Service & Repair Manual

Guide ISUZU DIESEL ENGINES LIMITED WARRANTY Isuzu Motors America, LLC (“ISZA”) warrants to purchaser (the “Buyer”) that its engines sold with this limited warranty when shipped, will meet all applicable specifications and will be free from defects in material and workmanship. The duration for this limited warranty is the warranty period (the “warranty period”) shown in the schedule below. Except as otherwise provided herein, the warranty period begins at the time of the earlier to occur of (1) first retail sale of the engine or the product into which the engine is incorporated (the “first retail sale”), or (2) the accumulation of 100 engine demonstration hours. As used herein, “first retail sale” includes rental or lease. This limited warranty is transferable to a second owner only if approved by ISZA after ISZA’s inspection of the engine and registration of the second owner.

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Small Engine Reference Design User Guide Welcome to the Freescale Small Engine Reference Design Kit. This product was designed to be a complete solution for the electronic control of a small engine. Small engines are defined as a one or two cylinder engine for use in anything from a motorbike to a lawn mower to a generator. While the decision was made to address a one-cylinder engine specifically, this design is extremely useful for a two-cylinder engine with little or no modification. Freescale’s concept of creating an engine control kit is intended to enable a market ranging from garage hobbyist to seasoned Tier 1 Powertrain Engineer using Freescale products.
Through the use of this kit, you can create an engine controller specific to a small engine application. Engine control is a discipline that requires intimate knowledge and experience in Chemical, Mechanical, and Electrical Engineering. For those familiar with mechanical control of an engine through a carburetor, the use of this reference design kit can help to advance your knowledge in the electrical area and provide a jump-start for a successful adoption of electrical engine controls to meet new emissions standards. Providing a kit such as this is intended to make semiconductor products from Freescale easier to use. The user is responsible for providing all input signals, output loads as well as the completed system design and development. This kit should serve as a starting point for the development of an application specific engine controller for a small engine. Example software and documentation are provided to assist in successful design and implementation. It is recommended to have the following skills and experience: embedded C-language programming, analog and digital circuit design and schematic analysis, microcontroller programming, fuel injection system debugging and calibration, and engine test environment experience. Additionally, there is further benefit to experience using the CodeWarrior Development Studio and the Freescale S12(X) microcontroller Units (MCUs). The User Reference Guide provides exercises and references to additional information to reduce the learning curve for inexperienced users.

Freescale’s goal is to enable the small engine market. To clarify this point, the hardware included in this kit can readily be configured and reprogrammed to run an engine. However, it lacks the application specific hardening (EMC, ESD, and environmental areas for example) and implementation optimization that make it a production ready module for any specific application. Further, the free example application software provided is a starting point capable of running an engine. It does not apply any advanced control strategy capable of addressing the pollution concerns and regulations facing the small engine industry. To do this would become application specific to an engine and could not be and should not be implemented by a semiconductor supplier as it is deeply outside their area of expertise. The example application software does show how to use the key functionality in the Freescale products that the kit is based on, which speeds up the development process by showing a working example.

The contents of this kit will save many months of work, even for experienced powertrain engineers just looking to evaluate Freescale products. A system has been created based on a one-cylinder closed-loop engine controller using integrated technology while being cost-effective for the small engine market. Example software is provided that can be customized to run an actual engine that has electronic fuel injection. Documentation is provided to aid in going through the process of developing an application. Finally, information on modifying the design to support the adaptation of the small engine reference design to your application goals.

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Isuzu 4J (4JA1, 4JB1, 4JB1T, 4JB1TC) Diesel Engine Service Guide Main Data and Specifications Torque Specifications (Standard Bolts – Special Parts Fixing Nuts and Bolts)
Recommended Liquid Gasket LOCTITE Application Procedure Servicing Engine Assembly (General Description – Removal and Installation) Engine Repair Kit Disassembly Inspection and Repair Reassembly Lubricating System (Main Data and Specifications – General Description – Oil Pump (Trochoid Type) – Oil Pump (Gear Type) – Oil Filter with Built in Oil Cooler) Cooling System (Main Data and Specifications – General Description – Water Pump) Fuel System (Main Data and Specifications – General Description – Injection Nozzle – Injection Pump Data) Turbocharger (Main Data and Specifications – General Description)

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Truck Engine Idling Guide  Diesel engines play an important role in the transport of goods and services nationwide. They are a durable and economical source of power. However, there is growing concern about the health effects associated with exposure to diesel exhaust. Diesel exhaust affects everyone, but people with existing heart or lung disease, asthma, or other respiratory problems are most sensitive to the small particles in diesel exhaust. Fortunately, new emission standards and new technology are helping to ensure that the cleaner diesel engines of the future will dramatically reduce these health risks. If you drive a truck, there are several
things that you can do now to save money and reduce pollution.

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MANUAL ENGINE COMPONENTS AND FILTERS MAHLE is a leading development partner and supplier of engine components and systems as well as filters for the automotive industry. In close cooperation with engine and vehicle manufactures, MAHLE engineers develop high-quality products worldwide. The same high-quality guidelines also apply to spare parts for the aftermarket. Numerous checks during and after production guarantee the highest quality of MAHLE products. If problems occur during operation, they can usually be attributed to the engine, e.g. incorrect ignition setting, mixture preparation or the electronic control unit. Operating or assembly errors as well as inadequate lubrication and fuels are some of the main breakdown causes. This brochure summarizes typical types of damage. It describes their probable causes and provides information on how to prevent such damage in the future. This should facilitate the search for the possible cause of damage. This information ensures the extensive and reliable functioning of our products and a corresponding long service life for engines. Furthermore, our experts are also confronted with complex damage processes which cannot be explained in this brochure due to space limitations. However, in the event that damage occurs to our products, we will be more than willing to examine them at our facility and to write an expert damage report for you. Please contact your local sales partner or MAHLE representative.

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Diesel Cylinder Heads & Engine Accessories Magnafluxed for cracks Repaired and brought back to specifications Built with NEW guides, injector tubes, freeze plugs, seals and keepers 100% Air decay and wet pressure tested Surface ground Machined in seat areas and vacuum tested Sealed with a rust preventative coating

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GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL  Guide All specific cautions and warnings contained in this manual shall be strictly adhered to. Otherwise, severe injury, death and/or damage to the equipment may result.or severe burns may result if personnel fail to observe safety precautions. Do not operate this generator set until the ground terminal stud has been connected to a suitable ground. Disconnect the battery ground cable before removing and installing components on the engine or in the electrical control panel system.

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Power Generation The Solution Thats Fits Guide The benefits of solar power are compelling – the fuel is free, abundant and inexhaustible. In fact in just one year, six times as much useable solar energy hits the Earth as there is in total reserves from non-renewable sources. It is environmentally friendly, aids in the diversification of our fuel and energy supply and is rapidly deployable.

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Nuclear Power for Electrical Generation The purpose of a nuclear power plant is not to produce or release “Nuclear Power.” The purpose of a nuclear power plant is to produce electricity. It should not be surprising, then, that a nuclear power plant has many similarities to other electrical generating facilities. It should also be obvious that nuclear power plants have some significant differences from other plants.

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It is extremely important to read and understand all of the instructions contained in this manual before starting your engine, especially the Safety Instructions. The importance of following the safety instructions at all times cannot be over-emphasized! Mitsubishi Engine 4M40Series engines start very easily and develops enough horsepower to cause serious injury or death to the operator and bystanders. We here at Mitsubishi Engine 4M40 Series are concerned for your safety and the safety of others so PLEASE follow the safety instructions at all times!