4LE1T Operators 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.
2.
ENGINE EXTERNAL VIEWS ..............................................................
1
1.
MODEL 4LE1T .............................................................................
1
2.
MODEL 4LE1NA ..........................................................................
3
GENERAL INFORMATION .................................................................
5
1.
EPA AND CARB CERTIFIED ENGINE DATA AND
SPECIFICATIONS ........................................................................
2.
5
EC EMISSION CONTROL LABLE: ENGINE LABEL
(ONLY EC TYPE) ......................................................................... 18
3.
4.
3.
ENGINE IDENTIFICATION........................................................... 19
4.
ISUZU ENGINE AFTER SERVICE............................................... 21
FUEL, LUBRICANT, AND COOLANT................................................. 22
1.
FUEL ............................................................................................ 22
2.
LUBRICANT................................................................................. 27
3.
COOLANT .................................................................................... 30
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.
6.
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
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.
MODEL 4LE1T
(1)
LH
Turbocharger
Air inlet
Starter
Generator
Water drain plug
Note:
Engine details may
vary depending on the
specifications.
IMLE0085
1
(2)
RH
PCV
Nozzle holder
Thermostat housing
Solenoid stopper
Water pump
Oil cooler
Oil filler cap
From oil filter
Oil drain plug
To oil filter
Note:
Engine details may
vary depending on the
specifications.
IMLE0086
2
2.
MODEL 4LE1NA
(1)
LH
Air inlet
Starter
Generator
Water drain plug
Note:
Engine details may
vary depending on the
specifications.
IMLE0087
3
(2)
RH
Nozzle holder
Thermostat housing
Water pump
Solenoid stopper
Oil filler cap
Oil filter
Fuel filter
Oil drain plug
Note:
Engine details may
vary depending on the
specifications.
IMLE0088
4
2.
1.
GENERAL INFORMATION
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)
Engine displacement
L(cid)
Compression ratio
4 – 85 × 96 (3.35 × 3.78)
2.179 (133)
21.5 to 1
Firing order
1–3–4–2
-1
*2 Rated power: SAE NET
kW(hp)/min
*2 Fuel flow at max rated power
(mm /stroke)
3
40 (53.6) / 2200
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.
5
ISUZU engine model name
AU-4LE1T
Injection nozzles
Throttle type
Specified fuel
Diesel fuel (ASTM D975 No.2-D)
*2 Starter
*2 Alternator
(V-kW)
12 – 2.2
(V-A)
12 – 50
Specified engine oil (API grade)
*2 Lub. oil volume
Coolant volume (Engine only)
*2 Engine dry weight
Overall length
*2 Engine dimensions
Refer to 3.LUBRICANT, Engine Oil Selection.
L(qts)
7.6 (8.0) – 10.3 (10.9)
L(qts)
2.8 (3.0)
kg(lb)
190 (419)
mm(in)
647.5 (25.5)
Overall width
mm(in)
523.6 (20.6)
Overall height
mm(in)
720.8 (28.4)
mm(in)
0.4 (0.0157)
MPa(psi)
14.7 (2132)
Valve clearance (cold)
Nozzle injection pressure
*2 Injection timing B.T.D.C.
Maker and type of turbocharger
12°
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.
6
(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)
Engine displacement
L(cid)
Compression ratio
1–3–4–2
-1
*2 Rated power: SAE NET
kW(hp)/min
*2 Fuel flow at max rated power
(mm /stroke)
Injection pump
Governor
2.179 (133)
21.5 to 1
Firing order
Exhaust emission control system
4 – 85 × 96 (3.35 × 3.78)
3
35 (46.9) / 1800
49.7
EM, IDI, TC
Bosch, PFR type
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.
7
ISUZU engine model name
BV-4LE1T
Injection nozzles
Throttle type
Specified fuel
Diesel fuel (ASTM D975 No.2-D)
*2 Starter
*2 Alternator
(V-kW)
12 – 2.0
(V-A)
12 – 35
Specified engine oil (API grade)
*2 Lub. oil volume
Coolant volume (Engine only)
*2 Engine dry weight
Overall length
*2 Engine dimensions
Refer to 3.LUBRICANT, Engine Oil Selection.
L(qts)
7.6 (8.0) – 10.3 (10.9)
L(qts)
2.8 (3.0)
kg(lb)
180 (397)
mm(in)
753.7 (29.7)
Overall width
mm(in)
486.2 (19.1)
Overall height
mm(in)
601.8 (23.7)
mm(in)
0.4 (0.0157)
MPa(psi)
14.7 (2132)
Valve clearance (cold)
Nozzle injection pressure
*2 Injection timing B.T.D.C.
Maker and type of turbocharger
10°
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.
8
(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)
Engine displacement
L(cid)
Compression ratio
1–3–4–2
-1
*2 Rated power: SAE NET
kW(hp)/min
*2 Fuel flow at max rated power
(mm /stroke)
Injection pump
Governor
2.179 (133)
21.5 to 1
Firing order
Exhaust emission control system
4 – 85 × 96 (3.35 × 3.78)
3
35.9 (48.1) / 2600
35.5
EM, IDI
Bosch, PFR type
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.
9
ISUZU engine model name
AV-4LE1N
Injection nozzles
Throttle type
Specified fuel
Diesel fuel (ASTM D975 No.2-D)
*2 Starter
*2 Alternator
(V-kW)
12 – 2.0
(V-A)
12 – 35
Specified engine oil (API grade)
*2 Lub. oil volume
Coolant volume (Engine only)
*2 Engine dry weight
Overall length
*2 Engine dimensions
Refer to 3.LUBRICANT, Engine Oil Selection.
L(qts)
5.9 (6.2) – 8.4 (8.8)
L(qts)
2.8 (3.0)
kg(lb)
170 (375)
mm(in)
695.7 (27.4)
Overall width
mm(in)
486.2 (19.1)
Overall height
mm(in)
601.8 (23.7)
mm(in)
0.4 (0.0157)
MPa(psi)
14.7 (2132)
Valve clearance (cold)
Nozzle injection pressure
*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.
10
(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)
Engine displacement
L(cid)
Compression ratio
1–3–4–2
-1
*2 Rated power: SAE NET
kW(hp)/min
*2 Fuel flow at max rated power
(mm /stroke)
Injection pump
Governor
2.179 (133)
21.5 to 1
Firing order
Exhaust emission control system
4 – 85 × 96 (3.35 × 3.78)
3
26.3 (35.3) / 1800
36.5
EM, IDI
Bosch, PFR type
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
ISUZU engine model name
BV-4LE1N
Injection nozzles
Throttle type
Specified fuel
Diesel fuel (ASTM D975 No.2-D)
*2 Starter
*2 Alternator
(V-kW)
12 – 2.0
(V-A)
12 – 20
Specified engine oil (API grade)
*2 Lub. oil volume
Coolant volume (Engine only)
*2 Engine dry weight
Overall length
*2 Engine dimensions
Refer to 3.LUBRICANT, Engine Oil Selection.
L(qts)
5.9 (6.2) – 8.4 (8.8)
L(qts)
2.8 (3.0)
kg(lb)
170 (375)
mm(in)
671 (26.4)
Overall width
mm(in)
496 (19.5)
Overall height
mm(in)
595 (23.4)
mm(in)
0.4 (0.0157)
MPa(psi)
14.7 (2132)
Valve clearance (cold)
Nozzle injection pressure
*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.
12
(5)
Engine family index
Engine
4LE1T
Engine family
*SZXL02.2UTA
Engine code
ALL
Injection nozzle
opening pressure
MPa(psi)
Injection timing
B.T.D.C.
(Static)
––
––
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
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
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
: XXXXXXX.XXXX
ENGINE FAMILY
MODEL SPECIFICATIONS.
: XXXXXXXXX-XX
ENGINE CODE
ADVERTISED POWER (SAE NET)
MODEL
: XX-XXXXX
: XX.X kW / XXXX RPM
:
XX
<
kW
<
XX
POWER CATEGORY
FUEL RATE : XX mm3/st.
XXXXXXXXXXXXXXXXXX
VALVE LASH (COLD)
EXHAUST EMISSION CONTROL SYSTEM
INL/EXH : XX / XX mm.
: XXXXXXXXXXXXXXXXXX
INITIAL INJECTION TIMING
LOW SULFUR FUEL OR ULTRA LOW
: XXX BTDC
SULFUR FUEL ONLY
CURB IDLE : XXX RPM
XXXXXXXXXX XXXXXXXXXX
THIS ENGINE IS CONFORMED 97/68/EC DIRECTIVE.
ENGINE TYPE : XXXXXXXXXX
ENGINE FAMILY : XXXXXXXXXX
TYPE APPROVAL NUMBER : XXXXXXXXXXXXXXXXXX
ENGINE I.D.NUMBER : XXXX-XXXX
XXXXXX
IMLE0097
14
4LE1NA
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
: XXXXXXX.XXXX
ENGINE FAMILY
MODEL SPECIFICATIONS.
: XXXXXXXXX-XX
ENGINE CODE
ADVERTISED POWER (SAE NET)
MODEL
: XX-XXXXX
: XX.X kW / XXXX RPM
POWER CATEGORY : XX < kW < XX
FUEL RATE : XX mm3/st.
XXXXXXXXXXXXXXXXXX
VALVE LASH (COLD)
EXHAUST EMISSION CONTROL SYSTEM
INL/EXH : XX / XX mm.
: XXXXXXXXXXXXXXXXXX
INITIAL INJECTION TIMING
LOW SULFUR FUEL OR ULTRA LOW
: XXX BTDC
SULFUR FUEL ONLY
CURB IDLE : XXX RPM
XXXXXXXXXX XXXXXXXXXX
THIS ENGINE IS CONFORMED 97/68/EC DIRECTIVE.
ENGINE TYPE : XXXXXXXXXX
ENGINE FAMILY : XXXXXXXXXX
TYPE APPROVAL NUMBER : XXXXXXXXXXXXXXXXXX
ENGINE I.D.NUMBER : XXXX-XXXX
XXXXXX
IMLE0110
15
EMISSION CONTROL LABEL: ENGINE LABEL (ONLY EPA TYPE)
Emission control label is attached at a visible point on the equipment.
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
SEE SERVICE MANUAL FOR
MY OFF-ROAD DIESEL ENGINES.
: XXXXXXX.XXXX
ENGINE FAMILY
MODEL SPECIFICATIONS.
: XXXXXXXXX-XX
ENGINE CODE
ADVERTISED POWER (SAE NET)
MODEL
: XX-XXXXX
: XX.X kW / XXXX RPM
POWER CATEGORY : XX < kW < XX
FUEL RATE : XX mm3/st.
XXXXXXXXXXXXXXXXXX
VALVE LASH (COLD)
EXHAUST EMISSION CONTROL SYSTEM
INL/EXH : XX / XX mm.
: XXXXXXXXXXXXXXXXXX
INITIAL INJECTION TIMING
LOW SULFUR FUEL OR ULTRA LOW
: XXX BTDC
SULFUR FUEL ONLY
CURB IDLE : XXX RPM
XXXXXXXXXX XXXXXXXXXX
ENGINE I.D.NUMBER : XXXX-XXXX
XXXXXX
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
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.
EMISSION CONTROL INFORMATION
ISUZU MOTORS LTD. MADE IN JAPAN
THIS ENGINE IS CONFORMED 97/68/EC DIRECTIVE.
ENGINE TYPE : XXXXXXXXXX
ENGINE FAMILY : XXXXXXXXXX
TYPE APPROVAL NUMBER : XXXXXXXXXXXXXXXXXX
ENGINE I.D.NUMBER : XXXX-XXXX
XXXXXX
IMLE0106
18
3.
ENGINE IDENTIFICATION
(1)
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
Engine model
Serial number
4LE1
000000
IMLE0092
20
(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.
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.
IMLE0073
4.
ISUZU ENGINE AFTER SERVICE
(1)
Isuzu Engine After Service
Please feel free to contact your ISUZU dealer for periodical inspection
and maintenance.
(2)
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.
IMWG0005
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.
2) Must have adequate viscosity.
3) Must have high cetane value.
4) Must have high fluidity at low temperature.
5) *Low sulfur or ultra low sulfur diesel fuel only.
6) Must have little residual carbon.
* EPA regulations
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 other 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
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). This blended fuel is
usually called Number 2-D also, but can be used in colder temperatures than
Number 2-D fuel which has not been "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:
24
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)
1)
2)
(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 sedimented 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
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)
1)
2)
(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 gets 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.
26
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.
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.
(8)
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.
2.
LUBRICANT
The quality of engine oil may 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,CI-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.
LUBRICATION
MAKER
ISUZU GENUINE
ISUZU GENUINE
ISUZU GENUINE
Caltex/Chevron
Shell
Diesel engine
crankcase
Elf
Total
Castrol
BP
IDEMITSU
ExxonMobil
GRADE
API
ACEA
CE
BESCO MULTI-Z TYPE CE (10W-30)
CD/CF/CF-4
*BESCO MULTI-Z (10W-30)
CD
BESCO S-3 (10W, 20W, 30, 40)
CF
Delo CXJ (15W-40/20W-50/40)
E3/E5
CE/CF/CI-4
Delo 400 Multigrade (15W-40)
E3
CH-4
Rimula X (15W-40)
CF
Rimula D (15W-40/30/40)
B2/E2
CF-4/CE
Perfo 3F (15W-40)
E2
CF-4
Rubia XT (15W-40)
E3
CH-4
RX Super Plus (15W-40)
E3/B3
CH-4
Tection J Plus (15W-40)
E3
CH-4
BP Vanellus C6 (15W-40)
CF
APOLLOIL EX (10W-40)
CF
APOLLOIL TOUGH RUNNER (10W-30,15W-40)
CF-4/CE
APOLLOIL MULTI RUNNER (10W-30, 15W-40)
CF-4
*2 APOLLOIL SUPER WIDE DH-1(10W-30, 15W-40)
CF-4
Essolube XTJ (15W-40)
CI-4
Exxon/Essolube XD-3 (15W-40)
E7/E5
CI-4 Plus
Mobil Delvac 1300 Super (15W-40)
E7/E5/E4/E3
CI-4 Plus
Mobil Delvac 1 (5W-40)
BRAND/TYPE
* Initial Engine Oil from Engine plant
*2 Initial Engine Oil from Engine plant (Only a Part of Models)
28
JASO
DH-1
DH-1
DH-1
DH-1
DH-1
DH-1
DH-1
DH-1
DH-1
DH-1
DH-1
(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
SAE 40
SAE 20, 20W
[Single-grade]
SAE 10W
Ambient
Temperature
-25 C -20 C -15 C
(-13 F) (-4 F) (5 F)
SAE 30
-0 C
(32 F)
15 C
(59 F)
25 C 30 C
(77 F) (86 F)
SAE 10W-30
[Multi-grade]
SAE 15W-40, 20W-40
SAE 5W-20
IMLE0040
29
3.
Always refer to the chart to determine the correct cooling water to
antifreeze solution mixing ratio.
0
Freezing point (℃)
COOLANT
-10
CAUTION: 1. Supplement inhibitors or additives claiming to provide
-20
-30
-40
-50
0
10
20
30
40
50
2.
Mixing ratio (%)
IMJJ0025
3.
4.
5.
30
increases cooling capability that have not been specifically
approved by Isuzu are not recommended for addition to the
cooling system.
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.
It is strongly recommended to use Isuzu genuine engine
coolant or equivalent for addition or replacement.
Coolants from other brands often do not contain
anti-corrosive, and use of such products could result in
corrosion of the engine and radiator.
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 oil change.
• Whenever a change is noticed in the sound of the exhaust
system.
• 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
CAUTION: As the remote filter is used, the engine oil is filled above the
Dipstick
specified level. (Turbocharged engine only)
Adjust the engine oil level as required.
(1)
1)
2)
With turbocharger
Dipstick
IMLE0067
32
Engine Oil Level
Place the engine on a level surface.
Remove the dipstick from the crankcase, wipe it with clothing.
Insert it fully and take out it gently again.
Dipstick
Max. level
Min. level
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.
• Drain oil to the max. oil level if oil level is above the max. level
mark.
• 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.
IMLE0068
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
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.
2. For model that employs the closed PCV, excessive oil may
cause hunting in oil pressure, increase in the oil
temperature, oil 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.
1)
IMLE0012
34
When the belt is depressed with the thumb (about 100 N (22 lb)
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)
1)
2)
Coolant Level Check
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.
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 correct.
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
(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
12V
Battery cable
Battery cable
Terminal
Battery cable
Terminal
IMLE0069
CAUTION: Never reverse "+" and "–" terminals when reconnecting cables
after disconnection.
Even a short period of reverse connection will damage the
electrical parts.
36
(6)
Regular position
Shortage
Proper
Battery Electrolyte Level
The amount of electrolyte in the batteries will be reduced after
repeated discharge 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.
WARNING: 1. When inspecting the batteries, be sure to stop the engine.
Excess
IMWG0013
2. 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.
3. 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.
4. When handling such metallic articles as a tool near the
+ terminal.
batteries, be sure not to contact ○
As the
− , it may cause a big danger.
machine body is ○
− terminal.
5. When disconnecting the terminals, start with ○
−
When connecting them, connect the ○ terminal last.
37
In case of the type with QOS system
OFF
2.
ENGINE STARTING
(1)
Pre-starting Preparation
1)
DRIVE
START
2)
AUTO RETURN
3)
4)
IMWG0014
In case of the type with control resistance
IMLE0041
38
Make sure that all hydraulic control levers etc. on the equipment are in
the NEUTRAL position.
Set the engine stop knob in the START position. (It is unnecessary for
the engine equipped with the engine shutdown switch.)
Switch ON the battery switch (if so equipped).
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.
(2)
1)
2)
1)
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) ··········· About 1.5 sec.
0°C (32°F) ··········· About 2 sec.
-15°C (5°F) ·········· 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
resistance 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)
1)
Engine Starting
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)
40
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-heating and starting operations.
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
3.
CHECK AND OPERATION AFTER THE
ENGINE START-UP
(1)
Warming-up Operation
-1
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.
(2)
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.
-1
Oil pressure : 147 kPa (21 psi) /1000min
-1
294 kPa (43 psi) /1800min
-1
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.
In the warning lamp type, make sure that the lamp is completely off
during the warming-up.
42
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)
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:
• 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.
• Fuel leakage
Check the fuel injection pump, fuel lines and fuel filter for leakage.
• Coolant leakage
Check the radiator and water pump hose connections also the
water drain cocks on the radiator and cylinder body for leakage.
• 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.
-1
Oil pressure : 147 kPa (21 psi) /1000min
-1
294 kPa (43 psi) /1800min
-1
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:
• The engine oil pressure gauge shows below 200 kPa (28 psi)
though the engine speed is raised.
• The oil pressure gauge indicator oscillates greatly in the engine
low speed range.
• 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
(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:
• Climbing a long hill on a hot day.
•
46
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:
• If your air conditioner (if equipped) is on, turn it off. And turn on
the heater.
• Don’t turn off your engine.
• 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:
• 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
If no steam or engine coolant can be seen or heard, open the engine
access cover. 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.
48
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
condition:
• 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
(3)
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.
(4)
Liquid and Exhaust Smoke Leakage
Be careful with lubricant, fuel, coolant and exhaust smoke leakage.
(5)
Abnormal Engine Noise
Pay attention to the noise from the engine or other related parts,
checking if the noise is normal.
(6)
State of the Exhaust Smoke
Be careful with exhaust smoke color, check if it is whitish or blackish.
50
5.
1)
2)
ENGINE STOPPING
Make sure that all of the control levers on the equipment are in
NEUTRAL position.
Before stopping the engine, cool down the engine by operating 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 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.
52
8.
OPERATION AND CARE FOR
TURBOCHARGED ENGINE
(1)
Engine Starting
1)
2)
3)
(2)
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 at idle. 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 shortened life.
53
9.
STARTING THE ENGINE AFTER BEING
LEFT UNUSED FOR A LONG 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
-1
1000 min .
54
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 equipped
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
Engine oil draining
Oil filler cap
WARNING: To help avoid the damage of being burned, do not drain oil
while the engine is still hot.
1)
One-touch type
Wipe clean around the oil filler cap taking care so that no foreign
particles entry. Remove the filler cap.
IMLE0093
2)
3)
4)
IMWG0035
56
Loosen the cap of oil drain cock and remove it. Connect the oil drain
hose to the oil drain cock and drain the oil.
After the completion of draining, disconnect the hose and wipe off the
oil on the drain cock.
Turn the cap of oil drain cock slightly and settle it. From that position,
turn more about 60 to 90 degrees.
Oil filler cap
1)
2)
3)
4)
Drain plug type
Wipe clean around the oil filler cap taking care so that no foreign
particles entry. Remove the filler cap.
Remove the drain plug by loosening it, and then drain oil.
After oil has been drained completely, replace the packing of the drain
plug with a new one, and then install the plug.
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
IMLE0093
and equipment may not be stained with the drained oil.
57
4LE1T
Oil filler cap
Oil level gauge
Oil filler cap
Oil drain plug
IMLE0094
58
4LE1NA
Oil filler cap
Oil level gauge
Oil filler cap
Oil drain plug
IMLE0095
59
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
Cartridge
Cartridge
IMLE0070
60
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
1)
2)
Engine oil refilling
Disconnect the oil drain hose and reinstall the cap of drain cock. (One touch type)
Install the drain plug. (Drain plug type)
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 about 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.
62
(3)
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.
(4)
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.)
(5)
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 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
lb) depressing force.)
Fan belt slackness : 8 – 10 mm (0.31 – 0.39 in)
IMLE0012
64
Lock nut (loosen)
Adjusting
bolt
1)
2)
3)
Mounting bolt
(loosen)
IMLE0096
Adjusting procedure
Belt tension adjustment is made by pivoting the alternator at the
alternator mounting bolt.
Loosen the lock nut and the alternator mounting bolt.
Pivot the alternator at the mounting bolt by adjusting the adjusting bolt.
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)
CAUTION: Belt tension may vary slightly after the alternator is fixed.
Therefore, recheck the belt tension after tightening the bolts.
4)
(2)
1)
2)
3)
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.
Fan Belt Change
Use of fan belt with poor quality will result in premature belt wear or
belt elongation 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.
No adjustment margin of the belt.
Abnormal wear, damages, or cracks on the belt.
Brake noise occurs while driving even if belt tension is adjusted.
65
(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.
1)
Coolant draining
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.
66
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.
IMLE0021
1)
2)
3)
Air Bleeder Plug
Filling with coolant
Close or tighten the coolant drain plug.
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"
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
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.
Torque (Air bleeder plug) : 24.5 to 30.5 Nm (2.5 to 3.1 kgm)
5)
6)
(4)
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, clean them at any time. Further, if the
fins are deformed, repair or replace them.
68
(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
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)
Air bleeding plug
Lever
Element
Float
Drain plug
IMLE0057
70
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 sedimenter, 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)
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)
1)
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 engine and check the fuel system for leakage.
CAUTION: Start the engine and check the fuel system for leakage.
Leakage causes a fire.
Injection pump
IMLE0022
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.
1)
2)
Change procedure
Use a specified filter wrench to remove the cartridge.
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
1)
Cleaning procedure
Turn the water sedimenter lever to the closed position.
CAUTION: If the cup is removed without turning the lever as instructed,
the fuel may flow out.
2)
3)
4)
5)
Loosen the ring nut, remove the cup, and take out the element.
Clean the cup and element, install new packing on the ring nut.
Tighten the cup to the body securely with the ring nut.
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
CLOSE
Air bleeder plug
C
O
OPEN
Lever
Ring nut
Element
Cup
Drain plug
IMLE0059
74
(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.
Electromagnetic
pump
Gasket
Filter
CAUTION: When removing the filter, always replace the gasket and clean
Gasket
the magnet part inside of the cover.
Cover
1)
IMHK0376
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)
Remove 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
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.
76
4.
AIR INTAKE 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 following 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
(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.
IMLE0044
78
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.
2. When disconnecting the terminals, do the negative terminal
first. When connecting the terminals, do the positive
terminal first then negative terminal next.
WARNING: 1. When checking the battery and cables, be sure to stop the
engine.
2. 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.
3. Highly flammable hydrogen gas is generated from battery.
Never make a spark or use fire near the batteries.
4. When handling such metallic articles as a tool near
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
Electrolyte
Specific
gravity
Electrolyte Specific Gravity
Over 1.300
IMWG0025
Battery Conditions
Over 100% (Over charged)
1.290 ~ 1.270
100%
1.260 ~ 1.240
75%
Below 1.230
Below 50% (Insufficiently charged)
CAUTION: The battery electrolyte is dilute sulfuric acid. So, be careful not
to stain your body and 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)
S20 ; 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
(2)
1)
2)
3)
(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 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.
82
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.
Good
(1)
No good
IMLE0071
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 nozzle
end.
83
(2)
Mark groove
TDC mark
1)
Timing gear
case cover
Crank pulley
2)
IMLE0072
3)
Cylinder No.1
intake
Cylinder No.1 exhaust
IMLE0026
84
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 l 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 ○ or
◎ in the table below.
Cylinder No.
Valve arrangement
When No. 1 cylinder is at TDC
in the compression stroke
When No. 4 cylinder is at TDC
in the compression stroke
I: Intake E: Exhaust
4)
1
2
E
I
○
○
E
◎
3
I
E
○
○
4
I
E
I
◎
◎
◎
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
1)
2)
3)
IMLE0027
86
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 '○' in the table below.
Step 2: Turn the crankshaft clockwise 180 degrees from the step 1
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. 3
marked with '○' 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 '○' 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 '○' in the table below.
Cylinder No.
Valve arrangement
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
(3)
1
2
I
E
○
○
I
○
3
E
4
I
E
○
○
I
E
○
○
○
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.
(4)
Cylinder Compression Pressure Measurement
The cylinder compression pressure measurement must be done every
1000 operation hours, or whenever the engine output is reduced.
2
Compression pressure: 3.04 MPa (31.0 kg/cm / 441 psi)
-1
Test condition:
Cranking speed 250 min
Coolant temperature 70 – 85°C (158 – 185°F)
Repair the engine and/or replace some parts of engine if compression
2
pressure is lower than 2.5 MPa (26 kg/cm / 363 psi)
87
(5)
Starter and Alternator Servicing
Do the starter and the alternator servicing every 1000 operating hours
on the following items.
• Starter commutator cleaning.
• Alternator slip ring cleaning.
• Carbon brushes and the brush contact check.
(6)
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.
88
6.
ENGINE CARE IN COLD SEASON
1.
FUEL
(1)
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
2.
COOLANT
Where the atmospheric temperature falls below freezing point, the cooling
system should be drained after engine operation, 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.
90
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
3.
ENGINE OIL
Engine oil viscosity largely affects engine startability, so the use of lubricant
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.
1)
2)
BATTERY
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.
To replenish the battery with distilled water, do it immediately before
the engine operation.
CAUTION: If 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.
92
5.
ENGINE STARTING
In cold engine starting at atmospheric temperature of below 0°C (32°F), pay
attention to the following items:
1) Do the preheating operation before cranking the engine with the
starter.
2) Set the engine throttle lever or pedal to the 1/3 position of the full lever
or pedal stroke.
3) If the engine does not start with the initial cranking, keep the batteries
stationary a while to recover their power and, reattempt the preheating
and the cranking operation.
4) In order to protect the starter, one time cranking must be limited to
within 10 seconds.
5) 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.
6) 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.
NO.
Description of check
and maintenance
(operation hours)
Daily
Remark
250
500
750
1000
1250
1500
○
○
○
○
○
○
1.
Oil level and oil fouling
○
2.
Oil leakage check
○
3.
Oil pressure gauge registration
○
4.
Oil pressure warning lamp
○
5.
Engine oil replacement
(Cartridge type)
6.
Engine oil replacement
(Remote filter type)
○
○
○
7.
Oil filter element replacement
○
○
○
8.
Fuel leakage check
○
9.
Draining water
in fuel filter
○
w/water
sedimenter
10. Fuel filter element replacement
○★
○
○★
○
○★
○
11. Water sedimenter element cleaning
○★
○
○★
○
○★
○
See "EXPLANATION OF
MAINTENANCE
SCHEDULE"
★ 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
NO.
12.
Description of check
and maintenance
(operation hours)
Daily
Electromagnetic pump filter
replacement or cleaning
○★
13. Injection nozzle check (*)
14. Coolant level and fouling check
○
15. Coolant leakage check
○
16. Radiator filler cap fitting condition
○
17.
Fan belt tension check (Replace if
necessary.)
18. Coolant temperature registration
Remark
250
500
○
750
○★
1000
○
1250
○★
1500
○
○★
○★
○◎
○
○
○
See "EXPLANATION OF
○
MAINTENANCE
SCHEDULE"
○
19. Coolant replacement
20.
Intercooler and radiator external
face cleaning
21. Cooling system circuit cleaning
○
22. Radiator filler cap function check (*)
★ 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 limit recall liability
prior to the completion engine useful life. Isuzu, however, urges that required maintenance service is performed at the indicated
intervals.
95
NO.
Description of check
and maintenance
(operation hours)
Daily
23. Electrolyte level check
○
24. Battery cleaning
○
Battery charge
25.
condition
Remark
250
Ammeter
registration
○
Charge warning
lamp
○
500
750
1000
1250
1500
26. Electrolyte gravity check
27.
Starter and alternator check and
cleaning (*)
See "EXPLANATION OF
MAINTENANCE
SCHEDULE"
○
28. Wiring and connection check
29. Preheating condition check
○
30. Air cleaner element replacement
31. Turbocharger check
○
32. EGR valve check and cleaning
○
33. EGR lead valve cleaning
○
34. EGR cooler cleaning
○
96
NO.
Description of check
and maintenance
35.
Fuel & cooling water rubber hoses
replacement
36.
Engine starting conditions and
noise conditions
37. Exhaust smoke condition
Daily
(operation hours)
○
See "EXPLANATION OF
○
38. Cylinder compression pressure (*)
○
39. Valve clearance check (*)
○
40.
Positive crankcase ventilation valve
cleaning
Remark
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 service 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.
Oil level and oil fouling 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.
2.
Oil leakage check
Replace any damaged or malfunctioning parts which could cause leakage.
3.
Oil pressure gauge
registration
Engine oil pressure is normal at the values of the following in warmed-up condition.
-1
Oil pressure : 147 kPa (21 psi) /1000min
-1
294 kPa (43 psi) /1800min
-1
343 to 686 kPa (50 to 100 psi) /2200min
Check and repair the lubrication oil system, if it is abnormal.
4.
Oil pressure warning
lamp
Warning lamp is off while engine running.
system.
5.
Engine oil replacement Change oil every 250 hours. (Cartridge type)
6.
Engine oil replacement Change oil every 500 hours. (Remote filter type)
7.
Oil filter element
replacement
Change element every 500 hours.
8.
Fuel leakage check
Inspect the fuel lines for damage which could cause leakage.
malfunctioning parts.
9.
Draining water in fuel
filter
The fuel system without the water sedimenter.
Drain the sedimented water in fuel filter every 250 operating hours.
98
If it stays on, check and repair the lubrication
Replace any damaged or
Change element every 500 hours.
Shorten depending on fuel management.
10. Fuel filter element
replacement
★
11. Water sedimenter
element cleaning
★
Clean the water sedimenter element every 500 hours.
Shorten depending on fuel management.
12. Electromagnetic pump Replace the paper-type filter at intervals of 500 operating hours. Clean the steel
filter cleaning
mesh-type filter at intervals of 500 operating hours.
★ Shorten depending on fuel management.
13. Injection nozzle check
Clean the injection nozzle tips every 1500 hours. (This is a required maintenance)
Check injection opening pressure and spray condition.
14. Coolant level and
fouling check
Check coolant level and add coolant if necessary.
15. Coolant leakage check Repair part for coolant leakage.
16. Radiator filler cap
fitting condition
The radiator cap must be installed tightly.
17. Fan belt tension check Check and adjust fan belt deflection.
Look for cracks, fraying and wear.
18. Coolant temperature
registration
Coolant temperature is normal at about 75 to 90°C (167 to 194°F).
the cooling system if coolant temperature is abnormal.
Check and repair
19. Coolant replacement
Change coolant at intervals of 12 months if coolant is long life coolant (LLC).
20. Intercooler and
radiator external face
cleaning
According to the equipment manufacturer’s specification.
99
21. Cooling system circuit Clean the cooling system circuit every 12 months or 1000 hours.
cleaning
22. Radiator filler cap
function check
Check radiator pressure cap periodically for proper operation according to the
equipment manufacturer’s specifications.
23. Electrolyte level check Replenish with distilled water if necessary.
24. Battery cleaning
Clean the terminals.
25. Battery charge
condition
Ammeter registration goes to plus (+) side while engine running.
lamp is completely being off while engine running.
Check charging circuit if the lamp is not off.
26. Electrolyte gravity
check
Check according to the equipment manufacturer’s specifications.
27. Starter and alternator
check and cleaning
Check wear condition of brush and commutator.
In the lamp type, the
28. Wiring and connection Check according to the equipment specifications.
check
29. Preheating condition
check
Check preheating condition of the system.
30. Air cleaner element
replacement
Change element according to the manufacturer’s specifications.
31. Turbocharger check
Check turbocharger every 1500 hours. (Clean blower as necessary.)
100
32. EGR valve check and
cleaning
Check and clean EGR valve every 1500 hours.
33. EGR lead valve
cleaning
Clean EGR lead valve every 1500 hours.
34. EGR cooler cleaning
Clean EGR cooler every 1500 hours.
35. Fuel & cooling water
rubber hoses
replacement
Check and replace every 24 months.
36. Engine starting
conditions and noise
conditions
Check engine stability and noise.
37. Exhaust smoke
condition
Check exhaust smoke color.
38. Cylinder compression
pressure
Check every 1000 hours.
39. Valve clearance check
Incorrect valve clearance will result in increased engine noise and lower engine output.
Thereby adversely affecting engine performance.
Check and adjust every 1000 hours.
40. Positive crankcase
ventilation valve
cleaning
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.
Symptom
Starter does
not turn.
Engine does
not start.
Starter turns
but engine
dose not
ignite.
Engine ignite but stall
immediately.
102
Cause
Action
Battery discharged.
Charge or change.
Imperfect cable connections.
◎
Starter or starter switch failure.
◎
Safety relay failure.
◎
Engine stop solenoid return failure.
◎
No fuel in the fuel tank.
Make sure that there is no fuel leakage and
replenish.
Clogged fuel filter element.
Remove water and change element.
Air in the fuel system.
Bleed air.
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.
Improper low idling speed adjustment.
◎
EGR valve fixing. (Open position.)
◎
Symptom
Cause
Action
Crack in injection pipe.
◎
Injection nozzle failure.
◎
Engine stop solenoid return failure.
◎
Uneven compression pressure between cylinders. ◎
Unstable engine running.
Engine overheat.
Incorrect control lever adjustment.
◎
Governor interior malfunction.
◎
Governor spring deteriorated.
◎
Air in the fuel system.
Bleed air.
Clogged fuel filter element.
Remove water and change element.
Piping failure (squeezed, etc.) in the fuel system.
◎
Uneven fuel injection amount between plungers.
◎
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.
Thermostat malfunction.
Change thermostat.
Radiator filler cap malfunction.
Change radiator filler cap.
Cooling system interior fouled.
Clean cooling system interior.
103
Symptom
Engine overheat.
Low oil pressure.
Lack engine output.
104
Cause
Action
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.
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.
◎
Too advance of injection timing.
◎
Too retard of injection timing.
◎
Incorrect injection pressure adjustment.
◎
Incorrect spray condition.
◎
Lack of fuel in tank.
Make sure that there is no fuel leakage and
replenish.
Symptom
Lack engine output.
At low speed, insufficient
torque.
Improper oil.
Excessive oil
consumption.
Oil coming
up.
Oil coming
down.
Oil leakage.
Cause
Action
Air mixing in injection pump.
Bleed air.
Fuel filter clogged.
Change element.
Overflow valve malfunction.
◎
Incorrect engine control adjustment.
◎
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.
EGR valve fixing. (Open position.)
◎
Wrong selection of kind of viscosity.
Change with oil of correct viscosity.
Too much oil quantity.
◎
Wrong selection of cylinder liner and piston ring.
◎
Faulty valve stem seal.
◎
Damaged packing.
Change packing.
Improper tightening.
Retighten oil filler cap.
Improper installation of filter and piping.
Reinstall filter and piping.
105
Symptom
Fuel leakage.
Excessive
fuel
consumption.
Too much
injection
amount.
Excessive
mechanical
loads.
Much black
smoke.
Improper
exhaust.
Much white
smoke.
Low
Battery
electrolyte
overdischarge.
level.
106
Cause
Action
Damaged packing.
Change packing.
Improper installation or tightening.
Reinstall or retighten air bleeder plug.
Injection pump misadjustment.
◎
Operation
Check the mechanical loads.
Clogged air cleaner.
Clean or change element.
Nozzle damage.
◎
Nozzle misadjustment.
Make a readjustment.
Injection timing failure.
◎
Injection amount misadjustment.
◎
Improper fuel.
Use fuel in this instruction manual.
EGR valve fixing. (Open position.)
◎
Oil coming up or down.
Change oil.
Water mixing in fuel.
Remove water.
Low compression pressure.
◎
Injection timing failure.
◎
Low coolant temperature.
Inspect or change thermostat.
Crack in battery body.
Change battery.
Natural consumption.
Change battery.
Symptom
Battery
overdischarge.
Charging
failure.
Excessive
electrical
loads.
Cause
Action
Loose or damaged belt.
Retighten or change belt.
Faulty alternator.
Change alternator.
Damaged wiring or contact failure.
Make an adjustment.
Low speed driving.
Charge or change.
Insufficient battery capacity.
Reduce electrical load or change battery capacity.
107
2.
INFORMATION GENERALE
1.
CARACTERISTIQUES TECHNIQUES ET DONNEES DU MOTEUR
CARTIFIE EPA ET CARB
(1)
Modèle AU-4LE1T
Désignation du modèle du moteur ISUZU
AU-4LE1T
Famille de moteur
*SZXL02.2XXX
Code de moteur
4LE1XXXXX-XX
Type de moteur
Type de soupape en tête en ligne, quatre temps,
à refroidissement à eau.
Type de combustion
Swirl chambre
No. de cylindres – alésage × course
Cylindrée du moteur
mm(in)
4 – 85 × 96 (3,35 × 3,78)
L(cid)
2,179 (133)
Rapport de compression
21,5 to 1
Séquence d′allumage
Puisance nominale: SAE NET
Débit de combustible au couple max.
1–3–4–2
-1
kW(cv)/min
3
(mm /course)
40 (53,6) / 2200
46,3
Système de commande d′émission d′échappement
EM, IDI, TC, EGR
Pompe à injection
Type PFR, Bosch
Régulateur
Type mécanique, vitesse variable
* Marque ; Placer un code de lettres pour l′année du modèle sur la partie supérieure des lattres.
Année du modèle 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.
108
Désignation du modèle du moteur ISUZU
AU-4LE1T
Buses à injection
Type à papillon
Combustible spécifié
Combustible Diesel (ASTM D975 No.2-D)
Démarreur
(V-kW)
12 – 2,2
Alternateur
(V-A)
12 – 50
Référez-vous à 3. LUBRIFIANT,
choix D′Huile à moteur.
Huile moteur spécifiée (API grade)
Volume d′huile de lubrication
L(qts)
Volume du liquide de refroidissement
(seulement moteur)
L(qts)
Poids à sec du moteur
kg(lb)
190 (419)
mm(in)
647,5 (25,5)
Longueur hors-tout
Dimensions du moteur
7,6 (8,0) – 10,3 (10,9)
2,8 (3,0)
Largeur hors-tout
mm(in)
523,6 (20,6)
Hauteur hors-tout
mm(in)
720,8 (28,4)
mm(in)
0,4 (0,0157)
MPa(psi)
14,7 (2132)
Jeu de soupape (à froid)
Pression d′injection d′injecteur
Calage d′injection B.T.D.C.
Fabricant et type de turbochargeur
12°
IHI, RHF-3
109
(2)
Modèle BV-4LE1T
Désignation du modèle du moteur ISUZU
BV-4LE1T
Famille de moteur
*SZXL02.2XXX
Code de moteur
4LE1XXXXX-XX
Type de moteur
Type de soupape en tête en ligne, quatre temps,
à refroidissement à eau.
Type de combustion
Swirl chambre
No. de cylindres – alésage × course
Cylindrée du moteur
mm(in)
4 – 85 × 96 (3,35 × 3,78)
L(cid)
2,179 (133)
Rapport de compression
21,5 to 1
Séquence d′allumage
Puisance nominale: SAE NET
Débit de combustible au couple max.
1–3–4–2
-1
kW(cv)/min
3
(mm /course)
Système de commande d′émission d′échappement
Pompe à injection
35 (46,9) / 1800
49,7
EM, IDI, TC
Type PFR, Bosch
Régulateur
Type mécanique, vitesse variable
* Marque ; Placer un code de lettres pour l′année du modèle sur la partie supérieure des lattres.
Année du modèle 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
Désignation du modèle du moteur ISUZU
BV-4LE1T
Buses à injection
Type à papillon
Combustible spécifié
Combustible Diesel (ASTM D975 No.2-D)
Démarreur
(V-kW)
12 – 2,0
Alternateur
(V-A)
12 – 35
Référez-vous à 3. LUBRIFIANT,
choix D′Huile à moteur.
Huile moteur spécifiée (API grade)
Volume d′huile de lubrication
L(qts)
Volume du liquide de refroidissement
(seulement moteur)
L(qts)
Poids à sec du moteur
kg(lb)
180 (397)
mm(in)
753,7 (29,7)
Longueur hors-tout
Dimensions du moteur
7,6 (8,0) – 10,3 (10,9)
2,8 (3,0)
Largeur hors-tout
mm(in)
486,2 (19,1)
Hauteur hors-tout
mm(in)
601,8 (23,7)
mm(in)
0,4 (0,0157)
MPa(psi)
14,7 (2132)
Jeu de soupape (à froid)
Pression d′injection d′injecteur
Calage d′injection B.T.D.C.
Fabricant et type de turbochargeur
10°
IHI, RHF-3
111
(3)
Modèle AV-4LE1N
Désignation du modèle du moteur ISUZU
AV-4LE1N
Famille de moteur
*SZXL02.2XXX
Code de moteur
4LE1XXXXX-XX
Type de moteur
Type de soupape en tête en ligne, quatre temps,
à refroidissement à eau.
Type de combustion
Swirl chambre
No. de cylindres – alésage × course
Cylindrée du moteur
mm(in)
4 – 85 × 96 (3,35 × 3,78)
L(cid)
2,179 (133)
Rapport de compression
21,5 to 1
Séquence d′allumage
Puisance nominale: SAE NET
Débit de combustible au couple max.
1–3–4–2
-1
kW(cv)/min
3
(mm /course)
Système de commande d′émission d′échappement
Pompe à injection
35,9 (48,1) / 2600
35,5
EM, IDI
Type PFR, Bosch
Régulateur
Type mécanique, vitesse variable
* Marque ; Placer un code de lettres pour l′année du modèle sur la partie supérieure des lattres.
Année du modèle 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.
112
Désignation du modèle du moteur ISUZU
AV-4LE1N
Buses à injection
Type à papillon
Combustible spécifié
Combustible Diesel (ASTM D975 No.2-D)
Démarreur
(V-kW)
12 – 2,0
Alternateur
(V-A)
12 – 35
Référez-vous à 3. LUBRIFIANT,
choix D′Huile à moteur.
Huile moteur spécifiée (API grade)
Volume d′huile de lubrication
L(qts)
Volume du liquide de refroidissement
(seulement moteur)
L(qts)
Poids à sec du moteur
kg(lb)
170 (375)
mm(in)
695,7 (27,4)
Longueur hors-tout
Dimensions du moteur
5,9 (6,2) – 8,4 (8,8)
2,8 (3,0)
Largeur hors-tout
mm(in)
486,2 (19,1)
Hauteur hors-tout
mm(in)
601,8 (23,7)
mm(in)
0,4 (0,0157)
MPa(psi)
14,7 (2132)
Jeu de soupape (à froid)
Pression d′injection d′injecteur
Calage d′injection B.T.D.C.
13°
113
(4)
Modèle BV-4LE1N
Désignation du modèle du moteur ISUZU
BV-4LE1N
Famille de moteur
*SZXL02.2XXX
Code de moteur
4LE1XXXXX-XX
Type de moteur
Type de soupape en tête en ligne, quatre temps,
à refroidissement à eau.
Type de combustion
Swirl chambre
No. de cylindres – alésage × course
Cylindrée du moteur
mm(in)
4 – 85 × 96 (3,35 × 3,78)
L(cid)
2,179 (133)
Rapport de compression
21,5 to 1
Séquence d′allumage
Puisance nominale: SAE NET
Débit de combustible au couple max.
1–3–4–2
-1
kW(cv)/min
3
(mm /course)
Système de commande d′émission d′échappement
Pompe à injection
26,3 (35,3) / 1800
36,5
EM, IDI
Type PFR, Bosch
Régulateur
Type mécanique, vitesse variable
* Marque ; Placer un code de lettres pour l′année du modèle sur la partie supérieure des lattres.
Année du modèle 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.
114
Désignation du modèle du moteur ISUZU
BV-4LE1N
Buses à injection
Type à papillon
Combustible spécifié
Combustible Diesel (ASTM D975 No.2-D)
Démarreur
(V-kW)
12 – 2,0
Alternateur
(V-A)
12 – 20
Référez-vous à 3. LUBRIFIANT,
choix D′Huile à moteur.
Huile moteur spécifiée (API grade)
Volume d′huile de lubrication
L(qts)
Volume du liquide de refroidissement
(seulement moteur)
L(qts)
Poids à sec du moteur
kg(lb)
170 (375)
mm(in)
671 (26,4)
Longueur hors-tout
Dimensions du moteur
5,9 (6,2) – 8,4 (8,8)
2,8 (3,0)
Largeur hors-tout
mm(in)
496 (19,5)
Hauteur hors-tout
mm(in)
595 (23,4)
mm(in)
0,4 (0,0157)
MPa(psi)
14,7 (2132)
Jeu de soupape (à froid)
Pression d′injection d′injecteur
Calage d′injection B.T.D.C.
10°
115
(5)
Famille indice de moteur
Moteur
Famille de moteur
Code de moteur
Pression d′injection
d′injecteur
MPa(psi)
Catage d′injection
B.T.D.C.
(degre)
4LE1T
*SZXL02.2UTA
Tout
––
––
4LE1T
*SZXL02.2VTB
Tout
––
––
4LE1N
*SZXL02.2VNA
Tout
––
––
4LE1N
*SZXL02.2VNC
Tout
––
––
* Marque ; Placer un code de lettres pour l′année du modèle sur la partie supérieure des lattres.
Année du modèle Y : 2000, 1 : 2001, 2 : 2002, 3 : 2003, 4 : 2004, 5 : 2005, 6 : 2006, 7 : 2007, 8 : 2008,
9 : 2009
116
ETIQUETTE DE COMMANDE D′EMISSION : ETIQUETTE DU MOTEUR (TYPE COMBINÉ EPA, CE)
L′étiquette de commande d′émission est fixée au centre du couvercle de la pompe d′injection situé sur la droite du corps
du cylindre, ou sur le couvercle de la culasse. L′emplacement de l′étiquette de commande d′émission fixée au moteur
peut varier selon les spécifications du moteur.
Voici-ci après un échatillon requis pour les informations concernant la commande d′émission du moteur, ensemble avec
son emplacement.
Ces étiquettes sont traduites de l′anglais en français.
4LE1T
INFORMATIONS IMPORTANTES SUR LE MOTEUR
ISUZU MOTORS LTD. FABRIQUE AU JAPON
CE MOTEUR EST CERTIFIE 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 A ALLUMAGE PAR COMPRESSION DE VEHICULE TOUT TERRAIN.
; XXXXXXX.XXXX
FAMILLE DE MOTEUR
; XXXXXXXXX-XX
PUISSANCE MOTRICE ANNONCEE ; SAE NET
CODE DE MOTEUR
; XX.X kW/ XXX T/MIN
; XX-XXXXX
MODELE
; XX < kW < XX
POUVOIR CATEGORIE
TAUX DE CARBURANT ; XX.X mm /st
JEU DE SOUPAPE (A FROID)
XXXXXXXXXXXXXXXXXX
ADM / ECHAP ; X.X mm.
SYSTEME DE CONTROLE D'EMISSION D'ECHAPPEMENT
; XXXXXXXXXXXXXXXXXX
CALAGE D'INJECTION
; XXX BTDC (INT.)
DIESEL A FAIBLE TENEUR EN SOUFRE OU DIESEL A
RALENTI EN COURBE ; XXX TR-MIN
TRES FAIBLE TENEUR EN SOUFRE UNIQUEMENT
XXXXXXXXXX XXXXXXXXXX
CE MOTEUR EST CONFORME A LA DIRECTIVE 97/68/CE.
TYPE DE MOTEUR ; XXXXXXXXX
FAMILLE DE MOTEUR ; XXXXXXX
NUMERO D'APPROBATION ; XXXXXXXXXXXXXXXXXX
NUMERO D'IDENTIFICAT ON DU MOTEUR ; XXXX-XXXX
XXXXXX
IMLE0100
117
4LE1NA
INFORMATIONS IMPORTANTES SUR LE MOTEUR
ISUZU MOTORS LTD. FABRIQUE AU JAPON
CE MOTEUR EST CERTIFIE 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 A ALLUMAGE PAR COMPRESSION DE VEHICULE TOUT TERRAIN.
; XXXXXXX.XXXX
FAMILLE DE MOTEUR
; XXXXXXXXX-XX
PUISSANCE MOTRICE ANNONCEE ; SAE NET
CODE DE MOTEUR
; XX.X kW/ XXX T/MIN
; XX-XXXXX
MODELE
; XX < kW < XX
POUVOIR CATEGORIE
TAUX DE CARBURANT ; XX.X mm /st
JEU DE SOUPAPE (A FROID)
XXXXXXXXXXXXXXXXXX
ADM / ECHAP ; X.X mm.
SYSTEME DE CONTROLE D'EMISSION D'ECHAPPEMENT
; XXXXXXXXXXXXXXXXXX
CALAGE D'INJECTION
; XXX BTDC (INT.)
DIESEL A FAIBLE TENEUR EN SOUFRE OU DIESEL A
RALENTI EN COURBE ; XXX TR-MIN
TRES FAIBLE TENEUR EN SOUFRE UNIQUEMENT
XXXXXXXXXX XXXXXXXXXX
CE MOTEUR EST CONFORME A LA DIRECTIVE 97/68/CE.
TYPE DE MOTEUR ; XXXXXXXXX
FAMILLE DE MOTEUR ; XXXXXXX
NUMERO D'APPROBATION ; XXXXXXXXXXXXXXXXXX
NUMERO D'IDENTIFICAT ON DU MOTEUR ; XXXX-XXXX
XXXXXX
IMLE0111
118
ETIQUETTE DE COMMANDE D′EMISSION : ETIQUETTE DU MOTEUR
L′étiquette de commande d′émission est fixé sur un emplacement visible de l′équipement.
Ces étiquettes sont traduites de l′anglais en français.
TYPE EPA SEULEMENT
TYPE EC SEULEMENT
INFORMATIONS IMPORTANTES SUR LE MOTEUR
ISUZU MOTORS LTD. FABRIQUE AU JAPON
CE MOTEUR EST CERTIFIE 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 A ALLUMAGE PAR COMPRESSION DE VEHICULE TOUT TERRAIN.
; XXXXXXX.XXXX
FAMILLE DE MOTEUR
; XXXXXXXXX-XX
PUISSANCE MOTRICE ANNONCEE ; SAE NET
CODE DE MOTEUR
; XX.X kW/ XXX T/MIN
; XX-XXXXX
MODELE
; XX < kW < XX
POUVOIR CATEGORIE
TAUX DE CARBURANT ; XX.X mm /st
JEU DE SOUPAPE (A FROID)
XXXXXXXXXXXXXXXXXX
ADM / ECHAP ; X.X mm.
SYSTEME DE CONTROLE D'EMISSION D'ECHAPPEMENT
; XXXXXXXXXXXXXXXXXX
CALAGE D'INJECTION
; XXX BTDC (INT.)
DIESEL A FAIBLE TENEUR EN SOUFRE OU DIESEL A
RALENTI EN COURBE ; XXX TR-MIN
TRES FAIBLE TENEUR EN SOUFRE UNIQUEMENT
XXXXXXXXXX XXXXXXXXXX
INFORMATIONS IMPORTANTES SUR LE MOTEUR
ISUZU MOTORS LTD. FABRIQUE AU JAPON
CE MOTEUR EST CONFORME A LA DIRECTIVE 97/68/CE.
TYPE DE MOTEUR ; XXXXXXXXX
FAMILLE DE MOTEUR ; XXXXXXX
NUMERO D'APPROBATION ; XXXXXXXXXXXXXXXXXX
NUMERO D'IDENTIFICAT ON DU MOTEUR ; XXXX-XXXX
XXXXXX
NUMERO D'IDENTIFICAT ON DU MOTEUR ; XXXX-XXXX
XXXXXX
IMLE0101
119
ETIQUETTE DE RESTRICTION DE TYPE DE CARBURANT UTILISE (POUR EPA)
L′étiquette de restriction du type de carburant utilisé se trouve sur le goulot de remplissage du réservoir de carburant.
Contenu de l′étiquette:
DIESEL A FAIBLE TENEUR EN SOUFRE OU DIESEL A TRES FAIBLE TENEUR EN SOUFRE UNIQUEMENT
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 is 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 & Service Group
Off-highway Powertrain Operations Dept.
6-26-1, Minami-oi, Shinagawa-ku, Tokyo, 140-8722, Japan
TEL 03-5471-1111
10/2008
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