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

2. GENERAL INFORMATION
1. STANDARD ENGINE DATA AND SPECIFICATIONS
(I) Model A-4BGlT Exp. STD Spec.
A-4BGlT
I Engine type
Cornbustion type
No. of cylinders- bore x stroke
Water cooled, four cycle, in line overhead valve type
Direct injection
mm(in)
4 - 105 x 125 (4.13 x 4.92)
I Engine displacement lit(cid) 1 4.329
(264.2)
I
Compression ratio I
17.0to 1
1 Firing order I
1-3-4-2
1* Ratedpower; SAE GROSS kW(hp)/minl 1
83(111)/2400
1* Max. torque; SAE GROSS Nm(lbft)/min-l 1
385(284)/1600
1 Injection pump Bosch A type
I
Governor I Variable speed, Mechanical type (RSV)
I Injection nozzle I
~~ Multi-hole type
1 Specified fuel ~~
Diesel fuel (ASTM D975 No. 2-D)
I
* Starter V-kW 1
12 - 3.0
I
* Alternator V-A I
12-60

A-4BGlT
Specified engine oil (API grade)
I
CD
I
( * Lub. oil volume (Oil pan)
l
Ilt I
13.0 - 11.0
I
I Coolant volume (Engine only)
l
Ilt 1 8.5
--I
I * Engine dry weight
kgI
360
I
Overall length mm 860
* Engine
dimensions Overall width mm
658
Overall height mm
855
I
Valve clearance (cold) mm I 0.4
I
1 Nozzle injection pressure MPa 1 18.1
I
I
Injection timing B.T.D.C
I
12O
1
I Maker and type of turbocharger
I
MHI (TD04H) I
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
in which the engine is installed.
If you are unable to locate these data applicable to your engine, please contact your equipment
supplier.

(2) Model A-4BGl Exp. STD Spec.
A-4BGl
Engine type Water cooled, four cycle, in line overhead valve type
Combustion type Direct injection
No. ofcylinders- borex stroke mm(in)
4 - 105 x 125 (4.13 x 4.92)
Engine displacement lit(cid) 4.329
(264.2)
Compression ratio
17.0to 1
Firing order
l-3-4-2
* Ratedpower; SAE GROSS kW(hp)/min-l
66.5 (89)/ 2500
* Max. torque;SAE GROSS Nm(lbft)/min-l 305(225)/1600
Injection pump Bosch A type
Governor Variable speed, Mechanical type (RSV)
Injection nozzle Multi-hole type
Specified fuel Diesel fuel (ASTM D975 No. 2 D)
* Starter V-kW 12 - 2.5
* Alternator V-A
12-60

A-4BGl
Specified engine oil (API grade) CC or CD
I ~~~~
* Lub. oil volume (Oil pan) .
ht 1 13,o - 11.0
I
I Coolant volume (Engine only)
l
ht I 8.5
I
I
* Engine dry weight
kgI
350.0
I
* Engine
dimensions
Overall length mm
860
Overall width mm 665
Overall height mm 790
I
Valve clearance (cold) mm
I
0.4
I
I ~~~~~
* Nozzle injection pressure
MPa 1 18.1
I
I
Injection timing B.T.D.C
I
14O
I
I Maker and type of turbocharger
I
NA
I
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
in which the engine is installed.
If you are unable to locate these data applicable to your engine, please contact your equipment
supplier.
8

2. EPA CERTIFIED ENGINE DATA AND SPECIFICATIONS
(I) Model A-4BGlT
ISUZU engine model name A-4BGlT
I
Engine family
I ~~~~~
XSZXL04a3DTA
1 Engine code
I
43DTA
Engine type
Combustion type
Water cooled, four cycle, in line overhead valve type
Direct injection
I
No. of cylinders- borex stroke mm(in) I
4 - 105 x 125 (4.13 x 4.92)
I
Engine displacement lit(cid) I 4.329 (264.2)
I
Compression ratio
I
17.0 to 1
Exhaust emission control system
Injection pump
Governor
Engine modification
Bosch A type
Variable speed, Mechanical type
Firing order
Max. rated power; SAE NET kW(hp)/min-l
I-3-4-2
81.4 (109.2) / 2400
Fuelflow at max. rated power mm3/stroke
Max. torque; SAE NET Nm(lbft)/min-‘l
80.60
381.5 (281.4) / 1600
I
Fuel flow at max. torque mm3/stroke I
88.88

A-QBGIT
. . .
I Injection nozzle
I
Multi-hole type
I Specified fuel Diesel fuel (ASTM 0975 No. 2-D)
I
Starter V-kW 1 12 - 2.5
I
I
Alternator
V-AI
12-60
I
Specified engine oil (API grade) CD
Lub. oil volume (Oil pan) lit (qts) 13.0 (13.7) - 11.0 (11.6)
I
Coolant volume (Engine only) lit (qts) 1 8.5 (9.0) I
I Engine dry weight kg (lb) 1 350.0 (771.6)
I
Engine
dimensions
Overall length mm (in)
Overall width mm (in)
Overall height mm (in)
878.0 (34.57)
686.0 (27.01)
855.0 (33.66)
I
Valve clearance (cold) mm (in) I 0.4 (0.0157)
I
Nozzle injection pressure
Injection timing B.T.D.C
MPa (psi) 18.1 (2625)
12O
I
Maker and type of turbocharger
I
MHI (TDO4H)
I
IO

(2) Model A-4BG1, B-4BGl
I ISUZU engine model name
I
A-4BGl I B-4BG 1
I
I Engine family
I
XSZXL04m3DNA
I
Engine code 43DNA-1 43DNA-2
I Engine type I Water cooled, four cycle, in line overhead valve type I
Combustion type
No. of cylinders- borex stroke mm(in)
Direct injection
4 - 105 x 125 (4.13 x 4.92)
I Engine displacement lit(cid) I 4.329 (264.2)
I
I
Compression ratio
I
17.0 to 1
I
I
Firing order
I
l-3-4-2
1
I Max. rated power; SAE NET kW(hp)/min-l I 64.7 (86.8) / 2500 1 46.3 (62.1) / 1750 ]
I
Fuelflow at max. rated power mm3/stroke
I
66.8 I 61.4
1
I Max. torque; SAE NET Nm(lbft)/minl I 308.0 (227.2) / 1600
I
264.1 (194.8) / 1500
I
I
Fuel flow at max. torque mm3/stroke
I
75.7 I 63.6
I
I Exhaust emission control system Engine modification
Injection pump
Governor
Bosch A type
Variable speed, Mechanical type
11

A-4BGl B-4BGl
Injection nozzle Multi-hole type
Specified fuel Diesel fuel (ASTM D975 No. 2-D)
Starter V-kW 12 - 2.5
Alternator V-A 12-60
Specified engine oil (API grade) CC or CD
Lub. oil volume (Oil pan) lit (qts) 13.2 (13.9) - 11.0 (11.6)
Coolant volume (Engine only) lit (qts) 8.5 (9.0)
Engine dry weight kg (lb) 350.0 (771.6)
Overall length mm (in) 931 .O(36.65)
Engine
dimensions . Overall width mm (in) 658.5 (25.93)
Overall height mm (in) 826.5 (32.54)
Valve clearance (cold) mm (in) 0.4 (0.0157)
Nozzle injection pressure MPa (psi) 14.7 (2132) 18.1 (2625)
Injection timing B.T.D.C . 14O 13O
Maker and type of turbocharger NA
c
12

EMISSION CONTROL LABEL: ENGINE LABEL (FOR EPA)
Emission control label is attached on the upper side of cylinder head cover. But the same emission control
label is attached at a visible point on the equipment when the label that is attached to the engine is not
visible due to the structure of the equipment.
The following is the sample of a label required for engine emission control information, along with location.
ISlJaJ
IMPORTANT ENGINE INFORMATION
ISUZU MOTORS LTD. MADE IN JAPAN
ENGINE FAMILY: XXXXXXXXXXX
ENGINE CODE:XXXX
MODEL : XXXX
ENGINE DISPLACEMENT : XXXXcm3
EXHAUST EMISSION :XXX IN3
CONTROL SYSTEM : EM
DATE OF ENGINE
ENGINE SPECIFICATION
ADVERTISED MAX.POWER.
SAE NET
(FAN DISENGAGED)
XXkW/XXXX min-1
XXHP/XXXX RPM
FUELRATE
XX mmht.
MANUFACTURE :xX/xx
THIS ENGINE IS CERTIFIED TO
V4LNVfIASH (COLD)
: X.X mm.
OPERATE ON DIESEL FUEL. EXH : X.X mm.
THIS ENGINE CONFORMS TO U.S. EPA INITIAL INJECTION
TIMING : XX” BTDC
REGULATIONSAPPLICABLE TO 1999 CURB IDLE : XXXmin-l/RPM
MODEL YEAR LARGENONROAD (*MODEL SPECIFICATION
COMPRESSION-IGNITION ENGINES. SEE SERVICE MANUAL)
P.NO. X-XXXXX-XXX-X

3. EC EMISSION CONTROL LABEL: ENGINE LABEL
Emission control label is attached on the right side of cylinder head cover.
The following is the sample of a label required for engine emission control information, along with location.
1 s ~3, u IMPORTANT ENGINE INFORMATION
ISUZU MOTORS LTD. MADE IN JAPAN
ENGINEFAMILYNAME XXXX
ENGINETYPE xxxx-x
ENGINEI,D.NUMBER xxxx-xxxxxx
TYPEAPPROVALNUMBER
e9*97/68CA*OO/OOOXX*3005*00
P. NO. X-XXXXX-XXX-X
14