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4LE1T Operators Manual

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1. 32 33 34 35 36 37 38 39 40 EGR valve check and cleaning EGR lead valve cleaning EGR cooler cleaning Fuel amp cooling water rubber hoses replacement Engine starting conditions and noise conditions Exhaust smoke condition Cylinder compression pressure Valve clearance check Positive crankcase ventilation valve cleaning Check and clean EGR valve every 1500 hours Clean EGR lead valve every 1500 hours Clean EGR cooler every 1500 hours Check and replace every 24 months Check engine stability and noise Check exhaust smoke color Check every 1000 hours Incorrect valve clearance will result in increased engine noise and lower engine output Thereby adversely affecting engine performance Check and adjust every 1000 hours Perform the adjustment cleaning repair or replacement every 1500 hours This is a required maintenance 101 8 SIMPLE ENGINE TROUBLESHOOTING This section contents simple troubleshooting Refer this section in case of engine failure If the cause can not be identified or if it is hard to correct contact ISUZU dealer as soon as possible The items marked with in Action are necessary to be repaired or adjusted Contact ISUZU dealer Action Battery discharged Charge or change Starter does Imperfect cable connections not turn Starter or starter switch
2. 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 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 carefully 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 All 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 to make changes in this Manual at any time without prior notice WARNING AND CAUTION SAFETY WARNINGS WARNING These mean there is something that could hurt you or other people In the warning 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 warnings If y
3. Combustible sp cifi Combustible Diesel ASTM D975 No 2 D D marreur 12 2 0 Alternateur 12 20 Huile moteur sp cifi e API grade R f rez vous a 3 LUBRIFIANT choix D Huile moteur Volume d huile de lubrication 5 9 6 2 8 4 8 8 Volume du liquide de refroidissement seulement moteur 2 8 3 0 Poids a sec du moteur 170 375 Longueur hors tout 671 26 4 Dimensions du moteur Largeur hors tout Hauteur hors tout 496 19 5 595 23 4 Jeu de soupape a froid 0 4 0 0157 Pression d injection d injecteur 14 7 2132 Calage d injection B T D C 10 115 5 116 Famille indice de moteur Moteur Famille de moteur SZXLO2 2UTA Code de moteur Pression d injection d injecteur MPa psi Catage d injection B T D C degre SZXLO2 2VTB SZXLO2 2VNA SZXLO2 2VNC Marque Placer un code de lettres pour l ann e du mod le sur la partie sup rieure des lattres Ann e du mod le Y 2000 1 2001 2 2002 3 2003 4 2004 5 2005 6 2006 7 2007 8 2008 9 2009 ETIQUETTE DE COMMANDE D EMISSION ETIQUETTE DU MOTEUR TYPE COMBINE EPA CE L tiquette de commande d mission est fix e au centre du couvercle de la pompe d injection situ sur la droite du corps du cylindre ou sur le couvercle de la culasse L emplacement de l
4. Type de combustion Swirl chambre No de cylindres al sage x course mm in 4 85 x 96 3 35 x 3 78 Cylindr e du moteur L cid 2 179 133 Rapport de compression 21 5 to 1 S quence d allumage 1 3 4 2 Puisance nominale SAE NET kW cv min 35 46 9 1800 D bit de combustible au couple max mm course 49 7 Syst me de commande d mission d chappement EM IDI TC Pompe injection Type PFR Bosch R gulateur Type m canique vitesse variable Marque Placer un code de lettres pour l ann e du mod le sur la partie sup rieure des lattres Ann e du mod le Y 2000 1 2001 2 2002 3 2003 4 2004 5 2005 6 2006 7 2007 8 2008 9 2009 Le code du moteur varie selon chaque moteur 110 Buses injection Type papillon Combustible sp cifi Combustible Diesel ASTM D975 No 2 D D marreur 12 2 0 Alternateur 12 35 R f rez vous a 3 LUBRIFIANT choix D Huile moteur Huile moteur sp cifi e API grade Volume d huile de lubrication 7 6 8 0 10 3 10 9 Volume du liquide de refroidissement seulement moteur Poids a sec du moteur 180 397 Longueur hors tout i 753 7 29 7 Dimensions du moteur Largeur hors tout i 486 2 19 1 Hauteur hors tout i 601 8 23 7 2 8 3 0 Jeu de soupape a froid i 0 4 0 0157 Pression d injection d injecteur i 14 7 2132 Calage d injection B T D C 10 Fabricant et type de tu
5. Deteriorated governor spring Incorrect valve clearance adjustment Make a readjustment Nozzle holder misalignment Cylinder bore wear Air cleaner clogging Clean element Such as inferior ventilation Check engine condition Ventilate and improve it At low speed insufficient EGR valve fixing Open position torque Wrong selection of kind of viscosity Change with oil of correct viscosity Improper oil Too much oil quantity i coming Wrong selection of cylinder liner and piston ring Excessive oil il i consumption ee Faulty valve stem seal Damaged packing Change packing Oil leakage Improper tightening Retighten oil filler cap Improper installation of filter and piping Reinstall filter and piping 105 Cause Damaged packing Action Change packing Fuel leakage Improper installation or tightening Reinstall or retighten air bleeder plug Excessive Too much fuel injection Injection pump misadjustment consumption amount Excessive mechanical Operation Check the mechanical loads loads Clogged air cleaner Clean or change element Nozzle damage Nozzle misadjustment Make a readjustment Much black r Smoke Injection timing failure Injection amount misadjustment Improper Improper fuel Use fuel in this instruction manual
6. THIS ENGINE IS CONFORMED 97 68 EC DIRECTIVE 22000 ENGINE TYPE XXXXXXXXXX ENGINE ILD NUMBER 000000 IMLE0097 4LE1NA ISU2Z EMISSION CONTROL INFORMATION ISUZU MOTORS LTD MADE IN JAPAN THIS ENGINE COMPLIES WITH U S EPA REGULATIONS FOR XX MY NONROAD DIESEL ENGINES AND CALIFORNIA REGULATIONS FOR XX MY OFF ROAD DIESEL ENGINES SEE SERVICE MANUAL FOR ENGINE FAMILY X000000 XXXX MODEL SPECIFICATIONS ENGINE CODE 110000000CXX ADVERTISED POWER SAE NET MODEL EK OOK KW X00 RPM POWER CATEGORY XX lt kW lt XX FUEL RATE XX mm st 20000000000000000X VALVE LASH COLD EXHAUST EMISSION CONTROL SYSTEM INUEXH XX XX mm 200000000000000000 INITIAL INJECTION TIMING LOW SULFUR FUEL OR ULTRALOW SOC BTOC SULFUR FUEL ONLY CURB IDLE XXX RPM HOOK KKK THIS ENGINE IS CONFORMED 97 68 EC DIRECTIVE ENGINE FAMILY XXXXXXXXXX ENGINE TYPE XX00000000 TYPE APPROVAL NUMBER XXXXXXXXXXXXXXXXXXK ENGINE 1 D NUMBER XXXX20XX a Se SIIN IMLE0110 15 EMISSION CONTROL LABEL ENGINE LABEL ONLY EPA TYPE Emission control label is attached at a visible point on the equipment s U e U EMISSION CONTROL INFORMATION ISUZU MOTORS LTD MADE IN JAPAN THIS ENGINE COMPLIES WITH U S EPA REGULATIONS FOR XX MY NONROAD DIESEL ENGINES AND CALIFORNIA REGULA
7. In the warning lamp type make sure that the lamp is completely off during the warming up Engine noise and exhaust smoke color Pay attention to engine noise and if any abnormal noise is heard check the engine to detect the cause Check the fuel combustion condition by exhaust smoke color The exhaust smoke color after engine warming up and at no load operation Colorless or light blue Normal Perfect combustion l Black Color Abnormal Imperfect combustion White color Abnormal Oil coming up and coming down CAUTION Engine noise after start up might be noisy than that of warmed up engine and the exhaust smoke color also being more whitish than the normal condition However it will be normalized after warming up engine Leakage in the systems CAUTION When checking leaking liquid from engine may be splattered during engine operation It may cause a burn Approach the engine gradually from a long distance and then check it 43 Check the following items e Lube oil leakage Check both sides and bottom of the engine assembly for lube oil leaks paying particular attention to the lube oil pressure gauge pipe joint lube oil filter and lube oil pipe joints e Fuel leakage Check the fuel injection pump fuel lines and fuel filter for leakage e Coolant leakage Check the radiator and water pump hose connections also the water drain cocks on the radiator and cylinder body fo
8. 42 4 CARE IN THE ENGINE OPERATION cree 45 5 ENGINE STOPPING rersvervsrvervssveressvevosseevosseeessseeessvevessseeesseevesseer 51 6 OPERATION AND CARE FOR NEW ENGINE rrvevvossvevssseevoseeer 52 7 ENGINE CARE FOR OVER COOLING vrunvranvvnnernnvnnnvnnvennvvnnvnnnene 52 8 OPERATION AND CARE FOR TURBOCHARGED ENGINE 53 9 STARTING THE ENGINE AFTER BEING LEFT UNUSED FOR A LONG PERIOD OF TIME runvrnneranernvvnnvennernnennvvnnvvnneennvnnnene 54 5 PERIODICAL INSPECTION AND MAINTENANCE rvrnvvnnvnnnvnnnvenernnens 55 1 LUBRICATING SYSTEM rruerunevnnvnanvnnnennvvnnvnnnvnnnennnennvenvennvennennnenee 55 2 COOLING SYSTEM rrnvrnnvnnnvnnnvnnvnanvnanenanernvennvnnnennnennsennvnnnvnnnennnene 64 3 FUELSYSTEM rrrunvnnvennvennvnnnvnnnvnnnnnnvnnnvnsnvnnnennnennvnnnvnnnennnennnennnenen 70 4 AIR INTAKE SYSTEM unvrnvvnnvnnnvennvennernvvnnvnanennnernvernvenevennernnennnener 77 5 ENGINE ELECTRICAL rarnnnvnnvvanvnnnvnnnennvennvnnnvnnnennnenvennvennvennennnenee 79 6 ENGINE ASSEMBLY AND OTHERS nine 83 6 ENGINE CARE IN COLD SEASON mrvnnvranvnnnvnnvvnnvvnnvrnnennnennvennennnennnene 89 FUEL cl isissesercisatnszateasdcvevesdssadvavadesssecdsasessuceraveadassivadeseacnesdacseasbesaned 89 2 COOLANT xerenerenennvvnnernnennnnnnvnnnvnnnenanennnennvennvnnnvnnnennnennnennvnnnennnennnene 90 3 ENGINE OIL vunvrvnennvvnnvvnnvvanennnvnnvennvnnnvnnnvnnnennnvnnnennvnnnvnnnenanennnennnenen 92 4 BATTERY rorrennevnnnernnnennnnernnnernnnerennennnnenennenenne
9. four cycle in line overhead valve type Combustion type Swirl chamber type No of cylinders bore x stroke mm in 4 85 x 96 3 35 x 3 78 Engine displacement L cid 2 179 133 Compression ratio 21 5 to 1 Firing order 1 3 4 2 2 Rated power SAE NET kW hpy min 26 3 35 3 1800 2 Fuel flow at max rated power mm stroke 36 5 Exhaust emission control system EM IDI Injection pump Bosch PFR type Governor Variable speed Mechanical type Mark Put a letter codes for model year on the top of the letters Y 2000 1 2001 2 2002 3 2003 4 2004 5 2005 6 2006 7 2007 8 2008 9 2009 Model Year Engine code varies depending on each engine 11 12 ISUZU engine model name BV 4LE1N Injection nozzles Throttle type Specified fuel Diesel fuel ASTM D975 No 2 D 2 Starter V kW 12 2 0 2 Alternator V A 12 20 Specified engine oil API grade Refer to 3 LUBRICANT Engine Oil Selection 2 Lub oil volume L qts 5 9 6 2 8 4 8 8 Coolant volume Engine only L qts 2 8 3 0 2 Engine dry weight kg lb 170 375 Overall length mm in 671 26 4 2 Engine dimensions Overall width mm in 496 19 5 Overall height mm in 595 23 4 Valve clearance cold mm in 0 4 0 0157 Nozzle injection pressure MPa psi 14 7 2132 2 Injection timing B T D C 10 Specification for items marked with an asterisk 2 will vary according to the type
10. tiquette de commande d mission fix e au moteur peut varier selon les sp cifications du moteur Voici ci apr s un chatillon requis pour les informations concernant la commande d mission du moteur ensemble avec son emplacement Ces tiquettes sont traduites de l anglais en fran ais 4LE1T 200000002000 2000000000 PUISSANCE MOTRICE ANNONC E SAE NET 5000000 OOK MOD TMIN KEW XX TAUX DE CARBURANT XXX mm at er AL JEU DE SOUPAPE A FR SYST ME DE CONTR LE D MISSION DECHAPPEMENT ADM CHAP XX mm JCALAGEDINJECTION DIESEL A FAIBLE TENEUR EN SOUFRE OU DIESEL A 200 BTDC NT TRES FAIBLE TENEUR EN SOUFRE UNIQUEMENT RALENTIEN COURSE 0X TR MIN 20000000 100000000 CE MOTEUR EST CONFORME LA DIRECTIVE 97 68 CE FAMILLE DE MOTEUR 200000 TYPE DE MOTEUR 00000000 NUMERO D APPROBATION 100000000000000000 NUMERO DIDENTIFICAT ON DU MOTEUR 000200 200000 IMLE0100 117 118 4LE1NA ISU2Z INFORMATIONS IMPORTANTES SUR LE MOTEUR ISUZU MOTORS LTD FABRIQUE AU JAPON CE MOTEUR EST CERTIFI POUR LE FONCTIONNEMENT AU CARBURANT DIESEL CE MOTEUR EST CONFORME AUX REGLEMENTATIONS DE L EPA AUX ETATS UNIS POUR LES MOTEURS DIESEL DE VEHICULE HORS ROUTE DE ANNEE AUTOMOBILE ETAUX REGLEMENTATIONS DE LA CALIFORNIE POUR LES MOTEURS ALLUMAGE PAR COMPRESSION DE VEHICULE TOUT TERRAIN FAMILLE DEMOTEUR 3000000000X CODE DE MOTEUR 200
11. Firing order 1 3 4 2 2 Rated power SAE NET kW hpy min 35 9 48 1 2600 2 Fuel flow at max rated power mm stroke 35 5 Exhaust emission control system EM IDI Injection pump Bosch PFR type Governor Variable speed Mechanical type Mark Put a letter codes for model year on the top of the letters Y 2000 1 2001 2 2002 3 2003 4 2004 5 2005 6 2006 7 2007 8 2008 9 2009 Model Year Engine code varies depending on each engine ISUZU engine model name AV 4LE1N Injection nozzles Throttle type Specified fuel Diesel fuel ASTM D975 No 2 D 2 Starter 12 2 0 2 Alternator 12 35 Specified engine oil API grade Refer to 3 LUBRICANT Engine Oil Selection 2 Lub oil volume 5 9 6 2 8 4 8 8 Coolant volume Engine only 2 8 3 0 2 Engine dry weight 170 375 2 Engine dimensions Overall length 695 7 27 4 Overall width Overall height 486 2 19 1 601 8 23 7 Valve clearance cold 0 4 0 0157 Nozzle injection pressure 14 7 2132 2 Injection timing B T D C Specification for items marked with an asterisk 2 will vary according to the type of equipment in which the engine is installed 13 4 Model BV 4LE1N ISUZU engine model name BV 4LE1N Engine family SZXLO2 2VNC Engine code ALE1XXXXX XX Engine type Water Cooled
12. du moteur 170 375 Longueur hors tout i 695 7 27 4 Dimensions du moteur Largeur hors tout i 486 2 19 1 Hauteur hors tout i 601 8 23 7 2 8 3 0 Jeu de soupape froid i 0 4 0 0157 Pression d injection d injecteur i 14 7 2132 Calage d injection B T D C 13 113 4 114 Mod le BV 4LE1N D signation du mod le du moteur ISUZU BV 4LE1N Famille de moteur SZXLO2 2XXX Code de moteur ALE1XXXXX XX Type de moteur Type de soupape en t te en ligne quatre temps refroidissement eau Type de combustion Swirl chambre No de cylindres al sage x course mm in 4 85 x 96 3 35 x 3 78 Cylindr e du moteur L cid 2 179 133 Rapport de compression 21 5to1 S quence d allumage 1 3 4 2 Puisance nominale SAE NET kW cv min 26 3 35 3 1800 D bit de combustible au couple max mm course 36 5 Syst me de commande d mission d chappement EM IDI Pompe injection Type PFR Bosch R gulateur Type m canique vitesse variable Marque Placer un code de lettres pour l ann e du mod le sur la partie sup rieure des lattres Ann e du mod le Y 2000 1 2001 2 2002 3 2003 4 2004 5 2005 6 2006 7 2007 8 2008 9 2009 Le code du moteur varie selon chaque moteur D signation du mod le du moteur ISUZU BV 4LE1N Buses a injection Type a papillon
13. exhaust EGR valve fixing Open position Oil coming up or down Change oil Water mixing in fuel Remove water Much white 3 Smoke Low compression pressure Injection timing failure Low coolant temperature Inspect or change thermostat Battery RSA Crack in battery body Change battery rdischarge EE i ove level Natural consumption Change battery 106 Loose or damaged belt Retighten or change belt Charging Faulty alternator Change alternator Battery rane Damaged wiring or contact failure Make an adjustment overdischarge Low speed driving Charge or change Excessive electrical Insufficient battery capacity Reduce electrical load or change battery capacity loads 107 2 1 1 108 INFORMATION GENERALE CARACTERISTIQUES TECHNIQUES ET DONNEES DU MOTEUR CARTIFIE EPA ET CARB Mod le AU 4LE1T D signation du mod le du moteur ISUZU AU 4LE1T Famille de moteur SZXLO2 2XXX Code de moteur 4LE1XXXXX XX Type de soupape en t te en ligne quatre temps a refroidissement a eau Type de moteur Type de combustion Swirl chambre No de cylindres al sage x course mm in 4 85 x 96 3 35 x 3 78 Cylindr e du moteur L cid 2 179 133 Rapport de compression 21 5 to 1 S quence d allumage 1 3 4 2 Puisance nominale SAE NET kW cv min 40 53 6 2200 D bit de combustible au couple max
14. failure Safety relay failure Engine stop solenoid return failure No fuel in the fuel tank sees Le that there is no fuel leakage and Engine does replenish not start Starter turns Clogged fuel filter element Remove water and change element but engine Air in the fuel system Bleed air dose not ignite Control rack is stuck at no fuel position Unproper preheating operation Glow plug malfunction Incorrect injection timing Low cylinder compression pressure Air in the fuel system Bleed air Engine ignite but stall Ti immediately Improper low idling speed adjustment EGR valve fixing Open position 102 Crack in injection pipe Injection nozzle failure Engine stop solenoid return failure Uneven compression pressure between cylinders Incorrect control lever adjustment Governor interior malfunction Governor spring deteriorated Unstable engine running Air in the fuel system Bleed air Clogged fuel filter element Remove water and change element Piping failure squeezed etc in the fuel system O Uneven fuel injection amount between plungers 0 06101 610 0 0 Incorrect valve clearance adjustment Make a readjustment Deteriorated valve spring Change valve spring Engine control restriction or seizure Insufficient coolant amount Replenish Fan belt slippage Make an adjustment Engi
15. limit recall liability prior to the completion engine useful life Isuzu however urges that required maintenance service is performed at the indicated intervals 95 Description of check and maintenance Electrolyte level check operation hours 750 1000 Battery cleaning Ammeter Battery charge registration condition Charge warning lamp Electrolyte gravity check Starter and alternator check and cleaning Wiring and connection check Preheating condition check Air cleaner element replacement Turbocharger check EGR valve check and cleaning EGR lead valve cleaning 96 EGR cooler cleaning Remark See EXPLANATION OF MAINTENANCE SCHEDULE Description of check and maintenance Fuel amp cooling water rubber hoses operation hours 35 replacement 36 Engine starting conditions and noise conditions 37 Exhaust smoke condition 38 Cylinder compression pressure O 39 Valve clearance check O Positive crankcase ventilation valve 40 O cleaning Remark See EXPLANATION OF MAINTENANCE SCHEDULE This is a required maintenance The failure to perform this maintenance item will nullify the emission warranty or limit recall liability prior to the completion engine useful life Isuzu however urges that required maintenance se
16. mm course 46 3 Syst me de commande d mission d chappement EM IDI TC EGR Pompe injection Type PFR Bosch R gulateur Type m canique vitesse variable Marque Placer un code de lettres pour l ann e du mod le sur la partie sup rieure des lattres Ann e du mod le Y 2000 1 2001 2 2002 3 2003 4 2004 5 2005 6 2006 7 2007 8 2008 9 2009 Le code du moteur varie selon chaque moteur Buses injection Type papillon Combustible sp cifi Combustible Diesel ASTM D975 No 2 D D marreur 12 2 2 Alternateur 12 50 R f rez vous 3 LUBRIFIANT choix D Huile moteur Huile moteur sp cifi e API grade Volume d huile de lubrication 7 6 8 0 10 3 10 9 Volume du liquide de refroidissement 2 8 3 0 seulement moteur Poids sec du moteur 190 419 Longueur hors tout i 647 5 25 5 Dimensions du moteur Largeur hors tout i 523 6 20 6 Hauteur hors tout i 720 8 28 4 Jeu de soupape froid i 0 4 0 0157 Pression d injection d injecteur i 14 7 2132 Calage d injection B T D C 12 Fabricant et type de turbochargeur IHI RHF 3 109 2 Mod le BV 4LE1T D signation du mod le du moteur ISUZU BV 4LE1T Famille de moteur SZXLO2 2XXX Code de moteur 4LE1XXXXX XX Type de soupape en t te en ligne quatre temps a refroidissement a eau Type de moteur
17. not put water directly on the alternator Entry of water into the alternator leads an electrolyte corrosion causing an alternator failure Pay attention particularly when cleaning the engine When the battery is charged with an external electric source be sure to disconnect the battery cables Wiring Connections Check all of the electric wiring connections for looseness and damage IMLEO071 6 ENGINE ASSEMBLY AND OTHERS To continue trouble free engine operation over a long period of time the servicing items need a skilled maintenance technician therefore consult your machine supply source on the following items when necessary 1 Fuel Injection Nozzle Use an injection nozzle tester to check the static injection starting pressure and the fuel spray conditions Injection nozzle pressure test interval Every 500 operation hours When the injection starting pressure is too high or too low or the fuel spray pattern is improper an abnormal fuel combustion take place in the engine leading a lowered output and blackish exhaust smoke Further it causes a piston seizure or piston damage etc In such cases contact ISUZU dealer or Bosch dealer to adjust the injection starting pressure or replace the nozzle Injection starting pressure Refer to the Engine Family Index WARNING While using a nozzle tester it may happen that high pressure blow off the fuel oil and injure the worker Keep off the nozzl
18. nozzles Throttle type Specified fuel Diesel fuel ASTM D975 No 2 D 2 Starter 12 2 2 2 Alternator 12 50 Specified engine oil API grade Refer to 3 LUBRICANT Engine Oil Selection 2 Lub oil volume 7 6 8 0 10 3 10 9 Coolant volume Engine only 2 8 3 0 2 Engine dry weight 190 419 2 Engine dimensions Overall length 647 5 25 5 Overall width 523 6 20 6 Overall height 720 8 28 4 Valve clearance cold 0 4 0 0157 Nozzle injection pressure 14 7 2132 2 Injection timing B T D C 12 Maker and type of turbocharger Specification for items marked with an asterisk 2 will vary according to the type of equipment in which the engine is installed IHI RHF 3 2 Model BV 4LE1T ISUZU engine model name BV 4LE1T Engine family SZXL02 2VTB Engine code ALE1XXXXX XX Engine type Water Cooled four cycle in line overhead valve type Combustion type Swirl chamber type No of cylinders bore x stroke mm in 4 85 x 96 3 35 x 3 78 Engine displacement L cid 2 179 133 Compression ratio 21 5 to 1 Firing order 1 3 4 2 2 Rated power SAE NET kW hpy min 35 46 9 1800 2 Fuel flow at max rated power mm stroke 49 7 Exhaust emission control system EM IDI TC Injection pump Bosch PFR type Governor Variable speed Mechanical type Mark Put a le
19. oil change Whenever a change is noticed in the sound of the exhaust system e Whenever the exhaust system is damaged or becomes corroded See Maintenance Schedule in Section 8 of this manual for parts requiring inspection Do not run the engine in confined areas such as garages or next to a building any more than needed to move the machine or the equipment Keep the exhaust tailpipe area clear of snow and other material to help reduce the buildup of exhaust gases or the equipment This is particularly important when parked in blizzard conditions 31 1 CHECK BEFORE OPERATION WARNING For Safety s sake conduct the inspection before start up with the engine stopped Without turbocharger km D an a o opi CAUTION As the remote filter is used the engine oil is filled above the specified level Turbocharged engine only Adjust the engine oil level as required IMLE0067 32 1 Engine Oil Level 1 Place the engine on a level surface 2 Remove the dipstick from the crankcase wipe it with clothing Insert it fully and take out it gently again Dipstick EIN Max level Min level IMLE0068 3 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 add too much engine oil e Drain oil to the max
20. oil level if oil level is above the max level mark e Add oil to the max oil level if oil level is below the min level mark Also check the sample oil on the dipstick for fouling and degrees of viscosity CAUTION Oil level check must be made ten or twenty minutes later after the engine has been stopped When the oil level check is necessary while the engine is running stop the engine and keep it stationary ten or twenty minutes until the oil thoroughly flows down to the crankcase Oil filler cap LA 4 Oil is poured either through the oil filler at the front of the cylinder head cover or through the oil filler on the right side of the timing gear case A certain period of time is required before the engine oil completely flows down from the oil filler to the crankcase Check the oil level ten or twenty minutes after oil replenishment CAUTION If the engine oil is splashed on the fan belt it causes belt slippage or slackness therefore take care to avoid it IMLE0093 33 WARNING 1 In adding oil take care not to spill it If you spill oil on engine or equipment wipe it properly or this could lead to a fire and the risk of personal injury and or equipment damage For model that employs the closed PCV excessive oil may cause hunting in oil pressure increase in the oil temperature oi
21. over cooling cause premature wear and increased fuel consumption When the coolant temperature is not raised to 75 to 90 C 167 to 194 F indefinitely take an action to recover this with means of radiator curtain or such like 2 OPERATION AND CARE FOR TURBOCHARGED ENGINE Engine Starting The warming up operation of the engine should be done in the way separately described In addition ensure the bearings supporting the rotating parts of the turbocharger are sufficiently lubricated Do not race cold engine When starting the engine after a long period more than one month of standing proceed as follows Pour engine oil into the turbocharger through the 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 foreign materials to enter through the opening On completion of this operation securely install the oil pipe and air intake duct Engine Stopping Whenever stopping the engine the last about 3 minutes of operation should be atidle After hard operation at least 5 minutes of operation should be at idle until the turbocharger cools down This allows the turbocharger to return to idle speed while engine oil pressure is available for lubrication CAUTION Failure to cool down turbocharger at idle could result in insufficient lubrication of its bearings and their s
22. to stop the engine Dilute sulfuric acid is used as battery electrolyte Be careful not to let your eyes hands skin clothes or metals come in contact with it If it gets on your eyes hands or skin wash with a large amount of water for five minutes at once Then see a doctor for treatment If it gets on clothes or metal wash with a large amount of water as well Never make a spark or use fire near the batteries batteries be sure not to contact positive terminal As the machine body is negative it may be very dangerous due to shorting causing a burn 79 1 Battery Servicing Battery maintenance schedules will vary with equipment and battery types Follow the equipment manufacturer s instructions Gravity of the 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 manufacturer s standard The relationship between the electrolyte specific gravity and the battery conditions are as follows Eye level gt P Electrolyte Specific gravity Electrolyte Specific Gravity Battery Conditions Over 1 300 Over 100 Over charged 1 290 1 270 100 1 260 1 240 75 IMWG0025 Below 1 230 Below 50 Insufficiently charged CAUTION The battery electrolyte is dilute sulfuric acid So be careful not to stain your body an
23. 000000 PUISSANCE MOTRICE ANNONC E SAE NET MOD LE 200000 OC OO TIMIN POUVOIR CAT GORIE XK lt kW lt XX TAUX DE CARBURANT XXX mist 1000000000000000 JEU DE SOUPAPE A FROID SYST ME DE CONTR LE D MISSION D CHAPPEMENT ADM CHAP XX mm 00000000000000000 JCALAGEDINJECTION DIESEL A FAIBLE TENEUR EN SOUFRE OU DIESEL A 200 BTDC QNT TRES FAIBLE TENEUR EN SOUFRE UNIQUEMENT 2000000000 200000000 CE MOTEUR EST CONFORME LA DIRECTIVE S7IUCE FAMILLE DE MOTEUR 000000 TYPE DE MOTEUR 10000000 NUMERO D APPROBATION X0000000000000000X NUMERO D DENTIFICAT ON DU MOTEUR 22006200 og J IMLEO111 ETIQUETTE DE COMMANDE D EMISSION ETIQUETTE DU MOTEUR L tiquette de commande d mission est fix sur un emplacement visible de l quipement Ces tiquettes sont traduites de l anglais en fran ais TYPE EPA SEULEMENT TYPE EC SEULEMENT I s U 2 INFORMATIONS IMPORTANTES SUR LE MOTEUR I s U 2 INFORMATIONS IMPORTANTES SUR LE MOTEUR ISUZU MOTORS LTD FABRIQUE AU JAPON ISUZU MOTORS LTD FABRIQUE AU JAPON CE MOTEUR EST CERTIFI POUR LE FONCTIONNEMENT AU CARBURANT DIESEL CE MOTEUR EST CONFORME AUX REGLEMENTATIONS DE L EPA AUX ETATS UNIS POUR LES MOTEURS DIESEL DE VEHICULE HORS ROUTE DE ANNEE AUTOMOBILE ETAUX REGLEMENTATIONS DE LA CALIFORNIE POUR LES MOTEURS AALLUMAGE PAR COMPRES
24. 15W 40 CF 4 DH 1 Exxon Essolube XD 3 15W 40 CI 4 Mobil Delvac 1300 Super 15W 40 CI 4 Plus E7 E5 DH 1 Mobil Delvac 1 5W 40 CI 4 Plus E7 E5 E4 E3 DH 1 Initial Engine Oil from Engine plant 2 Initial Engine Oil from Engine plant Only a Part of Models 28 2 Oil Viscosity Engine oil viscosity largely affect engine startability performance oil consumption speed of wearing and occurrence of seizure etc Using lubricants whose viscosity selected according to the atmospheric temperature is important CAUTION 1 Using a mixture of different brand or quality oils will adversely affect the original oil quality therefore never mix up different brand or different type oils 2 Don t use API CA CB grade and reconstituted engine oil 3 Engine damage due to improper maintenance or using oil of the improper quality and or viscosity is not covered by the warranty ENGINE OIL VISCOSITY GRADE AMBIENT TEMPERATURE Single grade SAE 20 20W KO SAE 40 SAE 10W XK SAE 30 gt Ambient 25 C 20 C 15 C 0 15 C 25 C 30 C Temperature 13 F 4 F 5 F 32 F 59 F 77 F 86 F SAE 10W 30 Multi grade SAE 15W 40 20W 40 SAE 5W 20 IMLE0040 29 Freezing point C 10 20 30 40 50 10 20 30 Mixing ratio 40 50 3 COOL
25. AL NUMBER XXXXXXXXXXXXXXXXXX_ ENGINE D NUMBER XXXX XXXX IMLE0106 1 ENGINE IDENTIFICATION Position of Display The engine serial number is stamped on the front upper right side of the cylinder body and the engine model is cast on the rear lower right side of cylinder body just above the oil cooler Further engine model is described also on an ID label on the top of the cylinder head cover 19 SSS O GP O Q 000000 4LE1 EE I Oy CO VE gt a Engine model Serial number IMLE0092 20 ALETXXX 00 B A H ISUZU MOTORS LTD IS LIS LS MADE IN JAPAN 2 Confirmation of Engine Serial Number It is advisable to check the engine serial number engine model name and type of machine together with the equipment manufacturer s name as it is required when you contact the distributor for repair service or parts ordering IMLE0073 GENUINE PARTS IMWG0005 WARNING Conduct confirmation of engine serial number with the engine stopped To avoid being injury don t check it while the engine is still hot 1 2 ISUZU ENGINE AFTER SERVICE Isuzu Engine After Service Please feel free to contact your IS
26. ANT Always refer to the chart to determine the correct cooling water to antifreeze solution mixing ratio 30 IMJJ0025 CAUTION 1 Supplement inhibitors or additives claiming to provide increases cooling capability that have not been specifically approved by Isuzu are not recommended for addition to the cooling system 2 When supplying or replacing coolant do not use water of well or river but be sure to use tap water soft water distilled water or demineralized water 3 It is strongly recommended to use Isuzu genuine engine coolant or equivalent for addition or replacement 4 Coolants from other brands often do not contain anti corrosive and use of such products could result in corrosion of the engine and radiator 5 If the density of Isuzu genuine engine coolant exceeds 60 the reduced specific heat characteristic of the coolant could result in overheating If the density is below 20 the anticorrosion characteristic may degrade Adjust the coolant density in the range from 20 to 60 according to the situation 4 ENGINE OPERATION Engine Exhaust Gas Caution Carbon Monoxide WARNING Do not breathe exhaust gas because it contains carbon monoxide which by itself has no color or odor Carbon monoxide is a dangerous gas It can cause unconsciousness and can be lethal We recommend that the exhaust system be inspected by competent technician Each time the machine has an
27. If the engine coolant is boiling wait until it stops before proceeding Look at the see through reserve tank The engine coolant level should be between the MAX and MIN marks on the reserve tank If necessary pour engine coolant into 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 engine is started If the engine coolant level in the reserve tank is low look for leaks at the radiator hoses and connections heater hoses and connections radiator and water pump If you find major leaks or spot other problems that may have caused the engine to overheat do not run the engine until these problems have been corrected If you do not find a leak or other problem carefully add engine coolant to the reserve tank Engine coolant is a mixture of ethylene glycol antifreeze and tap water soft water distilled water or demineralized water See Engine Care in cold season in Section 6 for the proper antifreeze and mixture WARNING To help avoid being burned do not spill antifreeze or engine coolant on the exhaust system or hot engine parts Under some conditions the ethylene glycol in engine coolant is combustible If the engine coolant level in the reserve tank is at the correct level but there is still an indication on the instrument panel of an overheat conditi
28. SION DE VEHICULE TOUT TERRAIN FAMILLEDEMOTEUR i XXXXXXXXXXX CODE DE MOTEUR 20000000 XX PUISSANCE MOTRICE ANNONCEE SAE NET MOD LE KKK XX WI X POUVOIR CAT GORIE XX KW lt XX TAUX DE CARBURANT XXX mm st 20000000000000000X JEU DE SOUPAPE AFROID SYST ME DE CONTR LE D MISSION DECHAPPEMENT ADM ECHAP XX mm 000000000000 CALAGE D INJECTION DIESELA FAIBLE TENEUR EN SOUFRE OU DIESELA 200 BTDC INT TRES FAIBLE TENEUR EN SOUFRE UNIQUEMENT RALENTI EN COURBE XXX TR MIN 200000000 00000000X CE MOTEUR EST CONFORME LA DIRECTIVE 97 88 CE FAMILLE DE MOTEUR XXXXXXX TYPE DE MOTEUR XXXXXXXXX NUM RO D APPROBATION X20000000000000000 ERO DIDENTIFICAT ON DU MOTEUR XXXX XXXX By NUMERO D DENTIFICAT ON DU MOTEUR XXXX XXXX IMLEO101 119 ETIQUETTE DE RESTRICTION DE TYPE DE CARBURANT UTILISE POUR EPA L tiquette de restriction du type de carburant utilis se trouve sur le goulot de remplissage du r servoir de carburant Contenu de l tiquette DIESEL A FAIBLE TENEUR EN SOUFRE OU DIESEL A TRES FAIBLE TENEUR EN SOUFRE UNIQUEMENT A EPA REGULATION LOW SULFUR OR ULTRA LOW SULFUR DIESEL FUEL ONLY DIESEL A FAIBLE TENEUR EN SOUFRE O DIESEL A TRES FAIBLE TENEUR EN SOUFRE UNIQUEMENT XXXXXXXXXX IMLE0066 120 All information illustrations and specifications contained in this manual are based on the latest product information available at the time of publication The right i
29. TIONS FOR XX MY OFF ROAD DIESEL ENGINES SEE SERVICE MANUAL FOR ENGINE FAMILY 1 XXXXXXXXXXX MODEL SPECIFICATIONS ENGINE CODE XXXXXXXXX XX ADVERTISED POWER SAE NET MODEL XXX XXX KW I XXXX RPM POWER CATEGORY XXskW lt XX FUEL RATE XX mm st VALVE LASH COLD INLJEXH XX XX mm 2 X200000000000000X INITIAL INJECTION TIMING LOW SULFUR FUEL OR ULTRA LOW XXX BTDC SULFUR FUEL ONLY CURB IDLE XXX RPM XXXXXXXXXX XXXXXXXXXX XXXXXXXXXXXXXXXXXX EXHAUST EMISSION CONTROL SYSTEM ENGINE I D NUMBER XXXX XXXX IMLE0105 16 FUEL TYPE IN USE LIMITATION LABEL FOR EPA The fuel type in use limitation label is attached on the filler neck of the fuel tank Contents of the label LOW SULFUR OR ULTRA LOW SULFUR DIESEL FUEL ONLY A EPA REGULATION LOW SULFUR OR ULTRA LOW SULFUR DIESEL FUEL ONLY DIESEL A FAIBLE TENEUR EN SOUFRE OU DIESEL A TRES FAIBLE TENEUR EN SOUFRE UNIQUEMENT XXXXXXXXXX IMLE0066 17 2 EC EMISSION CONTROL LABEL ENGINE LABEL ONLY EC TYPE Emission control label is attached at the front of injection pump cover located at the right side of cylinder body or the cylinder head cover The following is the detail of a label required for engine emission control information along with location I s U 2 U EMISSION CONTROL INFORMATION ISUZU MOTORS LTD MADE IN JAPAN THIS ENGINE IS CONFORMED 97 68 EC DIRECTIVE ENGINE FAMILY XXXXXXXXXX ENGINE TYPE XXXXXXXXXX TYPE APPROV
30. UZU dealer for periodical inspection and maintenance Isuzu 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 are supplied by the ISUZU distributors or the authorized parts suppliers Please designate ISUZU Genuine Parts when you need engine parts 21 3 FUEL LUBRICANT AND COOLANT 1 FUEL 1 Fuel Selection The following specific advantages are required for the diesel fuel 1 Must be free from minute dust particles Must have adequate viscosity Must have high cetane value Must have high fluidity at low temperature Low sulfur or ultra low sulfur diesel fuel only 6 Must have little residual carbon EPA regulations aR ND Diesel fuels Applicable Standard Recommendation JIS JAPANESE INDUSTRIAL STANDARD NO 2 DIN DEUTSCHE INDUSTRIE NORMEN DIN 51601 SAE SOCIETY OF AUTOMOTIVE ENGINEERS Based on SAE J 313C NO 2 D BS BRITISH STANDARD Based on BS 2869 1970 Class A 1 If fuel other than the specified one is used engine function will be lowered 22 2 Fuel Requirements CAUTION Use of other types of fuel than ultra low sulfur fuel may not conform to emission regulations CAUTION The fuel injection pump injection nozzle or other parts of the fuel system and engine can be damaged if you use any fuel or fuel additive oth
31. ant with selected viscosity according to the atmospheric temperature is important Refer to 3 2 LUBRICANT At low atmospheric temperature engine oil viscosity will increase to cause hard engine starting 4 BATTERY 1 Always pay attention to charging the batteries completely in cold season As the discharge current from the battery is large in cold engine starting it takes a comparatively long while to recharge the batteries than the recharge after the normal engine starting Particularly as the gravity 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 it immediately before the engine operation CAUTION ff the work is done after the engine has already been in an operation the distilled water replenished will not be mixed with the original electrolyte allowing the danger of freezing not mixed distilled water staying in the battery cell upper part 5 ENGINE STARTING In cold engine starting at atmospheric temperature of below 0 C 32 F pay attention to the following items 1 2 Do the preheating operation before cranking the engine with the starter Set the engine throttle lever or pedal to the 1 3 position of the full lever or pedal stroke If the engine does not start with the initial cranking keep the batteries stationary a while to rec
32. ating and starting operations 40 3 When repeating starting operation return the key to the OFF position and then pre heat and start the engine once again If the engine still remains unstarted something may be wrong with the engine Check the repeated parts to locate the cause CAUTION Do not use starting aids in the air intake system Such aids can cause immediate engine damage 41 42 1 2 CHECK AND OPERATION AFTER THE ENGINE START UP Warming up Operation Do the warming up operation at 1000 min about ten minutes after the engine has started As the lubrication for the entire engine systems will be done in this warming up do not speed up and load it abruptly Particularly observe this in cold season operation Check after the Engine Start up Check the following items in the engine warming up operation Engine oil pressure Although the engine oil pressure gauge readings vary depending on ambient temperature a type of oil or engine specification the gauge registers the values of the following in the warming up Oil pressure 147 kPa 21 psi 1000min 294 kPa 43 psi 1800min 343 to 686 kPa 50 to 100 psi 2200min In the oil pressure warning lamp type make sure that the lamp is off Charge condition The charge condition is normal when once the ammeter registers plus side greatly in the engine starting then gradually the meter registering will be minimized
33. bout 75 to 90 C 167 to 194 F Check and repair the cooling system if coolant temperature is abnormal Change coolant at intervals of 12 months if coolant is long life coolant LLC According to the equipment manufacturer s specification 99 21 22 23 24 25 26 27 28 29 30 31 100 Cooling system circuit cleaning Radiator filler cap function check Electrolyte level check Battery cleaning Battery charge condition Electrolyte gravity check Starter and alternator check and cleaning Wiring and connection check Preheating condition check Air cleaner element replacement Turbocharger check Clean the cooling system circuit every 12 months or 1000 hours Check radiator pressure cap periodically for proper operation according to the equipment manufacturer s specifications Replenish with distilled water if necessary Clean the terminals Ammeter registration goes to plus side while engine running In the lamp type the lamp is completely being off while engine running Check charging circuit if the lamp is not off Check according to the equipment manufacturer s specifications Check wear condition of brush and commutator Check according to the equipment specifications Check preheating condition of the system Change element according to the manufacturer s specifications Check turbocharger every 1500 hours Clean blower as necessary
34. clean them at any time Further if the fins are deformed repair or replace them 5 Cooling System Circuit Cleaning When the cooling system circuit is fouled with water scales or sludge particles cooling efficiency will be lowered Periodically clean the circuit interior with a cleaner Cooling system cleaning interval Every 12 months or 1000 operation hours 69 Air bleeding plug Lever Drain plug 70 IMLE0057 3 FUEL SYSTEM The fuel injection pump and fuel injection nozzle are precisely manufactured and therefore using the fuel which contains water or dust particles will result in either injection pump plunger seizure or injection nozzle seizure and the fouled fuel filter element with sludge or dust particles lead to decreased engine output In addition clogged filter element can cause low output or automatic air bleeding failure Perform inspection and maintenance periodically as follows 1 Removal of Water from the Fuel The water sedimenter is provided to separate the water contained in the fuel The sedimenter housing contains a float which moves up and down in accordance with level change of the separated water Be sure to drain the separated water when the float has come up to the element part Draining procedure With the water sedimenter lever positioned just above the fuel remains off loosen the air bleeding plug at the top of the water sedi
35. d clothes with it If stained rinse portion in clean water 80 Gravity conversion The specified electrolyte temperature for the gravity measurement is 20 C 68 F Measure the electrolyte temperature and do the conversion in accordance with the following formula when the temperature does not fall to the specified temperature S20 St 0 0007 t 20 Seo gravity at 20 C St gravity measured t electrolyte temperature when measured Battery terminal connections Periodically check the battery terminals for loose connection and corrosion For the check interval follow the machine manufacturer s standard Loose connection will cause hard engine starting or deficient battery charging If the terminals are excessively corroded disconnect the battery cables and polish them with a wire brush or sandpaper Never reverse the and terminals when reconnecting the cables Even a short period of reverse connection could damage the electrical parts Cleaning of Battery When the battery is fouled clean it with clean water or tepid water and wipe them with a dry cloth to remove the water Apply a light coat of vaseline or a grease to the battery post 81 82 3 Alternator Servicing The polarity of the alternator is negative grounding type When an inverted circuit connection takes place the circuit will be in short circuit instantaneously resulting the alternator failure Do
36. e 2 with TDC mark on the timing gear case cover Measure and adjust the valve clearance of the cylinder No 3 marked with O in the table below Step 3 Turn the crankshaft clockwise 180 degrees from the step 2 condition to align the mark groove 1 with TDC mark on the timing gear case cover Measure and adjust the valve clearance of the cylinder No 4 marked with O in the table below Step 4 Turn the crankshaft clockwise 180 degrees from the step 3 condition to align the mark groove 2 with TDC mark on the timing gear case cover Measure and adjust the valve clearance of the cylinder No 2 marked with O in the table below 3 4 Cylinder No 1 2 3 4 Valve arrangement LI E IT E I EY I ye Step 1 Aligning mark groove 1 with TDC mark Step 2 Aligning mark groove 2 with TDC mark Step 3 Aligning mark groove 1 with TDC mark Step 4 Aligning mark groove 2 with TDC mark I Intake E Exhaust Adjustment of Injection Timing The injection timing may not be readjusted Take care not to forget to insert a shim on the mounting surface when reassembling the injection pump after it was removed Cylinder Compression Pressure Measurement The cylinder compression pressure measurement must be done every 1000 operation hours or whenever the engine output is reduced Compression pressure 3 04 MPa 31 0 kg cm 441 psi Test condition Cranking speed 250 min Co
37. e end 83 Timing gear 7 case Cover LA Vil pr Cylinder No 1 Cylinder No 1 exhaust intake LL RTS IMLE0026 84 2 Valve Clearance Adjustment The valve clearance must be adjusted every 1000 operating hours or whenever the tappet is abnormally noisy or in an engine malfunction though the fuel system is properly working Valve clearance 0 40 mm 0 0157 in When the engine is cold The model 4LE1 engine has two types of the valve clearance adjusting method Confirm the aligning marks mark grooves on the outside diameter of the crank pulley Type I method with an aligning mark on the outside diameter of the crank pulley Adjustment Procedure Turn the crankshaft clockwise so that the mark groove on the crank pulley is aligned with the TDC mark cast out on the timing gear case cover Remove the cylinder head cover and check that the cylinder No 1 is at TDC in the compression stroke or at TDC in the exhaust stroke When the intake and exhaust valves are closed the cylinder is at TDC in the compression stroke and when the intake and exhaust valves are open it is at TDC in the exhaust stroke In accordance with the conditions of cylinder No 1 measure and adjust if required the clearance of the valves marked with either O or O in the table below Cylinder No 1 2 3 4 Valve arrangement EILJETTJETVTJET I When No 1 cylinder is at TDC i
38. e coil becomes red Turn the starter switch key clockwise to START position as soon as the control resistance coil red heat 39 WARNING Make sure that there is no flammable near outlet port of exhaust gas at engine starting It is very dangerous due to deformation discoloration or a fire 3 Engine Starting 1 Depress the engine throttle lever or throttle pedal and turn the starter switch key clockwise to START position The cranking period must not exceed ten seconds Continuous starter operation of more than ten seconds will lead to overdischarge of the batteries as well as starter seizure Release the starter switch after the engine starts The switch will return to the DRIVE position automatically For the engine equipped with a safety unit the starter circuit is automatically turned off when the engine starts This prevents the starter from overrunning If the engine cannot be started in one time attempt keep the batteries and the starter stationary at least 30 seconds for their functional recovery then repeat the pre heating and the starting operations CAUTION 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 despite repeated operations the engine does not start wait for a minute or more until the functions of the batteries and starter are recovered and then repeat pre he
39. er than those specifically recommended by Isuzu Such damage is not Isuzu s responsibility and is not covered by the Warranty To help avoid fuel system or engine damage please heed the following Some service stations mix used engine 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 damage such fuel can also affect emission control Before using any diesel fuel check with the service station operator to see if the fuel has been mixed with engine oil Do not use any fuel additive other than as recommended under Biocide in this section At the time this manual was printed no other fuel additive was recommended See your authorized dealer to find out if this has changed Take care not to run out of diesel fuel If you do run out of fuel you may need to bleed air out of the fuel injection pump to re start the engine after fuel has been added 23 24 Your engine is designed to use either Number 1 D or Number 2 D diesel fuel However for better fuel economy use Number 2 D diesel fuel whenever possible At temperatures less than 7 C 20 F Number 2 D fuel may pose operating problems see Cold Weather Operation which follows At colder temperatures use Number 1 D fuel if available or use a winterized Number 2 D a blend of Number 1 D and Number 2 D T
40. his 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 winterized Check with the service station operator to be sure you get the properly blended fuel Note that diesel fuel may foam during a fill up This can cause the automatic pump nozzle to shut off even though your tank is not full CAUTION Do not use home heating oil or gasoline in your diesel engine either may cause engine damage 3 Replacement Fasteners CAUTION Fuel may be under pressure Remove the fuel cap slowly to prevent fuel from spraying out and causing injury NOTICE Always use diesel fuel Use of low quality fuel may adversely affect the engine parts and cause failure Use of other than specified fuel may adversely affect the engine or emission control system and cause failure If other than specified diesel fuel is used the machine may not conform to specifications 4 5 Handling of the Fuel The fuel containing dust particles or water will cause engine failure Therefore the following notice must be observed Take care to prevent the fuel from entry of dust particles or water when filling the fuel tank When fueling is done from an oil drum directly keep the drum stationary over a long time so that clean fuel can be used after the dust particles or water is completely sedimented Always fully fill the fuel tank Drain the sedi
41. hortened life 53 54 9 STARTING THE ENGINE AFTER BEING LEFT UNUSED FOR ALONG PERIOD OF TIME When the machine or equipment is left unused for more than three months without running the engine warming up conduct a thorough inspection of the machine before starting the engine Crank the engine for 10 seconds and then stop it for 30 seconds with the fuel cut Repeat this procedure for three times This sends the oil to each part After starting the engine be sure to warm it up for more than ten minutes at 1000 min 5 PERIODICAL INSPECTION AND MAINTENANCE 1 LUBRICATING SYSTEM WARNING 1 During inspection and service a burn injury may occur due to hot engine body coolant or engine oil For the sake of safety conduct service work after the engine is stopped and cools down sufficiently 2 It is very dangerous to inspect and service the rotating parts For the sake of safety conduct service work after the engine is stopped Also make sure that it is not started during work Servicing of the engine oil or the oil filter element will affect on the engine performance as well as the engine life Change the engine oil and the oil filter element periodically with the specified ones Refer to 3 2 LUBRICANT 1 Engine Oil and Oil Filter Element Change Engine oil change and oil filter element change must be made according to the following change schedule For the engine equi
42. hot day e Stopping after high rpm If the Engine Coolant Temperature gage shows an overheat condition or you have reason to suspect the engine may be overheating take the following step e f your air conditioner if equipped is on turn it off And turn on the heater e Don t turn off your engine e With 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 temperature does not start to drop within a minute or two e Let the engine run at normal idle speed for two or three minutes If the engine coolant temperature does not start to drop turn off the engine and get out of the machine or equipment then proceed as follows WARNING To help avoid being burned Do not open the engine access cover if you see or hear steam or engine coolant escaping from the engine compartment Wait until no steam or engine coolant can be seen or heard before opening the engine cover Do not remove the radiator cap or engine coolant reserve tank cap if the engine coolant in the tank is boiling Also do not remove the radiator cap while the engine and radiator are still hot Scalding fluid and steam can be blown out under pressure if either cap is taken off too soon 47 48 If no steam or engine coolant can be seen or heard open the engine access cover
43. illing with coolant 1 Close or tighten the coolant drain plug 2 Fill up the radiator with the coolant until the level comes up to the filler port neck Fill gradually to prevent air entry Coolant volume Engine only Refer to Main Data Specifications 3 Loosen the air bleeder plug of the EGR cooler to bleed air from the EGR cooler Turbocharged engine only CAUTION If loosening the air bleeder plug be sure to replace it with new one IMLE0056 67 68 4 Tighten the plug when the coolant spills over from the air bleeder plug Turbocharged engine only CAUTION 1 Take care to prevent the spilt coolant from getting the exhaust system parts wet 2 If you spill coolant wipe it properly or this could lead to a fire 4 Torque Air bleeder plug 24 5 to 30 5 Nm 2 5 to 3 1 kgm Add coolant in the radiator and reservoir tank With the coolant poured operate the engine about five minutes at a low idle speed then the air contained in the coolant circuit is bled The coolant level will drop Stop the engine to replenish 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 compressed water For the cleaning interval refer to the instruction manual prepared by the equipment manufacturer If the fins are stuffed however
44. ining water w water O in fuel filter sedimenter 10 Fuel filter element replacement O O O O O O 11 Water sedimenter element cleaning O O O O O O X This is a recommended maintenance The failure to perform this maintenance item will nullify the emission warranty or limit recall liability prior to the completion engine useful life Isuzu however urges that recommended maintenance service is performed at the indicated intervals 94 Description of check operation hours and maintenance 1000 eg o o of 0 of 0 13 Injection nozzle check O O 00 14 Coolant level and fouling check O 15 Coolant leakage check O 16 Radiator filler cap fitting condition O 47 Frat ii check Replace if O O O O 18 Coolant temperature registration O 19 Coolant replacement 20 Intercooler and radiator external face cleaning 21 Cooling system circuit cleaning O 22 Radiator filler cap function check See EXPLANATION OF MAINTENANCE SCHEDULE X This is a recommended maintenance The failure to perform this maintenance item will nullify the emission warranty or limit recall liability prior to the completion engine useful life Isuzu however urges that recommended maintenance service is performed at the indicated intervals This is a required maintenance The failure to perform this maintenance item will nullify the emission warranty or
45. l seepage from the intake system and engine oil intrusion into the combustion chamber resulting in engine damage 2 Fan Belt Check Check the fan belt for tension and abnormalities WARNING For the sake of safety before conducting fan belt check make sure that the engine is stopped and is not be operated during check 34 IMLE0012 1 When the belt is depressed with the thumb about 100 N 22 Ib pressure at the midway between the alternator pulley and fan pulley the belt tension is correct as the following Fan belt slackness 8 10 mm 0 31 0 39 in When the belt tension is too high it will result in alternator failure Contrarily loose belt will cause belt slippage which may result in damaged belt and abnormal noise 2 Check the belts Replace them if any damage is found CAUTION Replace all belts as a set even when one is not usable Single belt of similar size must not be used as a substitute for a matched belt set Otherwise premature belt wear would result because of uneven belt length 3 Coolant Level Check 1 Without the reserve tank Remove the radiator filler cap and check the coolant level as well as the degrees of fouling Proper coolant level is about 10 mm higher from the radiator core top 2 With the reserve tank The coolant level must be between FULL and LOW marks on the reserve tank Check and see that the level is co
46. largely affect engine performance startability and engine life CAUTION Use of unsuitable engine oil will result in piston ring piston and cylinder seizure and accelerate the sliding surface wear causing increased oil consumption lowered output and finally engine failure To avoid this use the specified engine oil 27 1 Engine Oil Selection For engine oil use API grade CD CE CF CF 4 CH 4 CI 4 Cl 4 plus or ACEA grade A3 B3 A3 B4 A5 B5 E2 E3 E4 E5 E7 or JASO grade DH 1 The brands types of oil described below can be used regardless of specified API or ACEA grade above Their qualities are guaranteed by ISUZU GRADE LUBRICATION MAKER BRAND TYPE API ACEA JASO ISUZU GENUINE BESCO MULTI Z TYPE CE 10W 30 CE ISUZU GENUINE BESCO MULTI Z 10W 30 CD CF CF 4 ISUZU GENUINE BESCO S 3 10W 20W 30 40 CD Caltex Chevron Delo CXJ 15W 40 20W 50 40 CF DH 1 Delo 400 Multigrade 15W 40 CE CF CI 4 E3 E5 DH 1 Shell Rimula X 15W 40 CH 4 E3 DH 1 Rimula D 15W 40 30 40 CF Elf Perfo 3F 15W 40 CF 4 CE B2 E2 Total Rubia XT 15W 40 CF 4 E2 Diesel engine Castrol RX Super Plus 15W 40 CH 4 E3 crankcase Tection J Plus 15W 40 CH 4 E3 B3 DH 1 BP BP Vanellus C6 15W 40 CH 4 E3 IDEMITSU APOLLOIL EX 10W 40 CF DH 1 APOLLOIL TOUGH RUNNER 10W 30 15W 40 CF DH 1 APOLLOIL MULTI RUNNER 10W 30 15W 40 CF 4 CE DH 1 2 APOLLOIL SUPER WIDE DH 1 10W 30 15W 40 CF 4 DH 1 ExxonMobil Essolube XTJ
47. lug type 2 Fill with new engine oil by the oil filler port Wait about fifteen minutes until the oil gets down to the oil pan Then check the oil level with a dipstick Do not insert the dipstick by force The dipstick may be broken WARNING 1 In adding oil take care not to spill it If you spill oil wipe it properly or this could lead to a fire 2 Do not leave any flammables such as cloth or gloves in the engine compartment It may result in a fire 61 CAUTION 1 Prevent dust particles from entering through filler port at replenishment Be careful entry of dust particles may cause engine damage or accident 2 Replenishment of oil above Max level or below Min level may cause engine damage or accident Drain oil to the Max level if the oil level is above Max level Also replenish oil to the Max level if the oil level is below Min level 2 Check after Oil and Filter Changes The remote type oil filter is used so that it takes time to pressure feed oil to each part of engine after oil filter is changed Idle approx 30 seconds at the first start up after oil filter is changed Do not perform sudden loading or rapid acceleration In addition the time to pressure feed oil can be shortened by filling engine oil into oil filter Oil leakage check Idle the engine to raise the oil pressure then check for oil leakage Oil level recheck Stop the engine and keep it stationary abou
48. mented particles in the fuel tank frequently by opening the tank draining hole Water in Fuel During refueling it is possible for water and other contaminants to be pumped into your fuel tank along with the diesel fuel This can happen if a service station does not regularly inspect and clean its fuel tanks or if a service station receives contaminated fuel from its supplier s To protect your engine from contaminated fuel there is a fuel filter system on the engine which allows you to drain excess water 25 26 WARNING The water diesel fuel mixture is flammable and could be hot To help avoid personal injury and or property damage do not touch the fuel coming from the drain valve and do not expose the fuel to open flames or sparks Be sure you do not overfill the container Heat such as from the engine can cause the fuel to expand If the container is too full fuel could be forced out of the container This could lead to a fire and the risk of personal injury and or machine or equipment damage 6 3 7 Fuel Filter Be sure to use the genuine fuel filter The fuel injection system is precision structure so that its filter has a finer mesh than conventional one to extend life of the system Be sure to use Genuine fuel filter Replacement interval may be shortened depending on the characteristic of fuel Clogged fuel filter may cause to result in stopping the engine In a place where fuel get
49. menter and then loosen the drain plug at the bottom of the case to drain the separated water After draining be sure to tighten the plugs and conduct air bleeding of fuel Be careful not to over tighten the air bleeding plug Torque Drain plug 1 0 to 2 0 Nm 0 1 to 0 2 kgm Torque Air bleeding plug 1 5 to 3 0 Nm 0 15 to 0 31 kgm IMLE0022 CAUTION 1 If the cup is removed without turning the fuel filter lever just above the fuel may flow out 2 The cartridge and cup contain fuel Take care not to spill it during disassembly 3 Perform the fuel system air bleeding after the water in the fuel is drained 2 2 Fuel System Air Bleeding The entry of air into the fuel system will cause hard engine starting or engine malfunction When once the servicing such as emptying the fuel tank draining for the water sedimenter and the fuel filter element change is done be sure to conduct air bleeding Because of the automatic air bleeding system being employed turn the starter switch to the Drive position and activate the electromagnetic pump to bleed the air Air bleeding procedure When the starter switch is set to the Drive ON position to activate the electromagnetic pump fuel is forcibly sent to the fuel valve of each injection pump and further to the leak off pipe of each nozzle holder where air in the fuel leaks off automatically to the fuel tank Start the e
50. move the filter and replace or clean it Paper type Remove the filter and the gasket then install new ones Make the interval of replacement service shorten depending on fuel management and supply Steel mesh type Remove the filter and the gasket Clean the filter with the compressed air and rinse it in the fuel oil before installing the filter and the gasket Make the interval of cleaning service shorten depending on fuel management and supply 75 76 3 Install the cover When installing use a wrench and fully tighten it to the end CAUTION After installing the cover be sure to check airtightness 6 Governor Control Seals As the governor timing gear case 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 CAUTION The manufacturer does not warrant the claim on the engine with the broken governor seals 4 AIRINTAKE SYSTEM 1 Air Cleaner Engine performance and life vary with the air intake conditions A dirty air cleaner element reduces the amount of intake air causing reduced engine output or disordered engine Also a damaged element leads to abrasion of cylinders and valves resulting in increased oil consumption reduced output and shortened engine life Handling of air cleaner varies with the equipment model Perform periodic inspection and maintenance follo
51. n the compression stroke When No 4 cylinder is at TDC in the compression stroke I Intake E Exhaust 4 On completion of the valve clearance adjustment in 3 above make mark alignment as in 1 above by giving a turn to the crankshaft in normal direction Then measure and adjust the clearance of the other valves CAUTION The rocker arm is made of die cast aluminum Therefore be careful not to tighten the adjusting screw to excess Type II method with two aligning marks at point 180 degrees apart on the outside diameter of the crank pulley 85 86 IMLE0027 Adjustment Procedure Turn the crankshaft clockwise so that the TDC mark groove 1 on the crank pulley is aligned with the TDC mark cast out on the timing gear case cover Remove the cylinder head cover and check that the cylinder No 1 is at TDC in the compression stroke or at TDC in the exhaust stroke When the intake and exhaust valves are closed the cylinder is at TDC in the compression stroke and when the intake and exhaust valves are open it is at TDC in the exhaust stroke Valve clearance is adjusted on 4 progressive steps as following Step 1 When the cylinder No 1 is at TDC in the compression stroke measure and adjust the valve clearance of the cylinder No 1 marked with O in the table below Step 2 Turn the crankshaft clockwise 180 degrees from the step 1 condition to align the mark groov
52. ne overheat Thermostat malfunction Change thermostat Radiator filler cap malfunction Change radiator filler cap Cooling system interior fouled Clean cooling system interior 103 Engine overheat Radiator clogging Clean with soft brush Engine over loaded Check your driving Air cleaner element clogging Clean or change element Insufficient ventilator Check the ventilation Stopped coolant flow high concentration of antifreezer etc Clean inside of radiator and change coolant Low oil pressure Oil leakage Large oil consumption Wrong selection of kind and viscosity Change with oil of correct viscosity Over heat Stop vehicle operation and reduce engine rotation to 1000 revolutions for cooling drive for five minutes and stop engine Clogged filter and strainer Worn bearings and oil pump Faulty relief valve Lack engine output 104 Too advance of injection timing Too retard of injection timing Incorrect injection pressure adjustment 0 0 0 0 10 0 Incorrect spray condition Lack of fuel in tank Make sure that there is no fuel leakage and replenish Lack engine output Air mixing in injection pump Bleed air Fuel filter clogged Change element Overflow valve malfunction Incorrect engine control adjustment
53. ngine and check the fuel system for leakage CAUTION Start the engine and check the fuel system for leakage Leakage causes a fire 71 3 Fuel Filter Element Change Change interval Fuel filter element change inerval Every 500 operating hours CAUTION The fuel filter element may be clogged faster depending on the amount of dust particles in the fuel Therefore the element may need to change more often than Change interval above If the low engine output or engine stall is found the change of fuel filter element may recover them Change procedure 1 Use a specified filter wrench to remove the cartridge 2 Apply lightly fuel to the gasket of a new cartridge and turn in the cartridge until its sealed face comes in contact with the O ring Then tighten the cartridge to the correct tightening torque Torque Cartridge 13 7 Nm 1 4 kgm Cartridge IMLE0058 4 Water Sedimenter Element Cleaning Cleaning interval Fuel filter element cleaning interval Every 500 operating hours 72 Cleaning procedure 1 Turn the water sedimenter lever to the closed position CAUTION ff the cup is removed without turning the lever as instructed the fuel may flow out 2 Loosen the ring nut remove the cup and take out the element 3 Clean the cup and element install new packing on the ring nut 4 Tighten the cup to the body securely with the ring n
54. of equipment in which the engine is installed 5 Engine family index Injection nozzle Injection timing Engine family Engine code opening pressure B T D C MPa psi Static SZXLO2 2UTA SZXLO2 2VTB SZXLO2 2VNA SZXLO2 2VNC Mark Put a letter codes for model year on the top of the letters Y 2000 1 2001 2 2002 3 2003 4 2004 5 2005 6 2006 7 2007 8 2008 9 2009 Model Year 13 EMISSION CONTROL LABEL ENGINE LABEL EPA EC COMBIND TYPE Emission control label is attached at the center of injection pump cover located at the right side of cylinder body or on the cylinder head cover The location of emission control label attached on the engine may vary depending on the engine specification The following is the sample of a label required for engine emission control information along with location 4LE1T ISUZU Bisson contro INFORMATION ISUZU MOTORS LTD MADE IN JAPAN THIS ENGINE COMPLIES WITH U S EPA REGULATIONS FOR XX MY NONROAD DIESEL ENGINES AND CALIFORNIA REGULATIONS FOR XX MY OFF ROAD S DIESEL ENGINE SEE SERVICE MANUAL FOR ENGINE FAMILY XXXXXXXXXXX MODEL SPECIFICATIONS ENGINE CODE 200000000 XX ADVERTISED POWER SAE NET MODEL 22020000 W XXX RPM POWER CATEGORY XX lt kW lt XX FUEL RATE XX mm s VALVE LASH COLD INLJEXH XX XX mm INITIAL INJECTION TIMING SULFUR FUEL ONLY CURB IDLE XXX RPM 2000000000 X0000000K
55. olant temperature 70 85 C 158 1859F Repair the engine and or replace some parts of engine if compression pressure is lower than 2 5 MPa 26 kg cm 363 psi 87 88 5 6 Starter and Alternator Servicing Do the starter and the alternator servicing every 1000 operating hours on the following items Starter commutator cleaning e Alternator slip ring cleaning e Carbon brushes and the brush contact check Radiator Pressurization Valve Check A pressurization valve is incorporated in the radiator cap assembly Check the valve actuating pressure with a radiator compression tester For the pressurization valve actuating pressure and the check interval follow the equipment manufacturer s standards 6 ENGINE CARE IN COLD SEASON 1 1 FUEL Fuel Selection In the cold zone the fuel might be frozen resulting in hard engine starting therefore select a suitable 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 7 C 20 F If Number 1 D is not available a winterized blend of 1 D and 2 D is available in some areas during the winter months Check with the service station operator to be sure you get the properly blended fuel 89 90 2 COOLANT Where the atmospheric temperature falls below freezing point the cooling system should be drained after engine o
56. ompletely replace the packing of the drain plug with a new one and then install the plug 4 Tighten the drain plug Torque drain plug 78 4 Nm 8 0 kgm CAUTION Use a receptacle to receive the drained oil so that the engine and equipment may not be stained with the drained oil IMLE0093 57 58 4LE1T Oil level gauge Oil filler cap iller cap Oil drain plug IMLE0094 4LE1NA Oil level gauge Oil drain plug IMLE0095 59 60 Oil filter element removal Use a filter wrench to remove the cartridge type oil filter element There may remain the used engine oil in the cartridge and care should be taken not to spill it when removing the filter Discard the used filter Cartridge type Remote filter type EY Con Cartridge IMLE0070 Oil filter element installation 1 Apply lightly engine oil to the O ring 2 Turn in new cartridge until its sealed face comes in contact with the O ring 3 Use a filter wrench to further turn in the cartridge Oil filter element tightening torque 14 7 20 6 Nm 1 5 2 1 kgm IMWG0034 Engine oil refilling 1 Disconnect the oil drain hose and reinstall the cap of drain cock One touch type Install the drain plug Drain p
57. on e 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 a reduced speed Return to normal operating after about ten minutes if the gage pointer does not again show an overheat condition If no cause for the overheat condition was found see a qualified service technician Overcooling The engine operation at low coolant temperature will not only increase the oil and fuel consumption but also will lead to premature parts wear which may result in engine failure 49 50 3 4 5 6 Engine Hourmeter Engine Operation Hour Indicating If so equipped This meter indicates the engine operation hours Make sure that the meter is always working during engine operation Periodical engine maintenance is scheduled on the operation hours indicated 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 related parts checking if the noise is normal State of the Exhaust Smoke Be careful with exhaust smoke color check if it is whitish or blackish 5 ENGINE STOPPING 1 Make sure that all of the control levers on the equipment are in NEUTRAL position 2 Before stopping the engine cool down the engine by ope
58. ongation leading to engine damage such as overheat Therefore use of the ISUZU genuine fan belts are highly recommended When you check the belt and find the following condition replace the belt with new one 1 No adjustment margin of the belt 2 Abnormal wear damages or cracks on the belt 3 Brake noise occurs while driving even if belt tension is adjusted 65 66 3 Coolant Change CAUTION Use Isuzu genuine anti freeze ethylene glycol based or equivalent with the specified mixing ratio If oil is in coolant contact ISUZU Distributor as soon as possible CAUTION The coolant must be changed at intervals of 12 months If the coolant is being fouled greatly it will lead to engine overheat or coolant blow off from the radiator and cause a burn Shorten the interval of changing Coolant draining 1 Remove the radiator cap Open the drain cock at the radiator lower part to drain the coolant in the radiator WARNING When removing the radiator filler cap while the engine is still hot cover the cap with a rag then turn it slowly to release the internal steam pressure This will prevent a person from scalding with hot steam spouted out from the filler port IMLE0021 Air Bleeder Plug 2 Drain away the coolant from the engine by loosening the water drain plug at the rear of alternator on the left side of cylinder body F
59. ou dont you or others could be hurt ENGINE OR EQUIPMENT DAMAGE WARNINGS CAUTION These mean there is something that could damage your engine or equipment In the caution 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 caution will tell you what to do to help avoid the damage EMPHASIZED WARNINGS NOTICE These mean there is something that needs to be emphasized but which does not concern the possibility of personal injury or mechanical damage TABLE OF CONTENTS 1 ENGINE EXTERNAL VIEWS seen 1 1 MODEL ALE1T mmrvvorvervsrvevossvevosseevasvervsrveressvevesseevasseressseevssvevesseeres 1 2 MODEL LE INA 22500 ee nes 3 2 GENERAL INFORMATION rennes 5 1 EPA AND CARB CERTIFIED ENGINE DATA AND SPECIFICATIONS 2m med a NDS TAN 5 2 EC EMISSION CONTROL LABLE ENGINE LABEL ONLY EC TYPE nn Si atta easectinae 18 3 ENGINE IDENTIFICATION rrvvsveevsrvervsrveressverosseeeossverosseevusseeeusseee 19 4 ISUZU ENGINE AFTER SERVICE nee 21 3 FUEL LUBRICANT AND COOLANT rvsvvervssversssvevasservasservssvevesseevesse 22 12 FUEL seere 22 D LUBRICANT ee better dende 27 3 COOLANT Seen DA STA Sune 30 4 ENGINE OPERATION eee 31 1 CHECK BEFORE OPERATION rennes 32 2 ENGINE STARTING weccsssssssssssssssssssssssssssssssssssssssesssssesssscesssseessssees 38 3 CHECK AND OPERATION AFTER THE ENGINE START UP
60. over their power and reattempt the preheating and the cranking operation In order to protect the starter one 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 as this is a sign of weakened battery power charge the batteries with an external electrical source In an extreme cold temperature engine starting do the engine cranking a while with setting the throttle lever at no fuel position to allow the engine rotating or traveling parts come to an unrestricted condition from the adhesive cold lubricant after then do preheating and cranking to start the engine CAUTION Do not use starting aids in the air intake system Such aids can cause immediate engine damage 93 7 ENGINE MAINTENANCE SCHEDULE When performing the following items the daily inspection items should also be carried out Description of check operation hours i Remark and maintenance 750 1000 1 Oil level and oil fouling O 2 Oil leakage check O 3 Oil pressure gauge registration O 4 Oil pressure warning lamp O 5 Engine oil replacement O O O O O O Cartridge type Enoi il i See EXPLANATION OF 6 Kr NE O O O MAINTENANCE i mie i SCHEDULE 7 Oil filter element replacement O O O 8 Fuel leakage check O 9 Dra
61. peration but to eliminate the need for repeated draining and refilling the use of anti freeze solution is highly recommended A 50 50 mix Ethylene glycol base antifreeze tap water soft water distilled water or demineralized water which provides protection to 37 C 34 F is recommended for use in these ISUZU diesel engines Concentrations over 65 adversely affect freeze protection heat transfer rates and silicate stability which may cause water pump leakage Never exceed a 60 40 mix antifreeze tap water soft water distilled water or demineralized water which provides protection to about 50 C 58 F WARNING Under some conditions the ethylene glycol in the engine coolant is combustible To help avoid being burned when adding engine coolant do not spill it on the exhaust system or engine parts that may be hot If there is any question have this service performed by a qualified technician CAUTION 1 Methyl alcohol base antifreeze is not recommended because of its effect on the non metallic components of the cooling system and because of its low boiling point 2 High silicate antifreeze is not recommended because of causing serious silica gelation problems 3 Usage and mixing ratio etc should be followed to the antifreeze manufacturer s recommendations 91 92 3 ENGINE OIL Engine oil viscosity largely affects engine startability so the use of lubric
62. pped with the oil filter warning lamp if the lamp comes on while driving the filter element is clogged Replace the element regardless of the change interval Change interval Engine Oil Cartridge type Every 250 operating hours Remote filter type Every 500 operating hours Oil Filter Element Every 500 operating hours 55 Oil filler cap q A jae f lo S Oo EU DC 6 FAU Q LA ER 0 39 Id IMLE0093 Engine oil draining WARNING To help avoid the damage of being burned do not drain oil while the engine is still hot IMWG0035 56 One touch type 1 Wipe clean around the oil filler cap taking care so that no foreign particles entry Remove the filler cap 2 Loosen the cap of oil drain cock and remove it Connect the oil drain hose to the oil drain cock and drain the oil 3 After the completion of draining disconnect the hose and wipe off the oil on the drain cock 4 Turn the cap of oil drain cock slightly and settle it From that position turn more about 60 to 90 degrees Drain plug type ON Oil filler cap 1 Wipe clean around the oil filler cap taking care so that no foreign particles entry Remove the filler cap 2 Remove the drain plug by loosening it and then drain oil 3 After oil has been drained c
63. r leakage e Exhaust smoke or gas leakage Checking coolant level The coolant level could drop depending on the equipment because the mixed air is expelled in about 5 minutes after the engine started Stop the engine remove radiator cap and add coolant WARNING Hot steam will rush out and you could get burnt if the radiator cap is removed when the engine is hot Cover the radiator cap with a thick cloth and loosen the cap slowly to reduce the pressure then remove the cap 44 4 CARE IN THE ENGINE OPERATION In the engine operation always pay attention to the following items if the engine indicates any sign of abnormalities 1 Engine Oil Pressure Engine oil pressure is normal when the oil pressure gauge shows the values of the following in the engine warmed up condition Oil pressure 147 kPa 21 psi 1000min 294 kPa 43 psi 1800min 343 to 686 kPa 50 to 100 psi 2200min In the continuous engine operation engine oil pressure is slightly lower than the pressure at start up time Also make sure that the oil warning lamp is off If in continuous engine operation 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 engine oil amount in the oil sump and oil leakage e The engine oil pressure gauge shows below 200 kPa 28 psi though the engine speed is rai
64. rating it at low idle speed about three minutes In this operation check the engine noise and the engine oil pressure for abnormalities CAUTION In 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 This will result in turbocharger failure 3 To stop the engine turn the starter switch key to OFF position The engine stop solenoid automatically shut off the fuel to stop the engine Switch off the battery if so equipped CAUTION Leaving the starter switch key in the DRIVE position for a long while after the engine has been stopped will discharge the batteries wastefully 51 6 OPERATION AND CARE FOR NEW ENGINE Your ISUZU engine is carefully tested and adjusted in the factory however further thorough run in i e break in operation is necessary If the new engine is harshly operated lubricating oil film will be reduced leading to abnormal wear or seizure Particularly avoid a harsh engine operation within the initial 100 operation hours observing the following notice 1 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 with rapid acceleration rapid machine starting and continuous high speed operation 7 ENGINE CARE FOR OVER COOLING Engine
65. rbochargeur IHI RHF 3 111 3 112 Mod le AV 4LE1N D signation du mod le du moteur ISUZU AV 4LE1N Famille de moteur SZXLO2 2XXX Code de moteur 4LE1XXXXX XX Type de soupape en t te en ligne quatre temps T e moteur X T ype d refroidissement eau Type de combustion Swirl chambre No de cylindres al sage x course mm in 4 85 x 96 3 35 x 3 78 Cylindr e du moteur L cid 2 179 133 Rapport de compression 21 5to1 S quence d allumage 1 3 4 2 Puisance nominale SAE NET kW cv min 35 9 48 1 2600 D bit de combustible au couple max mm course 35 5 Syst me de commande d mission d chappement EM IDI Pompe injection Type PFR Bosch R gulateur Type m canique vitesse variable Marque Placer un code de lettres pour l ann e du mod le sur la partie sup rieure des lattres Ann e du mod le Y 2000 1 2001 2 2002 3 2003 4 2004 5 2005 6 2006 7 2007 8 2008 9 2009 Le code du moteur varie selon chaque moteur Buses injection Type papillon Combustible sp cifi Combustible Diesel ASTM D975 No 2 D D marreur 12 2 0 Alternateur 12 35 R f rez vous a 3 LUBRIFIANT choix D Huile a moteur Huile moteur sp cifi e API grade Volume d huile de lubrication 5 9 6 2 8 4 8 8 Volume du liquide de refroidissement seulement moteur Poids sec
66. rnnnenennenennevennenennevenneee 92 5 ENGINE STARTING rrvvnnvrnnvnnnvnnvennvvnnvvnnvnnnennnennnennvnnnvnnnennnennvennvener 93 7 ENGINE MAINTENANCE SCHEDULE rnvrnnvnnnvnanvnnnennvvnnvnanvvnnennnennnener 94 8 SIMPLE ENGINE TROUBLESHOOTING rennes 102 1 ENGINE EXTERNAL VIEWS 1 MODEL 4LE1T 1 LH Turbocharger Air inlet Starter Generator Note Engine details may vary depending on the specifications LE0085 2 RH Nozzle holder Thermostat housing Water pump Oil cooler Oil filler cap Note gt Engine details may N vary depending on the Oil drain plug re specifications From oil filter To oil filter LE0086 as 2 MODEL 4LE1NA 1 LH Air inlet Generator Water drain plug T Starter Note Engine details may vary depending on the specifications LE0087 2 RH Nozzle holder Thermostat ho
67. rrect When the coolant level is lower than the LOW mark replenish the reserve tank by the filler port but when the reserve tank is empty replenish by the radiator filler port WARNING When removing the radiator filler cap while the engine is still hot cover the cap with clothing then turn it slowly to gradually release the internal steam pressure This will prevent you from getting burnt with hot steam spouted out from the filler port CAUTION Use Isuzu genuine anti freeze ethylene glycol based or equivalent with the specified mixing ratio 35 36 4 Radiator Cap Condition After the replenishment of the coolant install the radiator cap Make sure the cap is securely installed 5 Battery Cable Connection Check the battery cable connections for looseness or corrosion The loosened cable connection will result in hard engine starting or insufficient battery charge The battery cables must be tightened securely 24V Battery cable 12V z Battery cable Terminal Terminal Battery cable IMLE0069 CAUTION Never reverse and terminals when reconnecting cables after disconnection Even a short period of reverse connection will damage the electrical parts Regular position Shortage D Proper D Excess 6 Battery Electrolyte Level The amount of electrolyte in the batteries will be reduced after repeated di
68. rvice is performed at the indicated intervals Note 1 The service intervals after 1500 operation hours should also be made every 250 operation hours in accordance with this check and maintenance schedule 2 When the servicing on the asterisked items are necessary consult the equipment supplier 97 EXPLANATION OF MAINTENANCE SCHEDULE The following is a brief explanation of the services listed in the preceding Engine Maintenance schedule 1 98 Oil level and oil fouling Oil leakage check Oil pressure gauge registration Oil pressure warning lamp Engine oil replacement Engine oil replacement Oil filter element replacement Fuel leakage check Draining water in fuel filter Check that the oil level is between the max level mark and the min level mark Drain oil to the max level mark if oil level is above the max level mark Add oil to the max level mark if oil is below the min level mark Replace any damaged or malfunctioning parts which could cause leakage Engine oil pressure is normal at the values of the following in warmed up condition Oil pressure 147 kPa 21 psi 1 000min 294 kPa 43 psi 1800min 343 to 686 kPa 50 to 100 psi 2200min Check and repair the lubrication oil system if it is abnormal Warning lamp is off while engine running If it stays on check and repair the lubrication system Change oil every 250 hours Cartridge type Change oil every 500 ho
69. s mixed with foreign matter perform early inspection and periodic replacement Depending on the machine the electromagnetic type fuel pump is equipped in this engine Periodical replacement or cleaning is required for this pump filter Refer to Filter Replacement or Cleaning When the filter exchange of this pump is necessary please inquire at your machine supply source or contact ISUZU dealer Biocides In warm or humid weather fungus and or bacteria may form in diesel fuel if there is water in the fuel CAUTION Fungus or bacteria can cause fuel system damage by plugging the fuel lines fuel filters or injector They can also cause fuel system corrosion 8 2 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 biocide manufacturer s instructions Biocides are available from your dealer service stations parts stores and other automotive places See your authorized dealer for advice on using biocides in your area and for recommendations on which biocides you should use Smoke Suppressants Because 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 from excessive ash deposits LUBRICANT The quality of engine oil may
70. s reserved to make changes at any time without notice INSTRUCTION MANUAL INDUSTRIAL 4LE1 INTERIM TIER4 STAGE 3A IDE 6260 Issued by ISUZU MOTORS LIMITED Planning amp Service Group Off highway Powertrain Operations Dept 6 26 1 Minami oi Shinagawa ku Tokyo 140 8722 Japan TEL 03 5471 1111 10 2008
71. scharge and recharge Check the electrolyte for the level in the batteries replenish with a commercially available electrolyte such as distilled water if necessary The battery electrolyte level checking procedure will vary with battery type Follow the equipment manufacturer s instructions CAUTION Do not replenish with dilute sulfuric acid in the daily service IMWG0013 WARNING 1 2 When inspecting the batteries be sure to stop the engine As diluted sulfuric acid is used as electrolyte be careful not to stain your eyes hands clothes and metals with the electrolyte If it gets in your eye wash with a large amount of water at once Then go and see a doctor As highly flammable hydrogen gas is rising from the batteries do not make a spark or use fire in any other way near the batteries When handling such metallic articles as a tool near the batteries be sure not to contact terminal As the machine body is O it may cause a big danger When disconnecting the terminals start with terminal When connecting them connect the terminal last 37 2 ENGINE STARTING In case of the type with QOS system 1 Pre starting Preparation DRIVE 1 Make sure that all hydraulic control levers etc on the equipment are in START the NEUTRAL position 2 Set the engine stop knob in the START position It is unnecessary for the engine equipped with the engine shutdown s
72. sed e The oil pressure gauge indicator oscillates greatly in the engine low speed range e When the engine oil pressure warning lamp goes on and off repeatedly When not lack of engine oil or no oil leakage is found contact your equipment supplier to determine the cause of the abnormal reading 45 46 2 Coolant Temperature The engine performance will be adversely affected if engine coolant temperature is too hot or too cold The normal coolant temperature is 75 to 90 C 167 to 194 F Overheating WARNING If the Engine Coolant Temperature Gage shows an overheat condition or you have other reason to suspect the engine may be overheating continued operation of the engine other than as spelled out here even for a short period of time may result in a fire and the risk of personal injury and severe vehicle or equipment damage Take immediate action as outlined following If you see or hear escaping steam or have other reason to suspect there is a serious overheat condition stop and park the machine or equipment as soon as it is safe to do so and then turn off the engine immediately and get out of the machine or equipment The engine cooling system may overheat if the engine coolant level is too low if there is a sudden loss of engine coolant such as hose splitting or if other problems occur It may also temporarily overheat during severe operating condition such as e Climbing a long hill on a
73. t twenty minutes Use the dipstick to recheck the oil level Replenish with engine oil if necessary to the specified level CAUTION When the engine is started the oil level will slightly drop from the initial level as the oil fully comes into the entire oil circuit 3 4 5 Engine Oil Additives Engine oils contain a variety of additives Your engine should not need any extra additives if you use the recommended oil quality and change intervals Used Oil Disposal Do not dispose of used engine oil or any other oil in a careless manner such as pouring it on the ground into sewers or into streams or bodies of water Instead 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 service station This also applies to diesel fuel which is contaminated with water See Diesel Fuel in Section 3 Used Engine Oil WARNING Used engine oil contains harmful contaminants that have caused skin cancer in laboratory animals Avoid prolonged skin contact Clean skin and nails thoroughly using soap and water not mineral oil fuels or solvents Launder or discard clothing shoes or rags containing used engine oil Discard used engine oil and other oils properly 63 2 COOLING SYSTEM 1 Fan Belt Tension Adjustment Adjust fan belt tension
74. tter codes for model year on the top of the letters Y 2000 1 2001 2 2002 3 2003 4 2004 5 2005 6 2006 7 2007 8 2008 9 2009 Model Year Engine code varies depending on each engine ISUZU engine model name BV 4LE1T Injection nozzles Throttle type Specified fuel Diesel fuel ASTM D975 No 2 D 2 Starter 12 2 0 2 Alternator 12 35 Specified engine oil API grade Refer to 3 LUBRICANT Engine Oil Selection 2 Lub oil volume 7 6 8 0 10 3 10 9 Coolant volume Engine only 2 8 3 0 2 Engine dry weight 180 397 2 Engine dimensions Overall length 753 7 29 7 Overall width 486 2 19 1 Overall height 601 8 23 7 Valve clearance cold 0 4 0 0157 Nozzle injection pressure 14 7 2132 2 Injection timing B T D C 10 Maker and type of turbocharger Specification for items marked with an asterisk 2 will vary according to the type of equipment in which the engine is installed IHI RHF 3 3 Model AV 4LE1N ISUZU engine model name AV 4LE1N Engine family SZXLO2 2VNA Engine code 4LE1 XXXXX XX Engine type Water Cooled four cycle in line overhead valve type Combustion type Swirl chamber type No of cylinders bore x stroke mm in 4 85 x 96 3 35 x 3 78 Engine displacement L cid 2 179 133 Compression ratio 21 5 to 1
75. urs Remote filter type Change element every 500 hours Inspect the fuel lines for damage which could cause leakage Replace any damaged or malfunctioning parts The fuel system without the water sedimenter Drain the sedimented water in fuel filter every 250 operating hours 10 11 12 13 14 15 16 17 18 19 20 Fuel filter element replacement Water sedimenter element cleaning Electromagnetic pump filter cleaning Injection nozzle check Coolant level and fouling check Coolant leakage check Radiator filler cap fitting condition Fan belt tension check Coolant temperature registration Coolant replacement Intercooler and radiator external face cleaning Change element every 500 hours Shorten depending on fuel management Clean the water sedimenter element every 500 hours Shorten depending on fuel management Replace the paper type filter at intervals of 500 operating hours Clean the steel mesh type filter at intervals of 500 operating hours Shorten depending on fuel management Clean the injection nozzle tips every 1500 hours This is a required maintenance Check injection opening pressure and spray condition Check coolant level and add coolant if necessary Repair part for coolant leakage The radiator cap must be installed tightly Check and adjust fan belt deflection Look for cracks fraying and wear Coolant temperature is normal at a
76. using Water pump Solenoid stopper bo i Sli EN GN NN Oil filler cap Note Engine details may vary depending on the specifications Fuel filter Oil drain plug LE0088 2 GENERAL INFORMATION 1 1 EPA AND CARB CERTIFIED ENGINE DATA AND SPECIFICATIONS Se rapporter la fin de ce document pour les informations EPA en frangais Model AU 4LE1T ISUZU engine model name AU 4LE1T Engine family SZXL02 2UTA Engine code ALE1XXXXX XX Engine type Water Cooled four cycle in line overhead valve type Combustion type Swirl chamber type No of cylinders bore x stroke mm in 4 85 x 96 3 35 x 3 78 Engine displacement L cid 2 179 133 Compression ratio 21 5 to 1 Firing order 1 3 4 2 2 Rated power SAE NET kW hpy min 40 53 6 2200 2 Fuel flow at max rated power mm stroke 46 3 Exhaust emission control system EM IDI TC EGR Injection pump Bosch PFR type Governor Variable speed Mechanical type Mark Put a letter codes for model year on the top of the letters Y 2000 1 2001 2 2002 3 2003 4 2004 5 2005 6 2006 7 2007 8 2008 9 2009 Model Year Engine code varies depending on each engine ISUZU engine model name AU 4LE1T Injection
77. ut 5 After installation turn the water sedimenter lever to the open position CAUTION 1 With the lever positioned just above the fuel remains off and therefore the engine cannot be started 2 During removal be careful not to stain the parts around with the fuel in the cup 3 After changing fuel filter element conduct fuel air bleeding 73 Air bleeder plug mS OPEN plug Drain IMLE0059 Electromagnetic 5 Filter Replacement or Cleaning Depending on the machine the electromagnetic type fuel pump is equipped in this engine Filters inside of the pump consist of paper type and steel mesh type Replace the paper type filter at intervals of 500 operating hours Clean the steel mesh type filter at intervals of 500 operating hours pump Gaskel E Filter eA Gasket o ol ra Cover I a H IMHK0376 CAUTION When removing the filter always replace the gasket and clean the magnet part inside of the cover 1 Remove the wirings attached on the pump cover Rotate the cover with a wrench and remove it CAUTION In detaching the cover place a tray to prevent the fuel contained in the pump from spilling over the engine Also make sure that there is no flammable near the fuel pump 2 Re
78. when belt slackness is greater than the specified amount and when the belts are replaced WARNING To help avoid being injury check and adjust fan belt tension with engine stopped Belt tension Belt tension is normal when it is depressed with the thumb at the midway between the fan pulley and alternator pulley about 100 N 22 Ib depressing force Fan belt slackness 8 10 mm 0 31 0 39 in IMLE0012 64 Mounting bolt loosen VA Lock nut loosen it Adjusting I bolt 7 Adjusting procedure Belt tension adjustment is made by pivoting the alternator at the alternator mounting bolt 1 Loosen the lock nut and the alternator mounting bolt 2 Pivot the alternator at the mounting bolt by adjusting the adjusting bolt 3 Tighten the mounting bolt and the lock nut Tightening torque 23 5 Nm 2 4 kgm M8 bolt or nut 48 1 Nm 4 9 kgm M10 bolt or nut IMLE0096 CAUTION Belt tension may vary slightly after 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 recheck the belt tension Particularly pay attention to this matter when installing new belts Belt tension may vary due to the initial belt conforming 2 Fan Belt Change Use of fan belt with poor quality will result in premature belt wear or belt el
79. wing the equipment manufacturer s instructions CAUTION 1 Shorten the cleaning or change interval when the equipment is used in dusty areas 2 Change the element if element damage is found during air cleaner cleaning 3 Take care not to cause air leakage sucking when reassembling the air cleaner 77 N NORMAL INDICATOR Red signal CLOGGED 78 IMLE0044 2 Air Cleaner with Dust Indicator This indicator is attached to the air cleaner When the air cleaner element is clogged air intake resistance becomes greater and the dust indicator signal turns into red indicating the element change timing When the signal turns into red clean the air cleaner or replace the element Then press the dust indicator button to reset the indication 5 ENGINE ELECTRICAL The ISUZU engines uses a 24 volt or 12 volt system and a negative grounding type for the electrical system CAUTION 1 Take care not to connect reversely the polarity of battery terminal Reverse connection damage the electrical parts causing a fire or accident When disconnecting the terminals do the negative terminal first When connecting the terminals do the positive terminal first then negative terminal next WARNING 1 2 Highly flammable hydrogen gas is generated from battery When handling such metallic articles as a tool near When checking the battery and cables be sure
80. witch 3 Switch ON the battery switch if so equipped 4 Insert the starter switch key into the switch key hole Turn the key clockwise to DRIVE position and make sure that the meters and warning lamps are actuated AUTO RETURN IMWG0014 In case of the type with control resistance OFF PRE HEAT _ PRIVE ee YS START AUTO N RETURN AUTO ay RETURN FEN IMLE0041 38 2 Pre heating Procedures As an engine starting aid pre heating is required in a cold engine starting The type with QOS system This pre heating uses QOS a quick pre heating system which automatically controls pre heating time utilizing coolant temperature to conduct the irreducible minimum of pre heating Turn the key to the DRIVE position and the glow plugs built in the engine will grow red hot to pre heat the engine At this time the pre heating indicator lamp on the meterboard is actuated When the pre heating indicator lamp goes out try starting the engine at once Relationship between water temperature and pre heating time For ref 20 C 68 F About 0 5 sec 5 C 35 F verre About 1 5 sec 0 C 32 F verre About 2 sec 15 C 5 F veses About 6 3 sec The type with a control resistance Turn the starter switch key counter clockwise to PRE HEAT position in order to heat the glow plugs on the engine The Pre heating time of 5 seconds is required until the control resistanc

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