Isuzu 4BG1 User manual

1999 MODEL YEAR

CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its
constituents are known to the State
of California to cause cancer, birth
defects, and other reproductive harm.
Revised (10-12)
Doosan purchased Bobcat Company from Ingersoll-Rand Company in
2007. Any reference to Ingersoll-Rand Company or use of trademarks,
service marks, logos, or other proprietary identifying marks belonging
to Ingersoll-Rand Company in this manual is historical or nominative
in nature, and is not meant to suggest a current affiliation between
Ingersoll-Rand Company and Doosan Company or the products of
either.

FOREWORD
The ISUZU industrial diesel engines are a product of ISUZU’s long
years of experience, advanced technology. ISUZU takes great pride
in the superior durability and operating economy of these engines.
In order to get the fullest use and benefit from your industrial
engine, it is important that you operate and maintain it correctly.
This Manual is designed to help you do this.
Please read this Manual careful/y and follow its operating and
maintenance recommendations. This will ensure many years of
trouble-free and economical engine operation.
Should your engine require servicing, please contact your nearest
ISUZU engine outlet. He knows your engine best and is ready to
meet your satisfaction.
Ail information, illustrations, and specifications contained in this
Manual are based on the latest product information available at the
time of publication.
ISUZU reserves the right
time without prior notice.
to
make changes in this Manual at any

CAUTION AND NOTICE
SAFETY WARNINGS
CAUTION: These mean there is something that could hurt you or other
people..
In the caution area, we tell you what the hazard is. Then we tell you what to do to
help avoid or reduce the hazard. Please read these cautions. If you don’t, you or
others could be hurt.
I
NOTICE: These mean there is something that could damage your engine or
equipment.
In the notice area, we tell you about something that can damage your engine or
equipment. Many times, this damage would not be covered by your warranty,
and it could be costly. But the notice will tell you what to do to help avoid the
damage.

TABLE OF CONTENTS
1. ENGINE EXTERNAL VIEWS ...........~........~.~.........................~~...~..... 1
2. GENERAL INFORMATION ..................................................~....~...... 5
1. STANDARD ENGINE DATA AND SPECIFICATIONS .............. 5
2. EPA CERTIFIED ENGINE DATA AND
SPECIFICA TIONS ...................................................................... 9
3. EC EMISSION CONTROL LABEL............................................. 14
4. ENGINE /DENT/F/CAT/ON ........................................................ 15
5. ISUZU ENGINE AFTER SERVICE............................................. 16
3. FUEL, LUBRICANT, AND COOLANT ............................................. 17
1. FUEL........................................................................................... 17
2. LUBRICANT ............................................................................... 23
3. COOLANT .................................................................................. 24
4. ENGINE OPERATION ...................................................................... 25
1. CHECK BEFORE OPERATION .................................................. 27
2. ENGINE STARTING .................................................................. 33
3. CHECK AND OPERATION AFTER THE ENGINE START-UP ... 36
4. CARE IN THE ENGINE OPERATION ,,..‘....,....................~......... 39
5. ENGIN& STOPPING ..............................‘..................................~ 45
6. OPERATION AND CARE FOR NEW ENGINE ......*...*.....*.......*. 46
7. ENGINE CARE FOR OVER-COOLING
l .,...~....~........~........~.....~..
46

8. OPERATION AND CARE FOR TURBOCHARGED ENGINE.... 47
9. STARTING THE ENGINE AFTER BEING LEFT UNUSED
FOR A LONG PERIOD OF TIME ......*....................*.........,......... 48
5. PERIODICAL INSPECTION AND MAINTENANCE ....
l ......... l ......... l 49
1. LUBRICATING SYSTEM ..,....,.......................................*........... 49
2. COOLING SYSTEM ................................................................... 55
3. FUEL SYSTEM .~.~~““...~..~~.........~~.............~.~~~~~.....,....................... 59
4. AIR INTAKE SYSTEM ............................................................... 64
5. ENGINE ELECTRICAL ............................................................... 66
6. ENGINE ASSEMBLY AND OTHERS ,,..,..,.,.,.,..*....................... 69
6. ENGINE CARE IN COLD SEASON ................................................. 75
7. ENGINE ELECTRICAL WIRING DIAGRAMS .................................. 80
8. ENGINE MAINTENANCE SCHEDULE ............................................ 82
9. SIMPLE ENGINE TROUBLESHOOTING ....................................... 90

1. ENGINE EXTERNAL VIEWS
EXTERNAL VIEW
A-4BGlT (LH)
Air breather
Outlet pipe Oil filler cap
\ \ I Turbocharger
Crank pulle;
Exhaust
manifold
Alternator
Fig. 1
Starter
:ick
Note:
Engine details may
vary depending on the
specifications.
1

EXTERNAL VIEW
A-4BGlT (RH)
Inlet manifold
Nozzle holder Fuel filter
/
Oil cc
Flywheel
housing I
Oil filter
\ Oil pan
Fig. 2
/
Cooling fan
‘Injection pump
Note:
Engine details may
vary depending on the
specifications,

EXTERNAL VIEW
A-4BG 1 (LH)
Outlet pipe Oil filler cap
\ .\ Air breather
I Exhaust
‘old
),, h -/!- \/mani’
/
Crank pulley
Alternator \ Starter
Blow-by hose
Fig. 3
stick

EXTERNAL .VlEW
A-4BGl (RH)
Nozzle holder \
Inlet manifold
I Fuel filter
Oil c(
/
Flywheel
housing \ Oil pan
Oil filter
, Cooling fan
Injection pump
1
Note:
Engine details may
vary depending on the
specifications.
Fig. 4
4