Isuzu 4BG1 Instruction Manual Download

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Summary of Contents for 4BG1

Page 1: ...1999 MODEL YEAR...

Page 2: ...an 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 Ing...

Page 3: ...u 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 requ...

Page 4: ...reduce the hazard Please read these cautions If you don t you or others could be hurt INOTICE These mean there is something that could damage your engine or equipment In the notice area we tell you a...

Page 5: ...BEL 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 STARTI...

Page 6: ...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...

Page 7: ...ERNAL 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 spec...

Page 8: ...TERNAL 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 specificatio...

Page 9: ...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...

Page 10: ...ERNAL 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...

Page 11: ...n 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...

Page 12: ...alve 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 s...

Page 13: ...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 Injectio...

Page 14: ...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 stand...

Page 15: ...ders 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 modificatio...

Page 16: ...lit qts 13 0 13 7 11 0 11 6 ICoolant 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 87...

Page 17: ...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...

Page 18: ...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 Overal...

Page 19: ...GINE 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 SPECI...

Page 20: ...he 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 ENGINE FAMILY NAME XXXX E...

Page 21: ...model is cast on the center left side of cylinder body Further engine model is described also on an ID label on the top of the cylinder head cover 2 Confirmation of Engine Serial Number It is advisabl...

Page 22: ...d maintenance 2 lsuzu Genuine Parts The ISUZU genuine parts are identical with those of used in the engine production and accordingly they are warranted by ISUZU MOTORS LIMITED The ISUZU genuine parts...

Page 23: ...pecific advantages are required for the diesel fuel 1 Must be free from minute dust particles 2 Must have adequate viscosity 3 Must have high cetane value 4 Must have high fluidity at low temperature...

Page 24: ...ne oil with diesel fuel Some manufacturers of large diesel engines allow this however for your diesel engine do not use diesel fuel which has been contaminated with engine oil Besides causing engine d...

Page 25: ...use a winterized Number 2 D a blend of Number I D and Number 2 D This blended fuel is usually called Number 2 D also but can be used in colder temperatures than Number 2 D fuel which has not been win...

Page 26: ...r water is completely sedimented Always fully fill the fuel tank Drain the sedimented particles in the fuel tank frequently by opening the tank draining hole Water in Fuel During refueling it is possi...

Page 27: ...rosion If fungus or bacteria has caused fuel system problems you should have your authorized dealer correct these problems Then use a diesel fuel biocide to sterilize the fuel system follow the biocid...

Page 28: ...e of extensive testing of treated fuel versus untreated fuel the use of a smoke suppressant additive is not recommended because of the greater possibility of stuck rings and valve failure resulting fr...

Page 29: ...CC or CD grade 2 Oil Viscosity Engine oil viscosity largely affect engine startability performance oil consumption speed of wearing and occurence of seizure etc Using lubricants whose viscosity selec...

Page 30: ...Single grade I Ambient 1 30 C temperature 22 F 15 C 0 C 15 C 25 C 30 C 5 F 32 F 59 F 77 F 86 F I IMulti grade Fig 7 3 COOLANT Use drinking water for coolant and replace it periodically 24...

Page 31: ...4I EAlGllilE OPERATION Engine Exhaust Gas Caution Carbon Monoxide...

Page 32: ...26...

Page 33: ...it fully and take out it gently again Check the oil level by the level marks on the dipstick The oil level must be between the Max level mark and the Min level mark as illustrated Take care not to ad...

Page 34: ...nary ten or twenty minutes until the oil thoroughly flows down to the crankcase 4 Oil is poured through the oil filler at the front of the cylinder head cover A certain period of time is required befo...

Page 35: ...ect When the belt tension is too high it will result in alternator failure Contrarily loose belt will cause belt slipage which may result in damaged belt and abnormal noise 2 Check the belts Replace t...

Page 36: ...Proper coolant level is about 10 mm higher from the radiator core top 2 Use clean drinking water as coolant When an anti freeze solution is required keep to the specified mixing ratio 4 Radiator Cap...

Page 37: ...trical parts Connections Fig 12 Regular position md 0 Shortage Proper Excess 6 Battery Electrolyte Level The amount of electrolyte in the batteries will be reduced after repeated discharge and recharg...

Page 38: ...I...

Page 39: ...he equipment are in the NEUTRAL position 2 Set the engine stop knob in the START position 3 Switch ON the battery switch if so equipped 4 Insert the starter switch key into the switch key hole Turn th...

Page 40: ...me varies depending on the types of pre heating system as follows l The type with an indication lamp 20 seconds are required until the indication lamp at the instrument board goes off 0 The type with...

Page 41: ...CE Continuous re engagement of the starter to the flywheel ring gear without giving them a break will result in the damaged starter pinion gear and flywheel ring gear 2 If despited repeated operations...

Page 42: ...ems in the engine warming up operation Engine oil pressure Although the engine oil pressure gauge readings vary depending on ambient temperature or a type of oil the gauge registers around 4 to 5kg cm...

Page 43: ...r Abnormal Imperfect combustion NOTICE Engine noise after start up might be noisy than that of warmed up engine and the exhaust smoke co our a so being more blackish than the normal condition However...

Page 44: ...cks on the radiator and cylinder body for leakage l Exhaust smoke or gas leakage Checking coolant level The coolant level could drop depending on the equipment because the mixed air is expelled in abo...

Page 45: ...ration the engine oil pressure warning lamp is off engine oil pressure is normal When the engine oil pressure gauge shows the following abnormal conditions stop the engine immediately and check the en...

Page 46: ...overheat condition stop and park the vehicle or equipment as soon as it is safe to do so and then turn off the engine immediately and get out of the vehicle or equipment The engine cooling system may...

Page 47: ...the transmission in Neutral increase the engine speed to about one half full operating speed or 1200 RPM maximum Bring the idle speed back to normal after two or three minutes If the engine coolant t...

Page 48: ...the reserve tank only never directly into the radiator Also do not check engine coolant level at the radiator Make sure the fan belts are not broken or off the pulleys and that the fan turns when the...

Page 49: ...l YOU MUST LET ENGINE COOL FIRST You may then add engine coolant directly to the radiator Once the Engine Coolant Temperature Gage no longer signals an overheat condition you can resume operating at...

Page 50: ...dicated on the hourmeter Liquid and Exhaust Smoke Leakage Be careful with lubricant fuel coolant and exhaust smoke leakage Abnormal Engine Noise Pay attention to the noise from the engine or other rel...

Page 51: ...n the turbocharged engine if the engine is stopped instantaneously a dry condition produced by high temperature will take place in the turbocharger rotating parts which may cause lack of lubrication T...

Page 52: ...100 operation hours observing the following notice I Do the warming up operation continuously until the engine is warmed up In this operation do not race the engine 2 Also do not operate the engine wi...

Page 53: ...oil inlet port with the air intake duct and oil inlet side pipe removed Then turn the impeller by hand to thoroughly lubricate the bearings When pouring oil in do not allow dust particles and other fo...

Page 54: ...D gP 2 c nz II mD 3 7 Bm ua...

Page 55: ...e schedule In the engine operation when the oil filter warning lamp lights on the filter element is clogging In such a case change the filter element regardless the specified change schedule Change in...

Page 56: ...be done while the engine is warm to minimize the draining time NOTICE Use a receptacle to receive the drained oil so that the engine and equipment may not be stained with the drained oil Main oil filt...

Page 57: ...ilter wrench Cartridge Drain plug Fig 19 ET i i Cartridge Fig 20 Partial oil filter Cartridge type Use a filter wrench to remove the cartridge type oil filter Main oit Partial oil fitter Fig 21 t i 1...

Page 58: ...take place Cartridge type Apply a coat of engine oil to the O ring Turn in the new cartridge until the sealing face is fitted against the O ring Use the filter wrench to turn in the cartridge an addit...

Page 59: ...for oil leakage Oil level recheck Stop the engine and keep it stationary about twenty minutes Use the dipstick to recheck the oil level Replenish with engine oil if necessary to the specified level NO...

Page 60: ...tead recycle it by taking it to a used oil collection facility which may be found in your community If you have a problem disposing of your used oil it is suggested that you contact your dealer or ser...

Page 61: ...ess is greater than the specified amount and when the belts are replaced Belt tension Belt tension is normal when it is depressed 8 to 12 mm 0 31 to 0 47 in with the thumb at the midway between the fa...

Page 62: ...may vary slightly afier the alternator is fixed Therefore recheck the belt tension after tightening the bolts 4 After the adjustment operate the engine about five minutes at a low idle speed and rech...

Page 63: ...y it will lead to engine overheat or coolant blow off from the radiator Coolant draining I Remove the radiator cap Open the drain cock at the radiator lower part to drain the coolant in the radiator 2...

Page 64: ...enish with the coolant Cleaning outside of Radiator Mud or dried grass caught between radiator fins will block the air flow resulting in lower cooling efficiency Clean the radiator fins with steam or...

Page 65: ...iodically as follows 1 Removal of Water from the Fuel The fuel system with the water sedimentor The water sedimentor is provided to separate the water contained in the fuel The sedimentor housing cont...

Page 66: ...fuel system air bleeding after the water in the fuel is drained Fig 26 2 Fuel System Air Bleeding 1 2 3 The entry of air into the fuel system will cause hard engine starting or engine malfunction Whe...

Page 67: ...terval Every 600 operating hours Change procedure Center bolt type fuel filter Loosen the drain plug at the lower top of the center bolt and drain the fuel in the fuel filter Loosen the center bolt to...

Page 68: ...e O ring To reinstall turn the filter assembly clockwise carefully to prevent the fuel from spilling until the O ring is fitted against the sealing face of the filter cover Turn 2 3 turn further with...

Page 69: ...ump is precisely adjusted most of the controls are sealed please do not break them When the adjustment is necessary contact with your machine supply source NOTICE The manufacturer does not warrant the...

Page 70: ...ulting in increased oil consumption reduced output and shortened engine life Handling of air cleaner varies with the equipment model Perform periodic inspection and maintenance following the equipment...

Page 71: ...e air cleaner element is clogged air intake restriction becomes greater and the dust indicator signal turns into red indicating the element change timing When the signal turns into red clean the air c...

Page 72: ...he batteries The battery charge condition is judged by the electrolyte gravity measurement Periodically measure the electrolyte gravity of the batteries For the internal check follow the equipment man...

Page 73: ...ture 30 St 0 0007 t 20 S20 gravity at 20 C St gravity measured t electrolyte temperature whe measured Battery terminal connections Periodically check the battery terminals for loose connection and cor...

Page 74: ...ted circuit connection take place the circuit will be in short circuit instantaneously resulting the alternator failure Do not put water directly on the alternator Entry of water into the alternator l...

Page 75: ...starting pressure and the fuel spray conditions Injection nozzle pressure test interval Every 400 operation hours When the injection starting pressure is too high or too low or the fuel spray pattern...

Page 76: ...he adjustment on the circle marked valves in the below tabel where No 1 cylinder is in the top dead center in the compression stroke After the above steps do the adjustment on the double circle marked...

Page 77: ...timing gear case cover Remove the timing check hole cover at the front of injection pump to check the alignment between the pointer a on the injection pump gear lock plate and the projected area mark...

Page 78: ...ue to feed the fuel with pumping the Feed pump When the fuel stop to flow out from No 1 delivery valve holder stop the pumping instantaneously 6 Observe and make sure that which mark injection startin...

Page 79: ...salignment between the two setting mark lines corresponds to about 2 in crank angle 4 Do a fine injection pump position adjustment while continuing the pumping operation to feed the fuel and stop to p...

Page 80: ...lower than 2 55 MPa 370 psi Starter and Alternator Servicing Do the starter and the alternator servicing every 1200 operating hours on the following items 0 Starter commutator cleaning l Alternator s...

Page 81: ...fuel for such engine operation Use ASTM 975 No 2 D fuel if you expect temperature above 7 C 20 F Use Number 1 D if you expect temperatures below 7OC 20 F If Number I D is not available a winterized bl...

Page 82: ...i freeze solution is highly recommended A 50 50 Ethylene glycol base antifreeze water mix which provides protection to 37OC 34 F is recommended for use in these ISUZU diesel engines Concentrations ove...

Page 83: ...f causing serious silica geiation problems 3 Usage and mixing ratio etc should be followed to the antifreeze manufacture s recommendations 3 ENGINE OIL Engine oil viscosity largely affects engine star...

Page 84: ...vity of the insufficiently charged battery s electrolyte is low it will easily be frozen Pay attention to keep the batteries warm in the cold season 2 To replenish the battery with distilled water do...

Page 85: ...e time cranking must be limited to within 10 seconds In cranking operation when a phenomenon that the starter pinion and the flywheel ring gear engagement to repeated disengage and engage take place a...

Page 86: ...he electrical wiring differs depending on the respective equipment merely standard wirings are shown in the diagrams Glow plug Control resi aity swi Fuse box 1 1 1 Batteryrelay I Battery Alternator c...

Page 87: ...switch I I i lamp v m ifi Oil Dress sw Y lamp 1 we w w Alternator 12V 60A Starter 12V 2 5kW Pugh off OVERHEATSW w m J Normal open No mark wire spec 0 85 iL Recommended application Improper connection...

Page 88: ...check 0 3 Oil pressure gauge registration 0 4 Oil pressure warning lamp 0 Engine oil and main oil filter 5 element replacement without 0 0 0 0 0 0 0 j partial oil filter See EXPLANATION OF 6 Engine o...

Page 89: ...temperature registration 19 Coolant replacement 2 Radiator external face cleaning operation hours Daily Remark 50 200 400 500 600 800 1000 1200 0 0 0 0 W 0 0 0 See EXPLANATION OF MAINTENANCE SCHEDULE...

Page 90: ...p 22 function check 23 Electrolyte level check 24 Battery cleaning Ammeter Battery registration 25 charge condition Charge warning lamp 26 Electrolyte gravity check Starter and alternator 27 check and...

Page 91: ...e 34 Valve clearance check Daily Remark 50 200 400 500 600 800 1000 1200 0 0 See EXPLANATION OF MAINTENANCE SCHEDULE 0 0 Note 1 The service intervals after 1200 operation hours should also be made eve...

Page 92: ...hich could cause leakage Oil pressure gauge Engine oil pressure is normal at about 3 to 5 kg cm2 in warmed up condition registration Check and repair the lubrication oil system if it is abnormal Oil p...

Page 93: ...d spray condition This is a recommended maintenance 14 Coolant level and fouling check Check coolant level and add coolant if necessary 15 Coolant leakage check Repair part for coolant leakage 16 Radi...

Page 94: ...it every 12 months Check radiator pressure cap perodically for proper operation according to the equipment manufacturer s specifications Replenish with distilled water if necessary Clean the terminals...

Page 95: ...moke condition Check exhaust smoke color 33 Cylinder compression Check every 1200 hours pressure 34 Valve clearance check Incorrect valve clearance will result in increased engine noise and lower engi...

Page 96: ...e Safety relay failure 7 Engine stop system does not Engine does not start Starter turns but engine does not ignite r Battery discharged return to the original position No fuel in the fuel tank No fue...

Page 97: ...erior malfunction Unstable engine running Engine hunting in medium speed range Governor spring deteriorated Air in the fuel system Insufficientfuel supply Clogged fuel filter element Fuel leakage from...

Page 98: ...r fouled Radiator clogging Improper servicing Engine over loaded Air cleaner element clogging Insufficientventilator Stopped coolant flow high concentration of antifreezer etc r Lack of oil E Improper...

Page 99: ...Injection nozzle malfunction S n raycondition L Governor malfunction 4 gine control Deteriorated governor spring Incorrect valve clearance Cylinder compression pressure l leakage L Poor cylinder com...

Page 100: ...der liner or piston ring wear Oil coming down Faulty valve stem seal r Damaged packing L oil leakage t Improper tightening Improper installationof filter and piping r Fuel leakage ____c Damaged packin...

Page 101: ...Improper fuel Much white smoke Oil coming up or down Water mixing in fuel Low compression pressure Injectiontiming failure Low coolant temperature r Low electrolyte level Crack in battery body Natural...

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Page 103: ...information available at the time of publication The right is reserved to make changes at any time without notice INSTRUCTION MANUAL INDUSTRIAL IDE 1905 9 Issued by ISUZU MOTORS LIMITED ENGINE SERVICE...

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Isuzu 4BG1, Instruction Manual

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