuel valve. This results to the pressurized fuel comes to the intake heater orifice. As a minute clearance is provided between the intake heater barrel and the orifice, the fuel passes the clearance with being squeezed to a necessary amount in order to develop a moderate burning.

ENGINE ELECTRICALS 11-11

l+-!•l 1

INTAKE HEATER FUEL TANK DISASSEMBLY STEP

... �- .... ,

-- ----�- - �)- ;- --,,

__ .,.,. /

Disassembly Steps 1. Set screw (disconnection from the piping) 2. Leak off pipe (disconnection from the piping)

3. Fuel pipe (disconnection from the piping) 4. Cover fixing bolts

INSPECTION AND REPAIR Make the necessary adjustment, repairs, and part replacements if excessive wear or damage is discovered during inspection.

Overflow pipe

Fuel Tank Fuel level Inspection

Cover

The fuel level can be visually checked through a trans parent cover. When the fuel level stays within the dotted line circle, the tank float is normal.

Fuel level

When the fuel leveling function is abnormal adjust the bending of the float seat.

Tank body

Level gauge

l•!+-1

REASSEMBLY

To assemble, follow the disassembly procedures in reverse order.

11-12 ENGINE ELECTRICALS

INTAKE HEATER REMOVAL AND INSTALLATION STEP

1 2

Orifice Type

Removal Steps 1. Terminal 2. Hexagon nut 3. Gasket

Ball Valve Type

Installation Steps 3. Gasket 2. Hexagon nut 1. Terminal

INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is dis covered during inspection.

lnteke Heater Continuity Test Use a circuit tester to check the heater coil and the igni ter insulation. 1. Touch one probe to the terminal. 2. Touch the another probe to the igniter shield. There should be continuity.

ENGINE ELECTRICALS 11-13

INTAKE HEATER SOLENOID VALVE REMOVAL AND INSTALLATION STEPS

2 2

OUT

Removal Steps 1. Lead wire connection 2. Fuel pipe connection 3. Fixing bolt

Installation Steps 3. 2. 1.

Fixing bolt Fuel pipe connection Lead wire connection

INSPECTION AND REPAIR Make the part replacement if excessive wear or damage is discovered during inspection.

lnteke Heater Continuity Test Use a circuit tester to check the solenoid coil insulation.

Touch one probe to the one of two lead wire ends and remaining one to the another lead wire end. There must be continuity.

MEMO

"QUALITY PARTS YOU CAN TRUST"

TROUBLESHOOTING 12-1

SECTION 12

TROUBLESHOOTING TABLE OF CONTENTS ITEM

PAGE

Hard starting

12- 2

1} Starter inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12- 2 2) Starter operates but engine does not turn over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12- 3 3) Engine turns over but does not start though fuel is being delivered to the injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12- 4 4) Engine turns over but does not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12- 5 Unstable low idling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . 12- 6 Insufficient power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12- 9 Excessive fuel consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-12 Excessive oil consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-14 Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-15 Whity exhaust smoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-17 Darkish exhaust smoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-18 Oil pressure does not rise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-19 Abnormal engine noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-21

Note:

Use this section to quickly diagnose and repair engine failures. Each troubleshooting chart has three headings arranged from left to right (1)

Check point

(2)

Trouble cause

(3)

Remedy

12-2 TROUBLESHOOTING

HARD STARTING 1)

� !

Defective neutral switch

I NG

Battery

Remedy

Trouble Cause

Checkpoint

Neutral switch (If so equipped)

STARTER INOPERATIVE

Replace the neutral switch

I Clean and/or retighten the battery cable terminals

Loose battery cable terminals Poor connections due to rusting

Recharge or replace the battery

Battery discharged or weak

Fan belt loose or broken

Adjust or replace the fan belt

Fusible link

Fusible link shorted

�

Replace the fusible Hnk

Starter switch

NG I

Defective starter switch or starter relay

Starter motor

Defective magnetic switch or starter relay

Defective starter motor

l •

Replace the starter switch or the starter relay

Repair or replace the magnetic switch

Repa;, o, ceplace the starte, motoc I

TROUBLESHOOTING 12-3

HARD STARTING 2) STARTER MOTOR OPERATES BUT ENGINE DOES NOT TURN OVER

Battery

Remedy

Trouble Cause

Checkpoint

Loose battery cable terminals Poor connections due to rusting

Clean and/or retighten the bat tery cable terminals

Battery discharged or weak

Recharge or replace the battery

Fan belt loose or broken

Adjust or replace the fan belt

Detective pinion

Starter motor

Engine

gear

Defective magnetic switch

• NG

�7

Replace the pinion gear

•...�

Repair or replace the magnetic switch

Brush wear Weak brush spring

Replace the brush and/or the brush spring

Piston, crank bearing seizure, or other damage

Repair or replace the related parts

12-4 TROUBLESHOOTING

HARD STARTING 3)

ENGINE TURNS OVER BUT DOES NOT START

FUEL IS BEING DELIVERED TO THE INJECTION PUMP Continued from the previous page OK

Injection nozzle injection starting pressure too low Improper spray condition

Injection nozzle

OK• Injection pump

:I • l\JG i !

•

Injection pump (VE pump)

LJ NG

Defective fuel injection nozzle resulting in fuel drippage after fuel injection

Adjust or replace the injection nozzle

r� i

•

Replace the delivery valve

Defective injection pump control NG · Repair or replace the injection rac operation pump contro rac n�_ _ _ _ - _ _ - -1- _ k_ -----� - - k _ _ - - _ _ _ '----_ ____

Remedy

Trouble Cause

Checkpoint

Injection pump plunger worn or stuck

Replace the injection pump plunger assembly

•

Injection pump drive shaft seizure LNG i or other damage

Replace the injection pump drive shaft

Injection pump governor spring seizure

Replace the injection pump governor spring

NG I

TROUBLESHOOTING 12-5

HARD STARTING 4)

ENGINE TURNS OVER BUT DOES NOT START

Engine stop mechanism

Remedy

Trouble Cause

Checkpoint NG

; Defective engine stop mechanism Control wire improperly adjusted I (In-line pump)

Replace the engine stop mechanism Adjust the control wire

Replace the fuel cut solenoid valve

FUEL IS NOT BEING DELIVERED TO THE INJECTION PUMP Fuel

Fuel piping

Fuel tank is empty

Clogged or damaged fuel lines Loose fuel line connections

Fill the fuel tank

ï¿½

Repair or replace the fuel lines Retighten the fuel line connections

OK Fuel filter

Fuel filter overflow valve does not close

Clogged fuel filter element

Repair or replace the foe! filter overflow valve

NG I

Replace the fuel filter element or the fuel filter cartridge

OK Fuel system Continued on the next page

Air in the fuel system

Bleed the air from the fuel system

12-6 TROUBLESHOOTING

UNSTABLE LOW IDLING Trouble Cause

Remedy

Low idling improperly adjusted

Adjust the low idling

Defective low idling speed control device

Throttle control system improperly adjusted

Adjust the throttle control system

Fuel system leakage or blockage

Repair or replace the fuel system

Air in the fuel system

Bleed the air from the fuel system

Checkpoint Low idling system

OK Low idling speed control device

Repair or replace the low idling speed control device

OK Throttle control system

OK Fuel system

r7 :

Watec particles in the foel system

Clogged fuel filter element

Change the fuel

OKâ&#x20AC;˘ Fuel filter

Continued on the next page

ďż˝ i

Replace the fuel filter element or the fuel filter cartridge

TROUBLESHOOTING 12-7

UNSTABLE LOW IDLING Continued from the previous page OK;

Injection pump

Remedy

Trouble Cause

Checkpoint

j j . . NG . � Defective governor lever operation �

Regulator valve improperly adjusted (VE pump only)

� I� �------------I NG

i--

Broken plunger spring

Adjust or replace the regulator valve

----------Replace the plunger spring

Worn plun ger

Replace the plunger assem ly _ _ _ _ _ _ _ _ _ _ _ _ _ _b - - _ _ _ - _ _ _ _ ___ ll � _ _ --- -� _ �_

NG ------�, Worn camshaft (In-line pump only)

Repair or replace the governor lever

1-----------'

Replace the camshaft

Worn roller tappet (In-line pump • NG i

only)

Replace the roller tappet

�--------------'

NG Continued on the next page

Worn cam disc (VE pump only)

Replace the cam disc

12-8 TROUBLESHOOTING

UNSTABLE LOW IDLING Checkpoint

Remedy

Trouble Cause

Continued from the previous page

OK I

Valve clearance

NG -

OK I Compression pressure

Valve clearance improperly adjusted

Blown out cylinder head gasket Worn cylinder liner Piston ring sticking or broken Improper seating between the valve and the valve seat

Adjust the valve clearance

Replace the related parts

TROUBLESHOOTING 12-9

INSUFFICIENT POWER Checkpoint Air cleaner

Remedy

Trouble Cause NG

Clogged air cleaner element

Clean or replace the air cleaner

� element

OKI Fuel

Water particles in the fuel

! _t-J(l_

Replace the fuel

OK Fuel filter

Fuel feed pump

Replace the fuel filter element or the fuel filter cartridge

Clogged fuel filter element

• NG i �

Defective fuel feed pump

w I

Repair or replace the fuel feed pump

OK Injection nozzle

Injection nozzle sticking

Replace the injection nozzle

Injection nozzle injection starting pressure too low � ! Improper spray condition

Adjust or replace the injection nozzle

OK Fuel injection pipes

NG I ��

Continued on the next page

Fuel injection pipes damaged or o st ruc ted _b

I NG

Replace the fuel injection pipes

� l �_ _ _ _ - - - _ _____ __ _J - _ _ _ _ _ _

_ _ _ _ - - - _

_ _ _

�

12-10 TROUBLESHOOTING

INSUFFICIENT POWER Remedy

Trouble Cause

Checkpoint

Continued from the previous page OK I

Injection pump

Defective delivery valve

Replace the delivery valve

Defective timer

;

Defective injection timing

Weak governor spring

_ _ NG

>--______ _ __.

,--

---- - NG

Continued on the next page

7�: NG

Improper control lever operation

---

�

Worn plunger

- -

_ _

_ _ _ _

Adjust or replace the control 1 ever--- --_ - � - - Adjust the injection timing Repair or replace the injection pump timer

I I

___ �

-----, Worn camshaft (In-line pump only)

Repair or replace the timer

Replace the governor spring

�_

Re place the plunger assem l y _ _ _ _ _ _ _ _ _ _

_ _

- -

_ _ _b_ _ _

Replace the camshaft

TROUBLESHOOTING 12-11

INSUFFICIENT POWER Continued from the previous page

Remedy

Trouble Cause

Checkpoint

Injection pump

Worn roller tappet

!�l

'-----------------'

�------------�

OK Turbocharger

n, '

Exhaust gas leakage from the exhaust system Air leakage from the intake system

Defective turbocharger assembly

Blown out cylinder head gasket Worn cylinder liner Piston ring sticking or broken Improper seating between the valve and the valve seat

OK Compression pressure

Replace the roller tappet

Repair or replace the related parts

Replace the turbocharger assembly

i--NG I l

Replace the related parts

OK Valve clearance

Valve clearance improperly adjusted

�-------------

------------------

OK Valve spring

OK Exhaust system

OK Full load adjusting screw seal

NG I

Valve spring weak or broken

Exhaust pipe clogged

Open and improperly set adjusting screw seal

l I

Adjust the valve clearance

Replace the valve spring

Clean the exhaust pipe

NG I

,···--

Adjust and reseal the adjusting screw

12-12 TROUBLESHOOTING

EXCESSIVE FUEL CONSUMPTION

Fuel system

Remedy

Trouble Cause

Checkpoint

Fuel leakage

Repair or replace the fuel system related parts

Clogged air cleaner element

Clean or replace the air cleaner element

Poorly adjusted low idle speed

Adjust the low idle speed

Injection nozzle injection starting pressure too low Improper spray condition

Fuel injection timing improperly adjusted

Adjust the fuel injection timing

NG -

Defective delivery valve resulting fuel drippage after fuel injection

Replace the delivery valve

OK I

Air cleaner

OK I

Low idling speed

Injection nozzle

Adjust or replace the injection nozzle

OK I

Fuel injection timing

Injection pump

f----

OK I

Turbocharger

Continued on the next page

f----

Air leakage from the turbocharger NG f---intake side

Repair the turbocharger intake side

TROUBLESHOOTING 12-13

EXCESSIVE FUEL CONSUMPTION Remedy

Trouble Cause

Checkpoint Continued from the previous page

OK Turbocharger

Defective turbocharger assembly

• Replace the turbocharger assembly

OK Valve clearance

OK Compression pressure

OK Valve spring

,-,

Valve clearance improperly adjusted

Blown out cylinder head gasket Worn cylinder liner Piston ring sticking or broken Improper seating between the valve and the valve seat

.�

Adjust the valve clearance

Replace the related parts

Valve spring weak or broken

Replace the valve spring

�

12-14 TROUBLESHOOTING

EXCESSIVE OIL CONSUMPTION

Engine oil

OK I Oil seal and gasket OK.

Remedy

Trouble Cause

Checkpoint

Air breather

Engine oil unsuitable Too much engine oil

Replace the engine oil Correct the engine oil volume

Oil leakage from the oil seal and/or the gasket

Replace the oil seal and/or the gasket

Clean the air breather

Clogged air breather

OK Inlet and exhaust valves Valve seals

Defective valve seals Worn valve stems and valve guides

Replace the valve seals, the valves, and the valve guides

Piston rings worn, broken or improperly installed

Replace the piston rings or properly install

Cylinder lines scored or worn

OKâ&#x20AC;˘ Piston rings OK Cylinder liners

Replace the cylinder liners

TROUBLESHOOTING 12-15

OVERHEATING

Cooling water

OK Fan belt

Remedy

Trouble Cause

Checkpoint

�

Insufficient cooling water

I I

Replenish the cooling water

Replace the fan belt

n NG

�

Fan belt loose or cracked causing slippage

OK I

Radiator

�

Def_ective radiator cap or clogged �� radiator core

Replace the radiator cap or clean the radiator core

OK Water pump

,----,

Defective water pump

'--·NG

•

Repair or replace the water pump

OK Cylinder head and cylinder body � sealing cap

Defective sealing cap resulting in water leakage

Replace the sealing cap

�.�

OK Thermostat

Defective thermostat

��

Replace the thermostat

Cooling system

Continued on the next page

Cooling system clogged by foreign material

Clean the foreign material from the cooling system

12-16 TROUBLESHOOTING

OVERHEATING Checkpoint

Remedy

Trouble Cause

Continued from the previous page

OK I

Fuel injection timing

l'JG

Fuel injection timing improperly adjusted

Adjust the fuel injection timing

TROUBLESHOOTING 12-17

WHITE EXHAUST SMOKE

uel F ,,________ __ _ _ _____

�17�· __ I

I Rep ace the fuel

Water particles in the fuel _ _ _ _- -

- - _ _ _ _-

- _ _ _�n�___ _ _ l_ _ _ _ _ _ _

NG .

Delayed fuel injection timing

uel injection timing

Remedy

Trouble Cause

Checkpoint

·,1

_ _

---�

Adjust the fuel injection timing

Compression pressure

OK i Turbocharger

Blown out cylinder head gasket Worn cylinder liner Piston ring sticking or broken Improper seating between the valve and the valve seat

Defective turbocharger

i NG

�

i�c1 i

Replace the related parts

Replace the turbocharger

OK Inlet and exhaust valves Valve seals

Defective valve seals NG i

Worn valves stems and valve guides

I NG I

OK I

Replace the valve seals, the valves, and the valve guides

I Piston rings worn, broken or improperly installed

Piston rings

Replace the piston rings or

� . ! properly install

Cylinder liners

Cylinder lines scored or worn

I NG i

-1

Replace the cylinder liners

12-18 TROUBLESHOOTING

DARK EXHAUST SMOKE

Air cleaner

Remedy

Trouble Cause

Checkpoint

f------

Clogged air cleaner element

Clean or replace the air cleaner element

Adjust or replace the injection nozzle

Injection nozzle

Injection nozzle injection starting pressure too low Improper spray condition

Fuel injection timing improperly adjusted

Adjust the fuel injection timing

Defective delivery valve resulting in fuel drippage after fuel injection

Replace the delivery valve

Excessive injection volume

Adjust the injection volume

f------

Fuel injection timing

f------

Injection pump

f------

TROUBLESHOOTING 12-19

OIL PRESSURE DOES NOT RISE

Engine oil

Oil pressure gauge or unit Oil pressure indicator light

Improper viscosity engine oil Too much engine oil

I�

Replace the engine oil Correct the engine oil volume

�-------------

�------i ------� i

Remedy

Trouble Cause

Checkpoint

•f. NG �

Defective oil pressure gauge or unit Defective indicator light

�

Repair or replace the oil pres sure gauge or unit Replace the indicator light

OK Oil filter

I NG

r7· '--------------� Clogged oil filter element

, NG

OK NG

Relief valve and by-pass valve

Replace the oil filter element or the oil filter cartridg e ____ _ - � _ __ - _ _ _ _ _ _ _

Relief valve sticking and/or weak by-pass valve spring

Replace the relief valve and/or the by-pass valve spring

Cloggect 01'I pump s ramer

Clean the 01·1 pump strainer

1 pump

Worn oil pump related parts

OK Rocker arm shaft

Continued on the nest page

I NG

Worn rocker arm bushing

Replace the oil pump related parts

Ii ' NG

Replace the rocker arm bushing

12-20 TROUBLESHOOTING

OIL PRESSURE DOES NOT RISE Trouble Cause

Checkpoint

Remedy

Continued from the previous page OK

Camshaft

Crankshaft and bearings

I NG

Worn camshaft and camshaft bearing

Worn crankshaft and bearings

NG -

Replace the camshaft and the camshaft bearings

Replace the crankshaft and/or the bearings

TROUBLESHOOTING 12-21

ABNORMAL ENGINE NOISE 1.

Engine Knocking Remedy

Trouble Cause

Checkpoint

Check to see that the engine has been thoroughly warmed up before beginning the troubleshooting procedure.

Fuel

Fuel unsuitable

Replace the fuel

OK Fuel injection timing

Fuel injection timing improperly adjusted

I . NG

Adjust the fuel injection timing

OK Injection nozzle

Improper injection nozzle starting pressure and spray condition

Compression pressure

Blown out head gasket Broken piston ring

2. Exhaust pipes

Adjust or replace the injection nozzle

Gas leakage Noise

Loosely connected exhaust pipes NG Broken exhaust pipes

Tighten the exhaust pipe connections Replace the exhaust pipes

Loose injection nozzles and/or glow plugs

Replace the washers Tighten the injection nozzles and/or the glow plugs

OK Injection nozzles and/or glow plugs Continued on the next page

Replace the head gasket or the piston ring

12-22 TROUBLESHOOTING

ABNORMAL ENGINE NOISE 2. Checkpoint

Gas leakage Noise Remedy

Trouble Cause

Continued from the previous page OK •

Exhaust manifold

Cylinder head gasket

Fan belt

Cooling fan

Water pump bearing

H [

Continuous Noise

Loose fan belt

Loose cooling fan

Worn or damaged water pump bearing

Defective alternator or vacuum pump

Tighten the exhaust manifold connections

Damaged cylinder head gasket

Alternator or vacuum pump

Loosely connected exhaust mani-

� fold and/or glow plugs

Replace the cylinder head gasket

1� 'l NG

Retighten the cooling fan

Replace the water pump bearing

n I

Readjust the fan belt tension

Repair or replace the alternator or the vacuum pump

•

Valve clearance

Valve clearance improperly adjusted

Adjust the valve clearance

TROUBLESHOOTING 12-23

ABNORMAL ENGINE NOISE 4. Checkpoint

Valve clearance

Slapping Noise Remedy

Trouble Cause

Valve clearance improperly adjusted

Adjust the valve clearance

Replace the rocker arm

Rocker arm

Damaged rocker arm

---------- - - �

Flywheel

,�'-�:

Crankshaft and thrust bearings

OK I Crankshaft and connecting rod bearings

r-.

Loose flywheel bolts

Retighten the flywheel bolts

Worn or damaged crankshaft and/or thrust bearings

Replace the crankshaft and/or the thrust bearings

Worn or damaged crankshaft and/or connecting rod bearings

Replace the crankshaft and/or the connecting rod bearings

Worn or damaged connecting rod� bushing and piston pin

Replace the connecting rod bushing and/or the piston pin

Worn or damaged piston and cylinder liner Foreign material in the cylinder

Replace the piston and the cylin der liner

OK I Connecting rod bushing and piston pin

OK I

Piston and cylinder liner

'··········--·--

NG � ;

Engine parts contact email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.Isuzu-6RB1.com www.HeavyEquipmentRestorationParts.com

MEMO

"QUALITY PARTS YOU CAN TRUST"

14-2 CONVERSION TABLE LENGTH FEET TO METERS ft.

10 20 30 40 50 60 70 80 90 100

miles

0.305 3.353 6.401 9.449 12.497 15.545 18.593 21.641 24.689 27.737 30.785

3.048 6.096 9.144 12.192 15.240 18.288 21.336 24.384 27.432 30.480

ft.

32.8084 65.6168 98.4252 131.2336 164.0420 196.8504 229.6588 262.4672 295.2756 328.0840

ft.

10 20 30 40 50 60 70 80 90 100

1.609 17.703 33.796 49.890 65 983 82.077 98.170 114.263 130.357 146.450 162.544

16.093 32.187 48.280 64.374 80.467 96.561 112.654 128.748 144.841 160.934

miles -

10 20 30 40 50 60 70 80 90 100

6.214 12.427 18.641 24.855 31.065 37.282 43.496 49.711 55,923 62.137

0.610 3.658 6.706 9.754 12.802 15.850 18.898 21.946 24.994 28.042 31.090

miles

•

0.621 6.835 13.049 19.262 25.476 31.690 37.904 44.117 50.331 56.545 62.758

3.219 19.312 35 406 51.499 67.592 83.686 99.779 115.873 131.966 148.060 164.153

miles

1.243 7 456 13.670 19.884 26 098 32.311 38.525 44.739 50.952 57.166 63.380

0.914 3.962 7.010 10.058 13.106 16.154 19.202 22.250 25.298 28.346 31.394

1.219 4.267 7.315 10.363 13.411 16.459 19.507 22.555 25.603 28.651 31.699

METERS TO FEET

ft.

9.8425 13.1234 16.4042 42.6509 45.9318 49.2126 75.4593 78.7402 82.0210 108.2677 111.5486 114.8294 141 0761 144.3570 147.6378 173.8845 177.1654 180.4462 206.6929 209.9738. 213.2546 239.5013. 242.7822 246.0630 272.30971 275.5906 278.8714 305.1181 308.3990 311.6798 337.9265 341.2074 • 344.4882

4.828 20.921 37.015 53 108 69.202 85.295 101.389 117 482 133.576 149.669 165.762

miles

6.437 22.531 38.624 54.718 70.811 86.905 103.000 119.091 135.185 151.278 167.372

8.047 24.140 40.234 56.327 72.420 88.514 104.607 120.700 136.794 152.888 168.981

1.864 8.078 14.292 20.505 26.719 32.933 39.146 45.360 51.574 57.187 64.001

2.485 8.699 14.913 21.127 27.340 33.554 39.768 45.981 52.195 58.409 64.622

miles

3.107 9.321 15.534 21.748 27.962 34.175 40.389 46.603 52.816 59 030 65.244

ft.

19.6850 22.9659 52.4934 55.7743 85.3018 88.5827 118.1102. 121.3911 150.9186 154.1995 183.7270 187.0079 216.5354 219.8163 249.3438 252.6247 1 282.1522 285.4331 314.9606 318.2415 i 347. 7690 351.0499

9 656 25.750 41.843 57.936 74.030 90.123 106.217 122.310 138.404 154.497 170.590

miles

•

11.265 12.875 27.359 28.968 43.452 45.062 59.546 61.155 77.249 75.639 91.733 93.342 107.826 109.435 123.919 125.529 140.013 141.622 156.106 157.716 1 172.200 173.809

miles

3.728 9.942 16.156 22.370 28.583 34.797 41.010 47.224 53.438 59.652 65.865

26.2467 59.0551 91.8635 124.6719 175.4803 190.2887 223.0971 255.9055 288.7139 321.5223 354.3307

KILOMETERS TO MILES miles

ft.

MILES TO KILOMETERS

2.438 5.486 8.534 11.582 14.630 17.678 20.726 23.774 26.822 29.870 32.918

2.134 5.182 8.230 11.278 14.326 17.374 20.422 23.470 26.518 29.566 32.614

1.829 4.877 7.925 10.973 14 021 17.069 20.117 23.165 26.213 29.261 32.309

1.524 4.572 7.620 10.668 13.716 16.764 19.812 22.860 25.908 28.956 32.004

3.2808 6.5617 36.0892 39.3701 68.8976 72.1785 1 101.7060 104 9869. 134.5144 • 137.7953. 167.3228' 170.6037 200.1312 203.4121 232.9396 236.2205 265.7480 269.0289 298.5564 301.8373 • 331.3648 334.6457

km -

4.350 10.563 16.777 22.990 29.204 35.418 41.632 47.845 54.059 60.273 66.487

•

miles

4.971 11.185 17.398 23.612 29.826 36.039 42.253 48.467 54.681 60 894 67.108

2.743 5.791 8.839 11.887 14.935 17.983 21.031 24.079 27.127 30.175 33.223

ft.

29.5276 62 3360 95.1444 127.9528 160.7612 193.5696 226.3780 259.1864 291.9948 324.8032 • 357.6116

•

10 20 30 40 50 60 70 80 90 100

miles

14.484 30.578 46.671 62.764 78.858 94.951 111.045 127.138 143.232 159.325 175.418

miles

5.592 11.806 18.020 24.233 30.447 36.661 42.875 49.088 55.302 61.516 67.729

10 20 30 40 50 60 70 80 90 100

CONVERSION TABLE 14-1

SECTION 14

CONVERSION TABLE TABLE Of CONTENTS ITEM

PAGE

length ........................................................................ 14- 1 Area .......................................................................... 14- 3

Volume ........................................................................ 14- 3 Mass ........ ....... . . . . . . . ................................................... 14- 5

Pressure . ....... . ................................... . .. ...... ......... ...... . . . 14- 6 Torque .......... ï¿½............................................................. 14- 7 Temperature ................................................................... 14- 8 LENGTH MILLIMETERS TO INCHES in.

0.0394

0.0787

0.1969

0.2362

30 31

11811

0.3543

0 2756

0.3150

0.3937

0.4331

0.5118

0.4724

18 19

0 7874

0.8268

0.8661

23 24 25

101 102

103

104

105 106

107 108 109

0.9055 0 9449

0 9843 3.9764

111

112

4.1339

115

4.0945 4.1732

4.2126 4,2520

4,2913

1.6142

1.6535

1.6929 1.7323

116

117

1,9685

3.1496

3.2677

3.3858

2.2441

2.3622

2.2835

2.4016 2.4409

124

122

123

125 126

127 128

129

2.6772 2.7559

2 7953

2,8346

2.8740 2,9134

2,9528

3.5827 3.6220

3,7008

3,8583

100

135

5.0787

3.5039

3,7402

4.9213

5.0394

3.4646

132

4,9606 5,0000

3.3465

3.6614

4.7638 4,8031

4.8425 4.8819

3.3071

2.6378

3.2283

3.5433

2,7165

3.1890

3.1102

3.4252

2.5591

3.0709

2.5984

2.5197

2.9921

3.0315

131

133

134 136

137

138

139

in.

rn.

65 66

4.4882

4.5669

121

4,5276

2.4803

4,3701

4.6063 4.6457 119 14.6850

118

63 64

4.4488

114

1.9291

4,4094

113

1 8898

1.7717 1.8110

1.8504

1.5748

46 47

2.1260

2 1654

1.4567

1.5354

2.0866

2.3228

1.4961

43 44

2.0472

1.4173

40 41

2.0079

1 3386 1.3780

I 2.2047

1.2992

1.2598

4.0157

4,0551

1.2205

0.7480

20 21

1.1417

0.6693

0.7087

1.1024

0.6299

28 29

0.5512

0.5906

1.0236

1.0630

0.1575

0.1181

in.

INCHES TO MILLIMETERS

3.7795

3.8189

3.8976

3.9370 5,1575 5.1968 5,2362

5,2756 5.3150

5.3543 5.3937

5.4331

5.4724

1 '16 1/8 3/16 1/4 5116 3/8 7/16 1/2

132 3/32 5132 7/32 9/32 11/32 13/32 15/32

1154

3164

0.3969

0.7938

1.1906 1.5875

5/64

1.9844

7 1 64

3.1750

9164

11164

13/64

15/64

17164

21164

23/64

25/64

27/64

2 7781

3.5 719

3.9688 4.3656 4,7625

5.1594

5.5563

5,9531 6.3500

6.7469

7.5406

7.9375

8.3344

8.7313

9.1281

9.5250

9.9219

10.3188

29/64

31/64

2.3813

7,1438

19/64

in,

10 7156 11,1125

11.5094

11.9063

12 .3031 1 12.7000

9116 518 11!16 3/4 13,16 7/8 15116 1

17;32 19132 21132 23132 25132 27132 29/32 31/32

33/64 35164

37/64

39/64 41/64

43164 45/64

4 7/64 49/64

51164 53/64

55/64 57164

59/64 61/64

63/64

13 0969

13.4938

13.8906

14.2875 14 6844

15,0813 15.4781 15 8750

16.2719 16.6688

17.0656 17.4625 17.8594

18,2563

18.6531

19.0500

19.4469

19.8438 202406 20,6375

21.0344

21.4313

21.8281

22.2250

22,6219

23,0188

23.4156

23.8125 24.2094

24,6063

25.0031 1 25.4000

MEMO

"QUALITY PARTS YOU CAN TRUST"

SPECIAL TOOL LIST 13-3

PART NO.

PARTS NAME

PAGE

9-8523-1186-0

Cylinder If ner remover

4-14

9-8522-0043-0

Cylinder liner installer

4-16

9-8522-0042-0

Connecting rod bushing installer & remover

4-23 4-24

9-8522-0025-0

Crankshaft gear installer

4-32

15.

1-85220-035-0

Flywheel housing oil seal installer

4-33

16.

9-8522-1289-0

Valve stem oil seal installer

5- 6

17.

1-88430-154-0

Tappet setting tool

5-10

18.

1-85220-014-0

Wear ring installer

5-14

19.

9-8522-1319-0

Piston ring compressor

5-15

20.

1-85210-028-0

Impeller remover

7- 4

ITEM NO.

ILLUSTRATION

11.

�

12.

13.

14.

•·-

�

13-2 SPECIAL TOOL LIST

SPECIAL TOOL LIST ITEM NO.

ILLUSTRATION

�

PART NO.

PARTS NAME

PAGE

9-8523-2001-0

Nozzle holder replacer

3- 5

9-8543-1505-0

Compression gauge adaptor

2-13

1-85210-036-0

Air Compressor Remover

3- 5

9-8521-0123-0

Taper bushing remover

3- 7

1-85230-006-0

Flywheel remover

3- 8

1-85210-027-0

Wear ring remover

3-10

9-8523-1436-0

Spring compressor

3-14 5- 6

1-8522-1025-0

Piston ring replacer

3-16 5- 4

9-8523-1222-0

Valve guide replacer

4- 3

5-8840-0086-0

Universal puller

4-13

�

7. �

8. �

�

11 10.

SPECIAL TOOL UST 13-1

SECTION 13

SPECIAL TOOL LIST TABLE OF CONTENTS ITEM

PAGE

Special tool list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 2

CONVERSION TABLE 14-3 AREA SQUARE INCHES TO SQUARE CENTIMETERS in 1

10 20 30 40 50 60 70 80 90 100

cm"

crn

in 10 20 30 40 50 60 70 80 90 100

'.!

1.550 3.100 4.650 I 6.200 I 7.750 9.300 10.850 12.400 13.950 15.500

cm'

0.155 1.705 3.255 4 .805 6.355 7.905 9. 455 11.005 12.555 14.105 15.655

cm2

25.806 32.258 90.322 96.774 154.838 161.290 219.354 225.806 283.870 290.322 348.386 354 .838 412.902 419.354 477.418 483.010 541.934 5 48.386 606.4 50 612.902 670.966 1677. 418

19.355 83.871 148.387 212.903 277.419 341.935 406.451 470.967 535.483 599.999 664.515

I i

cm2

cm'

6.452 12.903 70.968 77.419 135.48 4 141 935 200.000 I 206.451 264.516 270.967 329.032 i 335.483 393.548 399.999 458.064 464.515 522.580 529.031 587.096 593.547 651.612 658.063 i

64.516 129.032 193.548 258.064 322.580 387.096 451.612 i 516.128 580.64 4 1645.160

cm'

cm i

cm"

51.613 1 58 064 122.580 116.129 180.645 187.096 245.161 251.612 309.677 316.128 374.193 380.644 445.160 4 38.709 503.225 I 509.676 567.7 41 I 574.192 632.257 • 638.708 696.773 703.224

45.161 38.710 103.226 109.677 167.7 42 17 4.193 232.258 238.709 296.77 4 303.225 361.290 367. 741 432.257 425.806 490.322 496.773 554.838 561.289 619.354 625.805 683.870 1690.312

in'

cm'

10 20 30 40 50 60 70 80 90 100

SQUARE CENTIMETERS TO SQUARE INCHES I

2 in' 0.310 1.860 3.410 4.960 6.510 8.060 9.610 11.160 12.710 1 4.260 15.810

in 2

in1

in"

0.465 2.015 3.565 5.115 6.665 8.215 9.765 11.315 12.865 14.415 15.965

0.620 2.170 3.720 5.270 6.820 8.370 9.920 11.470 13.020 14.570 16.120

0.775 2.325 3.875 5.425 6.975 8.525 10.075 11.625 13.175 14.725 16.275

in t

0.930 2.480 4 030 5.580 7.130 ! 8.680 I 10.230 11.780 13.330 14.880 16.430

in1

in:2

1.085 2 635 4.185 5.735 7.285 8.835 10.385 11.935 13.485 15.035 16.583

cm'

in1

1.240 I 1.395 2.790 2.945 4.340 4.4 95 5.890 6.045 7.440 7.595 8.990 9.145 10.695 10.540 12.245 12.090 13.795 13.640 15.345 15.190 16.895 16.740

I I

10 20 30 40 50 60 70 80 90 100

VOLUME in''

CUBIC INCHES TO CUBIC CENTIMETERS 0

cm''(cc) 10 20 30 40 50 60 70 80 90 100

163,871 327.741 I 491.612 655.483 819.353 1 983.224 1147.094 1310.965 1474.836 1638.706

cm"(cc)

16.387 180.258 344.128 507.999 671.870 835.7 40 999.611 1163.482 1327.352 1491.223 1655.093

32.7741 196.645 I 360.515 524.386 i 688.257 I 852.1271 101 5.998 1179.869 I 134 3. 739 1507.610 1671.481

cm"(ccl

cm (cc) 3

49. 1 61 65.548 213.032 229.419 376.902 393.290 5 4 0.773 557.160 704.644 721.031 868.514 884.901 1032.385 1048.772 1196.256 I 1212.643 1360.126 1376.513 1523.997 1540.38 4 1 1687.868 1704.255

cm"(cc)

cm (cc)

81.935 245.806 209.677 573.547 737.418 901.289 1065.159 1229.030 1392.900 1556.771 1720.642

98.322 262.193 426.064 589.934 753 805 917.676 1081.546 1245.417 1409.288 1573.158 1737.029

cm"(cc)

10 20 30 40 50 60 70 80 90 100

ina

in3

in·'

in3

0.6102 1.2205 1.8307 2.4409 3.0512 3.6614 4.2716 4.8818 5.4 921 6.1023

0.0610., 0.6713 1.281 5 1.8917 2.5020 3.1122 3.7224 4.3326 4.9429 5.5531 6.1633

0.1220 0.7323 1.3425 1.9527 2.5630 3.1732 3.7834 4.3937 5.0039 5 6141 6.2243

0.1831 0.7933 1.4035 2.0138 2.6240 3.2342 3.844 4 4.454 7 5.0649 5.6751 6.2854

0.2441 0.8543 1.4646 2.0748 2.6850 3.2952 3.9055 4.5157 5.1259 5.7362 6.3464

0.3051 0.9153 1.5256 2.1358 2.7460 3.3563 3 9665 4 5767 5.1870 5.7972 6.4074

I I

in" 0.3661 0.9764 1.5866 2.1968 2.8071 3.4173 4.0275 4 .6377 5.2480 5.8582 6.468 4

i cm"(cc) 1147091 131.097 1 278.580 294.967 • 442. 451 458.838 i 606.321 I 622.708 770.192 786.579 1 934.063 950.450 1097.933 I 1114.320 1261.804 1278.191 1 425.675 1442.062 1589.545 1605.932 1753.416 1769.803 j

CUBIC CENTIMETERS TO CUBIC INCHES I

in:J 0.4272 1.0374 1.6476 2.2579 2.8681 3.4783 4.0885 4.6988 5.3090 5.9192 6.5295

in 3

ln:i

cm"(cc) 147 48 4 311.354 475.225 639.095 802.966 I 966.837 1130.7071 1294.578 I 1 458.449 1622.319 1786.190

10 20 30 40 50 60 70 80 90 100

cm 3(cc)

in"

0.4882 0.5492 1.0984 1.1594 1.7086 1.7697 2.1389 I 2.3799 2.9291 I 2.9901 3.5393 3.6004 4,1496 4.2106 4.8208 4.7598 5.3700 5.4310 6.0413 5.9803 6.6515 6.5905

10 20 30 40 50 60 70 80 90 100

14-4 CONVERSION TABLE VOLUME 0

U.S. gal.

10 20 30 40 50 60 70 80 90 100

liters

37,8543 75.7085 113.5629 151.4171 189.2713 227.1256 264,9799 302.8342 340.6884 · 378.5427 0

liters

10 20 30 40 50 60 70 80 90 100

Imp gal.

20 30 40 50 60 70 80 90 100

liters

10 20 30 40 50 60 70 80 90 100

gal.

2.6417 5.2834 7.9252 10.5669 13.2086 15,8503 18,4920 21.1338 23 7755 . 26.4172 0

liters

45.4590 90.9180 136,3770 181.8360 227.2950 , 272,7540 318.2130 363.6720 409.1310 I 454.5900 0

gal.

2.1998 4.3996 6.5994 8.7992 10.9990 13.1988 15.3986 17,5984 19.7982 21.9980

3,7854 • 41.6397 79.4940 i 117.3482 155.2025 • liters

193 0568 230.9110 268.7653 306,6196 344,4738 382.3281 1

0.2642 2.9059 5,5476 8.1893 10.8311 13.4728 16.1145 18.7562 21.3979 24.0397 26.6814 1

0.5283 3.1701 5.8118 8.4535 11.0952 13.7369 16,3787 19.0204 21.6621 24.3038 26.9455 2

4,5459 9.0918 50.0049 54.5508 95.4639 • 100.0098 140.9229 I 145.4688 • 186.3819 190.9278 231,8409 236,3868 277.2999 281,8458 322.7589 • 327,3048 368.2179, 372.7638 413.6769 418.2228 459,13591 463.6818 liters

0.2200 2.4198 4,6196 6.8194 9.0192 11.2190 13.4188 15.6186 17.8184 20.0182 22,2180 gal.

liters

0.4400 2.6398 4.8396 7 0394 9,2392 11.4390 13.6388 15.8386 18.0384 20.2382 22.4380 gal.

11.3563 15.1417 49.2105, 52.9960 87.0648 90.8502 124.9191 I 128.7045 162.7734 166.5588 200.6276 204.4131 238.4819 .242.2673 276.3362 280.1216 314.1904 317.9759 352.0447 355.8301 389.8990 393,6844

7.5709 45.4251 83,2794 121.1337 158.9879 196.8422 234.6965 272.5507 310.4050 348.2593 386.1135 2

liters

gal.

GALLONS (U. S.) TO LITERS

18,9271 56.7814 94.6357 132.4901 170.3442 208.1985 246.0527 283.9070 321.7613 359.6156 397.4698

liters

22.7126 26,4980 60.5668 64,3523 98.4211 102.2065 136.2754 140 0608 174.1296 177.9151 211.9839 '215.7693 249.8382 I 253.6236 · 287.6924 291.4779 325.5467 329.3321 363.4010 367.1864 401.2553 • 405,0407 liters

liters

LITERS TO GALLONS (U.S.)

0.7925 3,4342 6.0760 8.7177 11.3594 14.0011 16.6428 19.2846 21.9263 24.5680 27.2097 gal.

2.1134 4.7551 7.3968 ,10.0385 12.6803 15.3220 17.9637 20.6054 23.2471 25.8889 28.5306

gal.

GALLONS (IMP.) TO LITERS

1.5850 1.8492 4.2268 4.4909 7.1326 6 8685 9.5102 I 9.7743 12.1519 I 12.4161 14.7936 15,0578 17.4354 17.6995 20.0771 20.3412 22.7188 22.9830 25.3605 25.6247 28 0022 28.2664 gal.

gal.

U.S. gal.

30.2834 34 0633 71.9231 68.1377 105.9920 109.7774 143.8462 147,6316 181.7005 185.4859 219.5548 223.3402 257.4090 261.1945 295.2633 299 0487 • '333.1176 336.9030 370.9718. 374.7573 i 408.8261 1412.6115

1.0567 1.3209 3.9626 3.6984 6.6043 6.3401 9.2460 8.9818 11.6236 i 11.8877 14.2653 14.5295 16.9070 17.1 711 19.5487 119.8129 22.1904 22.4546 24.8322 25.0963 27.4739 27,7381 gal.

liters

gal.

liters

2 3775 5. 0193 7,6610 10.3027 12.9444 15.5861 18.2219 I 20.8696 23.5113 26.1530 28,7947 gal.

liters

LITERS TO GALLONS (IMP.)

0,6599 2.8597 5.0595 7,2593 9.4591 11,6590 13,8587 16,0585 18.2583 20.4581 22,6579 gal.

0,8799 3.0797 5.2795 7.4793 9.6791 11.8789 14,0787 16.2785 18.4783 20.6781 22.8779 gal.

1.0999 3.2997 5.4995 7.6993 9.8991 12.0989 14,2987 16.4985 18.6983 20.8981 23,0979 gal.

1.3199 3,5197 5.7195 7.9193 10,1191 12.3189 14,5187 16.7185 18.9183 21.1181 23,3179 gal.

liters

1.5399 1.7598 3.73971 3.9596 5.9395 ! 6.1594 8.1393 8.3592 10,3391 10.5590 12.5389 12,7588 i4.7387 14.9586 16.9385 17.1584 19.1383 19.3582 21.3381 21.5580 23.5379 23.7578 gal.

gal.

liters

10 20 30 40 50 60 70 80 90 100

10 20 30 40 50 60 70 80 90 100 I

1,9798 I 4.1796 6,3794 8.5792 i 10,7790 12.9788 15,1786 17.3784 19.5782 21.7780 23.9778 gal.

Imp gal.

13,6377 18,18361 22.7295 27.2754 31.8213 36.3672 40.9131 59.0967 63,6426 68.1885 72.7344 77.2803 81,8262 86,3721 104.5557 109.1016 113,6475 118, 1934 122.7393 127.2852 131.8311 150,0147 • 154.5606 ·159,1065 163.6524 168.1983 1172.7442 177.2901 195.4737 200.0195 204.5655 209.1114 213.6573 !218.2032 222.7491 I 240.9327 245.4 786 250.0245 254,5704 259.1163 263.6622 268.2081 286.3917 290.9376 295.4835 300,0294 , 304,5753 I 309,1212 313.6671 331.8507 j 336,8966 340.94251345.4884 350.0343 354,5802 359.1261 377,3097 • 381.8556 386,4015 • 390 9474 395.4933 400,0392 404.5851 1 422.7687 427,3146 431,8605 436.4064 440,9523 ! 445.4982 450 0441 468.2277 472,7736 477.3195 481.8654 486.4113 .. 490.9572, 495.5031 1 liters

10 20 30 40 50 60 70 80 90 100

liter

10 20 30 40 50 60 70 80 90 100

CONVERSION TABLE 14-5 MASS lbs.

10 20 ·30 40 50 60 70 80 90 100

100 200 300 400 500 600 700 800 900 1000

! I

0 N

98.07 196.13 294.20 392.27 490.33 558.40 686.47 784.53 882.60 980.67

10.197 20.394 30.592 40.789 50.986 61.183 71.380 81.578 91.775 101.972

2.205 24.251 46.297 68.343 90.390 112.436 134.482 156.528 178.574 200.621 222.667

I i

1.020 11 217 21.414 31.611 41.809 52.006 62.203 72.400 82.597 92.795 102.992

kg'

lbs.

19.61 9.81 107.87 117.68 205.94 215.75 304 01 313.81 402.07 411.88 500.14 509.95 598.21 i 608.01 696.27 706.08 794.34 i 804.1 5 892.41 902.21 990.47 1000.28 I N

4.409 26.455 48.502 70.548. 92.594 114.640 136.687 158.732 180.780. 202.825 224.871 I

lbs

22.046 44.092 66.139 88.185 110.231 132.277 154.324 176.370 198.416 220.462

0.907 5.443 9.979 14.515 19.051 I 23.587 28.123 32.659 37.195 41.731 46.266

lbs.

10 20 30 40 50 60 70 80 90 100

0.454 4.990 9.525 14.061 18.597 23.133 27.669 32.205 36.741 41.277 45.813

4.536 9.072 13.608 18.144 22.680 27.216 31.751 36.287 40.823 45.359

POUNDS TO KILOGRAMS

1.361 5.897 10.433 14.969 19.504 24.040 28.576 33.112 37.648 42.184 46.720

2.268 6.804 11.340 15.876 20.412 24.948 29.484 34.019 38.555 43 091 47.627

1.814 6.350 10.886 15.422 19.958 24.494 29.030 33.566 38.102 42.638 47.174

6.614 8.818 28.660 • 30.865 50.706 52.911 72.753 74.957 97.003 94.799 116.845 119.050 138.891 141 096 160.937 163.142 182.984 185.188 205.030 207.234 227.076 229.281 lbs.

2.722 7.257 11.793 16.329 20.865 25.401 29.937 34.473 39.009 43.545 47.081

KILOGRAMS TO POUNDS 11.023 33 069 55.116 77.162 99.208 121.254 143.300 165.347 187.393 209.439 231.485 lbs.

lbs

13.228 35.274 57.320 79.366 101.413 123.459 145.505 167.551 189.597 211.644 233.6901 lbs.

KILOGRAMS TO NEWTON

29.42 127.49 225.55 323.62 421.69 519.75 617.82 715.89 813.95 912.02 1010.08 N

39.23 137.29 235.36 333.43 431.49 529.56 627.63 725.69 823.76 921.83 1019.89

49.03 ! 58.84 147.10 156.91 245.17 254.97 343.23 353.04 441.30 451.11 539.37 I• 549.17 637.43 • 647.24 735.50 745.31 833.57 843.37 931.63 941.44 1029.70 1039.50

NEWTON TO KILOGRAMS

2.039 3.059 12.237 • 13.256 22.434 23.453 32.631 33.651 42.828 43.848 53.025 54.045 63.223 64.242 73.420 74.440 83.617 84.637 93.814 94.834 104.011 105.031

4 079 14.276 24.473 34.670 44.868 55.065 65.262 75.459 85.656 95.854 106.051

5.099 15 296 25.493 35.690 45.887 56.085 66.282 76.479 86.676 96.873 107.071

6.118 16.316 26.513 36.710 46.907 57.104 67.302 77.499 87.696 97.893 108.090

3.175 7.711 12.247 16.783 I 21.319 25.855 30.391 i 34.927 39.463 I 43.998 48.534

15.432 37.479 59.525 ! 81.571 103.617! 125.633 147.710 169.756 191.802 • 213.848 235.895 lbs.

68.65 166.71 264.78 362.85 460.91 558.98 657.05 755.11 853.18 951.25 1049.31

3 629 8 165 12.701 17.237 21.772 26.308 30.844 35.380 39.916 44.452 48.988

lbs.

4.082 8.618 13.154 17.690 22.226 26.762 31.298 35.834 40.370 44.906 49.442

17.637 39.683 61.729 83.776 105.822 127.868 149.914 171.961 194.007 216.053 238.099

19.842 41.888 63.934 85.980 108.026 130.073 152.119 174.165 196.211 . 218.258 240.3041 lbs.

lbs.

10 20 30 40 50 60 70 80 90 100

kg kg I . 8.158 9.177 7.138 19.375 17.335 18.355 27.532 28.552 29.572 i 37.730 38.749 I 39.769 47.927 49.966 48.947 58.124 60.163 I 59.144 68.321 69.341 70.361 78.518 79.538 80.558 88.716 89. 735 ! 90.755 98 913 i 99.933 100.952 109.110 110.130 1 111.149 1 kg

88.26 78.45 176.52 186 33 274.59 284.39 372.65 382.46 470.72 480.53 578.59 568.79 676.66 666.85 774.73 764.92 872.79 862.99 970.86 961 05 1059.121 1068.92

10 20 30 40 50 60 70 80 90 100

100 200 300 400 500 600 700 800 900 1000

14-6 CONVERSION TABLE PRESSURE POUNDS PER SQUARE INCHES TO KILOGRAMS PER SQUARE CENTIMETERS lb/in2 (psi)

10 20 30 40 50 60 70 80 90 100

kg/cm2

kg/cm'' 0.7031 1. 4061 2.1092 2.8123 I 3.5154 4 .2184 4.9215 5.6246 6.3276 7.0307

I I

0.0703 0.7734 1.4764 2.1795 2.8826 3.5857 4.2887 4.9918 5.694 7 6.3979 7.1010

kg/cm"

I I

0.1406 0.8437 1.5468 2.2498 i 2.9529 3.6560 I 4.3590 5.0621 5.7652 6.4682 7.1713 I I

I j

kg/cm2

kg/cm

0.2109 0.9140 1.6171 2.3201 3 0232 3.7263 4.4 293 I 5.1324 5.8355 6.5386 7.2 416

I I

0.2812 0.9843 1.6874 2.3904 3.0935 3.7966 4 .4996 5.2027 5.9058 6.6089 7.3119

kg/cm2

0.3515 1.0546 1.7577 2.4607 3.1638 3.8669 4.5100 I 5.2730 5.9761 . 6.6792 7.3822 I

kg/cm2

0.4218 1.1249 I 1.8280 2.5311 3.2341 3.9372 4.6403 i 5.3433 6.0464 6.7495 7.4525

kg/cm

kg/cm2

0.4921 1 .1952 1.8983 2.601 4 3.30 44 4.0075 4 .7106 5.4136 6.1167 6.8198 7.5228

0.5625 I 1.2655 1.9686 2.6717 i 3.3747 I 4.0778 4 .7809 5.4839 6.1870 6.8901 7.5932

kg/cm

lb/in2

(psi)

0.6328 1.3358 2.0389 2.7420 3.4450 4.1481 4.8512 5.5543 6.2573 6.9604 7.6635

10 20 30 40 50 60 70 80 90 100

KILOGRAMS PER SQUARE CENTIMETERS TO POUNDS PER SQUARE INCHES kg/cm 2 10 20 30 40 50 60 70 80 90 100

1 0 i lb/in2(psi) i lb/in 2 {psi)

lb/in''(psi) · lb/in2(psi)

14 .22 ! 28.45 156.45 1 70.68 14 2.23 298.68 312.91 284 .4 6 440.91 i 426.69 4 55.1 4 568.92 583.14 597.37 711.16 739.60 725.37 1 853.38 . 867.60 881.83 995 61 1009.83 1024.06 1152.06 1166.27 I 1137.84 1280.07 1294.20 1308.52 1 436.52 1422.30 i 1 450.75

4 5 I lb/in"(psi) I lb/in2(psi)

lb/in 2(psi) I lb/in 2 (psi)

4 2.67 56.89 71.12 85.34 99.56 18 4.90 199.12 227.57 1 213.351 241.79 327.13 369.80 355.58 384.02 3 41.35 483.58 497.81 469.36 512 03 I 526.25 i 611.59 1 625.81 640 04 654 .26 668.48 I 768.04 753.82 795. 49 810.11 I 182.21 . 896.05 910.27 924.50 938.72 952.9 4 • 1038.28 I 1052_50 I 1066.73 1080 95 1095.17 1194.73 1208.96 i 1223.18 1180.51 1237.40 1 1336.96 1322.74 1365. 41 1351.19 1379.63 1464.97 1 493. 42 1507.64 1521.861 1 479.19 j

I j

lb/in''(psi) 113.78 ·256.01 398.24 5 40.47 682.70 824.93 967.16 1109.39 1251.62 1393.85 1536 08

I I

lb/in2 (psi) ·

128 01 270.24 412.47 55 4.70 696.93 839.16 981.39 1123.62 I 1265.85 1408.08 1550.31

kg/cm2 10 20 30

50 60 70 80 90 100

KILOGRAMS PER SQUARE CENTIMETERS TO KILO PASCAL kg/cm"

KPa

10 20 30 40 50 60 70 80 90 100

1 I

KPa

98.1 1078.7 2059. 4 3040.1 4020.7 5001.4 5982.1 6962.7 79 43.4 8924.1 9904.7

980.7 1961.3 2942.0 3922.7 4903 3 5584.0 6864.7 78 45.3 8826.0 9806.7

KPa

I 196.1 294 .2 392.3 490.3 588.4 1176.8 1372.9 [ 1471.0 127 4.9 1569.1 2157.5 2255.5 2353.6 . 2451.7 2549 7 • 3334.3 3138.1 3236.2 3432.3 3530.4 4118.8 4413.0 4314.9 4216.9 4511.1 5099.5 5197.5 I 5295.6 5393.7 5491.7 6080.1 6178.2 i 6276.3 I 637 4.3 6472.4 i 7060.8 7256.9 7158,9 7355.0 7453.1 8041.5 . 8139.5 8237.6 8335.7 I 8433.7 9022.1 • 9120.2 9316 3 9218.3 9414 4 10002.8 I 10100.8 10297.0 10395.01 10198.9 1 .

KPa

I I

KPa

784.5 882.6 686.5. 1863.3 1661.1 I 1765.2 1 2843.9 2647.8 2745.9 3628.5 3726 5 j 3824.6 4101.2 I 4609.1 4805.3 5687.9 5785.9 5589.8 •I 6570.5 6668.5 ' 6766.6 77 47.3 7551.1 76 49.2 8629.9 8727.9 8531.8 9610.5 9708.6 9512.5 10689.2 10 493.1 10591.2 1 j

! 1

i I • I

kg/cm 2

10 20 30 40 50 60 70 80 90 100

KILO PASCAL TO KILOGRAMS PER SQUARE CENTIMETERS

KPa 1000

2000 3000 4000 5000 6000 7000 8000 9000 10000

kg/cm2

100

kg/cm"

1.020 I 10.197 • 11.217 20.394 21.414 30.592 31.611 41.809 40.789 50.986 52.006 61.1831 62.203 71.380 72.400 81.578 . 82.597 91.775 92.794 101.9721 102.992

200

kg/cm 2

400

300

kg/cm2

2.039 3,059 12 237 13.256 22.434 23.453 32.631 33.651 42.828 43.8 48 53.025 54.045 63.2231 64.242 73.420 74 .440 83.617 I 84 .637 93.814 94.834 104.011 I 105.031

kg/cm 2

I j

' 1 I 1

! I

500

kg/cm 2

600

kg/cm 2

700

kg/cm2

800

kg/cm·'

4 079 7.138 I 8.158 6.118 I 5.099 14.276 17.335 15.296 18.355 16.316. I 24.473 27.532 26.513 28.552 25. 4931 34.670 35.690 36.710 37.730 38.7 49 44.868 45.887 • 46.907 47.927 4 8.9 47 55.065 56.085 58.124 57.104 59.144 65.262 66.282 69.341 68.321 67.302 75.459 76.479 77.499 79.538 78.518 85.656 86,676 87.696 89.735 88.716 95.854 96.873 97.893 98.913 99.933 106.051 107.071 108.090 109.110 110.130

KPa

900

kg/cm 2

9.111 19.375 • 29.5721 39.769 4 9.966 60.163 70.361 80.558 90.755 100.952 111.149

1000 2000 3000 4000 5000 6000 7000 8000 9000 10000

CONVERSION TABLE 14-7 TORQUE FOOT POUNDS TO KILOGRAMMETERS ft lbs.

kg-m

1,383 2.765 4.148 5.530 6.913 8.295 9.678 11.060 1 2.442 13 826

10 20 30 40 50 60 70 80 90 100

kg-m

10 20 30 40 50 60 70 80 90 100

kg-m

0.138 1.521 2.903 4.286 5.668 7.051 8.434 I 9.816 I 11.199 12.581 13.964

kg-m

0.277 1.659 3.042 4.424 5.807 7.189 8.572 9.954 11.337 12.719 14.102

kg-m 0.415 1.797 3.180 4.562 5.945 7.328 8.710 i 10.093 11.475 12.858 14.240 I

kg-m

0.553 1.936 3.318 4.700 6 083 7.466 8.848 10.231 11.613 12.996 14.379

0.691 2 074 3.456 4.839 6.221 7.604 8.987 10.369 11.752 13.134 14.517

0.830 2.212 3.595 4.977 6.360 7.742 9.125 10.507 11.890 13.272 14.655

0.968 2.350 3,733 5.115 6.498 7.881 9.263 10.646 12.028 13.410 14.793

I I

kg-m

1.106 2.489 3.871 5.253 6,636 8.019 9.401 10.784 12.166 13.549 14.932

1.244 2.627 4 009 5.392 6.774 8.157 9.540 10.922 12.305 13.687 15 070

KILOGRAMMETERS TO FOOT POUNDS 2

ft lbs.

ft. lbs.

ft lbs.

72.33 14 4.66 217.00 289.32 361.65 4 33.98 506.31 578.64 650.97 723.30

7.23 79.56 151.89 224.22 296.55 368.88 44 L21 513.54 585.87 658.20 730.53

14.47 86.80 159.13 231.46 303.79 376.12 4 48.45 520.78 593.11 665.44 737.77

ft lbs.

2uo I 94.03 166.36 238.69 311 02 383.35 455.68 I 528.01 600.34 672.67 7 45.00 I

28.93 101.26 173.59 245.92 318.25 390.58 462.91 535.24 607 57 679.90 752.23

ft lbs.

36.17 I 108.50 180.83 I 253.16 325.49 397.82 I 4 70.15 542.48 614.81 687 14 759 47

ft lbs.

50.63 i 57.86 122.96 130.19 202.52 195.29 267.62 j 274.85 339.95 3 47.18 412.28 I 419.51 4 91.8 4 484.61 556.94 564.17 629.27 636.50 701.60 708.83 773.93 781.16

43.40 115.73 188.06 260.39 332.72 405.05 4 77.38 5 49. 71 622.0 4 694.37 766.70

ft lbs.

kg-m

ft lbs.

65.10 137.43 209.76 282.09 354.42 426.75 i 499 08 571.41 643.74 ! 716.07 788.40 I

I I I

I !

10 20 30 40 50 60 70 80 90 100

kg-m

10 20 30 40 50 60 70 80 90 100

KILOGRAMMETERS TO NEWTONMETERS kg-m

10 20 30 40 50 60 70 80 90 100

N-m I

98.07 196.13 I 294.20 392.27 490.33 588.40 686.47 784.53 882.60 980.67

N-m

9.81 107.87 205.94 304.01 I 402,07 500.14 598.21 696.27 I 794.34 892.41 990.47

N-m

I !

N-m

I I

N-m

19.61 29. 42 1 39.23 49 03 58.84 117.68 14 7.10 127.49 . 137.29 156.91 215.75 225.55 235.36 I 245.17 254.97 313.81 323.62 353 04 333. 43· 343.23 411.88 421.69 431.49 ! 441 30 I 451_11 509.95 519.75 539.37 j 5 49.17 529.56 I 608.01 617.82 627.63 637.43 647.24 706.08 735.50 I 745.31 115.89 725.69 804.15, 813.95 8 43.37 823.761 833.57 902.21 912.02 931.63 921.83 941.44 . 1000.28 1010.08 1019.89 1029.70 I 1039.50 1

I I

N-m

kg-m

N-m

68.65 88.26 78.45 176.52 166.71 186.33 274.59 I 284.39 264.78 382.46 372.65 362.85 460.91 , 470.72 480.53 578.59 558 98 568.79 j 1 676.66 666.85 657.05 774.73 764.92 755.11 872.79 853.18 862.99 951.25 961.05 970.86 1049.31 1059.12 1068.92

10 20 30 40 50 60 70 80 90 100

NEWTONMETERS TO KILOGRAMMETERS N-m

100 200 300 400 500 600 700 800 900 1000

kg-m 10.197 20.394 30.591 40.789 50.986 61.183 71.380 81.5 77 91.774 101.972

kg-m

1.020 . 2 039 11.217 12.236 21. 414 22. 433 1 31.61'1 32.630 41.808 42.827 52.005 53.024 62.202 63.221 72.399 73.418 82.596 83.615 92.793 , 93.812 102.990 104.009

kg-m

3.059 13.256 23.453 33.650 43.847 5 4.04 4 64.241 74. 438 84.635 94.832 105.029

kg-m 4.079

14.276 24,473 34.670 44.867 55.06 4 65.261 75.458 85.655 95,852 106.0 49

kg-m

5.099 15.296 25.493 35.690 45.887 56.084 66.281 76. 478 86.675 96 872 107.069

6.118 16.315 26.512 36.710 46.906 57.103 67.300 77. 497 87.694 97.891 108,088

kg-m

7.138 17.335 27.532 37.729 47.926 58.123 68.320 78.517 88.714 98.911 109.108

8.158 18.355 28.552 38.749 48.946 59.143 69.340 79.537 89.734 99.931 110.128

i I

kg-m

9.177 19.374 ! 29.571 I 39.768 49.965 60.162 70.359 I 80.556 , 90.753 I 1 oo.950 1111.147 j

I I

N-m·--

100 200 300 400 500 600 700 800 900 1000

14-8 CONVERSION TABLE TEMPERATURE FAHRENHEIT TO CENTIGRADE Of

-42 -40 -38 -36 -34 -32 -30 -28 -26 -24 -22 -20 -18 -16 -14 -12 -10 -8 -6 -4

-51.1 -50 -48.9 -47.8 -46.7 -45,6 -44.4 -43.3 -42.2 -41.1 -40.0 -38.9 -37.8 -36.7 -35.6 -34.4 -33.3 -32.2 -31.1 -30.0 -28.9 -27.8 -26.7 -25.6 -24.4 -23.3 -22.2 -21.1 -20.0

-60 -58 -56 -54 -52 -50 -48 -46

-44

-2 0 2 4 6 8 10 12

16 18 20 22 24 26 28 30 32 34 36 38 40 42

46 48 50 52

-18,9 -17 8 -16.7 15.6 14.4 13.3 -12.2 -11.1 -10.0 -8.9 -7.8 -6.7 -5.6 -4.4 -3.3 -2.2 1.1 -0 1.1 2.2 3.3

4.4

5.6 6.7 7.8 8.9 10.0 11.1 12.2

56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112

13.3 14.4 15.6 16.7 17.8 18.9 20.0 21.1 22.2 23.3 24.9 25.6 26.7 27.8 28.9 30.0 31 1 32.2 33.3 34.4 35.6 36.7 37.8 38.9 40.0 41 1 42.2 43.3 44.4

114

116 118 120 122 124 126 128 130 132 134 136 138 140 142 144 146 148 150 152 154 156 158 160 162 164 166 168 170

45.6 46.7 47.8 48.9 50.0 51.1 52.2 53.3

54.4

55.6 56.7 57.8 58.9 60.0 61.1 62.2 63.3

64.4

65.6 66 7 67.8 68.9

70.0 71.1 72.2 73.3 74.4 75.6 76.7

172 174 176 178 180 182 184 186 188 190 192 194 196 198 200 202 204 206 208 210 212 214 216 218 220 222 224 226 228

77.8 78.9 80.0 81.1 82 2 83 3 84.4 85 6 86.7 87.8 88.9 90.0 91.1 92.2 93.3 94.4 95.6 96.7 97.8 98.9 100 0 101 1 102.2 103.3 104.4 105.6 106.7 107.8 108.9

230 232 234 236 238 240

242

244 246 248 250 252 254 256 258 260 262 264 266 268 270 272 274 276 278 280 282 284 286

115.6 116.7 117.8 118.9 120.0 121.1 122.2 123.3 124.4 125.6 126.7 127.8 128.9 130.0 131.1 132.2 133.3 134.4 135.6 136 7 137.8 138.9 140.0 141.1

288 290 292 294 296 298 300 302 304 306 308 310 312 314 316 318 320 322 324 326 328 330 332334 336 338 340 342 344

142.2 143.3 144.4 145.6 146.7 147.8 148.9 150.0 151.1 152.2 153.3 154.4 155.6 156.7 157.8 158.9 160.0 161.1 162.2 163.3 164.4 165.6 166.7 167 8 168.9 170.0 1711 172.2 173.3

346 348 350 352 354 356 358 360 362 364 366 368 370 372 374 376 378 380 382 384 386 388 390 392 400 410 420 430 440

182.2 183.3 184.4 185.6 186.7 187.8 188.9 190.0 191.1 192.2 193.3 194.4 195.6 196.7 197.8 198.9 200.0 204.4 210.0 215.6 221.1 226.7

110 0 111.1 112.2 113.3

114.4

174.4 175.6 176.7 177.8 178.9 180.0

181.1

CENTIGRADE TO FAHRENHEIT -50 -49 -48 -47 -46 -45 -44 -43 -42 -41 -40 -39 -38 -37 -36 -35 -34 -33 -32 -31 -30 -29 -28 -27 -26 -25 -24 -23 -22 - 21 -20 -19

-58.0 -56.2 -54.4 -52.6 -50.8 -49.0 -47.2 -45.4 -43.6 -41.8 -40.0 -38.2 -36.4 -34.6 -32.8 -31.0 -29.2 -27.4 -25.6 -23.8 -22.0 -20.2 -18.4 -16.6 14.8 -13.0 -11.2 -9.4 -7.6 -5.8 -4.4 -2.2

-18 -17 -16 -15 -14 -13 -12 -11 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 10 11 12 13

0.4 1.4 3.2 5.0 6.8 8.6 10.4 12.2 14.0 15.8 17.6 19.4 21.2 23.0 24.8 26.6 28.4 30.2 32.0 33.8 35.6 37.4 39.2 41.0 42.8 44.6 46.4 48.2 50.0 51.8 53.6 55.4

14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

57.2 59.0 60.8 62.6 64.4 66.2 68.0 69.8 71.6 73.4 75.2 77 0 78.8 80.6 82.4 84.2 86.0 87.8 89.6 91.4 93.2 95.0 96.8 98.6 100.4 102.2 104.0 105.8 107.6 109.4 111.2 113.0

46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77

114.8 116.6 118.4 120.2 122.0 123.8 125.6 127.4 129.2 131.0 132.8 134.6 136.4 138.2 140.0 141.8 143.6 145.4 147.2 149.0 150.8 152.6 154.4 156.2 158.0 159.8 161.6 163.4 165.2 167.0 168.8 170.6

78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109

172.4 174.2 176.0 177.8 179.6 181.4 183.2 185.0 186 8 188.6 190.4 192.2 194.0 195 8 197.6 199.4 201.2 203.0 204.8 206.6 208.4 210.2 212.0 213.8 215.6 217.4 219.2 221.0 222.8 224.6 226.4 228.2

110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141

230.0 231.8 233.6 235.4 237.2 239.0 240.8 242.6 244.4 246.2 248.0 249.8 251.6 253.4 255.2 257.0 258.8 260.6 262.4 264.2 266.0 267.8 269 6 271.4 273.2 275.0 276.8 278.6 280.4 282.2 284.0 285.8

142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 1731

287.6 289.4 291.2 293.0 294.8 296.6 298.4 300.2 302.0 303.8 305.6 307.4 309.2 311.0 312.8 314.6 316.4 318.2 320.0 321.8 323.6 325.4 327.2 329.0 330.8 332.6 334.4 336.4 338.0 339.8 341.6 343.4

174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 200 210 220 230 240 250

345.2 347.0 348.8 350.6 352.4 354:2 356.0 357.8 359.6 361.4 363.2 365.0 366.8 368.6 370.4 372.2 374.0 375.8 377.6 379.4 381.2 383.0 384.8 386.6 388.4 390.2 392.0 410,0 428.0 446.0 464.0 482.0

MEMO

·•QUALITY PARTS YOU CAN TRUST"

MEMO

"QUALITY PARTS YOU CAN TRUST"