Isuzu AV-4LE1N Maintenance Manual

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 you don’t,

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 .............................................................. 1

1. MODEL 4LE1T............................................................................. 1

2. MODEL 4LE1NA.......................................................................... 3

2. GENERAL INFORMATION ................................................................. 5

1. EPA AND CARB CERTIFIED ENGINE DATA AND

SPECIFICATIONS........................................................................ 5

2. EC EMISSION CONTROL LABLE: ENGINE LABEL

(ONLY EC TYPE) ......................................................................... 18

3. ENGINE IDENTIFICATION........................................................... 19

4. ISUZU ENGINE AFTER SERVICE............................................... 21

3. FUEL, LUBRICANT, AND COOLANT................................................. 22

1. FUEL ............................................................................................ 22

2. LUBRICANT................................................................................. 27

3. COOLANT.................................................................................... 30

4. ENGINE OPERATION ......................................................................... 31

1. CHECK BEFORE OPERATION................................................... 32

2. ENGINE STARTING..................................................................... 38

3. CHECK AND OPERATION AFTER THE ENGINE START-UP .... 42

4. CARE IN THE ENGINE OPERATION .......................................... 45

5. ENGINE STOPPING..................................................................... 51

6. OPERATION AND CARE FOR NEW ENGINE ............................ 52

7. ENGINE CARE FOR OVER-COOLING ....................................... 52

8. OPERATION AND CARE FOR TURBOCHARGED ENGINE ...... 53

9. STARTING THE ENGINE AFTER BEING LEFT UNUSED

FOR A LONG PERIOD OF TIME ................................................. 54

5. PERIODICAL INSPECTION AND MAINTENANCE ............................ 55

1. LUBRICATING SYSTEM.............................................................. 55

2. COOLING SYSTEM ..................................................................... 64

3. FUEL SYSTEM............................................................................. 70

4. AIR INTAKE SYSTEM.................................................................. 77

5. ENGINE ELECTRICAL ................................................................ 79

6. ENGINE ASSEMBLY AND OTHERS ........................................... 83

6. ENGINE CARE IN COLD SEASON .................................................... 89

1. FUEL ............................................................................................ 89

2. COOLANT.................................................................................... 90

3. ENGINE OIL ................................................................................. 92

4. BATTERY..................................................................................... 92

5. ENGINE STARTING..................................................................... 93

7. ENGINE MAINTENANCE SCHEDULE ............................................... 94

8. SIMPLE ENGINE TROUBLESHOOTING ........................................... 102

1. ENGINE EXTERNAL VIEWS

1

1. MODEL 4LE1T

(1) LH

Air inlet

Generator

Turbocharger

Water drain plug

Starter

IMLE0085

Note:

Engine details may

vary depending on the

specifications.

2

(2) RH

PCV

Nozzle holder

Solenoid stopper

Oil filler cap

Oil drain plug

Oil cooler

From oil filter

To oil filter

Water pump

Thermostat housing

IMLE0086

Note:

Engine details may

vary depending on the

specifications.

3

2. MODEL 4LE1NA

(1) LH

Air inlet

Generator

Water drain plug

Starter

IMLE0087

Note:

Engine details may

vary depending on the

specifications.

4

(2) RH

Nozzle holder

Solenoid stopper

Oil filler cap

Oil drain plug

Fuel filter

Oil filter

Thermostat housing

Water pump

IMLE0088

Note:

Engine details may

vary depending on the

specifications.

2. GENERAL INFORMATION

5

1. EPA AND CARB CERTIFIED ENGINE DATA AND SPECIFICATIONS

Se rapporter à la fin de ce document pour les informations EPA en français.

(1) Model AU-4LE1T

ISUZU engine model name AU-4LE1T

Engine family *SZXL02.2UTA

Engine code 4LE1XXXXX-XX

Engine type Water-Cooled, four cycle, in-line overhead valve type

Combustion type Swirl chamber type

No. of cylinders – bore × stroke mm(in) 4 – 85 × 96 (3.35 × 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(hp)/min-1 40 (53.6) / 2200

*2 Fuel flow at max rated power (mm3/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.

6

ISUZU engine model name AU-4LE1T

Injection nozzles Throttle type

Specified fuel Diesel fuel (ASTM D975 No.2-D)

*2 Starter (V-kW) 12 – 2.2

*2 Alternator (V-A) 12 – 50

Specified engine oil (API grade) Refer to 3.LUBRICANT, Engine Oil Selection.

*2 Lub. oil volume L(qts) 7.6 (8.0) – 10.3 (10.9)

Coolant volume (Engine only) L(qts) 2.8 (3.0)

*2 Engine dry weight kg(lb) 190 (419)

Overall length mm(in) 647.5 (25.5)

Overall width mm(in) 523.6 (20.6)

*2 Engine dimensions

Overall height mm(in) 720.8 (28.4)

Valve clearance (cold) mm(in) 0.4 (0.0157)

Nozzle injection pressure MPa(psi) 14.7 (2132)

*2 Injection timing B.T.D.C. 12°

Maker and type of turbocharger IHI, RHF-3

Specification for items marked with an asterisk (*2) will vary according to the type of equipment in which the

engine is installed.

7

(2) Model BV-4LE1T

ISUZU engine model name BV-4LE1T

Engine family *SZXL02.2VTB

Engine code 4LE1XXXXX-XX

Engine type Water-Cooled, four cycle, in-line overhead valve type

Combustion type Swirl chamber type

No. of cylinders – bore × stroke mm(in) 4 – 85 × 96 (3.35 × 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(hp)/min-1 35 (46.9) / 1800

*2 Fuel flow at max rated power (mm3/stroke) 49.7

Exhaust emission control system EM, IDI, TC

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.

8

ISUZU engine model name BV-4LE1T

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 – 35

Specified engine oil (API grade) Refer to 3.LUBRICANT, Engine Oil Selection.

*2 Lub. oil volume L(qts) 7.6 (8.0) – 10.3 (10.9)

Coolant volume (Engine only) L(qts) 2.8 (3.0)

*2 Engine dry weight kg(lb) 180 (397)

Overall length mm(in) 753.7 (29.7)

Overall width mm(in) 486.2 (19.1)

*2 Engine dimensions

Overall height mm(in) 601.8 (23.7)

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°

Maker and type of turbocharger IHI, RHF-3

Specification for items marked with an asterisk (*2) will vary according to the type of equipment in which the

engine is installed.

9

(3) Model AV-4LE1N

ISUZU engine model name AV-4LE1N

Engine family *SZXL02.2VNA

Engine code 4LE1XXXXX-XX

Engine type Water-Cooled, four cycle, in-line overhead valve type

Combustion type Swirl chamber type

No. of cylinders – bore × stroke mm(in) 4 – 85 × 96 (3.35 × 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(hp)/min-1 35.9 (48.1) / 2600

*2 Fuel flow at max rated power (mm3/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.

10

ISUZU engine model name AV-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 – 35

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) 695.7 (27.4)

Overall width mm(in) 486.2 (19.1)

*2 Engine dimensions

Overall height mm(in) 601.8 (23.7)

Valve clearance (cold) mm(in) 0.4 (0.0157)

Nozzle injection pressure MPa(psi) 14.7 (2132)

*2 Injection timing B.T.D.C. 13°

Specification for items marked with an asterisk (*2) will vary according to the type of equipment in which the

engine is installed.

11

(4) Model BV-4LE1N

ISUZU engine model name BV-4LE1N

Engine family *SZXL02.2VNC

Engine code 4LE1XXXXX-XX

Engine type Water-Cooled, four cycle, in-line overhead valve type

Combustion type Swirl chamber type

No. of cylinders – bore × stroke mm(in) 4 – 85 × 96 (3.35 × 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(hp)/min-1 26.3 (35.3) / 1800

*2 Fuel flow at max rated power (mm3/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.

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)

Overall width mm(in) 496 (19.5)

*2 Engine dimensions

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 of equipment in which the

engine is installed.

13

(5) Engine family index

Engine Engine family Engine code

Injection nozzle

opening pressure

MPa(psi)

Injection timing

B.T.D.C.

(Static)

4LE1T *SZXL02.2UTA ALL –– ––

4LE1T *SZXL02.2VTB ALL –– ––

4LE1N *SZXL02.2VNA ALL –– ––

4LE1N *SZXL02.2VNC ALL –– ––

* 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

14

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

ENGINE FAMILY

ENGINE CODE

MODEL

POWER CATEGORY

ADVERTISED POWER (SAE NET)

: XX.X kW / XXXX RPM

FUEL RATE : XX mm

/st.

3

VALVE LASH (COLD)

INL/EXH : XX / XX mm.

INITIAL INJECTION TIMING

CURB IDLE : XXX RPM

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.

EXHAUST EMISSION CONTROL SYSTEM

SEE SERVICE MANUAL FOR

MODEL SPECIFICATIONS.

ENGINE FAMILY : XXXXXXXXXX ENGINE TYPE : XXXXXXXXXX

THIS ENGINE IS CONFORMED 97/68/EC DIRECTIVE.

ENGINE I.D.NUMBER : XXXX-XXXX

TYPE APPROVAL NUMBER : XXXXXXXXXXXXXXXXXX

XXXXXX

: XX-XXXXX

: XXXXXXXXX-XX

: XXXXXXX.XXXX

: XX < kW < XX

XXXXXXXXXXXXXXXXXX

: XXXXXXXXXXXXXXXXXX

LOW SULFUR FUEL OR ULTRA LOW

SULFUR FUEL ONLY

XXXXXXXXXX XXXXXXXXXX

: XXX BTDC

IMLE0097

15

4LE1NA

ENGINE FAMILY

ENGINE CODE

MODEL

POWER CATEGORY

ADVERTISED POWER (SAE NET)

: XX.X kW / XXXX RPM

FUEL RATE : XX mm

/st.

3

VALVE LASH (COLD)

INL/EXH : XX / XX mm.

INITIAL INJECTION TIMING

CURB IDLE : XXX RPM

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.

EXHAUST EMISSION CONTROL SYSTEM

SEE SERVICE MANUAL FOR

MODEL SPECIFICATIONS.

ENGINE FAMILY : XXXXXXXXXX ENGINE TYPE : XXXXXXXXXX

THIS ENGINE IS CONFORMED 97/68/EC DIRECTIVE.

ENGINE I.D.NUMBER : XXXX-XXXX

TYPE APPROVAL NUMBER : XXXXXXXXXXXXXXXXXX

XXXXXX

: XX-XXXXX

: XXXXXXXXX-XX

: XXXXXXX.XXXX

: XX < kW < XX

XXXXXXXXXXXXXXXXXX

: XXXXXXXXXXXXXXXXXX

LOW SULFUR FUEL OR ULTRA LOW

SULFUR FUEL ONLY

XXXXXXXXXX XXXXXXXXXX

: XXX BTDC

IMLE0110

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