Isuzu 4J Series Industrial Diesel Engine Workshop Manual A-4JA1 A-4JB1 4JB1 4JB1-TC A-4JG1 4JG2 A1-4JJ1 4JJ1 PDF - MISU4JOPEK.zip

This is a full workshop service and repair manual, complete with Electrical Wiring Diagrams, covering the Isuzu A-4JG1, A-4JB1, 4JB1, 4JB1-TC, A-4JG1, 4JG2, A1-4JJ1, and 4JJ1 engine models. Inside you'll find every technical detail needed to service, troubleshoot, fix, and overhaul these engines to the same standard as factory-trained technicians.

The workshop service and repair manual for the Isuzu A-4JG1, A-4JB1, 4JB1, 4JB1-TC, A-4JG1, 4JG2, A1-4JJ1, and 4JJ1 Models contains:

* Numbered table of contents easy to use so that you can find the information you need fast.

* Detailed sub-steps expand on repair procedure information

* Numbered instructions guide you through every repair procedure step by step.

* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.

* Notes, cautions and warnings throughout each chapter pinpoint critical information.

* Bold figure number help you quickly match illustrations with instructions.

* Detailed illustrations, drawings and photos guide you through every procedure.

* Enlarged inset helps you identify and examine parts in detail.

PRODUCT DETAILS:

Total Pages: 4,718 pages

File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)

Language: English

7-28240_EN - SERVICE MANUAL 4JB1 ISUZU ENGINES.pdf

7-28350_FR - MANUEL DE SERVICE MOTEURS ISUZU 4JB1.pdf

7-28360_DE - WARTUNGSANLEITUNG 4JB1 ISUZU-MOTOREN.pdf

9806-2180 - Isuzu A-4JG1 Industrial Engine Workshop Manual.pdf

9806-3060 - Isuzu Industrial Diesel Engine A1-4JJ1 Workshop Manual.pdf

EDBE-EN-01 - Hitachi_Isuzu 4JJ1 Diesel (Interim Tier 4 compatible) Engine Service Manual.pdf

IDE-2290 - Isuzu 4JG2 Service Manual (Forklift HDF20-30, -2 Series, Engine Base, Reference Only).pdf

IDE-2310 - Isuzu A-4JA1, A-4JB1 Models Industrial Diesel Engine Workshop Manual.pdf

IDE-2320 - Isuzu A-4JG1 Model Industrial Diesel Engine Workshop Manual.pdf

Isuzu 4JB1-TC Engine Mechanical Specification & Structure (Applicable To N_R Series).pdf

Isuzu 4J Series Engine Workshop Manual (applicable to MY94&up NHR55. NKR55. NPR55. NPR69).pdf

KM-4JJ1-E-01 (1_2) - Hitachi 4JJ1 Engine Manual.pdf

KM-4JJ1-E-01 (2_2) - Hitachi 4JJ1 Engine Manual.pdf

KM-4JJ1-E-02 (2_2) - Hitachi 4JJ1 Engine Manual.pdf

W1CDE-00 - Hitachi_Isuzu 4JA1 Engine (A-4JG1 PH-01, AA-4JG1 PH-02) Workshop Manual.pdf

MAIN SECTIONS

7-28240_EN - SERVICE MANUAL 4JB1 ISUZU ENGINES....2

7-28350_FR - MANUEL DE SERVICE MOTEURS ISUZU 4JB1....150

7-28360_DE - WARTUNGSANLEITUNG 4JB1 ISUZU-MOTOREN....298

9806-2180 - Isuzu A-4JG1 Industrial Engine Workshop Manual....446

9806-3060 - Isuzu Industrial Diesel Engine A1-4JJ1 Workshop Manual....669

EDBE-EN-01 - Hitachi_Isuzu 4JJ1 Diesel (Interim Tier 4 compatible) Engine Service Manual....903

IDE-2290 - Isuzu 4JG2 Service Manual (Forklift HDF20-30, -2 Series, Engine Base, Reference Only)....1907

MAIN PAGE....1907

SECTION 1. GENERAL INFORMATION....1910

SECTION 2. MAINTENANCE....1928

SECTION 3. ENGINE ASSEMBLY(1)....1940

SECTION 4. ENGINE ASSEMBLY(2)....1958

SECTION 5. ENGINE ASSEMBLY(3)....1994

SECTION 6. LUBRICATING SYSTEM....2022

SECTION 7. COOLING SYSTEM....2034

SECTION 8. FUEL SYSTEM....2044

SECTION 9. ENGINE ELECTRICALS....2056

SECTION 10. TROUBLESHOOTING....2082

SECTION 11. SPECIAL TOOL LIST....2108

SECTION 12. CONVERSION TABLE....2112

IDE-2310 - Isuzu A-4JA1, A-4JB1 Models Industrial Diesel Engine Workshop Manual....2126

INDUSTRIAL....2126

SECTION 1....2129

GENERAL INFORMATION....2129

GENERAL REPAIR INSTRUCTIONS....2130

NOTES ON THE FORMAT OF THIS MANUAL....2130

MAIN DATA AND SPECIFICATIONS....2134

SECTION 2....2145

MAINTENANCE....2145

MODEL IDENTIFICATION....2146

INJECTION PUMP IDENTIFICATION....2146

LUBRICATING SYSTEM....2146

FUEL SYSTEM....2147

COOLING SYSTEM....2150

VALVE CLEARANCE ADJUSTMENT....2151

INJECTION TIMING....2152

COMPRESSION PRESSURE MEASUREMENT....2154

RECOMMENDED LUBRICANTS....2155

ENGINE REPAIR KIT....2156

SECTION 3....2157

ENGINE ASSEMBLY ( 1 )....2157

GENERAL DESCRIPTION....2158

DISASSEMBLY....2159

SECTION 4....2175

ENGINE ASSEMBLY ( 2 )....2175

INSPECTION AND REPAIR....2176

SECTION 5....2209

ENGINE ASSEMBLY ( 3 )....2209

REASSEMBLY....2210

SECTION 6....2237

LUBRICATING SYSTEM....2237

MAIN DATA AND SPECIFICATIONS....2238

GENERAL DESCRIPTION....2239

OIL PUMP....2242

OIL FILTER WITH BUILT-IN OIL COOLER....2245

SECTION 7....2249

COOLING SYSTEM....2249

MAIN DATA AND SPECIFICATIONS....2250

GENERAL DESCRIPTION....2251

WATER PUMP....2253

THERMOSTAT....2259

SECTION 8....2261

FUEL SYSTEM....2261

MAIN DATA AND SPECIFICATIONS....2262

GENERAL DESCRIPTION....2263

INJECTION NOZZLE....2266

INJECTION PUMP DATA....2271

SECTION 9....2275

ENGINE ELECTRICALS....2275

STARTER....2276

ALTERNATOR....2290

SECTION 10....2303

TROUBLESHOOTING....2303

HARD STARTING....2305

UNSTABLE IDLING....2309

INSUFFICIENT POWER....2312

EXCESSIVE FUEL CONSUMPTION....2316

EXCESSIVE OIL CONSUMPTION....2318

OVERHEATING....2319

WHITE EXHAUST SMOKE....2321

DARK EXHAUST SMOKE....2322

OIL PRESSURE DOES NOT RISE....2323

ABNORMAL ENGINE NOISE....2325

SECTION 11....2329

SPECIAL TOOL LIST....2329

SECTION 12....2333

REPAIR STANDARDS....2333

General Rules....2333

Repair standards chart....2334

SECTION 13....2347

CONVERSION TABLES....2347

LENGTH....2348

AREA....2349

VOLUME....2349

MASS....2351

PRESSURE....2352

TORQUE....2353

TEMPERATURE....2354

IDE-2320 - Isuzu A-4JG1 Model Industrial Diesel Engine Workshop Manual....2357

Isuzu 4J Series Engine Workshop Manual (applicable to MY94&up NHR55. NKR55. NPR55. NPR69)....2582

TOP....0

ENGINE 4J SERIES....2582

Sec.00 SERVICE INFORMATION....2586

TROUBLESHOOTING....2587

HARD STARTING....2588

STARTER INOPERATIVE....2588

STARTER MOTOR OPERATES BUT ENGINE DOES NOT TURN OVER....2588

ENGINE TURNS OVER BUT DOES NOT START....2589

QUICK-ON START SYSTEM....2590

UNSTABLE IDLING....2591

INSUFFICIENT POWER....2592

EXCESSIVE FUEL CONSUMPTION....2594

EXCESSIVE OIL CONSUMPTION....2594

OVERHEATING....2595

WHITE EXHAUST SMOKE....2595

DARK EXHAUST SMOKE....2596

OIL PRESSURE DOES NOT RISE....2596

ABNORMAL ENGINE NOISE....2597

ENGINE KNOCKING....2597

GAS LEAKAGE NOISE....2597

CONTINUOUS NOISE....2597

SLAPPING NOISE....2598

ENGINE COOLING TROUBLE....2599

ENGINE ELECTRICAL PART TROUBLE....2600

TURBOCHARGER....2605

LUBRICATION CHART....2614

MAIN DATA AND SPECIFICATIONS....2615

SERVICE STANDARD....2619

SERVICING....2623

FIXING TORQUE....2636

SPECIAL TOOLS....2645

Sec.6A GENERAL ENGINE MECHANICAL....2649

CYLINDER HEAD....2650

VALVE SPRING, VALVE GUIDE OIL SEAL, VALVE GUIDE, PUSH ROD....2658

CAMSHAFT, TAPPET....2665

ROCKER ARM ASSEMBLY....2672

OIL PUMP....2675

CRANKSHAFT....2679

PISTON AND CONNECTING ROD....2695

CYLINDER BLOCK....2704

Sec.6A1 4JB1/4JB1T/4JB1TC/4JG2-ENGINE....2717

GENERAL DESCRIPTION....2718

ENGINE MOUNT (RH)....2720

ENGINE MOUNT (LH)....2722

INLET MANIFOLD....2724

EXHAUST MANIFOLD....2726

OIL COOLER ....2728

OIL FILTER CARTRIDGE....2730

CYLINDER HEAD COVER....2731

ROCKER ARM SHAFT ASSEMBLY....2733

VALVESTEM OIL CONTROLLER & VALVE SPRING....2736

TIMING GEAR ....2739

TIMING BELT ....2746

CYLINDER HEAD ASSEMBLY AND GASKET....2753

OIL PAN....2764

OIL PUMP ASSEMBLY....2767

PISTON, PISTON RING AND CONNECTING ROD....2770

CAMSHAFT AND TAPPET....2779

CRANKSHAFT FRONT OIL SEAL (Gear Drive Type)....2787

CRANKSHAFT FRONT OIL SEAL (Belt Drive Type)....2789

CRANKSHAFT REAR OIL SEAL (Gear & Belt Drive Type)....2792

FLYWHEEL AND PILOT BEARING....2799

CRANKSHAFT AND MAIN BEARINGS....2801

ENGINE ASSEMBLY....2812

Sec.6B ENGINE COOLING....2825

GENERAL DESCRIPTION....2825

ON-VEHICLE SERVICE....2830

WATER PUMP....2830

THERMOSTAT....2834

RADIATOR....2836

DRIVE BELT ADJUSTMENT....2839

Sec.6C ENGINE FUEL....2841

GENERAL DESCRIPTION....2842

ON-VEHICLE SERVICE....2847

FUEL FILTER ASSEMBLY....2847

FUEL FILTER CARTRIDGE....2848

INJECTION NOZZLE....2849

INJECTION PUMP ASM (4JB1/4JB1T, 4JG2 Gear Drive Type)....2866

INJECTION PUMP ASSEMBLY (4JG2 Belt Drive Type)....2871

INJECTION TIMING ADJUSTMENT....2881

Adjustment of Idling Speed....2882

INJECTION PUMP DATA....2883

INJECTION VOLUME AND GOVERNOR PERFORMANCE DIAGRAM....2885

FUEL TANK....2895

FUEL GAUGE UNIT....2897

ACCELERATOR CONTROL....2898

ACCELERATOR CONTROL CABLE....2898

ACCELERATOR PEDAL....2900

IDLING CONTROL CABLE....2902

AIR CLEANER ELEMENT....2904

Sec.6D ENGINE ELECTRICAL....2907

6D1 BATTERY....2907

GENERAL DESCRIPTION....2908

DIAGNOSIS....2908

ON-VEHICLE SERVICE....2910

BATTERY CHARGING....2910

JUMP STARTING....2911

REMOVAL AND INSTALLATION OF THE BATTERY....2913

MAIN DATA AND SPECIFICATIONS....2913

6D2 STARTING SYSTEM....2915

GENERAL DESCRIPTION....2915

ON-VEHICLE SERVICE....2917

UNIT REPAIR....2919

6D3 CHARGING SYSTEM....2927

GENERAL DESCRIPTION....2927

DIAGNOSIS....2930

ON-VEHICLE SERVICE....2931

UNIT REPAIR....2935

6D6 QOSII PREHEATING SYSTEM....2949

GENERAL DESCRIPTION....2949

SYSTEM DIAGRAM....2950

Inspection on QOSII System Operation....2951

QOSII SYSTEM TROUBLESHOOTING....2952

6D7 QOSIII PREHEATING SYSTEM....2955

GENERAL DESCRIPTION....2955

SYSTEM DIAGRAM....2956

Inspection on QOSIII System Operation....2959

Sec.6E EXHAUST GAS RECIRCULATION (EGR) SYSTEM....2963

GENERAL DESCRIPTION....2964

EGR SYSTEM WIRING DIAGRAM....2965

EGR SYSTEM OPERATION....2965

Exhaust Gas Recirculation (EGR) System Check....2966

INSPECTION....2967

Sec.6F ENGINE EXHAUST....2969

GENERAL DESCRIPTION....2970

THREE WAY CATALYTIC CONVERTER....2971

ON-VEHICLE SERVICE....2972

FRONT EXHAUST PIPE....2972

Exhaust Brake Unit....2973

INSPECTION....2973

Sec.6G TURBOCHARGER....2975

TURBOCHARGER....2976

MAIN DATA AND SPECIFICATIONS....2976

GENERAL DESCRIPTION....2977

IDENTIFICATION OF UNIT....2978

TURBOCHARGER SERVICING....2978

PRECAUTIONS....2978

DISASSEMBLY....2979

INSPECTION AND REPAIR....2981

REASSEMBLY....2983

IHI SERVICE NETWORK....2985

Isuzu 4JB1-TC Engine Mechanical Specification & Structure (Applicable To N_R Series)....2988

KM-4JJ1-E-01 (1_2) - Hitachi 4JJ1 Engine Manual....3050

COVER....3050

Introduction....3052

General Contents....3054

Control System....3056

4JJ1 Electronic Control Fuel Injection System (Common Rail Type)....3056

How to Use This Manual....3058

How to use this manual....3058

Table of abbreviation....3059

Conversion formula....3060

About colors of wirings....3061

About wiring diagrams....3062

How to read trouble diagnosis section....3063

Precautions on Service Work....3065

Electrical system....3065

Fuel injection system....3065

Procedure of Trouble Diagnosis....3067

About trouble diagnosis....3067

Trouble diagnostic procedure....3068

Interview....3069

Pre-inspection....3071

Trouble diagnosis....3071

How to read DTC....3072

Confirmation after repair....3074

List of final check items....3074

How to clear DTC....3075

Trouble diagnosis with scan tool....3076

Data reference value....3083